76

2.3 SHEAR WALL CONSTRUCTION

2.3.1 TENDER SPECIFICATIONS
1. Formwork

Formwork shall consist of shores, bracings, sides of beams & slabs, bottoms of slabs etc.
Including, anchors, hangers, inserts etc. and shall be designed & planned for the work by
contractor.
Formwork shall be so constructed that vertical adjustments can be made to compensate
for settlement using M.S. props only.
The contractor shall indicate in his tender the minimum quantity of formwork, staging &
scaffolding materials he proposes to mobilize for the work.
Fabricated structure steel staging & steel pipe scaffolding shall be used (wood & bamboo
staging is not permitted)



(a) Design
The design of formwork & its construction & erection is the sole responsibility of
contractor.
The design shall consider all the loads (vertical & lateral) including live & vibration
loadings.
Horizontal tubes will not be permitted to carry loads. They shall be used as bracings only
& only the vertical tubes will carry the load.

(b) Tolerances for Reinforced concrete Buildings
Variation from the plumb.
o In the lines & surfaces of columns, piers, walls 5mm per 2.5m, whichever is less.
o For exposed corner columns
- In any bay or 5 m maximum: 5 mm
- In 10 m or more: 10 mm
Variation from the level or from the grids indicated on drawings.
o In 5 m: 15 mm
o In 10 m or more: 25 mm
o In buried construction: Twice the above amounts
Variation in cross sectional dimensions of columns, beams, piers & similar members.
o Minus: 5 mm
o Plus: 10 mm
Variation in thickness of slabs, walls & similar members
o Minus: 5 mm
o Plus: 10 mm
Footing for columns, walls & similar members.
o Variation of dimension in plan
- Minus: 10 mm & plus: 50 mm
o Misplacement or Eccentricity
- 2% of footing width in direction of misplacement not more than 50mm
o Reduction in Thickness
- 5% of specified thickness subject to maximum of 50 mm
77

Tolerance in other structures shall conform to those given in ACI 347 clause 2.4 of
Recommended practice for concrete formwork.
Tolerances in fixing anchor bolts shall be as follows :
o Anchor bolts without sleeves : + 1.5 mm in plan
o Anchor bolts with sleeves : + 5 mm in elevation
o Embedded parts : + 5 mm in all directions
o For bolts 32 mm dia & above : + 3 mm in all directions
o For bolts through 28 mm dia : + 5 mm in all directions

(c) Formwork Requirements
Formwork shall be conform to the shapes, lines & dimensions including cambers of
concrete as required by design.
Ample struts, walers, shores etc. of MS shall be used to hold the formwork in proper
position.
Formwork shall be strong enough to permit the use of immersion vibrators.
Faces coming into contact with concrete shall be free from adhesive grout, plaster, paint
or other defeats.
All new and used ACROW props and shuttering material shall be maintained in good
condition with respect to shape, strength, smoothness of surfaces.
Shores supporting successive storage shall be placed directly over those below or be so
designed and placed that loads will be transmitted directly to them.
Excessive construction camber to compensate for shrinkage, settlement etc. That impair
strength of members will not be permitted.
Formwork for substructure concrete may be omitted when the given excavation is firm
enough to act as formwork.
Formwork during any stage of construction showing sign of distortion to such an extent
that it does not conform to exact contours as indicated on drawing shall be repositioned
and strengthened.
Formwork to beams & slabs shall be so erected that the formwork on sides of beams and
under the soffits of slabs can be removed without disturbing beam bottoms.
Re-propping of beams shall not be done except when props have to be reinstalled to bear
construction loads anticipated in excess of design loads.
Vertical props shall be supported on wedges or other measures shall be taken whereby
props can be gently lowered vertically while striking formwork.
If formwork of columns is erected to full height, one side shall be left open & built up in
sections as concrete pouring proceeds. Windows may be left for pouring concrete from
sides to limit drop of concrete to 1m.

(d) Mould Oil
It shall be ensured that faces coming into contact with concrete are perfectly cleaned &
two coats of mould oil applied.
It shall not become flaky or removed by rain or wash.
All corners exposed in finished structure shall be formed with moldings to form chamfers
or fillets. The standard dimensions shall be 20mm x 20mm. Vertical construction joins on
faces shall be chamfered.
Wire ties passing through walls are not allowed, bolts posing through shall be used.




