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Good Engineering Practice


At Sites
C. Material testing
B. Construction tolerances
D. Concrete
E. Detailing
A. Getting ready
2
A. Getting Ready
a. Study all drawings, report any discrepancies
b. Prepare site layout with temporary facilities & program
c. Set-out centerlines,boundaries & disturbances to
existing services
d. Take dated photographs of all adjoining buildings
prior to commencement of work at site and afterwards
e. Keep weather records countersigned by the
Consultants site representative
f. Prepare shop drawings of critical joints etc.
g. Co-ordinate work & arrange meetings with other
contractors
h. Participate in progress & other meetings with
Consultants
3
STEMS
STEMS CONSULTANTS (PTE) LTD
159, Model Far m Road, Colombo 08
No Name Address Tel ephone Fax
1
1
2
3
4
1
2
3
1
1
1
A B C
1
2
3
Li ft Suppl er
Contractor
El ectri cal Engi neer
Structural Engi neers
Servi ces Consul tants
Proj ect :
PROPOSED 35 STOREY TOWER AT
LOT A1 & B3, GALLE ROAD,
COLOMBO 03.
Pr oject Data Sheet
E-mai l
Cl i ent
Archi tects \ Lead
Consul tant
Consul tants
a. Prepare project data sheet
STEMS CONSULTANTS (PTE) LTD
159, Model Far m Road, Colombo 08. Bui l di ng
Date : 18/08/2007 at : 10 .30 am / pm at Si te / Offi ce
1 0 Attendance Sheet
No Name Organi zati on Si gnature Tel / Fax
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PILING PROGRESS
MEETING NO
APARTMENT BUILDING
PROPOSED 35 STOREY RESIDENTIAL
TOWER WITH 3 STOREY BASEMENT
AT LOT A1 & B3 , GALLE ROAD,
COLOMBO 03.
STEMS
Proj ect
Prepare an attendance sheet
4
STEMS Proj ect
STEMS CONSULTANTS (PTE) LTD
159, Model Far m Road, Colombo 08. Bui l di ng
Notes Of Meeting Attended (NOMA) Meeti ng No: 06
Date: 18/08/2007 Ti me: 10.30 am / pm Venue : Si te Offi ce
Notes Taken by: S A Karunaratne
Item Descri pti on Acti on by
APARTMENT BUILDING
PROPOSED 35 STOREY TOWER, LOT A1 &
B3, GALLE ROAD, COLOMBO 03
b. Prepare NOMA
c. Furnish copy same day to
Head-office
d. Act prior to receipt of official
minutes
a. Do not take Notes Of
Meetings Attended, NOMA
on pieces of paper
STEMS Proj ect
STEMS CONSULTANTS (PTE) LTD
159, Model Far m Road, Colombo 08 Cl i ent Imperi al Tea Exports (Pvt) Ltd, 121A, Bi yagama Rd, Pel i yagoda
Items to be discussed at First Site Meeting Meeti ng No:01
Date: 2004 - 11 - 06 Ti me: 10.30 am / pm Venue : Si te Offi ce
Item Acti on by
(1)
(2)
(3)
(4)
(5)
(6) Names of Ready-Mi x suppl i ers, i f to be changed advance noti ce and furni sh detai l s i n Item 5
(7) If consti tuent materi al s are changed Contractor shoul d furni sh test data and compati bi l i ty
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Blending & Warehouse Building,
151, Biyagama Road, Peliyagoda
Constructi on drawi ngs to be checked by Contractor and i nform Consul tant i f more detai l s are requi red
Mai n orthogonal gri ds to be checked by Consul tant after Contractor setout the bui l di ngs
Contractor to furni sh Consul tant a pl an of temporary faci l i ti es and l ocati ons wi th di mensi ons
Notes Taken by:
Descri pti on
Performance, Advance Payment Bonds and Insurance Cover from Contractor
Mi x desi gn, 40 No. Test cube resul ts, materi al tests and admi xtures, extreme care wi th sand.
Approval of fi l l materi al to be used i n ground i mprovements
Approval for concreti ng.
Test cubes, 06 numbers, 02 for 07 day tests and 04 for 28 days tests, proper i denti fi cati on, proper
moul ds, proper storage, curi ng and due date testi ng
Cover bl ocks - Same concrete grade wi th smal l chi ps
Structural Steel fabri cati on
Consul tant's si te staff offi ce
Temporary power, tel ephones, fax, photocopyi ng faci l i ti es, water and toi l ets etc
Typi cal format of records
Si te Instructi ons and Vari ati on Orders
Master programme and Cash Fl ow Chart and " S" Curve
Bi weekl y detai l ed programme matchi ng wi th master programme, monthl y progress report
El ectri cal Drawi ngs from Contractor to be checked by Consul tant
Date of commencement, Compl eti on date, Ti me l eft, Extensi ons
Si te Safety, Acci dents at si te
Items to be
Discussed at
First Meeting
5
STEMS Proj ect
STEMS CONSULTANTS (PTE) LTD
159, Model Far m Road, Colombo 08. Bui l di ng
CONCRETING APPROVAL FORM - A
Date: 18/08/2007 Ti me: am / pm Venue : Si te
1 Locati on
2 Stati on From: Axi s: Gri d: To: Axi s: Gri d:
3 Level From: To:
4 Preparati on of screed / Concrete surface:
5 Form work:
a) Qual i ty :
b) Ri gi di ty :
c) Verti cal i ty :
6 Rei nforcement:
a) Number :
b) Si ze :
c) Pi tch :
d) Spacer bl ocks :
e) Cl eani ng :
7 Concrete Vi brators i n worki ng order avai l abl e at si No: Si ze:
8 Concrete cube moul ds avai l abl e at si te: No:
9 Approved for concreti ng Si gnature
Name
Organi sati on STEMS CONSULTANTS (PTE) LTD
10 Not approved for concreti ng Reasons
Si gnature
Name
Organi sati on STEMS CONSULTANTS (PTE) LTD
11 Date of concreti ng Date:
Concrete test cubes cast No:
12 Cube Test Resul ts
PROPOSED 35 STOREY TOWER, LOT
A1 & B3, GALLE ROAD, COLOMBO 03.
APARTMENT BUILDING
7 day 28 day
a. Concreting Approval
Form A
STEMS Proj ect
STEMS CONSULTANTS (PTE) LTD
159, Model Far m Road, Colombo 08. Bui l di ng
CONCRETING APPROVAL FORM - B
Date: 18/08/2007 Ti me: am / pm Venue : Si te
1 Locati on
2 Stati on From: Axi s: Gri d: To: Axi s: Gri d:
3 Level From: To:
4 El ectri cal Works
a) El ectri cal condui ts & i nserts:
b) Earthi ng provi si ons:
5 Approved Si gnature
Name
Organi sati on
6 Water Suppl y, Waste Water, Sewerage & Fi re Protecti on works
a) Water Suppl y Pi pe Layout/ducts: Pi pe di a:
b) Waste Water Pi pe Layout/drai ns: Pi pe di a:
c) Sewerage Pi pe Layout/ducts: Pi pe di a:
d) Fi re Protecti on Pi pe Layout/ducts: Pi pe di a:
7 Approved Si gnature
Name
Organi sati on Building Services Consultants
Si gnature
Si ngapore Pi l i ng
Name of Resident
Agent
PROPOSED 35 STOREY TOWER, LOT
A1 & B3, GALLE ROAD, COLOMBO 03
APARTMENT BUILDING
b. Concreting Approval
Form B
6
No. QA -
1 ACTIVITY
2 DATE
3 STATUS OF ACTIVITY
4 ONGOINGWORK:
5 REF DRAWINGS:
6 REF. SPECIFICATION
7 COMMENTS
8 QUALITY ASSURANCEPROCEDURES Implement ed Yes / No
9 ITEMS TOBEINSPECTED
10 INSPECTIONREQUIRED Date Time
11

