CIVIL ENGINEERS

HAND BOOK FOR CONSTRUCTION SUPERVISION

S.K.GUMASTA RAJASTHAN ATOMIC POWER PROJECT 5&6

UNVEILED BY PROJECT DIRECTOR, RAPP-5&6 ON 11.02.05 AT RAPP-5&6 SITE.

PREFACE
In order to sustain within competitive environment, stress is given to reduce the gestation period with maintaining the quality standards of Construction & Commissioning of

Nuclear Power Programme. This is up most important to reduce the construction time and cost of nuclear power considering the above aspects. For reduction in cost of construction few of the requirements are listed as below: 1. Optimum use of skilled manpower. 2. Mechanization in construction. 3. Awareness of quality system to all supervisors / Engineers. 4. Create competitiveness within working group. 5. Continuous training and performance appraisal of

Supervisor / Engineers. Construction is major part of Civil Engineering which

includes awareness regarding the Quality Control, Material Selection, Storage & Handling, Mix Design, Managerial skill to handle the situations in Pre Construction, During

Construction and Post Construction stages. Effective and desired results with optimum use of departmental manpower engaged in Supervision of Construction activities is always a major concern of NPCIL vision and policy. Based on daily observation & experience that have been gathered during handling of various site execution activities, a need was felt to have a document containing brief description of the work and effort required for various stages of construction for improvement of effective supervision of construction.

This document has been prepared as handy tool for ready reference of Site Civil Engineers and Supervisors. It contains information basically for site related activities/ checklist being used on day-to-day basis.

Special emphasis have been given on the skill requires for supervision of the Civil Construction activities for Site Engineers/ Site Supervisor to handle the situation w.r.t. PreConstruction, During Construction & Post Construction

responsibilities. Following are the areas enlisted in this document: How to organize the job for effective and desired out put at site. Importance of Survey in Civil Construction. Excavation and blasting techniques. Requirement for formwork placement. Re steel fabrication and placement. Importance of Concrete cover. Pour planning. Pour checks. Brief description regarding concrete and mix design development. Requirement for concrete production transportation and placement. Post-concrete inspection. Various types of finishes in concrete. Defects in concrete and its repair. Various types of joints.

Assessment of safe working conditions while executing the job. Importance of Job hazard analysis. Awareness of QA requirements.

I am thankful to all my colleagues and senior Civil Engineers, who have shared their valuable experience which had paved the way for making this possible. I would like to extend sincere thanks to Sh. J.K.Jain, Sh. S.K.Shrivastava, Sh. H.P.Choudhary & Sh. V.K.Trivedi for their personal support. The inspiring support and

encouragement provided by Sh. N.K.Jain, ACE (E&I) and Sh. Sanjiv Sharma, PE (C) is also thankfully acknowledged. The development of this document as reference to the requirements of Site Supervisors and Site Engineers, who are directly connected with work was the vision of Sh. D.K.Jain, Chief Engineer (Civil). This could be made possible due to his able leadership, and effective guidance, continuous

motivation and appreciation at every stage for development of this document in presentable form. I am also grateful to Sh. C.P.Jhamb, Project Director, RAPP-5&6 for giving

Enthusiastic and inspiring support for development of this document.

S.K. GUMASTA RAPP-5&6

INDEX
SR. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 DESCRIPTION How to organize the job for effective and desired out put at site. Importance and requirement of survey. Excavation and blasting techniques. Requirement for formwork placement. Re steel fabrication and placement. Importance of Concrete cover. Pour Planning. Pour Checking. Brief descriptions regarding concrete and mix design development. Requirement for concrete production transportation and placement. Post-concrete inspection. Various types of finishes in concrete. Defects in concrete and its repair. Various types of joints. Assessment of safe working conditions while executing the job. Importance of Job hazard analysis. Awareness of QA requirements.

CHAPTER - 1 HOW TO ORGANIZE THE JOB FOR EFFECTIVE AND DESIRED OUT PUT AT SITE

CHAPTER - 1 How to organize the job for effective and desired out put at site
Learning is a continuous process for individual improvement & is important and essential for completion of jobs with required quality standard and maintaining the time schedule for achieving the targets. Optimum use of availability of skilled manpower is always a matter of concern to all of us in a present competitive world. Further it is needless to say that ABILITY IS USELESS UNLESS IT IS USED Hence it is a big challenge for us that How to organize the job for effective and desired out put at site. Following are the few points, which shall be helpful to achieve the above objectives: 1) Develop confidence within our self and our team for having capability to deliver the task. 2) 3) Understand the work in totality before actually proceeding it. Identify the requirement of material, equipments, availability of drawings / specification, qualified manpower and their availability. 4) Identify the possible hindrances, constraints well in advance and proactive approach to arrange the solution. 5) Prior requirement i.e. proper pour planning and checking before execution. 6) Identification of Pre construction / During construction /Post construction requirement of various sub activities.

7)

Proper access to site, good illumination, logical and proactive approach and quality consciousness.

8)

Understanding of job and analysis of job hazards prior to start of the work.

9)

Always believe Ability Has Nothing To Do With Opportunity hence deliver the results rather than discussing the excuses.

10) Communication to immediate superior for appraisal of work done. Such appraisal is appreciated, if it is done before it is asked for. Remembers - One should not require any reminder for complying the instruction of superiors. 11) Practice to be a good leader and not the boss for effective team sprit and desired output. 12) Motivate the team and set an inspiring example for others. 13) Always believe that Sincerity has no substitute.

CHAPTER - 2 IMPORTANCE AND REQUIREMENT OF SURVEY

CHAPTER - 2 IMPORTANCE AND REQUIREMENT OF SURVEY

Survey plays an important role in Construction activities. It is basic requirement to ensure the correct location and alignment including required elevation slop etc for structure or total layout of a plant. Survey is done for the maintaining above requirement. Brief of survey terms used is indicated below: SURVEYING: Surveying is the art of making such measurements as will determine the relative positions of points on the surface of the earth or on structure in order that the shape and extent of any portions of the earth/structure may be ascertained and shown on the map or plan. LEVELING: Leveling is the art of determining and representing the relative heights or elevations of different points on the surface of the earth/structure. 1 SEQUENCE TO BE FOLLOWED FOR SURVEY W.R.T. START OF THE WORK: Following are the salient points/ sequence of survey to be followed for start of the project activates/ pour: WORK IS DIVIDED IN TWO PARTS. A. B. To start a new project: - Establishing of Main grid lines and Benchmark with reference to known datum / reference to start in new work. For a pour in existing structure: - Use of existing reference/bench mark in existing structure to define the location, alignment and elevation of a pour.

USE OF SURVEY IN VARIOUS DAY-TO-DAY ACTIVITIES OF CONSTRUCTION. Before we deal with uses of survey for various activities, following steps are necessary to carryout.

A. B. C.

Transfer of reference line at each Building/floor to carryout checking of various activities. Transferring of Bench Mark at each Building/floor. Above two activities should be performed with great care and without any error, as the effectiveness of total checking depends on theses reference points.

D. E. F.

Establishing layout of the building. Establishing bench mark to check elevations of different floor etc. Use for checking of form works: i) Alignment checking ii) Checking of verticality.

G.

Tolerance for formwork i) Section dimension - 5 mm ii) Plumb/ verticality - 5mm in 5 mtr. But should not cumulative.

H.

Use in checking of critical EPs. Checking of location Checking of elevation Tolerance Before concreting 2 mm. After concreting 6mm. Tolerance on angle 0.500.

Survey

is

very

important

at

pre-construction,

during

construction and post construction stages. Site Engineers must be aware regarding requirement and importance of survey at pre-construction, during construction and post construction stages. Few of the requirements are summarized below: -

3 i. ii. iii. iv. v.

Pre construction survey is required for the following: Defining the plant area in 20m X 20m plant grid pattern with existing permanent reference. Location of various plant structures within defined grid established as above. Making specific benchmark to take up the work within building / structure. Marking and identification of a part of the structure in various pours at various elevation w.r.t defined Benchmark / reference. These marking are possible by: Theodolite. Measuring tapes. Dumpy level. Total station.

vi. vii.

At the start of construction- usually reference point is marked on reference pillars 2-3 meters away from the edge of structure. After construction, it is transferred to permanent structure and subsequently all reference to be taken from common reference to avoid any cumulative error.

4 i.

During construction is required for the following: During construction survey is very important. Following are the areas where survey during construction requires by supervisor / site engineers. ii. Maintaining alignment of wall and position of embedded part, pipe support/ piping sleeves etc. Maintaining the location of EPs / specifically critical EPs. Maintaining the concrete top elevation of plate EPs / Critical EPs. Maintaining the concrete top elevation during finishing of green cutting. Maintaining the slopes of floors. Maintaining the levels of sumps.

iii. iv. v. vi. vii.

viii.

During concreting survey is made to ensure the location of PVC water stop.

5 Post concrete survey: i. ii. iii. Post concrete survey is done for all critical pours to ensure the final position of EPs / Levels of concrete. It is required to done to assess the tolerance in alignment / level /pockets / bolts etc. in concrete structure. Post concrete survey is done to examine the spot of honey combed portion / visual observation of bulging and type of surface finish in concrete.

CHAPTER - 3 EXCAVATION AND BLASTING TECHNIQUES

CHAPTER - 3 EXCAVATION AND BLASTING TECHNIQUES

At NPCIL, Rajasthan Site, we face the greatest challenge of getting the excavation done at hard rock available here. Excavation at this site is a critical activity since blasting is the only economic solution available for excavation in hard rock here. Following is the salient point generally we refer before proceed for the work. 1. PLANNING OF WORK. In order to asses the requirement of

various machineries / explosives required to complete the blasting work with in schedule time considering hindrances / constraints etc., planning of the work including resource planning is very important for site engineers before starting the job. A brief for activities required for planning of the work is summarized below. Sr. no. i. ii. iii. iv. Description Total quantity of excavation to be done Total time available. Target excavation to be done per day. Desired output In Cu.m. No. of Days. Total Qty/No. of days.

