L & T PROJECT 2016

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SITE LOCATION
Govt. Medical College & Hospital Project, Madhepura
(19th May – 19th June 2016)
PROJECT REPORT
SUBMITTED BY:-
NAME-SHANKAR KUMAR
ROLL NO:-13UCE146
6TH SEMESTER, CIVIL ENGG. (2013 -2017)

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ACKNOWLEDGEMENT
I would like to express my gratitude to all those
who help me the possibility to complete this Voca-
tional (SUMMER) internship.
I whole heartedly thank Mr A.K. SINGH( Project
Manager) for giving me permission, constant encour-
agement and rendering all kinds of support in the
completion of my vocational training.
I would also like to thank Mr Tabeez Hussain
(Safety), Mr Abhishek ray (QA /QC), Mr Satyajit
Sinha (Rebar), Mr J. K. Tiwari, Mr G. Bag
(Formwork), Mr S.Dutta (Planning Manager), Mr
Hazra (CM), for helping and supporting me through-
out. I would like to thank Mr Debraj jana for their
constant encouragement and guidance.
Finally I would like to thank whole team of L&T
Construction for their help, support, interest and val-
uable hints.
With Regards.
Mr SHANKAR KUMAR

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SALIENT FEATURES
GOVT MEDICAL COLLEGE & HOSPITAL PROJECT MADHEPURA
Description Details
Employer Bihar Medical Services & Infrastructure Corporation Limited
Consultant (Design & Supervision) EDMAC Engineering Consultant (India) Pvt. Ltd
Contractor L&T Construction
Location
Near B.N Mandal University, Jhajhat-Sabaila,
District- Madhepura, Bihar-853113
Total Project Duration 24 Months
Land Area 25 Acre (Disputed area 1.5 Acres)
Built Up area 16.6 Lakh Sq ft.
- College 3.56 Lakhs Sq ft
- Hospital 4.61 Lakhs Sq ft
- Residential 7.26 Lakhs Sq ft
- Service Blocks 1.12 Lakhs Sq ft
LOI Date 23rd Jul’14
Work order issue date 7th Nov’14
Commencement Date 22nd Nov’14
Scheduled Completion Date 21st Nov’16
Defect Liability Cum Operation
and Maintenance Period
3 years

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CONTENTS
1. Introduction of project 6-12
Site Profile
Executive Summary
Site Layout
Area Statement
Hospital Layout
College Block Layout
Staff And Student Housing , Service Building
2. EHS 13-18
3. Preview 19-29
4. QA/QC 30-50
5. Execution 51-52
6. Rebar 53-56
7. Formwork 57-68
8. Concreting 69-80
9. Planning 81-82
10. Other 83-85

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ABOUT THE ORGANIZATION:
Larsen & Toubro Limited is the biggest legacy of two Danish Engineers, who
built a world-class organization that is professionally managed and a leader
in India's engineering and construction industry. It was the business of cement
that brought the young Henning Holck-Larsen and S.K. Toubro into India.
They arrived on Indian shores as representatives of the Danish engineering
firm F L Smidth & Co in connection with the merger of cement compa-
nies that later grouped into the Associated Cement Companies.
Together, Holck-Larsen and Toubro, founded the partnership firm of L&T in
1938, which was converted into a limited company on February 7, 1946.
Today, this has metamorphosed into one of India's biggest success stories. The
company has grown from humble origins to a large conglomerate spanning engi-
neering and construction.
Larsen & Toubro Construction is India’s largest construction organisation.
Many of the country's prized landmarks - its exquisite buildings, tallest
structures, largest industrial projects, longest flyover, and highest viaducts -
have been built by it. Leading-edge capabilities cover every discipline of
construction: civil, mechanical, electrical and instrumentation.
L&T Construction has the resources to execute projects of large magni-
tude and technological complexity in any part of the world. The business of
L&T Construction is organized in six business sectors which will primarily
be responsible for Technology Development, Business Development, Interna-
tional Tendering and work as Investment Centres. Head quarters in Chennai, In-
dia. In India, 7 Regional Offices and over 250 project sites. In overseas it
has offices in Gulf and other overseas locations.
L&T Construction’s cutting edge capabilities cover every discipline of construc-
tion –civil, mechanical, electrical and instrumentation engineering and ser-
vices extend to large industrial and infrastructure projects from concept to
commissioning.
L&T Construction has played a prominent role in India’s industrial and infra-
structure development by executing several projects across length and breadth of
the country and abroad. For ease of operations and better project manage-
ment, in-depth technology and business development as well as to focus atten-
tion on domestic and international project execution, entire operation of L&T
Construction is structured into four Independent Companies

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BUILDING & FACTORIES
The Buildings & Factories Independent Company is equipped with the
domain knowledge, requisite expertise and wide-ranging experience to un-
dertake Engineering, Procurement and Construction (EPC) of all types of build-
ing and factory structures.
• Commercial Buildings & Airports
 Residential Buildings & Factories
COMMERCIAL BUILDINGS
L&T possesses the capability for the design and construction of Hospitals in-
cluding procurement, installation and commissioning of medical equipment.
L&T undertakes turnkey construction of international class hotels, entertainment
centers, serviced apartments, commercial mall and mixed use developments.

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1. Introduction of project
Site Profile
Executive Summary
Sr. No Description Details
1. Seismic zone V
2. Terrain Plan
3. Soil Profile Silty Sand
4. Monsoon season June September
5. Annual rainfall 1168mm
6. Temperature Max. 36 deg Min. 9 deg. Centigrade
7. Water Table Varying From 1.5m to 4m
Description Details
Project duration 24 Months
Built-up area 16.6 Lac sq. Ft.
Estimated Cost
Due Date For Bid Submission Before 15 Hours On
14th
April 2014
Tender Validity 120 Days
Maintenance Period 3 Years

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Site layout
The site is irregular in plan measuring 25 acre in area and is the part of 180 acre
of B.N.Mandal University. The site is flanked by 60 ft. wide road on the Western
side. On the northern site lies the and of Engineering college and southern side
agriculture land. It consist 33 Buildings.
Area Statement
Sr. No. Building Type Built Up Area
(Sq. Ft.)
Zone
1. Hospital 496507A
2. Medical College 292423B
3. Nursing College 33207B
4. Residential 730698C
5. Other Faculties 96229—-
6. Services 14822—-
7. Total Built Up Area 1663886—--

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Hospital Buildings (Zone A)
G+5 (BUA 70244 Sq.
Ft)
G+3 (BUA 54439 Sq.
Ft)
G+6 (BUA 108112 Sq. Ft)
G+6 (BUA 108112 Sq.
Ft)
G+6 (BUA 108112 Sq.
Ft)

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College Buildings (Zone B)
Service Block and Other
NURSE RESIDENTIAL
G+7
Service Block-3
Boundary Wall
Length 2000 Meters (Front
Cleared for 1200 Meters)
G+3 (BUA 93388 Sq. Ft) G+3 (BUA 70245 Sq. Ft)
G+3 (BUA 85422 Sq. Ft)

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Residential buildings (Zone C)
Senior Residential
G+4
GIRL
HOSTEL
G+7 (BUA 343760 Sq. Ft)
G+4

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2.Environmental Health & Safety (EHS)
INTRODUCTION
Safety ensures the health and hygiene of people at working Site and keep safe
from dangers .In IS CODE ISWHO 18007-2007 .The rules of safety should be fol-
lowed .it help in maintain progress of project without any interruption .
Safety Required for:-
1. Human Suffering
2. Job Security
3. Quality
4. Productivity
5. Reputation
6. Statutory Requirement
Remember Thing at Working Site
1. Smoking & Alcohol Prohibited.
2. Don’t shelter under parked vehicle.
3. Avoid short-cuts in works.
4. Don’t use mobile during work.
5. Don’t pass or stand under the suspended load .
6. Don’t sleep in the workplace.
7. Don’t indulge horseplay or quarrel at workplace.
8. Don’t take up any electrical work; get it done by an authorized electrician.
9. Don’t throw any object..

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Basic EHS Rule :-
1. Follow all the Safety Rule at workplace.
2. Get all the information about own work.
3. Don’t go at restricted place.
4. Use PPE; like helmet, shoes, reflective jacket, goggles, gloves etc.
5. Any defect at workplace inform to supervisor.
Environmental Health & Safety (EHS) Policy

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Personal Protective Equipment (PPE)
The equipment which are used to
Protects our own body from danger
Is known as PPE.
Personal protective equipment are :-
1.Helmet
2.Shoes
3.Reflective Jacket
4.Goggles
5.Gloves
Safety devices relevant to site activities
 SAFETY APPLIANCES
The requirement of sufficient number of safety appliances are planned well in
advance and made available at stores.
 HEAD PROTECTION
Every individual entering the site must wear safety helmet, confirming to IS:
2925-1984 with the chinstrap fixed to chin. Helmet is used to protect the head
by falling object and collision of object with head.
Colour of Helmet
To acknowledge the person’s work.

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 FOOT AND LEG PROTECTION
Safety footwear with steel toe is essen-
tial on site to prevent crush injures to
ours toes and injury due to striking
against the object.
1. Safety shoes for every person work-
ing at site.
2. Gum Boot is used during concreting.
 HEARING PROTECTION
Excessive noise causes damages to the inner ear
and permanent loss of hearing. To protect ears use
ear plugs / ear muff as suitable.
 EYE PROTECTION
Person carrying out grinding works, operating breakers,
and those involved in welding and cutting works should
wear safety goggles & face shield suitably. Goggles,
safety spectacles, face shield confirm to IS: 5983-1980.
 HAND AND ARM PROTECTION
While handling cement and concrete & while carrying out hot works like gas
cutting, grinding & welding usage of hand gloves is a must to protect the hand.
1. Cotton Gloves (for materials
handling) -IS: 6994-1973.
2. Rubber & PVC Gloves
(electrical & chemical work)-IS:
4770-1970.
3. Leather Gloves—hot work / han-
dling of sharp edges.

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 RESIPRATORY PROTECTION
Required respiratory protection according to the exposure of
hazards to be provided. In cement store be must wear dust
mask.
 SAFETY NET
Though it is mandatory to wear safety harness while working at height on the
working platforms, safety net of suitable mesh size shall be provided to arrest
the falling of person and materials on the need basis.
 FALL PROTECTION
To prevent fall of person while
working at height, personnel
engaged more than 2m wear stand-
ard Full Body harness should be
conforming to IS: 3521-1999.
1. Lanyard should be of 12mm polypropylene rope and of length not more than
2m
2. Double lanyard based on the requirement

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 FLOOR OPENING PROTECTION
All floor opening shall be closed & barricaded and securely
arrested against any movement.
This should be provided immediately after de-shuttering.
 LIFT SHAFT PROCTECTION
All lift shaft shall be provided with a temporary lift gate with lock & key ar-
rangement .This should be provided immediately after de-shuttering.
Safety
FIRE SAFETY
Fire injures men and materials. Main cause of fire is fuel, heat & oxygen.
For prevent the fire:-
1. Before starting the hot works be must take work to permit from site engineer.
2. At workplace don’t throw matchstick and cigarette.
3. Inflammable object such as diesel petrol should be placed away from general
working site.
ELECTRICAL SAFETY
1. Double insulated cover wire should be used.
2. Electrical cable don’t pass through water.
3. To repair take help of electrician.

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3. Preview
Pile Work
Terminology
Allowable Load: It is load which is applied to a pile after taking into
account its ultimate load capacity, pile spacing, Overall bearing capacity of
the ground, the allowable settlement, negative skin friction including reversal
of loads.
Bearing Pile: A pile formed in the ground for transmitting load of a structure
to the soil by the resistance developed at its tips and or along its surface. It is
either vertical or batter pile. It may be ‘End bearing pile’ or friction pile if it
supports the load primarily along the surface.
Board Compaction Pile: It is bored cast-in-situ with or without bulb. In this
compaction of surrounding ground and freshly filled concrete in pile, bore is
simultaneously achieved by suitable method. A pile with a bulb is called a
“under-reamed bored compaction pile”. Under-reamed pile with more than
one bulb is called Multi-under-reamed pile.
Constant Rate of Penetration (CRP) Test: The ultimate bearing capacity
of preliminary piles and piles which are not used as working piles.
Constant Rate of Uplift (CRU) Test: The ultimate capacity in tension of
preliminary piles and piles which are not used as working piles.
Cut of Level: It is the level where the installed pile is cut off to support the pile
caps or beams.
Datum Bar: A rigid bar placed on immovable supports
Draft Bolt: A metal rod driven into hole bored in timber, the hole being
smaller in diameter than the rod.
Drop of Stroke: The distance through which the driving weight is allowed to
fall for driving the piles.
Factor of Safety: It is the ratio of the ultimate load capacity of a pile to the safe
load of a pile.
Initial Test: This test is carried out with a view to determine ultimate load
capacity and safe load capacity.

