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INTRODUCTION

Name of work
Construction of restricted height RUBs on LC No. C-10 between GA-GVMR station, LC
No. C-16 & LC No. C-18 between GVMR-NAC under ADEN/DNA section.

SIZE OF PRECAST RCC BOX:- 4m X 3.75m


MIX DESIGN USED :-M-35

DETAILING OF RCC
Location

Cut length

No. of bar

Diameter of bar
20mm

LC NO. 16
RCC BOX NO. 01

16mm

10mm

8.10

16

20mm

a2

8.10

16mm

4.80

15

16mm

8.10

16mm

4.80

15

4.55

16

f1

2.55

8*2=16

20mm

f2

2.55

8*2=16

20mm

g1

0.55

23*8=184

10mm

g2

0.55

22*8=176

10mm

g3

0.55

22*8*2=35
2

10mm

1.45

182+176=
358

10mm

a1

LC No. 16
BASE SLAB
No.01

DETAILING OF RCC BASE SLAB

20mm
16mm

20mm

12mm

LOCATION

CUT
LENGTH

NO. OF BAR

DIAMETER OF BAR

5.40 X 1.53

1.43

36 X 2=72

12mm

1.53

10 X 2=20

12mm

6.55

1 X 2=2

1.08

8+9=17

20mm
12mm

LC No. 16
BASE SLAB No. 02
5.40 X 1.53

1.43

36 X 2=72

12mm

1.53

10 X 2=20

12mm

6.55

1 X 2=2

1.08

6+6=12

20mm
12mm

LC No. 16
BASE SLAB No. 02
5.40 X 2.30

2.20

36 X 2=72

12mm

5.45

15 X 2=30

12mm

6.55

2 X 2=4

1.08

6 X 3=18

20mm
12mm

DETAILING OF RCC BASE SLAB


LOCATION

CUT

NO. OF BAR

DIAMETER OF BAR

LENGTH
LC No. 16
BASE SLAB No. 04
5.40 X 1.53

1.43

36 X 2=72

12mm

5.43

10 X 2=20

12mm

6.55

1 X 2=2

1.08

7+7=14

20m
m
12mm

LC No. 16
BASE SLAB No. 05
5.40 X 2.30

2.20

36 X 2=72

12mm

5.45

15 X 2=30

12mm

6.55

2 X 2=4

1.08

6 X 3=18

20m
m
12mm

LC No. 16
BASE SLAB No. 06
5.40 X 1.53

1.43

36 X 2=72

12mm

5.43

10 X 2=20

12mm

6.55

1 X 2=2

1.08

6 + 6=12

CROSS SECTION OF RCC BOX

20m
m
12mm

POSITION OF LIFTING HOOKS

CROSS SECTION OF PRE CAST BASE SLAB

MIX DESIGN
M-35
Design stipulation

Characteristic compressive strength required= 35.0 N/mm2

Maximum size of aggregate= 20 mm

Type of cement= OPC 43 grade

Exposure condition= Moderate

DESIGN STEPS
1. MATERIAL USED: Coarse aggregate:- 1 bag
Sand :- 1 bag
Cement:- 1 bag
2. TARGATE MEAN STRENGTH: For M-35
35+(1.65 X 6.0):- 44.90 N/mm2 (IS 10262:2009)
3. WATER CEMENT RATIO (W/C): W/C taken based on trails % experience is :- 0.43
4. CALCULATION OF CEMENT CONTENT: Water content :- 186.0 liter
Cement content :- 186.0/0.43=432.55 kg/m3
5. PROPORTION OF COARSE AND FINE AGGREGATE (Based on volume ) : For concrete volume of C.A.= 0.62
Volume of F.A.= 1-0.62=0.38

DESIGN MIX CALCULATION


A. Volume of concrete

1 m3

1 m3

B. Volume of cement

(432.55/3.15)x(1/1000)

0.137m

C. Volume of water

(186.0/1.0)x(1/1000)

0.186m3

D. Volume of plasticizer

NIL

NIL

E. Volume of all in aggregate

[A-(B+C+D)]

0.677m3

F. Mass of coarse aggregate

0.677x0.62x2.682x103

1125.74kg

G. Mass of fine aggregate

0.677x0.38x2.560x103

658.58kg

H. Correction for water absorption


for C.A.