Increase target excavation by 15% to Row no. iii X 1.5 cu.m / 20% due to uncontrolled conditions like per day. break down of of machineries/non materials / availability explosive

restriction in blasting due to nearness of on going works / critical structure. (Assuming blasting is permitted once in a day)

2 RESOURCE PLANNING i. Considering capacity of a poclain to handle No. excavated muck/day and using target poclain required poclain. ii. this data. of required of required can be

excavation/day, we can calculate - No. of calculated based on Considering the capacity of dumpers to No.

handle the excavated muck to disposal dumpers per day can yard / day and using the target excavation be calculate based on rate per day, we can calculate - No. of required dumpers. iii. Based on the experience at this site This will help to approx. depth of borehole in RM required calculate total Drilling to achieve one Cu.m. of excavation and required in RM. the total excavation is to be done, we can calculate total RM of drilling required. (Approximate assumption as 0.8 to 1.0 RM drilling as an average to achieve one Cum excavation at this site may be assumed for planning purpose. This data may vary for various types of work and their location.) iv. Considering the capacity of borehole drill No. machine to drill-RM/day and using the drilling target excavation rate per day, we can required calculate total no. of borehole drilling calculate machine requirement. (Approx. 70 to 80 data. RM drilling is done per day by a borehole drill machine can be safely assumed for planning purpose) v. Considering the capacity of jackhammer No. of jack hammer capability to drill RM/day and using the required target excavation rate per day, we can calculated can with be this of borehole machine can with be this this data.

calculate

total

no.

of

jackhammers data.

requirement.

(Approx. 50 to 80 RM

drilling per shift can be safely assumed for planning purpose) vi. Based on the experience at this site This will help up to amount of explosive required in Kg to calculate total achieve one Cu.m. of excavation and the quantity of explosive total excavation is to be done, we can required in kgs. This calculate (Approx. total 0.5 explosive to 0.7 requirement. will help us to assess Kg explosive the requirement of

requirement can be assumed to achieve storage of explosive / one Cum excavation at this site for magazine. planning purpose.)

3 BLASTING & BLASTING TECHNIQUES: A. BLASTING:I. Deflagration: II. Detonation: B. MUFFLED BLASTING The fragmentation of rock by means of explosives is called blasting. There are two type of explosion: Explosion by rapid burning Explosion by instantaneous decomposition Muffled blasting refers blasting with control of fly rock. It is defined as preventive action for flying stones by covering blasting area by steel plates / sand bags etc. Control of fly rock: - Blast hole shall be covered with 6 mm thick (min) MS plate 0.6 to 1.0 sq.m scrap steel plates/ sand full of gunny bags are used during muffled blasting for covering the area. C. CONTROL BLASTING In control blasting muffling is not only the requirement but also controlling the generation of peak particle velocity due to vibration in nearby Civil structure/ critical and sensitive installation without affecting their

performance of structures is main concern for control blasting. Control of vibrations- Short delay blasting with light charges: - Rapid sequence of shot firing with delay of 25 -100-mili seconds. D. LIMITED BLASTING: To safeguard existing structures and nearby operating station, permissible PPV is defined as below: 1. Peak particle velocity 10 mm/sec for near by civil structures. 2. Peak particle velocity 3 mm/sec. Safe vibration level for buildings. ??With electric & electronic equipment installed at basements. ??Safe charges per delay have also been specified by CWPRS for various distances and age of the concrete. E. LINE DRILLING: ?? drilling a series of hole at closely spaced By intervals around the perimeter of the excavation the blast may be trimmed to the finished dimensions with a minimum over break. F. PRE-SHEARING: ?? a development of line drilling method by Is instantaneously firing a closely spaced series of holes, blasted. ?? Firing of light charges produces tension cracks. ?? These cracks de-couple the main blast from the perimeter rock walls, which are thereby left intact and unbroken. ?? of holes 110 mm Dia lightly charged around the desired perimeter before the nearby main rounds are

?? Spacing 800 to 1000 mm c/c ?? Charged 300 to 400 gm /m G. EXPLOSIVES: Explosives are chemical compounds. They decompose quickly and violently and change into gases. Such gases have larger volume. The heat generated serves to expand gases greatly. EXPLOSIVES

LOW EXPLOSIVES (Deflagrates) H. LOW EXPOLOSIVES: Features of Gun Powder i. Gun powder ii. Composition: Rate of burning; iii. Other properties:-

HIGH EXPLOSIVES (Detonates) Gunpowder is the example of low explosives

75% Potassium Nitrate - oxygen supplier 15% charcoal powder - inflammable 10% sulphar. The speed of burning of gunpowder is of all order of 450 m/sec. The volume of gases produced is as large as 2000 times the volume of gunpowder used. ?? Made to explode by Safety fuse ?? Because of its low strength, it is not used in large scale blasting. ?? Can easily absorb moisture. ?? transport is risky being inflammable. Its ?? While Stemming explosion may take place needs proper care during handling.

iv.

I.

HIGH EXPOLOSIVES: i. Main constituents: -

Open cast gelignite, special gelatin, blasting gelatin super dyne is examples of high explosives. 1) TNT (Tri-Nitro Toluene) 2) Nitro-glycerin 3) Ammonium Nitrate 4) Collodion cotton

ii. Features: -

?? Should not be exploded by ignition ?? Detonators create shock waves of velocity ranges from 2000 m/sec to 7000-m/ sec. depending upon quality, nature and strength of explosive used. ?? The mechanical energy of the shock waves does the work of fragmentation of work.

J. Safety Fuse: -

1. Safety fuse consists of core of fine gunpowder wrapped with layers of tape, jute and is given a coat of water proofing. 2. It will burn without the help of oxygen, inside water and inside the blast hole. 3. Rate of burning = 2 feet /minutes. 4. Some brand names Bull brand Blue sump and Colite fuse. 5. High explosives can be detonated with the help of safety fuse, provided it is capped with an ordinary detonator.

How to determine length of a fuse: -

??The blaster should take into consideration the time he will need to light the fuses and to reach the shelter safely shall determine the length of a safety fuse. ??Suppose time for lighting 10 fuses requires = 2 min. = 5 min. ------Total time = 07 min So he will need to have 14 feet fuse since the rate of burning of fuse is 2 ft/min. ??Time to reach the shelter

DELAY

Delays are used to have small time gap between successive blasting to avoid strong vibration generation at a time. At our site as specified in tender document delay per Kg of blast to be used w.r.t. distance of sensitive or permanent installation while blasting

STEMMING: -

Too little stemming results - Allow explosion gases to vent out and fly rock problem. Too much stemming results - Poor fragmentation.

ORDINARY ELECTRIC AND DELAY DETONATORS

?? These are initiated by pressing an electric current with an apparatus called EXPLODER. ?? When electric current of about 0.5 amp is passed the fused head get heated ignite primary charge which in turn will initiate IInd charge and the detonation takes place. The difference between ordinary electric detonator and delay detonator is due to of insertion of a delay element, which has property of burning at specific rates. The heart of a detonator is fuse head . Any mal-functioning of this will lead to misfire.

INITIATION SEQUENCE OF DETONATION OF EXPLOSIVES

To be strictly followed for effective results.

USING DELAYS: -

When the explosive charges in two or more rows of holes parallel to a face are fired at the same time it is desirable to fire the charges in the holes nearest the
nd

face a short time ahead of those in IInd row. This will reduce the burden on the holes in IInd row and thereby permit the explosive in IInd row to break the row more effectively. The use of delays in the blast is one of the most powerful weapons in the fight against excessive blast damage and larger peak particle velocity and in-turn instability of surrounding area. P MISFIRES: While shooting explosives charges by blasting, it may be possible that one or more charges will fail to explode. This is referred to a misfire. It is necessary to dispose of this explosive before excavating loosened rock. HOW TO HANDLE ?? The most satisfactory method is to shoot it, if MISFIRES: possible. ?? electrical detonator is used, leg wires are available If and circuit is satisfactory, try again to set of charge. ?? Stemming should be removed with a wooden tool instead of metal. ?? Water and compressed air should be used to remove stemming. ?? new charge on top of missed one may also be A blasted to fire the charge.

4.
i.

ECONOMICS OF BLASTING
To achieve optimum results: Following parameters are required to be taken into consideration 1) Type of explosive, weight of explosive and distribution of explosive in holes. 2) Blast hole diameter If large flying of rock in air will be less but secondary blasting may be required to

will be less but secondary blasting may be required to handle large boulders generated. 3) Effective burden: - The distance between the row of holes under consideration and the nearest free face is know as effective burden. If burden is small - Generation of fly rock in lesser efficiency of blasting will be resulted. If burden is too large - Check the blast due to -Poor fragmentation. ii. iii. 5 Effective spacing: Sub drill depth: For good results effective spacing of holes = 1.25 x effective burden. To avoid excessive shovel operation at floor level depth of hole is kept little less than required. MONITORING OF ACTUAL PROGRESS AGAINST PLANNED PROGRESS OF BLASTING: 1) Compare for no. of holes blasted against no. of holes planned to blast per week. 2) Target excavation rate against achieved excavation rate per week / per month. 3) Reorganize the deployed resources in case large variations are noticed. 6 i. REQUIREMENT OF THE PRE BLASTING ACTIVITY: Proper resource planning w.r.t requirement of machineries / availability of explosives / requirement of storage of explosives/ availability of qualified and licensed blaster to be ensured. ii. Blasting notice to all concern and near by all agencies working in the area /CISF/safety group and to nearby working stations must be circulated. Blasting notice must indicate blasting timings for specific duration for which it is issued. -air and

iii. iv. v. vi. vii. 7 i.