Const r uct ion Engineer / KSJ Sit e Manager /KSJ
12
Reviewed .
Resident Engineer , Vallibel Lanka Lt d
QUALITY ASSURANCE REPORT
COLOMBO1.
PROPOSED ENTERTAINMENT COMPLEX AT COLOMBO 3.
VALLIBEL LANKA LTD
27-02, EAST TOWER
WORLDTRADECENTRE
ECHELONSQUARE
STEMS
STEMS CONSULTANTS (PTE) LTD
159, Model Far m Road, Colombo 08
Issued to: .. Copies to: UDA / CCS / T&SW
Prepared by: . Checked by : Approved by : ..
Mr S A Karunaratne Mr Gami ni Jayasi nghe Mr Ni hal Fernando
Stems Consultants (Pte) Ltd Engineer's Representative Engineer
Date : . Date : . Date : ..
Madi wel a Government Proj ect
Securi ty Bui l di ng
SITE INSTRUCTION / VARIATION ORDER NO. S/
Item Acti on by Descri pti on of Work
Proj ect
Bui l di ng
Request for Inspection
a. Format for Site Instructions
b. Make notes on drawing about
site instruction
STEMS
Time Sheet No 27
STEMS CONSULTANTS (PTE) LTD
159, Model FarmRoad, Colombo 08
Name S A Karunaratne
Week Endi ng 2001- 07 - Position Team Leader
Day
Date
1 2 3 4 5 6
0
1
0
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
1
0
1
1
1
2
1
3
1
4
N O T
MON
2
TUE
3
WED
4
THU
5
FRI
6
SAT
7
SUN
8
Stage: 1. Sur/Invest 2. F Study 3. Desi gn 4. Tender 5. Constructi on 6. Fol l ow up
Job Descri pti on: 01. Adm / P Mtg / Mtd 02. Data / Job Pl anni ng / Bri efi ng 03. Esti mate / Cost 04. Desi gns 05. Draughti ng
06. Speci fi cati ons 07. BOQ's 08. Checki ng 09. Amendments 10. Pri nti ng & Bi ndi ng
11. Correspondence 12. Si te Inv / M Testi ng / Testi ng 13. Si te Inspecti on 14. Supervi si on
8
Total Hours HOURS Stage Job Descri pti on
Bui l di ng:
Project:
Residence & Security Staff Buildings
Madiwela Government Project
Time Sheet
7
240 piles
MADIWELA GOVERNMENT PROJECT
PROGRAMME OF WORKS FOR THE SECURITY STAFF COMPLEX
N
e
w


