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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Chapter 1
Introduction

KSCB 1000 houses are a DBT (Design Build and Transfer) of low cost, mass
housing project for the urban poor initiated by the government of Karnataka. The project
consists of 448 houses to be built across an area of 5acres in sathagally consisting of 14
blocks of 32 G+3 houses and 552 houses to be built across an area of 5.62 acres in
Rajivnagar. Consisting of 15 blocks of 32 G+3 houses and 3 blocks 24 of G+3 houses

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Houses constructed for slum dwellers in Mysore under the Jawaharlal Nehru National
Urban Renewal Mission (JNNURM) have perhaps turned into a model for providing
housing to the urban poor and bagged national recognition.

Karnataka Slum Clearance Board (KSCB), Mysore, has been entrusted with the task
of building houses for the economically backward sections, under JNNURM. Each house
comprises a bedroom, a hall, a kitchen, a bathroom and a toilet with a carpet area of 301
sq. ft. The cost of each house is Rs. 3 lakh, including infrastructure development.
As part of the steps taken to make Mysore a slum-free city, multi-storeyed structures
are being built for the rehabilitation of slum dwellers, whose contribution is 10 per cent
of the expenditure incurred on the construction.
To bring in innovative and cost-effective technologies in the construction, the KSCB
invited tenders from competent companies capable of implementing cost-effective fast-
track innovative technologies under design, build and transfer (DBT).

1.1 Specialty of the project


In this project, the concept of monolithic construction technology is adapted. That
means the whole structure along with the slab is casted at a single pour [At a time]. In
order to construct a monolithic structure obviously we require formwork of greater
strength, which means the conventional formwork, is not suitable for the construction.
Hence we require an aluminum formwork which is called MIVAN SHUTTERING.

The concept of Mivan shuttering in the project has lot of advantages:

1. Requires no cranes or heavy lifting equipment.


2. Pour walls and floor slabs monolithically.
3. Remove floor slab formwork without disturbing shoring.
4. Form stairs in place as part of work cycle.
5. Requires no skilled labor.
6. Suitable for single story and high rise construction.

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7. Equipment adapts to different designs.


8. No need for use of timber or plywood.

Chapter 2
Literature survey
The traditional mode of construction for individual houses comprising load
bearing walls with an appropriate roof above or reinforced concrete (RC) framed
structure construction with infill masonry walls would be totally inadequate for mass
housing construction industry in view of the rapid rate of construction. Further, such
constructions are prone to poor quality control even in case of contractors with
substantial resources and experience.

“For undertaking mass housing works, it is necessary to have innovative


technologies which are capable of fast rate construction and are able to deliver good
quality and durable structure in cost effective manner”.

Several systems are adopted at different places in the world; eventually the
systems which are reasonably economical and easy for operation with skilled labor are
useful in India. Certain systems are in vogue and more and more contractors are trying to
bring in new technologies. These are essentially based on the basis of mode of
construction, namely, pre-cast construction or in-situ construction.

2.1 Cast-in-Situ Construction

Pre-cast and cast-in-situ are techniques that are used for quick construction. Pre-
cast includes the wall-panel units and slab units directly added to building structure. The
use of aluminum also evolved as one of the technique for quick construction by use of
aluminium and steel (tunnel) formwork. As a matter of fact the cost of the formwork
may be up to 25% of cost of the structure in building work, and even higher in
bridges, it is thus essential that the forms are properly designed to effect economy without
sacrificing strength and efficiency.

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2.2 “3-S” SYSTEM OF PRECAST CONSTRUCTION

An engineered system of building construction, namely “3-S” system was


developed by B.G.SHIRKE CONSTRUCTION TECH LTD., for achieving, speed,
strength, safety and economy in construction practices. The system involves structural
elements such as pre-cast hollow column shells pre-cast concrete beams, light weighed
reinforced cellular autoclaved concrete slabs for floor and roofs constituting the basic
structural formwork.

2.3 Present Technologies Available in INDIA

Some of the advanced technologies of formwork catering to the speed of


construction are given below:

To name a few:-

1) The Prefabrication Technology: - The Pre-cast concrete elements in roofs,


floors and in walls have become more common as these eliminate shuttering;
centering & plastering labor and saves material cost.

Fig 1.1: - Prefabricated Technology (Raymond, 2001)

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2) Tunnel Formwork Technology: - It is a technology constructing large no of


housing within short time using steel forms to construct walls & slabs in one
continuous pour.

Fig 1.2:- Tunnel formwork (Raymond, 2001)

3) Outinard Technology :- Outinard’s superior engineering, the use of high


quality steel and High Performance quality control result in a vastly superior Wall
Form system.

Fig 1.3: -Outinard Technology (Raymond, 2001)

4) Mascon Technology:-

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The Mascon Construction System is a system for forming the cast in-place
concrete structure of a building. It is also a system for scheduling and controlling
the work of other construction trades such as; steel reinforcement, concrete
placement, and mechanical and electrical trades.

Fig 1.4: - Mascon Technology. (Raymond, 2001)

Chapter 3

ABOUT MIVAN SHUTTERING


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3.1 Definition of formwork

“Forms or moulds or shutters are the receptacles in which concrete is placed, so


that it will have desired shape or outline when hardened. Once concrete develops the
adequate strength to support its own weight they can be taken out”.

“Formwork is the term given to either temporary or permanent moulds into which
concrete or similar materials are poured”.

3.2 Requirements of a good formwork

The essential requirements of formwork or shuttering are: -

a) It should be strong enough to take the dead and live loads during construction.
b) The joints in the formwork should be rigid so that the bulging, twisting, or
sagging due to dead and live load is as small as possible. Excessive deformation may
disfigure the surface of concrete.
c) The construction lines in the formwork should be true and the surface plane so
that the cost finishing the surface of concrete on removing the shuttering is the least.
d) The formwork should be easily removable without damage to itself so that it
could be used repeatedly.

3.3 MIVAN: - A Versatile Formwork

The system of aluminum forms (MIVAN) has been used widely in the
construction of residential units and mass housing projects. It is fast, simple, adaptable
and cost – effective. It produces total quality work which requires minimum maintenance
and when durability is the prime consideration. This system is most suitable for Indian
condition as a tailor–made aluminum formwork for cast–in–situ fully concrete structure.

3.4 Background

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Mivan is basically an aluminium formwork system developed by one of the


construction company from Europe. In 1990, the Mivan Company Ltd from Malaysia
started the manufacturing of such formwork systems. Now a days more than 30,000 sq m
of formwork used in the world are under their operation. In Mumbai, India there are
number of buildings constructed with the help of the above system which has been
proved to be very economical and satisfactory for Indian Construction Environment.

The technology has been used extensively in other countries such as Europe, Gulf
Countries, Asia and all other parts of the world. MIVAN technology is suitable for
constructing large number of houses within short time using room size forms to construct
walls and slabs in one continuous pour on concrete. Early removal of forms can be
achieved by hot air curing / curing compounds. This facilitates fast construction, say two
flats per day. All the activities are planned in assembly line manner and hence result into
more accurate, well – controlled and high quality production at optimum cost and in
shortest possible time.