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Follower Tube: A tube which is used following the main casing tube and it
requires to be extended further. The inner diameter of the follower tube
should be the same as the inner diameter of casing. The follower tube shall
preferably be an outside guide and should be water tight when driven in
water- bearing strata or soft clays.
Equipment of Pile
DIRECT MUD CIRCULATOR

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The equipment and accessories used for driven cast-in-situ piles shall depend
on type of sub-soil strata, ground water conditions, type of founding material
and penetration etc. Commonly used plants are as per Appendix ‘F’ and
few more are given below:
Dolly: A cushion of hardwood or some suitable material placed on the top of
the casing to receive the blows of the hammer.
Kent Ledge: Dead weight used for applying a test load to a pile.
Shoe: Pile Shoe should be of material as specified in the item. The pile shoes
may be either cast iron or mild steel. Cast iron pile shoes shall be made from
chill hardened iron as used for making grey iron casting confirming to IS
210. The chilled iron point shall be free from blow holes and other surface
defects. Cast steel piles shoe shall be of steel conforming to IS 2644. Straps
or other fastenings to cast pile shoes shall be of steel conforming to IS 1079
and shall be cast into the point to form an integral part of shoe.
Drop Hammer (or Monkey): Hammer, ram or monkey raised by a winch
and allowed to fall under gravity.
Single or Double Acting Hammer: A hammer operated by steam
compressed air or internal combustion, the energy of its blows being derived
mainly from source of motive power and not from gravity along.
Pile Frame (or Pile Rig): A movable steel structure for driving piles in the
correct position and alignment by means of a hammer operating in the guides
or (leaders) of the frame.

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Procedure of Pile driving
(i) Driven cast-in-situ concrete piles are installed by driving a metal casing
with a shoe at the tip/toe and displacing the material laterally.
(ii) These piles may be cast in metal shells which may remain permanently
in place or the casing may be withdrawn which may be termed as uncased
driven cast-in-situ cement concrete piles.
(iii) The metal casing shall be of sufficient thickness and strength to hold in
original form and show no harmful distortion when the adjacent casing is
driven and the driving core if any is withdrawn.
(iv) Driven cast-in-situ concrete piles shall be installed using a properly
designed detachable shoe at the bottom of the casing.
(v) Any liner or bore hole; which is temporarily located and shows partial
collapse that would affect the load carrying capacity of the pile, shall be
rejected or repaired as directed by the Engineer-in- Charge.
Pile Boring
(i) Under-reamed piles may be constructed by selecting suitable
installation techniques at given site depending on sub-soil strata conditions
and type of under-reamed piles and number of bulbs.
(ii) In construction with equipment suggested under Appendix ‘B’
initially boring guide is fixed with its lower frame level for making desired
angular adjustment for piles at batter/rake. Boring is done up to required
depth and under-reaming is completed.
(iii) In order to achieve proper under-reamed bulb, the depth of bore
hole should be checked before starting under reaming. It should also be
checked during under-reaming and any extra soil at the bottom of bore hole;
removed by auger before reinserting the under-reaming tool.
(iv) The completion of desired under-reamed bulb is ascertained by (a) The ver-
tical movement of the handle and (b) When no further soil is cut.
(v) In double or multi under-reamed piles, boring is fist completed to
the depth to the first (top) under-ream only and after completing the under ream-
ing boring is extended further for the second under-ream and the
process is repeated

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Placing of Concrete
(i) Before commencement of pouring of concrete, it shall be ensured
that there is no ingress of water in the casing tubes from bottom. Fur-
ther, adequate control during withdrawal of the casing tube is essential so
as to maintain sufficient head of concrete inside the casing tube at all
stages of withdrawal.
(ii) Wherever practicable concrete should be placed in a clean dry hole
where concrete is placed in dry hole and when casing is present, the top 3 m
pile shall be compacted using internal vibrators. The concrete should
invariably be poured through a trim pipe, with a funnel so that the flow
is directed and concrete can be deposited in the hole without segregation. Care
shall be taken during concreting to prevent as far as possible the segregation
of the ingredients. The displacement or distortion of reinforcement during
concreting and also while extracting the tube shall be avoided.
(iii) Where the casing is withdrawn from cohesive soils for the
formation of cast-in-situ pile, the concreting should be done with necessary
precautions to minimize the softening of the soil by excess water. Where
mud flow conditions exist, the casing of cast-in-situ piles shall not be
allowed to be withdrawn.
(iv) The concrete shall be self compacting and shall not get mixed with
soil, excess water, or other extraneous matter. Special care shall be taken in
silt clays and other soils with tendency to squeeze into newly deposited
concrete and cause necking. Sufficient head of green concrete shall be
maintained to prevent inflow of soil or wager into concrete. The placing of
concrete shall be continuous process from the toe level to the top of pile to
prevent segregation, a tube of tremie pipe ass appropriate shall be used to
place concrete in all piles. To ensure compaction by hydraulic static heads,
rate of placing concrete in the pile shaft shall not be less than 6 m (length of
pile) per hour.
(v) The diameter of the finished pile shall not be less than specified
and a continuous record shall be kept by the Engineer as to the volume of
concrete placed in relation to the length of pile cast. After each pile has been
cast and any empty pile hole remaining shall be protected and back filled as
soon as possible with approved material.
(vi) The minimum embedment of cast-in-situ concrete piles into pile cap shall
be 150 mm. Any defective concrete at the head of the completed pile shall be
cut away and made good with new concrete. The clear cover between the
bottom reinforcement in pile cap from top of pile shall not be less than 30 mm.

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The reinforcement in the pile shall be exposed for full anchorage length
to permit it to be adequately bonded into the pile cap. Exposing such
length shall be done carefully to avoid damaging the rest of the pile. In cases
where the pile cap is to be laid on ground a levelling course with cement con-
crete of Grade M-15 and of 100 mm thickness shall be provided.
(vii) Normally concreting of piles should be uninterrupted. In exceptional
case of interruption of concreting, but which can be resumed within 1 or 2
hours, the trim pipe shall not be taken out of the concrete. Instead it shall be
raised and lowered slowly from time to time to prevent the concrete
around the pipe from setting. Concreting should be resumed by introduc-
ing a little richer concrete with a slump of about 200 mm for each displacement
of the partly set concrete. If the concreting cannot be resumed before final set of
concrete already laid, the pile so cast may be rejected.
(viii) In case of withdrawal of trim pipe out of concrete, either accidental-
ly or to removed a choke in the trim pipe, the trim pipe may be reintro-
duced to prevent impregnation of laitance scum lying on the top of the
concrete already deposited in the bore. The trim pipe shall be gently lowered on
to the old concrete with very little penetration initially. A vermiculite plug
should be introduced in the trim pipe. Fresh concrete of slump between 150 mm
and 175 mm should be filled in the trim pipe which will push the plug forward
and swill emerges out of the trim pipe displacing the laitance/scum. The trim
pipe will be pushed further in steps masking fresh concrete sweep away laitance
scum in its way. When the trim pipe is buried by about 60 to 100 cm,
concreting may be resumed.
(ix) The top of concrete in a pile shall be brought above the cut-off
level to permit removal of all laitance and weak concrete before capping and
to ensure good concrete at the cut-off level for proper embedment into the
pile cap.
(x) Where cut-off level is less than 1.5 metres below the working level
concrete shall be cast to a minimum of 300 mm above cut-off level. For each
additional 0.3 m increase in cut-off level below the working level additional
coverage of 50 mm minimum shall be allowed. Higher allowance may be
necessary depending on the length of the pile. When concrete is placed by
Trim pipe method concrete shall be cast to the piling platform level to
permit
overflow of concrete for visual inspection or to a minimum of one metre
above cut off level. In the circumstances where cut-off level is below ground
water level the need to maintain pressure on the unset concrete equal to or
greater than water pressure should be observed and accordingly length of
extra concrete above cut-off level shall be determined

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Placing concrete under water
(i) Before concreting under water, the bottom of the hole shall be
cleared of drilling mud and all soft loose materials very carefully. In case a hole
is bored with use of drilling mud, concreting should not be taken up
when the specific gravity of bottom slurry is more than 1.2. The drilling mud
should be maintained at 1.5 m above the ground water level. Concreting
under water for cast-in- situ concrete piles may be done either with the use of
tremie method or by the use of approved method specialty designed to
permit under water placement of concrete. General requirements and
precautions for concreting under water are as follows:
(a) The concreting of pile must be completed in one continuous
operation. Also for bored holes, the finishing of the bore, cleaning of the
bore, lowering of reinforcement cage and concreting of pile for full length
must be accomplished in one continuous operation without any stoppage.
(b) The concrete should be coherent, rich in cement with high slump
& restricted water cement ratio.
(c) The tremie pipe will have to be large enough with due regard to
the size of the aggregate. For 30 mm aggregate the tremie pipe should be of
diameter not less than 150 mm and for larger aggregate, larger diameter of
tremie pipe may be necessary.
(d) The first charge of concrete should be placed with a sliding plug
pushed down the tube ahead of it to prevent mixing of water and concrete.
(e) The tremie pipe should always penetrate well into the concrete
with an adequate margin of safety against accidental withdrawal if the pipe is
surged to discharge the concrete.
(f) The pile should be concentrated wholly by tremie and the method
of deposition should not be changed part way up the pile to prevent the
laitance from being entrapped within the pile.
(g) All tremie tubes should be scrupulously cleaned after use.
When concreting is carried out under water a temporary casing should be in-
stalled to the full depth of the bore hole or 2 m into non collapsible
stratum, so that fragments of ground cannot drop from the sides of the hole
into the concrete as it is placed. The temporary casing may not be required
except near the top when concreting under drilling mud.

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Defective Pile
(i) In case defective piles are formed they shall be removed or left in
place whichever is convenient without affecting performance of the adjacent
piles or cap as a whole. Additional piles shall be provided to replace them as
directed.
(ii) Any deviation from the designed location alignment or load
capacity of any pile shall be noted and adequate measures taken well before
concreting of the pile cap and plinth beam, if the deviations are beyond
permissible limit.
(iii) During chipping of the pile, top manual chipping may be
permitted after three days of pile casting pneumatic tools for chipping shall
not be used before seven days after pile casting.
(iv) After concreting the actual quantity of concrete shall be compared
with average obtained from observations actually made in the case of a few
piles initially cast. If the actual quantity is found to be considerably less,
special investigations shall be conducted and appropriate measures taken.
Measurement of Pile
Dimensions shall be measured nearest to a cm. Measurement of length
on completion shall be along the axis of pile and shall be measured up to the
bottom of pile cap. No allowance shall be made for bulking, shrinkage, cut off
tolerance, wastage and hiring of tools, equipment for excavating, driving
etc.
Reinforcement of Pile
(i) The provision of reinforce-
ment will depend on nature and
magnitude of loads, nature of strata
and method of installation. It should
be adequate for vertical loads, lat-
eral load and moments acting indi-
vidually or in combination. It may
be curtailed at appropriate depths
only under the advice of the struc-
tural engineer. However, provision
of reinforcement shall be as speci-
fied in drawing.

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(ii) The minimum area of longitudinal reinforcement (any type or
grade) within the pile shaft should be 0.4 per cent of the sectional area
calculated on the basis of outside area of shaft or casing if used.
(iii) Reinforcement is to be provided in the full length irrespective of any other
considerations and is further subject to condition that a minimum number of
three 10 mm dia. mild steel or three 8 mm dia. high strength steel bars shall be
provided. The transverse reinforcement as circular stirrups shall not be less than
6 mm dia. Mild steel bars at a spacing of not more than the stem diameter or 30
cm, whichever is less.
(iv) For under reamed compaction piles, a minimum number of four
12 mm diameter mild steel or four 10 mm diameter high strength steel bars
shall be provided.
(v) For piles of lengths exceeding 5 m and or 37.5 cm diameter, a
minimum number of six 12 mm diameter HSD bars shall be provided.
(vi) For piles exceeding 40 cm diameter a minimum number of six 12
mm diameter high strength steel bars shall be provided
(vii) The circular stirrups for piles of length exceeding 5 m and
diameter exceeding 37.5 cm shall be bars of 8 mm diameter.
(viii) For piles subject to uplift loads, adequate reinforcement shall be
provided to take full up lift which shall not be curtailed at any stage.
(ix) For piles up to 30 cm diameter, if concreting is done by tremie,
equivalent amount of steel placed centrally, may be provided at sides.
(x) The minimum clear cover over longitudinal reinforcement shall be 50 mm.
In aggressive environment of sulphates etc. it may be increased to 75 mm.
Pile Cap
(i) Pipe cap are generally designed
considering pile reaction as either
concentrated loads or distributed
loads. The depth of pile cap
should be adequate for the shear,
diagonal tension and it should al-
so provide the necessary anchorage
of reinforcement both for the column
and the pile

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(ii) The pile caps may be designed by assuming that the load from
column or pedestal is dispersed at 45º from the top of the cap up to the mid
depth of the pile cap from the based of the column or pedestal. The reaction
from piles may also to be taken to be distributed at 45º from the edge of the
pile, up to the mid depth of the pile cap on this basis, the maximum bending
moment and shear forces should be worked out at critical sections.
(iii) Full dimension of the cap shall be taken as width to analyse the
section for bending and shear in respective direction. Method of analysis and
allowable stresses may be according to IS 456.
(iv) The clear overhang of the pile cap beyond the outermost pile in the group
shall normally be 100 to 150 mm depending upon the size of the pile.
(v) The cap is generally cast over a 75 mm thick levelling course of
concrete. The clear cover for the main reinforcement of cap slab shall be not
less than 75 mm.
(vi) The pile should project 50 mm into the cap concrete. The design
of grade beams if used shall be as given in IS 2911 (Part III)
Form-work/Mould of Pile Cap
(i) Only steel moulds manufactured out of sturdy steel sections and
sheets to cast the required size of the pile are to be used. Timber moulds
shall not be permitted, under any circumstances.
(ii) The mould shall sustain the stresses generated due to the use of
immersion/plate vibrators and some time even form vibrator, depending
upon the size and strength of the pile to be cast.
(ii) The manufacturing of the mould shall be so simple that the sides
could be opened within 16 to 24 hours of casting by simply loosening the
bolts without damaging the edges of the pile.
(iv) Fixing supports for the sides of the mould shall be done from
outside and no use of through bolts through the concrete shall be permitted to
support the opposite sides of the mould.
(v) Proper mechanism shall be introduced to fix the sides to the top of
the casting platform so that the plate from vibrators can be operated without
disturbing the mould.

