INTRODUCTION

A reinforced concrete slab is a common structural element of modern buildings,

consisting of a flat, horizontal surface made of cast concrete. Steel-reinforced slabs,
typically between 100 and 500 mm thick, are most often used to construct floors and
ceilings.
The RCC roof is made up of several ingredients. This compound is derived from three
key elements namely sand, cement, and water.
In many domestic and industrial buildings, a thick concrete slab supported on
foundations or directly on the subsoil, is used to construct the ground floor. These
slabs are generally classified as ground-bearing or suspended. A slab is ground-
bearing if it rests directly on the foundation, otherwise the slab is suspended. For
multi-story buildings, there are several common slab designs.
DESIGN CONSIDERATIONS
 The design of a roof slab consists of thickness of slab, size of bars, spacing of bars,
hooks, cranks and laps of bars, minimum cover of concrete etc. The mix of concrete
for the slab is usually by volume and is of proportion 1:2:4 (cement, sand and
aggregate)
 Due to the loading conditions the slab is subjected to possible or sagging bonding
movement on the bottom surface at the centre of the span and negative or hogging
bending moment at top near supports. To resist these moments main reinforcement is
provided at the bottom surface along the direction of span to resist positive bending
moment.
 Depending upon the span, an RCC slab may be designed as either one way reinforced
slab or two way reinforced slab.
 One way reinforced slab
 Two way reinforced slab

ONE WAY REINFORCED SLAB

 The slab which is supported on two opposite supports is called a one way slab.
 This slab is considered to be supported on two longer opposite sides.
 When the ratio between the length and breadth of the room over which the slab is
provided is more than 2.
 One way slab consists of main reinforcement spanning between the supports with
distribution of reinforcement at right angles to it.
 The overall thickness of the slab is usually kept 10 cm though the minimum
thickness can be 7.5 cm. The minimum area of reinforcement per unit width of a
slab shall not be less than 0.15%. of the gross cross sectional area of concrete. But
due to other limitations, it becomes necessary to provide a higher percentage of
steel in the slab.
 Spacing of bars of main reinforcement shall not be more than 3 times the effective
depth of slab and that for the distribution bars not more than five times the
effective depth. Spacing of not more than 20 cm diameter for main bars and not
more than 40 cm for distribution bars is usually provided.
 Bars smaller than 6 mm diameter or greater than 18 mm are not used for slabs. 10
mm or 12 mm plain M.S. bars or 8 mm or 10 mm tor-steel bars are generally used.
They are provided at the bottom of the slab allowing a minimum cover of 25 mm
of concrete.
 In addition to bars along the main direction, provided at the bottom, bars along the
longer span are also placed on top of the main bars and at right angles to them.
These are called ‗ distribution‘ bars or ‗temperature reinforcement‘ or ‗ transverse
bars‘. The distribution bars function to resist cracks due to variation of
temperature and shrinkage stresses. They also assist in distribution of loads. The
area of such reinforcement is usually 20 % of that of main reinforcement. Plain
M.S. bars of 6 mm diameter are usually used for this purpose.
 In all buildings, slabs cover the full width of the wall over which walls are raised.
This creates partially fixed conditions for the slab. In such cases, every alternate
bar is bent up. This arrangement is economical as compared to providing
 additional bars at the top. The main bottom bar is cranked at one-fifth of the span
at either end and taken up.
 Main and distribution bars are tied together with black mild steel wire of 16 gauge
by providing a cross and twisting the ends. If a smaller diameter of wire is used,
double strands of wire shall be provided in place of a single strand. About 5 kg. of
binding wire is required for tying 1 tonne of reinforcing bars.
 Considering a 2.5 M or 8‘0‖ wide verandah by way of example, the thickness of
the slab is 10 cm. Main bars are 10 mm plain M.S. or 8 mm tor-steel and are
placed at 20 cm centre at bottom of the slab along the short span allowing a cover
of 25 mm. Every alternate bar is cranked up to 0.5 M from the edge of the wall
and at both ends 6 mm plain M.S. bars are used as distribution bars and are placed
at 30 cm centres at the top of the bottom bars. For the cranked bars near the
supports at the top of the slab distribution bars of same size and same spacing are
provided below the top bars.
TWO-WAY SLAB
 Two way slab is said to be spanning in two directions, when the length
to breadth ratio falls below 2. In such a case, main reinforcement is
provided in both directions in the form of a mesh.
 In providing steel for a two-way slab, the bars in both directions shall
be of the same diameter and of the same kind i.e. either plain or tor-
steel. The bottommost layer will be along the shorter span. Same size
bars along the longer span shall be placed on top of these bars and at
right angles to them. No extra distribution bars are necessary. Cranking
of alternate bars shall be done at 1/5th span from support on all the
four sides and cranked bars taken to the top which come at the top of
slabs over the supports allowing usual cover.
 If the slab of one room continues over the adjacent room the portion of
the slab over the common intermediate support needs top
reinforcement. The bars in the middle portions in short span direction
will be at the bottom whereas those over the intermediate supports will
be at the top. The spacing of a given size of bar in all these positions
depends upon the lengths of spans and upon the loading conditions and
is determined by design considerations.
 It is desirable for the convenience of workmen and the supervisor to
adopt the same spacing for the bottom bars at the midsection of the
slab as that of the top bars over intermediate supports. Every alternate
bottom bar when cranked up at 1/5th of the span serves as the top bar
over supports which should be extended upto a distance equivalent to
1/4th of the adjacent span. When the cranking of bottom bars in two
adjacent spans is done in a staggered manner, the spacing of top bars at
supports becomes the same as that of the bottom bars at the mid-span.
 Shear stress in concrete is generally small and bond stress within
allowable limits. Stirrups are not used in slabs whether it is reinforced
one way or both ways.
WAFFLE SLAB (GRID SLAB)
 It is a type of reinforced concrete slab that contains square grids with deep sides.
 Waffle slab construction process includes fixing forms, placement of pods on
shuttering, installation of reinforcement between pods, installation of steel mesh on
top of pods, and pouring of concrete.
 Grid slabs are suitable for spans of 9-15m and live loads of 4-7KN/m2. Formwork,
including the use of pans, is quite expensive.

