CHAPTER

16
REINFORCED CONCRETE WORK

16.1 SCOPE

The work covered by this item consists of but not limited to reinforced concrete construction in
foundation footings, columns, lintels, beams, slabs, wall panels, retaining walls, water tanks, reservoirs
etc. The R.C.C. members may be cast in situ or precast in the work site or in a central manufacturing
workshop from where they are carried and fixed in the desired position in the proposed structure.

16.2 CEMENT

Cement shall be ordinary Portland cement Type-1 conforming to BDS 232-1974 or any other type as
specified in the design.

Requirements of cement shall conform to specifications as stated in section 5.2.1a of Bangladesh

National Building Code (BNBC) in addition to the requirement of BDS 232-1974.

No cement which has been stored through a monsoon or for a period more than six months shall be
used for reinforced concrete until samples have been tested and found to meet the requirement of
standard specification. Approval of the Engineer-in-charge shall be taken before any cement is used.

Cement bags containing clods giving indications of starting of initial setting shall not be used in R.C.C.
work. It is important that the strength of cement is ascertained by testing before use. Cement shall
never be measured loose but shall be so done in terms of bags, care being taken to determine the
volume content of cement in bags.

The cement shall be stored at site in such a manner as to permit easy access for proper inspection,
handling and identification of each shipment and in a suitable weather tight building that will protect
the cement from dampness and wastage.

Cement shall be protected from moisture and damage in transit and shall be stored in the site in a store
provided with wooden floor raised not less than 30 mm from the ground. Cement shall not be stacked
higher than six bags.

Cement bags shall not be piled against the wall, a space of 300 mm shall be left between the exterior
walls and cement bags. The bags shall be placed close together in the pile to reduce circulation of air as
much as possible. For extra safety, particularly during monsoon, the pile of cement bags shall be
enclosed completely by polythene sheet or covered with a tarpaulin.
Batches of cement shall be used for the work in the order in which they are delivered to the site. Each
consignment shall be stacked separately, so that the older cement may be identified readily to use
earlier.

Only one brand of cement shall be used for a particular casting work except by written permission from
the Engineer. Different types of cement shall be stored separately and shall not be mixed.

Use of rebagged cement shall not be allowed.

Engineer, at his discretion shall test cement which he feels to have deteriorated through age, damage to
bags, improper storage or for any other reason. In the event of any sample being found to be not in
accordance with BDS 232-1974 or any other standard as specified, the whole consignment from which
the sample comes shall be rejected and removed from the site immediately notwithstanding any
previous acceptance otherwise.

16.3 AGGREGATE

Concrete aggregate shall conform to the “ Coarse aggregate and fine aggregate from Natural source for
concrete (BDS 243-1963) and made from Grade ‘A’ brick conforming to BDS 208-“ Specification for
common building clay bricks”.

16.3.1 COARSE AGGREGATE

Coarse aggregate shall consist of either crushed stone or picked jhama brick chips as specified.

All coarse aggregate shall be cleaned and made free from dust and other impurities by screening and
washing in clean water immediately before use. Aggregate coated with clay, salt, organic matter or
crushed dust will not bond with surrounding cement paste.

Maximum nominal size of coarse aggregate shall not be larger than the most restricting of the following:

a) 1/5th the narrowest dimension between sides of form

b) 1/3rd the depth of slabs
c) 3/4th minimum clear spacing between individual reinforcing bars, or bundle of bars or
prestressing tendons or ducts.

The above limitations may be relaxed if, in the judgment of the Engineer, workability and methods of
construction are such that concrete can be placed without honey comb or voids. Minimum size of coarse
aggregate shall be such that it will be retained 100% by sieve No. 4.

It is of major importance that aggregate be non-reactive with cement and water and that it be
structurally sound, strong and durable.

The contamination of aggregate with top soil, humus or earthy materials containing products of organic
decay even in small amounts is practically certain to cause early disintegration of the member.
One other important characteristic of coarse aggregate is surface texture. A material of rugged surface is
by reason of its greater likelihood of mechanically adhering to cement paste more desirable than
another of vitreous, or smoothly structured surface.

Size and shape as well as the relative number of particles of different size, are important in determining
the suitability of materials for use as coarse aggregate. Since major function of aggregate is to act as
bulk filler, the particle offering least resistance to rearrangement among their kind are most desirable. In
other words, the aggregate should be well graded.

The angular shapes of coarse aggregate play a very important role in attaining the compactness and
strength of the concrete.

River shingles with its round surface give almost the same compressive strength as the sharp faced brick
chips. As such to attain greater strength of concrete boulders should be brought to site and broken to
proper size to use as coarse aggregate.

