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CONSTRUCTION

AND
QUALITY OF CONSTRUCTION
Compiled By: Prof. Dr. M. Shamim Z. Bosunia
19th June 2014

For an Engineer his works in profession, his


knowledge in the technique of construction and
his success in constructing a building is a thing of
great pride for him. It is his professional religion
and it is the self satisfaction aroused in him
which enables him to apply his body and mind so
diligently in the arduous and difficult task of the
construction. This feeling of pride and the
unspeakable satisfaction make his job pleasant
and make him completely forgetful of the strains
of his hard work and labor.

He is not only a builder of buildings but also


ultimately is builder of the nation as well. The
responsibility on him, however, junior/ young he
might be, even as a Work Assistant, is very great
indeed as a single brick in the foundation plays a
vital role in the stability of the massive structure
standing over the same.

It is to be borne in mind that the knowledge of


affecting economy in a construction consistent
with its strength and durability really makes a
man an Engineer. It should therefore be a
constant struggle by an Engineer to obtain the
maximum amount of durability and strength with
a minimum amount of expenditure. The question
of durability and strength, however, should
always have preference as the failure of
structures means losing the entire economy.

Building engineering like all such branches in the


technical field is a matter of strong
commonsense and the application of the
specialised methods and procedure in the
various lines in the construction. The field
engineers should therefore be very keenly alive
to his own sense of examination and judgment
and should rigidly follow the course of procedure
and specification hereinafter described.

REINFORCING STEEL

Reinforcing steel is the most vital component of


reinforced concrete structures. It is important that all
design engineers, construction engineers, steel
manufacturers and others who work with it understand
its nuances and significances very clearly.

Feature of Steel & Concrete Bonding


The thermal expansion coefficients of the two materials,
about 6.5 10-6 for steel vs. an average of 5.5 10-6 for
concrete, are sufficiently close to forestall cracking and
other undesirable effects of differential thermal
deformations.

Feature of Steel & Concrete Bonding


While the corrosion resistance of bare steel is poor, the
concrete that surrounds the steel reinforcement provides
excellent corrosion protection, minimizing corrosion
problems and corresponding maintenance costs. Durable
concrete produces an environment of pH equal to +13.5
for the embedded reinforcements.

Typical Theoretical Stress-Strain Curves for Rebars

Typical Cross-Sections of MS, CTD & TMT Rebars

Note:
MS
CTD
TMT

: Mild Steel
: Cold Twisted Deformed
: Thermomechanicaly Treated

Important Attributes of Reinforcement


To summarize, attributes of reinforcements that are
important for engineering of sound and durable RC
structures are:
Bond with concrete
Strength
Ductility
Resistance against corrosion

Ductility
Ductility of rebar is expressed as the ratio of ultimate
deformation at collapse to deformation at yielding. The
ductility of a mild steel rebar under the monotonic tensile
loading is given by

= u /y
Where , u and y are ductility factor, ultimate strain and
yield strain of the rebar's respectively. This makes
elongation a good indicator of ductility and is used as a
parameter to characterize the rebar for ductility.

Grades of Rebars Used for Seismic Design


Three grades of rebar; Grade415, Grade500 and
Grade550 or their equivalent are taken for this exercise It
is noted that there is only one grade of ASTM
A706/A706M rebar available, which is Grade-420
recommended for earthquake resistant design.
Australian/ New Zealand specification allows three
categories of rebars of Grade-500: Class L (low ductility)
500L, Class N (normal ductility) 500N, and Class E (high
ductility for earthquake prone region) 500E. Similar
observation can be made on Euro code.

CONCRETE AND INGREDIENTS

Concrete For Durable Construction


Durable Concrete
Concretes versatility, durability and economy have made it the
worlds most used construction material.
The durability of concrete may be defined as the ability of
concrete to resist weathering action, chemical attack, and
abrasion while maintaining its desired engineering properties.
The concrete ingredients, proportioning of those ingredients,
interactions between the ingredients, and placing and curing
practices determine the ultimate durability and life of the
concrete.

Section of Concrete

Cross section of hardened concrete made with (Left) rounded siliceous


gravel and (Right) crushed limestone. Cement-and-water paste completely
coats each aggregate particle and fills all spaces between particles.

