Construction Materials

1.0. Stones 2.0. Cement 3.0. Sand 4.0. Reinforcement 5.0. Bricks 6.0. Concrete 7.0. Plastering 8.0. Land Area 9.0. % of Construction Cost 10.0. Painting 11.0. Materials Testing 12.0. Civil Engineering Basic Knowledge 13.0. Testing of Materials 11.0. Quality Assurance 12.0. Shuttering 13.0. Electrical 14.0. Plumbing

Ali Amzad
ali_amzad2006@yahoo.com

Stones
Stone Gravel/Coarse Aggregates Coarse aggregates are normally small pieces of stone which give concrete its strength. The two most commonly used sizes are inch or 20 mm and inch or 12 mm. At times both are used together in the ratio of 60:40 or even up to 70:30. While selecting the coarse aggregate, the following points should be kept in mind : Coarse aggregate should be solid, in the shape of a cube and free from dirt. Any form of contamination should be immediately removed. The right proportion of large and small size pieces should be selected. This is to ensure that the space between the large stonechips is filled in by the smaller pieces.

Cement
Q. What is portland cement? Portland cement is composed of calcium silicates and aluminate and aluminoferrite It is obtained by blending predetermined proportions limestone clay and other minerals in small quantities which is pulverized and heated at high temperature around 1500 deg centigrade to produce clinker. The clinker is then ground with small quantities of gypsum to produce a fine powder called Ordinary Portland Cement (OPC). When mixed with water, sand and stone, it combines slowly with the water to form a hard mass called concrete. Q. Is there any shelf life of cement? Cement is a hygroscopic material meaning that it absorbs moisture In presence of moisture it undergoes chemical reaction termed as hydration. Therefore cement remains in good condition as long as it does not come in contact with moisture. If cement is more than three months old then it should be tested for its strength before being taken into use. Q. Does fineness of cement affect strength gain? Fineness defines the surface area of cement particles present in per unit weight, which implies that more fineness means more particles in unit weight. This enhances the reaction rate which in turn will result in faster gain of strength at earlier stages as well as liberates higher heat, therefore proper curing in initial days is very essential. Q. What is initial and final setting time of cement? Initial set is when the cement paste loses its plasticity and stiffens considerably. Final set is the point when the paste hardens and can sustain some minor load. Both are arbitrary points and these are determined by Vicat needle penetration resistance.

Q. What are the reasons for slow or fast setting of concrete or mortar? Slow or fast setting normally depends on the nature of cement. It could also be due to extraneous factors not related to the cement. The ambient conditions play an important role. In hot weather, the setting is faster, in cold weather, setting is delayed Some types of salts, chemicals, clay, etc if inadvertently get mixed with the sand, aggregate and water could accelerate or delay the setting of concrete. Q. What are the different grades of Ordinary Portland Cement (OPC)? The Bureau of Indian Standards (BIS) has classified OPC in three different grades The classification is mainly based on the compressive strength of cement-sand mortar cubes of face area 50 cm2 composed of 1 part of cement to 3 parts of standard sand by weight with a water-cement ratio arrived at by a specified procedure. The grades are: (i)33 grade (ii)43 grade (iii)53 grade The grade number indicates the minimum compressive strength of cement sand mortar in N/mm2 at 28 days, as tested by above mentioned procedure.

Q. What is Portland Pozzolana Cement? Portland Pozzolana Cement (PPC) is obtained by either intergrinding a pozzolanic material with clinker and gypsum, or by blending ground pozzolana with Portland cement. Nowadays good quality fly ash is available from Thermal Power Plants, which are processed and used in manufacturing of PPC. Q. What are the advantages of using Portland Pozzolana Cement over OPC? Pozzolana combines with lime and alkali in cement when water is added and forms compounds which contribute to strength, impermeability and sulphate resistance It also contributes to workability, reduced bleeding and controls destructive expansion from alkali-aggregate reaction. It reduces heat of hydration thereby controlling temperature differentials, which causes thermal strain and resultant cracking n mass concrete structures like dams. Q. Does the shade of cement affect quality? No. The quality of cement depends upon the raw materials used and the quality control measures adopted during its manufacture, and not on the shade of the cement. The cement gets its colour from the nature and colour of raw materials used, which will be different from factory to factory, and may even differ in the different batches of cement produced in a factory. Further, the colour of the finished concrete is affected also by the colour of the aggregates, and to a lesser extent by the colour of Q. What is the effect of long storage periods on cement? Cement which is in the form of a fine powder has a tendency to absorb moisture present in the atmosphere. When it absorbs moisture it hydrates, and when subsequently used does not contribute to the strength development. Jute bags (gunny bags) in which cement is bagged are neither airtight nor damp-proof and do not prevent absorption of moisture. Cement deteriorates in quality long storage. Cementon bagged in woven polythene bags or paper bags are not likely to deteriorate to the extent mentioned above. The loss of strength also depends on the condition of the godown. It is advisable to use cement within three months of its bagging, or to test the cement for its strength if stored for longer periods. Hence cement bought first should be used first. Q. How should cement be stored? Precautions that must be taken in the storage of Portland cement are given below in a series of DONTs. (i)Do not store bags in a building or a godown in which the walls, roof and floor are not completely weatherproof. (ii)Do not store bags in a new warehouse until the interior has thoroughly dried out. (iii)Do not be content with badly fitting windowsand doors, make sure they fit properly and ensure that they are kept shut. (iv)Do not stack bags against the wall. Similarly, dont pile them on the floor unless it is a dry concrete floor. If not, bags should be stacked on wooden planks or sleepers. (v)Do not forget to pile the bags close together. (vi)Do not pile more than 15 bags high and arrange the bags in a header-and-stretcher fashion. (vii)Do not disturb the stored cement until it is to be taken out for use. (viii)Do not take out bags from one tier only. Step back two or three tiers. (ix)Do not keep dead storage. The principle of first-in first-out should be followed in removing bags. (x)Do not stack bags on the ground for temporary storage at work site. Pile them on a raised, dry platform and cover with tarpaulin or polythene sheet. Q. How to identify the time for which the cement was stored before use? On the cement bag, week number, month and year of manufacturing are being mentioned and this can be checked before use.

Proper usage of Cement An optimum quantity of cement must be used for any construction. It is a myth that high grade cements can be used in lower quantities. If lower quantities of cements are used, then an additional quantity of water is required. This would mean a distorted water to cement ratio, and the result would reduce the strength and durability of the A common misunderstanding is that high grade cements result in better results. The grade of cement only indicates its compressive strength after a period of 28 days. However, blended cement continues to increase in strength beyond that period. Therefore, with the long term objective of a lasting home, blended or composite cements are usually preferred. Yet another misconception is that quick seeking cement should be used. It is advisable to allow all concrete structures the requisite time for setting. Ask the mason or contractor to be patient if they complain about the time it takes to set. Slower setting cement does not necessarily mean that it will not provide long-term strength. Some people believe that the colour of cement determines its quality. This is totally untrue. The colour of the cement is determined by the quantity of the raw materials used in its manufacture Some Additional Tips If you have doubts about the quality of cement, the first step would be to consult the manufacturer. However, this simple test will also suffice. Make a paste of a cement with one-fourth the quantity of water and make cubes or blocks of 50x50x20 mm size. Leave aside the cubes/blocks for a day. Test them to see how easily they break. If the cement is of good quality, the blocks will not crumble if you try to crush it with your fingers. Cement is known to react with water and, therefore, protection from moisture is of paramount importance. It would be best to store the cement bags in an enclosed godown. Ideally, the bags should also be placed on a platform at least 6 inches above floor level, leaving a gap away from the walls. Normally, each stack should not have more than 15 bags. A first in first out process should be followed. Cement should always be used within 23 months of its manufacture.