In this system of formwork construction, cast – in – situ concrete wall and floor
slabs cast monolithic provides the structural system in one continuous pour. Large room
sized forms for walls and floors slabs are erected at site. These forms are made strong and
sturdy, fabricated with accuracy and easy to handle. They afford large number of
repetitions (around 250). The concrete is produced in RMC batching plants under strict
quality control and convey it to site with transit mixers.

The frames for windows and door as well as ducts for services are placed in the
form before concreting. Staircase flights, façade panels, chajjas and jails etc. and other
pre-fabricated items are also integrated into the structure. This proves to be a major
advantage as compared to other modern construction techniques.

The method of construction adopted is no difference except for that the sub –
structure is constructed using conventional techniques. The super–structure is constructed
using MIVAN techniques. The integrated use the technology results in a durable
structure.

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3.5 Modular Formwork


The formwork system is precisely-engineered system fabricated in aluminum.
Using this system, all the elements of a building namely, load bearing walls, columns,
beams, floor slabs, stairs, balconies etc can be constructed with cast in place concrete.
The resulting structure has a good quality surface finish and accurate dimensional
tolerances. Further, the construction speed is high and the work can be done in a cost
effective manner.

The modular nature of the formwork system allows easy fixing and removal of
formwork and the construction can proceed speedily with very little deviation in
dimensional tolerances. Further, the system is quite flexible and can be easily adapted for
any variations in the layout.

The availability of concrete from ready mix concrete facility has augured well for
the use of this work system. However, the proliferation of RMC facilities in the cities in
India and the willingness to use mechanized means of transport and placing of concrete,
the use of aluminum formwork system has received a boost. The quality of the resulting
concrete is found to be superior.

Structurally speaking, the adoption of the closed box system using monolithic
concrete construction has been found to be the most efficient alternatives. The stresses in
both the concrete and steel are observed to be much lower even when horizontal forces
due to wind or earthquake are taken into consideration.

The formwork system can be used for construction for all types of concrete
systems, that is, for a framed structure involving column beam –slab elements or for box-
type structure involving slab-walls combination.

3.6 SITE MANAGEMENT


The essence of the system is that it provides a production line approach in the
construction industry. The laborers are grouped together to form small teams to carry out

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various tasks within a certain time frame such as, reinforcement, fabrication and erection,
formwork erection, concreting etc.

Scheduling involves the design and development of the work cycle required to
maximize efficiency in the field. The establishment of a daily cycle of work, which when
fully coordinated with different trades such as reinforcement fixing, mechanical services
installation, and the placing of concrete, includes a highly efficient working schedule in
the system, not just for formwork but for all parallel trades as well.

Optimum use of the labour force is made by ensuring that each trade has
sufficient work on each working day. Experienced site supervisors are sent to site to train
supervisory staff and labour for proper handling of the equipment and to assist in
establishing the desired work cycle. The disciplined and efficient handling of work
ensures that all other trades follow in a united and predetermined manner. The improved
coordination and construction management enables the equipment to be used at optimum
speed and efficiency and speed of the output are outstanding. Thus a disciplined and
systemized approach to construction is achieved.

3.7 SPEED OF CONSTRUCTION

3.7.1 Work cycle

MIVAN is a system for scheduling & controlling the work of other connected
construction trades such as steel reinforcement, concrete placements & electrical inserts.
The work at site hence follows a particular sequence. The work cycle begins with the
deshuttering of the panels. It takes about 12-15hrs. It is followed by positioning of the
brackets & platforms on the level. It takes about 10-15hrs simultaneously.

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The deshuttered panels are lifted & fixed on the floor .The activity requires 7-10
hrs.Kicker & External shutters are fixed in 7 hrs. The wall shutters are erected in 6-8 hrs
One of the major activity reinforcement requires 10-12 hrs. The fixing of the electrical
conduits takes about 10 hrs and finally pouring of concrete takes place in these.

This is a well synchronized work cycle for a period of 7 days. A period of 10-12
hrs is left after concreting for the concrete to gain strength before the beginning of the
next cycle. This work schedule has been planned for 1010-1080 sq m of formwork with
72-25cu m of concreting & approximate reinforcement.

The formwork assembling at the site is a quick & easy process. On leaving the
MIVAN factory all panels are clearly labeled to ensure that they are easily identifiable on
site and can be smoothly fitted together using formwork modulation drawings. All
formwork begins from corners and proceeds from there.

The system usually follows a four day cycle: -

Day 1: -The first activity consists of erection of vertical reinforcement bars and
one side of the vertical formwork for the entire floor or a part of one floor.

Day 2: -The second activity involves erection of the second side of the vertical
formwork and formwork for the floor

Day 3: - Fixing reinforcement bars for floor slabs and casting of walls and slabs.

Day 4: -Removal of vertical form work panels after 24hours, leaving the props in
place for 7 days and floor slab formwork in place for 2.5 days.

3.7.2 Design Aspects

The comparison is done between buildings constructed by: -

i) Conventional RC columns, beams, and slab construction (RC moment


resisting framed structure)
OR

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ii) RC load-bearing walls and slabs.

In the case of RC moment-resisting framed structures, the horizontal forces due to wind
or earthquake are resisted by the frames resulting in the bending moments in columns to
resist bending moment and vertical loads would be more than that required to resist
vertical loads without bending moment. Similarly, additional reinforcement will be
required in beams at supports.

In the case of RC load-bearing walls, monolithic casting of slab along with RC


walls results in a box type structure, which is very strong in resisting horizontal forces
due to wind or earthquake. In view of large depth of shear walls, the resulting stresses
due to bending moment and vertical loads are smaller and in many cases, concrete alone
is capable of resisting these forces

On evaluating these alternatives, it is seen that the beam column frame system in

i) Performs poorly against earthquake forces compared to RCC wall and slab
construction. Recent changes in the IS Codes, as well as recommended
good practice demand provision of additional reinforcement comply with
ductility requirements.
ii) The sizing and detailing of columns needed to be –that they are 20%
stronger than beams they support.
3.7.3 Economics

The cost per flat (or per m² built up area) using MIVAN shuttering system
depends upon the number of repetition and period of completion of the project. As the
formwork can be reused over 250 times, the initial cost per unit of forming area is less
when compared to traditional methods. The reduction of cost is also due to the
elimination of brickwork and plaster and also due to reduction in time. The cost of the
project gets substantially reduced due to shear wall construction. These are due to the
reduced consumption of steel, masonry, and plaster even though the use of concrete
decreases. For the same number of repetition, the cost will be less if the period of
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completion is longer. This is because for a shorter completion period, the area of
formwork is more than required for longer completion period.

The aluminum formwork provides an integrated scaffolding system which reduces


the cost of scaffolding requirements. The mechanical and electrical installation is
simplified as conduits are embedded in the structure by precise engineering of outlets and
service ducts.Thus, we can conclude that the overall cost of the project is lesser when
compared to project using traditional methods of formwork.

