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Notes
FORMWORK AND GOOD FORMWORK PROPERTIES
What is formwork?
When concrete is fresh and in its liquid state it must be restrained within a
mould in order for it to set in its required shape. Formwork is the term used to
For most in-situ pours, the formwork is made of wood. A smooth outer surface
provides the main support for the concrete as it sets. This is normally made of
plywood.
GOOD FORMWORK:
There are two factors that decide how well the concrete will look in the final
result.. one is how the concrete is placed and compacted, and the other is the
Formwork usually needs to be used many times for it to be cost efficient. This
can only be done if it is carefully handled, cleaned and stored, regardless of
what material it is made from.
3) Weight of concrete
4) Temperature
5) Type of cement
6) Vibration
8) Chemical additives
1) Height of concrete pour: Before concrete hardens, it acts like a liquid and
pushes against the forms the way water presses against the walls of a storage
tank. The amount of pressure at any point on the form is directly determined by
the height and weight of concrete above it. Pressure is not affected by the
thickness of the wall.
2) Concrete pour rate: Concrete pressure at any point on the form is directly
proportional to the height of liquid concrete above it. If concrete begins to
harden before the pour is complete, the full liquid head will not develop and the
pressure against the forms will be less than if the pour were completed before
any of concrete hardened.
Once concrete hardens it cannot exert more pressure on the forms even though
liquid concrete continues to be placed above it. The following diagrams
illustrates how form pressure varies when the pour rate is increased from one
level to another level. For ease of explanation, it is assumed that concrete
hardens in one hour (typically) at 21°C.
Fig: Concrete pressure on formwork during hardening
When the pour rate is increased the pressure also increases as shown below:
5) Type of Cement: The cement type will influence the rate at which concrete
hardens. A high early strength concrete will harden faster than normal concrete
and will allow a faster pour rate. When using a cement which alters the normal
set and hardening time, be sure to adjust the pour rate accordingly.
7) Concrete Slump: When concrete has very low slump, it acts less like a
liquid and will transmit less pressure. When using concrete with a slump greater
than 100 mm, the formwork should be designed to resist full liquid head.
The main faults in construction joints are lack of preparation and poor
compaction. The old concrete should be washed and a layer of rich concrete laid
before pouring is continued. Poor joints allow ingress of moisture and staining of
the concrete face.
Grout leakage occurs where formwork joints do not fit together properly. The
result is a porous area of concrete that has little or no cement and fine
aggregate. All formwork joints should be properly sealed.
(f) Segregation
Segregation occurs when the mix ingredients become separated. It is the result
of
1. dropping the mix through too great a height in placing (chutes or pipes
should be used in such cases)
A poor curing procedure can result in loss of water through evaporation. This
can cause a reduction in strength if there is not sufficient water for complete
hydration of the cement. Loss of water can cause shrinkage cracking. During
curing the concrete should be kept damp and covered.
Excess water increases workability but decreases the strength and increases the
porosity and permeability of the hardened concrete,which can lead to corrosion
of the reinforcement. The correct water-to-cement ratio for the mix should be
strictly enforced
Following are the good construction practices and techniques that shall
be followed for good quality and durable construction of structure:
1. Masonry work:
2. Concrete work:
4. Plastering:
Plastering should be done after masonry has been properly cured and allowed to
dry so as to undergo initial shrinkage before plaster.
Control joint should be provided in the concrete and terrazzo floor either
by laying floors in alternate panels or by introducing strips of glass,
aluminium or some plastic material at close interval in grid pattern.
When flooring is to be laid on RCC slab, either a base course of lime
concrete should be provided between the RCC slab and the flooring or
surface of slab should be well roughened, cleaned and primed with cement
slurry before laying of floor.
5. RCC Lintels:
Bearing for RCC lintels should be on the liberal side when spans are large so as
to avoid concentration of stress at the jambs.
For introducing the slip joint, the bearing portion of supporting wall is rendered
smooth with plaster (preferably with neat cement finish), which is then allowed
to set and partly dry. Thereafter either it is given thick coat of whitewash, or 2
to 3 layers of tarred paper is placed over the plaster surface, before casting of
slab.
For RCC work in exposed condition i.e. sunshades, balconies, canopies, open
verandah etc., to prevent shrinkage cum contraction cracks, adequate quantity
of temperature reinforcement shall be provided. In such condition quantity shall
be increase by 50 to 100 % of the minimum amount prescribed.