Sand

Bricks
Bricks and their Selection Bricks can be tested just by observation. Visually they should be in the correct shape with sharp corners. A uniform colour also ensures good quality. One test is to break a brick, it should not scatter into small pieces. Another process of testing is to strike two bricks against each other. Good quality bricks produce a ringing sound when struck with each other. Also, a good brick when dropped from a height of about a meter should not break. Another practical test is to soak a brick in water for about 24 hours. The weight of the brick before and after soaking should be checked. If the brick shows an additional weight of more than 15% after soaking, it should be rejected. For example, a dry brick weighing 2 kg should not weigh more than 2.3 kg after being soaked in water for 24 hours. Brickwork The following mortars are suggested: for a 4 inch wall (divider walls in the middle of the house) cement:sand = 1:4 for a 9 inch wall (outer walls) cement:sand =1:6 Before beginning work, ensure that the bricks have been soaked in water for 8 hours. Do not use completely wet bricks as the cement mixture will not stick properly. After joining the bricks, the correct cutting or raking of the mortar is essential. This helps the adhesion of the plaster. The thickness of the brick joints should not be more than 1 cm. The vertical joints should never be continuous. It is best not to lay bricks higher than 5 feet at a time, as the mortar should given adequate time to set. The task of joining should begin from 2 corners (3-4 layers). The parts in between should be filled within the leftover frames. The line level and plumb need to be continuously checked. Curing must be done for at least 10 days. In this context, please read the section on the quality of bricks carefully.

Reinforcement
Q. What is steel reinforcement? Why is it required in a concrete structure? Steel reinforcements are used, generally, in the form of bars of circular cross section in concrete structure. They are like a skeleton in human body. Plain concrete steel or any other reinforcement is strong in compression but weak in tension. Steel is one of the best forms of reinforcements, to take care of those stresses and to strengthen concrete to bear all kinds of loads. Q. What is bar-bending-schedule? Bar-bending-schedule is the schedule of reinforcement bars prepared in advance before cutting and bending of rebars. This schedule contains all details of size, shape and dimension of rebars to be cut. Q. What are the different types of steel reinforcements being used in a reinforced concrete structure? Mild steel bars conforming to IS: 432 (Part I) and Cold-worked steel high strength deformed bars conforming to IS: 1786 (grade Fe 415 and grade Fe 500, where 415 and 500 indicate yield stresses 415 N/mm2 and 500 N/mm2 respectively) are commonly used. Grade Fe 415 is being used most commonly nowadays. This has limited the use of plain mild steel bars because of higher yield stress and bond strength resulting in saving of steel quantity. Some companies have brought thermo mechanically treated (TMT) and corrosion resistant steel (CRS) bars with added features. Bars range in diameter from 6 to 50 mm. Cold-worked steel high strength deformed bars start from 8 mm diameter. For general house Q. Why cover blocks are required to be placed before concreting? What are their sizes? Cover blocks are placed to prevent the steel rods from getting exposed to the atmosphere, and to place and fix the reinforcements as per the design drawings. Once the steel is exposed to the atmosphere, corrosion starts. Sometimes it is commonly seen that the cover gets misplaced during the concreting activity. To prevent this, tying of cover with steel bars using thin steel wires called binding wires (projected from cover surface and placed during making or casting of cover blocks) is recommended. Covers should be made of cement sand mortar (1:3). Ideally, cover should have strength similar to the surrounding concrete, with the least perimeter so that chances of water to penetrate through periphery will beof minimized. Provision of minimum as per the Indian standards for durability of the whole Shape the cover blocks could be cubicalcovers or cylindrical. However, cover indicates thickness of the cover block. Normally, cubical cover blocks are used. As a thumb rule, minimum cover of 2 in footings, 1.5 in columns and 1 for other structures may be ensured.

Q. How important are transverse reinforcements like links and stirrups? What precautions should be taken while tying them? Transverse reinforcements are very important. They not only take care of structural requirements but also help main reinforcements to remain in desired position. They play a very significant role while abrupt changes or reversal of stresses like earthquake etc. They should be closely spaced as per the drawing and properly tied to the main/longitudinal reinforcement. Q. What is a lap or development length? Where and how should they be provided? Lap length is the length overlap of bars tied to extend the reinforcement length.. Lap length about 50 times the diameter of the bar is considered safe. Laps of neighboring bar lengths should be staggered and should not be provided at one level/line. At one cross section, a maximum of 50% bars should be lapped. In case, required lap length is not available at junction because of space and other constraints, bars can be joined with couplers or welded (with correct choice of method of welding). Q. What is anchorage length? This is the additional length of steel of one structure required to be inserted in other at the junction. For example, main bars of beam in column at beam column junction, column bars in footing etc. The length requirement is similar to the lap length mentioned in previous question or as per the design instructions.

Q. What is the checklist for steel reinforcement before the placement/pour of concrete? Reinforcement should be free from loose rust, oil paints, mud etc. it should be cut, bent and fixed properly. The reinforcement shall be placed and maintained in position by providing proper cover blocks, spacers, supporting bars, laps etc. Reinforcements shall be placed and tied such that concrete placement is possible without segregation, and compaction possible by an immersion vibrator. Q. For a given diameter, how do we calculate the weight of steel per meter length of the steel bar For steel reinforcement bar, weight per running meter is equal to d2/162 Kg, where d is diameter of andany vice versa? the bar in mm. For example, 10 mm diameter bar will weigh 10x10/162 = 0.617 Kg/m. Q. Can we receive the quality test certificate of steel from the supplier? Yes. We can receive the test certificate of the batch of materials supplied at our site. The certificate will confirm the compliance of quality of supplied materials as per the requirement of relevant Indian standard code.

CONCRETE
Q. What is concrete? Concrete is a mixture of cement, sand, stone aggregates and water. Q. What is RCC? If a concrete mix is placed in and around a cage of steel rods, it is called Reinforced Cement Concrete (RCC).

Q. What is mortar? Mortar is a mix of cement, sand and water, to be used for brick works/block works and plaster. Q. How much water should be added in a concrete mix of one bag of cement for normal construction work? Normally the amount of water that is required per bag of cement is 25 -28 liters only. Q. How does color affect the quality of cement & its concrete? Quality of cement has nothing to do with its color. Q. What precautions should one take for water to be used in concrete construction? It is good to use potable quality of water. It should be free from impurities and harmful ingredients. Seawater isnt recommended. The water fit for mixing is fit for curing too. Use of minimum quantity of mixing water, consistent with the degree of workability required to enable easy placing and compaction of concrete, is advisable Ensure that water is measured and added Low water to cement ratio is essential for good performance of the structure in the long run.