3.7.4 QUALITY:

High quality Formwork panels ensure consistency of dimensions. On the removal


of the formwork mould a high quality concrete finish is produced to accurate tolerances
and verticality. The high tolerance of the finish means that no further plastering is
required. Typically a 3mm to 4mm skin coat is applied internally prior to finishing and a
6mm build up coat prior to laying tiles. Care must be taken so that the concert and in
particular the enforcement does not become contaminated due to excessive or negligent
application of the releasing agent.

3.8 The Advantages of this system are:-

The MIVAN formwork is specifically designed to allow rapid construction of all types of
architectural layouts.

1) Total system forms the complete concrete structure.


2) Custom designed to suit project requirements.
3) Unsurpassed construction speed.
4) High quality finish.
5) Cost effective.
6) Panels can be reused up to 250 times.
7) Erected using unskilled labor.

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Quality and speed must be given due consideration along with economy. Good
quality construction will never deter to projects speed nor should it be uneconomical. In
fact, time consuming repairs and modifications due to poor quality work generally delay
the job and cause additional financial impact on the project. Some experts feel that
housing alternatives with low maintenance requirements may be preferred even if the
initial cost is high.

3.9 LIMITATION OF MIVAN FORMWORK:

Even though there are so many advantages of MIVAN formwork the limitations
cannot be ignored. However the limitations do not pose any serious problems. They are
as follows: -

1) Because of small sizes finishing lines are seen on the concrete surfaces.

2) Concealed services become difficult due to small thickness of components.

3) It requires uniform planning as well as uniform elevations to be cost effective.

4) Modifications are not possible as all members are caste in RCC.

5) Large volume of work is necessary to be cost effective i.e. at least 200 repetitions
of the forms should be possible at work.

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6) The formwork requires number of spacer, wall ties etc. which are placed @ 2 feet
c/c; these create problems such as seepage, leakages during monsoon.

7) Due to box-type construction shrinkage cracks are likely to appear.

8) Heat of Hydration is high due to shear walls

Chapter 4

DETAILS ABOUT PROJECT

Details of KSCB project:


Detailed topographical survey was conducted for each of these sites and the contour
maps are attached at the ends of these report.
Recconnoitary survey was done to get some idea of surroundings, public infrastructure
including storm and sewer lines, any land reclamation task needed etc. The site in
sathagalli do not need any land reclamation work except for some contour management
leveling earthwork.
Based on the availability of the land area each site, town planning norms and NBC
Housing blocks of four floors (G+3) with eight houses in each floor (32 houses per block
with carpet area of 28.145sq. per house) have been architecturally designed as detailed in
the drawing.

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The major advantage of the technology proposed is that more than 90% of the work is
completed by only three critical items of work. They are Concrete, Formwork and
Reinforcing steel. Hence, Quality Control and time management will be very efficient.
Following specifications are considered for Flooring, External, Internal Finishes and
Opening.

i) Flooring is Granolithic flooring with red oxide finish.

ii) External painting is oil bound distemper.

iii) Door frames are RCC with CRP structures (12mm thick).

iv) Windows and ventilator frames and shutters using Mild Steel ‟Z” section and pin head
glass.
Following are the basic minimum infrastructure is designed and considered for
estimation.

i) Roads and road site drainage in each layout.

ii) Water supply.

iii) Under ground drainage system.

iv) Electricity and street lights.

v) Ground water recharges system as a component of Rain Water Harvesting.

vi) All the site requires new network of storm water, drain.

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Chapter 5
GENERAL REQUIREMENTS OF THE PROJECT
Sanitation:
Adequate toilet facilities shall be provided for the workmen within easy access of their
place of work. The total number to be provided shall be not less than one per 30
employees in any one site. Toilet facilities shall be provided from the start of building
operations, and connection to a sewer shall be made as soon as practicable.
Every toilet shall be so constructed that the occupant is sheltered from view and protected
from the weather and falling objects.
Toilet facilities shall be maintained in a sanitary condition and sufficient quantity of
disinfectant shall be provided.
Drinking Water & Washing Facility:
An adequate supply of drinking water shall be provided, and unless connected to a
municipal water supply, samples of the water shall be tested at frequent intervals by the
authority.
Washing facilities shall be installed, and when practicable shall be connected to
municipal water supply and shall discharge to a sewer.

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Fire Protection:
In addition to the provision of fire extinguishers, as specified in this part of the manual,
other fire extinguishing equipment shall also be provided and conveniently located within
the building under construction or on the building site, as required by the Authority.
All fire extinguishers shall be maintained in a serviceable condition at all times in
accordance with good practice.
It shall be ensured that all workmen and supervisory staff are fully conversant with the
correct operation and use of fire extinguishers provided at the construction site.
Access shall be provided and maintained at all times to all fire fighting equipment,
including fire hose, extinguishers, sprinkler valves and hydrants.

All work waste, such as scrap timber, wood shavings, sawdust, paper, packing materials
and oily waste shall be collected and disposed of safely at the end of each day’s work.
Particular care shall be taken to remove all waste accumulation in or near vertical shaft
openings like stairways, lift-shaft, etc.
An independent water storage facility shall be provided before the commencement of
construction operations for fire-fighting purposes. It shall be maintained and be available
for use at all times.
Clothing:
It shall be ensured that the clothes worn by the workmen be not of such nature as to
increase the chances of their getting involved in accident to themselves or to others. As a
rule workmen wearing loose garments shall be prohibited from the worksite.
Workmen engaged in processes which splash liquid or other materials which will injure
the skin shall have enough protective clothing to cover the body.
Individuals engaged in work involving use of naked flames (such as welding) shall not
wear synthetic fibre or similar clothing which increases the risk of fire hazards.
Workmen shall use safety helmets, hand gloves, safety shoes & safety belts as the case
may be for prevention of injury. All necessary safety appliances shall be issued to the
workers prior to starting of work.
FIRST-AID:

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A copy of all pertinent regulations and notices concerning accidents, injury and first aid
shall be prominently exhibited at the work site.
Enough first-aid kit shall be provided at site. A telephone may be provided and telephone
numbers of the hospitals shall be prominently displayed.
Complete reports of all accidents and action taken thereon shall be forwarded to the
competent authorities.Geo technical investigation for the proposed Construction of 448
houses K.S.C.B HOUSES At Sathagahalli, Mysore

OBJECTIVES:
The primary objective of this investigation is,

1. To establish the type of subsoil and depth of Ground water

2. To assess the allowable bearing pressure at different depths based on field and
laboratory resting and hence to recommend on the depth and type foundation

3. To recommend on the ground improvement method, if required, based on the ground


condition

SCOPE OF THE WORK:


The scope of the work includes,

1. Drilling the bore holes at the specified location using Hand auger up to the refusal
strata or to a maximum of 6.0m, whichever occurs earlier.