FLAT PLATES
 Flat plates can be constructed as one-way or two-way slabs and it is directly supported
by columns or walls.
 It is easy to construct and requires simple formworks.
 Flat plates are most suitable for spans of 6 to 8m, and live loads between 3 and
5KN/m2. Added to that, the range of spans for prestressed flat plates is between 8-
12m, and it can also be constructed as post-tensioned slabs.
  The advantages of adopting flat plates include low-cost formwork, exposed flat
ceilings, and faster construction. Flat plates have low shear capacity and relatively
low stiffness, which may cause noticeable deflection.

FLAT SLABS
 This is typically a reinforced slab supported directly by columns or caps, without the
use of beams.
 This type of slab is generally easy to construct and requires little formwork.
 The loads are directly transferred to the columns.

Flat slabs are most suitable for spans of 6 to 9m, and for live loads of 4-7KN/m2.
They need more formwork than flat plates, especially for column capitals. In most cases, only
drop panels without column capitals are used. It can be constructed as a post-tensioned flat
slab.

HOLLOW CORE SLAB

 It is a type of precast slab through which cores are run. Not only do these cores
decline slab self-weight and increase structural efficiency but also act as service
ducts.
 It is suitable for cases where fast constructions are desired.
  There is no restriction on the span of the hollow core slab units, and their standard
width is 120mm and depth ranges from 110mm to 400mm.
 The slab units are commonly installed between beams using cranes and the gaps
between units are filled with screeds.
 It has been observed that, hollow core slab can support 2.5 kN/m2 over a 16m span.
 It is suitable for offices, retail or car park developments.

BUBBLE DECK SLAB

 It is constructed by placing plastic bubbles which are prefabricated and the
reinforcement is then placed between and over plastic bubbles and finally, fresh
concrete is poured.
 The plastic bubbles replace the ineffective concrete at the center of the slab.
 Bubble Deck slabs reduce weight, increase strength, larger spans can be provided,
fewer columns needed, no beams or ribs under the ceiling are required. Consequently,
not only does it decline the total cost of construction but it is also environmentally
friendly since it reduces the amount of concrete.
PURPOSE
A slab is a structural element, made of concrete that is used to create flat horizontal surfaces
such as floors, roof decks and ceilings. A slab is generally several inches thick and supported
by beams, columns, walls, or the ground.

 To Provide a flat surface

 To support load

 To act as Sound, heat and fire insulator

 The upper slab becomes the ceiling for the storey beneath it

 Space between slab and ceiling can be used for placing building utilities

ADVANTAGES OF RCC SLAB

 It’s a Good Long-Term Investment
People build their dream houses because they want to enjoy that property for as long
as possible. And if you‘re looking for roofing system that you can rely on for many
years, concrete is one of your best bets.
 What‘s great about concrete roofing is that it‘s still on the affordable side, yet it
doesn‘t make it less of a good choice because there are other promising qualities to
look forward to. Its price starts at $4 per square foot which is considered as a low to a
mid-range type of material based on its cost.
A concrete roofing can stay intact and sturdy for more than 50 years. Some properties
built with concrete even last for up to a century. It‘s one of the most long-lasting
roofing materials available in the market. To reach its maximum performance, you
need to partner with a credible roofing partner. This is to make sure that the
installation is done correctly and according to the industry‘s standard.

 It can Withstand Harsh Weather Conditions

Worried about the threats of Mother Nature? Calamities come and go. It‘s difficult to
gauge the intensity as well as the timing. Sometimes it just arrives unexpectedly. If
you want total protection all year round, we can recommend going for a concrete
roofing because it can effectively shield the property. It doesn‘t easily break and it can
resist strong impacts.

 Hassle-Free Maintenance
As busy people, we don‘t want to be disturbed from our day-to-day tasks. However,
it‘s also our responsibility to focus on our roofing‘s needs so that it wouldn‘t give us
many headaches in the future. If this is something that you are dreading about, there‘s
a good news. Flat concrete roofs are generally low maintenance, meaning they are
easy to clean and aren‘t too difficult to access.
Like any other roofing, debris and dirt can pile up over time. However, roofers can
easily remove these from the surface without damaging the roof itself.

 Tried and Tested Durability

Concrete material is proven to be tough and durable. As a matter of fact, it‘s not only
used for roof construction. There are many other different forms of usage but they all
boil down to its strength and stability. You can see concrete in building walls,
residential flooring, even in large-scale projects like bridges and dams, among others.
Many industries rely on concrete for their construction needs because of its tried and
tested durability.
If you want to experience the strength of concrete, it‘s not enough that you choose the
most premium materials available in the market. You also have to consider the
installation process as well as the maintenance procedures that will follow.