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(vi) In case of square piles provision for forming clampers of the pile
for the corners shall be made in the mould itself.
(vii) The mould should be such that when the pile is de-moulded all the
surfaces of the pile except the side from which the concrete is laid should get
form finish. No rendering or finishing shall be permitted on any surface of
the concrete after de-moulding.
(viii) Piles whose surfaces are plastered or rendered, edges repaired
etc. shall be rejected and removed from site.
(ix) After every casting, when the sides of the mould are opened the
same shall be cleaned nicely and form oil manufactured by reputed company
shall be applied over the surface before the mould is adjusted for filling the
concrete, for next pile. The normal practice of applying grease mixed with
diesel or waste oil instead of the form-oil shall not be permitted.

30
4.Quality Assurance & Control (QA & QC)
Quality is the key component which propels performance and defines lead-
ership traits. At L&T Construction, Quality Standards have been internal-
ised and documented in Quality Assurance manuals. L&T Construction recog-
nizes the crucial significance of the human element in ensuring quality.
Structured training programmes ensure that every L&T employee is con-
scious of his/her role and responsibility in extending L&T Construction’s
tradition of leadership through quality. A commitment to safety springs from a
concern for the individual worker every one of the thousands braving the
rigours of construction at numerous project sites. L&T, Buildings & Factories
IC has a well-established and documented Quality Management System (QMS)
and is taking appropriate steps to improve its effectiveness in accordance
with the requirements of ISO 9001:2008. Relevant procedures established
clearly specify the criteria and methods for effective operation, control and
necessary resources and information to support the operation and monitor-
ing of these processes.
QUALITY IMPLEMENTATION AT SITE
L&T, Buildings & Factories IC has established procedure for monitoring, meas-
uring and analysing of these processes and to take necessary actions to
achieve planned results and continual improvement of these processes. It has
also maintained relevant procedures to identify and exercise required control
over outsourced processes, if any. Systems and procedures have been estab-
lished for implementing the requisites at all stages of construction and they
are accredited to the International standards of ISO 9001:2008, ISO
14001:2004 and OHSAS 18001:2007. L&T continues to maintain the trail blaz-
ing tradition of meeting the stringent quality standards and adherence to time
schedules in all the projects.
PROJECT QUALITY PLAN (PQP):
The Project Quality Plan is prepared and formulated as a Management Summary
of Quality related activities required to meet the terms of contract. This Quality
plan sets out the Management practices and describes the Quality Management
System based on PDCA (Plan, Check, Do and Act) Principle.
PURPOSE:
This Project Quality Plan is prepared and formulated as a Management
Summary of Quality related activities required to meet the terms of contract.
This Quality plan sets out the Management practices and describes the Quality
Management System.

31
List of Mandatory Tests
Materials Test Field / Lab
test
Test proce-
dure
Min.
quantity
of mate-
rial for
the test
Water i) PH value
ii) Limits of acidity
iii)Limits of alkality
iv) Percentage of solids
Lab
Lab
Lab
Lab
IS 3025 —
Cement i) Fineness
ii) Soundness
iii)Consistency
iv) Setting time (Initial
& Final )
v) Compressive
strength
Lab
Lab
Lab
Lab
Lab
IS 4031 (Part II)
IS 4031 (Part
III)
IS 4031 (Part
VI)
IS 4031 (Part V)
IS 4031 (Part
VI)
Each lot
Sand i) Silt content
ii) Particle size distri-
bution
iii)Bulking of sand
Field
Field / Lab
Field
Appendix C
Appendix B
Appendix D
20 cum
40 cum
20 cum
Aggregate i) Aggregate impact
value
ii) Flakiness & Elonga-
tion index
iii)DLBD
iv) Specific gravity
Lab
Lab
Lab
Fresh con-
crete
i) Slump Field
Hard con-
crete
i) Compressive
strength
Lab
Reinforce-
ment
i) Rolling margin
ii) Bend & Rebend
iii)Tensile strength
Lab
Lab
Lab
Brick i) Compressive
strength
ii) Water absorption
Lab
Lab

32
TEST OF CEMENT
FINENESS
AIM
To determine the fineness of cement by dry sieving as per IS: 4031 (Part 1) -
1996
PRINCIPLE
The fineness of cement is measured by sieving it through a standard sieve. The
proportion of cement, the grain sizes of which, is larger than the specified mesh
size is thus determined.
APPARATUS
1. 90µm IS Sieve
2. Balance capable of weighing 10g to the nearest 10mg
3. A nylon or pure bristle brush, preferably with 25 to 40mm bristle, for clean-
ing the sieve.
PROCEDURE
1. Weigh approximately 10g of cement to the nearest 0.01g and place it on the
sieve.
2. Agitate the sieve by swirling, planetary and linear movements, until no more
fine material passes through it.
3. Weigh the residue and express its mass as a percentage R1, of the quantity
first placed on the sieve to the nearest 0.1 %.
4. Gently brush all the fine material off the base of the sieve.
5. Repeat the whole procedure using a fresh 10g sample to obtain R2. Then cal-
culate R as the mean of R1 and R2 as a percentage, expressed to the nearest 0.1
%. When the results differ by more than 1 % absolute, carry out a third sieving
and calculate the mean of the three values.
REPORTING OF RESULTS
Report the value of R, to the nearest 0.1 %, as the residue on the 90µm sieve.

33
CONSISTENCY
AIM
To determine the quantity of water required to produce a cement paste of stand-
ard consistency as per IS: 4031 (Part 4) - 1988.
PRINCIPLE
The standard consistency of a cement paste is defined as that consistency which
will permit the Vicat plunger to penetrate to a point 5 to 7mm from the bottom
of the Vicat mould.
VICAT APPARATUS
Vicat apparatus conforming to IS: 5513 - 1976 Balance, whose permissible vari-
ation at a load of 1000g should be +1.0g Gauging trowel conforming to IS:
10086 - 1982.
PROCEDURE
i) Weigh approximately 400g of cement and mix it with a weighed quantity of
water. The time of gauging should be between 3 to 5 minutes.
ii) Fill the Vicat mould with paste and level it with a trowel.
iii) Lower the plunger gently till it touches the cement surface.
iv) Release the plunger allowing it to sink into the paste.
v) Note the reading on the gauge.
vi) Repeat the above procedure taking fresh samples of cement and different
quantities of water until the reading on the gauge is 5 to 7mm.
Express the amount of water as a percentage of the weight of dry cement to the
first place of decimal.
INITIALAND FINAL SETTING TIME
AIM
To determine the initial and the final setting time of cement as per IS: 4031 (Part
5) -1988.

34
APPARATUS
Vicat apparatus conforming to IS: 5513 - 1976 Balance, whose permissible vari-
ation at a load of 1000g should be +1.0g Gauging trowel conforming to IS:
10086 - 1982.
PROCEDURE
i) Prepare a cement paste by gauging the cement with 0.85 times the water re-
quired to give a paste of standard consistency.
ii) Start a stop-watch, the moment water is added to the cement.
iii) Fill the Vicat mould completely with the cement paste gauged as above, the
mould resting on a non-porous plate and smooth off the surface of the paste
making it level with the top of the mould. The cement block thus prepared in the
mould is the test block.
INITIAL SETTING TIME
Place the test block under the rod bearing the needle. Lower the needle gently in
order to make contact with the surface of the cement paste and release quickly,
allowing it to penetrate the test block. Repeat the procedure till the needle fails
to pierce the test block to a point 5.0 ± 0.5mm measured from the bottom of the
mould . The time period elapsing between the time, water is added to the cement
and the time, the needle fails to pierce the test block by 5.0 ± 0.5mm measured
from the bottom of the mould, is the initial setting time.
FINAL SETTING TIME
Replace the above needle by the one with an annular attachment. The cement
should be considered as finally set when, upon applying the needle gently
to the surface of the test block, the needle makes an impression therein, while
the attachment fails to do so. The period elapsing between the time, water is
added to the cement and the time, the needle makes an impression on the surface
of the test block, while the attachment fails to do so, is the final setting time.
The results of the initial and the final setting time should be reported to the near-
est five minutes.

35
TEST OF AGGREGATE
SIEVE ANALYSIS
AIM
To determine the particle size distribution of fine and coarse aggregates by siev-
ing as per IS: 2386 (Part I) - 1963.
PRINCIPLE
By passing the sample downward through a series of standard sieves, each of
decreasing size openings, the aggregates are separated into several groups, each
of which contains aggregates in a particular size range.
APPARATUS
A SET OF IS SIEVES
i) A set of IS Sieves of sizes - 80mm, 63mm, 50mm, 40mm, 31.5mm, 25mm,
20mm, 16mm, 12.5mm, 10mm, 6.3mm, 4.75mm, 3.35mm, 2.36mm, 1.18mm,
600µm, 300µm, 150µm and 75µm
ii) Balance or scale with an accuracy to measure 0.1 percent of the weight of the
test sample.
PROCEDURE
i) The test sample is dried to a constant weight at a temperature of 110 + 5oC
and weighed.
ii) The sample is sieved by using a set of IS Sieves.
iii) On completion of sieving, the material on each sieve is weighed.
iv) Cumulative weight passing through each sieve is calculated as a percentage
of the total sample weight.
v) Fineness modulus is obtained by adding cumulative percentage of aggregates
retained on each sieve and dividing the sum by 100.
The results should be calculated and reported as:
i) the cumulative percentage by weight of the total sample
ii) the percentage by weight of the total sample passing through one sieve and
retained on the next smaller sieve, to the nearest 0.1 %.

36
WATER ABSORPTION
AIM
To determine the water absorption of coarse aggregates as per IS: 2386 (Part III)
-1963.
APPARATUS
i) Wire basket - perforated, electroplated or plastic coated with wire hangers for
suspending it from the balance
ii) Water-tight container for suspending the basket
iii) Dry soft absorbent cloth - 75cm x 45cm (2 nos.)
iv) Shallow tray of minimum 650 sq.cm area
v) Air-tight container of a capacity similar to the basket
vi) Oven SAMPLE A sample not less than 2000g should be used.
PROCEDURE
i) The sample should be thoroughly washed to remove finer particles and dust,
drained and then placed in the wire basket and immersed in distilled water at a
temperature between 22 and 32oC.
ii) After immersion, the entrapped air should be removed by lifting the basket
and allowing it to drop 25 times in 25 seconds. The basket and sample should
remain immersed for a period of 24 + 1⁄2 hrs. afterwards.
iii) The basket and aggregates should then be removed from the water, allowed
to drain for a few minutes, after which the aggregates should be gently emptied
from the basket on to one of the dry clothes and gently surface-dried with the
cloth, transferring it to a second dry cloth when the first would remove no fur-
ther moisture. The aggregates should be spread on the second cloth and exposed
to the atmosphere away from direct sunlight till it appears to be completely sur-
face-dry. The aggregates should be weighed (Weight 'A').
iv) The aggregates should then be placed in an oven at a temperature of 100 to
110oC or 24hrs. It should then be removed from the oven, cooled and weighed
(Weight 'B').
Water absorption = [(A-B)/B] x 100%

37
AGGREGATE IMPACT VALUE (AIV)
AIM
To determine the aggregate impact value IS 2386(Part IV),1983
APPRATUS
I. Impact testing machine
II. Sieve size of 2.36,10,12.5mm.
Preparation of test sample:
a) Take a sample of aggregate passing through 12.5mm IS sieve & retained on a
10mm sieve.
b) Dry the aggregate sample in oven for a period of for hours at a temperature of
100-1100
C and then cool it.
c) Fill the measure in three layers and tamp each layer by 25 stocks of temping
rod .
d) determine net weight of aggregate (A) in the measured.
Test Procedure
a) Place the test sample in the cup
b) Compact the sample by subjecting it to 25 stocks with the tamping rod.
c) Compact the sample by subjecting it to 15 blows oh hammer at an interval of
does not less than 1 seconds. Raise the hammer 380mm above the upper sur-
face of aggregate and allow it to fall freely on the aggregate.
d) Remove the crushed aggregate from the cup.
e) Sieve the aggregate 2.36 mm sieve.
f) Sieve the aggregate passing through the sieve (B)
g) Weigh the aggregate retain on the sieve (C)
h) Discard the result if the total weight (B+C) is less than initial weight (A) and
make the fresh sample repeat the test twice.
Calculation
AIV (%) =BX100/A.