78

(e) Removal of formwork
In normal circumstances (when temperatures are above 20C) following striking period
shall be used
Table 2.2.1 Formwork stripping period for various elements
Elements For OPC
Walls, columns & vertical side of beams
Slabs (props left under)
Beam soffits (props left under)
Removal of props to slab
Span up to 4.5m
Span above 4.5m
Removal of props to beams
Span up to 6m
Span above 6m
24 to 48 hrs.
3 days
7 days

7 days
14 days

14 days
21 days

After removing the formwork, if it is found that timber has been embedded in concrete, it
shall be removed.
Reinforced temporary openings shall be provided to facilitate removal of formwork.
Tie rods, clamps which must be removed entirely shall be loosened not earlier than 24
hrs. nor later than 40 hrs. after concrete has been poured. Cutting ties back from faces of
walls is not permitted.


2.3.2 MATERIAL SPECIFICATIONS
1. Peri liwa shutter plates

Material- Steel fame and plywood
Source/company- PERI
Rate- Rs 8000/m
2

Specifications-
o The LIWA has been designed for a fresh concrete pressure of 50 kN/m
2

o Total thickness 100mm (85mm steel frame + 15mm ply wood)

2. Plastic shutter plates

Material- Plastic
Source/make- NOVA
Rate- Rs. 5000/m
2

Specifications-
o Can bear loads up to 60 kN/m
2

o Total thickness of 80mm (5mm plastic plate + 75mm plastic projection)

3. Shuttering Oil

Material- Mould Oil
Source/make - CERA Chemical
Rate- Rs. 78/ lit
Coverage- 35 m
2
/lit.
79


4. Tie rods

Source/make - KR SCAFF (Tamilnadu)
Rate- Rs. 83/m

5. PVC tube & PVC cone

Source/make- Delux
Rate (PVC tube)- Rs. 14/m
Rate (PVC tube)- Rs. 2.5/piece

6. Walers

Available in lengths of 1.2m, 1.98m & 2.14m
Two channels of ISMC 100 connected back to back by spacer plate of (150 x 30 x 3) mm.

7. Edge Walers

Company : PERI
2 Rolled hollow sections (RHS) (50 x 25 x 2) mm used
Weight 2.75 kg


8. Wing nut

Company KR SCAFF
Specification 100 KN pull capacity
Rate Rs. 48/piece

9. Adjustable props

Company- ACROW
Rate- Rs. 1555/Nos.
Specifications-
o Closed height: 2300 mm
o Open height (max.): 4230 mm
o 29 kN safe working load

10. Clamps

(a) Wedge clamp LIWA
Used to connect two plates when no filler material is there between two adjacent plates.
Company : PERI

(b) Wedge clamp compensation LIWA
Company : PERI
Used to connect two adjacent plates when filler of max. 5cm size is used in-between two
plates.

80

(c) DOMINO Alignment coupler
Company : PERI
It fastens, aligns and tightens in a single operation.
Used for standard panel connections or with fillers up to 120mm wide.


2.3.3 TOOLS & EQUIPMENT USED

Bar bending machine: SPARTAN SBM 42
Bar cutting machine: SPARTAN SCM 42
Transit mixer: SCHWING STETTER
Needle vibrator: WACKER NEUSON
Plumb Bob
Line - Dori
Hooked rod for binding wires (Aakdi)
Hammer
Measure tape
Concrete Boom Placer
o Model: S 36X (4 section roll and fold system, height 36m)
o Specifications :



Table 2.2.2 Boom Placer (S 36X) and Portable pump specifications
Concrete Pump
Type P1800
Max. Pumping output (m
3
/4) 96
Max. number of strokes / min 19
Max. concrete Pump (bear) 85

Placing Boom S 36X
Pumping line diameter (mm) 125
Length of end hoes (m) 4
Reaching height (m) 35.2
Hori. Reach from Centre of slewing axis
(m)
31.25
Lifting angle 96
1
st
folding angle 180
2
nd
folding angle 180
3
rd
folding angle 238
Slewing range 2 x 360


2.3.4 ENABLING WORKS
Ramp construction
House keeping
81

Safety Harness provision
Diesel Generator provision (for keeping up vibration during power cutoff )