Y
e
a
r



H
o
l
i
d
a
y
s
Tender Document Approval
by TEC
Tender Document Approval
by TEC
Tender & Award For
Building Works
Test Pile Installation &
Report
Pile Drawings & Tender
Documents
Piling Tender & Award
Pile Installation
Building Design &
Drawings
May
2001
June January February March Apri l
2000
ITEMS OF WORK
Preparation of Tender
Documents
November December
Programme of Works Up-to Building Tender
B. Construction tolerances
8
Construction tolerances
Misalignment of
Face of Building in plan Face of Building in plan 5mm in 3000mm & max. 25mm 5mm in 3000mm & max. 25mm
Nothing over boundary line Nothing over boundary line
Footings & Pile Caps Footings & Pile Caps
a) a) wrt wrt C L of wall or column C L of wall or column
b) Dimension in plan b) Dimension in plan
c) Thickness c) Thickness
2% of footing width; max. 50mm 2% of footing width; max. 50mm
+ 50mm ; + 50mm ; - - 10mm 10mm
+ 10% ; + 10% ; - - 5% ; max. + 10mm 5% ; max. + 10mm
Vertical Vertical
a) Lines & surfaces of wall, a) Lines & surfaces of wall, colum colum
b) Column & wall from plumb b) Column & wall from plumb
5mm in 5000mm & max. 12mm 5mm in 5000mm & max. 12mm
12mm in 30m: 20mm in 60m & 12mm in 30m: 20mm in 60m &
25mm up to 90m and above 25mm up to 90m and above
Max. deviation of mean level Max. deviation of mean level
a) a) 3m height from lower floor 3m height from lower floor
b) b) 6m height from lower floor 6m height from lower floor
c) c) 12m height from lower floor 12m height from lower floor
d) d) I n any upper floor I n any upper floor
6mm 6mm
12mm 12mm
20mm 20mm
20mm 20mm ctd ctd - -
Levels & Gradient Levels & Gradient
a) In 3m length of floor & beam soffit a) In 3m length of floor & beam soffit
b) In 6m length of floor & beam soffit b) In 6m length of floor & beam soffit
c) For the whole length c) For the whole length
6mm 6mm
10mm 10mm
20mm 20mm
Lintels, sills, parapets & grooves Lintels, sills, parapets & grooves
a) In a 6m length a) In a 6m length
b) In 12m or more b) In 12m or more
6mm horizontally 6mm horizontally
10mm horizontally 10mm horizontally
Cross Sections Cross Sections
a) Dimension a) Dimension < 150mm < 150mm
b) Dimension 150mm & > 150mm b) Dimension 150mm & > 150mm
+10mm ; +10mm ; - -3mm 3mm
+12mm; +12mm; - -6mm 6mm
Openings Openings
a) Sizes and locations a) Sizes and locations
b) Additional margins for windows, doors b) Additional margins for windows, doors
or lift door installations Contractors or lift door installations Contractors
responsibility responsibility
+6mm ; +6mm ; - -6mm 6mm
Stairs Stairs
a) Deviation in risers a) Deviation in risers
b) Deviation in treads b) Deviation in treads
In consecutive step + 2mm In consecutive step + 2mm
I n any flight, + 6mm I n any flight, + 6mm
In consecutive step + 3mm In consecutive step + 3mm
I n any flight, + 6mm I n any flight, + 6mm
9
Removal of formwork & props
minimum periods recommended
Beam sides, walls & columns (unloaded) Beam sides, walls & columns (unloaded) 24 hours 24 hours
Slab (props left in place) Slab (props left in place) 4 days 4 days
Beam Beam soffits soffits (props left in place) (props left in place) 7 days 7 days
Props to slabs between beams Props to slabs between beams 14 days 14 days
Props to beams & flat slabs Props to beams & flat slabs 14 days 14 days
Props to cantilevers Props to cantilevers 28 days 28 days
C. Material Testing
10
Proctor Compaction Test
(a) Standard (S P C T)
(b) Modified (M P C T)
Proctor
CBR
(a). 5.5 lb hammer; 12 drop; volume of 4 mould 944cm
3
(b). 10 lb hammer; 18 drop; volume of 6 mould 2123cm
3
11
(b) Proctor Compaction Apparatus for Heavy
Compaction
(a) Proctor Compaction Apparatus for Light
Compaction
(a)
(b)
(a)
12
(1) Optimum Water Content 13.1%
(2) Maximum Dry Density 1.87 g/cm3
13
Moisture Content in percent for complete saturation = W
sat
Density of water in g/cm
3
=
w
Specific gravity of soil = G
s
Dry density of soil in g/cm3 =
d
W
sat
= (
w
/
d
1/G
s
)
d =