Q. What is the minimum recommended concrete mix proportion for RCC works? 1:1.5:3, where 1 part of cement is to be mixed with 1.5 parts of sand and 3 parts of coarse aggregates. Water requirement for the mix would be less than 25 liters per bag of cement.

Q. What are the common mistakes, which affect the quality of concrete? The ways in which concrete maybe spoilt are many, most common of them being: Use of too much or too little water for mixing, or water carelessly added during mixing. Incomplete mixing of aggregate with cement Improper grading of aggregates resulting in segregation or bleeding of concrete. Inadequate compaction of concrete Using concrete which has already begun to set. Placing of concrete on a dry foundation without properly wetting it with water. Use of dirty aggregate or water containing earthy matter, clay or lime. Too much troweling of the concrete surface. Leaving the finished concrete surface exposed to sun and wind during the first ten days after placing without protecting it and keeping it damp by proper methods of curing.

Q. What are the factors responsible for governing the compressive strength of concrete? The compressive strength is governed by the following factors: (i)w/c ratio (ii)characteristics of cement (iii)characteristics of aggregates (iv)time of mixing (v)degree of compaction (vi)temperature and period of curing (vii)age of concrete (viii)air entertainment (ix)conditions of testing Q. Within how much time the freshly prepared mortar / concrete should be consumed? The mortar / concrete should be consumed as early as possible after addition of water to it. The hydration of cement starts the moment water is added to it. As the hydration progresses the cement paste starts stiffening and loses its plasticity. The concrete should not be disturbed after this. Normally, this is about 45 50 minutes. Q. Why is compaction essential? Green concrete has all the three phases solids, water air. In order to make the concrete impervious & attain its maximum strength it is required to remove the entrapped air from the concrete mass when it is still in plastic state. If the air is not removed completely, the concrete loses strength considerably. It has been that 5% voids reduce the strength by about 30% and 10% voids reduce the strength by over 50%. Compaction eliminates air bubbles and brings enough fine material both to the surface and against the forms to produce the desired finish. One can use such hand tools as steel rods, paddling sticks, or tampers, but mechanical vibrators are best. Any compacting device must reach the bottom of the form and be small enough to pass between reinforcing bars. Since the strength of the concrete member depends on proper reinforcement location, be careful not to displace the reinforcing steel. CURING Q. What is curing and why is it so important? The term curing is used to include maintenance of a favorable environment for the continuation of chemical reactions, i.e. retention of moisture within, or supplying moisture to the concrete from an external and protection against extremes of temperature. Q. What is the correct method of curing? If a concrete mix is placed in and around a cage of steel rods, it is called Reinforced Cement Concrete (RCC). Walls: Water should be sprinkled from the top such that it covers the whole area of the wall and it should be remain wet. Slab: Ponding should be done on the slab by constructing bunds of mortar of approximately 1mX1m and water should be stored. Beams and columns :The beams and columns can be maintained wet by tying gunny bags around the periphery and by maintaining it wet always. Q. What methods are commonly employed to ensure sufficient moisture for curing? Ponding, continuous sprinkling, covering with wet cloth, cotton mats or similar materials, covering with specially prepared paper, polyethylene, sealing coat applied as a liquid commonly known as curing compound which hardens to form a thin protective membrane, are some of the methods by which concrete is cured.

Q. When should curing be started and when is it complete?

Curing should be started just after the surfaces begin to dry. Normally 7 to 14 days curing is considered adequate.

Concrete Work For RCC work, the ingredients of concrete should be in the ratio of 1:1.5:3 (cement one part, sand 1.5 parts and coarse aggregates 3 parts). All of these items are measured by volume and are best measured using a container of wood or steel. Traditionally, the size of this container would be 350x250x400 mm, which holds 35 litres. While preparing the mixture, 25 litres of water must be added per bag of cement. If the mix is prepared in a machine, it should be mixed for at least 2 minutes so that the mixture blends well with the water. If you are mixing by hand, then it is advisable to prepare a dry mix of cement and sand in a tray. After blending, when the colour appears uniform, the coarse aggregate may be added and then finally add the water. The concrete mix should be cast before it begins to set. Normally, concreting should be completed within 30 minutes to an hour. In case of any delay, do not add any more water just to improve its flowing consistency. The casting of concrete should be done continuously, i.e., layer over layer. The mixture should be poured from a maximum height of 1.5 metres. This avoids the ingredients separating. The mixture must then be properly compacted. It is best to complete this task with a needle vibrator. If this is unavailable, an iron rod could be substituted. This is done to ensure that there are no air bubbles in the concrete, as this would weaken it.

Curing The process of maintaining moisture in the concrete is called curing. Concrete begins to dry after casting. So, the parts exposed to the environment should be cured to ensure that the concrete surface is never dry. This needs to be done continuously, till the mandated period of curing. Usually, 10-14 days of curing is considered optimal. It is best to make small curing ponds or bunds on flat or horizontal surfaces. For vertical surfaces, you may wrap jute or hessian cloth on the surface and then pour water onto it. This helps keep the surface wet for longer periods.

Plastering
Q. Why plastering is required? Plaster protects structure from temperature variations; external attacks of sulphates, chlorides, etc. Plaster also provides smooth & aesthetic surface on RCC & Brickwork surface.

Q. What precautions should be taken during plaster works? Preferably use cements which releases low heat of hydration. Blended Cement is a good choice. a) Use optimum water at the time of mixing. b) Do not use dry cement on the plaster surface. c) At the junction of Brickwork & RCC, chicken mesh or fiber mesh may be used. d) Wet the surface before plastering. e) Cure the surface for at least 10 to 12 days. Plastering Plaster is the skin of your house. Just as our skin gives shape and texture to our body, and protects your house from damage caused by salts, acid and rain. It also makes your house look beautiful. Therefore, it is important to pay close attention to it. Ensure that the wall is slightly wet before starting the plastering. Dry walls adsorb water from the plaster and this will cause the plaster, in time, to fall off. Check that the mason has not prepared the mix for the whole day. The mix must be prepared only in small quantities; as much as will be used in an hour. Your mason can, however, keep a large quantity of dry mix ready. The usual mix proportion is: 1:5 to 1:6 for internal plaster 1:4 to 1:5 for external plaster 1:3 to 1:4 for the ceiling However, if the sand particles are very fine, 1:4 ratio mix is suitable for all three areas. Use wooden float for finishing as steel floats can sometimes cause small cracks. Curing should be done for 1014 days.