2. Conducting Standard Penetration test at every 1.5m depth or where ever strata changes,
in each of the boreholes.

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3. Collecting undisturbed and Representative samples in each of the strata for the
laboratory tests.

4. Conducting suitable laboratory tests on Soil samples for different Index and
Engineering properties.
This report consists of the details about the various laboratory tests and field tests
performed and the recommendations made based on the results of the tests.

STANDARD PENETRATION TEST:


Standard Penetration tests (SPT) were conducted at different depths in all the bore
holes as the bore hole was advanced down and the „N‟ values were recorded. The SPT
was carried out according to IS: 2131-1981 SPT (Standard Penetration Test, Re affirmed
in 1992). The number of blows required to drive a 50mm diameter split spoon sampler
for a depth of 30cm using a 65kg hammer is recorded as „N‟ value. The results of all the
penetration tests performed in each of the bore holes are shown in their respective Bore
logs. The test is halted if,

i) 50 blows are required for any 150mm penetration.

ii) 100 blows are required for 30cm penetration.

iii) 10 successive blows produce no advance.


and correspondingly the N – value is recorded as “REFUSAL”.

Laboratory tests:
The following laboratory tests were carried our as per the Indian Standards IS-2720.

a) In situ density and water content


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b) Grain size analysis

c) Atterberg limits

d) Shear tests

Test results:
SOIL PROPERTIES AT SATHAGALLI SITE
Bore Depth Liquid Plastic Silt sand Gravel Field Cohesion Angle of
hole # mt limit% limit% clay density Kg/cm2 internal
g/cc friction

ᶲ in degrees

1 1.5 23 18 33 60 7 1.89 0.021 27

1.8 21 NP 25 65 10 1.92 0.030 32

2 1.5 24 18 31 62 7 1.90 0.022 28

2.0 22 NP 23 66 11 1.93 0.020 29

3 1.5 21 NP 24 65 11 1,93 0.020 30

4 1.0 22 NP 21 70 9 1.95 0.022 29

5 1.3 23 NP 22 60 18 1.91 0.021 32

6 1.5 21 NP 23 65 12 1.92 0.030 31

7 1.0 21 NP 24 60 16 1.93 0.026 32

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SOIL PROPERTIES AT RAJIV GANDHI NAGARA SITE

SOIL PROPERTIES AT SATHAGALLI SITE


Bore Depth Liquid Plastic Silt sand Gravel Field Cohesion Angle of
hole # mt limit% limit% clay density Kg/cm2 internal
g/cc friction

ᶲ in degrees

1 1.0 31 20 32 68 0 1.89 0.023 27

2.0 29 19 28 65 7 1.92 0.035 28

2 1.5 32 21 30 65 5 1.88 0.021 26

3.0 24 NP - - - 1.92 0.019 31

3 1.5 26 19 26 70 4 1.91 0.023 26

4 1.0 23 NP - - - 1.90 0.029 28

5 1.0 28 20 30 62 8 1.89 0.022 27

2.0 22 NP 27 65 8 1.92 0.031 28

6 1.0 22 NP - - - 1.86 0.030 28

7 1.0 31 21 32 60 8 1.89 0.025 27

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1.5 23 NP - - - 1.91 0.019 31

Recommendations:

Based on the extensive field investigation and laboratory testing, the following
conclusions and recommendation are drawn
Allowable bearing pressure
Both shear failure and settlement criteria are considered while arriving at the final value
of Allowable Bearing pressure. The values of allowable bearing pressure are calculated at
different depth (for a footing width of 1m). This helps the structural designer to select the
allowable bearing pressure, which gives a factor of safety of 3.0 against shear failure and
for an allowable settlement of 25mm is recommended.
Location: Proposed Building at Sathagalli
Depth below ground level, m Allowable Bearing Pressure, T/m2
1.5m 25
Minimum Depth:
The minimum depth of foundation should be at least 1.5m below the natural ground level.
Any compressible, loose, filled – up top soil should be avoided as the foundation base.
For the present structure the minimum depth of foundation is 1.5m below the natural
ground level.

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Type of foundation

The type of foundation at a given Allowable bearing pressure is controlled by the


magnitude and type of loading.

 Individual footing may be designed with the above recommended Allowable Bearing
pressures and all the column footing should be proportional for equal settlement.

 The area of coverage of the footings should not be more than half of the total
construction area.

Other Precautions

(i) Any accumulation of water in the foundation trench should be avoided before
Concreting for the foundation.

(ii) The bottom of the foundation trench should be well compacted before Concreting.

Chapter 6

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COST COMPARISION BETWEEN CONVENTIONAL METHOD AND MIVAN


TECHNOLOGY
For all engineering works it is required to know beforehand and probable cost of
construction known as estimated cost.in preparing all estimate,the quantities of different
items of work are calculated by simple mensuration method and from these quantities
cost is calculated.

Since mivan Technology is adopted in this project the number of construction


activities has been reduced, which inturn increases the quantities in some activity.

For Example,

The number of activities such as Blockwork,Plastering and painting is reduced. Whereas


the quantities of steel and concrete increases.

Before advent of mivan Technology,the conventional method (i,e Framed structures


with load bearing wall) is adapted for high rise building for KSCB Projects.Some of the
slum clearance project in mysore which is located in the area Gokulam,B.M Shree Nagar
and Yadavagiri. These projects are constructed by conventional method Eventhough it is
a modular structures.

Hence inorder to know the cost difference as well as feasibility of the project we
are carring out estimation for conventional method and it is compared with the cost and
quantities while using mivan technology.

In conventional method we have considered same carpet area but instead of concrete
wall,we have taken Non-load bearing wall with framed structure.

The analysis of the structure is carried out by using STAAD PRO software,by taking
dimension of the column as 200X450 and the beam size of 200X375.

a .Quantity Estimation for Different Items with Mivan Technology

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Estimation Work For "F" Block

Sath
Description Sathgalli Site "F"Block
"F
Sl Qty with 5% Operating
Unit Actual A
No. wastage rate**
Item Category BOQ
Per Per
Qty Per hous
house block
1 Earthwork Mass excavation CUM 13.13 420.00 400.00 87.89 1153.56

Excavation- Ordinary
2 Earthwork CUM 15.34 490.85 467.48 93.00 1426.54
soil

3 Earthwork Excavation-Hard rock CUM 1.97 63.00 60.00 641.00 1261.97


4 Earthwork Back filling CUM 16.72 534.93 509.46 75.48 1261.77
5 Concrete PCC below Foundation CUM 0.79 25.20 24.00 3019.28 2377.68
PCC below Below
6 Concrete CUM 0.82 26.25 25.00 3122.68 2561.57
flooring
7 Concrete Footing CUM 1.64 52.50 50.00 3629.34 5954.39