Daily blasting permits indicating no. of holes/app. Blast charge requires / departmental representative to attend / witness the blasting to be taken This daily permit needs clearance from department safety head and the CISF authorities well in advance preferable one day in advance Drilling of required no. of holes of desired dia and inclination to be ensured in one day advance Availability of muffling plates / sand bags to be ensured at site in one day in advance Availability of PPV meter at site for monitoring the vibration to be ensured at site. REQUIREMENT OF DURING BLASTINGS ACTIVITY: Loading of required explosive in blast holes to be ensured by licensed blaster only.

ii.

Connecting the blast charge with desired delays in specific circuits to be ensured by licensed blaster only.

iii.

Ensuring the cordon-off the area for entry of vehicle / explosive / Labour. Using whistle / red flag / siren.

iv. 8 i. ii. iii. iv.

Blasting to be done and measurement of PPV should be recorded. REQUIREMENT OF AFTER BLASTING ACTIVITY: Blaster must checks for misfire if any and accordingly arrange for reblast if necessary as per procedure. Give clearance if no misfire noticed for entry of vehicles / movement of workers etc.. Check for any damage occurred in near by area. It is requires to be reported in the blasting report, if any. Generation of blasting reports including statement of reconciliation for the explosive materials brought to site, consumed at site and balance taken away from the premises of the project in presence of CISF.

v.

Compare the PPV observed against permissible Peak Particle Velocity for the area.

Following details also must be known for effective monitoring of blasting operation. BLASTING AREAS: Blasting areas where concreting is being done i.e. w.r.t. green age of the concrete. This data is obtained from the conclusion drawn by CWPRS at site in their survey. In nutshell it refer that blasting in the nearby area where green age of the concrete is 0-4 hrs. is not harmful. But for the concrete having age between 412 hrs. - No Blasting to be permitted in near by area.

CHAPTER 4 FORM WORK PLACEMENT

CHAPTER - 4
FORM WORK PLACEMENT
1. Formwork is defined as total system of support of fresh concrete to be placed it includes: ?? Total frame / mould of various shape in which concrete remain in contact. ?? Total system of supporting arrangement i.e. by frame, pipes, acro-span, trusses etc. ?? Nuts, bolts tie rods, bracing including other supporting system for satisfactory sustaining the load of concrete + live loads until the concrete attain the strength to with stand the same. 2. a) Various type of formwork are used in construction: CONVENTIONAL FORMWORK: - Includes formwork i.e. shuttering made up by steel plates and industrial plywood includes pipe supports / wooden ball support. b) DOCA FORM WORK: - Specially designed form work with simple methods for fixing in position and removing from the position. This tread name of formwork had proved confidence in various complicated structure for their satisfactory completion. This can be used for large slabs, big columns, deep beams, large size retaining walls, and hyperbolic cooling towers etc. c) SLIP FORM WORK: - In structure where shapes are regular of having a uniform variation like shaft of water tank, chimney, towers etc. and not having penetrations. This type of form work can effectively used for rapid construction in this case form work is design in such a way that it moves continuously ahead to receive the fresh concrete in such a way that when it leaves the concrete already placed should attain the sufficient strength to withstand the load of concrete + live load, while concreting is done. In this case concreting is done continuously till the work is over for the shape

Example: - Shaft of water tank for 15-20 Mtr. can be completed in 4 to 5 days. d) JUMP FORM; - Where Shape / Geometry of the structure is not uniform and height of the structure is more. Jump formwork can be used. For example about 100 to 110 m high and 90m to 55 m dia of cooling tower shell varying hyperbolically being constructed with the jump form at RAPP-5&6 site. 3. Site Engineer / Supervisor must give attention to following areas while checking the formwork / scaffolding. PRE CONSTRUCTION REQUIREMENT: Alignment level position of formwork w.r.t permanent reinforcement. ?? Type of finish requirement decides the type of formwork. ?? Spacing of the support system Tightening of bolt, tie rods etc. ?? Accuracy of dimensions. ?? Gap in the successive shutters to avoid the slurry leakage. ?? Where penetration / EPs are to be made, the supports are to be re-ensured to maintain dimension, alignment and level of the same. ?? Bracing and adequate support for projections/ cantilever must be checked. ?? Wherever construction joints are to be left, the position of shear keys, and support arrangement to be ensured. ?? Safety aspects to be taken care while checking the formwork the proper access to reach other portion of form work to be ensure, an case needs attention during the concreting. ?? Form fixing to be checked w.r.t removal of form work point of view. It should be easily removable without damaging the final concrete.

REQUIREMENT DURING CONSTRUCTION ?? set of skilled carpenter to be ensured to attend the area A immediately in case, supports / forms gets displaced while concreting / vibration of concrete. ?? Proper illumination in internal and external location of pours to be ensured. ?? Application of surface retarder immediately before the concreting where green cutting is required. POST CONSTRUCTION REQUIREMENT: - In general the codal practice for removing the formwork to be strictly followed for removal of form. ?? For special structures like dome of reactor and shell of Cooling Towers: -Specified procedure to be followed for removal of form. ?? Specific care to be observed for safety during disturbing. ?? Specific care to be observed while removing formwork at high structure should not damage the structure at floor. Removal of the formwork at various constructions needs attention as summarized below Forms should not be removed until the concrete has achieved strength that is at least twice the stress to which the concrete may be subjected at the time of removal of formwork. However, under normal circumstances, where no significant variation temperature is seen the following striking period should be followed: Removal of forms and supports (As per IS456-2000) Sr. no. 1. 2. 3. Min. period before striking formwork. Vertical formwork to columns, walls, 16-24 hours. beams. Soffit formwork to slabs (props left under 3 days. after removal of formwork) Soffit formwork of beams (props left 7 days. under after removal of formwork) Position of formwork

4. 5. 6. 7.

Props Props Props 6) Props 6m)

of slabs (spanning up to 4.5 m) 7 days. to slabs (span over 4.5 m) 14 days. to beams & arches (spanning up to 14 days. to beams & arches (spanning over 21 days.

?? Striking should be done slowly to avoid damage to projections and without shocks or vibration. ?? When forms are stripped, there should be no excessive deflection or distortion and no evidence of damage to the concrete due to removal of support. ?? When forms are removed before the specified curing is completed, curing should be continued up to the specified time. ?? The concrete supporting forms and shores not be removed from beams, floors and walls until these structural units are strong enough to carry their own weight or any approved superimposed load. In no case should supporting forms and shores be removed from horizontal members before concrete strength has achieved this specific concrete strength. ?? is always recommended to remove forms for columns and piers It before forms for beams and slabs.

CHAPTER - 5 RE-STEEL FABRICATION & PLACEMENT

CHAPTER - 5 RE-STEEL FABRICATION & PLACEMENT

Steel reinforcement is a major and most important constituent of concrete. The correct shape and its position and cutting length is the main area required to be seen by Site Engineer. Silent feature for Fabrication & Placement of concrete reinforcement is briefly described below. TYPE OF REINFORCEMENT: 1) High strength deformed bars (Conforming to IS: 1786) (a) Cold worked deformed bars. (b) TMT bars 2) Mild Steel Bars (Conforming to IS: 432) 3) (A) MATERIAL PROPERTIES FOR HSDB i. CHEMICAL PROPERTIES Constituents Fe415 Carbon 0.30 Sulphur 0.060 Phosphorus 0.060 Sulphur & Phosphorus 0.11 For weldebility % of C > 0.25 ii. PHYSICAL PROPERTIES Mechanical properties of high strength deformed bars: S. No. Property 0.2% proof stress Fe415 415 Fe500 500 12.0 Fe550 550 8.0 Fe500 0.30 0.055 0.055 0.105 Fe550 0.30 0.055 0.050 0.10

% Elongation on 14.5 gauge with 5.65 A

Tensile Strength

10% more than actual 0.2% proof stress or not less than 485 N/mm2

8% more than actual 0.2% proof stress or not less than 554 N/mm2.

6% more than actual 0.2% proof stress or not less than 585 N/mm2.

3 (B) MATERIAL PROPERTIES FOR MILD STEEL: i) CHEMICAL PROPERTIES Constituents Carbon Sulphur Phosphorus Upto 20 mm 0.23 0.055 0.055 Above 20 mm 0.25 0.055 0.055

ii) PHYSICAL PROPERTIES MECHANICAL PROPERTIES OF MS BARS: S. No. Property 0.2% proof stress % Elongation on gauge with 5.65 A Tensile Strength Grade-1 (less than 20 mm) 250 23% 410 mpa Grade-1 (Above 20 mm) 240 23% 410 mpa

Material Sampling and Acceptance to be ensured as per requirement. (4) CUTTING & BENDING OF RE-STEEL BARS: Cutting & Bending shall be done in accordance of requirements laid down in IS: 2502 as per the Bar Bending schedule. The reinforcement bars shall be cold bended. Fabricated bars should be tagged indicating the following information: (a) BBS (b) Structure (c) Bar mark (d) No. of Bars. (5) PLACEMENT OF BARS: Placement of re-steel bars shall be done as per arrangement shown in approved reinforcement drawings. (6) Reinforcement work shall be checked for the following: FABRICATION: (i) Diameter of the bar