9. Finish on wall:
Finishing items i.e. distemper and painting etc. should be carried out after the
plaster has dried and has under gone drying shrinkage.
All items of masonry are properly cured and allowed to dry before
plastering work is done, thus concealing the cracks in masonry in plaster
work. Similarly plaster work should be cured and allowed to dry before
applying finishing coat. So as to conceals the cracks in plaster under finish
coat.
In case of concrete work before taking masonry work either over it or by
its side, the most of the drying shrinkage, creep and elastic deformation of
concrete should be allowed to take place, so as to avoid cracks in masonry
or a the junction of masonry and concrete.
11. Provision of reinforcement for thermal stresses:
Care should also be taken that in the vicinity of the old building, no excavation
below the foundation level of that building is carried out.
When plastering the new work, a deep groove should be formed separating the
new work from the old.
Renewal of finishing coats on old walls of old portion should be deferred for 2 or
3 months after the imposition of additional load due to new construction so that
most of the likely cracking should take place before finish coat is applied thus
concealing the cracks.
Filling in plinth should be done with good soil free from organic matter,
brickbats and debris etc. It should be laid in 25 cm thick layers, well watered
and compacted to avoid possibility of subsequent subsidence and cracking of
floors.
QUALITY CONTROL MEASURES AT SITE
Quality control and safety represent increasingly important concerns for project
managers. Defects or failures in constructed facilities can result in very large
costs. Even with minor defects, re-construction may be required and facility
operations impaired. Increased costs and delays are the result. In the worst
case, failures may cause personal injuries or fatalities. Accidents during the
construction process can similarly result in personal injuries and large costs.
Indirect costs of insurance, inspection and regulation are increasing rapidly due
to these increased direct costs. Good project managers try to ensure that the
job is done right the first time and that no major accidents occur on the project.
As with cost control, the most important decisions regarding the quality of a
completed facility are made during the design and planning stages rather than
during construction. It is during these preliminary stages that component
configurations, material specifications and functional performance are decided.
Quality control during construction consists largely of insuring conformance to
these original design and planning decisions.
With so many risks on the job, it is no surprise that construction workers are more prone to
serious injuries and in some cases, fatalities, than other industries. As a result, employers must
continually strive for workplace safety compliance and most importantly, their employees’ health
and vitality.
1 Scaffolding
Workers assigned to scaffolding jobs should be properly trained and continually aware of their
environment as falling debris, electrocution from power lines, and falls related to unstable
platforms can result in serious injuries. Supported and suspended scaffolds should be properly
outfitted with guardrails to prevent workers from falling from an open side, and workers should
be secured in appropriate fall protection.
2 Fall protection
All employees whose work conditions include the danger of falling should undergo fall
protection training regularly. Company training courses should identify specific hazards and
familiarize employees with all fall protection equipment used in the workplace. A review of the
written prevention and rescue plan will assure employees that help is never far away.
Fall protection equipment should be inspected each time it is used and by a qualified person once
every year — and that inspection should be documented. The equipment should be inspected
according to manufacturer’s recommendation and OSHA requirements. A thorough visual
inspection for signs of stress and wear should be performed every time a harness is used.
3 Ladder safety
The misuse of portable ladders can lead to injuries such as sprains and broken bones, but in
extreme cases also head and neck trauma — or even death. Ladders should be secured and
safely positioned at appropriate angles and prior to use be visually inspected for damaged
components including hinges, rungs/steps, side rails and feet. Side rails should extend at least 3
feet above the landing and be secured at the top to a sturdy support.
4 Respiratory safety
OSHA has established a respiratory protection standard covering detailed procedures for
reducing and eliminating respiratory hazards.
5 PPE
Personal protective equipment (PPE) is worn to reduce employees’ exposures to occupational
hazards and is required to be available on-site by OSHA. In fact, new OSHA regulations dictate
that where PPE is required, employers are now responsible for providing it. Otherwise,
employers are ultimately responsible for determining the level of PPE their employees use for
optimum protection. Hard hats, eye, ear and hand protection, earplugs and other protective
equipment provide protection from falling objects, head injuries, sparks, dust/fragments and
burns.
