REINFORCED CEMENT CONCRETE WORK.

SPE-CIFICATIONS 91 92
a>
 85 76
Surface
Measurements
Materials
Form
Reinforcement
Rate
Reinforced
Compaction
Finishing
Consistency
Placing
Curing
Expansion
Stacking &Treatment
forwork
&Tolerance
Construction
Strength
Testing
Inspection
General
Design
Form
Steef in
Concreting
Water, Cement
requirement
of
ofof
work
M~asurements position
joints
Storage
joints
concrete
concrete
of Form
Requirement
Cement, fine work
(Centring
reillforcement in &Coarse
Concrete Work
construction
and Shuttering) -
CONTENTS
aggregate 77
73
83
78
71
81
85
82 -
·74
74
80
76 71
78
/81
74 68
/ LIST OF BIS CODES

65
 ..J Production
Form
Definition
Materials
5.4.11
Precastwork
Measurements
Rate
Batching
Mixing
Data
Laying
Scope
Curingfor
Marking
General
Fixing ofConcrete
Concrete
Reinforced
Measurements
Cement
Mix design
Requirements Concrete
. Concrete Jali 93
98
97
91
99
92 90
89
91
92
93
Encasing
Design
-.....•
Wrapping MixRolled
Concreting Steel Sections
5.6.8
5.6.6
5.6.4
5.7 - 5.6.7
5.6.5

66
 5.8.9 Approval ofof Acceptance
Standard design mix 99

5.8.12
5.8.10 5.8.14
5.8.13
5.8.15
5.8.11
Example Tolerances
Measurements
Rate
for mix
Work strength design
Test 99
99

100
103
103
103

5.9 Precast Reinforced Concrete 103

Door &. Window frames

5.9.2 Shape & dimensions - 103

5.9.3 Materials 103
5.9.4 Castings 103
5.9.5 Mould 104
5.9.6 Protections & Curing 104
5.9.7 Hinges 104
.5.9.8 Arrangements for-door & window fixtures 104
5.9.9 Fastners 104
5.9.10 Erection 104

Appendix A - Work test for concrete 105

_ (Mandatory lab test)
Appendix B - Rebound Hammer test 107

Appendix C - Additional tests for concrete 108

Appendix D - Register of work Test of concrete 110

Fig. ],2 &3 Typical set up of steel wall form work & ties 113 to 1I5
Fig. 4 & 5 Typical standard units & Components of form work. 116 &117

Fig. 6 &7 Typical arrangements of column form work. 118 & 119
Fig. 8 Typical details of Beam Head and Stiffener 120

Fig. 9 Typical details of multi-stage shuttering 121

Fig. 10 to 23 Details of expansion joints 122 to 126

Fig. 24 & 25 Seismic separation joints, details at floor and roof level 127

Fig. 26 . Construction joints 128

Fig. 27 & 28 Encasing rolling steel sections 129

Fig. 29 & 30 R.C.C. door & window frames 130 to 13 1

67
 '.
Chapter - 5
LIST OF MANDATORY TESTS:

Meterial Clause Test Field/Laboratory Test Procedure Minimum Frequency of testing

test quantity of
material/work
for carrying
out the test.

Water for const 5.1.1 a) Chemical & Lab IS 8025~1964 water from Before comme , .
mction purposes physical each source -cement of work
properties and thereafter every three
months till .
completion of work
of chapter
c)
b) Cube Field
Lab
test5.4.9
Slumptest 5.4.1 t A'
Appendix'D'
.Appendix Page 10504, concrete Once in a day

a) 20 cum a) Every 20 cum

in slab, beams of a day's
&..ronnected "
Corcreing
Columns
b) 5 cum in . b) ~very 5 cum
Columns

Note: For all other small items and where RCC done in a day is less than 5 cum;test
may be carried out as required by Engineer-in-Charge. '
,

5.4.10.5. d) Hammer Field Appendix 'B' Once in every three months or as

(A) Test page ... 107 directed by the :i

Engineer- in-charge
 R.c.c. Work

List of Bureau oflndian Standard Codes.

I. 1608-1972
1343-1980
IS 4925
IS 2751
2502
1786-1985
1791-1985
1200-1982
226-1975
1566-1985
1599-'
1200-1974
456
516
716-1987
1199 - --1959
-1959
432-1982 1979
1968
1963
1985
1978 (Pt.I)
(Pt. II) Structural
Code
Method
Batching
engineering
Code
civil of Ste'el
of practice
Practices
Practice
for
of
Specification bend for
for
test
measurement
test
Plants for
(part5-Form
engineering
Recommended
.Method for for
for
sampling Plain
strength
hard-drawn
forhigh
mild
batch
for and
bending
work-concrete
practice
tensile testing of
for and
Prestressed
work)
strength
steel
type Reinforced
steel
analysis
and
Pentachlorophenoland Concrete
building
of wire
of
concrete
deformed
medium
fixin[
work
welding
of steel and
concrete. fabric
ofConcrete
mixes
steel
of
mild
products concrete
civil
bars for
tensile
and
steel Concrete
forsteel
wiresbars
for
concrete
plain and
reinforcement
concrete
II Hard
hard
deformed
and reinforcement
drawn
drawn
bars
Specification
requirement. steel
for steel
for wire.
wire
reinforced
steel wire
concrete for
forconcrete reinforcement
construction
concrete
batching
'I mild steel and medium tens~le steel bars. and reinforcement
mixing plant - Part

69
19. IS 6523 - 1983 Specification for precast reinforced concrete door, window
frames

20. IS -10262-1982 Recommended guidelines for concrete mix Design

21. IS 13311 (Pt. 1)1992 Indian Standard for non destructive testing of concrete.
Method of test for ultrasonic Pulse velocity

22. IS 13311 (Pt. II) -1992 Indian standard for non-destructive testing of concrete -
Method of testing by rebound hammer.