w
/(w/100 + 1/G
s
)
Moisture Content in percent = w
Wet density of soil in g/cm3 =
S P C T is generally used in small fills,
parking lots and for building structures
M P C T is generally used in large fills, roads,
Airport Runways and Concrete Parking
Aprons and for building structures
Field compaction done with different type of
rollers
(a) Clayey and Silty Soils use Sheepsfoot rollers
(b) Granular Soils use Smooth-drum or Vibratory rollers
%age of Optimum Compaction attained
in the field is Relative Density or R (%)
1) R(%) for S P C T is 95% - 100%
2) R(%) for M P C T is 90% - 95%
3) R(%) for granular fills is 95% - 100%
Common R(%) field test is Sand Replacement Method
14
California Bearing Ratio
(CBR) testing
(Laboratory) apparatus
CBR
California Bearing Ratio (CBR) testing apparatus
15
California Bearing Ratio
(CBR) testing apparatus
in the field
CBR relationship of
force & penetration of a
cylindrical plunger of 3
inch
2
at a standard rate
into soil. 0.05 per
minute
CBRin essence evaluate strength of subgrades
High CBR lower pavement thickness & vise versa
CBR value CBR value Subgrade Subgrade strength strength
3% and less 3% and less Poor Poor
3% 3% - - 5% 5% Normal Normal
5% 5% - - 15% 15% Good Good
Other field apparatus used to determine CBR
(a)Hand held Mexe Penetrometer
indicate CBR values upto 3m depth
(b) Dynamic Cone Penetrometer
could be used to evaluate results using a formula
16
Stress
Penetration
Curves of
CBR Tests
Reinforcement
& Concrete
17
R/F bar tests to BS 4449
a) Proof / Yield stress > Characteristic strength of 460 or 250 N/mm
2
b) Tensile strength > Proof / Yield stress
c) %age elongation 12% for 460A & 14% for 460B
d) %age elongation 22% for MS - 250
e) Stress ratio (TS / YS) >= 1.05 for 460A & 1.08 for 460B
f) Stress ratio (TS / YS) >= 1.15 for MS
460A rib pattern
460B rib pattern
Bar Diameter ( Bar Diameter ( ) mm ) mm
6 6 8 8 10 10 12 12 16 16 20 20 25 25 32 32 40 40
0.222 0.222 0.395 0.395 0.616 0.616 0.888 0.888 1.579 1.579 2.466 2.466 3.854 3.854 6.313 6.313 9.864 9.864
9 9 6.5 6.5 6.5 6.5 4.5 4.5 4.5 4.5 4.5 4.5 4.6 4.6 4.5 4.5 4.5 4.5
0.242 0.242 0.421 0.421 0.656 0.656 0.928 0.928 1.650 1.650 2.577 2.577 4.027 4.027 6.597 6.597 10.308 10.308
0.202 0.202 0.369 0.369 0.576 0.576 0.848 0.848 1.508 1.508 2.355 2.355 3.681 3.681 6.028 6.028 9.420 9.420
Reinforcement weight - kg / m
3
rd
row :- Average weight
4
th
row :- + Tolerance
5
th
row :- Upper limit kg/m
6
th
row :- Lower limit kg/m
18
Chemical analysis and Carbon equivalence
Element Element Grade 250 Grade 250 Grade 460 Grade 460
% Max % Max % Max % Max
Carbon Carbon 0.25 0.25 0.25 0.25
Sulphur Sulphur 0.060 0.060 0.050 0.050
Phosphorus Phosphorus 0.060 0.060 0.050 0.050
Nitrogen Nitrogen 0.012 0.012 0.012 0.012
Max. Carbon equivalent Max. Carbon equivalent
values (CEV) values (CEV)
0.42 0.42 0.51 0.51
CEV = C + Mn/6 + (Cr + Mo + V)/5 + (Ni +Cu)/15
STEMS
STEMS CONSULTANTS (PTE) LTD Computed By: S A Karunaratne
159, Model Farm Road, Col ombo 08 Date: 2006-11-24
Analysis of 36 No. cube test results furnished by SUPERMIX to Singapore Piling
for Grade 35 concrete to be used for concreti ng i n Luxary Apartment Bui l di ng
at Lot A1 & B3, Gal l e Road, Col ombo 03.
(Anal ysi s carri ed out i n pl ace of tri al batchi ng to veri fy the " Mi x Desi gn" )
Resul t
No Date Cast Date Tested Age Days N/mm
2
at test fi fi - fm (fi - fm)
2
1 1-9-06 29-9-06 28 34.5 -6.60 43.52
2 1-9-06 29-9-06 28 40 -1.10 1.20
3 1-9-06 29-9-06 28 41 -0.10 0.01
4 31-8-06 28-9-06 28 47.5 6.40 41.00
5 31-8-06 28-9-06 28 42 0.90 0.82
6 31-8-06 28-9-06 28 41.5 0.40 0.16
7 30-8-06 27-9-06 28 35.5 -5.60 31.33
8 30-8-06 27-9-06 28 39 -2.10 4.40
9 30-8-06 27-9-06 28 37.5 -3.60 12.94
10 14-8-06 11-9-06 28 36.5 -4.60 21.13
11 14-8-06 11-9-06 28 38 -3.10 9.59
12 14-8-06 11-9-06 28 39 -2.10 4.40
13 13-8-06 10-9-06 28 43 1.90 3.62
14 13-8-06 10-9-06 28 42.5 1.40 1.97
15 13-8-06 10-9-06 28 40 -1.10 1.20
16 8-8-06 5-9-06 28 37.5 -3.60 12.94
17 8-8-06 5-9-06 28 39.5 -1.60 2.55
18 8-8-06 5-9-06 28 35.5 -5.60 31.33
19 30-7-06 28-8-06 29 47 5.90 34.84
20 30-7-06 28-8-06 29 41.5 0.40 0.16
21 30-7-06 28-8-06 29 46 4.90 24.04
22 27-7-06 24-8-06 28 43 1.90 3.62
23 27-7-06 24-8-06 28 44 2.90 8.43
24 27-7-06 24-8-06 28 43.5 2.40 5.77
25 23-7-06 21-8-06 29 41.5 0.40 0.16
26 23-7-06 21-8-06 29 46 4.90 24.04
27 23-7-06 21-8-06 29 41.5 0.40 0.16
28 22-7-06 21-8-06 30 41.5 0.40 0.16
29 22-7-06 21-8-06 30 41.5 0.40 0.16
30 22-7-06 21-8-06 30 42 0.90 0.82
31 30-6-06 28-7-06 28 44 2.90 8.43
32 30-6-06 28-7-06 28 35.5 -5.60 31.33
33 30-6-06 28-7-06 28 45 3.90 15.23
34 29-6-06 23-8-06 55 39.5 -1.60 2.55
35 29-6-06 23-8-06 55 41 -0.10 0.01
36 29-6-06 23-8-06 55 45.5 4.40 19.38
37 0.00 0.00
38 0.00 0.00
39 0.00 0.00
40 0.00 0.00
36
Total = 1479.5 403.41
Average = Total /36 fm = 41.10
s = (fi - fm
2
/ 36 3.35
1.64 s = 5.49
Therefore fcu = fm - 1.64s = 35.61 N/mm
2
> 35N/mm2
Note: Concrete Cube resul ts are acceptabl e
However, No. of cube resul ts l ess than 40 and Contractor i s responsi bl e
Analysis of recently
cast concrete test cube
results in place of mix
design trial mix tests
19
A6
B6
C6 D6
AB
BA
BC
CB CD
DC
DA
AD
150 Cast Cube mould markings
Casting concrete cylinders & cubes for tests
(i) Place concrete in three layers
(ii) Compact each layer 35 blows; 350mm long
16mm rod or 25mm
2
area bar (600mm bullet
nosed rod)
150 x 300 CAST MOULD
STEMS Proj ect 35 Storey Tower, Lot A1 & B3, Col ombo 03
STEMS CONSULTANTS (PTE) LTD Computed By: S A Karunaratne
159, Model Farm Road, Col ombo 08 Date: 2007-08-18
Compressi ve Strength (28 Day Test Resul ts) - To BS 5328: Part 4: 1990: Cl ause 3.16.2
Set Of Resul ts No CC/02/239
Speci fi ed Compressi ve Strength = 30 N/mm^ 2
Number of Cube Resul ts avai l abl e= 3
Test Cube Resul t 1 = 45.5 N/mm^ 2 Condi ti on (b) Sati sfi ed 45.5 > 27 N/mm^ 2
Test Cube Resul t 2 = 48 N/mm^ 2 Condi ti on (b) Sati sfi ed 48 > 27 N/mm^ 2
Test Cube Resul t 3 = 50 N/mm^ 2 Condi ti on (b) Sati sfi ed 50 > 27 N/mm^ 2
Test Cube Resul t 4 = 0 N/mm^ 2 Not Appl i cabl e
Average Resul ts = 47.83 N/mm^ 2 Condi ti on (a) Sati sfi ed 47.83>=32 N/mm^ 2
Therefore Concrete Cube Resul ts i s OKAY
Set Of Resul ts No CC/02/251
Speci fi ed Compressi ve Strength = 30 N/mm^ 2
Number of Cube Resul ts avai l abl e= 2
Test Cube Resul t 1 = 34.5 N/mm^ 2 Condi ti on (b) Sati sfi ed 34.5 > 27 N/mm^ 2
Test Cube Resul t 2 = 29.5 N/mm^ 2 Condi ti on (b) Sati sfi ed 29.5 > 27 N/mm^ 2
Test Cube Resul t 3 = 0 N/mm^ 2 Not Appl i cabl e
Test Cube Resul t 4 = 0 N/mm^ 2 Not Appl i cabl e
Average Resul ts = 32 N/mm^ 2 Condi ti on (a) Sati sfi ed 32>=31 N/mm^ 2
Therefore Concrete Cube Resul ts i s OKAY
Set Of Resul ts No CC/02/223
Speci fi ed Compressi ve Strength = 30 N/mm^ 2
Number of Cube Resul ts avai l abl e= 3
Test Cube Resul t 1 = 49.5 N/mm^ 2 Condi ti on (b) Sati sfi ed 49.5 > 27 N/mm^ 2
Test Cube Resul t 2 = 47.5 N/mm^ 2 Condi ti on (b) Sati sfi ed 47.5 > 27 N/mm^ 2