38
FLAKINESS INDEX
AIM
To determine the flakiness index of coarse aggregate IS : 2386 (Part I)
APPRATUS
a) Balance
b) Metal gauge
c) Sieve set
PROCEDURE
a) Take the sample about the 3 Kg.
b) Divide the sample into four quadrants.
c) Select to opposite quadrants and sieve them through the sieves arrange in the
following order 63mm 50mm 40mm 31.5mm 25mm 20mm 16mm 12mm
10mm 6.3mm
d) Take the aggregate sample sieve through the 63 mm and retained on 50 mm
sieve find the weight W1 gm.
e) Pass the sample through the 63-50mm size of thickness gauge
f) Find the weight of aggregate passing through the respective slot (i.e. through
63-50mm) of the gauge W1 gm.
g) Repeat the sample procedure with 50-40mm, 40-25mm, 31.5-25mm, 25-
20mm, 20-16mm, 16-12.5mm, 10-6.5mm size of the thickness gauge
CALCULATION
Flakiness index =weight of passing aggregate/ total weight of aggregate
SPECIFIC GRAVITY
AIM
To find out specific gravity of sample IS: 2720 (Part III) section 1-1980
APPRATUS
a) Pycnometer bottle
b) Conical brass cap &washer

39
PROCEDURE
a) Clean pycnometer and dry it.
b) Find the mass(M1) of pycnometer, brass cap &washer
c) Take about 500gm of oven sample & put in pycnometer.
d) Find the mass of pycnometer filled with oven dried sample(M2).
e) Fill the pycnometer to half of its height with distilled water & mix it thor-
oughly with a glass rod.
f) Add more water &stir it.
g) Replace the screw top &fill pycnometer flush with the hole in the conical cap.
Dry pycnometer from outside &fill the mass (M3).
h) Empty pycnometer , clean it thoroughly &fill it with distilled water up to the
hole of conical cap & find the mass (M4)
CALCULATION
Specific gravity=(M2 -M1)/(M2 -M1)-(M3-M4)
TEST OF SAND
SILT CONTENT
AIM
To determine the silt content in sand
PROCEDURE
a) Fill the jar with 100ml water
b) Add to it of NaOH & prepare NaOH solution
c) Add sample of sand in the measuring jar up to height of 100ml Approx.
d) Fill the jar with additional 100ml water
e) Stir the contents in the jar thoroughly and allow it settle 10-15 mins.
f) Measure the height of sand layer (d1) and height of silt layer (d2) in the jar
CALCULATION
Silt content %=d2X100/d1
The sand shall not contain more than 8% of silt as determined by field test with
measuring cylinder.

40
BULKING OF SAND
AIM
To change the volume of sand with water content
Method -1:Put sufficient quantity of sand loosely into a container until it is
about two-third full. Level off the top of the sand and push a steel rule vertically
down through the sand at the middle to bottom, measure the height. Suppose
this is ‘X’ cm. Empty the sand out of the container into another container where
none of it is lost. Half fill the first container with water. Put back about half the
sand and rod it with a steel rod, about 6 mm in diameter, so that its volume is re-
duced to a minimum. Then add the remainder and level the top surface of the
inundated sand. Measure its depth at the middle with the steel rule. Suppose this
is ‘Y’ cm. The percentage of bulking of the sand due to moisture shall be calcu-
lated from the formula:
Percentage bulking = (X/Y -1) X 100
Method-2: In a 250 ml measuring cylinder, pour the damp sand, consolidate it
by staking until it reached the 200 ml mark. Then fill the cylinder with the water
and stir the sand well (the water shall be sufficient to submerge the sand com-
pletely). It will be seen that the sand surface is now below its original level.
Suppose the surface is at the mark of Yml, the percentage of bulking of sand due
to moisture shall be calculated from the formula.
Percentage bulking= (200/Y – 1) x 100
TEST OF BRICK
COMPRESSIVE STRENGTH
AIM
To determine the compressive strength of concete.
SPECIMAN
Five whole bricks shall be taken from the samples as specimens for this test.
Length and width of each specimen shall be measured correct to 1 mm

41
APPRATUS
The apparatus consists of compression testing machine, the compression plate of
which shall have a ball seating in the form of portion of a sphere the centre of
which shall coincide with the centre of the plate.
PROCEDURE
(a) Pre-conditioning: The specimen shall be immersed in the water for 24 hours
at 25ºto 29ºC. Any surplus moisture shall be allowed to drain at room tempera-
ture. The frog of the bricks should be filled flush with mortar 1:3 (1 cement : 3
clean coarse sand of grade 3 mm and down) and shall be kept under damp jute
bags for 24 hours, after that these shall be immersed in clean water for three
days.
After removal from water, the bricks shall be wiped out of any traces of mois-
ture.
(b) Actual Testing: Specimen shall be placed with flat faces horizontal and
mortar filled face upward between three 3 ply plywood sheets each of thickness
3 mm and carefully centred between plates of the testing machine. Plaster of
Paris can also be used in place of plywood sheets to ensure a uniform surface.
Load shall be applied carefully axially at uniform rate of 14 N/mm2 per minute
till the failure of the specimen occurs.
Reporting the Results
The compressive strength of each specimen shall be calculated in N/mm2as un-
der :
Maximum load at failure (in N)
Compressive Strength = ————————————————
Area of Specimen (in sq. mm)
In case the compressive strength of any individual brick tested exceeds the up-
per limit of the average compressive strength specified for the corresponding
class of brick, the same shall be limited to the upper limit of the class specified
in 6.1.2 for the purpose of calculating the average compressive
strength. Compressive strength of all the individual bricks comprising the sam-
ple shall be averaged and reported.
Criteria for Conformity
A lot shall be considered having satisfied the requirements of average compres-
sive strength if the average compressive strength specified in 6.1.2 for the corre-
sponding class of brick tested is not below the minimum average compressive
strength specified for the corresponding class of bricks by more than 20 per
cent.

42
WATER ABSORPTION
AIM
To determine the water absorption of aggregate.
SPECIMAN
Five whole bricks shall be taken from samples as specimen for this test.
APPRATUS
A balance required for this test shall be sensitive to weigh 0.1 percent of the
weight of the specimen.
PROCEDURE
(a) Pre-conditioning: The specimen shall be allowed to dry in a ventilated oven
at a 110°C to 115°C till it attains a substantially constant weight. If the specimen
is known to be relatively dry, this would be accomplished in 48 hours, if the
specimen is wet, several additional hours may be required to attain a constant
weight. It shall be allowed to cool at room temperature. In a ventilated room,
properly separated bricks will require four hours for cooling, unless electric fan
passes air over them continuously in which case two hours may suffice.
The cooled specimen shall be weigh (W1) a warm specimen shall not be used
for this purpose.
(b) Actual Testing: Specimen shall be completely dried before immersion in the
water. It shall be kept in clean water at a temperature of 27°C ± 2°C for 24
hours. Specimen shall be wiped out of the traces of water with a damp cloth af-
ter removing from the water and then shall be weighed within three minutes af-
ter removing from water (W2).
Reporting the Test Results
The water absorption of each specimen shall be calculated as follows and the
average of five tests shall be reported.
Water absorption=(W2-W1)X100/W1
Criteria for Conformity
A lot shall be considered having satisfied the requirements of water absorption if
the average water absorption is not more than 20% by weight.

43
TEST OF FRESH CONCRETE
SLUMP
AIM
To determine the workability of fresh concrete by slump test as per IS: 1199 -
1959.
APPARATUS
i) Slump cone
ii) Tamping rod
PROCEDURE
i) The internal surface of the mould is thoroughly cleaned and applied with a
light coat of oil.
ii) The mould is placed on a smooth, horizontal, rigid and non- absorbent sur-
face.
iii) The mould is then filled in four layers with freshly mixed concrete, each ap-
proximately to one-fourth of the height of the mould.
iv) Each layer is tamped 25 times by the rounded end of the tamping rod
(strokes are distributed evenly over the cross- section).
v) After the top layer is rodded, the concrete is struck off the level with a trowel.
vi) The mould is removed from the concrete immediately by raising it slowly in
the vertical direction.
Vii) The difference in level between the height of the mould and that of the
highest point of the subsided concrete is measured.
viii) This difference in height in mm is the slump of the concrete.
The slump measured should be recorded in mm of subsidence of the specimen
during the test. Any slump specimen, which collapses or shears off laterally
gives incorrect result and if this occurs, the test should be repeated with another
sample. If, in the repeat test also, the specimen shears, the slump should be
measured and the fact that the specimen sheared, should be recorded.

44
TEST OF HARD CONCRETE
COMPRESSIVE STRENGTH OF CUBE
AIM
To find out compressive strength of cube
APPRATUS
i) Compressive testing machine– capacity 100 tonnes hand operated
ii) Specimen dimension 150mm X 150mm X 150mm.
PROCEDURE
a) Remove the cube from the water after curing period
b) Place the cube in the compression testing machine in such a way that the load
can be applied to the faces other than top and bottom of the cube as cast
c) Apply the load gradually without any shock at the rate of 31.5 per minute un-
til cube fails to make any more load
CALCULATION
Compressive strength = failure load (Kg)
Surface area of cube in cm2
REBOUND HAMMER TEST
If a rebound hammer is regularly used by trained personnel in accordance with
procedure described in IS 13311 (part II) and a continuously maintained individ-
ual charts are kept showing a large number of reading and the relation between
the reading and strength of concrete cubes made from the same batch of con-
crete, such charts may be used in conjunction with hammer readings to obtain an
approximate indication of the strength of concrete in a structure for element. If
calibration charts are available from manufactures, it can be used. When making
rebound hammer test each result should be the average of at least 12 readings.
Reading should not be taken within 20mm of the edge of concrete members and
it may be necessary to distinguish between readings taken on a trowled face and
those on a moulded face. When making the tests on a precast unit, special care
should be taken to bed them firmly against the impact of the hammer

45
TEST OF SOIL
OMC & MDD TEST
This test is done to determine the maximum dry density and the optimum mois-
ture content of soil using heavy compaction as per IS: 2720 (Part 8 ) – 1983.The
apparatus used is:-
i) Cylindrical metal mould – it should be either of 100mm dia. and 1000cc vol-
ume or 150mm dia. and 2250cc volume and should conform to IS: 10074 –
1982.
ii) Balances – one of 10kg capacity, sensitive to 1g and the other of 200g capaci-
ty, sensitive to 0.01g
iii) Oven – thermostatically controlled with an interior of non corroding material
to maintain temperature between 105 and 110oC
iv) Steel straightedge – 30cm long
v) IS Sieves of sizes – 4.75mm, 19mm and 37.5mm
PREPARATION OF SAMPLE
A representative portion of air-dried soil material, large enough to provide about
6kg of material passing through a 19mm IS Sieve (for soils not susceptible to
crushing during compaction) or about 15kg of material passing through a 19mm
IS Sieve (for soils susceptible to crushing during compaction), should be taken.
This portion should be sieved through a 19mm IS Sieve and the coarse fraction
rejected after its proportion of the total sample has been recorded. Aggregations
of particles should be broken down so that if the sample was sieved through a
4.75mm IS Sieve, only separated individual particles would be retained.
Procedure To Determine The Maximum Dry Density And The Optimum Mois-
ture Content Of Soil
A) Soil not susceptible to crushing during compaction –
i) A 5kg sample of air-dried soil passing through the 19mm IS Sieve should be
taken. The sample should be mixed thoroughly with a suitable amount of water
depending on the soil type (for sandy and gravelly soil – 3 to 5% and for cohe-
sive soil – 12 to 16% below the plastic limit). The soil sample should be stored
in a sealed container for a minimum period of 16hrs.
ii) The mould of 1000cc capacity with base plate attached, should be weighed to
the nearest 1g (W1 ). The mould should be placed on a solid base, such as a con-
crete floor or plinth and the moist soil should be compacted into the mould, with
the extension attached, in five layers of approximately equal mass, each layer
being given 25 blows from the 4.9kg rammer dropped from a height of 450mm
above the soil. The blows should be distributed uniformly over the surface of
each layer. The amount of soil used should be sufficient to fill the mould, leav-
ing not more than about 6mm to be struck off when the extension is removed.
The extension should be removed and the compacted soil should be levelled

46
off carefully to the top of the mould by means of the straight edge. The mould
and soil should then be weighed to the nearest gram (W2).
iii) The compacted soil specimen should be removed from the mould and placed
onto the mixing tray. The water content (w) of a representative sample of the
specimen should be determined.
iv) The remaining soil specimen should be broken up, rubbed through 19mm IS
Sieve and then mixed with the remaining original sample. Suitable increments
of water should be added successively and mixed into the sample, and the above
operations i.e.
ii) to iv) should be repeated for each increment of water added. The total number
of determinations made should be at least five and the moisture contents should
be such that the optimum moisture content at which the maximum dry density
occurs, lies within that range.
B) Soil susceptible to crushing during compaction –
Five or more 2.5kg samples of air-dried soil passing through the 19mm IS
Sieve, should be taken. The samples should each be mixed thoroughly with dif-
ferent amounts of water and stored in a sealed container as mentioned in Part A)
C) Compaction in large size mould –
For compacting soil containing coarse material upto 37.5mm size, the 2250cc
mould should be used. A sample weighing about 30kg and passing through the
37.5mm IS Sieve is used for the test. Soil is compacted in five layers, each layer
being given 55 blows of the 4.9kg rammer. The rest of the procedure is same as
above.
Bulk density Y(gamma) in g/cc of each compacted specimen should becalculat-
ed from the equation,
Y(gamma) = (W2-W1)/ V
where, V = volume in cc of the mould.
The dry density Yd in g/cc
Yd = 100Y/(100+w)
The dry densities, Yd obtained in a series of determinations should be plotted
against the corresponding moisture contents, w. A smooth curve should be
drawn through the resulting points and the position of the maximum on the
curve should be determined The dry density in g/cc corresponding to the maxi-
mum point on the moisture content/dry density curve should be reported as the
maximum dry density to the nearest 0.01. The percentage moisture content cor-
responding to the maximum dry density on the moisture content/dry density
curve should be reported as the optimum moisture content and quoted to the
nearest 0.2 for values below 5 %, to the nearest 0.5 for values from 5 to 10 %
and to the nearest whole number for values exceeding 10 %.