16.3.2 FINE AGGREGATE

For concrete, any sound filler materials that will pass through a sieve having square opening of ¼ inch
size shall be reckoned as sand or fine aggregate. It should be well graded particles and retained on No.
100 sieve in which not more than 5% dust is allowed. Coarseness of sand plays a very important role in
the compactness and strength of concrete. Every endeavor should be made to obtain the coarsest
variety of sand and the minimum fineness modulus (F.M.) of sand for concrete work shall be 2.5. Particle
larger than ¼ inch in size are declared as coarse aggregate.

It should be free from clay and other foreign materials as far as possible. The amount of clay contained
in sand may be ascertained by stirring samples of sand in clear water in glasses and allowed to settle for
about 15 minutes after brisk stirring. The thickness of clay deposit will be apparent and any staff
containing appreciable amount of clay shall be rejected.

Sand shall be well graded and must contain all sizes from the maximum specified down to the smallest
size.

Sand should be washed thoroughly to get rid of the clay and other undesirable materials particularly salt
before use in R.C.C.

16.4 WATER

Water used in mixing concrete shall be clean and free from injurious amount of oils, acids, alkalis, salts,
organic materials and other substances that may be harmful to concrete or reinforcement.

Nonpotable water shall not be used in concrete only if specified mortar test cubes made with
nonpotable water produce at least 90% of the strength achieved with potable water.

Under no circumstances, saline water shall be used for concrete.

16.5 STEEL REINFORCEMENT

Reinforcing steel shall conform to “Specifications for Steel Bars and Wires for the Reinforcement of
Concrete” (BDS 1313)

Reinforcing steel shall be deformed bars of Grade 40 and Grade 60 having f y equals to 275 MPa and 400
MPa respectively. Bars manufactured only from billet steel shall be used as reinforcing bars. Bars
produced from scraps shall not be used as reinforcing bars under any circumstances.

Before use reinforcing bars shall be tested either from BUET or any other standard Laboratory approved
by the concerned Executive Engineer (Design), to ascertain its yield stress, ultimate strength, chemical
composition, percentage elongation etc. The result shall have to conform with the design strength
specified by the Design Engineer.

Allowable tensile values of reinforcing bars shall be:

a) fs = 125 MPa ( 18000 Psi) with mild steel (Billet) deformed bars Grade 40 having minimum
fy = 276 MPa ( 40,000 Psi)
b) fs = 165 MPa ( 24000 Psi) with deformed bars Grade 60 having minimum f y = 415 MPa
( 60,000 Psi)

16.6 CONCRETE STRENGTH

Standard cylinder crushing strength of concrete at 28 days shall be minimum:

a) 17 MPa ( 2500 Psi) with brick jhama chips and mix proportion ( 1:2:4)
b) 20 MPa (3000 Psi) with brick jhama chips and mix proportion ( 1:1.5:3)
c) 25 MPa (3500 Psi) with crushed stone coarse aggregate and mix proportion ( 1:1.5:3)

7 days crushing strength shall not be less than 70% of the specified 28 days crushing strength.

Testing of concrete shall done frequently and test result furnished to the design office for checking and
record.

Slump test shall be performed at site for every days concrete mix to ascertain the consistency and water
cement ratio of the mix.

16.7 GENERAL DESIGN REQUIREMENTS

1. Structural drawings shall be read in conjunction with Architectural drawings. For any contradiction
between structural and architectural drawings, structural designer shall be consulted for any correction
and modification.

2. All written dimensions shall be followed and not scaled from drawings. For dimensions of structural
members like slab, beam, column etc. structural drawing shall be followed.

3. No deviation from structural design is advised without the approval of the concerned designer.
4. Cement, aggregate, M.S. Rod shall be tested either in BUET or any other standard Laboratory
approved by the concerned Executive Engineer (Design) and test results shall be furnished regularly to
the design office for checking and record.

5. Polythene sheet as per P.W.D. schedule of rates shall be laid underneath all concrete work to prevent
leakage.

6. Plain and reinforced concrete casting must not be done without the presence of an officer in the rank
of Sub-Divisional Engineer. Shuttering, propping and levelling work of R.C.C. shall be checked and
certified by the Executive Engineer in the site order book.

7. Cement block of required thickness made of (1:2) cement mortar shall be used under or sides of the
reinforcing bars to maintain clear cover. Under no circumstances, broken bricks shall be used as clear
cover blocks.

8. Conduits and pipes embedded in concrete shall satisfy the following requirements:

a) Concealed PVC or any other pipe laid in the slab for electrical or any other trade shall be placed
at the middle between top and bottom reinforcement. Under no circumstances, it shall be laid
beneath the bottom reinforcement.
b) Conduits and pipes with their fittings, embedded within a column shall not displace more than
4% of the area of cross section of column.
c) Conduits and pipes shall not be larger in outside dimension than 1/3 rd the overall thickness of
slab, beam or wall in which they are embedded.
d) Conduits and pipes shall not be placed closer than three times the diameter or width on centers.
e) Concrete cover for pipes, conduits or fittings shall not be less than 0.75’’ (20 mm) for concrete
not exposed to weather or in contact with ground nor 1.5’’ ( 40 mm) for concrete exposed to
earth or weather.