Planning & Estimation

Q. What are carpet area, built-up area & super built-up area? Carpet Area: This is the area of the apartment/building, which does not include the area covered by the walls. Built up Area: The carpet area plus the area of the walls. Super Built up Area: This includes the built up area along with the area under common spaces such as the lobby, lifts, stairs, etc. Q. What are the things one should keep in mind before finalizing a land deal? Some points which one must pay attention to prior to land deal a) House plot should not be under any acquisition proceedings of any government bodies . b) Verify from the planning authorities whether the land was designated for residential use. c) The survey number of land is critical. d) Certificate obtained from registrars office should confirm that there is no encumbrance on the property. e) The title deed of the land should be clear and an advocate should be consulted for this. f) Verify the rates after contacting some property consultants and some people who have purchased their plots recently. You should also refer guidelines and the market rates published in the government manual of your city/town. g) Stamp duty at the time of registration is mandatory. Q. What are the important considerations before selecting a piece of land? While selecting the land one should give importance to following issues a) Required size of plot and construction area b) Existing rates area wise c) Distances from Railway Station, Bus Stand and Air Port. d) Distance from your work place. e) Distances from hospital and medical clinics. f) Available infrastructure like water supply, drainage, road etc Q. What are the points, one should pay attention to while awarding the contracts for house construction? Whatever the type of contract, one needs to pay close attention to the following aspects a) Type of materials b) Quality of work c) Advance payment, if any d) Progress & time schedule e) Future measurement & payment conditions Q. What would be an approximate cost per sq.ft of my house construction? To give an idea, depending on the finishes you choose, the construction cost should be as follows Type of finish in the construction Cost (in rupees) per sq.ft of construction Top Class Finish 750 - 1000 Medium Class Finish 480 - 700 Simple Class Finish 350 - 550 Q. What is the ratio of material, labor and other expenditures for house construction? 60:30:10

% of Construction Cost
Q. What would be the approximate cost break up for various works in terms of percentage of construction cost of house? Expenditure in terms of percentage of construction cost of the building ( % ) 3-5 6-10 2-4 0-2 1-3 10-14 3-5 8-10 4-6 3-5 6-8 2-4 2-4 6-8 4-6 3-7 6-12 1-3 6-8

Sl.No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0

Materials/Activities Design & fee for engineer/architect Labour Contractor for concrete Lay out & Excavation Water Soil/Mooram Cement Sand Bricks Stone aggregates Steel rods (Sariya) Doors & Windows Shuttering/ Formwork Bore Well Plumbing & Sanitation Electrical works Flooring Painting Boundary walls & Main gate Others

Q. Give me break up of stage wise construction cost to plan my financial requirement.

Stage
Excavation, Concrete for foundation & plinth Superstructure concrete & brick work Roof Slab Flooring Plastering & Painting Doors, Windows & Woodwork

Cost of Total Construction (%)

15 25 15 5 10 13

Water Supply, Sanitary & Fittings, Electrification and other special items Total

17 100

Q. What is the EMI in house loans? Once you take house loans, you will repay your amount in monthly installments depending upon the loan amount, total duration and interest rate. This means you have to pay certain amount per lakh rupees during the entire period. This is called Equated Monthly Installments (EMI). The longer is the repayment period smaller will be the EMI. Generally, EMI doesnt exceed the 50% of household income.

entage of

upon the loan amount, total ng the entire period. This is ll be the EMI. Generally, EMI

Checklist for Painting Work

Before start painting work 1. Fix scaffolding properly Planks, bamboos and Ballies dont rest on or touch the surface to be painted. Proper stage scaffolding is erected for painting of ceiling. Double scaffolding is provided for exposed surface. 2. Fill surface voids, pores and cracks All masonry or plaster surface voids, pores and cracks, nail holes are filled with filler before starting paint work. 3. Clean painting surface and room The surface is thoroughly cleaned off mortar droppings, dust, grease and other foreign matters. Old work, all loose material and scales are removed by sand papering. The room is thoroughly clean/broom and the whole building is cleaned at least one day before painting. 4. Dry up priming coat for 48 hours The priming coat applied already should be dried out for at least 48 hours before starting painting. 5. Fix electrical, water supply, sanitary pipes and door and window frames All electrical fittings, water supply, sanitary pipes and door and window frames are fixed in required position and if found any short coming, it should be corrected and repaired before starting painting. 6. Wet the surface with water before applying cement paint The surface is wet with water before applying cement paint. The surface of cement paint is cured (watered) after 24 hours of painting. 7. Employ skilled painter The painter employed for painting is skilled enough to do the job well. 8. Allow newly plastered surface to mature for six months Newly plastered surface should be allowed to mature for a period of at least six months prior to painting work. If you want to start painting before six months, a coat of alkali resistant priming paint should be done. 9. Fix ladders properly Ladders used for painting work are tied with pieces of clothes on the top end of vertical members to avoid damage or scratches on painting surface.

While painting the surface/wall 10. Mix adequate distemper for one room

Enough distemper is mixed to finish/paint one room at a time. Color preparation for oil bond distemper is compute 11. Do painting in right weather condition Paint work must not be done in adverse weather condition like hail storm and dust storm especially for exposed work. The paint work is not done in cold weather i.e. room temperature is not below 5 degree Celsius. 12. Stir paint well to maintain uniformity The paint is stirred well in its original containers with the help of a solid wooden or iron stick during application of paint to maintain uniform consistency. 13. Do subsequent coats after 24 hours Subsequent painting coat should be done at least 24 hours after the first is dried well. 14. Paint edges, corners, all doors and window accessories well All edges, corners, top and bottom, bolts, nuts, sides, rebate, cleats, stops, bidding and sash putty with glass pan are painted well. There is no damage to furniture and fixtures during paint job. At the time of spray painting, cover doors, windows, bushes etc. 15. Utilize proper brushes The brush should be of 15 cm long, double bristles for wall paint. After each days work brushes are washed in hot water thoroughly with soap solution or with thinner and hung down to dry. Clean containers in hot water with and soap solution 16. Wear protective glasses be safe also. While painting over head, wear protective glasses to avoid the fall of paint in your eyes. 17. Avoid alcohol and smoking The painter should not drink alcohol during painting work as toxic fumes from paint are dangerous for his health. While painting, do not smoke to avoid fire near painting area. 18. keep children away from painting area Dont allow children to enter painting area as some paints contain harmful toxic elements. They should be not allowed to spoil painting work, if so wash them thoroughly with soap and water. 19. Park your vehicle away from painting area to protect it from the fumes of paint.

Check after painting is over 20. No brush mark is left on surface Any brush mark is not left on the surface after the paint is dry. To avoid splashes of paint on wall the paint should be done on ceiling prior to walls.

21. Clean paint drops thoroughly Paint drops on floor, electric fittings, door and window fitting and glass panes are thoroughly cleaned with good quality paint remover. After cleaning paint drops there are no scratches on glass panes and fittings etc.

Civil Engineering Basic Knowledge

#Cement's intial setting time should be 30 min(Minimum) and 90 min(maximum). #Final setting time of cement should be=10 hours #What type of test should perform for a road's improved subgrade sand filling: 1.FM of fine aggregates 2.California bearing ratio 3.Dynamic cone penetration test 4.MDD of fine aggregate 5.Field Dry Density. #What type of test should perform for earth filling in Embankment with specified soil: 1.Plastisity index. #What type of test should perform for Concrete Work: 1.Setting time of cement 2.Compressive strength of cement 3.Gradation of Coarse aggregates. 4.FM of fine aggregates. 5.Water absorption of coarse aggregates 6.Loss angels abrasion test 7.Concrete cylinder casting & testing #What type of test should perform for M.S High strength deform bar 1.Tensile strength,Elongation and unit wt. #What type of test should be perform for Brick work: 1.Setting time of cement 2.Compressive strength of cement 3.FM of fine aggregates 4.Compressive strength of brick 5.Water absorption of brick 6.Efflorescence of brick. #Local sand FM limit should be 0.5 to 0.8 #Toak sand FM limit should be 1.2 to 1.8 #Coarse sand or shylhet sand FM should be 2.5 #At improved sub grade 0.5 to 0.8 FM sand should be used. 1.Ms Flat bar weight determine equation=0.00785A 2.Brick require for 1 square meter one brick flat soling=32nos. 3.Brick require for 1 squre meter one layer herring bone bond soling=52nos. 4.Cement require for 9.3 squre meter neat cement finishing=1/2bag or 25kg 5.A head mason can work 25-30 cum brick work in a day. 1.Lintel thicknessshould be 15cm.