DISADVANTAGES OF RCC SLAB

 Leakage Problems
Concrete isn‘t waterproof. While it can protect the property from storms, snow, hail,
and other natural phenomena, it has the tendency to absorb water. And when this
happens, you know for a fact that unwanted water damages could follow through
(particularly leakage and moisture retention).
 The problem with leaks is that it can worsen over time. There are instances when
leaks aren‘t even visible to normal eyes. Thus, the water damage proliferates and
spreads throughout the property. When these things happen, the structural integrity
goes down to a critical level.For every roofing concern, there is a solution. In this
case, you have to be more hands-on. You need to end every opportunity for leaks to
spread immediately. This is possible if you‘ll partner with a licensed roofing
company. They can handle difficult roofing inspection tasks and recommend
necessary roof repair procedures to avoid further water damages to take place.

 Plant Growth
Plant growth is a common issue among surfaces that retain moisture. Since concrete
cannot repel water, there‘s a tendency for water to stick around especially if you don‘t
notice it. When there‘s water, plants like fungi, molds, and mildew can easily
proliferate.
The good thing about concrete is that you can easily remove these plants along with
the streaks and marks that they leave behind. Some people use a pressure washer to
completely erase the traces of molds. To make sure that they wouldn‘t come back
again, be sure to follow the recommended roof inspection schedule.

 Installation Process
Concrete is somehow tricky. It comes off as a soft and malleable material, then it
turns into a completely solid structure. If you don‘t have much experience in dealing
with concrete, you wouldn‘t be able to set it up the right way. In some cases, experts
even use reinforced joints during the installation process. Improper installation and
poor workmanship can compromise the outcome and could even make it more prone
to leakage. Furthermore, it could also shorten the supposedly long lifespan.

COMPARISON BETWEEN DIFF ROOF TYPES

Steel Roof
 adequate strength against high tensile stresses,
 Roofs of buildings that have large spans between supports are constructed by steel.
 These types of roofs are lightweight materials such as sandwich panels manufactured
by aluminium, zinc, PVC, or rock wool.
 Mostly, used on industrial buildings and not suitable for the regions that receive
intense snow precipitation.
Reinforced concrete roof
 This type of roofs is constructed to provide perfect thermal insulation and to have a
strong and long-lasting roof structure.
 It can be built in different forms such as framework, arch, and shell.
 The most popular type of such roofs are reinforced concrete flat roof (RCFR).

Wooden roof
 It is also called as free standing wooden roof (FSWR).
 Tile is the typical covering material of this roof.
 Such a roof is erected on load-bearing walls, beams, or a reinforced concrete floor.
When it is erected on walls or beams, span between supports should be a maximum of
4 metres.
 This type of wooden roofs is built on detached house or farm structures in rural areas.
 The other type (i.e., a wooden roof erected on a reinforced concrete floor) is preferred
in the majority of low- or high-rise housing buildings in Turkey as it is easily and
economically constructed.
  It is mostly applied together with middle-sloped and hipped roof types.

RAW MATERIALS FOR RCC SLAB ROOF

Cement
Coarse aggregate

Fine aggregate

M.S. Steel bar

Binding wire

Water

Shuttering materials such as wooden Ballies, Planks, and Iron Plates etc.
VARIOUS RATIOS OF RCC
RCC denotes Re-in forced Cement Concrete in which cement, sand and Bajri are laid with
the help of mild steel. This is most important part of the structure. Generally 1:2:4 and 1:1.5:
3 ratios of RCC are used in construction work.

RCC 1:2:4
Where cement concrete 1:2:4 is used; it means 1 part of cement, 2 parts of fine
aggregate/coarse sand and 4 parts of coarse aggregate. This ratio of cement concrete gives
high strength of cement concrete and is recommended for following works.
• For general RCC work in buildings
• Bed plates
• Lintels
• RCC shelves
• Pavement etc.

RCC 1:1.5:3
Where cement concrete 1:1.5:3 is used; it means 1 part of cement 1..5 part of fine
aggregate/coarse sand and 3 parts of coarse aggregate. This ratio of concrete also gives very
high strength of cement concrete and is recommended for following works.
• Structure carries in heavy loads
• Important RCC structures such as columns, beams, slabs, cantilever, Chhajja, porch, and
balcony etc.
• Minimize the effects of earthquakes.
• Gives more strength accordingly if Tor or Ribbed steel is used with cement concrete
1:1.5:3.

LIMITATIONS/CHALLENGES
How Much Weight Can a Concrete Roof Support
A concrete roof can safely support around 1,200 pounds (0.54 t) per square foot.
But when leaks, cracking, chipping, and other damage rear its ugly head, that figure can drop
exponentially.
Before asking ―how much weights can a concrete roof support‖, you need to make certain it
is in optimal shape.

INSTALLATION - COMPONENTS, PROCEDURE

MATERIALS AND MACHINERY FOR SLAB CASTING

Batching plant

Concrete pump
Vibrators

Slump tray
Slump cone and other associated tools

Rubber hammer

Chute and CI Pipes

Power float machine

Shovel

SLAB PRE-CONCRETING CHECKS

There are many checks that need to be performed prior to concreting of reinforced concrete
slab:

Checking Slab Formwork

 Check whether the formwork is fixed properly or not for example sleeves and
supports.
  Damaged materials employed for formwork or shutter should not be utilized.
 All formwork surfaces in contact with concrete need to be treated with shuttering oil
and dampen with water sometime prior to concrete placement.
 check the level of the projected top surface of the slab and place level strips if
necessary to mark the exact level.

Checking Slab Reinforcement

 Check and approve that reinforcements are fixed as per the approved drawings.
 Examine reinforcement spacing (including vertical and horizontal spacing) and cover.
 Ensure that adequate supports for reinforcements are provided to prevent any
movement during concreting process.
 Loose ties along the splices of reinforcement bars must be tightened again.
 Free end of binding wires shall be bended inward.