7 Confined spaces
Working in confined spaces can be an inconspicuous risk, as fatalities most often occur due to
invisible circumstances such as oxygen-deficient, toxic or combustible atmospheres. Also known
as permit-required confined spaces, they should be tested prior to entry and continuously
monitored using a properly configured and calibrated monitor. The monitors, once connected to
a docking station, also help maintain a proper calibration record for these confined spaces.
Workers must also use lockout/tagout (LOTO) to safeguard themselves from the unexpected
energization or startup of machinery and equipment, or the release of hazardous energy during
service or maintenance activities in confined spaces such as vessels. Approximately 3 million
workers service equipment and face the greatest risk of injury if every worker in the confined
space does not properly “lock out” the hazard and then “tag out” of the space once their work is
completed. Compliance with the OSHA lockout/tagout standard 29 CFR 1910.147 prevents an
estimated 120 fatalities and 50,000 injuries each year.
8 Recordkeeping
Maintaining up-to-date records of equipment inspections and injury logs is not only required by
OSHA, but is also the best way to protect employers from legal ramifications in the event of
injury and death.
9 Welding safety
Welding injuries, from minor flash burns to eye injuries, can be painful and cause disfigurement
or career-ending disabilities. Wearing the proper PPE is an easy way welders can protect
themselves against these risks and preserve their livelihood.
Unfortunately, overconfidence leads welders to think they are immune to such injury, or they
may choose not to use PPE because it is too expensive or the job is too small. Some welders
under-protect themselves because they feel the PPE is too warm or restrictive to wear.
Fortunately, workers now can find new PPE garments made of lightweight materials that wick
away sweat to stay comfortable. Welders now have many options in materials, flame-retardant
traits, fabric weight and accessories to suit up for the job.
Welding helmets should be equipped with the proper filter lens in either a passive or an
autodarkening style to shield against the arc’s bright light. Remember that ANSI Z87.1 lists
welding helmets as secondary eye protection that must be used with the primary protection
provided by safety glasses or goggles.
Airborne hazards should also be assessed and the necessary engineering controls implemented to
maintain acceptable exposure levels using ventilation, fans or fume extractors.
10 Training
The key to preventing many workplace accidents and injuries is frequent and effective employee
training programs. These programs exist for virtually all construction safety components
including fall protection, fire safety and welding safety among others.
Although many employers provide on-the-job training through their on-staff safety specialists,
there are voluntary educational programs available for additional certification such as OSHA’s
Outreach Training Program.
Concrete Technology
Prestressed Concrete
Definitions::
• “Pre-stressed concrete is a form of reinforced concrete that builds in
compressive stresses during construction to oppose those found when in
use.”
• In other words it is a combination of steel and concrete that takes
advantages of the strengths of each material.
Tasks Include:
Occupations:
1. CIVIL ENGINEER
Plans, designs, organises and oversees the construction and operation of civil
engineering projects.
2. GEOTECHNICAL ENGINEER
Plans, directs and conducts survey work to analyse the likely behaviour of soil
and rock when placed under pressure by proposed structures, and designs
above and below ground foundations.
3. QUANTITY SURVEYOR
Alternative Titles:
Building Economist
Construction Economist
Estimates and monitors construction costs from the project feasibility stage,
through tender preparation, to the construction period and beyond.
4. STRUCTURAL ENGINEER
Analyses the statical properties of all types of structures, tests the behaviour and
durability of materials used in their construction, and designs and supervises the
construction of all types of structures.
Tasks Include:
planning and designing power stations and power generation equipment
determining the type and arrangement of circuits, transformers, circuit-
breakers, transmission lines and other equipment
developing products such as electric motors, components, equipment and
appliances
interpreting specifications, drawings, standards and regulations relating to
electric power equipment and use
organising and managing resources used in the supply of electrical
components, machines, appliances and equipment
establishing delivery and installation schedules for machines, switchgear,
cables and fittings
supervising the operation and maintenance of power stations,
transmission and distribution systems and industrial plants
designing and installing control and signalling equipment for road, rail and
air traffic
may specialise in research in areas such as power generation and
transmission systems, transformers, switchgear and electric motors,
telemetry and control systems
Tasks Include:
7. MECHANICAL ENGINEER
Plans, designs, organises and oversees the assembly, erection, operation and
maintenance of mechanical and process plant and installations. Registration or
licensing may be required.