2.3.5 CONCRETE POUR CARD (FOR TOWER 32 SHEAR WALLS)
Table 2.2.3 Concrete Pour card (Shear walls)
Date 25/01/2014
Grade of concrete M40
Quantity of concrete 5.4 m
3
Location Tower 32
Are shuttering, Reinf. & Services completed Yes
Starting time 4 pm
Completion time 4:30 pm
Number of cubes taken for testing --
Slump value 120 mm


2.3.6 CONSTRUCTION PROCEDURE
Observations for shear walls 4SW12 (plastic formwork) and 4SW22 (PERI formwork) of
certain tower (Tower 32) starting from the starter construction till deshuttering have been
made.
1. Starter construction
In starter construction, one carpenter and 2 helpers have been deployed. It took 2 hours to
finish the starters of both the walls. Wooden runners of 50mm (width) x 70mm (depth)
are used for fabricating starter. Before fixing the starter, reinforcement is fixed into place
which is preceded by removal of wooden pieces used for making shear keys beneath the
shear walls. Shear keys are approximately 150mm (length) x 30mm (depth) spaced at
450mm clear spacing (and parallel to length of wall).
The wooden runners are cut into required lengths so that the internal corners of starter
coincide with the corners of walls as marked on the raft top by surveyors. The alignment
of starter is ensured by means of line-dori tied at the ends of walls through rods secured to
the reinforcement of wall. Line-dori is tied along one face of the wall.
To prevent inward or outward tilting of starter, rods (tied to reinforcement) and wooden
strips (nailed to runners) are used. The grade of concrete used for starter has to be one
grade higher than grade used for shear wall. Thus M45 grade of concrete is used for
starter. Once it is concreted, it is compacted by rodding it through a rod at several
locations.
82

This is followed by placing of wooden pieces parallel to length of wall so as to have shear
keys with dimensions as mentioned before. These wooden pieces are removed at a later
stage.


Figure 2.2.1 Starter arrangement
2. Shuttering
The plan (or drawings) of panels to be used for a particular shear wall is rendered to the
carpenter so that he becomes aware regarding the panel lengths, numbers and their
arrangement. As per the requirement, the PVC pipes are cut down by the labor.
The shutter plates are cleaned and formwork releasing agent is applied (2 coats). In case
of PERI formwork, the shutter plates are held at the position and are tied to the
reinforcement of wall through binding wire (for this purpose, a hole is provided at the top
PERI plates). Two such adjacent plates are clamped at three locations by standard wedge
clamp (height of each plate=3m).
In case of plastic formwork, connections are secured by insertion of plastic handle locks
in the slots and rotating them 90 through steel spigot. The connections are secured
between 2 adjacent vertical and 2 adjacent horizontal panels (height of each
panel=1.24m).
The tie rods are provided at the junctions of plates in both formwork systems. These tie
rods are put into the sleeves (PVC tube and cone) and are tightened by
wingnuts/griplocks.
In PERI formwork, wherever the fillers are encountered, the wedge compensation clamp
or domino alignment couplers are used (depending upon the filler thickness) to secure
connection. Moreover, for the insertion of tie rods, walers are put into place at such
locations.
Wooden spreaders are placed at about 400mm clear spacing near the top of formwork to
prevent inward tilting of formwork. Once erection of formwork is done, they are aligned
83

by placing adjustable props. For checking the plumb, a plumb bob is provided on two
perpendicular faces at the ends of wall.
To bring the wall into plumb, the props are adjusted accordingly (before concreting and
just after concreting). To ensure the horizontality, a line dori is also tied at the top of the
wall along one face.

Table 2.2.4 Comparison between PERI and Plastic formworks
Sr.no. PERI formwork PLASTIC formwork
1
Difficult to handle since it is heavy (35
kg/m
2
)
Easy to handle since it is light-weight.
2
Productivity is more since number of
connections is less.
Productivity is less since number of
connections are more.
3 Number of lateral props required is less. Number of lateral props required is more.
4
Cost incurred for material and labour is
less.
Cost incurred for material and labour is
more.