Schematic Representation of Manufacture and


Hydration of Portland Cement

Development of Strength of Pure Compounds

Cement Standards and Type of Cement

ASTM (USA)
BDS EN (Bangladesh)
BS (UK)
EN (European)
BIS (Indian)
ISO (international)

ASTM C150
Specification for Portland Cement
Type I
Type II
Type III
Type IV
Type V
A
LA

General Purpose Cement, OPC


Moderate heat/Moderate Sulphate
Resistance
High Early Strength
Low Heat of Hydration
High Sulphate Resistance
Air -Entraining
Low Alkali

Bangladesh Government has adapted EN197-1:2000


standard as local cement standard in 2003 and has given its
new standard as

BDS EN 197-1:2003

BDS EN 197-1:2003 (Composition)


Main constituents
Pozzolan
Fly ash
Burnt.
Limestone
natural
Shale
calcareous
natural
siliceous
calcined
K
S
D b)
P
Q
V
W
T
L
LL
CEM I
Portland cement
I
95-100
II/A-S
80-94
6-20
Portland slag cement
II/B-S
65-79
21-35
Portland-silica fume cement
II/A-D
90-94
6-10
II/A-P
80-94
6-20
II/B-P
65-79
21-35
Portland pozzolana cement
II/A-Q
80-94
6-20
II/B-Q
65-79
21-35
II/A-V
80-94
6-20
II/B-V
65-79
21-35
Portland fly ash cement
CEM II
II/A-W
80-94
6-20
II/B-W
65-79
21-35
II/A-T
80-94
6-20
Portland-burnt shale cement
II/B-T
65-79
21-35
II/A-L
80-94
6-20
II/B-L
65-79
21-35
Portland limestone cement
II/A-LL
80-94
6-20
II/B-LL
65-79
21-35
6-20
II/A-M
80-94
Portland composite cement c)
21-35
II/B-M
65-79
III/A
35-64
36-65
CEM III Blast furnace cement
III/B
20-34
66-80
III/C
19-May
81-95
11-35
IV/A
65-89
CEM IV Pozzolanic cement C)
36-55
IV/B
45-64
18-30
V/A
40-64
18-30
CEM V Composite cement c)
31-50
V/B
20-39
31-50
a) The values in the table refer to the sum of the main and minor additional constituents.
b) The proportion of silica fume is limited to 10%.
c) In Portland-composite cements CEM II/A-M and CEM II/B-M, in Pozzolanic cement CEM IV/A and CEM IV/B and in composite cements CEM V/A
V/B the main constituents other than clinker shall be declared by designation of the cement.
Main
Types

Notation of the 27 products(type of


common cement)

Clinker

BF Slag

Silica
Fume

Minor
additional
constituents
a)
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
and CEM

Supplementary Cementitious Materials (SCMs)

Fly ash (Class C)


Fly ash (Class F)
Slag
Lime Stone
Silica fume
Calcined shale

Metakaolin (calcined clay)

Pozzolanic Reaction (PCC)


Cement Hydration
Cement + Water
Pozzolanic
Fly Ash +

CSH + Ca(OH)2

Reaction of Fly Ash

Ca(OH)2 + Water

CSH = Calcium Silicate Hydrate

CSH

Strength Development

Water
Needed for two purposes:
Chemical reaction with cement
Workability
Only 1/3 of the water is needed for chemical
reaction
Extra water remains in pores and holes
Results in porosity
Good for preventing plastic shrinkage cracking and
workability
Bad for permeability, strength, durability.

Durability
Durability is the ability of a Material or Structure to withstand its
design service conditions for its design life without significant
deterioration.

Durability Design Phylosophy


Potential durability of concrete is defined as the resistance of
the cover concrete to the conduction of chlorides, sulphates,
permeation of Oxygen and absorption of Water.

Factors influencing Durability of concrete

The Environment
Type and quality of constituent materials
Cement content and W/C ratio of concrete
Workmanship especially in compaction and curing
Cover to embedded steel
Shape and size of the member

Durable Concrete

Low permeability
Resistance to sulfate attack
Chloride attack on reinforcement
Resistance to Alkali Silica reaction
Low heat of hydration
High workability

Performance of Composite Cement in Concrete


Improved pump
ability, compact
ability

Low
effective alkali
content

Improved fresh concrete


properties

Performance of
Composite Cement

High
chemical resistance
(sea water, chloride diffusion,
Lower
sulphate attack)
early strength

Lower
heat of
hydration
Low
permeability,
dense structure

High
long term strength

Concrete

FINE AGGREGATE
Sand must be cleaned, washed and of definite gradation.
TEST for Sand:
Fineness Modulus (FM)
Salinity
Bulking
Testing for impurities
For Good Concrete works FM must be 2.5 or above.

CAUTION: Without sieve analysis tests mixing of coarse sand and


fine sand must not be allowed. This is a very bad practice in out
construction.