Test Cube Resul t 3 = 46.5 N/mm^ 2 Condi ti on (b) Sati sfi ed 46.5 > 27 N/mm^ 2
Test Cube Resul t 4 = 0 N/mm^ 2 Not Appl i cabl e
Average Resul ts = 47.83 N/mm^ 2 Condi ti on (a) Sati sfi ed 47.83>=32 N/mm^ 2
Therefore Concrete Cube Resul ts i s OKAY
Set Of Resul ts No 0
Speci fi ed Compressi ve Strength = 30 N/mm^ 2
Number of Cube Resul ts avai l abl e= 4
Test Cube Resul t 1 = 30 N/mm^ 2 Condi ti on (b) Sati sfi ed 30 > 27 N/mm^ 2
Test Cube Resul t 2 = 50 N/mm^ 2 Condi ti on (b) Sati sfi ed 50 > 27 N/mm^ 2
Test Cube Resul t 3 = 34 N/mm^ 2 Condi ti on (b) Sati sfi ed 34 > 27 N/mm^ 2
Test Cube Resul t 4 = 29 N/mm^ 2 Condi ti on (b) Sati sfi ed 29 > 27 N/mm^ 2
Average Resul ts = 35.75 N/mm^ 2 Condi ti on (a) Sati sfi ed 35.75>=33 N/mm^ 2
a. Concrete test cube
compliance
20
D. Concrete
Type of concrete Type of concrete Max. total % Max. total %
of chloride ion of chloride ion
by mass of by mass of
combined combined
aggregate aggregate
Max. total % of Max. total % of
chloride ion by chloride ion by
mass of mass of
cement cement
Prestressed Prestressed
concrete concrete
R/C with cement to R/C with cement to
BS 12 BS 12
R/C with cement to R/C with cement to
BS 4027 & BS 4248 BS 4027 & BS 4248
0.10 0.10 0.01 0.01
0.05 0.05 0.40 0.40
0.03 0.03 0.20 0.20
Chloride in fine aggregate & in concrete
21
Maximum shell content in offshore sand
Size Size
Limit on shell Limit on shell
content (%) content (%)
Fractions of single size or of graded or Fractions of single size or of graded or
all all- -in aggregate, coarser than 10mm in aggregate, coarser than 10mm
8 8
Fractions of 10mm single size, or of Fractions of 10mm single size, or of
graded or all graded or all- -in aggregate finer than in aggregate finer than
10mm & coarser than 5mm 10mm & coarser than 5mm
20 20
Aggregate finer than 5mm Aggregate finer than 5mm No No
requirement requirement
GRADES GRADES
C C
Avera Avera 4 4
Results Results
Avera Avera 3 3
Results Results
Avera Avera 2 2
Results Results
BS & {ICTAD} BS & {ICTAD}
Indivi Indivi. Result > . Result >
C8/10 C8/10 12(2) 12(2) 11(1) 11(1) 10(0) 10(0) 8(2) ; {8(2)} 8(2) ; {8(2)}
C12/15 C12/15 17(2) 17(2) 16(1) 16(1) 15(0) 15(0) 13(2) ; {13(2)} 13(2) ; {13(2)}
C16/20 C16/20 23(3) 23(3) 22(2) 22(2) 21(1) 21(1) 17(3) ; 17(3) ; {18(2)} {18(2)}
C20/25 C20/25 28(3) 28(3) 27(2) 27(2) 26(1) 26(1) 22(3) ; 22(3) ; {23(2)} {23(2)}
C25/30 C25/30 33(3) 33(3) 32(2) 32(2) 31(1) 31(1) 27(3) 27(3)
C28/35 C28/35 38(3) 38(3) 37(2) 37(2) 36(1) 36(1) 32(3) 32(3)
C32/40 C32/40 43(3) 43(3) 42(2) 42(2) 41(1) 41(1) 37(3) 37(3)
C40/50 C40/50 53(3) 53(3) 52(2) 52(2) 51(1) 51(1) 47(3) 47(3)
Compliance criteria of concrete cube test results
Cast 6 cubes; Test 01 at 07 days (0.75 of 28 days strength) ; Test 04 at 28 days
(b) Lowest individual strength of any cube > 0.85 of characteristic strength
The difference of strength of two specimens < 15% of mean strength
(a) Average of 3 cubes >=characteristic strength
Two test specimens form a single result for compliance with the above chart
(Max Mini) of 3 results < 20% of average of 3 results
For small projects -ICTAD
22
What is C35A concrete
Grade 35 concrete for structures retaining Aqueous
(Water like) - (suffix - A) liquids
Maximum cement content 400 kg/m
3
Minimum cement content 325 kg/m
3
Maximum free water cement ratio 0.55
(Water reducing agents could be used)
Aggregates Maximum water absorption <3%
Coarse aggregate with low coefficient of
thermal expansion
Fully compactable Low permeability (Durability)
Control early thermal and shrinkage effects
Placing and Finishing
Placing and Finishing
Concrete
Concrete
23
READY MIXED CONCRETE
Central Mixed Central Mixed Transit Mixed Transit Mixed
Aggregate added at speed Aggregate added at speed
10 to 18 rpm up to 100 10 to 18 rpm up to 100
revolutions revolutions
Materials are batched in a Materials are batched in a
central plant central plant no addition no addition
of water of water
Transport Agitator Truck 2 Transport Agitator Truck 2
to 6 rpm to 6 rpm
Mixing in transit or at Mixing in transit or at
discharge speed 4 to 16 discharge speed 4 to 16
rpm of truck mixer rpm of truck mixer
For uniformity of mixing For uniformity of mixing
limit to 300 revolutions limit to 300 revolutions
For uniformity of mixing For uniformity of mixing
limit to 300 revolutions limit to 300 revolutions
Cement balls up to 200mm Cement balls up to 200mm
if no proper controls if no proper controls
The speed of mixing affects the rate of stiffening The speed of mixing affects the rate of stiffening
Basic Requirements for
Basic Requirements for
Placing Concrete (1)
Placing Concrete (1)
Preserve concrete quality Preserve concrete quality
Water Water- -cement ratio cement ratio
Slump Slump
Homogeneity Homogeneity
Avoid separation of aggregate and Avoid separation of aggregate and
mortar mortar
24
Basic Requirements for
Basic Requirements for
Placing Concrete (2)
Placing Concrete (2)
Avoid excessive horizontal movement Avoid excessive horizontal movement
Consolidate adequately Consolidate adequately
Maintain sufficient placement capacity Maintain sufficient placement capacity
Choose the right equipment for the concrete Choose the right equipment for the concrete
Depositing Concrete
Depositing Concrete
Start placing along perimeter at one end Start placing along perimeter at one end
with each batch discharged against with each batch discharged against
previously placed concrete previously placed concrete
Do not Do not
(a) dump in separate piles & then (a) dump in separate piles & then
level and work together level and work together
(b) (b) deposit in large piles & then deposit in large piles & then move move
horizontally into position horizontally into position
These practices result in segregation These practices result in segregation
(mortar flows ahead of coarser material) (mortar flows ahead of coarser material)
Slab Construction
25
Incorrect Placement with
Incorrect Placement with
Conveyor Belt
Conveyor Belt
Baffle
Mortar
Rock
Mortar
Mortar
Rock
Shallow
hopper
Placement with
Placement with
Conveyor Belt
Conveyor Belt
Belt Scraper
No
Separation
Provide at least 0.6 m
(24 in.) headroom for
downpipe, elephant
trunk or equivalent
26
Depositing Concrete
Depositing Concrete
Deposit in horizontal layers of Deposit in horizontal layers of
uniform thickness uniform thickness
Reinforced Reinforced 150 mm to 500 mm 150 mm to 500 mm
Mass Mass 375 mm to 500 mm 375 mm to 500 mm
Consolidate each layer before Consolidate each layer before
next is placed next is placed
Timely placement & Timely placement &
consolidation prevents flow lines consolidation prevents flow lines
and cold joints and cold joints
Walls
Placing Concrete
Placing Concrete
in piles
in piles
Used: Tremie
Advantages: Can be used to
funnel concrete down through
the water / bentonite into the
structure.
Watch for: Discharge end
always has to be buried in fresh
concrete to ensure seal
between water and concrete