1125.74x(1.02/100)

11.48kg

I. Correction for water absorption


for F.A.

658.58x(2.12/100)

13.96kg

J. Total water

186+11.48+13.96

211.44kg

TRIAL MIXES DETAILS PER m3


TRIAL MIX NO.

W/C Ratio

0.45

0.43

0.41

Cement

413.33kg

432.55kg

453.65kg

Send(F.A.)

650.23kg

644.62kg

637.94kg

Aggregate(C.A.)

1123.78kg

1114.26kg

1102.71kg

Water

211.66kg

211.44kg

211.18kg

Slump

44mm

52mm

66mm

Compressive strength
water 28 days

43.14 N/mm2

45.68N/mm2

47.52N/mm2

RECOMMENDATION
Per m3 by weight:FREE WATER

CEMENT

SAND

AGGREAGATE

211.44kg

432.55kg

644.62kg

1114.26kg

By Ratio:FREE W/C

CEMENT

SAND

AGGREAGATE

0.488

1.0

1.490

2.576

COMPRESSION TEST ON CC CUBES (3 NOS.)

7 Days strength result

Description of the
CC Cubes

Actual Compressive Strength


(in N/mm2)

Average Compressive Strength

15X15X15 cm

34.94

35.56

(in N/mm2)

35.79
35.96

28 Days strength result

Description of the
CC Cubes

Actual Compressive Strength (in


N/mm2)

Average Compressive Strength

15X15X15 cm

37.31

38.82

(in N/mm2)

38.69
40.45

CALCULATION (for 3 days)


1st CASE:- 1000kN = 100 tons
1kN = 1000 N x reading
= 1000 x 770
For 150 x 150mm = (77x10000)/22500 = 34.94 N/mm2
2nd CASE:-1000kN = 100 tons
1kN = 1000 N x reading
= 1000 x 790
For 150 x 150mm = (79x10000)/22500 = 35.79 N/mm2
3rd CASE:- 1000kN = 100 tons
1kN = 1000 N x reading

= 1000 x 800
For 150 x 150mm = (80x10000)/22500 = 35.96 N/mm2
Average Compressive Strength= (34.94+35.79+35.96)/3
= 35.56 N/mm2

CALCULATION (for 28 days)


1st CASE: 1000kN = 100 tons
1kN = 1000 N x reading
= 1000 x 840
For 150 x 150mm = (84x10000)/22500 = 37.31 N/mm2
2nd CASE: 1000kN = 100 tons
1kN= 1000 N x reading
= 1000 x 870
For 150 x 150mm = (87x10000)/22500 = 38.69 N/mm2
3rd CASE:1000kN = 100 tons
1kN = 1000 N x reading
= 1000 x 900
For 150 x 150mm = (90x10000)/22500 = 40.45 N/mm2
Average Compressive Strength = (37.31+38.69+40.45)/3
= 38.82 N/mm2

RESULT & DISCUSSION FOR CEMENT

TEST SAMPLE
REF

SPECIFIED
REQUIREMENTS

RESULT OBTAINED

AS PER IS 8112

Rock strong
OPC 43 Grade
Cement

PHYSICAL TEST

Specific Gravity

3.15

--------

Initial setting Time

132.0 min

>30 min

Final setting Time

214.0 min

<600mm

Fineness

3.40%

<10%

Soundness

1.0 mm

<10 mm

(a) At 72 + - 1h

28.22 N.mm2

>23.0 N/mm2

(b) At 168 + - 2h

37.95 N/mm2

>33.0 N/mm2

(c) At 672 + - 4h

48.40 N/mm2

>43.0 N/mm2

Compressive strength

RESULT & DISCUSSION FOR AGGREGATE (20mm)