Surface area Calculation Example:


Agg. Size. (Say) 1X1X1 Cube
Vol. = 1x1x1 = 1in3
Surface Area= 6 surface x1x1 =6 in2
Now if the 1x1x1 cube is cut into
8 pieces of x x
Vol.=8x x x = 1in3
Surface Area=8x6x x =12in2
Which is Double of the 1X1X1 Cube.
Hence, for smaller aggregates more cement to the extent of
double amount is required.

Workability

Bleeding And Settlement


Bleeding is the development of a layer of water at the top or
surface of freshly placed concrete. It is caused by sedimentation
(settlement) of solid particles (cement and aggregate) and the
simultaneous upward migration of water (Fig-5). Bleeding is
helpful to control plastic shrinkage cracking.
Excessive bleeding increases the water-cement ratio near the top
surface; a weak top layer with poor durability may result. A water
pocket or void can develop under a prematurely finished surface.

Bleed Water on Surface of Concrete Slab

Concrete of a Stiff Consistency (Low Slump)

Consolidation
The vibratory action permits use of a stiffer mixture containing a
larger proportion of coarse and a smaller proportion of fine
aggregate. The larger the maximum size aggregate in concrete with a
well-graded aggregate, the less volume there is to fill with paste and
the less aggregate surface area there is to coat with paste; thus less
water and cement are needed. Concrete with an optimally graded
aggregate will be easier to consolidate and place. Consolidation of
coarser as well as stiffer mixtures results in improved quality and
economy. On the other hand, poor consolidation can result in porous,
weak concrete with poor durability.

Effect of Void in Concrete Due to Consolidation

Corrosion in Concrete
Corrosion in Concrete

Electro
Micrograph
showing
Corrosion in Poor Concrete

Electro Micrograph showing NO


Corrosion in Good Concrete

Hardened Concrete

Relationship of Strength Gain and Moist Curing

Concrete strength increases with age as long as moisture and a


favorable temperature are present for hydration of cement

Plastic Shrinkage Crack

Typical Plastic Shrinkage Cracks

Damage Induced by Corrosion

Crack Due to Pressure of Rusting Reinforcements

Common problems due to corrosion

Delamination of Concrete Cover

Chemical Resistance
Portland cement concrete is resistant to most natural
environments; however, concrete is sometimes exposed to
substances that can attack and cause deterioration. Concrete in
chemical manufacturing and storage facilities is especially
prone to chemical attack. The effect of sulfates and chlorides is
discussed above. Acids attack concrete by dissolving cement
paste and calcareous aggregates.

Deterioration of Concrete Exposed to Seawater

COMPRESSIVE STRENGTH of CONCRETE is:


Specified in the Design
Measured by the Cylinder Test in which the :

i) 7 day strength = 65% of Specified Design Strength


ii) 28 day strength = Specified Design Strength

Cylinder Casting Requirements (ASTM designation:C31/C31M-03a)

CONSOLIDATION METHOD
TAMPING
VIBRATION

Mold size

Dia. x Ht.
in (mm)

4X8
(100x200)

Tamping Rod
(mm)
Dia.

Length

10

300

No. of Rodding No. of


Layers Per Layer Layers

25

Vibrator
insertions per
Layer

Approx
Depth of Layer

One-half depth
of specimen

One-half depth
of specimen

6X12
(150x300)

16

500

25
8

12

FINE AGGREGATES:
Sylhet Sand of F.M 2.50
Local Sand of F.M 1.25

COARSE AGGREGATES:
20 mm (3/4 inch) down, well-graded stone chips used
12 mm (1/2 inch) down, well-graded stones chips used
20mm (3/4 inch) down, well-graded brick chips used

A mixture of 3/4 and 1/2 downgraded stone chips


are used in most mixtures
3/4 downgraded brick chips are sometimes used in
slabs

EXCEPTIONS are:
i. Railing
ii. Dropwall Fins
For such Exceptions 12 mm (1/2 inch) down graded stone
chips will be used.

POTABLE WATER is to be used in concrete mix


Potable water means water YOU CAN DRINK.
For CASTING, use WASA water supply

Water from any other source WILL NOT BE ALLOWED

Admixtures will be used:


As mentioned in the respective Drawings and Specs
After approval by the Engineer
Examples of Admixtures used:
Water Proofing Admixture
Plasticizer
Jointing Admixture

SLUMP TEST is performed:


To check w/c of concrete and workability
During any type of casting

CURING TIME
Standard Curing Time: 28 days
Use of SCMs might lengthen curing time
METHODS OF CURING:
Horizontal Surface by ponding of water
Other Surfaces: by wrapping moist jute fabric and
sprinkling water on them frequently with a hose
pipe
**Note: Date of Casting must be marked on Structure
to confirm curing period

Unless mentioned otherwise in drawings,

Average Lap Length can be


Provided= Ld

Ld can be selected from the following Charts:

For All Rebars:


Provide 90o STANDARD HOOKS (L-BENT)
if it is not specified in drawings

For beam bottom bar, lap should NOT be provided


at middle third zone of the span

For beam top bar, lap may be provided at middle


third zone of the span
Not more than 50% of the bars shall be spliced at
one place
For slab bottom bar, lap should NOT be provided at
middle third zone of the span.