Other pre-concreting checks

 Ensure that workers use safety tools and equipment for example safety helmet, safety
shoes, goggles, gloves, and vest.
 Safety devices and safety warnings should be provided from site entrance to the
casting area.
 Check whether adequate lighting is provided in case of night concreting.
SLAB CONCRETING WORK PROCEDURE
1. Providing Construction Joint
The construction joint shall be pre-decided and fixed prior to start of the concreting. It
is planned to have two construction joints for main building as decided. In case of
major break down of the Batching plant, the additional Construction joint may be left.
The location of the construction joint shall be at the one-third span. Construction joint
shall be straight and have profile of ‗L‘shape so that successive layer of concrete shall
be perfectly bonded with previous laid layer. Preparation of construction joint shall
include roughening, removing all laitance adhering to the joint and application of
thick slurry before start of the new concrete.

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

3. Concrete Pouring
Proper walkways/platforms shall be arranged so that the supports of the pipeline and
manpower are not directly stand on reinforcement.
Sufficient carpenters along with supervisor shall inspect the behavior of supports
below the slab during the casting.
Extra Props shall be stocked below slab to provide additional supports in case of any
failure of supports.
Before discharging concrete from the mixer, concrete shall be inspected and
acceptance shall be conducted like slump tests.
Required number of concrete specimens shall be taken for compressive strength test
and other tests.
It is recommended to discharge the concrete within 90 minutes from the batching
plant loading time.
Compact the concrete properly by using mechanical vibrators, extra vibrator shall be
available in case of any shortage or mechanical problems.
4. Finishing Concrete Surface
Use the power float for the smooth finish surface purpose.
The casted area or member shall be protected by placing barricade to prevent plants
and machineries damaged the concrete.
Concrete pour card shall be filled by Quality Engineer and to be submitted to the
Engineer including concrete delivery notes, this task will be done whenever required.

5. Curing Concrete
The curing shall be started immediately after thumb set of the concrete laid. Hessian
clothe /Plastic shall be covered over the set concrete to reduce moisture evaporation
from the concrete during hardening and thus to minimize shrinkage crazy cracks.
These cracks are inheriting property of the concrete specially appears during casting
of flat surfaces. Final curing shall be done by ponding and stacking water for
minimum period of 7 days.
COMMON DEFECTS IN FLAT/RCC ROOFING
Slopes are not proper and a lot of depression exists on the surface where water is
stagnated.Drip courses are not constructed according to required specifications.
 Broken tiles which create depression are used in tile tracing.
 Support for water tanks is not finished properly.
 Cement concrete ‗Gola‘ with joints of walls and roof is not properly finished.
 Mouth of the rain water pipe is higher than the top ‗Khurra‘.

1. Blisters
 Blisters, as the name suggests, are formed when bubbles of entrapped air get stuck
underneath an already sealed surface and produce bumps of varying sizes.
 These defects are typically identified when the concrete slab is being laid and simply
requires some alteration to the actual concrete mix in order to prevent more blisters
from appearing.
 Blisters are more of an annoyance than they are a structural problem and shouldn‘t
cause any long-term issues for homeowners. In fact, you‘ll probably never know if
your concrete slab even has blisters. You may be able to identify them on a concrete
floor, should you have a basement with exposed concrete.
2. Cracking
 One of the biggest problems with concrete slabs is that they have a tendency to crack
under certain instances. Some common causes of cracking include thermal
contraction, subgrade settlement, drying shrinkage, external or internal restraint to
shortening, and applied loads.
 The construction crew will typically address cracks that develop during hardening.
However, it‘s the ones that develop over time that eventually cause issues for
homeowners. These settlement cracks can develop over embedded items like
reinforcing steel, or adjacent to other foundation materials.
 Aside from external factors, the strength of the concrete is most important in
determining how well it‘s able to prevent cracking. Most people don‘t realize that
concrete comes in a variety of strengths, but the reality is that not all concrete mixes
are equal. Inadequate strengths can lead to future cracks – especially if there are
improperly placed tension control joints.
 Specifically, there are three types of cracks in concrete slabs. Shrinkage cracks aren‘t
severe, because they rarely indicate any structural defect. However, they can
occasionally be a source of radon or water entry into the structure. Settlement cracks
indicate that there was inadequate site preparation when the slab was poured. These
cracks need further analysis to determine whether or not they indicate a larger
problem. Finally, frost heaves are the most serious. They can indicate a substantial
risk and should be dealt with as soon as possible.
3. Curling
 ―Curling is the distortion (rising up) of a slab‘s corners and edges due to differences
in moisture content or temperature between the top and bottom slab,‖ says the
Portland Cement Association. ―The top dries out or cools and shrinks more than the
wetter or warmer portion.‖
 Curling is typically dealt with before it becomes a problem, as it usually shows up
during the drying process. However, if not fixed during construction, curling can lead
to significant cracking in the ensuing years.
4. Surface Scaling/Spalling
 Surface scaling occurs when the surface of hardened concrete degrades to a depth of
1.5mm to 5mm during the first year or so of placement. This is generally the result of
an issue with the curing of the concrete and cannot be controlled by the homeowner.

ROOF REPAIRS & MAINTENANCE

Performance is based on good design, quality materials, proper installation, and a preventive-
maintenance program. Roof maintenance is critical to preventing roof problems and keeping
the roof in watertight condition. Early identification and repair of roof problems will help
provide a long-lasting roof system.