70
 5. REINFORCED CEMENT b) Hard drawn steel wire conforming to IS
CONCRETE WORK 432 (Pt, II) 1982
c) High strength deformed steel bars con-
5.0 General: Reinforced cement concrete forming to IS 1786-1985
work may be cast-in-situ or Precast as may be
directed by Engineer-in-charge according to d) Hard diawn~teel wire fabric conforming
to IS 1566-1982
the nature of work.Reinforced cement con-
crete work shall comprise of the following e) Structural steel section conforming to IS
which may be p~jd separately or collectively as 226-1975
per the description of the item of work.
5.1.2.2 Types and Grades
a) Form work (Centring and shuttering)
_ Reinforcement supplied in accordance with
b) Remforcement this standard shall be classified into the follow-
ing types.
, c) Concreting: 1) Cast-in-situ 2) Precast
a) Mild steel bars: It shall be supplid in the
5.1 Materials following two grades

5.1.1' Water, cement, fine and coarse aggre- i) Mild steel bars grade I designated as
gate shilll be as specified under respective Fe 41O-S
clauses of chapter 03-mortars and chapter 04-
concrete work as applicable. - ii) Mild steerbars grade II designated
as Fe 410-0
5.1.2 Steel for reinforcement
b) Medium tensile steel bars, grade II desig-
5.1.2.1 The steel used for reinforcement shall nated as Fe 540-W-HT.
be any of the following types
5.1.2.3 Mild steel and Medium tensile steel
. a) Mild steel and medium tensile bars con-
.forming to IS 432 (Pt.I) .1982 Physical requirement are given in the follow-
ing table I

TABLE I

S.No. Type and nom4tal size Ultimate Yield Elongation

of bar tensile stress percent
stress' N/mm2 minimum
N/mm2 minimum
minimum

1. 225
Mild steel grade;215
'23
240
250
340
350
23
330
20
I 370
540
410
510
370
including
For bars upto & including
20mm.
and including. 16mni
20mm

2.

3.

71

Elongation Percent on gauge length 5.6 5 ISO
where so is the cross sectional area of the test
piece.
Note 1. Grade (II) Mild steel bars are not rec-
ommended for the use in structures
located in earthquake zone subjected
to severe damage and for structures
subjected to dynamic loading (other
than wind loading) such as railway and
highway bridges.
-
2. Welding of reinfocement bars covered
in this specification shall be done in
accordance with the requirements of
IS 2751 - 1979.
Nomimil mass/weight The tolerance on
mass/weight for round and square bars shall be
the percentage given in Table II of the mass/
weight calculated on the basis that the masses
of the bar/wire of nominal diameter and of
density 0.785 kg/cm3• or .00785 kg/mm3•

Table II
(Tolerance on nominal mass)

Nominal size in mm
Tolerance on the nominal mass Percent
Batch Individual Individual
sample + sample for coil (-x-)

~) over
For
upto
over 16
and -4
-6
for individual
coil
10',batch
upto and ±4
±8 sample+6
±8
tolerance
including plus
is not
tolerance
including
10 ±7not'specifie~
±3
appliable
16 is+5
(x)

Tolerance shall be determined in accordance with method given in IS 1786-1985

TESTS - Following type of lab test shall be fied above, two further samples shall be
carried out selected for testing in respect of each
failure. Should the test pieces from both
1) Tensile Tests these additional samples pass, the materi-
This shall be d~me as per IS 1608 - 1972 als represented by the test samples shall
be deemed to comply with the require-
2) Bend Test ment of the particular test. Should the test
1)1is shall be done as per IS 1599 - 1974 piece from either of these additional
samples fail, the material represented by
3) Re-test
the test samples shall be considered as not
This shall be done as per IS 1786 - ·1985
having complied with standard.
4.) RebendTest
5.1.2.4 High strength deformed bars & wires
This shall be done as per IS 1786 - 1985
'Shall conform to IS 1786 - 1985. The physical
Should anyone of the test pieces' first properties for all sizes of steel bars are men~
tioned below in Table III.
selected fail to pass any of the tests speci-

72
 TABLE-ill

S.No. 0.2% TensileProperty

proof
Elongation, Fe
8550
12
Fe
less
545
strength 550
500
stress
6%but 500
not
actual
.8%
actual
proof
0.2% but
more
more
than less
0.2%
N/mm2 not
than
stress
proof 14.5
thanthan
. 415
10% Grade
. more585 N/mm2
X
of -Sectional
stress,
N/mm2
gauge
Stress
percent min.
the test
Where /length
Amin.
yield Area
ispiece.
the -
5.65."jA,
on

Tests: Selection and preparation of Test sample
All the tests pieces shall be selected by the
Engineer-in-Charge or his authorised repre-
sentative either-
a) From cutting of bars
or
b)
Ifhe so desires, from any bar after it has
been cut to the required or specified size
and the test piece taken from any part of
it.
In neither case, the test pieces shall be
detached from the bar or coil except in tlje
presence of the Engineer~in-Charge or
his authorised representative.
bars as rolled arid su~sequently cold
worked and shall be subjected to physical-
tests without any further modifications.
N?deductions in size by machining or
otherwise shall be permissible. No test
_piece shall be enacted or otherwise sub-
ject to heat treatment. Any straightening
which a test piece may require shall be
done cold.
Tensile test: This shall 'be done as per IS
1599:..1966
RE - test : This shall be done as per IS
1786-1985,
Rebend test:' This shall be done as perlS 1786-
1985. -

The test pieces obtained in accordance 5.1.3 Stacking arid storage : Steel for rein-
with as above shall be full sections of tl)e forcement shall be stored'in such a way as to

6-4/CPWD/ND/92 73
 prevent distorting and corrosion. Bars of dif-
ferent classifications, sizes and lengths shall be
stored separately to facilitate issue in such sizes
and lengths to cause minimum wastage in
cutting from standard length.
Forms shall be so constructed as to be remov-
able in sections in the desired sequence, with-
out damaging the surface of concrete or
distrubing other sections. Care shall be taken to
see that no piece is keyed into the concrete.