SIEVE SIZE

RESULT OBTAINED

AS PER IS PARAMETER

20.0 mm
GRADING

PASSING%

(a) 40.0mm

100.0

(100.0)%

(b) 20.0mm

97.85

(95-100)%

(C) 10.0mm

41.26

(25-55)%

(D) 4.75mm

3.64

(0-10)%

Specific Gravity

2.682

------------

Water Absorption

1.02

------------

Flakiness Index

13.20

------------

Impact Value

18.62

------------

Abrasion Value

20.14

------------

Free Surface Moisture

NIL

------------

RESULT & DISCUSSION FOR SAND

SPECIFIED REQUIREMENT

RESULT OBTAINED

AS PER IS 383-1970
PARAMETER

GRADATION

PASSING%

(a) 10.0mm

100.0%

(100.0)%

(b) 4.75mm

95.12%

(90-100)%

(c) 2.36mm

82.26%

(75-100)%

(d) 1.18mm

63.15%

(55-90)%

(e)600micron

42.20%

(35-59)%

(f) 300micron

17.42%

(8-30)%

(g) 150micron

3.81%

(0-10)%

Specific Gravity

2.560%

-----------

Water absorption

3.20%

-----------

Silt content

1.70%

------------

Free Moisture Surface

1.08%

RESULT AND DISCUSSION FOR STEEL BAR

Ord
er
No.

Nomin
al
Size

Lot.
No.

Qty.

Chemical
Analysis

(mm)

83
8

FP
BAR
10

S110279

83
8

FP
BAR
16

S110247

83
8

FP
BAR
20

S110249

3.54

2%
Proof
Stress
(N/mm2
)

Tensi
le
Stren
gth
(N/m
m2)

Elong
ation

Total
elon
gatio
n

Ben
din
g
Test

Reb
end
Test

Gra
de

521

630

20.0

0.00

OK

OK

Fe
500

C%

S%

P%

.22

.040

.046

3.47

.22

.042

.040

534

619

9.246

0.00

OK

OK

Fe
500

4.96

.19

.038

.040

519

646

20.00

0.00

OK

OK

Fe
500

RESULT AND DISCUSSION FOR 43 GRADE CEMENT


Sl.N
o

Particular

Requirement of IS:81121989

Test result

CHEMICAL REQUIREMENTS

0.66 To 1.02

0.930

(CaO-0.7 SO3)/
(2.8 SiO2+1.2 Al2O3+0.65Fe2O3)
2

Al2O3/Fe2O3

0.66 min

1.37

Insoluble Residue(% by mass)

3.0% max

1.58

Magnesia(% by mass)

6.0% max

1.98

Sulphuric Anhydrite(% by mass)

3.0% max

2.48

Total loss on ignition(%)

5.0% max

1.47

Total Chloride(%)

0.10% max

0.01

RESULT AND DISCUSSION FOR 43 GRADE CEMENT (Cont..)


Sl
No
.

Particular

Requirement of IS:81121989

Test result

1.

PHYSICAL REQUIREMENTS

Not less than 225 m2/kg

332

Lechatlier
Expansion (mm)

10.0 max

1.00

Auto-clave (%)

0.8 max

0.080

initial

30 min

125

final

600 max

175

23 Min

30.5

Fineness (m2/kg)
2

Soundness:

Setting time
(minutes)

Compressiv

3 days

e strength

7 days

33 min

40.5

28 days

43 min

51.0

(25-29) 0c

27

Temperature during Testing

RESULT AND DISCUSSION FOR 33 GRADE CEMENT


Sl.N
o

Particular

Requirement of IS:1489 (part


I) -1991

Test result

CHEMICAL REQUIREMENTS

I.R.= X + 4(100-X)/100

32.60

Insoluble Residue(% by mass)

Where X=% of Pozzolona used

Magnesia(% by mass)

6.0% max

1.48

Sulphuric Anhydrite (% by mass)

3.0% max

2.55

Total loss on ignition(%)

5.0% max

1.29

Total Chloride(%)

0.05% max

0.01

Sl
No.

Particular

Requirement of IS:8112-1989

Test result

1.

PHYSICAL REQUIREMENTS

Not less than 300 m2/kg

359

Fineness (m2/kg)
2

Soundness

Setting time (minutes)

Compressive strength

Lechatlier
Expansion
(mm)

10.0 max

1.00

Auto-clave
(%)

0.8 max

0.072

initial

30 min

155

final

600 max

205

3 days

16 Min

34.5

7 days

22 min

40.5

28 days

33 min

46.5

(25-29) 0c

27

Temperature during Testing

FOR NIGHT BLOCK WORKING


Sl.No

Description

Quantity

Electric generator of 10 kV

1 no. + 1 spare

500 Watt hallozen & electric wire etc.

15 no. hallozen and Electric wire


for connection

Electrician and helper

As per requirement

MACHINARY REQUIRED FOR LOUNCHING IN TRAFFIC BLOCK

Sl.No

Description

Quantity.