(ii) Shape of the bar (iii) Finished length of the bar (iv) Bending radius (v) Visual inspection for crack during fabrication LAYING (i) Location (ii) Alignment and array (iii) Spacing / numbers (iv) Binding / tying (v) Cover (vi) Staggering if any (vii) Splicing numbers and location Inspection status shall be mentioned in the form of Pour Card. (7) PLACING OF REINFORCEMENT Rough handling, shock loading prior to embedment and the dropping of reinforcement for a height should be avoided. Reinforcement should be secured against displacement outside the specified limits. (8) TOLERANCES ON PLACING OF REINFORCEMENT Unless otherwise specified by Engineer-In-Charge, 10 mm the reinforcement shall be placed within the following tolerances: a) For effective depth 200 mm or less (9) TOLERANCE FOR COVER Unless specified otherwise, actual concrete cover should not deviate from the required nominal cover by 0, +10 mm. Sl. No. 1 2 3 4 Diameter of Rod 6mm 8mm 10mm 12mm Weight in kg/RM 0.222 0.395 0.617 0.888 b) For effective depth more than 200 mm 15 mm

5 6 7 8 9 10 11 12

16mm 20mm 22mm 25mm 28mm 32mm 36mm 45mm

1.578 2.466 2.984 3.853 4.834 6.313 7.990 12.485

CHAPTER - 6 IMPORTANCE OF CONCRETE COVER

CHAPTER - 6
In addition to integrity, strength and other design requirement, durability of structure during its design life is extremely important. No matter care have been exercised while designing the concrete mix, formwork and effective methods have been used for placing, consolidating and curing of concrete. But if care towards required concrete cover is not made than the efforts made towards all the above could loose their significance, which result, pour durability of structure. The importance of concrete cover is more significant in structures located in aggressive environment. The cover also protects the reinforcement to get it exposed in environment and prevent formation of oxygen concentration cell, which is the major reason for starting the corrosion of reinforcement. Site engineer must understand the importance of the concrete cover and necessary care must be exercised to ensure it as per drawing requirement. Following care shall help in achieving the above objectives: 1. 2. 3. 4. Proper alignment of formwork and re steel at location, to be ensured. Concrete cover block should be of similar mix design. Proper cover blocks in columns, beam bottom, beam side and slab as per drawing requirement. Additional cover requirement for the structure where it is exposed to sea, aggressive environment or alternate drying and wetting, should be given due care as per drawings requirement. 5. 6. 7. Specific care to be ensure during vibration of concrete, so that concrete cover block remains intact as placed. Cover blocks must be properly tied to the reinforcement. Properly cured cover blocks only to be used at site. There fore, as per requirement of cover block site engineer must ensured that they have to be casted well in advance.

IMPORTANCE OF CONCRETE COVER

CHAPTER 7 POUR PLANNING

It is needless to say that any work whether construction activities or our day-to-day activities, requires specific plans for completion of the same successfully. This facilitates: ?? Total under standing of the work. ?? Various requirements at different stages of execution of the work. ?? Sequence of the work to be followed. ?? Proactive approach of attending possible hindrances if any. ?? Developing an over all aptitude for systematic approach for completion any work. The brief description regarding pre requisite for pour planning and w.r.t supervision of Civil Engineering Construction is summarized below: -

CHAPTER 7 POUR PLANNING

POUR PLANNING: Pour planning refers to ensure systematic arrangement of all requisite to take up a defined work within schedule time and preferably ahead of schedule plan.

FOLLOWING ARE REQUISITE FOR PLANNING OF A POUR.

A. IDENTIFICATION OF POUR. These include identification of: i. Location of a pour in a building and reference grids. ii. Elevation. B. AVAILABILITY OF LATEST DRAWINGS: It is required to check the latest revision of referred drawings and also following details: i. ii. iii. iv. v. To check for DCN if any. To check for FCN if any. To check for ECN if any. To check the hold in the drawing if any. To check the reference drawings listed in the drawings.

C. Quantum of the work: Depending upon the size and importance of the pour, following information helps for effective pour planning: 1) Quantity of concrete to be done in single stretch. 2) It is preferable to have plan for the daily activities to be completed w.r.t. the schedule date of pouring. D. DAILY ACTIVITIES HELPS US TO KNOW ABOUT THE FOLLOWING: ?? Total no of sub activities required to be done within schedule time. ?? Total quantity of material required being handle. ?? Sequencing of activities can be planned effectively. ?? Requirement of equipments / machinery can be plan. ?? Requirement of construction material and their availability schedule. ?? also ensure NPCIL acceptance of Material before actual use at It site. ?? Availability of qualified manpower for various construction activities. Work procedure duly approved. ?? Various requirement for sub activities to be identified for: ?? Pre construction ?? During construction ?? Post construction. E. DEPLOYMENT OF MACHINERIES: Since requirements and pour size has been frozen, pre planning of deployment of machineries is to be ensured with following details: ?? Availability of machineries on the day of concreting. ?? The conditions of equipment - Whether break down or working. ?? Availability of qualified crew to handle the machineries during construction ?? Availability of manpower for maintenance, if there is breakdown during execution of work.

?? ensure the safe access for deployment of machines at site To including: F. AVAILABILITY OF AREA LIGHTING AND PROPER ILLUMINATION AT WORK SITE. G. ENSURING SAFE ACCESS.: Inspection of access for ramps, any intervening obstacles from batching plant to site and at site up to pouring point. H. Stand by arrangement in case failure of equipment/Mechinary / Lighting arrangement. I. Arrangement of Sun / Rain protection. J. Arrangement for green cutting requirement and avalibility of approved material for green cutting. K. Availability of required number of mould for concrete cubes / Cylinder as per requirement. L. Review of improvement of pour plans done for earlier pours w.r.t effective out put obtained v/s planned. M. Necessary alteration or addition in requirements based on the review as per Para L above

CHAPTER 8 POUR CHECKING

CHAPTER 8
POUR CHECKING
The pre construction stage can be broadly classified as Pour Planning stage and Pour Checks stage. ?? Once pour is planned, it is required to check the various sub activities listed earlier in chapter 4 in parallel for speedy clearance of the pour. ?? This is ensured to avoid any delay required for rectification if any after pour is ready.

Following procedures is to be followed during pour checking: A. SITE REGISTER: - During parallel checking record of sub activities are to be cleared or observation to be recorded requiring rectification. This should be maintained at site regularly. B. Pour Card: - This gives pour inspection information. This enables to know about all concerned officials have extended their clearance for the specific pour. A Checklist can be prepared for specific activities, which shall help for clearing the pour card. C. Drawing control record: - Reference drawing must be checked with updated drawing control record. Further ECN, DCN, FCN, or hold if any between various grids and elevation also needs to be checked. Details of pour plan and sequence of concreting to be done at site and must be properly defined before start of the work. D. Other requirements: - Following information is also to be identified before start of the work. ?? Type of finish required. ?? Slope and its extent on the surface of concrete. ?? Location of sump in a pour if any. ?? Location of green cutting requirement in a pour.

?? Level of bulb of PVC water stops, its location and alignment. ?? Location and alignment of EPs. ?? Planned schedule after for the availability concreting. of If workers required during the and shift immediately

arrangement must be ensured. ?? addition to above following details are also important for Site In Supervisor / Site Engineer ?? Concrete requisition slip shall be given at least 24 hrs. in advance for all major pours to ensure availability of approved construction material. ?? Pour card clearance should be ensure before start of the work. ?? Assessment of job hazard and preventive measures to be ensured by Site Engineer. ?? Aptitude for safety and house keeping helps for faster and safer completion. ?? Post-concrete inspection report to be prepared for all major pours. E. Following are also required before start of concrete: ?? ensure availability and functioning of vibrators. To ?? Proper walkways. ?? Adequate Lighting arrangement. ?? Availability of walky talkies / Phones. ?? Covering material, for sun / rain protection. ?? Dewatering arrangement: - If work is being done during the monsoon and at lower elevation. ?? Stand - by arrangement of machineries to be ensured before start of the work. ?? Stand - by arrangement of power supply to be ensured before start of the work. ?? Ensure the availability of supervision staff for next few hours after last concrete is placed at site to maintain proper finishing, slope, etc as per requirement.

?? Awareness of reporting system to whom matter to be informed, in case of emergencies. (Knowledge of telephone nos. of immediate superior official is essential.) ?? During pour checking apart from the above requirement should important for a site supervisor / site engineer. ?? Pour card i.e pour inspection clearance. ?? Assessment of job hazard and preventive measures. ?? Aptitude for safety and house keeping. ?? Post-concrete inspection report ?? Concrete requisition slips at least 24 hrs in advance to be given to ensure, availability of approved material for the work. ?? Post-concrete inspection report ?? Rectification, if found any non-conformance during Post concrete inspection.

RESPONSIBILITIES OF SUPERVISOR / SITE ENGINEERS: CHECKING REQUIREMENT PRE CONCRETING: i. Site engineer has to ensure that necessary checking at the pour wise reference to various agencies have been checked and cleared. ii. Assessment of safe access, approach for machineries, workers etc is available. iii. Requirement w.r.t ramp, slope of access & approach and skilled manpower to handle the machineries like placer boom, concrete pumps, vibrators, concrete pipes, and necessary stand by spare parts is available. iv. Proper communication system from the batching plant to the place of pouring the concrete is available. v. Details regarding location from grid to grid - indicating final level / slope or finish to be maintained is identified. vi. Arrangement for green cutting and stand by arrangement for concreting is ensured.

CHECKING REQUIREMENT DURING CONCRETING i. ii. Skilled manpower like carpenter is available to review the position of formwork during concreting. Proper slope /levels/finishing/green cutting to be made on the finish concrete surface. iii. Alignment of support system of formwork needs continuous attention during concreting. CHECKING REQUIREMENT POST CONCRETING Once last batch of concrete is received and placed at site, site supervisor/ Engineer responsibility dose not ends with placement of the final load of concrete. Before he leaves the site he must ensure the arrangement required as per planning of the pour is available. Further the requirement of maintain green cutting / protection of the concrete surface from sun / rain and curing arrangement for the area to be ensured effectively. Post concrete inspection to done as per requirement w.r.t. 1) Alignment. 2) Dimension. 3) Levels. 4) Slopes. 5) Type of Finish. 6) Location & Levels of embedded parts.