8 Concrete Plinth wall CUM 2.43 77.70 74.00 3639.68 8837.60

9 Concrete Super structure- walls CUM 10.57 338.10 322.00 3619.00 38237.00

10 Concrete Super structure- Slab CUM 4.27 136.50 130.00 3644.85 15547.56

11 Concrete Staircase CUM 0.15 4.90 4.67 3650.00 559.31


12 Concrete Plinth Protection CUM 0.00 0.00 0.00 0.00 0.00
13 Formwork PCC SQM 1.25 39.90 38.00 175.78 219.18
14 Formwork Footing SQM 3.75 120.00 114.29 175.78 659.20

15 Formwork Foundation wall SQM 25.69 822.15 783.00 175.78 4516.17

16 Formwork Super structure- Wall SQM 182.36 5835.52 5557.64 175.78 32055.25

17 Formwork Super structure-Slab SQM 36.99 1183.56 1127.20 175.78 6501.44

18 Formwork Staircase SQM 2.37 75.92 72.30 175.78 417.01

19 Steel Rebar Tons 0.79 25.20 24.00 44255.20 34850.97

Steel Railing- Corridor M/T 0.03 0.84 0.80 65142.00 1709.98

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Below plinth beam n


21 Masonry CUM 0.04 1.38 1.31 2647.00 113.78
Entrance steps
22 Plastering Entrance steps SQM 0.13 4.20 4.00 956.45 125.53

23 Joinery Doors SQM 7.28 232.85 221.76 1240.80 9028.68

24 Joinery Windows and ventilators SQM 4.56 145.95 139.00 1551.00 7074.01

25 Flooring SQM 32.06 1025.85 977.00 172.68 5535.74

26 Painting OBD-Internal SQM 151.43 4845.75 4615.00 36.19 5480.24

28 Painting External - cement based SQM 66.61 2131.50 2030.00 82.72 5509.93

30 Painting Railing enamel SQM 6.89 220.50 210.00 82.72 569.99


Water Proof
31 SQM 9.98 319.20 304.00 139.59 1392.41
course

TOTAL AMOUNT 194938.4

b. Estimation for Different Items with conventional method

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Description Sathgalli Site "F"Block Sathga


Qty with 5%
Sl Actual Operating
Unit wastage
No. Item Category BOQ rate**
Per Per
Qty Per hou
house block
1 Earthwork Footing Excavation CUM 5.85 187.272 480 92.7 542.29

2 Earthwork Back filling CUM 2.92 93.63 75.48 220.4

3 Concrete PCC below Foundation CUM 0.303 9.72 24.00 3019.28 914.75
4 Concrete PCC below flooring CUM 0.82 26.25 25.00 3122.68 2561.5
5 Concrete Footing CUM 4.55 145.8 50.00 3629.34 16514
Concrete Plinth beam CUM 0.34 10.916 3629.34 1238.0
Concrete Columns CUM 1.82 58.32 3629.34 6614.4
Concrete Beams CUM 2.55 81.87 3629.34 9254
Concrete Super structure- Slab CUM 4.27 136.50 130.00 3644.85 15547.5
Concrete Staircase CUM 0.15 4.90 4.67 3650.00 559.31
Formwork PCC SQM 0.54 17.28 125 67.5
Formwork Footing SQM 9.11 291.6 125 1138.7
Formwork Columns SQM 23.03 737.1 165 3799.9
Formwork Plinth SQM 3.41 109.16 125 426.4
Formwork Beam SQM 32.4 1037.02 165 5346
Formwork Super structure-Slab SQM 36.99 1183.56 1127.20 165 5954.85
Formwork Staircase SQM 2.37 75.92 72.30 175.78 417.01
Steel Columns Tons 0.145 4.661 44255.20 6417
Steel Column stirrups Tons 0.043 1.393 44255.20 1902.9

Steel Beams with stirrups Tons 0.288 9.227 44255.20 12760.7

Steel Slab Tons

Masonary 200&100 CUM 11.69 374.29 3169 37066.


Cieling with lime 38.78
Plastering SQM 310.3 140.63 5453.6
rendering
Internal wall with lime
Plastering SQM 167.1 5347.4 110 18464
rendering
Plastering with sponge
Plastering SQM 87.96 2814.96 94.50 8312
finish

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Joinery Doors SQM 7.28 232.85 221.76 1240.80 9028.6


Joinery Windows and ventilators SQM 4.56 145.95 139.00 1551.00 7074.0
Flooring SQM 32.06 1025.85 977.00 172.68 5535.7
Painting OBD-Internal SQM 151.43 4845.75 4615.00 36.19 5480.2

Painting External - cement based SQM 66.61 2131.50 2030.00 82.72 5509.9

Painting Railing enamel SQM 6.89 220.50 210.00 82.72 569.99


Water Proof
SQM 9.98 319.20 304.00 139.59 1392.4
course

Detailed Estimate for the construction with Conventional method:-


1. Earth work excavation for footing of building by using excavator
= 1.6x1.3x1.7 = 3.53m3/one footing
Total Number of footings =54
= 3.53x54x =187.272m3/Block
For one house= 187.272 = 5.85m3/house
32
2. Back filling available excavated earth in sides of footings up to plinth
= 50% of excavated area
= 0.5x187.272 =93.63m3/Block
For one house= 93.63 = 2.92m3/house
32
3. P.C.C below foundation of mix 1:4:8 using 40mm down size
= 1.5x1.2x0.1=0.18 m3 x54 No of footing
= 9.72 m3/block
For one house = 9.72 = 0.303m3/house
32
4. Footing concrete of mix 1:2:4 using 20mm down size
= 1.2x1.5x1.5=2.7 m3 x54 No of footing
= 145.8 m3/block
For one house = 145.8 = 4.55m3/house
32
5. Concrete for plinth beam
Total running length of plinth= 272.90m
Required volume of concrete=272.9x0.2x0.2
=10.916 m3/block
3
For one house = 10.916 = 0.34m /house

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32
6. Concrete for column
Floor to floor height = 3m
Dimension of column= 0.2x0.45= 0.09
No.of columns= 54
Total quantity for each floor
=3x0.09x54=14.58 m3
No.of floors = 4
=14.58x4
= 58.32m3
7. Concrete for beam
Running length of the beam = 272.90m for each floor
Dimension of beam =0.375x0.2
=0.075
Total Quantity= 272.90x0.075
=20.46m3
No.of floors = 20.46x4
=81.87 m3
8. Concrete for slab
=1.2x1.5x1.5
=2.7x54
=145.8 m3
No.of floors =4
=145.8=34.125m
4
Areax0.12=34.125
Area= 34.125 =284.375m3
0.12
Peripheral area= 284.375m3
Thickness of slab= 0.12
=303.75x0.12=34.125 m3
=34.125x No.of floors
=34.125x4= 136.5m3
9. Form work for Pcc:-
=(1.5+1.2)2X0.1
=0.54 m3X54
=29.16 m2/block
For one house = 29.16 = 0.91m2/house
32
10. Form work for columns
PCC=(1.5+1.2)x2=5.4x0.1
=0.54x54
=29.16 m3
11. Columns
=(0.45+0.2)x2 x2.625=3.412x54No of footing
Department of Civil Engineering, VVIET, Mysore. Page 32
CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