3. Concreting and Deshuttering
Concreting in shear walls is carried out by Boom placer. Five unskilled labors were
deployed for concreting in following manner.
o 2 labors- for compaction/vibration of concrete
o 1 labor- for delivering concrete through hose.
o 2 labors- for adjusting props and tamping at the bottom (to prevent honeycombing)

It took about 30 minutes to concrete both the walls. The concrete pour height was 3 m
(opposed to 1.5m as prescribed by IS code). The concrete is poured into 2 layers and each
layer compacted by needle vibrator at four locations (2-at boundary elements and 2-in
between). The concrete which gets deposited on formwork top is removed by trowel.
Once the top layer of concrete is vibrated, shear keys as mentioned before are placed over
it (which are removed later on).
After about 16 hours of concreting, deshuttering is carried out. Number of labors involved
in deshuttering is 3. It takes about 4 hours to deshutter PERI formwork whereas 7 hours
for PLASTIC formwork.
The pipe use as sleeve was just 1mm thick (instead of 3mm stipulated value) because of
which it got broken by concrete pressure thereby leading to sticking up of tie rods inside
84

the wall. Hence, the only resort was to cut off the projecting tie rods (which is not
permitted as per contract specifications).
After deshuttering, the shear walls are cured through water sprinkling and hessian cloth
coverings for 14 days. Also, the verticality and cover adequacy are checked by clients
quality department.


2.3.7 MANPOWER EMPLOYED, PRODUCTIVITY AND COST
ASPECT
1. Labor wages & Productivity
Table 2.2.5 Labor wages and productivity for both formworks
Sr. Item Peri Liwa Plastic
1
Labour (nos.)
Skilled
Helper

2
3

1
2
2
Labour wages (paid by labour contractor)
Skilled
Helper

230/8 hrs.
200/8 hrs.

250/8 hrs.
180/8 hrs.
3 SPCL pays to labour contractor 110/m 130/m
4 Quantity of formwork payable 25.27 m 21.05 m
5 SPCL paid for labour Rs.2779.7 Rs.2763.5
6 Time taken 10 hrs 21 hrs
7
Productivity (actual)
(estimated)
0.525 m/lab/hr
0.375m/lab/hr
0.358/m/lab/hr
0.375m/lab/hr
8 Labour contractor pays to labour Rs.1450 Rs.1601.5
9 Profit of labour contractor
Rs.1329.7
Rs.52.69/m
Rs.1135.5
Rs.53.94/m
85

10
If SPCL had their own labour then,
Profit + overheads/m
(Wages: Skilled-300/8 hrs
Unskilled-250/8 hrs)
[2779.7-1687.5]
=Rs.1092.2
=Rs.45.22/m
2736.5-2100
=Rs.636.5
=Rs.30.24/m






2. Rate analysis for Plastic formwork (Shear wall 4SW12)
Table 2.2.6 Rate analysis for Plastic formwork
Sr.no. Item description Unit Quantity
Rate
(Rs./Unit)
Amount
(Rs.)
(1)
Materials

-Plastic shutter plate & locks (571
nos.)


m

22.59


5000/80


1411.87

Shuttering oil (2 coats)
lit.

1.3

78/lit

101.4
Tie rods (1m)
(0.5m)

nos.
nos.
22
12
83/200
47/200
9.13
5.64
Props nos.
39

1555/100

606.45

Walers (1.98m)
(1.2m)
Kg
Kg
36.96 x 13
22.43 x 7
48/250
48/200
92.25
30.14
PVC tube M 8.2 14/m
114.8

PVC cone nos. 56 2.5/piece 140
Wingnut nos. 68 48/100 32.64
I- beam (1.7m) nos. 4 1195/100 47.8
(2)
Labor

m 21.05 130 2736.5
Total cost incurred for 22.59 m m 244.75/m 5328.8
Rate quoted in BOQ 567/m
(Profit margin + over heads) /m


322.24/m
(131.66%)





86

3. Rate analysis for PERI formwork(Shear wall 4SW22)
Table 2.2.7 Rate analysis for PERI formwork
Sr.
No
Item Description Unit Quantity Rate (Rs.)
Amount
(Rs)
(1)
Materials

-PERI shutter plate & wedge clamps (19
nos.

m

25.8

8000/120

1720
Shuttering oil (2 coats) lit 1.5 78/lit 117
Tie rods (1m)
(0.5m)
nos.
nos.
27
9
83/200
47/200
11.2
2.11
Props nos. 29 1555/100 450.95
Walers (1.98m)
(1.2m)
kg
kg
32.96x5
22.43x7
48/250
48/250
35.48
30.14
Edge walers kg 2.75x7 48/250 3.7
PVC tube m 7.32 14 102.48
PVC cone nos. 48 2.5 120
Wingnut nos. 60 48/100 28.8
(2) Labors m 25.26 110 2778.6
Total cost incurred for 26.25m 211.65/m 5400.46
Rate quoted in BOQ 567/m
(Profit margin + over heads) / m
567-211.65.
= 366.27/m
(175.6%)