5.2 Form wor\ (centring & shuttering) 5.2.3.1 Material for form work

5.2.1 Forrn work: Form work shall include a) Propping and centring
all temporary or permanent forms or moulds
required for forming the concrete which is cast- All propping and centring should be
either of steel tubes with extension
in-situ, together with all temporary construc-
tion required for their support. p~eces or built up sections of rolled
steel.'
5.2.2 Design & Tolerance in Construction
5.2.3.2 a) Centring/staging
Form work shall be designed and constructed
to the shapes, lines and diamensions shown on Staging should be as designed with
the df.awings with the tolerances given below. required extension pieces as ap-
proved by Engineer-in-Charge to
a) Deviation from specified ensure proper slopes, as per design
dimensions of cross section for slabs/beams etc. and as per lev-
of columns and beams + 12 mm els as shown in drawings. All the
staging to be either of Tubular steel
b) Deviation from dimensions structure with adequate bracings as
of footings + 12mm approved or made of built up struc-
tural sections made from rolled
i) Dimension in Plan +50 mm structural steel sections.
ii) Eccentricity in plan
0.02 times the width of the foot- b) In case of structures with two or
more floors, the weight of concrete,
ings in the direction of deviation
but not more than 50 mm. centring and shuttering of any up-
per floor being cast shall be 'suitably
iii) 'Thickness supported on one floor below the
+ 0.05 times the specified thick- top most floor already cast.
ness.
If

(Note- Tolerance appl y to concrete dimenscons c) Form work arilt'concreting of upper

floor shall not be done until con-
only, and not to positioning of vertical steel or
crete of lower floor has set atleast
dowels.)
for 14 days.
5.2.3 General Requirement : It shall be
strong enough to withstand the dead and live 5.2.3.3 Shuttering: Shuttering used shall be
of sufficient stiffness to avoid excessive de-
loads and forces caused by ramming and vibra-
tions of concrete and other incidental loads, flection and joints shall be tightly butted to
avoid leakage of slurry. If required, rubberised
imposed upon it during and after casting of
concrete. ltshall be made sufficiently rigid by lining of material as approved by the Engineer-
using adequate number of ties and braces, in-Charge~shall be provided in the joints.
Screw jacks or hard board wedges where re- '
Steel shuttering used for concreting should be
_ quired shall be provided to make up any settle-
sufficiently stiffened; The steel shuttering
ment in the form work either before or during
should also be properly repaired before use and
the placing of concrete.

74
properly cleaned to avoid stains, honey comb- 5.2.3.7 Removal of Form work (Stripping
ing, seepage of slurry through joints etc. time)

(a) Runner Joists In normal circumstances and' where ordinary

RSJ, MS Channel or any other suitable portland cement is used, forms may generally
section of the required size shall be used be removed after the expiry of the following
as runners. periods:

(b) A ssembly of beam head over props. a) Walls, columns and 24 to 48 hours
Beam head is an adopter that fits snugly vertical faces of . as may be decided
on the head plates of props to provide all structural by the Engineer-in-
wider support under beam bottoms. members charge

5.2.3.4 From work shall be properly designed b) Slab

for self weight, weight of reinforcement, weight i) Spanning upto
of fresh concrete, and in addition, the various 4.50 M 7 days
live loads likely to be imposed during the ii) Spanning over
construction process (such as workmen, mate- 4.50M 14 days
rials and equipment). In case the height of
centring exceeds 3.50 metres, the prop may be c) Beams and arches
provided in multi-stages. A typical detail of i) Spanning upto
multistage shuttering is given in Fig.9. 6M 14 days
5.2:3.5 Camber : Suitable camber shall be ii) Spanning over
6 M & Upto 9 m 21 days
provided in horizontal members of structure,
iii) Spanning over
especially in cantilever spans to counteract the 9M
effect of deflection. The form work shall be so 28 days
assembled as to provide for camber. The cam- Note-1
ber for beams and slabs shall be 4 mm per metre
(1 in 250) or as directed by the Engineer-in- For othertypes of cement, the stripping time
charge, so as to offset the subsequent deflec- recommended for ordinary portland cement
tion. For cantilevers the camber at free end may be suitably modified. If portland pozzo-
shall be 1/50 th of the projected length or as lana or low heat cement has been used for,
directed by the Engineer-in-charge. concrete, the stripping time will be 10/7 of the
period stated above.
5.2.3.5.1 Typical arrangement of fonn work
for 'Beams, columns and walls 'are shown in Note-2
Figure 1 to 8 a.nd form secured by wall ties is
shown in Figure 3. The number of props left under, their sizes and
disposition shall be such as to be able to s~fely
5.2.3.6. WALLS carry the full dead load of the slabs, beam or
arch as the case may be together with any live
The form faces have to be kept at fixed distance load likely to occur during curing or further
apart and an arrangement of wall ties with construction.
spacer tubes or bolts is considered best. A
typical wall form with the componcnts identi- Note-3
fied is given in Fig. 1,2&3, The two shutters of
the wall are to be kept in place by appropriate For rapid hardening cement, 3/7 of above peri-,~,
ties, braces and studs. Some of the accessories ods will be sufficient in all cases except for
used for wall forms are shown in Fig3. vertical side of slabs, beams and columns which
should be retained for atleast24 hours.