47
WATER CONTENT
1. OVEN DRY METHOD
AIM
To determine the water content in soil by oven drying method as per IS: 2720
(Part II) - 1973.
PRINCIPLE
The water content (w) of a soil sample is equal to the mass of water divided by
the mass of solids.
APPARATUS
i) Thermostatically controlled oven maintained at a temperature of 110 ± 5oC
ii) Weighing balance, with an accuracy of 0.04% of the weight of the soil taken
iii) Air-tight container made of non-corrodible material with lid
iv) Tongs
SAMPLE
The soil specimen should be representative of the soil mass. The quantity of the
specimen taken would depend upon the gradation and the maximum size of par-
ticles as under:
PROCEDURE
i) Clean the container, dry it and weigh it with the lid (Weight 'W1').
ii) Take the required quantity of the wet soil specimen in the container and
weigh it with the lid (Weight 'W2').
iii) Place the container, with its lid removed, in the oven till its weight becomes
constant (Normally for 24hrs.).
iv) When the soil has dried, remove the container from the oven, using tongs.
v) Find the weight 'W3' of the container with the lid and the dry soil sample.
The water content w = [(W2 −W3) ×100%] /(W3 −W1)

48
2.CALCIUM CARBIDE METHOD(RAPID MOISTURE METER TEST)
AIM
To determine the water content in soil by calcium carbide method as per IS:
2720 (Part II) - 1973.
PRINCIPLE
It is a method for rapid determination of water content from the gas pressure
developed by the reaction of calcium carbide with the free water of the soil.
From the calibrated scale of the pressure gauge the percentage of water on total
mass of wet soil is obtained and the same is converted to water content on dry
mass of soil.
APPARATUS
i) Metallic pressure vessel, with a clamp for sealing the cup, along with a gauge
calibrated in percentage water content
ii) Counterpoised balance, for weighing the sample
iii) Scoop, for measuring the absorbent (Calcium Carbide)
iv) Steel balls - 3 steel balls of about 12.5mm dia. and 1 steel ball of 25mm dia.
v) One bottle of the absorbent (Calcium Carbide)
PREPARATION OF SAMPLE
Sand - No special preparation. Coarse powders may be ground and pulverized.
Cohesive and plastic soil - Soil is tested with addition of steel ball in the pres-
sure vessels. The test requires about 6g of sample.
PROCEDURE
i) Set up the balance, place the sample in the pan till the mark on the balance
arm matches with the index mark.
ii) Check that the cup and the body are clean.
iii) Hold the body horizontally and gently deposit the levelled, scoop-full of the
absorbent (Calcium Carbide) inside the chamber.
iv) Transfer the weighed soil from the pan to the cup.
v) Hold cup and chamber horizontally, bringing them together without disturb-
ing the sample and the absorbent.
vi) Clamp the cup tightly into place. If the sample is bulky, reverse the above
placement, that is, put the sample in the chamber and the absorbent in the cup.
vii) In case of clayey soils, place all the 4 steel balls (3 smaller and 1 bigger) in
the body along with the absorbent.

49
viii) Shake the unit up and down vigorously in this position for about 15 se-
conds.
ix) Hold the unit horizontally, rotating it for 10 seconds, so that the balls roll
around the inner circumference of the body.
x) Rest for 20 seconds.
xi) Repeat the above cycle until the pressure gauge reading is constant and note
the reading. Usually it takes 4 to 8 minutes to achieve constant reading. This is
the water content (m) obtained on wet mass basis.
xii) Finally, release the pressure slowly by opening the clamp screw and taking
the cup out, empty the contents and clean the instrument with a brush.
The water content on dry mass basis,
W = (m/100 – m)*100%
IN-SITU DRY DENSITY (CORE CUTTER METHOD)
AIM
To determine the in-situ dry density of soil by core cutter method as per IS: 2720
(Part XXIX) - 1975.
APPARATUS
i) Cylindrical core cutter
ii) Steel dolley
iii) Steel rammer
iv) Balance, with an accuracy of 1g
v) Straightedge
vi) Square metal tray - 300mm x 300mm x 40mm
vii) Trowel
PROCEDURE
i) The internal volume (V) of the core cutter in cc should be calculated from its
dimensions which should be measured to the nearest 0.25mm.
ii) The core cutter should be weighed to the nearest gram (W1).
iii) A small area, approximately 30cm square of the soil layer to be tested should
be exposed and levelled. The steel dolly should be placed on top of the cutter
and the latter should be rammed down vertically into the soil layer until only
about 15mm of the dolly protrudes above the surface, care being taken not to
rock the cutter.

50
The cutter should then be dug out of the surrounding soil, care being taken to al-
low some soil to project from the lower end of the cutter. The ends of the soil
core should then be trimmed flat in level with the ends of the cutter by means of
the straightedge.
iv) The cutter containing the soil core should be weighed to the nearest gram
(W2).
v) The soil core should be removed from the cutter and a representative sample
should be placed in an air-tight container and its water content (w) determined .
Bulk density of the soil γ= (W2 −W1)/V g /cc
Dry density of the soil γd = [100γ/100+w] g cc
QUALITY ASSURANCE
QUALTY LAB

51
5.Execution
METHOD STATEMENT FOR CIVILAND MECHANICAL
1. METHOD STATEMENT FOR CIVIL
METHOD STATEMENT FOR SURVEY WORKS
OBJECTIVE: To formulate guidelines for Setting out and routine survey
works
REFERENCE:
1. Drawing
2. Technical Specifications for Civil works
3. Inspection and test plan
4. Survey Layout showing control stations
MAJOR EQUIPMENTS:
Calibrated Auto - level, Theodolite (LC-1"), Total
Station and necessary measuring tools
METHOD STATEMENT FOR BUILDING UP OF PILES UPTO
CUTOFF LEVEL
OBJECTIVE: Building up of Plies up-to cut-off levels
REFERENCE:
1. Drawing
2. Technical Specifications for Civil works
3. Technical Data sheet of Nitobond EP
METHOD STATEMENT FOR REINFORCEMENT WORK
1. OBJECTIVE: This procedure covers method for cutting, bending and
tying of reinforcement and inspection of works.
2. REFERENCE: Reinforcement placing and handling shall be as per IS-456
MAJOR EQUIPMENTS: Bar cutting & bending machines, rebar tying tool.
METHOD STATEMENT FOR FORMWORK
1. OBJECTIVE: This Procedure covers fixing and removal of formwork and
checking of formwork.
2. REFERENCE:
1. Approved Drawings
2. 2. IS 456 & IS 6461(Part 5)
3. Tender Document

52
METHOD STATEMENT FOR BOLTS PROCUREMENT & FIXATION
1. OBJECTIVE: This Procedure covers procuring and fixing of bolts.
2. REFERENCE:
1. Tender Specification
METHOD STATEMENT FOR CONCRETING WORKS
1. OBJECTIVE: This Procedure covers fixing and removal of formwork and
checking of formwork.
2. REFERENCE:
1. Tender Specification
3. IS 10262, IS 3370 & IS 456
4. IS 383
METHOD STATEMENT FOR BACKFILLING
1.OBJECTIVE: The scope of back-filling covers the filling in plinths, pits,
trends, depressions in layers 200mm thick including watering and compaction
by Roller / plate compactor.
2. REFERENCE:
1. Drawing
2. Bill of Quantities

53
6. Rebar
The steel used for reinforcement shall be any of the following types:
(a) Mild steel and medium tensile bars conforming to IS 432 (Part I)
(b) High strength deformed steel bars conforming to IS 1786
(c) Hard drawn steel wire fabric conforming to IS 1566
(d) Structural steel conforming to Grade A of IS 2062
(e)Thermo-mechanically treated (TMT) Bars.
Elongation % on gauge length is 5.65 A1/2
is the cross sectional areas of the test
piece.
Mild steel is not recommended for the use in structures located in earthquake
zone subjected to severe damage and for structures subjected to dynamic load-
ing (other than wind loading) such as railway and highway bridges.
Welding of reinforcement bars covered in this specification shall be done in ac-
cordance with the requirements of IS 2751.
Nominal mass/weight :The tolerance on mass/ weight for round and square
bars shall be the percentage of the mass/ weight calculated on the basis that the
masses of the bar/ wire of nominal diameter and of density 7.85 kg/ cm3or
0.00785 kg/mm3
METHOD FOR REINFORCEMENT WORK
1.All reinforcement shall be placed above the ground by using wooden sleepers
or concrete blocks.
2.For reinforcement, care shall be taken to protect the reinforcement from expo-
sure to saline atmosphere during storage, fabrication and use.
3.Against requirement from site, bars shall be cut and bent to shape and dimen-
sion as shown in bar bending schedule based on Good For Construction (GFC)
drawings.
4.Reinforcement shall be tied as per the latest GFC drawing and any extra bars
provided at site shall be recorded in the pour card/ lap register.
5.Unusable cut rods and scrap reinforcement shall be properly placed at yard.
Bar Bending Schedule: 1.Prepare bar bending schedule based on the latest
GFC drawings and to be submitted to Engineer for review
2.Bar bending schedule shall clearly specify the following:
a) Bar dia.
b) Numbers.
c) Cut-lengths.
d) Shapes

54
3.Bar bending schedule shall take into account the following field/ design re-
quirement.
a) Desirable lap locations and staggering of laps.
b) Lap lengths.
c) Development length/ Anchorage length.
BAR BENDING SHEDULE (BBS)
Structure B2 Grid Size 300 X 600 Date 06-06-16
Location A1(first) DWG. No Contractor Total weight MT 0.325
Sr. No. Bar
Mark
Dia. Spacing Shape of bar Cutting
length
No. of bars Weight
1 Top 25 10515 3 121.71
2 Bottom 25 10515 3 121.71
3 Anchor-
age bar
16 2225 6 21.12
4 Stirrup 8 2252 61 54.27
Structure C4 Grid Size 650 X 1150 Date 05-06-16
Location H5(2-3) DWG. No Contractor Total weight MT 0.325
Sr. No. Bar
Mark
Dia. Spacing Shape of bar Cutting
length
No. of bars Weight
1 Master
ring
12 3472 27 74.07
2 Middle
ring
12 1779.2 27 42.7
3 Inner
ring
12 1567.6 108 150.49
4 Link bar 12 738 27 17.72

55
Cutting, Bending and Placing:
1.All reinforcement shall be free from loose mill scales, loose rust and coats of
paints, oil, mud or any other substances which may destroy or reduce bond. Use
wire brush to clean the reinforcement.
2.Cutting and bending shall conform to the details given in the approved bar
bending schedule.
a) Cutting of Rebar by heat is not permitted, only cutting by grinding or shear-
ing is permitted.
b) No heating is allowed to facilitate bending of Rebar.
3.Place the reinforcement as per GFC drawings ensuring the following aspects
properly.
a) Type & size of bar.
b) Number of bars.
c) Location and lengths of laps, splices.
d) Curtailment of bars.
e) In two way reinforcement, check the direction of reinforcement in various
layers.
f) Adequate number of chairs, spacer bars and cover blocks.
g) Size of cover blocks.
h) All the bars shall be tied with double fold 18g soft GI annealed binding wire.
4.Reinforcement may be placed with in the following tolerance whenever re-
quired:
a) for effective depth 200mm or less ±10mm.
b) for effective depth more than 200mm ±15mm.
c) The cover shall in no case be reduced by more than one third of the specified
cover or 0 /+ 10mm.
d) The cover should suit various cover requirement as per Drawing Notes.
5.The sequence of reinforcement shall be correlated with fixing of inserts,
sleeves, conduits, anchors and formworks.
6.In walls, place accurately bent spacer bars wired to vertical or horizontal bars
between successive rows.
7.No steel parts of spacers sure allowed inside the concrete cover. Spacer blocks
made from cement, sand and small aggregate shall match the mix proportion of
the surrounding concrete. Alternatively PVC cover blocks of approved make can
be used.
8.Spacers, cover blocks should be of concrete of same strength or PVC
9.Spacers, chairs and other supports detailed on drawings, together with such
other supports as may be necessary, should be used to maintain the specified
nominal cover to the steel reinforcement.
10.Spacers or chairs should be placed at a maximum spacing of 1.0 mtr. and
closer spacing may sometimes be necessary.
11.All reinforcement shall be placed and maintained in the positions shown in
the drawing by providing proper cover blocks, spacers, Supporting bars. .

56
12.Rough handling, shock loading (Prior to embedment) and the dropping of re-
inforcement from a height should be avoided. Reinforcement should be secured
against displacement.
Method Statement for fixing of rebar coupler
1. Purpose:- Purpose of this procedure to establish monitor and control in con-
struction and methodology as well as quality control procedure which details
the activity & checking of rebar coupling works. This procedure is exercised
to comply the project requirement along with customer satisfaction.
2. Process:- First we should go for threading process. Rebar threading machine
needs to fixed along with a long table in a free space.
A. The end of the bar is swan square.
B. The swan end of the reinforcement is then enlarged by a patented cold forg-
ing process. The core diameter of bar is increased into a pre-determined di-
ameter.
C. Finally the thread is mechanically cut onto the enlarged end of the bar by re-
quired deice.
3.Procedure for inspection:- Below mentioned steps should be followed to
check the same at site for inspection.
A. Check the thread length of the reinforcement.
B. Type and number of threading required.
C. Check the protection of threading by capping.
D. Check the tightness of the coupler by pipe wrench testing.