CHAPTER - 9 BRIEF DESCRIPTION REGARDING CONCRETE AND MIX DESIGN DEVELOPMENT

CHAPTER - 9 BRIEF DESCRIPTION REGARDING CONCRETE AND MIX DESIGN DEVELOPMENT

WHAT IS CONCRETE: ?? Concrete is a basically heterogeneous mixture of cement, aggregates & water along with or without admixture. ?? Cement- we are using 43 Grade ordinary port land cement. ?? Aggregates Coarse aggregates produced from main plant excavated rock. ?? Fine aggregates Natural sand from Jhalawar river - Manufactured sand produced at site. ?? Water ?? Admixtures - Chemical admixture - Mineral admixture NORMAL CLASSIFICATION OF CONCRETES: (A) Based on density. ?? Lightweight concrete (Density varies from 300 Kg/cu.m to 1850 Kg/cu.m). ?? Normal weight concrete -(Density varies from 2200 to 2600 Kg/cu.m)(As per sepc. reqt. - Density = 2360 Kg/cu.m) ?? Heavy concrete (Density = 3300 Kg/cu.m) (As per our reqts. Density = 3630 Kg/cu.m). (B) Based on control ?? Nominal mix ?? Controlled mix (C) Based on strength ?? Lean concrete ?? Normal strength concrete ?? High strength concrete

(D) Based on performance ?? Normal concrete ?? High performance concrete (E) Special concretes ?? Fiber reinforced concretes ?? Polymer concretes ?? Ferro cement etc. HIGH PERFORMANCE CONCRETE: High performance concrete is the one, which is specially designed to perform the intended use as per specified requirements in both its fresh and hardened state. ?? Constructability in fresh state. ?? High strength. ?? Impermeability in its hardened state.

According to Neville: High performance concrete is concrete selected so as to be fit for the purpose for which it is required. There is no mystery about it, no unusual ingredients are needed and no special equipment has to be used. All we use is an understanding of the behavior of the concrete and will to produce a concrete mix within closely controlled tolerances. INTENDED USE OF CONCRETE IN NUCLEAR STRUCTURES:?? Radiological protection provided by structures: Uniform shielding & no through cracks. ?? Serviceability: By limiting deformation and leak tightness ?? Strength

PERFORMANCE REQUIREMENTS OF CONCRETE FOR NUCLEAR STRUCTUES:

MAIN PARAMETERS ?? Compressive strength ?? High tensile strength ?? High crack resistance ?? Good impact resistance ?? Low permeability ?? Low shrinkage ?? Low heat of Hydration ?? Low Creep ?? Good workability ?? Uniform density ?? Durability.

CHARATERISTICS OF M-45 GRADE CONCRETE

?? Grade of concrete ?? Characteristic compressive strength ?? Characteristic cylinder strength ?? Characteristic split tensile strength ?? Workability at the time of placement ?? Placement temperature less than 19 C. What we do to achieve the intended properties in the high performance concrete using the same ingredients it nothing but a stringent quality control and exhaustive study/ testing of the concrete ingredients and to have better control in selection of ingredients for HPC designing the mix accordingly.
0

M-45 45 mpa 36 mpa. 3.05 mpa. - 175 25 mm slump.

MATERIAL TESTING REQUIREMENTS FOR HPC. ?? Cement: Ordinary Portland cement 43 grade confirming to IS 8112 ?? Coarse Aggregates ?? Fine Aggregates ?? Water ?? Admixtures a) Chemical Admixtures: - As per ASTM C-494 99 ?? Type A- Water reducing admixtures ?? Type-B- Retarding admixtures ?? Type-C- Accelerating admixtures ?? Type- D- Water reducing & retarding admixtures ?? Type-E-Water reducing & accelerating admixtures ?? Type-F- Water reducing & high range admixtures. ?? Type-G- Water reducing, high range and retarding admixtures b) MINERAL ADMIXTURES: ?? ash Fly ?? Silica fume ?? Combination of fly ash & silica fume

BASIC STEPS FOR DESIGNING CONCRETE MIXES AS PER IS 10262

??TARGET STRENGTH FOR MIX DESIGN: fck = fck + 1.656 fck = Characteristic compressive strength at 28 days. s= Standard deviation for each grade of concrete. Characteristic strength is defined as that value below which not more than 5% results are expected to fall. Code provides values of standard deviations for various grades of concrete as per degree of control Mean str. x = ex n Standard deviation e = e (x-x)2 n-1 Coeff. Of variation = ? x 100 x

MEAN

1.65 95%

B) SELECTION OF WATER CEMENT RATIO: - Water cement ratio may be selected based on concrete target strength for different cement strength & the same is to be checked according to limitations given for environmental exposure conditions by IS code IS 456-2000.

C) ESTIMATION

OF ENTRAPPED AIR: Entrapped air % of volume of 3% 2% 1%

Max size of agg. (mm) concrete 10 20 40

a) Selection of water content & fine to total aggregate ratio from tables given in IS code according to max. size of aggregates. b) From water qty. Calculate cement from W/C ratio. Min. cement content to be ensured as per durability requirements fixed by IS under the specified environmental exposure conditions. c) Calculate volume of aggregates content in the mix d) Doses of admixtures and final adjustment of water content maintaining w/c ratio as per workability requirements are established based on actual trials in which minor adjustment are to be done in aggregates quantity to ensure correct yield. e) Temperature requirements can be met by the addition of ICE replacing equal qty. of water depending on concrete ingredient temperatures & ambient conditions. ACCEPTANCE CRITERIA AS PER IS 456-2000 Compressive strength (a) Mean strength determined from any group of four consecutive test results complies with the appropriate limits in column 2 of table below: (b) Any individual test result complies with the appropriate limits in column 3 of table below.

Specified grade M15 M20 Or Above

Mean strength for (a) Individual test (N/mm2) results in (N/mm2) =fck + 0.825 x ? or fck + 3 =fck 3 (N/mm2) (N/mm2) which ever is greater =fck + 0.825 x ? or =fck 4 (N/mm2) fck + 4 (N/mm2) which ever is greater

HPC should performs satisfactorily in the working environment during its anticipated exposure condition during service: -

THE FACTORS INFLUENCING DURABILITY INCLUDE: a) The environment b) The cover to embedded steel. c) The type and quality of constituents materials d) The cement content & water /cement ratio of concrete. e) Workmanship to obtain full compaction & efficient using. f) The shape & size of the member

(a) ALKALI AGGREGATES REACTION: ALKALI SILICA REACTION Alkali react in the silica (amorphous or partly crystallized) resulting in swelling causes an expansive pressure.
SiO2 + NaOH + nH2O ----- Na2 SiO3 . nH2O

(b) SULPHATE ATTACK

aluminates hydrate as follow:

The main chemical reaction is the forming of tricalcium sulfo

3 CaSO 4 + 3 CaO.Al2 O 3 + nH2O= 3 CaO.Al2O 3.3 CaSO 4.30-32 H2O Due to its high amount of crystalline water, this compound is highly expansive. The expansion causes the concrete to crack. CREEP: - Creep can be defined as the time dependent increase in strain without increase of stress i.e. under sustained stress. Under sustained stress with time the gel, the absorbed water layer, the water held in the gel pores and capillary pores yields, flows & readjust themselves which behavior is termed as creep in concrete.

Age of loading 7 days 28 days 1 year SHRINKAGE: a) Plastic shrinkage b) Drying shrinkage Total Shrinkage strain = 0.0003

Creep coefficient ration of ultimate creep strain plastic strain 2.2 1.6 1.1

CHAPTER - 10 REQUIREMENT FOR CONCRETE PRODUCTION, TRANSPORTATION, AND PLACEMENT.

CHAPTER - 10
REQUIREMENT FOR CONCRETE PRODUCTION, TRANSPORTATION, AND PLACEMENT.
It is important for Site Engineer/ Site Supervisor engaged in the Civil Engineering construction that the required quality of the work should be obtained while executing the work. Out of the total Civil work, concreting constitute the major part of the work hence required to exercise due care while production of concrete either through a Batching Plant or Concrete mixer, transportation of concrete either through manually or mechanically by transit mixers and placement of the concrete to the desired location in a pour either through manually or machineries i.e by crane or through a concrete pump or placer booms or through a chute. Awareness regarding the requirement at every stages are to be decided based on the requirement and mode of production/ transportation / placement methods for concrete. Following are few areas requirements are listed for exercising care by Site Engineer for the above for effective and desired output. A. CARE REQUIRED DURING PRODUCTION OF CONCRETING: The care required during production of concreting depends on various factors. 1. Based on the production of the concrete. Using concrete mixtures Using batching plants. 2. Depending on the weather condition i.e. is hot weather concreting or cold weather concreting. 3. Based on the time of concreting i.e. concreting done during day or night. 4. Based on distance of batching plant from the point of placement

5.

Based on the mode of transportation proposed i.e. manual / through transit mixture.

6.

Based on the mode of placement of concrete i.e. by manual/ by crane / by concrete pump / placer boom / by chute etc.

7. 8.

Based on the Rate of pour required. Based on the vertical drop of concrete from batching plant in to transit mixture.

a.

In addition to above site engineer required to ensure the following based on the requisition of concrete received for production of concrete.

i.

Availability of tested and approved construction material in required quantity.

ii.

The safe access for transportation of construction material to batching plant / concrete mixture.

iii.

Availability of power supply / DG supply / diesel fuel etc for running the batching plant / mixture for the desired duration.

iv.

Based on the past record of batching plant /mixture for production of concrete for no. of running hours / cumulative concrete production in cu. m., availability of spare parts to be ensured which needs frequently repair / replacement to avoid any delay during concreting.

v.