mass.
27
Consolidating
Consolidating
Concrete
Concrete
Internal Vibration Internal Vibration
External Vibration External Vibration
Internal Vibration
Internal Vibration
d
R
1 R
Vibrator
Radius of Action
28
Internal Vibrators
Internal Vibrators
of of
head, head,
mm mm
frequency, frequency,
vibrations vibrations
per minute per minute
radius of radius of
action, action,
mm mm
Rate of Rate of
placemen placemen
t,m t,m
3 3
/h /h Application Application
20 20- -40 40 9000 9000- -15,000 15,000
80 80- -150 150 0.8 0.8- -4 4
30 30- -60 60
8500 8500- -12,500 12,500
130 130- -250 250 2.3 2.3- -8 8
50 50- -90 90
8000 8000- -12,000 12,000
180 180- -360 360 4.6 4.6- -15 15
Stiff plastic Stiff plastic
concrete (less than concrete (less than
80 80- -mm slump) mm slump)
Plastic concrete in Plastic concrete in
thin walls, thin walls,
columns, beams, columns, beams,
precast piles, thin precast piles, thin
slabs, slabs,
Plastic and flowing Plastic and flowing
concrete in thin concrete in thin
members. Also members. Also
used for lab test used for lab test
specimens. specimens.
Systematic Vibration of
Systematic Vibration of
Each New Lift
Each New Lift
CORRECT CORRECT
Vertical penetration a few inches into
previous lift (which should not yet be
rigid) of systematic regular intervals
will give adequate consolidation
INCORRECT INCORRECT
Haphazard random penetration of the
vibrator at all angles and spacings
without sufficient depth will not assure
intimate combination of the two layers
29
Placing Concrete in a
Placing Concrete in a
Sloping Lift
Sloping Lift
CORRECT CORRECT
Start placing at bottom of slope so
that compaction is increased by
weight of newly added concrete.
Vibration consolidates the concrete.
INCORRECT INCORRECT
When placing is begun at top of slope
the upper concrete tends to pull
apart especially when vibrated below
as this starts flow and removes from
concrete above.
External Vibration
External Vibration
Form vibrators Form vibrators
Vibrating tables Vibrating tables
Surface vibrators Surface vibrators
Vibratory hand floats or trowels Vibratory hand floats or trowels
30
Floating (Power or Hand)
Floating (Power or Hand)
To embed aggregate To embed aggregate
particles just beneath the particles just beneath the
surface surface
To remove slight To remove slight
imperfections, humps, and imperfections, humps, and
voids voids
To compact the mortar at To compact the mortar at
the surface in preparation the surface in preparation
for additional finishing for additional finishing
operations. operations.
Troweling
Troweling
Creates smooth, Creates smooth,
hard,dense surface hard,dense surface
Exterior concrete should Exterior concrete should
not be not be troweled troweled because: because:
it can lead to a loss of it can lead to a loss of
entrained air caused by entrained air caused by
overworking the surface overworking the surface
troweled troweled surfaces can be surfaces can be
slippery when wet. slippery when wet.
31
Curing and Protection
Curing and Protection
Cure for 7 days Cure for 7 days
Impervious Cover
Sprinkling of water
Curing Agent
Minimum period for curing Minimum period for curing
& protection & protection
Surface concrete Surface concrete
temperature temperature
o o
C C
5 5 - - 10 10 > 10 > 10 25 25
Average Average 4 Days 4 Days 3 Days 3 Days 2 Days 2 Days
Poor Poor
Average Average
6 6 4 4 3 3
All except All except
(1) with (1) with
ggbfs ggbfs or or
pfa pfa
Poor Poor 10 10 7 7 4 4
All All Good Good No curing No curing
(1) OPC, (1) OPC,
RHPC, RHPC,
SRPC SRPC
Type of Type of
cement cement
Ambient Ambient
conditions conditions
after after
concreting concreting
Table 6.5 of BS 8110
32
Controlling temperatures in
mass concrete
Volume > 300m
3
& thickness > 600mm
i. Concrete temperature to 60
0
C maximum
ii. Temperature difference at center & surface
to 20
0
C maximum
Limit
a. Temp > 71
0
C - internal expansion & cracking
b. Temp > 88
0
C - reduced compressive strength
Or minimum dimension > 1.8m
50kg cement temperature increase very
approx. 4.29
0
C 7.14
0
C ; control with
fly ash / ggbfs
Temperature rise in concrete above ambient Temperature rise in concrete above ambient
surrounding surrounding in in
0 0
C C
Section Section
thickness thickness
(mm) (mm)
18mm plywood 18mm plywood (Steel) (Steel) formwork formwork
cement content cement content - - kg/ m kg/ m
3 3
220 290 360 400 220 290 360 400
10 10 - -14 14 14 14 - - 19 19 18 18 - - 26 26 21 21 - - 31 31
5 5 - - 7 7 7 7 - - 10 10 9 9 - - 13 13 10 10 - - 15 15
9 9 - - 13 13 13 13 - - 17 17 16 16 - - 23 23 19 19 - - 27 27
13 13 - - 17 17 18 18 - - 24 24 23 23 - - 33 33 27 27 - - 39 39
18 18 - - 23 23 24 24 - - 32 32 33 33 - - 43 43 39 39 - - 49 49
15 15 - - 19 19 20 20 - - 27 27 27 27 - - 36 36 31 31 - - 43 43
18 18 - - 23 23 25 25 - - 32 32 34 34 - - 43 43 40 40 - - 49 49
22 22 - - 27 27 31 31 - - 37 37 42 42 - - 48 48 47 47 - - 56 56
> 1000 > 1000
700 700
500 500
< 300 < 300
33
150mm sand layer or felt
25mm polystyrene or
Shear R/F
Main R/F
polythene layer
Additional R/F mesh
Formwork
First concrete pour
Balance concrete
to be poured
Surface Insulation
Arrangement
(warm the surface &
reduce temp difference
Working Safely with Concrete
Working Safely with Concrete
Protect: Protect:
Your Eyes Your Eyes
Your Back Your Back
Your Skin Your Skin
34
E. Detailing
COVER & SPACERS
FOR REINFORCED CONCRETE
35
Cover to R/F
oCover to R C Member is the minimum
thickness of concrete over the R/F steel
measured from exposed surface to the
closest reinforced steel surface.
oCover is subjected to ingress of moisture
along with other chemicals, impact & wear
oCover should be dense having low
permeability, durable, strong, free from
honeycombs, cracks, voids & should be
wear resistant
Cover to R/F
oCover protects R/F steel from corrosion
oCover ensures R/F bond to concrete to develop
its strength
oSpacers ensure location of R/F
at the right location
oIncorrect R/F placement can lead even to
failures
oFor eg. lowering top R/f or raising bottom
R/F by 12mm in a 150mm slab, load carrying
capacity could reduce by 20%
36
Location Location Minimum cover Minimum cover
Concrete in contact Concrete in contact
with ground with ground
75mm 75mm
- - Do with formwork Do with formwork 50mm 50mm
Columns Columns Main Main 40mm, links 40mm, links 25mm 25mm
Walls Walls 25mm & > 25mm & > of bar of bar
Beams Beams 35mm & > 35mm & > of bar, Links of bar, Links - -
20mm 20mm
Slabs Slabs 20mm 20mm
End of bars End of bars 25mm & > 2 25mm & > 2 of bar of bar
At the foot of chairs At the foot of chairs > Cover to main bars of member > Cover to main bars of member
Minimum cover to reinforcement
Ex t ensi vel y c or r oded sl ab and beam
37
Devices used to provide cover
oStone chips get dislodged, & undesirable
oWood spacers inexpensive, difficult to
remove & undesirable
o Cement mortar cover blocks inexpensive,
porous, full of voids and allow moisture
penetration & undesirable