9. The following minimum concrete cover shall be provided for reinforcing bars for cast-in-place
reinforced concrete:

Non-Saline Zone

 Slabs, wall ¾” ( 20 mm)

 Beams, Girders, Columns ( to ties , stirrups or spirals) 1 ½ ‘’ ( 40 mm)
 Concrete in contact with soil 3’’ ( 75 mm)

10. Beams, girders or slabs supported on R.C.C. columns or walls shall not be cast or erected until
concrete in the vertical support member is no longer plastic.

11. Clear distance between parallel bars ( except in columns and between multiple layers of bars in
beams) shall not be less than the nominal bars diameters, 1 1/3 rd times the size of coarse aggregate nor
1 inch (25 mm).
12. Where reinforcing bars in beams and girders are placed in two or more layers, the clear distance
between layers shall not be less than 1’’ inch and the bars in upper layers shall be placed directly above
those in the lower layers.

13. In column, the clear distance between longitudinal bars shall not be less than 1 ½ times the bar
diameter, 1 ½ times the maximum size of coarse aggregate nor 1 ½ inch (40 mm).

14. Corner reinforcement shall be provided in any exterior corner of two way slab system. Spacing of
reinforcement shall be equal to the spacing of maximum positive reinforcement.

15. Continuous slabs with nearly equal spans, larger of the two adjacent spans not to exceed the shorter
by more than 20%, uniformly loaded in which not more than about one half the tensile reinforcement is
to be bent, the position of Bend-ups and extra bars shown thus.

16. Minimum lap lengths for deformed bars in tension with f y= 415 MPa and f’c= 25 MPa
17. Minimum lap lengths for deformed bars in compression with f y= 415 MPa and f’c= 25 MPa

18. Minimum lap lengths for deformed bars in tension with f y= 276 MPa and f’c= 17 MPa

19. Minimum lap lengths for deformed bars in compression with f y= 276 MPa and f’c= 17 MPa

20. Minimum lap lengths for deformed bars in tension with f y= 276 MPa and f’c= 25 MPa

21. Lap lengths for deformed bars in compression with f y= 276 MPa and f’c= 25 MPa

22. The lapping in the reinforcement shall be avoided as far as possible at the point of maximum
bending moment and shall be staggered at different places where it occurs.

23. For small openings in solid slabs, the cross sectional area of the extra bars placed parallel to the
principal reinforcement shall be at least equal to the area of the principal reinforcement interrupted at
the opening. A bar shall be placed diagonally across each corner of the opening. Such openings shall be
at such places where shear stress is small and bending moment not the maximum.
24. Details of expansion joint at roof slab:

25. Details of expansion joint at floor slab:

26. Exterior corners of two way roofs or floors with or without parapet having provision for future
extension), supported freely on masonry walls, shall be anchored down to the lintel by providing short
column at the corner and necessary reinforcing steel in the slab for the restraining moment thus
developed to avoid horizontal crack in the masonry wall.

16.8 R.C.C. WORK IN SALINE ZONE

In the coastal area of Bangladesh and offshore islands saline environment prevails. Due to salinity in
the weather many existing buildings have shown cracks, spalling of concrete and corrosion in the
reinforcing bars.

Special provisions in the design and construction of R.C.C. structures have to be made to make the
buildings safe and durable which include denseness and non-porosity of concrete by using rich concrete
mix and increased protection ( Clear Cover) of reinforcing bars for areas where concrete is exposed to
corrosive atmosphere and external source of chloride.

Following are some of the measures and design criteria decided by the Chief Engineer on the basis of
recommendations of a high powered committee which is to be followed for Saline Zone.

1. For R.C.C. work brick aggregate shall be replaced by crushed stone aggregate where saline
weather is prevalent.
2. Standard cylinder crushing strength of concrete at 28 days shall be minimum 24 MPa (3500 Psi)
with crushed stone as coarse aggregate. Minimum mix ratio of Reinforced concrete shall be 1:1
½ :3 by volume. 7 days crushing strength shall not be less than 70% of the specified 28 days
crushing strength.
3. Fineness Modulus (F.M.) of sand for R.C.C. work shall be minimum 2.5.
4. Deformed bar of Grade 40 or Grade 60 shall be used as prescribed by Superintending Engineer,
Design Circle.
5. Clear cover for reinforcement shall be as follows:
a) Slabs 40 mm ( for
buildings beyond 6 km from sea shore or river bank it may be reduced to 25 mm)
b) Beams and columns (from stirrups and ties ) 50 mm
c) Concrete cast against and permanently exposed to earth 75 mm
 6. Sweet water shall be used for all R.C.C. work .
7. All R.C.C. work shall be mixed by mixer machine and no hand mixing shall be allowed.