Availability of supporting machines like welding arrangement, skilled / unskilled crew for repairing the system.

vi.

Proper calibration of batching plant / weigh batcher prior to start the work. This is generally done at fixed frequencies.

vii. viii. ix.

Required rate of pour. Ensuring safety aspects at batching plant. Proper illumination and communication system at batching plant for effective coordination with engineers at point of placement.

B. CARE REQUIRED DURING TRANSPORTATION OF CONCRETE: The care required during transportation of concrete depends on various factors: 1. Mode of transportation, i.e based on the mode of transportation proposed i.e. manual / through transit mixture. 2. Based on distance of batching plant from the point of placement. 3. Based on the mode of placement of concrete i.e. by manual/ by crane / by concrete pump / placer boom / by chute etc. 4. Depending on the weather condition i.e. is hot weather concreting or cold weather concreting. 5. 6. 7. Based on required rate of pour. Based on stand by arrangement of transit mixers. Based on arrangement for availability of fuel, proper air pressure in tyres condition of transit mixers. 8. Based on safe access from batching plant to point of placement and necessary turning areas for transit mixers safely at site. 9. Walkie - Talkie to be provided in transit mixers for effective coordination. 10. Restriction of traveling speed of loaded and empty transit mixers 11. Ensure availability of water in water tank of transit mixers for immediate cleaning after concreting is done. 12. Sun protection of transit mixers and its pipes with gunny bags and ensuring the wetness of the same. C. CARE REQUIRED DURING PLACEMENT OF CONCRETE: It is the most important criteria of concrete since it decides the final quality and strength of concrete is structures. The cares required during placement of concrete are as follows: -

1.

Required consistency to be maintained from the point of production to point of placing. RPM of transit mixture should be around 4-5 RPM.

2. 3. 4. 5. 6. 7. 8. 9.

Ensure safe access for labours / skilled workers. Ensure planned arrangement of layout of concrete pipe route. Ensure Sun / Rain protection for green concrete. Ensure proper arrangement of vibratos. Ensure the location of EPs / Water stop / level of concrete etc as per drawing during concreting. Ensure type of finish and slope required in concrete. Ensuring the green cutting application within planned duration after concreting is done. Ensure that no cold joints should form. of delay in receiving the successive batch of concrete at site. Keep the check on time taken from batching plant to the time at point of placement w.r.t consistency and temperature.

10. Use of cement slurry to maintain the concrete green in case

11. Avoid over vibration in concrete. 12. Avoid vibration of initially hardened layer over which new concrete is been placed. 13. Maintain all safety aspects particularly while working in height and hazardous area. 14. Ensure proper illumination and communication. 15. Have leadership quality during difficult situations at site especially work done in night hrs/ total power cut situation / during any accident at site / during any industrial relation problem at site.

CHAPTER - 11 POST-CONCRETE INSPECTION

CHAPTER - 11 POST-CONCRETE INSPECTION

Responsibility of Site Engineer is not only to ensure proper pour planning and effective execution of the work but also to ensure that desired results w.r.t quality of the work, i.e finishing, slope, alignment and bulging etc. After formwork is removed site engineer must ensure the following w.r.t post concrete inspection. 1. Depending up on the tolerance available as per drawing and specification post concrete inspection to be made very next day after removal of the formwork. 2. Depending upon inspection testing plan record must be generated to have specific identification of nonconformance noticed beyond the acceptable limit. 3. Specific attention is given in the following area particularly: DEFECTS IN THE CONCRETE NOTICED. i. ii. Identification of honeycomb portion. Identification of bulging beyond the acceptable limit. beyond the acceptable limit. iv. Identification of improper slope in the concrete floor against requirement beyond the acceptable limit. v. Identification of poor construction joint needs immediate repair and attention to make it ready to received next course of concrete. vi. Identification of projected reinforcement or any other support casted for giving support of formwork needs to be treated properly after the purpose achieved for which it has been left.

iii. Identification of poor finish achieved against requirement

vii. Identification of tie holes which is to be repaired immediately before going ahead for next pours. viii. Removal of the left shutter / formwork piece / gunny bags etc. to be ensured, from concrete surface. ix. Identification of location of critical EPs if it is dislocated from the position or identification any left out of EPs if due to over sight or mismatch in the drawings. x. Identification of the location of the PVC water stop and their joints. xi. Identification of cracks to be ensured along with the comments if it is serious. xii. Identification of grouting nozzles etc to be made which have to be placed before next course of concrete. xiii. It must be ensured that scaffolding, pipes, other construction material should not be stacked on already constructed walls / locations where further pours are to be done and PVC water stop is partly embedded. This shall protect the PVC water bar from getting damaged. Necessary non-conformance to be issued for repair and rectification and final inspection to be made to ensure correctness of the above issues. *****

CHAPTER - 12 VARIOUS TYPES OF FINISHES IN CONCRETE

CHAPTER - 12 VARIOUS TYPES OF FINISHES IN CONCRETE

Various construction requirements particularly for the surface finish are decided based on the functional requirement / Aesthetical requirement in structure. VARIOUS TYPES OF FINISHES IN CONCRETE: Type of Finishes in concrete: (1) Formed Surface Finish F1: - Shall apply to all formed surfaces for which finish F2, F3 or any other special finish is not specified. Finish F1: - Shall include filling all form tie holes. Finish F2: - Shall apply to all formed surfaces so shown in the drawings or specified by the Engineer. Finish F2- shall include filling all form tie holes repair of gradual irregularities exceeding 6 mm, removal of ridges and fins and abrupt irregularities by grinding. Finish F3- shall apply to all formed surfaces exposed to view or where shown on the drawings or specified by the Engineer. Finish F3- shall include all measures specified for finish F2 and in addition, filling air holes with mortar and treatment of the entire surface with sack rubbed finish. It shall also include clean up of loose and adhering debris, where a sack rubbed finish is specified, the surfaces shall be prepared within two days after removal of the forms. The surfaces shall be wetted and allowed to dry slightly before mortar is applied by sack rubbing. The mortar used shall consist of one part cement to one and one half parts by volume of fine (IS No 16 mesh) sand. Only sufficient mixing water to give the mortar a workable consistency shall be used. The mortar shall then be rubbed over the surface with a fine burlap or linen cloth so as to fill all the surface voids. The mortar in the voids shall be allowed to stiffen and solidify after which the whole surface shall be wiped clean with burlap so that the entire surface presents a uniform appearance without air holes and irregularities. Curing of surface shall be continue for a period of ten days.

2) UNFORMED SURFACES

Finish U1

Finish U1 requires the surface in the specified slope /grade and

the gradual surface irregularities not exceeding 6 mm when measured with respect to a plane surface parallel to slope with a template 300 mm long. Screeding the surface of the concrete to the required slopes and grade as specified on drawings. Surfaces to be covered with concrete topping, terrazzo and similar surfaces shall be smooth screeded and leveled to produce even surface, irregularities not exceeding 6 mm.

Finish U2
Requirements shall be same as for U1 finish except the abrupt irregularities shall be repaired slope and grade. The surface shall have wooden finish.

Finish U3
Requirement shall be same as for U2 finish except that the surface shall have steel trowel finish and the edges of the concrete shall have the finish with edging tools. Repair of gradual irregularities exceeding 6 mm, finishing joints and edges of concrete with edging tools.

SURFACE PREPARATION FOR CONCRETE

Site engineers must ensure the following points for surface preparation while proposing concreting against rock surface or existing concrete surface. (A) Rock Surface (i) Inspection of rock surface for soundness. (ii) Cleaning of the surface to receive concrete. (B) Concrete Surface (i) Surface preparation: a) By Green Cutting b) By Chipping c) Cleaning of the surface (ii) Wetting of the surface prior to concreting.

Chapter - 13 DEFECTS IN CONCRETE AND ITS REPAIR

CHAPTER 13
DEFECTS IN CONCRETE AND ITS REPAIR
Post concrete inspection is a tool to identify the possible general defects in newly hardened concrete. The typical defects are: a. Occurrence of surface blemishes. b. Honey comb. c. Cavity holes due to tie rods. d. Various types of cracks in concrete. i. Plastic shrinkage cracks. ii. Plastic settlement cracks. iii. Drying shrinkage cracks etc. A. Occurrence of surface blemishes. The exposed surface area of concrete is blemished when spots or area vary noticeably and detract from the appearance of surrounding surface areas. Before treatment of blemishes, the contract documents should be referred to for identifying the acceptable level of blemishes for the various surface to be produced under the terms of given in the contract. Any repair process for treatment of blemishes so chosen should also be evaluated to determine if it would produce a less apparent and more pleasing appearance than the original blemish Repair When concrete surface is noticed with air bug holes: Site engineer can follow either of the following methods for corrective action. 1) Sack rubbing to repair the blemishes and the fill air bug holes. 2) Action should be such that the treatment is less apparent and more pleasing appearance. 3) Such treated surface should be cured properly

B. HONEY COMB: - During concreting if the voids left in the concrete due to failure of mortar to effectively fill the space among coarse aggregate than structure is said to have defect of honeycomb. Such defects occur due to: ? ?Congested reinforcement. ? ?Improper vibration. ? ?Difficult construction. ? ?Improper mix i.e. improper aggregate ratio of fine aggregate to total aggregate. ? ?Leakage of slurry from formwork gaps or damaged formwork. Site engineer can follow the either of the methods to minimize the defects: ? ?Ensure proper vibration. ? ?Ensure proper consistency using water-reducing admixture to increase slump. ? ?Ensure no gaps in the formwork to prevent slurry leakage. ? ?Using polymer modified cement sand mortar by hand of toweling this method can be used if honeycomb is less than concrete cover. ? ?If it is more than concrete cover that the area must be chipped off and concrete must be replaced with normal insitu concrete of same grade. C. Cavity holes due to tie rods. Tie rods, made of reinforcement steel, are often used to ensure that the form assembly remains intact when subjected to concrete pressure during concreting process. These tie rods are fixed with cones at both ends. These cones are open from outer end hence, when the formwork is removed, they are visible as holes. As this rods are made of reinforcement and their ends are open to atmosphere, if left expose for a long period, they are susceptible to correction. ? ?Repair method: - By dry pack mortar