Most concrete roof areas are covered by a waterproof barrier, usually called a waterproof
membrane. These waterproof membranes can come in several different forms and can be
made of many different products
The two main forms of waterproof membranes that are applied to concrete roof areas are:

Sheet membrane types

 Most often made from reinforced bitumen, and also made from plastic sheet derivatives
such as TPO and PVC and rubber compounds.
 Sheet membranes are adhered to the concrete roof substrate by different products and
techniques, including hot flame torch, glues, mechanical fixings, heat welding etc.
Liquid membrane types
 Normally these membranes are any acrylic or polyurethane based high solids coatings
which are applied by brush, roller or spray.
 They are often built up in 2-3 heavy applications and reinforced in high movement areas
with reinforcing fabrics such as fibreglass or polyester cloth.
Our concrete roof repair & maintenance services include:
 Replacement and rectification of existing aged or failing membrane systems
 Removal and replacement of any ballast or covering layers
 Replacement and rectification of any associated perimeter flashings
 Rectification of any new or existing penetrations from plant and machinery refits
 Application of all types of membrane systems

Repairs to Flat Terraced Roof:

Old terraced roofs show cracks. These, when open out, provide passage for rain water,
causing roof leakage. These need to be repaired whenever visible.

Process of repair:
i. The cracks should be cleaned first and given V-shape by cutting with chisel at least 6 mm
wide at the top. Repairing of the cracks may now be done with cement or may be filled with
bituminous mixture.

ii. The cracks should be thoroughly flooded with water and should be allowed to soak in.
Cement sand slurry in the proportion of 1: 3 should be grouted for filling the cracks.

iii. Bituminous mixture or bitumen and sand in the proportion of 1:1 by weight shall be
poured in the cracks and filled solidly in the cleaned and dried cracks.

INSULATION

Without insulation, concrete slabs cast directly on the ground can cause a significant amount
of extraneous energy transfer by conduction, resulting in either lost heat or unwanted heat. In
modern construction, concrete slabs are usually cast above a layer of insulation such as
expanded polystyrene, and the slab may contain underfloor heating pipes. However, there are
still uses for a slab that is not insulated, for example in outbuildings which are not heated or
cooled to room temperature . In these cases, casting the slab directly onto a substrate of
aggregate will maintain the slab near the temperature of the substrate throughout the year,
and can prevent both freezing and overheating.

Lightweight, rigid polyisocyanurate (PIR) foam insulation boards (such as Celotex GA4000
and XR4000), are among the most thermally efficient, commonly available insulation
materials. They keep the depth of the floor construction down, meaning less excavation, and
are easily handled and laid to quickly insulate large areas. Thinner polyisocyanurate (PIR)
foam insulation boards, such as Celotex TB4000, can be considered for the perimeter upstand
insulation.

For low-rise buildings on poor ground, the floor slab can be designed as a ‗raft‘ to act as the
foundation. While Celotex PIR boards have a good compressive strength, they cannot be laid
below a raft slab and take the structural load of the building. They can, however, be installed
above the raft slab, in the same arrangement as described above. For non-domestic uses you
should seek the advice of a structural engineer regarding the suitability of any insulation
product in a specific floor system.
In a solid or ground-bearing (because it is continuously supported by the ground across its
whole area) concrete floor, the choice of insulation position relative to the concrete slab is
commonly linked to the building‘s heating system.
PREVENTION AND REMEDIES

SELECT RIGHT QUALITY CEMENT FOR SLAB

The cement used should have low heat of hydration and after setting it should be water-tight
(impermeable).
The cement which is favourable considering the above aspects is PPC (Portland Pozzolana
Cement). PPC should be used when sufficient time is available for construction. Because the
slab using concrete containing PPC has a slow rate of strength gain, in comparison to OPC.
Since PPC is Grade 33, a higher cement content is required for achieving the same strength as
OPC. So, a Design mix should be adopted preferably when using PPC.
If the time is unavailable and the formwork needs to be reused within a shorter time period,
then OPC 53 is the best cement. Using best practices of construction, OPC 53 grade cement
can be an economical option both in terms of saving time and amount of cement used in
concrete.

OPC 53

SELECT THE RIGHT QUALITY OF AGGREGATES FOR

SLAB
The gradation of aggregates (percentage proportions of various sizes) should be satisfactory
so as to minimise voids and maximize density and compressive strength. This also affects
workability.
Usually coarse aggregates of 20 mm nominal size are used, as they are easily available and
they are usually smaller than one-fifth of the depth of the slab. Coarse aggregate of 10 mm
size is used along with 20mm for better packing density, so as to minimise voids and
maximize density and compressive strength.
The maximum total amount of deleterious materials allowed is 5 percent. The fine aggregates
should not contain salts. River sand should have low silt content, less than 3% by weight, the
fineness modulus to be in the range of 2.6 – 3.0.
 Coarse Aggregates of 20 mm

TO BATCH AND MIX CONCRETE FOR SLAB

At general sites, Cement is batched by its weight or the number of bags of cement (each bag
contains 50 kg of cement). The aggregates are batched by volume, and hence the amount of
water present in them and the bulking of sand should be taken into account.
The moisture content of aggregates should be tested as frequently as possible, so as to
maintain the water-cement ratio constant. Contractors usually add Additional amount of
water for increasing workability. This should be avoided as it decreases the strength and
density of the concrete.
Use chemical admixture to reduce water requirement in concrete to achieve ease of placing
(workability).