57
8. Formwork
INTRODUCTION
Form work shall include all temporary or permanent forms or moulds required
for forming the concrete which is cast-in-situ, together with all temporary con-
struction required for their support.
It shall be strong enough to withstand the dead and live loads and forces
caused by ramming and vibrations of concrete and other incidental loads, im-
posed upon it during and after casting of concrete. It shall be made sufficiently
rigid by using adequate number of ties and braces, screw jacks or hard board
wedges where required shall be provided to make up any settlement in the form
work either before or during the placing of concrete.
Form shall be so constructed as to be removable in sections in the desired se-
quence, without damaging the surface of concrete or disturbing other sections,
care shall be taken to see that no piece is keyed into the concrete.
Material for Form Work
(a)Propping and Centring: All propping and cantering should be either of steel
tubes with extension pieces or built up sections of rolled steel.
Cantering/Staging : Staging should be as designed with required extension
pieces as approved by Engineer-in-Charge to ensure proper slopes, as per design
for slabs/ beams etc. and as per levels as shown in drawing.
(a) All the staging to be either of Tubular steel structure with adequate bracings
as approved or made of built up structural sections made form rolled structural
steel sections.
(b) In case of structures with two or more floors, the weight of concrete, cen-
tring and shuttering of any upper floor being cast shall be suitably supported on
one floor below the top most floor already cast.
(c)Form work and concreting of upper floor shall not be done until concrete of
lower floor has set at least for 14 days.
Shuttering: Shuttering used shall be of sufficient stiffness to avoid excessive de-
flection and joints shall be tightly butted to avoid leakage of slurry. If required,
rubberized lining of material as approved by the Engineer-in-Charge shall be
provided in the joints. Steel shuttering used or concreting should be sufficiently
stiffened. The steel shuttering should also be properly repaired before use and
properly cleaned to avoid stains, honey combing, seepage of slurry through
joints etc.
(a) Runner Joists: RSJ, MS Channel or any other suitable section of the required
size shall be used as runners.

58
(b) Assembly of beam head over props. Beam head is an adopter that fits snugly
on the head plates of props to provide wider support under beam bottoms.
(c) Only steel shuttering shall be used, except for unavoidable portions and very
small works for which 12 mm thick water proofing ply of approved quality may
be used.
Form work shall be properly designed for self weight, weight of reinforcement,
weight of fresh concrete, and in addition, the various live loads likely to be im-
posed during the construction process (such as workmen, materials and equip-
ment). In case the height of centring exceeds 3.50 metres, the
prop may be provided in multi-stages.
Camber: Suitable camber shall be provided in horizontal members of structure,
especially in cantilever spans to counteract the effect of deflection. The form
work shall be so assembled as to provide for camber. The camber for beams and
slabs shall be 4 mm per metre (1 to 250 ) or as directed by the Engineer-in-
Charge, so as to offset the subsequent deflection, For cantilevers the camber at
free end shall be 1/50th of the projected length or as directed by the Engineer-in-
Charge.
Walls : The form faces have to be kept at fixed distance apart and an arrange-
ment of wall ties with spacer tubes or bolts is considered best. The two shutters
of the wall are to be kept in place by appropriate ties, braces and
studs, some of the accessories used for wall.
Removal of Form work (Stripping Time) :In normal circumstance and where
various types of cements are used, forms, may generally be removed after the
expiry of the following periods:
Type of Form work Minimum period Be-
fore Striking Form
work for OPC 33
grade
Minimum period
Before Striking
Form work for
OPC 43 grade
Minimum pe-
riod Before
Striking Form
work for PPC
(a) Vertical form work to columns,
walls, beams
16-24 h 16-24 h 24-36 h
(b) Soffit form work to slabs
(Props to be re-fixed immediately
after removal of formwork)
3 days 3 days 4 days
(c) Soffit form work to beams
(Props to be re-fixed immediately
after removal of formwork
7 days 7 days 10 days
(d)Props to slabs:
(1)Spanning up to 4.5m
(2) Spanning over 4.5m
7 days
14 days
7 days
14 days
10 days
20 days
(e) Props to beams and arches:
(1) Spanning up to 6m
(2) Spanning over 6m
14 days
21 days
14 days
21 days
20 days
30 days

59
Surface Treatment
Oiling the Surface : Shuttering gives much longer service life if the surfaces
are coated with suitable mould oil which acts both as a parting agent and also
gives surface protections.
A typical mould oil is heavy mineral oil or purified cylinder oil containing not
less than 5% pentachlorophenol conforming to IS 716 well mixed to a viscosity
of 70-80 centipoises.
After 3-4 uses and also in cases when shuttering has been stored for a long time,
it should be recoated with mould oil before the next use.
The second categories of shuttering oils / leavening agents are Polymer based
water soluble Compounds. They are available as concentrates and when used di-
luted with water in the ratio of 1:20 or as per manufacturer specifications. The
diluted solution is applied by brush applications on the shuttering both of steel
as well as ply wood. The solution is applied after every use.
The design of form work shall conform to sound Engineering practices and
relevant IS codes.
Inspection of Form Work The completed form work shall be inspected and
approved by the Engineer-in-Charge before the reinforcement bars are placed in
position.
Proper form work should be adopted for concreting so as to avoid honey comb-
ing, blow holes, grout loss, stains or discoloration of concrete etc. Proper and
accurate alignment and profile of finished concrete surface will be ensured by
proper designing and erection of form work which will be approved by Engineer
-in-Charge.
Shuttering surface before concreting should be free from any defect/ deposits
and full cleaned so as to give perfectly straight smooth concrete surface. Shut-
tering surface should be therefore checked for any damage to its surface and ex-
cessive roughness before use.
Erection of Form Work (Centring and shuttering): Following points shall be
borne in mind while checking during erection.
(a) Any member which is to remain in position after the general dismantling is
done, should be clearly marked.
(b) Material used should be checked to ensure that, wrong items/ rejects are not
used.
(c) If there are any excavations nearby which may influence the safety of form
works, corrective and strengthening action must be taken.
(d) (i) The bearing soil must be sound and well prepared and the sole plates
shall bear well on the ground. (ii) Sole plates shall be properly seated on their
bearing pads or sleepers. (iii) The bearing plates of steel props shall not be dis-
torted. (iv) The steel parts on the bearing members shall have adequate bearing
areas.

60
(e) Safety measures to prevent impact of traffic, scour due to water etc. should
be taken. Adequate precautionary measures shall be taken to prevent accidental
impacts etc.
(f) Bracing, struts and ties shall be installed along with the progress of form
work to ensure strength and stability of form work at intermediate stage. Steel
sections (especially deep sections) shall be adequately restrained against tilting,
over turning and form work should be restrained against horizontal loads. All
the securing devices and bracing shall be tightened.
(g) The stacked materials shall be placed as catered for, in the design.
(h) When adjustable steel props are used. They should: 1. be undamaged and not
visibly bent. 2. have the steel pins provided by the manufacturers for use. 3. be
restrained laterally near each end. 4. have means for centralizing beams placed
in the fork heads.
(i) Screw adjustment of adjustable props shall not be over extended.
(j) Double wedges shall be provided for adjustment of the form to the required
position wherever any settlement/ elastic shorting of props occurs. Wedges
should be used only at the bottom end of single prop. Wedges should not be too
steep and one of the pair should be tightened/ clamped down after adjustment to
prevent shifting.
(k) No member shall be eccentric upon vertical member.
(l) The number of nuts and bolts shall be adequate.
(m) All provisions of the design and/or drawings shall be complied with.
(n) Cantilever supports shall be adequate.
(o) Props shall be directly under one another in multistage constructions as far
as possible.
(p) Guy ropes or stays shall be tensioned properly.
(q) There shall be adequate provision for the movements and operation of vibra-
tors and other construction plant and equipment.
(r) Required camber shall be provided over long spans.
(s) Supports shall be adequate, and in plumb within the specified tolerances.
STEEL WALL FORMWORK

61
ADJUSTABLE CURVED WALL FORM

64
L & T FORMWORK SYSTEM
1. Foundation form work
2. Wall / column form work
3. Flex system form work & Flex table system
For floor heights up to 4 m using CT props and for floor height up to 5.5m us-
ing Eurex props
4. Heavy duty tower system
For heavy loads and floor heights more than 5.5m
5. L & T Access scaffold system For finishing purposes
6. Stair tower
1. FOUNDATION FORMWORK
Foundation formwork is made up of steel .It is
used for foundation purposes . It should be so easy
to De-shutter so that de-shuttering can be done
within 16-24 hrs .
2. ALUFO COLUMN FORMWORK SYSTEM
it is used for giving support of concrete in designing the shape of column .Alufo
column formwork is basically made-up of aluminium and plywood . the four
major size of formwork is used as :-
1.750x1800 3.450x1800
2.750x1200 4.450x1200

65
3. FLEX SYSTEM
In this system all parts are separable .It consist of
CT PROP , Primary system ,secondary system and sheathing plate. It is also
used for beam and slab casting .if height is below 4.5m between floor .
4.STAIR TOWER
Stair formwork is used for going at first floor or above . the stairs and platforms
are form specially
perforated steel for slip free and safe usage. all staircase and landing double
guard railed together with toe-boards at circumference of platform.

66
5.HEAVY DUTY TOWER SYSTEM
It is used to support the slab and beam where height of floor is greater than
4.5m .the heavy duty tower has greater strength than low duty tower .its size
are .9m,1.2m &1.8m etc. It can bear maximum load of 25 tonnes.
6. .ACCESS TOWER
It is a light duty tower which use only in transporting materials and labour .it is
use only up to 40m .After this their is chance of buckle due to moment . It's
maximum strength is 250kg/sq.m

69
8. Concreting
METHOD FOR CONCRETING
1. Concrete mix design for Different Structure should be as per Notes in the spe-
cific approved drawing
2. For Design Mix Concrete, the mix shall be designed to provide the grade of
concrete having the required strength, workability & durability requirements
given in IS: 456 for each grade of concrete taking into account the type of ce-
ment, minimum cement content and maximum W/C ratio conforming to expo-
sure conditions as per tender specifications.
3. Mix design and preliminary tests are not necessary for Nominal Mix concrete
(M5, M7.5, M10, M15, M20 as Specified in IS 456 - Table 9) .However works
tests shall be carried out as per IS:456
4. No concreting shall be done without the approval of engineer. Prior notice
shall be given before start of concreting.
5. Cement shall be measured by weight in weigh batching machines of an ap-
proved type, aggregate shall be measured by volume / weight. The machines
shall be kept clean and in good condition and shall be checked adjusted for ac-
curacy at regular intervals when required by the engineer. Material shall be
weighed within 2.5% tolerances, inclusive of scale and operating errors. The
weigh batching machines / Measuring Boes shall discharge efficiently so that no
materials are retained.
6. Concrete shall be mixed in mechanical mixers of an approved type. In no case
shall the mixing of each batch of concrete continue for less than 2 minutes. The
water to be added in concrete 3.6 shall be adjusted based on moisture contents in
fine and coarse aggregates. During hot and cold weather, suitable methods to re-
duce the loss of water by evaporation in hot weather and heat loss in cold weath-
er will be adopted as per procedure set out in IS: 7861.
7. The compaction of concrete will be done by immersion type needle vibrator
which shall be inserted into concrete in vertical position not more than 450 mm
apart. Vibration will be 3.7 applied systematically to cover all areas immediately
after placing concrete and will be stopped when the concrete flattens and takes
up a glistening appearance or rise of entrapped air ceases or coarse aggregate
blends into the surface but does not completely disappear. The vibrator shall be
slowly withdrawn to ensure closing of the hole resulting from insertion.
8.Unless otherwise approved, continuous concreting shall be done to the full
thickness of 3.8 foundation rafts, slabs, beams & similar members. For placing
on slope concreting will be started at the bottom and moved upwards. Concrete
shall not fall from a height of more than 1m to avoid segregation

70
9. Special care shall be taken to guarantee the finish and Water-Tightness of
concrete for liquid retaining structures, underground structures and those if spe-
cifically mentioned. The minimum 3.9 level of surface finish for liquid retaining
structures shall be Type F-2 and it shall be Hydro tested to approved procedure.
Any leakage during hydro test or subsequently during direct liability period, if
occurred shall be effectively stopped either by cement /epoxy pressure grouting
or any other approved method.
10. Curing of concrete with approved water shall start after completion of Initial
setting time of concrete and in hot weather after 3 hours. Concrete will be cured
for a minimum period of seven days when OPC with high water cement ratio is
used, curing for minimum 10 days in hot weather or low water cement ratio is
used and where mineral admixture used minimum curing period is 14 days.
Freshly laid concrete shall be protected from rain by suitable covering. Curing
shall be done by continous sprays or ponded water or continously saturated cov-
erings of sacking canvas, hessian or other absorbent material for the period of
complete hydration with a minimum of 7 days. Curing shall also be done by
covering the surface with an impermeable material such as Polyethylene ,which
shall be well sealed and fastened. Alternatively Curing compound of approved
make can be applied immediately after stripping of formwork.
11.The workability of concrete shall be checked by the site engineer. 3.12 The
prepared surface shall be inspected and certified in pour card.
12.Staining or discoloration shall be washed out. If surface is not up to the ac-
ceptable standard, as 3.13 per IS 456, cement wash is to be provided on exposed
concrete surface of foundation, beam, column, wall etc.
13.All blemishes and defect if any, shall be rectified immediately after the re-
moval of formwork.
14.For each sample of concrete pour 150mm cubes shall be prepared and
cured.3 no's shall be crushed at 7days and other 3 no's at 28 days. Record shall
be made for each test in enclose doormats as per ITP.
15.PVC water stoppers shall be provided in construction joints as per AFC
drawing confirming to IS-12200. Prior approval shall be taken for location &
material. Alternatively G.I. sheet of 200mm wide and 18 gauge the shall also be
used for the same with the approval of Engineer

71
CONCRETE MIX DESIGN
Concrete is the basic engineering material used in most of the civil engineering
structures. Its popularity as basic building material in construction is because of,
its economy of use, good durability and ease with which it can be manufactured
at site. The ability to mould it into any shape and size, because of its plasticity in
green stage and its subsequent hardening to achieve strength, is particularly
useful.
Concrete like other engineering materials needs to be designed for properties
like strength, durability, workability and cohesion. Concrete mix design is the
science of deciding relative proportions of ingredients of concrete, to
achieve the desired properties in the most economical way.
With advent of high-rise buildings and pre-stressed concrete, use of higher
grades of concrete is becoming more common. Even the revised IS 456-2000
advocates use of higher grade of concrete for more severe conditions of expo-
sure, for durability considerations. With advent of new generation admixtures, it
is possible to achieve higher grades of concrete with high workability levels
economically. Use of mineral admixtures like fly ash, slag, meta kaolin and sili-
ca fume have revolutionised the concrete technology by increasing strength and
durability of concrete by many folds. Mix design of concrete is becoming more
relevant in the above-mentioned scenario.
However, it should be borne in mind that mix design when adopted at site
should be implemented with proper understanding and with necessary pre-
cautions. Durocrete mix design manual is an attempt to increase the aware-
ness among the users, about concrete mix design. It is made with intention
of serving as ready reckoner for personnel, implementing mix design at site.
Advantages of mix design
Mix design aims to achieve good quality concrete at site economically.
I. Quality concrete means Better strength Better imperviousness and durability
Dense and homogeneous concrete
II. Economy
a) Economy in cement consumption
It is possible to save up to 15% of cement for M20 grade of concrete with the
help of concrete mix design. In fact higher the grade of concrete more are the
savings. Lower cement content also results in lower heat of hydration and hence
reduces shrinkage cracks.
b) Best use of available materials:
Site conditions often restrict the quality and quantity of ingredient materials.
Concrete mix design offers a lot of flexibility on type of aggregates to be used in
mix design. Mix design can give an economical solution based on the available
materials if they meet the basic IS requirements. This can lead to saving in trans-
portation costs from longer distances.