o Concrete cover blocks, Plastic spacers


& Metal spacers costly, produced with
quality & desirable
SPACERS
SPACERS
Spacers are components which provide
cover (between 15 to 100mm
in increments of 5mm,)
between reinforcement and formwork
or blinding.
Two main groups of spacers are:
Clip-on type
Wire-on type attach to bar by tying wire
38
Cementitious spacers
The mix used for spacer blocks should be
comparable in strength , durability,
porosity and appearance to the
surrounding concrete.
Concrete spacers made at site must
not be used according to BS 8110.
How practical in Sri Lanka?
Making 75mm concrete cover blocks
39
t = nomi nal cover
t
Concrete cover blocks
Seat mi n. =
S
t2
+ 75mm
Upstand hei ght =
h - c
t
- c
b
- t1
- t2
- b1
- b2
Leg l ength mi n.
S
b2
+ 75mm
Re - bar chair
Shape of traditional spacers
Concrete cover blocks and re-bar chairs
40
PLASTIC CHAIRS
41
Tying wire
16 gauge black annealed wire.
Corrosion resistant wire of equal strength
may be used.
Projecting ends of tying wire should not
encroach into concrete cover.
No need to tie at every intersection
SLABS
Perimeter bars tied at every intersection
Bars up to 20mm tie at alternate
intersections
Greater centres for R/F 25mm & above but not
exceeding 50 of the smallest bar.
TYING OF BARS
SPACERS FOR SLABS continued
42
Section Section
Key
Pl an vi ew of spacer
Si de vi ew of spacer
nomi nal si ze of bar
nearest to surface
500mm max