CRACKS IN CONCRETE CRACK IN CONCRETE: - This defect permits the ingress of aggression agent in the structure and adversely affect. A. The durability. B. Water tightness. C. Integrity of structure i.e. strength Sound transmission: - Crack trough NDT techniques D. Various types of cracks in concrete. PLASTIC SHRINKAGE CRACKS: - This caused due to repaid loss of moisture due to temperature of ambient air and concrete, relative humidity and prevailing wind velocity at the surface of concrete. Site engineer should take following precautions to prevent rapid moisture loss due to hot weather and dry wind. I. Covering the concrete by plastic sheet. II. To provide sunshade during concreting. III. Use fog nozzles to saturate air above green concrete surface. IV. Use of windbreaker to reduce wind velocity. PLASTIC SETTLEMENT CRACKS: -concrete is consolidated after initial placement vibration and finishing. The plastic concrete generally give local retrain by reinforcement etc. and result cracks or known as plastic settlement crack. Site engineer should follow following preventive measure to minimize the plastic settlement cracks. ?? Maintain proper cover in concrete. ?? Provision of time interval between placement of concrete in slabs and beams. ?? Use or minimum slump concrete.

Drying shrinkage cracks: - When concrete is wet, it tends to expand. It reduces its volume, when loss of moisture from cement paste occurs. It can be explained in simple words. If this shrinkage can occur without any restrain no cracks will appear. But combination of shrinkage and restrain provided by another part of structure or by sub grade develops the tensile stress in concrete. This is resulting in crack known as drying shrinkage crack. Site engineer should follow the following methods to reduce this effects: ?? Use less w/c ratio in a concrete mix. ?? Use large amount of aggregate. ?? Proper consolidation of concrete. REPAIRING OF CRACKS: - In spite of precaution observed some times cracks are seen in the concrete surface and needs repair. The repairing of cracks mainly depends on: ?? Location and width of cracks. ?? Extent of crack ?? General condition of concrete. Following methods can be used for repair of cracks: 1) 2) GROUTING: - Wide crack can be filled by either cement grout or various chemical grouts. Dry packing: - Method used for minor dormant cracks but not effective for active cracks. Cracks are widened to a slot of 15-20mm vide and 20-25 deep with base width slightly more than surface width. This is packed by cement mortar with low w/c ratio. 3) Gravity filling: - Cracks can be filled upto with low viscosity epoxies.

4)

Routing and sealing: - This method is used where structural repair is not necessary. This procedure is more accurate for flat and horizontal surface like floors / pavements. These methods can be commonly used for water proofing by sealing cracks on concrete surface on concrete surface, where water stands or hydrostatic pressure applied.

5)

Injection grouting: - Repairing of narrow crack width upto 0.05 mm can be done. In this method GI or PVC nozzle is drilled in the cracked over upto depth of thickness of half the member and grouting is done.

Every Engineer has to deliver the output based on the requirement and facing the challenges to meet the quality standards with optimum use of manpower. It is need less to say that in a competitive environment, the restricted and compressed time schedule, the structural adequacies for the various problems are need to be reviewed as listed below: (1) (2) (3) (4) Overall strength and stability of the structure. Surface finish and appearance of the structure i.e. cracks leaching discoloration etc. Effect of leakage /seepage and effect of un-stability due to local parameters like improper backfilling/ undulations etc. Durability with respect to corrosion, carbonation and sulphate attack. Various type defect and damages in structures have been noticed over a period of time in various localities this has resulted a need for an Engineer to understand these defect and their respective possible causes. Responsibility is not only limited to identification of the damages but require to recommend necessary corrective measures including investigations if necessary.

Brief details of defects and damages occurred in concrete are indicated below along with their possible causes and suggested investigations for ready reference: CONCRETE Visible Defect Rust on surface. Possible Causes Iron compounds in aggregates, nails/wires left in formwork. Rust stains on surface. Corrosion of binding wires, Check cover and corrosion of reinforcement steel. Cracking of concrete cover, exposure of reinforcement and spelling of concrete Corrosion of reinforcement Check cover, test for and other steel due to moisture and chloride ingress, frost attack and poor quality of concrete low density, high porosity and high water to cement ratio). Surface crazing. Concrete Mix too wet and poor curing. Random diagonal cracking, lateral cracking at equal spacing Repetitive vertical or horizontal cracks. Inadequate protection against shrinkage, over rich or over wet and noncohesive concrete. Joint spacing too large. Examine joint details/spacing check concrete sample and aggregates used. Check concrete mix and construction method used. Check reinforcement, spacing of joint, analyze samples of concrete. chlorides and carbonation, check reinforcement adequacy. carbonation of concrete. Investigation Suggested Chemical analysis of samples.

Wet and damp spots, deteriorated applied finishes without cracking.

Honeycombs due to poor placement of concrete mix, poor compaction or water stopper missing.

Check concrete after recovering applied finishes, checks detailing of joints, check for water stopper, test and analyze concrete.

Cracks at intervals.

Restrained shrinkage, reinforcement too near the surface, corrosion of reinforcement, moisture movements. Faulty movement joints, faulty or missing water stopper, inadequate or improperly constructed join, inadequate reinforcement.

Check spacing of joints 9design), check distribution of reinforcement, concrete sample. Check concrete at joints, check water bars and reinforcement details.

Rust stains below mortar covering of external pre-stressing. Map cracking.

Tendon corrosion, poor grouting of tendons.

Check location/ extent of corrosion.

Alkali-silica reaction (ASR), Check concrete early drying out conditions, over rich mixes, over compaction and poor curing. constituents, pertographic analysis.

Surface abrasion.

Excessive wear.

Check abrasive loading, check quality of concrete surface, check history of usage.

Cracking or spelling with or without staining direction of reinforcement steel).

Corrosion of reinforcement Check condition of steel or pre-stress tendons alkali silica reaction (ASR), restrained by reinforcement. embedded steel, check cover, carbonation, chloride content, check presence of ASR.

(generally parallel to the corrosion of encases steel,

Deflection.

Shrinkable aggregate, premature removal of formwork, overloading.

Analysis of concrete samples design check. Investigate foundation design and substrate.

Local settlements along with diagonal cracks on footings (foundation)

Poor sub grade compaction, inadequate reinforcement, ground movement due to water / erosion/ mining/ shrinkage clays, peat or other causes.

Vertical or slightly inclined cracks on sides and soffit on central part of RCC beams.

If less than 0.3 mm: Normal if wider than 0.5 mm: Overload, excessive shrinkage of slab, premature removal of props.

Check design, compare actual load with design load, check span/ depth ration with codal requirements, check temperature gradient Check actual shear resistance against codal allowance.

Diagonally inclined cracks in beams, generally at or close to the supports. Vertical cracks in RCC beams at regular intervals.

Overloading, inadequate beams depth, inadequately provided reinforcement to prevent shear. Shrinkage around stirrups.

Helical cracks in RCC beams face and extending around the section perimeters. Excessive deflection of RCC beams.

Tensional shear stresses.

Check actual tensional resistance against codal requirement

Inadequate depth, overloading, formwork defect, inadequate or displace reinforcement, shrinkable aggregate, materials defective or deteriorated, bond failure between reinforcement and concrete.

Check span/depth ratio with codal requirements, compare actual and theoretical deflections, check loading history, cover meter check, test concrete, check for defects in construction.

Pre-stressed concrete beams with excessive deflection, excessive handing, loose or defective anchorage segment separation, grout disturbance and distribution not proper, segmental shear cracks. Bowing of pre-stressed columns.

Overloading, overstressing Check deflection, and or poor concrete, inadequate pre-stresses, displaced tendons, material defective or deteriorated. stresses against actual load, check conditions of all tendons, check design, check cover by cover meter.

Distortion during erection, concrete creep or shrinkage, tendon fractures, defective material or material deterioration.

Check loading conditions, check design and construction defects, check cover by cover meter, check tondon condition at any fracture. Check span/depth ratio with code requirements, compare actual and theoretical deflections,

Excessive deflection in slabs and / or heaving of tiles or cracking of tiles on the top surface.

Inadequate depth, overloading, for long period, defective formwork, inadequate or

displaced steel reinforcement, material defective or deteriorated, lack of continuity. Cracking of slab and / or finishes over supports. Plastic and drying shrinkage cracks, slab designed as simply supported but constructed as continuous or with fixed supports, inadequate top reinforcement in continuously designed slab, excessive support memento relaxation, inadequate top steel at supports, top steel displace.

check loading history, check cover by cover meter, check for shrinkable aggregates. Check design, check construction defects and cover by cover meter.

CHAPTER - 14 VARIOUS TYPES OF JOINTS

CHAPTER - 14
VARIOUS TYPES OF JOINTS
The site engineer is required to complete the work as per drawing requirement to the minimum possible time. It is a fact that the entire work can not be completed in just single pour due to the constraint of non availability of resources as per requirements, due to technical reasons i.e considering thermal strain and expansion & contraction properties of structure. Generally there are following types of joints are to be handled during Civil construction. 1) CONSTRUCTION JONTS: 2) EXPANSION JOINT AND CONTRACTION JOINT: 3) COLD JOINT: CONSTRUCTION JONTS: Construction joints occur wherever concreting is stopped or delayed and when the fresh concrete placed against hardened concrete subsequently cannot be integrated into previous by vibrating. Horizontal construction joints occur at levels between two successive lift of concrete, whereas vertical construction joints occur where structure of such length that is not feasible to place the entire length in one continuous operation. Construction joints, are required by the construction operation. Construction joint locations depend on sequence of concreting operations or are part of the contract drawings. Construction joint location need to be planned ahead of placing of concrete and should adhere to those pre identified locations. Generally, they mark the top of a lift, the end of a monolith, or the end of a days work. They should be properly located and well bonded.