75

In case of cantiliver slabs and beams, the
centring shall remain till structures for counter
acting or bearing down have been erected and
have attained sufficient strength.
Proper precautions should be taken to allow for
the decrease in the rate of hardening that occurs
with all types of cement in cold weather and
accordingly stripping time shall be increased.
Work damaged through premature or careless
removal of fonns shall be reconstructed.
5.2.4 Surface Treatment
5.2.4.1 Oiling the surface
Shuttering gives much Jonger service life if the
surfaces are coated with suitable mould oil
which acts both as a parting agent and also_
gives surface protections
A typical mould oil is heavy mineral oil or
purified cylinder oil containing not less than -
5% pentachlorophenol confonning to IS 716-
1987 well mixed to a viscosity of 70-80
centipoise.
After 3-4 uses and also in cases when shutter-
ing has been stored for a long time; it should be
reooated with mould oil before the next use.
5.2.4.2. The design of fonn work shall con-
form to sound Engineering practices and rel-
evant IS codes
5.2.5 Inspection of Form work
The completed fonn work shall be inspected
and approved by the Engineer -in-charge before
the reinforcement bars are placed in position.
Proper fonn work should be adopted for con-
creting so as to avpid honey combing, blow
holes, grout loss, s'tains or discolouration of
76
concrete etc. Proper and accurate -alignment
and profile of finished corecrete surface will be
ensured by proper designing and erection of
fonn work which will be approved by Engi-
neer-in-Charge.
Shuttering surface before concreting should be
free from any defect/deposits and fully cleaned
so as to give perfectly straight smooth concrete
surface. Shuttering surface should be therefore
checked for any damage to its surface and
excessive roughness before use.
5~2.5.1 Erection ofFonn Work (centring and
shuttering). Following points shall be borne in
mind while checking during erection.
a) Any member which is to remain in posi-
tion after the general dismantling is done,
should be clearly marked.
/
b) Material used should be checked to en-
sure that, wrong items / rejects are not
used.
c) If there are any excavations nearby which
may influence the safety offonn works,
corrective and strengthening action must
be taken.
d) i) The bearing soil must be sound and
well prepared and the sole plates
shall bear well on the ground.
ii) Sole plates shall be properly seated
on their bearing pads or sleepers.
iii) The bearing plates of steel props
shall not be distorted.
iv) The steel parts on the bearingmem-
bers shall have adequate b~aring
areas.
-e) Safety measures to prevent impact of
traffic, scour due to water etc, should be
taken. Adequate -precautionary measures
shall be taken toprevem accidental im-
pacts ~tc.
f) Bracing, struts and ties shall be installed
along with the progress of fonn work to
ensure strength and stabili ty of fonn work
 a) -. or
provided
The MEASUREMENTS
Splayed
Screw number
Supports
When
Dressing
Required
Cantilever
Filleting
No
Props
The oredges,
restrained
Bolts,
Working
be
have
There
Where means
wire
atundamaged
Guy provisions
Raklng
All
Double the
required,
ropessteel
supports,
adjustments
adjustable
member
shallshall
with
camber
to
intennediate
stacked of
for
ties,
be
supports
fonn
be oil
shall nuts
notchings,
laterall
directly and
centralising
scaffolds,
circular
wedgesor y.ladders,
clamps,
pins
adequate
of
andthe
the
stays
struts,not
shall
stage.
materials near
provided
of
adequate,
to
stop
besteel bolts
allowance
eachbeams
adjustable
prevcnt
shaH shallprops
be be
eccentric
Steel
shall and
chamfered
under be shall
end,
spreaders,
temporary
design
visibly
cutting provision
shall
braces,
be and/ordraw~
bebygangways,
bent. 5.2.6
openings
the
tensioned
provided
wedges
are
in
adhesion
provided
adequate.
upon
one
sections be
for
nails
props
plumb
edges
another
placed as
used,
for and
over
verti-
of
nle;
(es-
as
s)
b)
g)
r)
q) riorany
mm
ing wide
together.
crete,
wedging,
long
otherof other
spans.
the
battens,
within
movement
arrangements
properly.
well
and as
in
to
mud
similar
items
the
beams,
inserting
easing,
construction
sheathing
specified
andsills,
items.
to
fonns
strutting,
tooperation
support
piles
hold
striking
plant for
columns
vibrators, the
the
and
orand
before
bolting,
to~erances.
of and
and sheathing
pouring
fonn
other
the con-
~e.
cleaning
removal.
equipment.
pouring con-
nailing,
vibrators and
work.
suitable
5.2.6.1
The d) General
p)
e)
±)
c)
h)
fonn ..splayed
work external
shall include angles
the not
followingexceeding 20
crete.
single
and
overlaps
placed
holes fot
prop.
fonnworkthe Wedges
and passings
in removing
forkheads. beshould
shouldrubbish restrained
at notthe
angles,
from beinte-
against
sheath-too
s-2.

77
 5.2.6.2. CLASSIFICA TION OF MEA-
SUREMENTS
Where it is stipulated that the fonn work shall
be paid for separately, measurements shall be
taken of the area of shuttering in contact with
the concrete surface. Dimensions of the fonn
work shall be ,measured correct to a cm. The
measurements shall be taken separately for the
following
a) Foundations, footings, bases of columns
etc~ and for mass concrete and precast
shelves. '
b)· Walls (any thickness) including attached
pilasters, butteresses, plinth and string
courses etc.
p) Small surfaces, such as cantilevers ends,
brackets and ends of steps, caps and boxes
to pilasterS and columns and the like.
q) Chullah hoods, weather shades, chajjas,
corbels etc. induding edges and
r) Elevated water reservoirs.
ceeding 3.5 metre height in one floor shall be •.
5.2.6.3 Centring,
measured and paid and shuttering where ex-l ~
for separately.
5.2.6.4 Where it is not specifically stated in
the description of the item that fonn work shall
be paid for separately, the rate oftthe RCC item
shall be deemed to include the cost of fonn
work.