2.Parapet wall height should be 1 meter. 3.Window height should be 120cm. 4.D.P.C thickness should be 2.5cm 5.Plinth height should be 45cm. 6.Measuremnt of riser should be 15cm. 7.Building height should be 315 cm 8.plaster thickness at ceiling should be 6mm. Q1:1 cum cement=how much bag?answer:30 bags. Q2:1cum khoa=how much brick?answer=300 nos Q3:1bag cement=0.0347 cum cement. Q1.1:What is the volume of per bag cement?Answer:1.25 cubic ft Q1.2:what is the weight of per bag cement?Answer:50kg or 112pb Q1.3:How much water absorb of a brick if the brick take rest for 24 hours in under neath the water? answer:1/5 or 1/6 of the brick wt. Q1.4:what is the mesurement of a brick?answer:9.5in*4.5in*2.75in(without morter) answer: 10in*5in*3in(with morter) Q2.1:What is the weight of a first class brick? answe: 3.85kg Q2.2:What is the crushing strength of a first classbrick in per square in? not less than 1000 pound. Q2.3:What is the tensile strength of a first class brick in per square in? less than 3000 pound. Q2.4:Which sand is mostly used for construction in Bangladesh? Domar sand or Dimla sand. answer:

answer: not

answer:

#See the Roof truss Elements

#See the 3d view of

Roof

Truss

1.Riser height of a staircase should be 15 cm 2.A building height should be 315 cm

#See the 3d view of

Roof

Truss

3.Plaster thinkness at celling should be 6 mm 4.Dry volume of a cc work is 3 times greater than wet volume of a cc work. 5.1 cum water weight =1000kg 6.At DPC work how much Cem-seal or Impemo require for one bag cement?=1kg 7.At DPC work how much Padlo require for one bag cement?=2.5kg 8.At brick work the joint thickness between two bricks should be= 12 mm 9.The lapping measurement at Compreesion zone should be=24D(without hook) 10.The lapping measurement at Tensile zone should be=40D(Excluding Hook) 11.One hook length shoulb be=9D 12.For crank extra length measurement should be=0.50d 13.Stirrup length measurement Equation=2(A+B)+30 cm 14.Weight of step of a staircase=11.5r (r=rise in cm) 15.MS angle weight determine equation=0.00785A 16.MS plate weight determine equation=7.85t

17.Before use a brick for brick work how many time the brick should take rest underneath the water?=2 hours 18.How much brick require for 1 sqm brick flat soling?=32 nos 19.How much brick require for 1 sqft brick flat soling?=3 nos 20.How much sand require for 1 sqm brick flat soling?=0.02 cum 21.How much brick require for 1 sqm herring bonebond?=54 nos 22.How much brick require for 1 sqft herring bonebond?=5 nos 23.How much sand require for 1sqm herring bone bond?=0.03 cum 24.How much brick require for 1 sqm edging?=8 nos 25.Cement require for 1 sqm neat cement finishing?=3kg

Testing
COMPRESSIVE STRENGTH OF CONCRETE CUBES

Compressive strength of concrete: Out of many test applied to the concrete, this is the utmost important which gives an idea about all the characteristics of concrete. By this single test one judge that whether Concreting has been done properly or not. For cube test two types of specimens either cubes of 15 cm X 15 cm X 15 cm or 10cm X 10 cm x 10 cm depending upon the size of aggregate are used. For most of the works cubical moulds of size 15 cm x 15cm x 15 cm are commonly used. This concrete is poured in the mould and tempered properly so as not to have any voids. After 24 hours these moulds are removed and test specimens are put in water for curing. The top surface of these specimen should be made even and smooth. This is done by putting cement paste and spreading smoothly on whole area of specimen.

These specimens are tested by compression testing machine after 7 days curing or 28 days curing. Load should be applied gradually at the rate of 140 kg/cm2 per minute till the Specimens fails. Load at the failure divided by area of specimen gives the compressive strength of concrete. Following are the procedure for Compressive strength test of Concrete Cubes APPARATUS Compression testing machine PREPARATION OF CUBE SPECIMENS The proportion and material for making these test specimens are from the same concrete used in the field. SPECIMEN 6 cubes of 15 cm size Mix. M15 or above MIXING Mix the concrete either by hand or in a laboratory batch mixer HAND MIXING (i)Mix the cement and fine aggregate on a water tight none-absorbent platform until the mixture is thoroughly blended and is of uniform color (ii)Add the coarse aggregate and mix with cement and fine aggregate until the coarse aggregate is uniformly distributed throughout the batch (iii)Add water and mix it until the concrete appears to be homogeneous and of the desired consistency SAMPLING (i) Clean the mounds and apply oil (ii) Fill the concrete in the molds in layers approximately 5cm thick (iii) Compact each layer with not less than 35strokes per layer using a tamping rod (steel bar 16mm diameter and 60cm long, bullet pointed at lower end) (iv) Level the top surface and smoothen it with a trowel CURING The test specimens are stored in moist air for 24hours and after this period the specimens are marked and removed from the molds and kept submerged in clear fresh water until taken out prior to test. PRECAUTIONS The water for curing should be tested every 7days and the temperature of water must be at 27+-2oC. PROCEDURE (I) Remove the specimen from water after specified curing time and wipe out excess water from the surface. (II) Take the dimension of the specimen to the nearest 0.2m (III) Clean the bearing surface of the testing machine (IV) Place the specimen in the machine in such a manner that the load shall be applied to the opposite sides of the cube cast. (V) Align the specimen centrally on the base plate of the machine. (VI) Rotate the movable portion gently by hand so that it touches the top surface of the specimen. (VII) Apply the load gradually without shock and continuously at the rate of 140kg/cm2/minute till the specimen fails (VIII) Record the maximum load and note any unusual features in the type of failure. NOTE Minimum three specimens should be tested at each selected age. If strength of any specimen varies by more than 15 per cent of average strength, results of such specimen should be rejected. Average of there specimens gives the crushing strength of concrete. The strength requirements of concrete.

CALCULATIONS Size of the cube =15cm x15cm x15cm Area of the specimen (calculated from the mean size of the specimen )=225cm 2 Characteristic compressive strength(f ck)at 7 days = Expected maximum load =fck x area x f.s Range to be selected is .. Similar calculation should be done for 28 day compressive strength Maximum load applied =.tones = .N Compressive strength = (Load in N/ Area in mm2)=N/mm2 #NAME? REPORT a) Identification mark b) Date of test c) Age of specimen d) Curing conditions, including date of manufacture of specimen f) Appearance of fractured faces of concrete and the type of fracture if they are unusual RESULT 2 Average compressive strength of the concrete cube = .N/ mm (at 7 days) 2 Average compressive strength of the concrete cube =. N/mm (at 28 days) Percentage strength of concrete at various ages: The strength of concrete increases with age. Table shows the strength of concrete at different ages in comparison with the strength at 28 days after casting.