The following districts and thanas have been identified as Zone of saline weather vide Chief Engineer’s
Memo. No, 1997-D-8 dt. 18.8.93 and No. 1610 D-4 dt. 28.8.93

Dist. Thana
Cox’s Bazar Cox’s Bazar
Kutubdia
Mohesh Khali
Chokoria
Ramu
Teknaf
Ukhia
Chittagong Bashkhali
Port Area
Mirersharai
Shitakunda
Anwara
Patia
Sandwip
Lakshmipur Lakshmipur (Char Area)
Raipur
Ramgati
Feni Sonagazi
Noakhali Hatiya
Companigonj
Noakhali Sadar (Char Area)
Bhola All Thanas
Barisal Bakergonj (Durgapasha Union)
Barisal Sadar ( Chandra Mohan Union)
Barguna Amtali
Patharghata
Barguna
Betagi
Perojpur Matbaria
Khulna All Thanas
Bagerhat Mongla port
Sharankhola
Satkhira Kaligonj
Ashashuni
Shyamnagar
Patuakhali Patuakhali
Dumki
Galachipa
 Bauphal
Dashmina
Kalapara
Mirjagonj

16.9 ADMIXTURE

An admixture is an extra component sometimes added to a concrete mixture for the purpose of creating
a special property or for neutralizing a normal characteristic of the concrete, or to correct some
deficiency of the mixture.

Chemical admixtures are added to concrete for the purpose of modifying the normal plastic life of the
mixture or for influencing its rate of gaining hardness and strength. A disadvantage of most chemical
admixtures is that small changes in their amount cause great change in their action. Furthermore, some
may retard one type of cement and accelerate another.

Thus, successful use of admixtures requires, precautionary study with the associated cement before
they are used, because their adequacy of performance is difficult to measure at a construction site
during the progress of work as consistency of action is not visually evident, abnormality of behavior is
not immediately disclosed and may not become known until some years after the structure is built.

There are several dispassionate reasons why some Engineers are skeptical of admixtures in general.
Successful use of this requires watchful observation and vigorous control, other-wise if they are used
beyond certain limits, they may disastrous. Successful use can only be achieved by expert technicians.

Prior approval by the Engineer shall be required for the use of admixture in concrete.

16.10 WATER- CEMENT RATIO

For complete hydration of a given amount of cement, an amount of water equal to 25 percent of that of
cement, by weight is needed chemically. An additional 10-15 percent must be present, however, to
provide mobility for the water in the cement paste during the hydration process so that it can reach the
cement particles. This makes for a total minimum water cement ratio of 0.35-0.4 by weight. This
corresponds to 4.5 gallon of water per sack of cement, the most customary way of expressing the water
cement ratio. Water cement ratio in concrete is generally considerably larger than this minimum to
provide the necessary workability of the concrete mix.

Provided the mix is sufficiently workable to be adequately compacted, the concrete with least amount
of water gives the maximum strength. The quantity of water to be used in the mix should be minimum,
consistent with the workability of the mix. Workability indicates the condition with which concrete can
be placed and compacted in the forms. It should be remembered that an excess water in concrete mix
makes the concrete weak, porous and permeable to moistures, reduces the durability of the concrete
and increases the shrinkage stress in it, resulting in cracks.

Concrete consistency is frequently measured by the slump test. A metal mould in the shape of a
truncated cone 12 inch high is filled with fresh concrete in a carefully specified manner. Immediately
upon being filled, the mould is lifted off and the slump of the concrete is measured as the difference in
height between the mould and the pile of concrete.

The slump is a good measure of total water content in the mix and should be kept as low as is
compatible with workability.

The following limits of slump should be followed as guideline:

Sl No. Type of work In inch

1. Slab, beam & column 2’’-6’’
2. Foundation, Footing , wall etc. 1’’-5’’
3. Mass concrete 1’’-3’’

16.11 CONCRETE MIX PROPORTION

Proportions of materials for concrete shall be such that:

a) Workability and consistency are achieved for proper placement into forms and around
reinforcement, without segregation or excessive bleeding.
b) Resistance to weather and other special exposure conditions to meet the durability
requirements, are attained.
c) The mix attains the designed strength. Concrete proportions, including water-cement ratio shall
be established on the basis of field experience and /or trial mix with materials to be used.

Normally a mix proportion of 1:2:4 with brick chips as coarse aggregate shall be used for small works. In
big and important structures and also in the saline zone, a richer mix proportion of 1:1 ½:3 with either
brick chips or crushed stone as coarse aggregate shall be used depending upon the strength
requirements and denseness of the concrete.