Crane of 80-100 MT capacity with 2 operator on each crane


and 10 skilled labour

2 no. + 1
spare

Excavator Tata Hitachi or similar with operator

2 nos.

JCB with tools & operator

2 nos.

Dumper with hydraulic lift system

6 nos.

Gas cutting equipment

2 no. + 1
spare

TENDER CONDITION FOR SUPPLY OF CEMENT BY CONTRACTOR

Supply of cement by contractor at the rate for relevant NS item will be governed by
the following condition:

Cement for use in the works shall be procured by the contractor from the
main procedures.

Cement older than 3 months from the date of manufacture shall not be
accepted.

Cement bags perfectly in paper bags packing should bear the following
markings:1. Manufactures name.
2. Registered Trade Mark of manufacture, if any.
3. Type of cement.
4. Weight of each bag in kg. or No. of bags/tons.
5. Date of manufacture.
Quality test certified for cement as per IS:4031 shall be furnished by the
contractor.
Railway may also take samples during course of execution of works.
Frequency of testing shall be as prescribed by the relevant IS code.
Following test shall be carried out:1. fineness
2. compressive strength
3. initial and final setting time
4. consistency
5. soundness
In case the sample tested do not pass the quality test conduced ,the entire
batch of cement supply shall be rejected and return to the contractor.
For storage of cement, the contractor shall have to construct a temporary
godown of adequate capacity.
It will be obligatory on the part of the contractor to weight the truck of
cement in the presence of inspector in charge and supply an original copy of
weight slip along with consignment.

The inspector in charge will verify the quantity of cement brought to the sight
of work and returned one verified weight slip to the contractor after the same
is stacked inside the cement godown under his supervision.
The record of cement brought to the site of work, daily consumption, daily
opening balance and closing balance shall be maintained at site jointly by the
inspector in charge of work and contractor or his authorized representative.
The contractor shall make the cement godown available for inspection along
with contractor record to the site engineer or his representative as and when
required.
The contractor shall ensure that after completion of the work of the contract
for any reason what so ever, the temporary cement godown shall be
dismantled.
All disentailed material/debris shall be removed and the clear site shall be
handed over back to railway.
All the released material shall be the property of the contractor and no
payment shall be made by the railways.
The final bill and earnest money/security deposits shall not be released
unless the godown is dismantled and the site is cleared.
Tolerance requirement for cement
Cement supplied at one time will be taken as a batch.

The number of batches taken for the sample from each bags shall be as
under:
Sl.No

Batch size

Sample size

100 to 150

20

151 to 280

32

281 to 500

50

501 to 1200

80

1201 to 3200

125

3201 to above

200

The bags in sample shall be selected as random.

The specified net mass(50 kg) shall be not more than 5% of the bags in the
sample.

In case of truck load of 10 to 25 tons, the overall tolerance on net mass of


cement shall be -0.5 to +0.5%.

Any batch of cement not conforming to above tolerance will be rejected.

The consumption of cement on work shall be assessed on the basis of


cement constants per unit quantity of various items of work.

In case of design mix of concrete of specified strength where the cement is to


be used by weight by where specially ordered in the NS item rate or tender
condition, a verification of +1%(max) will be allowed in the consumption of
cement.
Staking of cement in the godown shall be done on a layer of wooden
sleepers, so as to avoid contact of cement bags with the floor.
Cement shall be stored in such a manner as to permit easy access for proper
inspection.

Cement should be stacked not more than 10 layers height.


The stacks of cement bags shall be covered with Tarpaulin during monsoons
so as to avoid the possibility of deterioration of cement by moisture in the
atmosphere.

Cement brought to the site from godown in excess of the requirement


calculated based on the cement factors shall be taken back by the contractor
on completion of the work after written approval of ADEN/XEN on proper
documents.
Payment as per relevant NS item will be made on the basis of quantity of
cement actually consumed and the quantity calculated as per cement factors
for various items.
Cement actually consumed on works shall normally match the quantity
calculated as per cement factors for various items.
Empty cement bags will be the property of contractor.