=737.1 m2/block
For one house = 737.1 = 23.03m2/house
32
12. Form work for plinth
Running length = 272.9x0.2x2 sides
=109.16 m2/block
For one house = 109.16 = 3.41m2/house
32
13. Form work for beam
Running length=(0.375x2+0.2) x272.90
=259.255 m2
No.of blocks = 4
= 259.255x4=1037.02 m2/block
For one house = 1037.02 = 32.4m2/house
32
14. Steel
Columns
Floor to floor height= 3m
Column rods inside footing=1.5+0.3=1.8m
Column rods above the terrace = 0.75m
Lap length at each floor = 50D
= 50x12=600mm
= 0.6m
= 0.6xno.of floors
= 0.6x4
= 2.4m
12mm diameter of 6 no.of bars provided for each column
=50D
=50x12=0.6m
=0.6x3=1.8 m

Additional length of rod = 1.8m


=1.8+1.8+0.75+12
=16.35m
No.of bars = 6x16.35
=98.1x54
=5296.4m
Weight of 12mm bars= D2
162
=122

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162
= 0.88
=5296.4x0.88
=4661.7 kg/block
For one house = 4661.7 = 145kg/house
32
=0.145 tons
15. Column stirrups are to be provided with 8mm diameter bars at200mm c/c
Length of one stirrup = (0.370+0.12)x2=0.980m
No.of stirrups= 13500 =67.5
200
=68 no.of stirrups
= 68x0.980
=66.15x54
=3572.1m
2
Weight of 8mm bars= D
162
=82
162
=1.393 tons
For one house = 1.393 = 0.043 tons
32
16. Form work for beams with stirrups
Running length of beam=272.90+(0.45x54)
=297.2m
Details of beam:
6 No of bars of dia 12mm at 175mm c/c
=297.2mx6 No.of rods
=1783.2m
Providing additional 16 No
Lap joints at 40D
=480=500mm Lap length
Total length of Lap joints
= 0.5x16x6=48m
Total length = 1783.2+48m
= 1831.2m
No.of floors= 4 No`s
=4x1931.2m
=7324.8m
D2 =6.445 tons
162

Stirrups:
Total running length=297.2m
175mm
Department of Civil Engineering, VVIET, Mysore. Page 34
CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

1699 No`s
For each floors
(0.325+0.150)x2
1.05mx1699
=1,783.95x0.39
For each floors= 695.7405 Kgs
No.of floors= 4x695.7405 Kgs
=2.782.96 kgs

Total
6.445+2.782
=9.227 tons

17. Providing 12mm thick cement plaster in single coat with cement mortar 1:3, to
ceiling including rounding off corners wherever required smooth rendering, Providing
and removing scaffolding, including cost of materials, labour, curing complete as per
specifications.(P.No.96, I.No.15.9)
For Ceiling
Bed room 1 Sqm 2 3,05 - 2,05 12,51
Living 1 Sqm 2 3,05 - 3,80 23,18
Bed room 2 Sqm 4 2,50 - 3,05 30,50
Living 2 Sqm 4 8,80 - 3,05 107,36
Bed room 3 Sqm 2 3,05 - 2,95 18,00
Living 3 Sqm 2 3,05 - 3,80 23,18
Kitchen 1 Sqm 2 2,00 - 2,75 11,00
Kitchen 2 Sqm 4 2,75 - 2,00 22,00
Kitchen 3 Sqm 2 2,00 - 1,70 6,80
WC1 Sqm 4 1,16 - 1,22 5,66
WC2 Sqm 2 1,10 - 1,22 2,68
Corridor 1 Sqm 1 1,08 - 6,75 7,26
Corridor 2 Sqm 1 9,33 - 1,08 10,03
Bath 1 Sqm 2 1,00 - 0,90 1,80
WC1 Sqm 2 0,90 - 1,00 1,80
Passage 1 Sqm 2 0,90 - 0,80 1,44
Bath 2 Sqm 4 1,90 - 1,00 7,60
WC 2 Sqm 4 1,00 - 0,90 3,60
Passage 2 Sqm 4 0,80 - 0,90 2,88
Bath 3 Sqm 2 1,00 - 1,90 3,80
WC 3 Sqm 2 0,90 - 1,00 1,80
Passage 3 Sqm 2 0,90 - 0,80 1,44
Passage 4 Sqm 3 1,05 - 1,28 4,03

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310,34 124,63

18.Providing 12mm thick cement plaster in single coat with cement mortar 1:6 to
brick masonry including rounding off corners wherever required smooth rendering, :
Providing and removing scaffolding, including cost of materials, labour, curing
complete
For inside
Bed room 1 Sqm 2 10,20 - 3,00 61,20
Living 1 Sqm 2 13,70 - 3,00 82,20
Bed room 2 Sqm 4 11,10 - 3,00 133,20
Living 2 Sqm 4 23,70 - 3,00 284,40
Bed room 3 Sqm 2 12,00 - 3,00 72,00
Living 3 Sqm 2 13,70 - 3,00 82,20
Kitchen 1 Sqm 2 9,50 - 3,00 57,00
Kitchen 2 Sqm 4 9,50 - 3,00 114,00
Kitchen 3 Sqm 2 7,40 - 3,00 44,40
WC1 Sqm 4 4,76 - 3,00 57,12
WC2 Sqm 2 4,64 - 3,00 27,84
Corridor 1 Sqm 1 15,65 - 3,00 46,95
Corridor 2 Sqm 1 20,81 - 3,00 62,43
Bath 1 Sqm 2 3,80 - 3,00 22,80
WC1 Sqm 2 3,80 - 3,00 22,80
Passage 1 Sqm 2 3,40 - 3,00 20,40
Bath 2 Sqm 4 5,80 - 3,00 69,60
WC 2 Sqm 4 3,80 - 3,00 45,60
Passage 2 Sqm 4 3,40 - 3,00 40,80
Bath 3 Sqm 2 5,80 - 3,00 34,80
WC 3 Sqm 2 3,80 - 3,00 22,80
Passage 3 Sqm 2 3,40 - 3,00 20,40
Passage 4 Sqm 3 4,66 - 3,00 41,94
1466,88
Deduction
MD Sqm 8 0,90 - 2,10 15,12
D Sqm 8 0,90 - 2,10 15,12
D2 Sqm 16 0,75 - 2,10 25,20
KW Sqm 8 0,90 - 1,37 9,86
W Sqm 14 1,50 - 1,37 28,77
W1 Sqm 2 0,90 - 1,37 2,47
W2 Sqm 2 0,60 - 1,37 1,64
V Sqm 12 0,45 - 0,45 2,43
OP Sqm 8 1,00 2,10 16,80

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

OP1 Sqm 8 0,75 2,10 12,60


130,01
Quantity 1336,87
For Outside
Sqm 1 251,39 - 3,00 754,17
754,17
Deduction
MD Sqm 8 0,90 - 2,10 15,12
W Sqm 14 1,50 - 1,37 28,77
W1 Sqm 2 0,90 - 1,37 2,47
W2 Sqm 2 0,60 - 1,37 1,64
V Sqm 12 0,45 - 0,45 2,43
50,43
Quantity 703,74
Net Quantity 2040,61 94,50