CHOOSE RIGHT FORMWORK FOR SLAB CASTING

The formwork has the function of a mould for freshly produced/placed concrete, so that it can
harden and attain the desired shape. It should remain rigid while placing and compacting the
concrete.
The formwork should be water-tight to prevent loss of cement slurry, as it results in decrease
in cement and water content. It also leads to honeycombing of concrete. Brown tape needs to
be affixed at plate joints to make it water-tight.
The formwork should be fitted with connections and props in such a manner that they can be
removed with ease and reused with minimum repairs to them.
The faces of the formwork in contact with the concrete should be cleaned and treated with a
form release agent so as to form a thin uniform coating.
CHOOSE QUALITY REINFORCEMENT FOR SLAB
The reinforcement should be tied properly to minimise the movement of rebars and the
binding ties should not protrude into the cover region /zone.
The spacing between successive re-bars should be maintained and the alternate bars should
be extended 0.3 times the span to the adjacent slab.
The lower reinforcement mat is supported on cover blocks and the upper reinforcement mat is
supported using steel chairs and edge U-bars.
The laps in different bars should be staggered and the lap length should be as prescribed in IS
456 – 2000

DO WATERPROOFING THE SLAB WHILE CASTING

Integral waterproofing for terrace slabs can be carried about by mixing waterproofing
admixtures in the concrete before placing. Integral Waterproofing admixtures are of two
types – crystalline, hydrophobic & powdered/filler. These admixtures reduce the porosity of
the concrete.
 Crystalline Waterproofing Admixture powdered/filler form

COMPACT SLAB PROPERLY

The concrete should be compacted so as to mould it around the reinforcement within the
formwork to eliminate large voids, honeycombs and entrapped air. This results in maximum
density and minimum voids, which ensures high compressive strength
The most commonly used compaction equipment are vibrators, either internal (needle type)
or external (screed/pan type).
Special care should be taken to make sure compaction is properly carried out at the edges &
corners.

FINISH THE SURFACE OF SLAB

The surface of the poured concrete should be finished using a wooden float or rake, as close
as possible to its final plane. This should be done after excess concrete has been removed and
the surface has been levelled using a screed.
Adequate sloping (generally 1 in 45) should be ensured, if it‘s a terrace slab, to facilitate
drainage of rainwater. The valleys should be checked for leakages after the concrete has set
and should be filled with grout in the construction phase itself.
If there is bleed water (water which accumulates at the surface), then the surface should not
be finished, let water evaporate before finishing. Check concrete mix if excess bleeding is
observed.
CURE SLAB CONCRETE
Curing can be done either by ponding or using membranes, it should be carried for 7-10 days.
Ponding is the best method of curing. The slab is divided into smaller rectangular areas using
mortar or clay, and these small ponds are filled with water. This method of curing requires a
large amount of water. Curing should be started 24 hours after casting of concrete.
Membrane curing can be adopted in regions where water is scarce. The membrane is a
waterproof material which is used to cover the slab, which prevents the evaporation of water.

MISCELLANEOUS THINGS TO KEEP IN MIND

The slab should not be overloaded with piles of construction materials after it has been cast.
This should be avoided till 28 days from the day of casting of slab.
Honeycombs (If any) should be finished with polymer modified repair mortar.
De-shuttering of slab should be done 7-10 days or more after casting the slab depending upon
the span and the type of cement used.
The formation of cold joints in the slabs should be avoided, never delay placing of concrete
batched beyond the initial setting time of concrete (~90 min.)

PRECAUTIONS TO BE TAKEN DURING

CONSTRUCTION OF R.C.C. ROOF ON MASONRY
WALL AND PROJECTING OUTSIDE THE BUILDING
 While designing, precaution shall be taken to provide adequate thickness of the slab
and reinforcement at the support and also adequate development length of the
reinforcement beyond the wall, so that they can develop adequate stress.
 During construction, before shuttering and laying of reinforcement, the top of the wall
shall be plastered and smoothened. The tensile steel provided at the support for the
negative moment gets pressed due to walking of the labourers over it. This decreases
the lever arm of the steel resulting in lesser moment of resistance.
 This should be taken care of by suitably providing chairs made of steel bars so that the
steel remains at the correct position. The top of the slab generally comes down a bit
for the same reason and due to inadequate strength of the staging and shuttering. This
also shall be taken care of and constant watch shall be kept during pouring of concrete
and afterwards so that the shuttering and the staging are not disturbed.
 Apart from these, other normal precautions required for R.C. construction is to be
taken to ensure that the shuttering mould was water-tight, the props did not yield or
were not dislodged, packing and compacting of concrete by vibration, maintaining the
desired water-cement ratio and consistency of concrete etc.

REASONS FOR FAILURE OF LIME TERRACING:

Waterproofing of roof assumes great importance as leakage of roof is a common phenomenon and
causes serious discomfort to all. The most common method of waterproofing is by laying lime
terracing 75 mm to 100 mm thick over the R.C.C. slab.

The laid terracing often fails.

The causes of failure are:

a. Dimensional change of thickness

The thickness specified and the actual thickness laid differs. Average 100 mm or 75 mm thick
terracing is specified.

b. Stagnation of water on roof:

Stagnation of water on roof is often observed due to undulation of the surface or due to
chokage of the outlet mouths.

c. Slope:
Slope of the roof surface provided is inadequate for quick drainage of water, specially in
regions of heavy rainfall. Slope should be increased for quick drainage. Quick drainage
would not allow time for absorption and subsequent seepage.

d. Bad quality of materials:

Quality of materials used generally for terracing is not as desired. Limestone from which lime
is manufactured should contain at least 75 % free lime.

e. Skilled labour:
The labourers engaged for lime terracing are mostly unskilled.
Due to all the above causes or any of these, the product lime terracing becomes defective and
all subsequent problems arise.