SPECIAL CONDITION OF CONTRACT


The contractors shall satisfactorily maintain the work completed by him/them for
the following period from the date of completion certificate.
Sl.No.

Description of work

Maintenance period

Earth work & supply of material

NIL

Repair and maintenance work

03 months

New works(except earth work)

06 months

SUPPLY OF WATER: As regards the supply of water the condition as laid down on the relevant
chapters & annexure of the standard schedule of rates of 1996 shall apply
except the right of the travelling water tanks shall be bond by the railways.
For the plants and machineries for the use of contract the contractor will be
required to pay such higher charges as stipulated in the northern railway
schedule of rates or may be fixed by the divisional engineer.
For mixing cement concrete where it is required to be done by the
mechanical mixers by the Railway, the contractor will be debited to
Rs150/mixer for each working day at site inclusive at crew staff.
SOURCES OF BUILDING MATERIALS: Stones patties ashlar will be obtained from fedoras and quarries or equivalent
stone lime will be obtained from goton .
All other building materials will be obtained from the nearest sources after
obtaining the approved of the quality by the engineer.

In case of location where it is not possible to get the material by road or


working in between the section the assistance may be offered by the Railway
by way of display and labor.

RECORD BOOKS
Following records are maintained in project :1. Site order book.
2. Cement register.
3. Steel register.
4. Cube testing register.
5. Material passing register.
6. Sieve analysis register.
1. SITE ORDER BOOK: - It is used to instruct the work agency and is required at
site.

PERFORMA

Sl.N
o

Dat
e

Description of
instruction to
agency

Action
taken by
agency

Signature of
agency

Signature of officers of
department

2. CEMENT REGISTER: - It is used for day to day consumption of cement

PERFORMA:

Sl.N
o

Dat
e

Cemen
t
receive
d at
site

Ceme
nt
used

Ceme
nt
balanc
e

Signature
of agency

Signature of
officers of
department

Description of
works

3. STEEL REGISTER:- It is maintained for records of steel as hidden measurement.


PERFORMA:
Sl.N
o.

Dat
e

Locatio
n

Shap
e of
bar

Cut
lengt
h of
bar

No
.
of
ba
r

Dia
of
bar

Total
lengt
h

(mm
)

Wt
per
mete
r

Total
weigh
t

Signature of
contractor

4. CUBE TESTING REGISTER:- It is used for checking compressive strength of


cube for 7 days & 28 days.
PERFORMA:

Sl.
N
o

Date
of
castin
g

Loca
tion

Cu
be
no.

Mix
use
d

7 Days testing

Date
of
testin
g

Stre
ngt
h
(N/
mm
2)

Avg.
strengt
h
N/mm2

testing

Date
of
testi
ng

28 Days

Stre
ngt
h
N/m
m2

Avg.
streng
th
N/mm
2

Signat
ure of
contra
ctor

PLANNING OF WORK
Where Railway bank height about 2 to 3 meters from original ground level,
where RUB proposed.
Estimate sends to head quarter for proposed RUB work.
Estimate sanction for RUB by competent authority.
Tender invite for RUB work by Head quarter office.
Work sanctioned for RUB.
Working drawing & detailed drawing received from Head quarter for sanction
of work.
Mix designed prepared, which is used in work.
Materials checked at site before use.
Segments casting work starts before shuttering & steel reinforcement
Casting of segment RCC box & base slab near level crossing where RUB site
proposed as per mix concrete design.
Curing work start 24 hours after casting and up to 28 days completely.
Cube testing result taken after 7 days & 28 days after casting.
Preparation of launching of RUB box.

Drainage system to be provided for removing of rain water.


Height gauge to be provided both sides of bridge 20m away bridge.
1 in 20 slopes is provided in a ramp.

REFERENCES

1. IS 383-1970:- Specification for coarse and fine aggregate from natural


source for concrete.
2. IS 2386-1963:- Methods of test of aggregate for concrete.
3. IS 456-2000:- Code of practice for plan and reinforced concrete.
4. IS 10262-2009:- Recommended guidelines for concrete mix design.
5. Sp 23:- Hand work on concrete mixes.