c) Arches
Waffle
Domes,
Edges
Suspended
Well
Lintels
Columns,
Stairs
Spiral or
of ribbed
vaults,
slabs
steining
Cornices
Vertical
Chimneys and
beams,
(excluding
staircases
and and and
floors, slabs
shells
mouldings
girders,
pillars, posts
horizontal
shafts roofs,
breaks
roofs, inarchribs
landings,
bressummers
and
(including
landigs) floors
shelves
struts.
finsexcept
landings) and .
individmllly
Spiral 5.2.6.5 No deductions from the shuttering due
Staircase
wherebelow
ness)
cantilevers
folded
or
and plates
fonning
wallstheir
(to be 200
box,
supports mm
louvers
measured in
and in width
and or thick-
bandsmetres
balconies.
running to the openings/obstructions shall be made if
f)
i)
n)
m)
h)
g)
0)
d)
e)
j)
k)
1) the area of such openings/obstructions does not
exceed 0.1 square metre. Nothing extra shall be
paid for fonning such openings.

5.2.7 Rate-The rate of the fonn work in-

cludes the cost oflabour and materials required
for all the operations described above
I

5.3. -/ Reinforcement:

5.3.1 General requirements: Steel Con-

forming to para 5.1.2 for reinforcment.shall be
, clear and free from loose milscales, dust, loose
rust, coats of paints, oil or other coatings which
may destroy or reduce bond. It shall be stored
in such a way as to avoid distortion and to
prevent deterioration and corrosion. Prior to
assembly of reinforcement on no account any
oily substance shall be used for removing the
rust.

5.3.1.1 Assembly of reinforcement

Bars shall be bent correctly and accurately to

the size and shape as shown in the detailed
drawing or as directed by Engineer-in-Charge.
Preferably bars of fullle!1gth shall be used.
Necessary cutting and straightening is also
included. Over lapping of bars, where neces-
sary shall be done as directed by the Engineer-

78
in-Charge. The overlapping bars shall not touch
each other and these shall be kept apart with
concrete between them by 25 mm or 11/4 times
the maximum size of the coarse aggregate
whichever is greater. But where this is not
possible, the overlapping bars shall be bound
together at intervals not exceeding twice the
dia. of such bars with two strands annealed
steel wire of 0.90 mm to 1.6 mm twisted tight.
The overlaps/splices shall be staggered as per
directions of the Engineer-in-Charge. Butinno
case the over lapping shall be provided in more
than 50% of cross sectional area at one section.
5.3.1.2 Bonds and Hooks Forming End An-
chorages
Reinforcement shall be bent and 1hed in accor-
dance with procedure specified in IS 2502-
-1963, code of practice for bending and fixing of
bars for concrete reinforcement. The details of
bends and hooks are shown below for guid-
ance.
a) U type Hook
In case of mild steel plain bars standard U
type hook shall be provided by bending
ends of rod into semicircular hooks hav-
ing clear diameter equal to four times the
diameter of the bar.
U- TYPE HOOK
"..
Note:- In case of work in seismic zone, the
79
size of hooks at the end ofthe rod shall be eight
times the diameter of bar or 'as given in the
structural drawing.
b) Bends
Bend forming anchorage to a M.S. plain
bar shall be bent with an internal radius
-equal to two times the diameter of the bar
with a minimum length beyond the bend
equal to four times the diameter of the
bar.
f
4cl ~I\.J,
~
2-d.
zJ
BENDS
5.3.1.3 Anchoring bars in tension
Deformed bars may be used without end an-
chorages provided, development length require-
ment is satisfied. Hooks should normally be
provided for plain bars in tension. Develop-
ment length of bars will be determined as per
clause 25.2.1 ofIS 456-1978.
5.3.1.4 Anchoring bars in compression
The anchorage length of straight bar in com-
pression shall be equal to the 'Development
length' of bars in compression as specified in
clause 25.2.1 of IS 456-1978. The projected
length of hooks, bends and straight length~
beyond bend, if provided for a bar in compres-
sion, shall be considered for development
length.
5.3.1.5 Binders, stirrups, links and the like:
In case of binders, stirrups, links etc. the straight
portion beyond the curve at the end shall be not
less than eight times the nominal size of bar.
5.3.1.6 Welding of bars
Wherever facility' for electric arc welding is
available, welding of bars shall be d9ne in lieu
of overlap. The loc~t;ion and type of 'welding
shall be' got appr~ved by the Engineer-in-
Charge. Welding sliallbe as per IS '2751- 1979
for mild steel bars and for cold worked bars.
5.3.2
/' Placing in position
5.3.2.1 Fabricated reinforcement bars shall be
placed in ~siti6n as shown in the drawiiigs or,
as directed by the Engineer-ill-Charge. The
bars crossing one another shall be tied together
<u every intersection with two strands of an-
nealed steel wire 0.9 to 1.6 mm thickness
twisted tight to make the skeleton of the steel
won: ri'gid so that the reinforcement does not
get displaced du'ring deposition of concrete.
Tack welding in crossing' bars shall also be
permitted in lieu of binding with steel wire-if
approved by Engineer-in-Charge.
5.3.2.2 The bars shall be kept in correct posi-
tion by the folloWing,'methods :
a) In case of beam and slab construction
precast cover blocks in cement mortar 1:2
(1 cement: 2 coarse sand) about 4 x 4 cm
section and of thickness equal to, the
,.. d·:
specified cover shall be placed'between
the bars and shutterings, so, as to secure
and maintain the requisite cover of con-
crete over reinforcement.
b) In case of cantilevered and dou~ly rein-
forced beams or slabs, the"veryical dis-
tance between the horizontal bars'shall be
, maintained by introducing chairs, spac-
ers or support bars of steel at 1.0 metre or
at shorter spacing to avoid sagging.
¥ <
,-,~,wirKrequired
c) In case of columns and walls, the vertical
bars shall be kept in position by means of
timber templates with slots accurately cut
in them; or with block of cement mortar
1:2 (1 cement: 2 coarse sand) of required
siz~ ,s~tably tied to the reinforcement to
ensure that they are in correct position
during concreting.
80
d)" In case of other R.C.C'- structure such as
arches, domes, shells, storage tanks etc. a
combination of cover blocks, spacers and
'templates shall be used ,as directed by
Engineer-in-Charge.
5.3.2.3' Tolerance' on placing of reinforce-
merit '
Unless otherwise specifi~9 by the Engineer-in-
Charge, reinforcement shall be placed within
, the following tolerances :
Tolerance
in spacing
a) Foreffectivedepili,
200mm or less • ±lOmm
b) For effective depili, more
ilian 200 mm ±15mm
The cover shall in no case be reduced b~}nore
than one third of specified cover or 5 mm which
ever is less. '
5.3.2.4 Bending at construction joints ,
Where reinforcement bars are bent aside at
construction joints and afterwards bent back
into their original position care should be take.n
to ensure that at no time the radius of the bend
is Jess than 4 bar diameters for plain mild streel
or6 bar diameters for deformed bars. Care shall
also be taken when bending back bars ,to ensure ff
that the concrete around the baris not damaged.
5.3:3 Measurement
'Reinforcement including aHthorisedspacer bars
and lappages shalL be measured in, length of
different diameters, as actually (not more than
as specified in the drgs.) used in the worlt:
'nearest to a centimetre and their weight calcu-
lated on the basis of standard weight given in
table - IV 1?elow.,Wastage and unauthorised
;';-::"
overlapsShall not be p~d for. Annealed steel
for binding or tack welding shall,
not be measured, its cost being included in the
rate of reinforcement.-
Wherever tack weldiiig isu~ in lieu of bind-
ing, suchW~lds shall not be measured. Chairs
separators etc. shall be provided as directed by
the Engineer-in-Charge & measured separately
and paid for.
 Table IV