72
c) Other properties:
Mix design can help us to achieve form finishes, high early strengths for early
de-shuttering, concrete with better flexural strengths, concrete with pump-ability
and concrete with lower densities.
What is mix design?
Concrete is an extremely versatile building material because, it can be designed
for strength ranging from M10 (10Mpa) to M100 (100 Mpa) and workability
ranging from 0 mm slump to 150 mm slump. In all these cases the basic ingredi-
ents of concrete are the same, but it is their relative proportioning that makes the
difference.
Basic Ingredients of Concrete: -
1. Cement – It is the basic binding material in concrete.
2. Water – It hydrates cement and also makes concrete workable.
3. Coarse Aggregate – It is the basic building component of concrete.
4. Fine Aggregate – Along with cement paste it forms mortar grout and fills the
voids in the coarse aggregates.
5. Admixtures – They enhance certain properties of concrete e.g. gain of
strength, workability, setting properties, imperviousness etc.
Concrete needs to be designed for certain properties in the plastic stage as well
as in the hardened stage.
Properties desired from concrete in plastic stage: - Workability Cohesiveness
Initial set retardation
Properties desired from concrete in hardened stage: - Strength Impervious-
ness Durability
Concrete mix design is the method of correct proportioning of ingredients of
concrete, in order to optimise the above properties of concrete as per site re-
quirements.
In other words, we determine the relative proportions of ingredients of concrete
to achieve desired strength & workability in a most economical way.
Information required for concrete mix design
The site engineer should give following information while giving material for
mix design to the mix design laboratory: -
Grade of concrete (the characteristic strength)
Workability requirement in terms of slump

73
Other properties (if required): -
i. Retardation of initial set (to avoid cold joints in case of longer leads or for
ready mix concrete)
ii. Slump retention (in case of ready mix concrete)
iii. Pump-ability (In case of ready mix concrete)
iv. Acceleration of strength (for precast members or where early deshuttering is
desired)
v. Flexural strength (normally required for concrete pavements)
Ascertain whether condition of exposure to concrete is mild, moderate severe or
very severe. Proper investigation of soil should be done to ascertain presence of
sulphates & chlorides, in case of doubt.
Following factors indicate degree of control at site: -
Batching – weigh batching / volume batching.
Type of aggregates – whether mixed graded aggregate will be used or 20mm,
10mm aggregates will be used separately.
Testing of concrete – whether casting & testing of concrete cubes will be done
regularly at site.
Source of aggregate – whether sources of sand and aggregate will be standard-
ised or likely to change frequently.
Supervision – whether qualified staff will be present to supervise concreting
work and make necessary corrections e.g. correction for moisture in sand and
changes in material properties.
Site laboratory – whether the site will have necessary laboratory equipment like
sieves, weighing balance etc. to check material properties.
Material properties and how they affect mix design Cement
a) Strength/grade of cement: Grade of cement e.g. 43 grade or 53 grade can in-
fluence the mix design. Grade of cement indicates minimum strength of cement
in N/mm2 tested as per standard conditions laid down by IS codes (OPC 43
grade – IS 8112-1989, OPC 53 grade – IS 12269 – 1987 e.g. a 43 grade cement
should give minimum strength of 43 N/mm2 at 28 days). Higher the strength of
cement, higher is the strength of concrete for the same water/cement ratio. In
other words a higher strength of cement permits use of higher water/cement ra-
tio to achieve the same strength of concrete. The IS 10262 - 1982 for mix design
gives the different curves of cement based on the actual strength of cement on
28th day. These cement curves give water/cement ratio required to achieve a
given target strength. Information on grade of cement may not be as useful as
the actual 28days strength of cement. This is because some of the 43 grade ce-
ments practically give strengths more than 53 N/mm2. When a 53-grade cement
is stored for a long time, its strength may deteriorate and become equivalent to
33 grade or 43 grade cement.

74
Thus 28 days strength of cement is required to select the cement curve before
starting the mix design. Finding the 28 days strengths of cement consumes time.
It is not practical in many cases to wait for 28 days strength of cement to start
the mix design. In such cases 28 days strength reports of the manufacturers may
be used and can be supplemented by accelerated strength of cement found by
reference mix method given in IS 10262 Apart from strength of cement, the type
of cement e.g. Ordinary Portland Cement, puzzolana cement (blended cement)
etc, is also important factor affecting the gain of strength. Blended cements
achieve strengths later than Ordinary Portland Cements and require extended
curing period. However, use of these cements result in more durable concrete by
offering greater resistance to sulphate and chloride attacks.
b) Initial & Final setting time of cement: The initial setting time of cement in-
dicates the time after which the cement paste looses its plasticity. Operations
like mixing, placing and compaction should be completed well before the initial
setting time of cement .The minimum initial setting time specified by IS 456 –
2000 (Clause 5.4.1.3 page no 14 and IS 8112-1989 page 2) is 30 minute. Most
of the cements produced today give an initial set of more than 60 minutes. Be-
ginning of hardening of cement paste indicates the final setting of cement. The
maximum limit for final setting permitted by IS 8112: 1989 (Clause 6.3. page 2)
is 600 minute. Most of the cements produced today give a final setting of be-
tween 3 to 5 hours. Curing can be started after final setting of cement. The initial
setting and the final setting can be extended by use of retarders in order to avoid
cold joints when lead-time for placing concrete is longer.
Fine Aggregates
a) Gradation of fine aggregates: The gradation of sand is given by sieve analy-
sis The sieve analysis is done by passing sand through a set of standard sieves
and finding out cumulative passing percentage through each sieve. The IS
383 – 1970 classifies fine aggregates in 4 zones starting from zone I repre-
senting coarse sand, to zone IV representing the finest sand. The limits of cu-
mulative percentage passing for each sieve for above zones are given in table
4 of IS 383 The fineness of sand found by sieve analysis governs the propor-
tion of sand in concrete .The overall fineness of sand is given by factor called
fineness modulus. Fineness Modulus is given by division of the summation
of cumulative retained fractions for standard sieves up to 150-micron sieve
size by 100.
a) Silt Content by weight: This is found by wet-sieving of sand and material
passing 75 micron sieve is classified as silt. This silt affects the workability of
concrete, results in higher water/cement ratio and lower strength. The upper
limit for 75-micron sieve in case of sand is 3% by weight. This limit has how-
ever been extended to 15% in case of crushed sand in IS 383 – 1970 Table 1

75
Coarse Aggregate
a) Maximum size of coarse aggregate: Maximum size of aggregate is the
standard sieve size (40mm, 25mm, 20mm, 12.5mm, 10mm) through which at
least 90% of coarse aggregate will pass. Maximum size of aggregate affects
the workability and strength of concrete. It also influences the water demand
for getting a certain workability and fine aggregate content required for
achieving a cohesive mix. For a given weight, higher the maximum size of
aggregate, lower is the surface area of coarse aggregates and vice versa. As
maximum size of coarse aggregate reduces, surface area of coarse aggregate
increases. Higher the surface area, greater is the water demand to coat the
particles and generate workability. Smaller maximum size of coarse aggre-
gate will require greater fine aggregate content to coat particles and maintain
cohesiveness of concrete mix. Hence 40 mm down coarse aggregate will re-
quire much less water than 20 mm down aggregate. In other words for the
same workability, 40mm down aggregate will have lower water/cement ratio,
thus higher strength when compared to 20mm down aggregate. Because of its
lower water demand, advantage of higher maximum size of coarse aggregate
can be taken to lower the cement consumption. Maximum size of aggregate is
often restricted by clear cover and minimum distance between the reinforce-
ment bars. Maximum size of coarse aggregate should be 5 mm less than clear
cover or minimum distance between the reinforcement bars, so that the aggre-
gates can pass through the reinforcement in congested areas, to produce dense
and homogenous concrete.
It is advantageous to use greater maximum size of coarse aggregate for con-
crete grades up to M 35 where mortar failure is predominant. Lower water/
cement ratio will mean higher strength of mortar (which is the weakest link) and
will result in higher strength of concrete. However, for concrete grades above
M40, bond failure becomes predominant. Higher maximum size of aggregate,
which will have lower area of contact with cement mortar paste, will fail earlier
because of bond failure. Hence for higher grades of concrete (M40 and higher) it
is advantageous to use lower maximum size of aggregate to prevent bond fail-
ure.
The fineness modulus of sand varies from 2.0 to 4.0; higher the FM coarser is
the sand. Type of Sand Fine Medium Coarse - F M - 2.0 to 2.8 - 2.8 to 3.2 - 3.2
and above.
b) Specific gravity of fine aggregates: This is the ratio of solid density parti-
cles to the density of water. Higher the specific gravity, heavier is the sand parti-
cles and higher is the density of concrete. Conversely a lower specific gravity of
sand will result in lower density of concrete. Specific gravity of sand is found
with help of pycnometer bottles. The specific gravity of fine aggregates found in
Pune region varies from 2.6 to 2.8

76
c) Grading of coarse aggregate: The coarse aggregate grading limits are given
in IS 383 – 1970 - table 2, Clause 4.1 and 4.2 for single size aggregate as well as
graded aggregate. The grading of coarse aggregate is important to get cohesive
& dense concrete. The voids left by larger coarse aggregate particles are filled
by smaller coarse aggregate particles and so on. This way, the volume of mortar
(cement-sand-water paste) required to fill the final voids is minimum. However,
in some cases gap graded aggregate can be used where some intermediate size is
not used. Use of gap-graded aggregate may not have adverse effect on strength.
By proper grading of coarse aggregate, the possibility of segregation is mini-
mised, especially for higher workability. Proper grading of coarse aggregates al-
so improves the compact ability of concrete.
d) Shape of coarse aggregate: Coarse aggregates can have round, angular, or
irregular shape. Rounded aggregates because of lower surface area will have
lowest water demand and also have lowest mortar paste requirement. Hence
they will result in most economical mixes for concrete grades up to M35. How-
ever, for concrete grades of M40 and above (as in case of max size of aggregate)
the possibility of bond failure will tilt the balance in favour of angular aggregate
with more surface area. Flaky and elongated coarse aggregate particles not only
increase the water demand but also increase the tendency of segregation. Flaki-
ness and elongation also reduce the flexural strength of concrete. Specifications
by Ministry of Surface Transport restrict the combined flakiness and elongation
to 30% by weight of coarse aggregates.
e) Strength of coarse aggregate: Material strength of coarse aggregate is indi-
cated by crushing strength of rock, aggregate crushing value, aggregate impact
value, aggregate abrasion value. In Maharashtra the coarse aggregates are made
of basalt rock, which has strengths in excess of 100 N/mm2. Hence aggregates
rarely fail in strength. e) Aggregate Absorption: Aggregate can absorb water up
to 2 % by weight when in bone dry state, however, in some cases the aggregate
absorption can be as high as 5%. Aggregate absorption is used for applying a
correction factor for aggregates in dry condition and determining water demand
of concrete in saturated surface dry condition.
Decision Variables in Mix Design
A. Water/cement ratio B. Cement content C. Relative proportion of fine &
coarse aggregates D. Use of admixtures
A. Water/cement ratio Water to cement ratio (W/C ratio) is the single most im-
portant factor governing the strength and durability of concrete. Strength of con-
crete depends upon W/C ratio rather than the cement content. Abram’s law states
that higher the water/cement ratio, lower is the strength of concrete. As a thumb
rule every 1% increase in quantity of water added, reduces the strength of con-
crete by 5%. A water/cement ratio of only 0.38 is required for complete hydra-
tion of cement