19. Providing lime rendering for plastering to wall and ceiling , including cost of
materials, labour, curing.
For Ceiling Sqm 1 310,34 310,34
For Inside Sqm 1 1466,88 1466,88
1777,22 16,02

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Chapter 7
CONSTRUCTION PROCESS

The technology is based on adopting an aluminium formwork or mould for construction


of the walls and the roof of a house in one pour of concrete to have one house per day on
an average, according to the authorities.
“The supplier of the mould with whom the construction agency has entered into an
agreement is Wall Ties and Form Inc., which is based in Kansas, U.S. and high grade
aluminum alloy is used as the raw material,” the officials said.
The mould can be handled manually and gives leak-proof joints when fitted in place. In
this technology, the steel bars along with the electrical conduits and water supply pipes
are placed inside the mould of walls and slab. The concrete is then poured from the top
inside the mould of both the wall and the slab at one time.
All walls and roofs with electrical conduit, water supply and sanitary fixtures are
available at the same time when the mould is taken out. After this, all doors and windows
are fixed in places left in the concrete walls for that purpose. The surface of the concrete
walls and slab are smooth and ready to receive paints directly.
FOUNDATION:

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The excavation for the substructure is done by power shovel and dozers, after that a plain
concrete bed is laid before the footing is placed. However for water logged areas raft
foundation is laid.

The foundation is monolithic with 1200mm in depth below the ground level with footing
of 800mm width which includes the pedestal of 600mm above the ground level with a
thickness of 150mm and continuous with a wall thickness of 120mm as a main wall and
with 100mm thick of partition walls in water closet, bathroom and kitchen.

After the foundation is over the filling with earth is done with with the help of
compaction then later the surface is leveled by the earth vibrator. After the finishing is
done, over the compacted layer plain cement concrete is poured and the level and the
accuracy is checked by with the help of ordinary dumpy level.
Reinforcement for superstructure:
Before laying of formwork The reinforcement of walls include 8mm and 12mm
diameters bars of Fe415 grade. The 12 mm bars is mainly used in opening such as doors
and windows to carry the load (since the lintel is not provided) extra reinforcement is
done in opening. The cover blocks for the walls are provided to maintain the uniform
distance in the reinforcement laid.
The wall ties and forms are basically used to cast the whole structure at a time in-
situ. The grade of concrete used is M20 with super plasticizer(Kem suplast TB 101
SChembond chemicals) having 70% - 80% of 12mm down size aggregate and remaining
with 20mm down size to avoid the bleeding and segregation of concrete since the
concrete is poured from a height of 3m. This design is for only to walls where as for slabs
the concretes used is 100%screed used with 12mm down size aggregate, flyash and
admixture with plastizer(SUPER Plastizer- RHEOBUILD 918 RMBASF). The concrete
is vibrated with a wacker vibrator(needle type) With 25mm diameter of the needle(for
walls) and 35mm diameter(for slabs). The concrete is compacted in 3 layers and the
quality control is checked by a wooden hammer by hammering the form work to find the

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complete compaction of concrete for ensuring the compactness and to avoid the honey
combing.

Figure showing reinforcement for F Block:

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Since the structure consists of 8 houses in a floor only 4 houses are casted at a time
therefore for casting another half is carried out after the 7th day of the 4 houses, since the
construction joint is common to occur which may lead to cracks and the compactness or
unity is not found so to remove that a compound form BASF RHEOMIX141 is used.
This compound is applied to the surface of the walls where the continuation of walls or
roof takes place there by forming a rigid joint with waterproofing.

The electrical conduit ducts are laid during the erection of the fabricated reinforcement
there by the drilling of holes on the walls is avoided. However the plumbing and sanitary
lines are not concealed inside the walls, but opening is made before the section is casted.
TENSILE TEST RESULTS FOR BLOCK F:
Sl # Nominal Mass (wt) UTS Elongation
Dia (mm) Kg/mt (N/mm2) %
1 8 0.395 596.20 27.5
2 8 0.408 654.17 25.0
3 8 0.392 620.79 25.0
4 12 0.860 589.84 23.3
5 12 0.857 599.05 23.3
6 12 0.858 583.72 26.7

RHEOMIX 141
Description
RHEOMIX 141 is a (SBR) styrene-butadiene co-polymer latex specifically designed for
use with cement compositions. It is used in mortar and concretes as an admixture to
increase resistance to water penetration, improve abrasion resistance and durability. It is
used with cement as a reliable water-resistant bonding agent.

Primary uses
• Concrete repair.
• Floor screeds and toppings.
• External rendering.
Department of Civil Engineering, VVIET, Mysore. Page 41
CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

• Waterproofing and tanking.


• Fixing slip bricks and tiles.
• Corrosion protection of steel.

Composition
RHEOMIX 141 is a milky, white liquid, produced from styrene and butadiene by high
pressure emulsion polymerisation. The latex consists of microscopic particles of synthetic
rubber dispersed in an aqueous solution. RHEOMIX 141 modified mixes may be slightly
darker than corresponding unmodified mixes.

Dosage rate

For all normal use the standard dose of 5ltr of RHEOMIX 141 per 50kg cement is
adequate. For extreme conditions and/or when adhesion, waterproofing, water vapour
resistance or chemical resistance are critical, the dosage should be increased to 10ltr of
RHEOMIX 141 per 50kg cement. For this higher dosage, the extra water addition
required is low and, therefore, use of wet aggregate may result in excessive workability.
Compatibility
RHEOMIX 141 is specifically designed for use with Portland cements. It is also
compatible with sulphate-resisting cement, Types II and V. Lime (more than 10% cement
weight), air entraining agents and masonry cement must not be used in conjunction with
RHEOMIX 141.

Casting of slab:
The slab is casted along with the walls at a time, but the concrete used is 100% screed
which has only 20mm downsize aggregate. The reinforcement is normal with 12mm
diameter bar as main reinforcement and 8mm diameter bar as distribution steel. The
cover block used is pvc cover block with 25mm thick.

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Figure showing concreting for first floor roof slab in Block F

Curing of concrete:

The form work is deshuttered within one day and as soon as the forms are removed
the surface of wall will be still in green state so a curing compound called BASF
MASTERKURE181 a coloured compound is used for application. This compound is
available in both clear and coloured stated, since here the coloured compound is used to
ensure the full application of the compound. This compound forms a membrane which
avoids the water to evaporate from the surface of the walls there by complete curing is
done not by wasting the resource. The ponding method is used for curing of slab. The
structure is cured for 3 days as per the schedule but to avoid the shrinkage cracks and
other, the curing was extended to 7 days as per the revised schedule.