Cross Sectional Area and Mass of Steel Bar

Nominal Size Cross Sectional Area Mass per metre Run

mm Sq.mm Kg

6 28.3 0.222
7 38.5 0.302
8 50.3 0.395
10 78.6 0.617
12 113.1 0.888
16 201.2 1.58
18 254.6 2.00
20 314.3 2.47'
22 380.3 2.98
25 491. 1 3.85
28 616.0 4.83
32 .804.6 6.31
36 1018.3 7.99
40 1257.2 9.85
45 1591.1 12.50'
50 1964.3 15.42

Note: These are as per clause 5.2 ofIS 1786-1985

5.3.4 Rate: The rate for reinforcement shall
. include the cost. of labour and materials re-
quired for all operations described above such
as cleaning of reinforcement bars, straighten-
ing, cutting, hooking, bending, binding, plac-
ing in position etc. as required or directed
including tack welding on crossing of bal'S in
lieu of binding with wires.
5.4 CONCRETING
. 5AO The concl'ete shall be as specified un-
der chapter 04 concrete work: The proportion
by volume of !ngredients shall be as specified.
5.4.1 . Consistency: The concrete which will
flow slugishly into the forms and 'around the
reinforcement without any segregation of coarse
aggregate from the mortar, shall be used. The
consistency shall depend on whether the con-
crete is vibrated on or hand tamped. It shall be
determined by slump test as prescribed in chap-
ter"concrete under para 4.2.3 workability.
5.4.1.1 Where considered necessary, the work-
ability of the concrete may also be ascertained
by compacting factor test and VEE BEE
consistometer method specified in I.S. 1199-
1959 ..For suggested ranges of values of work-
ability of c~ncrete by the above two methods,
reference may be made to I.S. 456 - 1978.