Age 1 day 3 days 7 days 14 days 28 days

Strength per cent 16% 40% 65% 90% 99%

Quality Assurance
1.0 Objective The objective of this procedure is to ensure quality of works in all construction projects under taken by the organisation. It is the primary responsibility of contractor to ensure quality in construction and it is the collective responsibility of both construction and quality assurance division to assure quality work, while the former will take care of field works, both the divisions will ensure that the tests are conducted as per BIS specifications in reputed laboratories.

1.1 Application This procedure is applicable to all the projects entrusted to KSPHC by the client organization for construction. 2. Responsibility Responsibility and Authority for various activities of Quality control is described in procedure part. 3. Terms and definitions 1) 2) 3) 4) 5) 6) 7) 8) 9) Activity smallest identified item of work in a project process. Concession Permission to use or release a product that does not conform to specified requirement. Customer / Client Organization or person that receives a product / service. Deviation Permit Permission to depart from the originally specified requirements of a product prior to realization. Document Information and its supporting medium. Project Construction of Residential / Non-Residential buildings entrusted by Client organisations to KSPHC. Quality Assurance Part of quality management focused on providing confidence that quality requirements will be fulfilled. Quality Characteristic Inherent characteristic of a product, process or system related to a requirement. Record Anything (Such as a document or a photograph) providing permanent evidence of or information about past events; it also includes documents in digital form

10) Requirement need or expectation that is stated, generally implied or obligatory. 11) Specification Document and stated requirements of the product. 12) Verification Confirmation, through the provision of objective evidence, that specified requirements have been fulfilled.

4.0

Procedures

Following abbreviations and terms are used in the table; D = Document R = Record PR = Procedure CL = Check list PC = Pour card TP = Test procedure STD = Relevant BIS TR = Test Records CMD = Chairman and Managing Director ED = Executive Director CE = Chief Engineer SE = Superintending Engineer EE = Executive Engineer DES = Designs QC = Quality control and Contracts Govt. = Government of Karnataka Client = User department TP = Third party PRC = Project review committee consisting of CMD, ED, FA, CE and other designated employees as determined by the CMD / ED.

4.1

General :

As all the building materials including electrical fittings etc., required for a project are brought by the Contractors, the procedure part details the tests to be conducted by the Contractors on the same and KSPHC functionaries has to verify whether these materials conform to the acceptance criteria or not. 4.2 Planning for Quality Control Concerned Executive Engineer of a division who is considered as the project manager shall plan for achieving quality in the construction project using the following guidelines. In this endeavour, he shall delegate required responsibilities and authorities to other staff of the division / sub-division to plan and achieve quality. Quality control planning for a particular project shall include responsibilities and authorities for the following personnel in the project: a) b) c) Contractor (or his quality control engineer) JE / AE / AEEs of sub-divisions Executive Engineer of the division

It shall be noted that EE-QC / AEE-QC will be playing role to assist the respective divisions in initiating mid-term course corrective action in order to prevent complaints from the client organization with regard to project (Buildings) requirements based on their observations during their site visits.

Concerned Executive Engineer of a division may prepare project specific quality plan (example, type of building / construction techniques adapted may require minimal or enhanced control measures to avoid problems)

Project quality plan shall define: a) b) c) d) e) f) g) Nature of quality control / test activity to be performed Personnel responsible to perform Documents (such as BIS Codes, Bill of quantities, Specifications etc.,) Personnel authorised to approve the results of tests conducted Personnel authorised to approve deviations and accord concessions or a suitable disposition Criteria for approval of materials / work completed Record requirements

4.3 Informative notes BUILDING MATERIALS AND CONSTRUCTION The plan may contain more than one means of controlling the quality of various construction materials which may be naturally occurring or produced by the Contractor or obtained from other agencies for example Coarse aggregates, fine aggregates, bricks etc., The construction materials also includes those manufactured in factories and readily available in open market like cement, Reinforcement steel, electrical materials etc., The Core Plan may describe the methods for controlling and auditing the quality of material procured or produced by the Contractor. 4.4 ELECTRICAL MATERIALS AND CONSTRUCTION For the purpose of this section, the following definitions apply: Electrical Work: means any work associated with the installation, modification, removal, inspection, or testing of electrical System Components. a) Quality Control of Electrical Items The EE Electrical shall provide guidelines for the project EE / AEE / AE that describe how the Contractor should carry out quality control for the electrical items and /or groups of electrical items that are used in a typical construction contract that includes Electrical Work. 4.5 Inspection by contractor : For each electrical item or group of electrical items listed, the Contractor shall identify what inspection will be done. As a minimum, the Contractor shall monitor and inspect the work in accordance with Schedule B specifications. 4.6 General Procedure for Quality Assurance : Responsibility EE (Divisional) Activity D/R To ensure tested R materials are used on works To collect reports and R post on website To ensure free floor of information between field staff and Head Office Reference Formats F:23-1 to

Sl.No. 1

F: 23-6, 2 EE (QC)

SE(DES)

Non conformities in QSP will be periodically pointed out by internal auditors for implementing corrective and preventive action. SE (DES) will inspect the works periodically to ensure compliance to quality. It should be specifically noted that EE (Quality assurance is meant to assure quality with responsibility and not meant for making comments without any proof or basis. Any deviation noticed by him should be communicated to concerned EE (Divisional) in specified format with proposed corrective action. Differences will be completely sorted out at SE (DES) level and informed to CE only if his intervention is required. All fines, penalties etc will be levied on the contractors only with specific written instructions / approval from CE are higher authorities.

5. Materials Quality Control of Building / Raw Materials: As all the building materials including electrical fittings etc., required for a project are brought by the Contractors, the procedure part details the tests to be conducted by the Contractors on the same and KSPHC functionaries has to verify whether these materials conform to the acceptance criteria or not. Sl. No. 1 Respon-sibility for verfication AEE / AE / JE Materials Sampling Details Details of test Permissible limits As indicated in the F:23-1 D / Reference F:23-1 R

Water

a)From local source

a)Once before actual usage b) As and when the source is changed

AEE / AE / JE

Cement

AEE / AE / JE

Reinforcement Steel

AEE / AE / JE

Sand

b)From outside sources One sample for every 75 i.Initial Setting tonnes if the same brand is used if there is a change in brand tests to be conducted Time ii.Final Setting Time iii. Strength For every 30 tonnes of same i.Tensile diameter strength ii.Minimum yield stress iii.Minimum percentage elongation For every 100 cum of sand i. Fineness Modulus received from the same source ii. Silt Content j. For every 100 cum of CA Field test for gradation brought from same source For every 25,000 bricks or i.Compressive strength when the source / brand is changed ii.Water absorption For every 25,000 laterite Compressive strength stones or when the source / brand is changed