77
(Although this is the theoretical limit, water cement ratio lower than 0.38 will
also increase the strength, since all the cement that is added, does not hydrate)
Water added for workability over and above this water/cement ratio of 0.38,
evaporates leaving cavities in the concrete. These cavities are in the form of thin
capillaries. They reduce the strength and durability of concrete. Hence, it is very
important to control the water/cement ratio on site. Every extra lit of water will
approx. reduce the strength of concrete by 2 to 3 N/mm2 and increase the work-
ability by 25 mm. As stated earlier, the water/cement ratio strongly influences
the permeability of concrete and durability of concrete.
B. Cement content Cement is the core material in concrete, which acts as a
binding agent and imparts strength to the concrete. From durability considera-
tions cement content should not be reduced below 300Kg/m3 for RCC. IS 456 –
2000 recommends higher cement contents for more severe conditions of expo-
sure of weathering agents to the concrete. It is not necessary that higher cement
content would result in higher strength. In fact latest findings show that for the
same water/cement ratio, a leaner mix will give better strength. However, this
does not mean that we can achieve higher grades of concrete by just lowering
the water/cement ratio. This is because lower water/cement ratios will mean
lower water contents and result in lower workability. In fact for achieving a giv-
en workability, a certain quantity of water will be required. If lower water/
cement ratio is to be achieved without disturbing the workability, cement con-
tent will have to be increased. Higher cement content helps us in getting the de-
sired workability at a lower water/cement ratio. In most of the mix design meth-
ods, the water contents to achieve different workability levels are given in form
of empirical relations. Water/cement ratios required to achieve target mean
strengths are interpolated from graphs given in IS 10262 Clause 3.1 and 3.2 .
The cement content is found as follows: -
Cement content (Kg/m3)
Water required achieving required workability (Lit/m3)
Water/cement ratio
Thus, we see that higher the workability of concrete, greater is cement content
required and vice versa. Also, greater the water/cement ratio, lower is the ce-
ment content required and vice versa.
C. Relative proportion of fine, coarse aggregates gradation of aggregates
Aggregates are of two types as below:
a. Coarse aggregate (Metal): These are particle sretainedon standard IS 4.75mm
sieve.
b. Fine aggregate (Sand): These are particles passing standard IS 4.75mm sieve.
Proportion of fine aggregates to coarse aggregate depends on following:
i. Fineness of sand: Generally, when the sand is fine, smaller proportion of it is
enough to get a cohesive mix; while coarser the sand, greater has to be its pro-
portion with respect to coarse aggregate.

78
ii. Size & shape of coarse aggregates: Greater the size of coarse aggregate
lesser is the surface area and lesser is the proportion of fine aggregate required
and vice versa. Flaky aggregates have more surface area and require greater pro-
portion of fine aggregates to get cohesive mix. Similarly, rounded aggregate
have lesser surface area and require lesser proportion of fine aggregate to get a
cohesive mix.
iii. Cement content: Leaner mixes require more proportion of fine aggregates
than richer mixes. This is because cement particles also contribute to the fines in
concrete.
D. Use of admixtures Now days, admixtures are rightly considered as the fifth
ingredient of concrete. The admixtures can change the properties of concrete.
Commonly used admixtures are as follows:
i. Plasticisers & super plasticisers
ii. Retarders
iii. Accelerators
iv. Air entraining agents
v. Shrinkage compensating admixtures
vi. Water proofing admixtures
i. Plasticisers & super plasticisers Plasticisers help us in increasing the worka-
bility of concrete without addition of water. It means that we can achieve lower
water/cement ratio without reducing the workability at the same cement content.
Cement particles tend to form flocs trapping a part of mixing water in them.
Hence not all the water added is useful for generating workability. Plasticisers
work as dispersion agents (de flocculent) releasing the water trapped in the flocs
resulting in workability. Use of plasticisers is economical as the cost incurred on
them is less than the cost of cement saved; this is more so in concrete designed
for higher workability.
Compatibility of plasticisers with the cement brand should be checked before
use. Also plasticiser should not be added in dry concrete mix. Plasticizers are
used for moderate increase of workability whereas super plasticizers are used
where very large increase in workability is required. Plasticizers are normally
lingo sulphonated formaldehydes and are normally added in small dosages. This
is because large dosage can cause permanent retardation in concrete and ad-
versely affect its strength. Super plasticizers are naphthalene or melamine based
formaldehyde. They can be used in large dosages without any adverse effect on
concrete. This is contrary to popular perception that term super plasticizers
means more potent, hence lower dosage is required when compared to normal
plasticizers. In practice super plasticizers are used in large dosages for generat-
ing higher workability and better slump retention. Compatibility of plasticizers
with cement should be ascertained before use in concrete. Since action of plasti-
cizers is based on ionic dispersion certain plasticizers are more effective with
certain cements, thus requiring lower dosages.

79
Non-compatible plasticizers if used, will not adversely affect the concrete, but
its high dosage will make it uneconomical for use.
ii. Retarders: They are used for retarding (delaying) the initial setting time of
concrete. This is particularly required when longer placing times are desired as
in case of ready mixed concrete. Retarders are commonly used to prevent for-
mation of cold joints when casting large concrete. Retarders are normally added
in lower dosages as large dosages can cause permanent retardation in concrete.
Retarders are recommended in case of hot weather concreting to prevent early
loss of slump. It is important to note that retarders reduce early strength of con-
crete e.g. 1-day and 3-day strength. However, 28 days strength is not affected.
iii. Accelerators They are used for accelerating the initial strength of concrete.
Typical accelerators increase the 1-day (up to 50 %) and 3-days (up to 30 %)
strength of concrete. Most of the accelerators show little increase for 7 days
strength. For this reason, accelerators are commonly used in precast concrete el-
ements for early removal of moulds. Accelerators may not be much useful for
early de-shuttering where early strengths are required in range of 5 to 7 days.
This is because accelerators are expensive and their ability to increase strengths
decreases after 3-5 days. A better option for early de-shuttering would be the use
of plasticizers, reducing the water/cement ratio and achieving a higher grade of
concrete. It is believed that accelerators may cause retrogression of strength af-
ter 28 days when compared with normal concrete.
Concrete Mix Design Methods
The basic objective of concrete mix design is to find the most economical pro-
portions (Optimisation) to achieve the desired end results (strength, cohesion,
workability, durability, As mentioned earlier the proportioning of concrete is
based on certain material properties of cement, sand and aggregates. Concrete
mix design is basically a process of taking trials with certain proportions. Meth-
ods have been developed to arrive at these proportions in a scientific manner. No
mix design method directly gives the exact proportions that will most economi-
cally achieve end results. These methods only serve as a base to start and
achieve the end results in the fewest possible trials.
The code of practice for mix design-IS 10262 clearly states following: - The
basic assumption made in mix design is that the compressive strength of worka-
ble concretes, by and large, governed by the water/cement ratio. Another most
convenient relationship applicable to normal concrete is that for a given type,
shape, size and grading of aggregates, the amount of water determines its work-
ability. However, there are various other factors which affect the properties of
concrete, for example the quality & quantity of cement, water and aggregates;
batching; transportation; placing; compaction; curing; etc. Therefore, the specif-
ic relationships that are used in proportioning concrete mixes should be consid-
ered only as the basis for trial, subject to modifications in the light of experience
as well as for the particular materials used at the site in each case.

80
Different mix design methods help us to arrive at the trial mix that will give us
required strength, workability, cohesion etc. These mix design methods have
same common threads in arriving at proportions but their method of calculation
is different.
Basic steps in mix design are as follows:
Find the target mean strength.
Determine the curve of cement based on its strength.
Determine water/cement ratio.
Determine cement content.
Determine fine and coarse aggregate proportions
BATCHING PLANT

81
9. Planning
Construction planning is a fundamental and challenging activity in the manage-
ment and execution of construction projects. It involves the choice of technolo-
gy, the definition of work tasks, the estimation of the required resources and du-
rations for individual tasks, and the identification of any interactions among the
different work tasks. A good construction plan is the basis for developing the
budget and the schedule for work. Developing the construction plan is a critical
task in the management of construction, even if the plan is not written or other-
wise formally recorded. In addition to these technical aspects of construction
planning, it may also be necessary to make organizational decisions about the
relationships between project participants and even which organizations to in-
clude in a project.
Essential aspects of construction planning include the generation of required
activities, analysis of the implications of these activities, and choice among the
various alternative means of performing activities.
In developing a construction plan, it is common to adopt a primary empha-
sis on either cost control or on schedule control. Some projects are primarily di-
vided into expense categories with associated costs. In these cases, construction
planning is cost or expense oriented. Within the categories of expenditure, a dis-
tinction is made between costs incurred directly in the performance of an activi-
ty and indirectly for the accomplishment of the project. For example, borrowing
expenses for project financing and overhead items are commonly treated as indi-
rect costs. For other projects, scheduling of work activities over time is critical
and is emphasized in the planning process. In this case, the planner insures that
the proper precedence’s among activities are maintained and that efficient
scheduling of the available resources prevails. Traditional scheduling procedures
emphasize the maintenance of task precedence’s (resulting in critical path sched-
uling procedures) or efficient use of resources over time (resulting in job shop
scheduling procedures). Finally, most complex projects require consideration of
cost and scheduling over time, so that planning, monitoring and record keeping
must consider both dimensions. In these cases, the integration of schedule and
budget information is a major concern.
A parallel step in the planning process is to define the various work tasks
that must be accomplished. These work tasks represent the necessary framework
to permit scheduling of construction activities, along with estimating the re-
sources required by the individual work tasks, and any necessary precedence’s
or required sequence among the tasks. The terms work "tasks" or "activities" are
often used interchangeably in construction plans to refer to specific, defined
items of work.

82
Planning department in L&T uses Microsoft Project as a powering tool for
reducing risk. Microsoft Project gives efficiency to plan a project, identify the
resources required and identify the tasks required in a sequence, increasing
probability of delivery of the project to the time, cost and quality objectives. Mi-
crosoft Project gives you a powerful, visually enhanced way to effectively man-
age a wide range of projects and programs. From meeting crucial deadlines, to
selecting the right resources, Microsoft project empowering your teams.
The initial schedule of major construction activities S0 is prepared according
to the Clients preference. S0 is the basis for all types of scheduling. Preliminary
schedules representing the monthly work estimates are prepared based on expe-
rience considering local climate conditions, environment, learning curve, pace
of work, mobilization, etc. in Microsoft Project. Productivities of different activ-
ities are estimated and validated during the course of execution. Man power re-
quirement is calculated based on these productivities. Drawings released by the
Client. Revisions and change orders are issued as and when there is a change
and distributed to all the units. The planning system is updated in the first week
of every month. Two progress schedules are maintained – original schedule pre-
pared in the starting of the project, planned schedule which is modified accord-
ing to the requirements and conditions. Actual progress is compared with the
planned schedule and in case any delay in progress is then a Catch up schedule
is prepared and executed accordingly to overcome the delay.

83
10. Other Work
BRICK WORK
Bond The arrangement of the bricks in successive courses to tie the brick work
together both longitudinally and transversely. The arrangement is usually de-
signed to ensure that no vertical joint of one course is exactly over the one in the
next course above or below it, and there is greatest possible amount of lap.
Bed Joint Horizontal joint in brick work or masonry. Closer Any portion of a
brick used in constructing a wall, to close up the bond next to the end brick of a
course
Coping or Weathering The cover applied over or the geometrical form given
to a part of structure to enable it to shed rain water.
Corbel A cantilever projecting from the face of a wall to form a bearing
Cornice Horizontal or ornamental feature projecting from the face of a wall
Course A layer of bricks including bed mortar.
Cross joint A joint other than a bed joint normal to the wall face.
Efflorescence A powdery incrustment of salts left by evaporation. This may be
visible on the surface or may be below surface. In the latter case, this is termed
as crypto Efflorescence.
Header A brick laid with its length across the wall.
Indenting The leaving recesses into which future work can be bonded. Jamb
The part of the wall at the side of an opening.
Joint A junction of bricks.
Jointing The operation of finishing joints as the masonry work proceeds.
Pier A thickened section forming integral part of the wall placed at intervals
along the wall primarily to increase the stiffness of the wall or to carry a vertical
concentrated load. The thickness of a pier is the over all thickness including the
thickness of the wall, or when bonded into one leaf of a cavity wall the thickness
obtained by treating this leaf as an independent wall.

84
Dimension Of Brick:-
The brick may be modular or non-modular. Sizes for both types of bricks/tiles
shall be as per Table. While use of modular bricks/tiles is recommended, non-
modular (FPS) bricks/tiles can also be used where so specified. Non-modular
bricks/tiles of sizes other than the sizes mentioned in Table may also be used
where specified.
Type of Bricks/Tiles Nominal Size Actual Size
Modular Bricks 200 × 100 × 100 mm 190 × 90 × 90 mm
Modular tile bricks 200 × 100 × 40 mm 190 × 90 × 40 mm
Non-modular tile bricks 229 × 114 × 44 mm 225 × 111 × 44 mm
Non-modular bricks 229 × 114 × 70 mm 225 × 111 × 70 mm

86
CONCLUSION
This summer internship gifted me with the opportunity of build up my
knowledge in the field of civil engineering. It was here that I was able to collect
the elementary ideas regarding building construction, piling works, execution
work and finishing work which most probably, shall be of great assistance in my
future.
My project is regarding ‘Construction of Government Medical College and
Hospital. Here, I learnt construction aspect of the building and building draw-
ings.
Here, in L&T, I met several civil engineers who guided me constantly and
helped me in successfully completing my project. I was inspired by the efficien-
cy, dedication and consistency of the engineers with which they accomplish eve-
ry work within the time limit. I increased my corporate interaction through this
internship which helps my personality to enhance my career as a civil engineer.
Working with the highly talented engineers of Civil Department, L&T was a
great experience for me which shall further guide me in achieving my career
goal.

L & T PROJECT 2016

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L & T PROJECT 2016