Alternatives to Lime Terracing:

a. Plastering with sand and cement mortar:

Plastering with sand and cement mortar 1: 4, 20 mm thick and then applying a coat of
bitumen at the rate of 10 kg per 10 sqm of the plastered roof surface will provide a
waterproof course over R.C.C. roof.

b. Cement concrete screed:

Cement concrete screed 1: 1½: 3, 25 mm thick laid in panels of 500 x 500 mm and the
junctions of the panels properly filled and sealed with bituminous sealant will provide a
waterproof course.
c. A layer of single brick laid flat:
A coat of bitumen at the rate of 10 kg per 10 sqm of roof surface shall be applied. Over the
coat of bitumen, a layer of polythene sheet should be laid to completely seal the passage of
water. Polythene layer should be protected by a layer of single bricks laid flat.
The joints are filled with lime surki mortar. The surface is then covered with a coat of
bitumen at the rate of 10 kg per 10 sqm or slightly more according to necessity. The bitumen
would seal the joints.
d. Application of bituminous emulsion:
After cleaning the roof surface and checking the slope for drainage, one or two coats of
bituminous emulsion may be applied with a brush. These can be applied in cold.

e. Laying tarfelt
Tarfelt is a good waterproofing course but it is semi-permanent.
The surface should be checked for slope, and then cleaned. A coat of bitumen is spread
uniformly over which the tarfelt of good quality, having IS mark, should be laid. Over the
tarfelt, again, a layer of bitumen at the rate of 10 kg per 10 sqm should be spread. Finally, the
surface should be protected by sand blinding or spreading of gravel.

f. Laying of tiles:
Tiles may be laid over the R.C.C. roof as waterproofing course. Prior to laying of the tiles,
the roof surface shall be checked for slope and cleaned. If there be any undulation or any
defect, those shall be mended. Tiles — either clay or cement tiles or terrazzo tiles — may be
laid in the same manner and following the specification of laying tiles on the floors.
Waterproofing of roof can also be done by special chemicals — polyurethene, etc
ADVANCEMENTS / INNOVATIONS

SUSTAINABLE CONCRETE

PRECAST CONCRETE
PRECAST USES LESS CONCRETE THAN IN-SITU
CONCRETE
Technically advanced, high quality precast uses less concrete than an in-situ alternative. The
clever designs of precast flooring systems deliver a ‗materialisation benefit‘ – an up to 30 per
cent saving in the volume of concrete that is used in a typical suspended floor.

PRECAST CONCRETE IS ENVIRONMENTALLY

FRIENDLY
Most of a building‘s carbon emissions are during its life. In precast‘s case, the carbon that is
produced during the manufacture of cement is offset, with minimal maintenance costs, lower
heating and cooling costs, and the concrete reabsorbing up to 40 percent of the carbon over the
structure‘s life. In addition, there‘s minimal waste during manufacture and what are otherwise
waste products like fly ash and slag are used. At the end of its life precast structures can be fully
recycled.

PRECAST CONCRETE IS COMFORTABLE AND

HEALTHY
Indoor air quality is critical to the health and wellbeing of families and workers alike. With
precast‘s high thermal mass, a building can be designed with minimal need for artificial heating
and cooling. The stability of the precast over its life delivers an environment free of fumes and
chemicals. And there‘s no need for chemical treatment up front or later on.

PRECAST CONCRETE IS A SAFE, LONG TERM, LOW

COST INVESTMENT
Precast concrete structures are strong, extremely tough and durable and last for years – an
insurer‘s dream. Precast requires almost no maintenance and can offer a substantial energy saving
from its high thermal mass. And peace of mind comes from knowing that it‘s tried and tested, and
that it won‘t burn, rot or be water damaged.

PRECAST CONCRETE IS HIGH QUALITY

Being manufactured in a factory-controlled environment, manufacturing precast employs
advanced technologies in reusable steel moulds, resulting in high quality products and less waste.
 ECO FRIENDLY CONCRETE

What Is Eco-Friendly Concrete?

Concrete that uses less energy in its production & produces less carbon dioxide than normal
concrete is referred to as Eco-friendly or Green Concrete. Environment friendly. Considered
to be cheap to produce. Less energy consumption & greater durability.

Need of Eco-Friendly Concrete?

Need of green concrete for better environment and sustainable construction can be
characterized by the following factors;
Consumption of Natural Resources: More than 5 cubic billion yard concrete is produced
globally, requiring huge natural resources for producing cement and aggregates.
Global Warming: One ton of cement releases one ton of CO2 into the atmosphere
(greenhouse gas) contributes to global warming.
Water Consumption: Concrete industry uses over one trillion gallons of water each year
globally.

Features of Eco-Friendly Concrete

The concrete which can fall in the category of Eco-friendly must have the following
characteristics.
Optimize use of available materials
Better Performance
Enhanced cohesion workability / consistency
Reduced shrinkage / creep
Durability - Better service life of concrete
Reduced carbon footprint
No increase in cost

BRANDS
AMBUJA CEMENT
 Founded and established in the year 1983,
 a part of World‘s second largest Cement Manufacture Company.
 the most trusted brand of cement industry in india and their cements are known for
their good quality cement.
 world‘s lowest cost producer of cement
 emphasize on efficiency and stick to quality while manufacturing cement.
 most awarded Cement Company by Government and autonomous bodies.