16.12 PREPARATION BEFORE MIXING OF CONCRETE

Before mixing concrete, preparation shall include the following:

a) All equipment for mixing and transporting concrete shall be cleaned.

b) The platform where the concrete shall be poured from mixer machine shall be cleaned with
water and free from debris and other harmful materials.
c) Containers for measuring aggregates, sand, water, cement shall be checked and approved by
the Site Engineer.
d) All debris should be removed from spaces to be occupied by the concrete.
e) Form shall be properly cleaned and coated.
f) Masonry filler units that will be in contact with concrete shall be soaked thoroughly.
g) Coarse aggregate shall be thoroughly watered and cleaned of all foreign materials, silt and mud.
h) Reinforcement shall be thoroughly cleaned of deleterious materials.
i) Concrete blocks for maintaining clear cover shall be properly placed.
j) Water shall be removed from the place of deposit before concrete is placed.
 k) All laitance and other unsound materials shall be removed before additional concrete is placed
against hardened concrete.
l) All reinforcement shall be checked to verify whether the rods of the specified number, diameter,
length and shape with proper laps have been provided and the necessary clearance maintained
as shown in the design drawing. It shall also be checked if the rods have been tied rigidly by
wires, with the correct spacing in between. The effective depth shall be checked to see whether
it conforms to that shown in the drawings.
m) No rectification works, for any part of the proposed R.C.C. work, whether it relates to bending,
binding of the reinforcement or to the correction of the formwork shall be allowed to be left for
the day of casting of the concrete. All such rectifications and corrections shall have to be done
and completed on the day before casting is taken up.
n) The supporting brick walls should be smoothened to avoid adhesion or grip of the concrete of
the slab with the wall resulting in cracks in the wall due to contraction and shrinkage stresses
developed when setting. This may be done by plastering the top surface of the wall and neat
cement finishing and properly curing with water and the placing polythene sheet on the top
before laying concrete.
o) For important work, vibrator should be kept ready for vibrating the concrete.
p) Shuttering shall be properly wetted before laying of concrete.
q) Opening for fixing W.C. pans, pipes, clamps for fan hooks may be kept in the forms before
casting concrete, so that the concrete is not to be partially dismantled and disturbed afterwards.
r) An officer not below the rank of Sub-Divisional Engineer shall approve in writing the form work,
reinforcement detail, the quantity of cement, sand and coarse aggregate at least one day before
casting work is started.

16.13 MIXING OF CONCRETE

a) All concrete shall be mixed in a mixture machine unless otherwise approved by the Site Engineer.
Every batch shall be mixed in accordance with standard specification and shall be subject to rejection if
not conforming to specification.

b) All concrete shall be mixed thoroughly until there is a uniform distribution of materials and shall be
discharged completely before the mixture is recharged.

c) Every batch shall be mixed for at least 90 seconds or until a uniform consistency of the mixture is
obtained.

d) Platform where concrete shall be unloaded and the drum of the mixtures machine shall be cleaned at
regular intervals.

e) The volume of concrete mixed in each batch shall not exceed the manufacturers rated capacity.

f) A detail record shall be kept to identify:

i) No. of batches produced

ii) Proportion of materials used

iii) Approximate location of final deposit in the structure

 iv) Time and date of mixing and placing

g) Remixing of concrete shall not be permitted and any concrete mixed and not used within half
an hour must be discarded. Mixing which may have undergone initial setting must also be
discarded.

16.14 HANDLING AND PLACING OF CONCRETE

A most thorough and careful design can be completely defeated by improper practices in the handling of
ingredients and placing of concrete. Unrestrained dropping, steep cutting and horizontal flow of
concrete are extremely harmful and should not be tolerated. Whenever possible concrete should be
placed in a form at its final resting place in a structure. Lateral flow of concrete causes the coarse
aggregate and the mortar to come to rest at different places in a form and this may result in porous,
honey combed or other unsuitable concrete.

In almost all situations concrete should be deposited vertically and in horizontal layers of reasonable
depth. Great lift of a simple pour encourages segregation of coarse and sedimentation of the finer
constituents of mixtures and moreover may cause unwanted displacement of forms.

No deposition of concrete shall be done before the surface on which concrete is to be poured,
reinforcements and forms have been inspected and approved by the Engineer.

Concrete shall be transported from mixing to placing of final deposit as readily as practical while plastic
and within the initial setting time, so that it flows readily into spaces between and around
reinforcement. Partially hardened concrete shall not be deposited. Retampered concrete or concrete
that has been remixed after initial set shall not be used.

After concreting is started, it shall be carried on as continuous operation until placing of a panel or
section is completed. During pouring of concrete, the mason shall not be allowed to use his mug and
water.