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Curing of internal walls of Block F

MASTERKURE® 181 :
Acrylic based, concrete curing compound
DESCRIPTION :
MASTERKURE 181 is a ready to use clear membrane curing compound based on
selected acrylic resins, which when applied on to freshly placed concrete surfaces
provides an efficient curing membrane with excellent non yellowing properties. It can be
supplied with a fugitive dye as MASTERKURE 181FD.
The curing membrane also acts as a primer for selected surface coatings thereby avoiding
the need to remove it before application of such coatings.

MASTERKURE 181 conforms to ASTM C309 : Type 1, Class B.

FIELDS OF APPLICATION MASTERKURE 181 is recommended for curing freshly


placed or deshuttered concrete and mortar, both indoors and outdoors, such as;
• Concrete floors
• slip formed concrete

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

• repaired patches
• Runways and pavements
• Bridge abutments
• exposed architectural concrete

TYPICAL PERFORMANCE DATA


ASTM C309 specifies the maximum permissible water loss after application of the curing
compound as 0.55 kg/m2 in 72 hours.
Typical results for MASTERKURE 181 on concrete test

Application rate Measured loss of water in 72 hours


5 m2/L 0.47 kg/m2

APPLICATION :

Use MASTERKURE 181 as supplied without dilution. It should be applied after the final
finishing operation as soon as the concrete or mortar surface has hardened sufficiently to
prevent marring. The surface should be damp but with no free water on it. In the case of
formed concrete, apply immediately after striking the formwork. Delaying the application
until the next day will allow substantial loss of moisture reducing the effectiveness of the
curing membrane. For best results, apply an even coat by a low pressure spray equipment
(knapsack sprayer) or a wide short nap roller, or brush. With all methods, take adequate
care to prevent marring of concrete surface. Apply the curing compound evenly on all
exposed concrete surfaces. It is important to avoid leaving patches of untreated areas. Use
MASTERKURE 181FD with the fugitive dye to identify areas treated, or ensure that
there are no breaks during application till a well marked area is completely treated.
PROPERTIES
Supply form: liquid
Colour : clear / colored
Density: 0.79 kg/L
Drying time (hr : min) at 20oC (ASTM C 309) : 1.35 (Specified : 4 hrs max)

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Mix design report

THIS DESIGN IS FOR SLAB WITH 100% SCREED


Strength : 20 N/mm2
Aggregate size : 20 mm down size
Water cement ratio : 0.43
Slump : 125±25 mm
Slump with super P : 125±25 mm
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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Air % : non air entrained


MIX ANALYSIS

Mix design report

THIS DESIGN IS FOR SLAB WITH 90% SCREED


Strength : 20 N/mm2
Aggregate size : 12 mm down size
Water cement ratio : 0.50
Slump : 125±25 mm
Slump with super P : 125±25 mm
Air % : non air entrained

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

MIX ANALYSIS

3 Days Compressive strength:

Sl no Dimensions Breaking load Compressive Average


(mm) (KN) strength Compressive
N/mm2 strength
N/mm2
1 150 X 150 160 7.11
2 150 X 150 150 6.66 7.11
3 150 X 150 170 7.56

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

7 Days Compressive strength:


Sl no Dimensions Breaking load Compressive Average
(mm) (KN) strength Compressive
N/mm2 strength
N/mm2
1 150 X 150 307 13.642
2 150 X 150 320 14.232 14.098
3 150 X 150 324.5 14.422

28 Days Compressive strength:


Sl no Dimensions Breaking load Compressive Average
(mm) (KN) strength Compressive
N/mm2 strength
N/mm2
1 150 X 150 542 24.088
2 150 X 150 563 25.022 24.60
3 150 X 150 556 24.71

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Finishes:
Painting
The building finishes requires very less maintenance since the formwork used will
provide a smooth finish surface since no need to provide an extra coating of plastering
with cement mortar. The finished internal surface of the house is coated with one coat of
putty and two coats of oil based distemper.

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Doors and windows:

The door provided is a composite type which is highly durable and water proof. Since the
door frame is casted along with the wall there is no need to fix the frame as done in
conventional method.
The windows are steel framed with glazed finish. To provide effective ventilation and day
lighting. The glass is fixed to the window panel with the help of silicone sealant which
has high durability and also has good aesthetic view when compared to conventional
lappa.

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

Person applying silicone sealant

SILICONE SEALANT( Anabond AB101):


Anabond Room Temperature Vulcanising Silicone Sealants are single component sealants
which when cured will provide a permanent elastic joint seal. The cured sealant exhibits
the following properties:

Retains elastomeric qualities even under severe temperature change i.e. 500C to 2000 C.

 Excellent U.V. resistance and Weathering properties.

 Suitable for both indoor and outdoor applications.

Application:

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

As a Glazing and Caulking Sealant between Glass and Aluminium in constructions.

As a Sealant for Bus and Rail Coach building freight.

As a joining/ insulating/ sealing material in industry.


This sealant is used 3 numbers for a house this is available in 300ml bottle.

Plumbing and sanitation:


Since the plumbing and sanitary lines are laid outside the building it will be very useful in
fast installation and also in repair when ever is needed. All the plumbing fixtures are
installed and the sanitation lines are through underground which flow in separate without
overlapping of the waterlines and sanitation.

CONCLUSION

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

The task of housing due to the rising population of the country is becoming
increasingly monumental. In terms of technical capabilities to face this challenge, the
potential is enormous; it only needs to be judiciously exploited.

Civil engineers not only build but also enhance the quality of life. Their creativity
and technical skill help to plan, design, construct and operate the facilities essential to
life. It is important for civil engineers to gain and harness the potent and versatile
construction tools.

Traditionally, construction firms all over the world have been slow to adopt the
innovation and changes. Contractors are a conservative lot. It is the need of time to
analyze the depth of the problem and find effective solutions. MIVAN serves as a cost
effective and efficient tool to solve the problems of the mega housing project all over the
world. MIVAN aims to maximize the use of modern construction techniques and
equipments on its entire project.

We have tried to cover each and every aspect related to aluminium (MIVAN) form
construction. We thus infer that MIVAN form construction is able to provide high quality
construction at unbelievable speed and at reasonable cost. This technology has great
potential for application in India to provide affordable housing to its rising population.

Thus it can be concluded that quality and speed must be given due consideration
with regards to economy. Good quality construction will never deter to projects speed nor
will it be uneconomical. In fact time consuming repairs and modification due to poor
quality work generally delay the job and cause additional financial impact on the project.
Some experts feel that housing alternatives with low maintenance requirements may be
preferred even if at the slightly may preferred even if at the higher initial cost.

RESULT

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CONSTRUCTION OF KSCB PROJECT BY MIVAN SHUTTERING 2011

 By comparing the cost of the project by both methods, we can conclude that
Mivan technology is the economic method for mass housing projects.

 As from the cost comparison, the Mivan technology reduces the overall cost of
the project by…………%

 By adopting Mivan technology in the project not only reduces the cost but also
increases the speed of construction, since some of the construction activities are
completely eliminated and others are reduced to a extent.

Department of Civil Engineering, VVIET, Mysore. Page 55