ACC CEMENTS
 Established and founded in the year 1936,
 India‘s second largest cement manufacturer company.
 17 Cement factories in almost all key locations in country.
 they have 50 ready mix concrete plants.
 also sell bulk cement for large customers which are cost effective alternate to
bagged cement.
 Their product F2R acc cement is good for roof casting

BIRLA PERFECT PLUS

 Premium quality specially engineered PPC Cement from the house of MP
Birla Cement for specific applications of Foundation, Pillar & Roofing works.
 The product technology has multiple advantages in improving performance &
life of the concrete.
 The highest quality standards have unique characteristics to make high
performance superior grade concrete.

HOW TO CALCULATE THE CONSTRUCTION COST

FOR RCC ROOF SLAB?
In order to make reinforced concrete, first the form work, then the reinforcement cage is
created, and then the right level of concrete mixture is filled and cured for at least a month to
help it reach its full strength. The entire process can be done with the help of a small
contractor, but you need to estimate the construction cost to decide whether the quotation
offered by your contractor is acceptable or not.
The construction cost for RCC roof slab depends on lots of variables like:

 Thickness of slab
 One-way or two-way slab
  Construction method and
 Thickness of beam and column

However, you can get a rough estimate with a simple RCC roof slab steel calculation
formula. To find out the exact amount it will take to construct an RCC roof slab, let‘s take an
example.
If the RCC Roof Slab size is 25 X 20 Sq. Ft. and the concrete mix ratio is 1:2:4 then to find
out the construction cost, you will need to calculate

1. Concrete slab area

2. Concrete cost
3. Labour cost
4. Shuttering cost
5. Steel cost

The steel quantity for the slab will be around 60 to 65 kg per cubic meter. You can take
assistance from civil engineers or market experts to find out the steel cost in your area.

Given that the concrete slab area is 25′ x 20′

To convert it into cubic meter
(25x.3048)x (20x.3048)
= 7.62 x 6.096 = 46.451 Sq meter
The minimum roof slab thickness is 125mm.
So 46.451 x .125
= 5.806 CUM

The Approx ready mix concrete rate is 3000/cum;

and
Labor charges for Mason -3no, MC-4no
= (3×500)+(4×350)
= 2900
Shuttering cost is 500
So the concrete cost = (5.806×3000) + 2900+ 500
= Rs 20819/-
To get a rough idea for the construction cost you can get a hint from this formula, however, in
general, it is assumed that to construct an RCC roof slab the approx cost would be Rs 180 to
200-00 per Sq Ft, where the cost for steel, labor, shuttering and material is included. But
please note, this also vary location to location. E.g construction cost would be different in
cities like delhi, mumbai, gurgaon, chennai, jaipur, chandigarh etc.
CASE STUDIES

Largest Flat Roof with a Single Span

Location: Jaipur, Rajasthan

About Project
 The Satsang Hall is adjacent to the Govind Devji Temple, the personal temple of the
royal family of Jaipur.
 The hall is situated in the City Palace complex (the residence of the Maharaja) in the
old Walled City.

Requirement
 The Govind Devji Temple Trust desired a Satsang Hall that could seat 5,000 devotees at
any given time.
 The primary requirement of the trust was that the hall had a total area of 15,600 Sq. Ft.
should not have any pillars in between.

Solution
 Given the large width of the hall and the requirement of constructing a flat, usable roof,
the only structure that could work was a grid slab.
 A grid or waffle slab is a roof constructed employing a crisscross square grid of deep
ribs.
 The entire grid roof of 36 meters x 38 meters is resting on four peripheral beams, which
are 1420 x 2718 deep.
 The outer beams, in turn, rest on eight columns on the outer periphery, four at the
corners and four in the middle of each side.
 We faced several engineering challenges while designing a structure of this size.
 Our major concern was to minimize the deflection (the sagging of the roof – a
phenomenon that occurs when pillars are distant from each other).
 By increasing the thickness of a very insignificant member (the slab) from 115 mm to
200 mm, the deflection was brought within permissible limits.
 Both the post-tensioning technology and the increase in slab thickness contributed to
creating this structural marvel.
 The location of the Hall was another challenge it had to contend with. The construction
of the roof required 90 trucks to enter the busy site during a period of 36 hours.
 REFERENCE LINKS
 https://www.yourarticlelibrary.com/building-engineering/rcc/r-c-c-roofs-and-
floors/85819
 https://www.gharexpert.com/tips/articles/Construction/1519/Roofing-Ceiling-1519-
RCC-Roofing_0
 http://ecoursesonline.iasri.res.in/mod/page/view.php?id=118890
 https://builtoffsite.com.au/emag/issue-04/10-reasons-precast-concrete-sustainable/
 https://edensstructural.com/understanding-different-concrete-slab-problems-and-
defects/
 https://happho.com/how-avoid-defects-like-cracks-rcc-slab/
 https://www.slideshare.net/Hjafferi/eco-friendlyconcrete-green-concrete
 https://civilsir.com/the-best-cement-for-rcc-roof-slab-construction-in-india-bihar-
jharkhand/
 https://www.mpbirlacement.com/mp-birla-cement-perfect-plus/
 https://theconstructor.org/concrete/slab-casting-work-procedure/1656/
 https://roofandbuildingservice.com.au/services/commercial-industrial-roof-repair-and-
maintenance/concrete-roof-repair-and-maintenance/
 https://www.gharexpert.com/tips/articles/Construction/1519/Roofing-Ceiling-1519-
RCC-Roofing_0
 https://www.sciencedirect.com/science/article/pii/S1877042814020965
 https://theconstructor.org/practical-guide/concrete-slab-construction-cost/28153/
 https://dailycivil.com/one-way-slab-vs-two-way-slab/
 https://ptsindia.net/largest-flat-roof-with-a-single-span/