The following factors are to be considered for location and treatment of construction joints to make them perfect and avoid cold joints. ?? When the work is to be interrupted, horizontal and vertical construction joints and bonding keys should be located in conformity with the relevant contract specifications/drawings. ?? Construction joints should be located in the floor slab and beams near the middle of the span (where the shear is least) and should be vertical in the absence of provisions in construction drawings. In a column, the joint should be formed about 75 mm below the lowest soffit of the beams framing in to it. ?? Because construction joints frequently leak and degrade in the weather, as far as possible, they should be avoided. Before fresh concrete is placed. Existing concrete surface must be made rough by hacking or green cutting. ?? The rough surface should be thoroughly wetted for about two hours and should be dried and coated with 1:1 freshly mixed cement sand slurry, immediately before pacing the new concrete. GREEN CUTTING FOR CONSTRUCTION JOINT TREATMENT: Where higher degree of quality of construction joint treatment is required as per contract specification/or drawings, green cutting should be applied. The entire construction joint should be treated by Green cutting using air / water jet at a suitable pressure to remove the laitance from the green concrete surface to received subsequent pour of concrete over it. A suitable, approved brand of surface retarder should be used to retard setting time of green concrete to a depth of 5 to 8 mm. Green cutting should b done only after the final setting of concrete, so that the additional water available from air water jet used for green cutting on the surface does not harm the quality of the concrete. Prior to commencement of the green cutting operation, a mockup should be

made for each grade of concrete, with different types of cement and different kinds of exposure of the proposed construction joint. EXPANSION AND CONTRACTION JOINTS: - Expansion and contraction joints should be strictly as per the relevant construction drawings only. Line and level of water stop and expansion boards, if any at these joints should be safeguarded from damage or dislocation during placing and consolidation of concrete.

*****

CHAPTER - 15 ASSESSMENT OF SAFE WORKING CONDITIONS WHILE EXECUTING THE JOB.

CHAPTER15
ASSESSMENT OF SAFE WORKING CONDITIONS WHILE EXECUTING THE JOB.
Responsibility of Site engineer with respect to safety requirements at site is most important parameter.
Every site engineer must ensure availability of safe working condition while executing the job. Following few areas must be given attention. 1. 2. Suitable scaffolds shall be provided for workmen for all works that cannot safely be done from the ground.. Scaffolding or staging more than 3.5 m above the ground or floor, swing of suspended from an overhead support or erected with stationary support shall have standard guard rail properly attached bolted, braced or otherwise secured at least 1.0 meter high above the floor or platform of staging.. 3. 4. 5. 6. Working platforms of scaffolds shall have toe boards at least 15 cm in height to prevent materials from falling down. Working platform, gangways and stairways shall be so constructed that they shall not sag unduly or unequally Safe means of access shall be provided to all working platforms and other elevated working places Adequate precautions shall be taken to prevent danger from electrical lines and equipment. No scaffolding, ladder, working platform, gangway runs, etc. shall exist within 3 meters of any uninsulated electric wire. 7. 8. 9. Proper house keeping must be maintained at site. Necessary personnel protective equipments must be used while working. Safety work permits to be ensured while working at height, hazardous operations, work in radiation area, work in and around water body.

10. Slope of ladder shall not be steeper than 1 in 4 i.e. 1 horizontal to 4 vertical. 11. Ladder shall not be used for climbing with carrying materials in hands. 12. Due care must be taken while removal of formwork. 13. Use of safety belt to be ensured while `working at height. 14. Proper illumination and frequent checking of scaffold to be maintained. 15. All loose material should be removed. 16. Any material having fire hazard to loose formwork pieces, wooden block must be removed from the working area. 17. Ensure deployment of only quality and skilled manpower for handling. The movement of construction, concrete, formwork, re-steels pipes etc at site. 18. Ensure to avoid any temporary steep slope or ramp at site for movement of works and machineries. 19. Maintain a house keeping culture at site. Ensure to stack all construction material like formwork, pipes etc properly stacked so that safe approach is maintained. 20. Construction material likes re steel, aggregate, sand, also to stacked properly. 21. Ensure proper communication while entering in a hazardous area. 22. Inculcate the safety as culture and habit within the group.

CHAPTER - 16 IMPORTANCE OF JOB HAZARD ANALYSIS.

CHAPTER - 16 IMPORTANCE OF JOB HAZARD ANALYSIS.

Work can only be said to complete successfully if requirements with respect to quality have been maintained without any accident during execution of the work. Safe working condition not only increases the output, but also gives satisfaction and confidence while working in any of difficult conditions. For a Site engineer it always preferred that we must know about the work in totality. This will help us to identify the various sub activities involved in the work and to assess the possible hazards during executing the work. Action required to prevent such possible hazards must be enlisted and honest efforts must be made to avoid any unsafe conditions during execution of the work. It is preferred that job hazard analysis should be done before start of the work. Sample format for job hazard analysis in given below for ready reference. Name of the work Duration of the activities Sr.no Activities ::Possible hazards Action to be taken for prevention of hazards MAJOR ACTIVITY TO BE TAKEN UP: -

CHAPTER - 17 AWARENESS OF QA REQUIREMENTS

CHAPTER 17
AWARENESS OF QA REQUIREMENTS
A most impartment part for implementing any QA requirement needs to understand about the intent and meaning of the quality. The brief description about the terms generally used related to QA are summarized below. Quality: - Totality of feature and characteristic of product or service that bears on its ability to satisfy stated or implied need. Stated needs means contractual needs. Implies Need means Identifies and defined needs i.e Usability, Safety, Reliability, Availability and Maintainability. Specification: - Document that describes the requirement with which the product / service has to confirm. It should refer to pattern, drawing, or code. Or indicate the criterion by which checks to be made. Checks used to confer the specification requirement. Procedures. : - An identified and defined sequential activities to perform the task is known as procedure. It is specified way to perform the activity. It contain purpose and Scope, What, When, By Whom, Where, How the activities to be done, Reference, Control Required and record to be maintained. Inspection: - Activities such as measuring examining, testing, gauging are made and compared with the standard to determine the conformity of requirement. Quality assurance: - Adequate and proper planning and systematic action which are necessary to provide adequate confidence that product or service will satisfy given requirement for quality.

Quality Control: - The operational techniques are performed to full fill the requirement of quality. 1) Monitoring a process. 2) Removes causes of conformity at relevant stages to increase economic effectiveness Process: - A set of interrelated resources and activates which transforms input to output. Quality surveillance: - The continuing monitoring and verification of status of procedure, methods, conditions referred as quality surveillance. In relation to stated reference to ensure that specified requirement is made. Quality surveillance: - Takes in to accounts the areas to deterioration or degradation with time. Quality System: - It is defined as organization structure management function that determines and implement quality policy. Quality Management: - It is aspect of overall management function that determines and implements quality policy. Quality policy: - It is defined overall intensions and direction of an organization management. Total quality management: 1) It is a management approach of an organization cantered on quality. 2) Based on participation of all its members. as regard to quality formally expressed by top

3) Aiming at long-term success through customer satisfaction, and benefits to the member of organization at safety. Quality manual: - A document stating the quality policy and describing the quality system of and organization. QA Plans: - It is a systematic way of describing the extent and responsibility for checking and acceptance of various sub activities with respect to defined references and specification. Quality Audit: - It is systematic and independent examination to determine. 1) Whether the quality activities and related result comply with the planned arrangement. 2) Whether there planned arrangement are implemented effectively or not. 3) Planned arrangements are suitable to achieve the objective. Site engineer must know that there are three Quality Assurance manual in our organization. (i) Topical QA manual: A document stating quality policy and describe the quality system of total organization. (ii) Project QA manual: A document stating quality policy and describe the quality system of specific project in line with requirement stated in topical QA manual. (iii) Specific work related QA manual: A document stating quality policy and describe the quality system of agency executing the specific job / contract in a project in line with requirement stated in topical QA manual and Project QA manual.

Site engineer also must ensure the following while supervising the work: 1) Implementation of relevant specification required for the work. 2) Implementation of work procedure for specific construction activity. 3) Inspection and testing plan for the referred work. 4) Ensure availability and use of proper approved construction material at site. 5) Ensure the deployment of qualified manpower at site for various construction activities. 6) Ensure concrete pour plan arrangement as per schedule plan. 7) Proper supervision during pre execution, during concreting and post concreting. 8) Ensure repair of defects / deficiencies, if found as per approved procedure. 9) Ensure appropriate documentation for the work.

Effective and desired results with optimum use of departmental manpower engaged in Supervision of Construction activities is always a major concern of NPCIL vision and policy. He has provided Enthusiastic and inspiring support for development of this document

C.P. JHAMB PROJECT DIRECTOR, RAPP-5&6 Providing dedicated & committed leadership

Development of this document as handy tool and reference to requirement of Site Supervisors and Site Engineers directly connected with the work was the vision of Sh. D.K.JAIN, Chief Engineer (Civil), RAPP-5&6. This could be made possible due to his efficient and able leadership, effective guidance, continuous motivation and appreciation at every stage.

D.K.JAIN CHIEF ENGINEER (CIVIL), RAPP-5&6 A man with inspiring and strong vision.