81
5.4.2 Placing of Concrete
. process is not interferred with.
5.4.2.1 Concreting shall be commenced only
after Engineer- in-charge has inspected the cen-
tering, shuttering and reinforcement as placed
and passed the same. Shuttering shall be clean
and free from all shavings, saw dust, pieces of
wood, or other foreign material and surfaces
shall be treated as prescribed in 5.2.4.
5.4.2.2. In case of concreting of slabs and
beams, wooden plank or cat walks of chequerred
MS plates or bamboo chalies or any other
suitable material supported directly on the
centring by means of wooden blocks or lugs
shall be provided to convey the concrete to the
place of deposition without disturbing the rein-
forcement in any way. Labour shall not be
allowed to walk over the reinforcement.
5.4.2.3 In case of columns and walls, it is
desirable to place concrete without construc-
tion joints. The progress of concreting in the
vertical direction, shall be restricted to one
metre per hour.
5.4.2.4 The concrete shall be depositep. in its
final position in a manner to preclude segrega-
tion of ingredients. In deep trenches and foot-
ings concerte shall be placed through chutes or
as directed by the Engineer-in-Charge. In case
of columns and walls, the shuttering shall be so
adjusted that the vertical drop of concrete is not
more than 1.5 metres at a time.
5.4.2.5. During cold weather, concreting shall
not be done when the temperature falls below
4.5° C. The concrete placed shall be protected
against frost by suitable convering. Concrete
damaged by frost shall be removed and work
redone.
5.4.2.6 During hot weather precaution shall be
taken to see that the temperature of wet con-
crete does not exceed 38° C. No concrete shall
be laid within half an hour of the closing time
of the day, unless permited by the Engineer-in-
Charge.
5.4.2.7. It is necesary that the time between
mixing and placing of concrete shall not ex-
82
ceed 30 minutes so that the initial setting
5.4.3. Compaction
5.4.3.1 Concrete shall be com pacted into dense
mass immediately after placing by means of
mechanical vibrators designed for continuous
operations. The Engineer-in Charge may how-
ever relax this conditions at his discretion for
certain items, depending on the thickness of the
members and feasibility of vibrating the same
and permit hand compaction instead. Hand
compaction shall be done with the help of
tamping rods so that concrete is throughly.
compacted and completely worked around the
reinforcement, embeded fixtures, and into cor-
ners of the form. The layers of concrete shall be
so placed that the bottom layer does not finally
set before the top layeris placed. The vibrators
shall maintain the whole of concrete under
tre;:tment in an adequate state of agitation, such
that deaeration and effective compaction is
attained at a rate commensurate with the supply
of concrete from the mixers. The vibration
shall continue during the whole period occu-
pied by placing of concrete, the vibrators being
adjusted so that the centre of vibrations ap-
proximates to the centre of the mass being
compacted at the time oCplacing.
5.4.3.2. Concrete shall be judged to be prop-
erl y compacted, when the mortar fills the spaces
between the coarse aggregate and begins to
cream up to form an even surface. When this
condition has been attained, the vibrator shall
be stopped in case of vibrating tables and
external vibrators. Needle vibrators shall be
withdrawn slowly so as to prevent formation of
loose pockets in case of internal vibrators. In
case both internal and external vibrators are
being used, the internal vibrator shall be first
withdrawn slowly after which the external vi-
brators shall be stopped so that no loose pocket
is left in the body of the concrete. The specific
instructions of the makers of the particular type
of vibrator used shall be strictly complied with.
Shaking of reinforcement for the purpose of
compaction should be avoided. Compaction
shall be completed before the initial setting
starts, i.e. within 30 minutes of addition of
water to the dry mixture.
5.4.4. Construction Joints
5.4.4.1. Concreting shall be carried out con-
tinuously upto the construction joints, the po-
sition and details of which shall be as shown in
structural drawing or as indicated in fig 26 or as
directed by Engineer-in-charge. Number of
such joints shall be kept to minimum. The
joints shall be kypt at places where the shear
force is the minimum. These shall be straight
and shall be at right angles to the direction of
main reinforcement.
5.4.4.2. In case of columns the joints shall be
horizontal and 10 to 15 cm below the bottom of
the beam running int~ the column head. The
portion of the column between the stepping off
level and the top of the slab shall be concreted
with the beam.
5.4.4.3. When stopping the concrete on a ver-
tical plane in slabs and beams, an approved
stop-board (see fig 26 c) shall be placed with
necessary slots for reinforcement bars or any
other obstruction to pass the bars freely without
.bending. The construction joints shall be keyed
by providing a triangular or trapezoidal fillet
nailed on the. stop-board. Inclined or feather
joints shall not be permitted. Any concrete
flowing through the joints of stop-board shall
be removed soon after the initial set. When
~oncrete is stopped on a horizontal prane, the
surface shaH be roughened and cleaned after
the initial set.
5.4.4.4: When the work has to be resumed, the
joint shall be throughly clealled with· wire
brush and loose particles removed. A coat of
neat cement slurry at the rate of 2.75 kg of
cement per square metre shaH then be applied
, on the roughened surface before fresh concrete
is laid.
5.4.5 Expansion joints
Expansion joints shall be provided as shown in
the structural drawings or as indicated in Fig 10
to 25 or as directed by Engineer-in-charge, for
'83
the purpose of general guidance. However it is
recommended that structures exceeding 45 m
in length shall be divided by one or more
expansion joints. The filling ofthse joints with
bitumen filler, bitumen felt or any such mate:'
rial and provision of copper plate, etc. shaH be
paid for separately in running metre. The mea-
surement shall be taken upto two places of
decimal stating the depth and witdth of joint.
'5.4.6. Curing
After the concrete has begun to harden Le.
about 1 to 2 hours after its laying, it shaH be
protected from quick drying by covering with
moist gunny bags, sand, canvass hessian or a~y
other material approved by the Engineer-in-
charge. After 24 hours of laying of concrete,
the surface shaH be cured by ponding with
water for a minimum period of7 days from the
date of placing of concrete.
5.4.7. Finishing
5.4.7.1. In case of roof slabs the top sufface
shall be finished even and smooth with wooden
trowel, before the concrete begins to set.
5.4.7.2. Immediately on removal of forms, the
R.C.c. ,work shall be examined by the Engi-
neer-in~Charge, before any defects are made
good. '
a) The work that has sagged or contains
honey combing to an extent deterimental
,to structural safety or architectural con-
. cept shaH be rejected as given in para
5.4.9.4.for visual inspection test.
b) Surface defects of a minor nature may be
accepted. On acceptance of such a work
,by the Engineer-in-Charge, the same shaH
be rectified as follows :-
1. Surface defects which require re-
pair ~
when forms are removed,
'
usu-
allycOrfsist of bulges due to move-
mentofforms, ridges at form joints,
honey-combed areas, damage re-
sulting from the stripping of forms
and bolt holes, bulges and ridges are
 bond between concrete and plaster.
Normally,
Shallow
removed
Holes
Large
The
Tiered andpatches
left
by
surface
exposed
holes
e surrounding concrete, pos-
fine taken as
hardened with
patches
bywhichare
careful
deep bolts
surfaceis
extending
thepossible,
concrete.
appear
first
chipping
patchesare
to
ofR. treated
filled
require
receive
rightC. darker
or
C. tool-
with
fill-
plaster
work
through shall
c)
7.
d) or~ ..'sonry
where
be
it
the
Where
,j
cement
0.5sqm
evensurface
RCC
forshaIl
ishing
crete.
~and) 6the
ing itin
surface
material
plastered
Where
be
'Curing
white
completely,
RCC
shall be
thickness
hacking.
~oved,
ture, it
shall
''Cto
The
:3
locations
edied is
in
convenient.
exceeding'wall,
important,
the 6fine
to
each
cleaned
surface
determined
The
work
hessian
possible,
pOund mortar,
mm
made be
true
which
in
with
uniform
mm
shall
must
portland
roughening
purpose
Before
place.
taking without
shall
by in
prevent
such
be
same
thick,
may
for
ofitA sand)
be
after
addingjoined
location
to
the
is
may
these to
be
and
be
t!ris
of not
byexact
done
plaster
the
membrane
con~idered
care
exposed
early
amount
of
remains
line
patches
cement more
trial
plastering
necessary
the
this
tortmove
thickness
with
is
and
surface
give
properly
yVettedso
started
cement not
to
required
surface
of
is brick
permanently
form.
asplastered
~hould
mortarJ:3
colour
smooth
roughend
than
.quantity
distrurbing
be shall
used
defect
cases
10 be
carefully
patch
difficult
to but
20not
is
shall
will
specification.asdone
the
curing
exposed
drying.
care
surface
the
to
theto
soon
deduction
in
finished
done.
percent
beto
be 6Damp
for not
ma-
Any
being
so
plastered,mm.be
(1
and
give
patch-
con-
some
laitance
surface
cure
exceeding
is _
as
by
that
hold
.rem-
mostof
fin-
com-
the
the
immediately
surrounding
'exposed
mixed as to view
dry as inwhole
after
concrete structure.
shuttering
by
the completed float-
wit:}:l is re-
just struc-