Concrete shall be deposited continuously in layers not exceeding 12’’ or of such thickness that no
concrete will be deposited on concrete which has hardened sufficiently to cause formation of seams and
planes of weakness within the section.

In order to secure full bond at the construction joints to the surface of concrete already placed including
vertical and inclined surfaces, shall be thoroughly cleaned of foreign materials and laitance and slightly
roughened. Shortly before new concrete is deposited, the joints shall be saturated with water. After free
water disappears, the joints shall be given a thorough coating of neat cement slurry to the consistency
of a heavy paste. New concrete shall be deposited before the neat cement dries.

The concrete in R.C.C. slabs shall be laid to proper thickness. To achieve this two strips of concrete about
6” wide and a little over the specified thickness should first be placed 6’-0” to 8’-0” apart, compacted
and levelled to the exact thickness. Concrete is then poured within the intervening space between the
strips ( locally known as paya) and properly compacted to the desired thickness.

Care shall be taken that during concreting, the rods are not displaced and the effective depth of the
slabs and the beams, the spacing of the stirrups and rings and the clear cover to then bars are
maintained. Care shall be taken to see that the top negative rods are not displaced at all which seriously
affects the design and the desired strength of the structure. Particular attention shall be given to the
spacing and placing of rods in the cantilevers.

To ensure the above, the following procedures among others in practice shall be adopted:

a) Wooden block with handle shall be placed on the shuttering to check the depth of casting.
b) Before and during casting, the main reinforcing bars both positive and negative shall be kept in
position. Negative reinforcement shall be kept in position with steel chairs. Adequate
precautions against displacement and depression of rods due to trampling of the workers, shall
be taken. If the rods are displaced, this shall be reset to their correct position and tied rigidly
again before concreting can be done.
c) For maintaining the correct clear cover of the bottom reinforcement in the slabs and beams,
concrete blocks of proper size should be used and these may be incorporated in the casting.
Care must be taken so that no wooden block or any other foreign stuff remains within the
concrete mass. Pieces of bricks must not be used as clear cover blocks. To avoid exposure of
reinforcing bars and subsequent corrosion due to oxidation, special care shall be taken so that
design clear cover is maintained properly.

Care must be taken so that the lines of rods are straight and parallel to the edges of the slab in both the
direction. The ends of the rods shall have uniform clearance to the formwork.

Walking on recently poured concrete shall not be allowed. In unavoidable circumstances wooden planks
may be laid on concrete for the purpose.

16.15 COMPACTION OF CONCRETE

Concrete shall be thoroughly consolidated by suitable means such as tamping, rodding and spading and
shall be thoroughly worked around reinforcement and embedded fixtures and into corners of forms.
This is essential for the elimination of large casual voids, the complete encasement of reinforcement and
the proper contact of concrete with form faces and embedded fixtures. Compaction is achieved by hand
tamping with a variety of hand tools but now more commonly and successfully with power driven
vibrators.

Proper use of mechanical vibrator is beneficial to the compressive strength and bond strength between
concrete and steel. But the consistency of concrete to be vibrated as measured by its slump should not
exceed 3 inch. Internal type vibrators, immerged in concrete, shall be used.

Concrete shall be rodded thoroughly, so that proper density is obtained and no honeycombed surface
appears after the removal of formwork. Where beams are deep and where spacing of rods allows,
wooden bargahs 2 ½” square and about 5’-0” long shall be used in addition to the M.S. Rods for
compacting the concrete.

Tamping on the laid concrete in slab shall be done with fairly heavy wooden straight edges (patta) fixed
with handle by two masons at either end till the level of the finished surface is attained, proper
compaction made and laitance comes out on the surface. Wooden mallets shall also be used for
obtaining a uniform compaction and for filling up depressions.
While using mechanical vibrators for compaction of concrete the following precautions shall be taken:

1) The vibrator shall be applied at the point of deposit and the area of freshly deposited concrete.
The vibrators shall be inserted and withdrawn out of the concrete slowly. The vibration shall be
of sufficient duration and intensity to thoroughly compact the concrete but shall not be
continued so as to cause segregation. Vibration shall not be continued at any one point to the
extend that localized areas of grout are formed. Application of vibrators shall be at points
uniformly spaced and not further apart than twice the radius over which the vibration is visibly
effective.

Vibrator shall not be applied directly or through the reinforcement to sections or layers of concrete
which have hardened.

Vibrators shall not be used to transport concrete in the forms.

Vibrators in the running conditions shall not be allowed to rest on reinforcement which extends to
concrete that has partially hardened.

16.16 SURFACE FINISHING

Concrete surface shall be made smooth and levelled and brought to proper grade.

Steel trowel finish shall be made for exposed floor slab and roof slabs without lime terracing.

Wood float finish shall be done for all slabs to receive lime concrete and brick paving.