Lap Splices are to be confined by hoops with maximum


spacing or pitch of d/4, where d is the effective depth of
beam.
However, maximum spacing cannot exceed 100 mm.

All Beam and Slab Rebars should be extended into the support
upto Development Length
50 x Dia of Main Bar (min.)

For Footing, Column & Beam


in contact with Earth \ Water.

CLEAR COVER = 75 mm

Clear Distance between longitudinal bars shall not be less


than 1.5 times bar diameter, 1.5 times the size of coarse
aggregate nor 40mm.

1.5 db / 1.5* size of CA / 40mm

a)Free End of Slab incapable of Embedding


of Steel Bar in Beam / Wall
b) Others

Some inner Stirrups are provided to receive additional


Shear in Beam:

3 - LEG STIRRUP :

Some inner Stirrups are provided to receive additional


Shear in Beam:

4 - LEG STIRRUP :

At least 3 (three) Nos. Ties must be continued through


Beam-Column joint.

Bundle bar is the combination of 2 or more re-bars in


contact for acquiring more reinforcing area

Requirements for BUNDLE BAR:


Maximum re-bar can be bundled 4 Nos.
Bundle bars must enclosed with tie or stirrup of 12mm.
Bundle bars must terminate with at least 40db stagger

except where the bundle Terminated. Where db is


individual bar diameter.
Concrete cover is as per standard.
Development Length 48bdeq (both tension and
compression) at Mid height of column.

- Any Loose Pocket found in Foundation Bed is to be


filled up with Compacted Sand of FM 2.5 min.
- Depth of Foundation as per Drawing.

Conceal Beam:
-Dont use any Conceal Beam in any Slab.
-It does not have the effective function like standard beam.

If 25x25 column with 26 nos. 25mm bars are provided with


fc =3.5ksi and fy=60ksi
Pu=0.56[0.85x3.5x605 + 19.5x60] = 1663 k
For the same load 1663 k if a larger column of
27x27 is designed Then As required 14 in2.
COMPARISON:
Size: 25x25 Column
Area: Ag= 625 in2
As= 19.5 in2

27x27 Column
Ag=729 in2
As= 14 in2

Comparing these two sections 15% Less cost is required for the larger
column of 27x27 .
But the lateral stiffness of the larger column is improved by 36% against
the 25x25 column against Earthquake and Wind load.

Column Shuttering :
- All Columns shall be Cast at
full height.

- For this Sufficient Support &


Tension must be provided to
ensure proper Alignment.
-Adequate Blocks must be Tied
carefully to ensure required
Clear Cover.
-No Kicker will be provided.

Kicker :
No kicker will be provided for
Column, Retaining wall, Lift core , UGWR & OHWT
Shear Groove:
Shear Groove must be provided for
Column, Retaining wall, Lift core, UGWR & OHWT
OHWT Column:
Column height at OHWT will be up to Top slab of Reservoir.

Beam-Column Joint:
Top bar of Beam must be extended into Column
to a length
40db from column face at beam-column joint.

Casting:
At least a clear gap of 3-days will be given
in between two consecutive layers of concrete casting
(column on footing/pile-cap, second layer of column on
first layer, etc.).
In case of slab, two consecutive segments of slab may
be cast with a gap of at least 2-days provided laborers
do not need to walk over the previous casting

Casting Duration:
12 working hours with same set of Labors.

Back Fill Adjacent to Retaining Wall :


Use Sand of FM 2.5 @ 2' Width all around the Retaining Wall
Rest of the Area will be filled with Vity Sand.

Sanitary Holes :
Keep Holes of all Outlets in Toilet & Kitchen before Casting Slab.
Put 12" Long same Rebar which are to be Cut in the Slab at
both sides.

Alignment of Column Main Bars :


There must be at Least 2 Nos. of Ties in Column over Slab level
during Casting of the Slab to Ensure Alignment of Column Main
Bars.

For Any Construction the utmost importance


should be on the QUALITY of its products.
For this :

Quality of Materials must be ensured


Quality of Construction must be strictly
controlled

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