4. Rate analysis & Productivity for Concreting
Grade of concrete used for shear walls- M 40
Mix design proportion- 1 : 1.9 : 2.47 : 0.36

(Cementitious) (FA) (CA) (Water)
1 : 1.9 : 2.47 : 0.36
(kg/m
3
)- (320+100) 798 1034.4 151.2

Here, 320 kg is cement and 100 kg is GGBS.
Chemical admixture (ECMAS HP-900): 250 ml per 50 kg of cementitious material.

Cost per m
3
= 320x5.2 + 100x3.128 + 798x0.67 + 622.44x0.6 + 414.96x0.53 + 2.1x54
87

= 3218.2528 Rs/m
3

Concrete volume for 4SW12
o Concrete level up to 2.45 height
o Concrete volume= plan area x height
= (1.015) x 2.45
= 2.487 m
3
Concrete volume for 4SW22
o Concrete level up to 2.99 m height
o Concrete volume= plan area x height
= 0.965 x 2.99
= 2.885 m
3

Concrete productivity = 10.59 m
3
/hour

(a) Labor cost

Time taken for concrete for both shear walls is 30 minutes.
o No. of labors= 5
o Wages (Rs) = 200/8 hrs.
o Labor cost incurred= Rs. 62.5
= Rs. 11.63 / m
3

Total cost / m
3
= Rs. 3229.88/ m
3

Rate quoted in BOQ = Rs. 5456/m
3

(Profit + Overheads) per m
3
= Rs. 2226.12 /m
3
(68.92 %)


5. Rate Analysis for Reinforcement

For Shear wall 4SW12
o Quantity of reinforcement in kg from BBS= 413.91 Kg
o Total cost of material= 43 x 413.91= Rs. 17798.13
o Labor cost= Rs. 4.5/kg x 413.91= Rs. 1862.59
o Total cost incurred= Rs. 19660.725
o Now cost per kg= 47.5 Rs/kg
o Cost quoted in BOQ= 60.645 Rs./kg
o (Profit + Overheads)/kg = 13.145 Rs./kg (27.67 %)

For Shear wall 4SW22
o Reinforcement in kg from BBS = 389.31 kg
o Total cost of material= 389.31 kg x 43 Rs/kg= 16740.33 Rs.
o Labor cost = Rs. 4.5/kg x 389.31= 1751.89 Rs
o Total cost incurred= 18492.22 Rs
o (Profit + Overheads)/kg= 13.145 Rs/kg (27.67%)






88

6. Analysis of Total Cost & Profit + Overheads

Table 2.2.8 Analysis of Total Cost & Profit + Overheads for Shear walls
Sr. No. Activity
Price as per BOQ
(Rs.)

Cost incurred (Rs.)
Profit + Overheads
(Rs.)
SW 12 SW 22 SW 12 SW 22
SW 12
(Plasti
c)
SW 22
(PERI)
1 Formwork 11935.35 14322.42 5328.8 5400.46 6606.55 8921.96
2 Reinforcement 25101.57 23609.7 19660.73 18492.22 5440.8 5117.48
3 Concreting 13569.07 15740.56 8033.14 9318.7 5535.93 6421.8
Total 53605.99 53672.68 33022.67 33211.38
17583.32
(53.2
5%)
20461.3
(61.61%
)


2.3.8 INSPECTION AND QUALITY CHECKS
1. Checklist for shuttering

Are all the safety norms being covered as per HSEM process?
Check for shuttering for availability and arrangement.
Are all the plates / plywood cleaned and polished properly.
Type of oil / polish used on the surface of shuttering.
Check for suitability, stability, safety & rigidity of assembled forms.
Check for provision for service piping.
Vertical members-Shear walls
o Checking alignment of all vertical members at floor level with respect to grid lines.
o Check plumb for vertical members (minimum 2 sides)
o Check right angle and diagonals of the vertical members from the top.
o Check for alignment with respect to adjacent vertical members.
o Check for adequate support as per shattering design
o Check for adequate of cover block.