Broom finishing shall be made for all slab to receive artificial patent stone, terrazzo flooring, using wire
brooms after the concrete is partially set.

Plastering to the concrete surface, where necessary, should be done immediately after the removal of
formwork before concrete dries up and hardens.

16.17 CURING

Curing means preventing or delaying up of intrinsic moistures inside the capillaries of concrete for
adequate hydration of cement in the mix in order that concrete may continue to gain strength. Curing
also helps against shrinkage cracking in plastic as well as in hardening concrete.

Directly after concrete has been placed in the formwork, water begins to evaporate from the fresh
concrete surface. If this evaporation is not prevented, plastic shrinkage cracks and surface porosity will
develop. It is therefore important to protect the concrete surface against drying out as soon as placing
and compaction have been completed and before the water shine disappears completely.

The following are the main methods of curing:

a) Retaining Formwork:
 This method is useful for curing vertical surfaces of structural elements like walls or columns or
ceiling of floor slabs. Formwork used for casting concrete are normally, kept in place for four to seven
days and they afford good protection against heat, wind, rain and cold. Wood left in place furnish good
protection. To aid curing forms should be oiled and wetted before casting and may also be wetted
during hardening.

b) Covering concrete surfaces with wet materials:

This is the most widely used method. It is done by covering the concrete surfaces by wet hessian, which
should be continuously kept wet. Normally for the first 24 hours, the concrete, is protected by
formwork. In structural concrete, formwork supporting the vertical surfaces are sometimes struck off
after 24 hours. These surfaces such as those of columns and walls are then kept moist by surrounding it
with hessian cloth. Horizontal surfaces such as those of road-slabs, house-slabs, etc. are covered by wet
hessian, damp sawdust or straw. The frequency of wetting depends upon the temperature, velocity of
wind, humidity etc.

c) Ponding method:

This is the most efficient method of curing. For the first 18 to 24 hours, the exposed surface is covered
with moist hessian or canvas. After that small banks of dykes of clay or lean mortar are built around and
along the slab, dividing the slab into number of rectangular ponds. These ponds are filled with water.
This method is suitable for the constructions of floors, roof slabs, roads and air fields.

16.18 EMBEDDED PIPES AND CONDUITS

The contractor shall coordinate with all other trades in placement of pipes, conduits, equipments and
other accessories and shall provide the necessary openings in the concrete slabs. Concrete shall not be
poured before placement of pipe and other concealed service lines.

The piping shall be so fabricated and installed that it will not require any cutting, bending or
displacement of the reinforcement from its proper location. If any bending or displacement is required
the attention of the Engineer shall be drawn for his decision.

All pipes, conduits or fixtures required to be embedded in the concrete shall be placed and secured in
position before casting is commenced.

Special care shall be taken in case of conduit pipes for electrical wirings so that it is not laid in the slab
below the bottom reinforcement, which shall invariably result in cracks in the slabs. These pipes shall
be placed between the top and bottom reinforcements. Placing of conduit pipes parallel to the main
reinforcement shall be avoided as far as practical. Conduit pipes shall be placed diagonal to the
reinforcement as far as practical to avoid cracks in the slab.

For the purpose of payment no deduction shall be made on account of displacement of concrete by
pipes, utilities and other embedments and reinforcements unless otherwise specified.

Conduits and pipes of aluminium shall not be embedded in structural concrete unless effectively coated
or covered to prevent aluminium concrete reaction or electrolytic action between aluminium and steel.
Conduits, pipes and sleeves passing through the slab, beam or wall shall not impair significantly the
strength of the construction.

Conduits and pipes with their fittings, embedded within a column shall not displace more than 4 percent
of the area of cross section on which strength is calculated.

Conduits shall not be larger in outside dimension than 1/3 rd the overall thickness of slab, wall or beam in
which they are embedded.

Conduits shall not be spaced closer than 3 diameters or widths on center.

16.19 FORMWORK AND SCAFFOLDING

Forms are intended to define the contour and locate the position of individual members with reference
to the structure, as a whole. Forms shall result in a final structure that conforms to shape, line,
dimensions of the members as required by the design, drawings and specifications. To limit satisfactorily
the size, shape and position of parts of the structure, it is necessary that forms be built to resist the
forces imposed upon them.

All forms shall be of wood or metal as specified and shall be built mortar tight and of sufficient rigidity to
prevent distortion due to the pressure of the concrete and other loads incident to the construction
operation. Forms shall be constructed and maintained so as to prevent warping and the opening of
joints due to shrinkage of the timber.

The forms shall be substantial and unyielding and shall be so designed that the finished concrete will
conform to the proper dimensions and contours.

Forms shall be so constructed that it can be dismantled without causing damage to the concrete or
disturbing the centering and shuttering of other materials.