As per

F:23-2

F:23-2

As per F:23-3

F:23-3

As per F:23-4 As per F:23-5 As per

F:23-4

AEE / AE / JE

Coarse aggregates

F:23-5

AEE / AE / JE

Burnt clay bricks

F:23-6

AEE / AE / JE

Laterite

F:23-6 As per Agreement Document As per Agreement Document

AEE / AE / JE

Hollow Blocks

Concrete For every 25,000 blocks or Compressive strength when the source / brand is changed

AEE / AE / JE

Solid Concrete Blocks For every 25,000 blocks or Compressive strength when the source / brand is changed

As per Agreement Document

10

AEE / AE / JE

M.S Door frames, window frames

5 % of the materials to be tested for a. Dimension b. Workmanship c. Fixtures for method of hinging Physical measurement, Physical observation, Physical verification

As per Agreement

11

AEE / AE / JE

Water closets, Wash basins, Urinal basins

10 % of the materials to be tested for a. Brand name as per agreement b. ISI marking

Physical verification Physical verification

As per Agreement / Specification

12

AEE / AE / JE

G.I pipes

10 % of the materials to be Physical measurement, tested for Specifications Physical measurement Physical observation Physical observation Physical observation

As per Agreement / Specification As per Agreement / Specification

13

AEE / AE / JE

G. I Fittings, Peet 10 % of the materials to be valves, CI pipes, PVC tested for pipes a. ISI marking b. Brand name (wherever applicable)

14

AEE / AE / JE

Taps

10 % of the materials to be tested for ISI marking 2% of the materials to be tested for a. Dimension

Physical observation

15

AEE / AE / JE

Glazed wall tiles

As per Agreement / Specification As per Agreement / Specification

Physical measurement b. Uniformity of colour, shade Physical observation and texture c. Verification of marking on the packing box and tiles Physical observation 16 AEE / AE / JE Ceramic tiles 2% of the materials to be tested for a. Dimension Physical measurement b. Uniformity of colour, shade Physical observation and texture c. Verification of marking on the packing box and tiles Physical observation 17 AEE / AE / JE Eco Board door shutters / PVC door shutters 10% of the materials to be tested for a. Dimension b. Workmanship Physical measurement Physical observation Physical measurement Verification Verification d.Manufacturers certificate 18 AEE / AE / JE Flush shutters for door 10% of the materials to be tested for a. Dimension b. Manufacturers certificate Physical observation test Physical verification test As per Agreement / Specification As per Agreement / Specification

c. Fixtures

As per Agreement / Specification

6 .0 Quality Plan for construction activities : As all the building construction activities including electrical works etc., are carried out by the Contractors, the procedure part details the documents to be referred by the KSPHC functionaries to verify whether these works conform to the requirement or not.

Sl No 1

Respon-sibility Activity JE / AE / AEE / Excavation EE foundation DOCUMENTS INVOLVED 1) Excavation plan / Building plan 2) Specification in the agreement documents and 2 JE / AE / AEE / Foundation concreting 1) Specification in the EE agreement documents 2) Construction drawings JE / AE / AEE / Random rubble stone 1) Specification in the EE masonry and C.R agreement documents stone masonry 2) Construction drawings

of

JE / AE / AEE / Brick Masonry work EE

1) Specification in the agreement documents 2) Construction drawings 1) Specification in the agreement documents 2) Construction drawings 1) Specification in the agreement documents 2) Construction drawings

JE / AE / AEE / Reinforced EE concrete

cement

JE / AE / AEE / Joineries EE

JE / AE / AEE / Finishings including 1) Specification in the EE plastering and painting agreement documents works 2) Construction drawings JE / AE / AEE / Water Supply works EE 1) Specification in the agreement documents 2) Construction drawings 1) Specification in the agreement documents 2) Construction drawings 1) Specification in the agreement documents 2) Construction drawings

JE / AE / AEE / Sanitary works EE

10

JE / AE / AEE / Electrical works EE

7.0 Plan for conducting quality control inspection by Quality Control Division As all the building construction activities including electrical works etc., are carried out by the Contractors and regular supervision on day to day basis are carried out by various functionaries of the construction / electrical Divisions, the procedure part details the inspection plan for the KSPHCs Quality Control functionaries to verify whether the raw materials / works conform to the requirement or not. Sl. No. Activity Responsibility Description Frequency / Duration Every Month a programme of inspection plan to be submitted to the Top Management

Planning of Inspection

EE(QC)

a. The QC Division shall plan and schedule the inspections of QC staff for the on going works

b. The various works required As and when directed by the to be inspected by QC staff Top Management may also be identified by the Top Management, based on the criticality of works or any other reason 2 Inspection EE(QC)/ AEE(QC)/ AE(QC)/JE(QC) a. QC staff shall visit the site 10% of the works shall be of the work to be inspected inspected and conduct inspection of the Building Materials / Test reports / works b. Any deviations noticed by F : 23-7 QC staff should be communicated to concerned EE (Division) through site quality observation register with proposed corrective action. 3 Action Taken report EE ( Division) The concerned EE Within 15 days from the date (Division) shall send action of observation taken report on the QC findings / observations after attending to the necessary corrective actions to SE (DES) The ATR shall then be verified in subsequent inspections

SE (DES)

13.0

Reference

a) ISO 9001: 2000 Clause Number 8.0 b) Quality Manual Clause Number 8.2.4 14.0 Associated Documents a) Procedure for control of documents QSP01 b) Procedure for control of records QSP 02 c) Procedure for control of monitoring and measuring devices QSP 19 d) Procedure for control of non conforming products QSP 24 e) Procedure for corrective action QSP 26 f) Procedure for preventive action QSP 27 15. Revisions Revision 00 First issue. 16.0 Distribution of procedure

Chief Coordinator-QMS shall issue this procedure to all the functional heads. Top Management Committee

*Approved by

*Board of Directors of KSPHC in its 107th meeting held on 04-12-2004 vide resolution No. 2004 / 047 has constituted a Top Management Committee consisting of CMD, ED, CE and FA with MR and CC as co-opted members. Further the Board has authorised CMD to approve and issue the QSPs after review by the Top Management Committee.

Shuttering
This is the temporary formwork meant to support your construction while the concrete work is in progress. It comprises of wood props, plywood and steel plates. A good formwork should be strong, solid and without any gaps so that water leakage through through the joint or any gap is almost minimum. 24 gauge micron polythene sheet should be used to prevent any water leakage. Apply a layer of releasing agent (like diesel or grease mix) to the formwork where the concrete is to be poured. This enables it to be removed with ease and ensures a smooth finish.

The shuttering percentage depends on the nature of structural element where u r concreting. For sake of generalization the following coefficients can be adopted 1. Foundations - 2 sqm/cum of concrete (considering 2.0 x 2.0 x 0.25m footing size) 2. Columns - 13.5 sqm/cum of concrete (considering 0.3 x0.3m column) 3. Beams - 11 sqm/cum of concrete (considering 0.23 x 0.45m beam) 4. Slabs - 6.5sqm/cum of concrete (considering 0.15m thick slab)

FORMWORK
C Forms are molds to receive concrete in its plastic form. C Formwork is temporary structure, as such, it is not normally shown on the drawings.