50 , but <= 1000mm & staggered 500mm max


Plan Plan
a) Individual bars b) Welded fabric
Spacers for bottom R/F in solid slabs
Section Section Section
50 max.
Li ne spacers @
500mm max

Continuous chairs
50 max. Continous chairs @ max. 50
50 for bars or welded fabric
Using individual chairs Using continuous chairs
Key
Line spacer
Side view of spacer Side view of individual chair
Plan view of cts chair Plan view of individual chair
End view of cts chair nominal size of bar nearest to surface
Plan Plan Plan
Spacers for Top R/F Spacers for Top R/F in
in slabs with bottom R/F slabs without bottom R/F
43
Spacers on al ternate bars
Section Elevation
a) Without horizontal R/F
Spacers at 50 or at a maxi mum
of 1000mm centres
Section Elevation
b) With horizontal R/F
Key Pl an & si de vi ew of spacer
Wi re ti e
Spacers for slab edges
Spacers in a slab
44
BEAMS
TYING WITHIN BEAMS
Every intersection of a corner of a link
with longitudinal bar should be tied.
Other bars within the links should
be tied at 50D centres
SPACERS FOR BEAMScontinued
Every bar end
shoul d have a
sui tabl e spacer
1000mm max. Up to 250mm, one spacer
Beam elevation Narrow beam
Deep beam
> 100
Spacers @ Spacers @
50 max. 50
250 to 500mm Wi de beam > 500mm
two spacers
Spacers for si des of deep beams
Normal Deep beam Wide beam
beam
Spacers for beams
45
Spacers in a deep beam
COLUMNS
TYING WITHIN COLUMNS
Main vertical bars and links should be
tied at every intersection
Spacers for spiral links follow same rules
as for circular columns
SPACERS FOR COLUMNScontinued
46
Spacers @
50 maximum
Al l spacers fi xed to
l i nks at top, mi ddl e Face
& bottom of each l i ft, < 50
not exceedi ng 100
Face > 50
Spacers along column Wide column
Faces l ess Spacers @ 50 maximum
than 50 At l east four per group
One spacer
per 50 of
bar for
each facet

Small column Multifaceted columns Circular column


Spacers for columns
WALLS
TYING WITHIN WALLS
Follow guidelines given for slabs
Spacers on opposite faces should coincide
when viewed in elevation
SPACERS FOR WALLScontinued
47
Continuous chairs at a
maximum of 1000mm centres
50 or
500mm
Spacers at a max. of 50 but not less than 500mm
in both directions
Elevation Section
Key Plan & end view of spacer
Plan view of continuous chair
Side view of continuous chair
End view of continuous chair
Plan Spacers for walls
Spacers in wall R/F
48
Earthquake effects mitigation
detailing

- Dia. Of cross tie
Shape of stirrups & crossties
135
o
90
o
135
o
Stirrup or hoop Crosstie
Values given in ( ) are for mild
steel reinforcement)
beam confinement zones and wall end zones
Stirrups & crossties for columns, beam-column joints
135
o
>=6 (10)
>=80mm (100mm)
Dia >=
5
hoop
49
Actual shape of stirrup
Reinforcement in a wall
Wheel Spacer
Cross Tie
50
135
0
hook
Column Vertical R/F
arrangement
0.5l
l
n
/2
l
n
/2
for R/F lap
Structurally
l
n
for R/F lap
(a)
(b) <= 50% R/F lapped
Best location
1.5l
(b)
Practically
Best location
0.5l
1
2. All other joints are defined
as unconfined
1. Where beams frame into all four
sides of a column; each beam width
2
>= 3/4 of adjoining column width;
is defined as confined joint
(a) > 50% R/F lapped
1.25l
51
Column Transverse R/F
arrangement
X
At least 60% of transverse
R/F provided in the
zone below
provided in confinement
confinement zone
below to be provided
Sc<=100mm;
>=50mm; <=b
min
/3
along the height of the
Si <=100mm
shallowest beam
Column confinement zone
So <=200mm; <=bmin/2
o3
o3
o4
o4
o5
O
max
= 25 times the dia. of transverse R/F
l
n Column central zone
At least 40% of
transverse R/F
>=bmax; >=ln/6; >=500mm
o5
bmin
bmax
Detail X
Unconfined joint
Confined joint Si <=150mm
Column confinement zone
>=b
max
; >=l
n
/6; >=500mm
o1 o2 o1
Link arrangement
at laps in columns
d = 2

b = 10

Double links at bends
Links at laps as in the
confinement zones
Crank detail
Column link arrangement at laps
52
FAILURE OF
COLUMNS
Beam longitudinal R/F arrangement
Wall
l
>= l
>= 50

>= l >= l
l
n
1/4 of max. support R/F
a
a
b
b
(a+b)>=l
a>= 0.4 l
b>=12

Bottom R/F of adjacent
span
Note: Do not provide bent-up bars
53
Beam Transverse R/F
arrangement
combination of
staggared with
closed links
Beam with
closed links
Side bars
Crossties
alternatively
= 2h
k
<= 300mm, <= h
k
/2)
50mm
s
k
<= h
k
/4
s
k
<= 8
s
k
<= 150mm
( =min. longitudinal rebar diameter)
Beam
zone
confinement confinement
s
k
<= 24 ( =Diameter of stirrup)
= 2h
k
Beam
zone
Beam central zone
s
k
<= 50mm
(Min. links <= 12
h
k
BEAM FAILURE INSUFFICIENT
REINFORCEMENT

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