The formwork shall be water tight specially for the roof slab. Bamboo matting may be placed on planks
or steel sheets to provide a rough surface after stripping of the formwork. Alternately ceiling may be
roughed up by chiseling immediately after stripping off the formwork.

Suitable camber shall be provided in the formwork for horizontal members. The camber for beams and
slabs shall be 1 in 250 and for cantilevers 1 in 50 of the projected length.

Scaffold shall be made from strong and suitable bamboo poles, wooden post or steel pipes. They shall
be adequately tied to vertical member resting on firm floor.

Strong ropes shall be used to tie up bamboo poles. Bamboo for vertical supports shall not be less than
75 mm in diameter and shall be straight as far as possible. Bamboos may be used as vertical support for
upto a height of 4m if horizontal bracings are provided at the centre. Splicing shall not be allowed. Good,
sound and uniform bamboos shall be collected in sufficient quantities for providing scaffolding,
providing temporary stage etc. the bamboos shall be free from any defects. Joining bamboos with only
nail shall be prohibited. Steel centering frame may be used for any height. In case of patented materials,
the instruction of the manufacturer regarding the load carrying capacity shall be allowed. Post to post
support shall be provided with wooden planks. When tubular steel and timber centering is to be used in
combination necessary precaution shall be taken to avoid any unequal settlement.

Tubular steel centering shall be thoroughly inspected before erection. Defective members shall be
discarded. Adjustment screws shall be set to their approximate final adjustment after assembling the
basic unit and the unit shall be levelled and plumbed.

The centering frames shall be braced to make a rigid and solid unit. Struts and diagonal braces shall be in
proper position and secured. As erection progresses, all connecting devices shall be in place and
fastened for full stability of joints and units.

In addition, cross bracing with bamboo or wooden posts shall be provided alongwith tie or guys of steel
wire or rod not less than 6 mm.

Wooden planks or steel sheets shall be placed across horizontally below bamboos or wooden post to
provide suitable footrest and carry construction materials. The whole assembly shall be securely lashed
together.

The props shall be placed on timber planks, false brick work or steel sheet covering several posts at a
time so as to eliminate the possibility of any sinking of the earth below particularly when the earth is
likely to be moistened by water.

Care shall be exercised that centering of columns are true to plumb and thoroughly cross braced to keep
them in position.

Due attention shall be given not to disturb the top layer of brick work at the time of fixing the shuttering.
If this happens, the top coarse should be replaced by fresh brick work.

The shape, strength, rigidity, water tightness and surface smoothness of reused forms shall be
maintained at all time. Any warped or bulged timber must be resized before being reused. Forms which
are unsatisfactory in any respect shall not be reused.

Half seasoned soft wood, laminated board or other smooth sheet shall be used for formwork for a fair
faced finish.

The formwork made of materials liable to absorb water shall always be sprinkled with water to prevent
water absorption from concrete. Water shall not be profusely used and the formwork shall be in a
saturated surface dry condition.

All forms shall be tested both individually and in combination before final use to detect any flaw or
defect. Measures shall be taken immediately to remedy any fault, if detected, before the formwork is
ready for use. The frame and its joints shall be checked from time to time for the decay in ropes,
bamboos, planks etc. The defective parts shall be replaced before the formwork is used.

Scaffolding and formwork shall be checked to see if all the props are stiffly supported over the firm base.
If any forms found off base, wooden edges shall be inserted below the prop to obtain the required
degree of rigidity, with regard to horizontal movement. Pieces of planks shall be used under each prop
to distribute the load to sufficient area of the ground.
The props should be adequately braced and their spacing shall not be more than 2’-6” square below
R.C.C. slab centering. Very strong bamboos and salbullah props shall be used for the shuttering of R.C.C.
beams.

No clay plaster, packing with pieces of paper, jute, cotton waste etc. shall be allowed to make up the
gaps between the centering.

Metal ties or anchorages like bolts and nuts within the forms in vertical members shall be loosened and
withdrawn before initial setting of concrete. The resulting hole shall be filled with rich mortar and the
surface left smooth, sound, even and uniform in colour.

Forms shall not be removed until the concrete has developed sufficient strength to support all predicted
loads.

Forms shall be removed in such a manner as to ensure the complete safety of the structure.

For all R.C.C. work with proportion 1:1 ½ :3 steel shuttering shall be used.

An officer not below the rank of Sub-Divisional Engineer, shall check all reinforcing details and levelling
of the centering. In case of slab supporting on brick work, the top level of the brick wall shall be levelled
either by a levelling instrument or water level and shuttering shall be levelled with respect to the top of
the brick work.

The form shall not be removed before expiry of the minimum period specified below:

1) Bottom of the = 15 days

2) Bottom of the beams & girders = 21 days
3) Sides of beams = 7 days
4) Sides of columns = 3 days
5) Sides of pedestals & footings = 2 days