Foqmwoqk foq Beams and Slabs

Foqmwoqk Mateqials
C Wood ^Either all-wood or some wood components C Plywood C Aluminum C Steel C Plastics

Lumbeq
CDesignated by Cross Sections, Nominal Dimensions (prior to finishing) ^After cut length wise, finishing operations reduces actual dimensions 2 x 4 Plank 1 1/2 x 3 1/2 2 by 4 in S4S ^Lengths are multiples of 2 ft (8, 10, 12, 14, 16,) ^Specified by type and grade aType: pine, oak, fir aGrade: Selected (A, B, C, D) and Common (1, 2, 3, 4) aSelected (A best, D poor quality) Cost Kind, grade, size, length, milling, quantity, freig

Plywood
C 4 ft wide - 8, 10, 12 ft long C 1/4, 3/8, 1/2, 5/8, 3/4 inch thick

Plywood Oqientation
Weak Orientation of Plywood (Face grain parallel to span) Strong Orientation of Plywood (Face grain perpendicular to span)
Face Grain Direction Face Grain Direction

Aluminum
CPure aluminum chemically attacked by wet concrete CLight weight allow larger forming units CHigh reuse value
Aluminum beam nailer - type

Steel
CFor heavy concrete work CWith reasonable care will last indefinitely CHigh initial cost and high handling cost

Estimating Issues
CNormally, the forms are used more than once CMore usage of forms reduce the price CWood forms have less usage potential than aluminum or steel forms CComplicated shapes of concrete are more expensive because of labor cost and reuse of forms. CMajority of cost is _____?? Not ____?? CYou have to have a construction plan to determine the reuse cycle CNumber of reused largely controls _____?? Cost.

Effect of Reuse on Concqete Foqmwoqk Cost

Number of uses 1 2 3 4 5 6 7 9 Cost per square foot of contact area 1.00 0.62 0.50 0.44 0.40 0.37 0.36 0.32

Estimating Issues (Foqmwoqk)

CDo not deduct ^Intersection of beams ^Intersection of beams & columns & walls ^Any opening < 100 sq. ft.

Measuqement
CUnit of Measurement Square Foot Contact Area SFCA CMeasure just contact area, not area of formwork Contact Area = 2h(L+B)
B L

Wood normally measured: CLinear feet of one size CBoard Feet ^FBM (Foot Board Measure) 1x12x1(long) or 144 cubic inches ^example: 2x8 x 16ft long = 1.33 BF/LF x 16 = 21.28 FBM

Additional Costs
CNails ^For first use, 10 - 20 lb. Per 1000 fbm ^Additional used, 5 - 10 lb. Per fbm CForm Oil ^300 - 500 ft2/gal CTies ^Ties keep forms apart and resist bursting pressure of concrete ^Stay in concrete, pull out ^Types: aSteel bands aRods aThreaded aw/ Nuts and clamps

Design and Estimating of Foqms

CDesign determine Sheathing thickness, stud size, wale size, tie size CUse of design tables CWatch for 1 Rate of pour 2 Temperature and weather 3 Proportions of mix and consistency 4 Method of placement and vibration

Woqkshop Example
CEstimate the cost of formwork for concrete wall (96 x 254) CThe rate of placing concrete = 4 ft/hour CMaximum temperature of concrete = 70F

Wall tie

2- 2x 4 wale

2x 4x 10- 0 stud

3/4 plywood sheathing

2x 4 x 10- 0 brace @ 6- 0

Concrete Footing 254

2x 4 sill 2x 4x 3- 0 Stake @ 6- 0

Side Elevatio n

Design of Foqms foq concqete Walls

Minimum Temperature of concrete, F Rating of filling forms, ft/h Maximum pressure, lb/ft2 50 2 510 4 870 17 29 23 35 36 27 27 36 28 24 2 35 35 6 1230 14 24 21 33 33 25 25 33 24 21 20 31 31 2 409 24 42 28 43 44 33 33 43 37 32 29 46 48 70 4 664 19 33 25 38 39 29 29 38 31 27 24 38 39 6 921 16 28 23 35 36 27 27 35 27 24 22 34 35 2 350 26 45 29 45 46 35 34 45 39 34 31 49 50 90 4 550 21 36 26 40 41 31 30 41 33 29 26 41 41 6 750 18 31 24 37 38 29 28 37 29 26 23 37 37

Maximum spacing of studs for safe value of sheathing, in For 1- in sheathing 22 For 2- in sheathing 38 Maximum spacing of wales for safe value of studs, in 2 x 4 studs 1- in sheathing 26 4 x 4 studs 1- in sheathing 40 2 x 6 studs 1- in sheathing 41 2 x 6 studs 2- in sheathing 31 4 x 4 studs 2- in sheathing 31 3 x 6 studs 2- in sheathing 41 Maximum spacing of form ties for safe values of wales, in Double 2 x 4 wales 2 x 4 stud 1S 34 Double 2 x 4 wales 4 x 4 stud 1S 30 Double 2 x 4 wales 2 x 6 stud 1S 27 Double 2 x 6 wales 2 x 6 stud 1S 43 Double 2 x 6 wales 3 x 6 stud 1S 43

The wall is 9-6 high and 25-4 long. CFrom design table: Max. pressure, 664 lb/ft2 Max. spacing of studs, 19 in, use 18 in Max. spacing of wales, 25 in, use 24 in Max. spacing of form ties, 31 in CThe 3/4 plywood sheathing will be placed with the 4 ft wide in the vertical direction and the 8 ft length in the horizontal direction. CThe total quantity of sheathing will be: No. sheets in vertical direction, 9-6 4/sheet = 2.37, use 3 sheets No. sheets in horizontal direction, 25-4 8/sheet = 3.16, use 4 sheets No. sheets required per side, 3 x 4 = 12 No. sheets required for wall, 12 x 2 = 24

CStuds required: Length of wall, (25 x 12)+4 Spacing of studs, 18 in No. studs required per ########### side, (304/18)+1 No. studs required for ########### wall, 2 x18 Lumber required, 36 pc, 2 x4 x 10 ft = 240 fbm CWales required: Height of wall, 114 in Spacing of wales, 24 in No. required per side, 114/24 For each wale, use 2 pc of 2x4 x 12 ft CLumber required: 20 pc, 2x4 x 12 ft = 160 fbm 20 pc, 2x4 x 14 ft = 187 fbm Total lumber 587

= 304 in

= 4.75, use 5 wales and 2 pc of 2x4 x 14 ft lumber

Electrical Works
Select electrical goods for your house carefully (these must be ISI marked). Make provisions for switch boards at the beginning of construction, or it will clash with the dcor of your house later on. Make proper arrangements for earthing in your house and have it checked regularly. Do not make several temporary connections from one point. Avoid using too many joints in the electrical wiring. Use good quality wires and insulation material. To protect your electric equipment, use a fuse on every power board. Do not use extension boards for permanent connections. Keep the power supply cord safe from water, heat and oil. Keep electrical materials away from children. Note: Use electricity with restraint. Have your connections, wiring etc. checked regularly. Get your electric work done only from a registered or license-holding electrical contractor.

Plumbing
Use good quality ISI marked GI pipes and fittings for the water supply. PVC pipes for sewage discharge are both durable and convenient. The joints of pipes and fittings must be leak-proof. They should be double checked before laying the tiles.