84
e) The surface of RCC 'slab on which the
cement concrete or mosaic floor is 'to be
laid shallbe roughenedwithbrushes~hile
the concrete is green. This shall be done
without disturbing the concrete.
5.4.8: I Strength of Concrete
The compressive strength on work tests for
differentmixes shall be as given in table below.
Table
5.4.9. Testing of Concrete
5.4.9.0. Regular mandatory tests on the consis-
tency and workability of the fresh concrete
shall be done to achieve the specified compres- ,
sive strength of concrete. These will be of two
types
(a) Mandatory Lab. Test
(b) Mandatory Field Te~t
Results of Mandatory Field Test will prevail
over mandatory Lab. Test.
5.4.9.1.
(a) Work Test-Mandatory Lab. Test shall be
carried out as prescribed in Appendix A,
page 105
(bY Mandatory Field Test (Hammer Test).
sp.allbe camed out as prescribed in Ap-
pendix B, page 107
, -
5.4.9.2. Additional Test - Additional test, if
required; shall be carried out as prescribed in
Appendix C, page 108
85
5.4.9.3. Slump Test: This test shall be carried
out as prescribed in Appendix D of Chapfer 04
concrete
5A.9.4. Visual Inspection Test: The concrete
will be inspected after removal of the form
work as desribedin para 5.4.7.2. The q\festion
of carryillg out mandatory test or other tests
described in Appendix C (para 5A9.2.) will
arise only after satisfactory'report of visual
inspection.
The concrete is liable to be rejected if
(i) it is pOrous or honeyco]I1bed'as per para'
5.4.7.2.(a)
(ii) its placing has been interrupted without
providing a proper construction joint'
(iii) the reinforcement has been displaced be-
yond t~ler~mcespecified; or construction
tolerances have not been met.
However, the hardened concrete may be ac-
cepted after carrying out suitable remedial mea-
sures to the satisfaction of the Engineer-in-
charge at the risk and cost of the contractor.
5.4.10 Standard of Acceptance
5~4.10.1Mandatory Lab. Test.
For concrete sampled ~nd tested as prescribed
in Appendix A, page 105 the following re-
quirement shall apply.
5.4.10.2. Out of six sample cubes, three cubes
shall be tested at 7 days and remaining three
cubes at 28 days, if found necessary.
5.4.10.3 7 days' tests
Sampling: The average of the strength of three
specimen shall be accepted as the compressive
strength ofthec0!1crete provided the variation
in strength of individual specimen is not more
than ± 15% of the average. Difference between
the maXimum and minimum strength should
not exceed 30% of average strength of three
speCimen.If the difference between maximum
and minimum strength exceeds 30% of the
average strength, then 28 days' test shan have
to be carried out.
Strength : If the actual average strength of
sample accepted in para 'sampling' above is
equal to or higher than specified strength upto
15%, then strength of the concrete shall be
considered in order.
In case the actual average strength of sample
accepted in the above para is lower than the
specified or higher by more than 15% then 28
days' test shall have to be caf!ied out to deter-
mine the compressive strength of concrete
cubes.
5.4.10.4. 28 days' test
(a) The average of the strength of three speci-
men be accepted as the cQmpressive
strength of the concrete provided the
,strength of any individual cube shall nei-
ther be less then 70% nor higher than
130% of the specified strength.
(b) If the actual average strength of accepted
sample exceeds specified strength by more
than 30%, the EI"!-gineer-in-charge, if he
so desires, may further investigate the
matter. However, if the strength of any
individaul cube exceeds more than 30%
of specified strength, it will be restricted
to 130% only for computation of strength.
(c) If the actual average strength of accepted
sample is equal to or higher than specified
strength upto 30% then strength of the
concrete shall be considered in order and
the concrete shall be accepted at full rates.
(b) If the actual average strength of accepted
sample is less than specified strength but
not less than 70% of the specified strength,
the concrete may be accepted at reduced
rate at the discretion of Engineer-in-
charge (See para 5.4.13.2).
(e) If the actual average strength of accepted
sample is less than 70% of specified
strength, the Engineer~in-charge shall
reject the defective portion of work repre-
sented by sample and nothing shall be
paid for the rejected work. Remedial
86
measures necesary to retain the structure
shall be taken at the risk and cost of
contractor. If, however, the Engineer-in-
Charge so desires, he may order addi-
tional tests (See appendix C page 108) to
be carried out to ascertain if the structure
can be retained.' All the charges in con-
nection with these additional tests shall
be borne by the contractor.
5.4.10.5.Acceptance Criteria of Mandatory
Field Test
(A) Preparation of Standard test cubes for
calibration of rebound hammer at site.
(a) In the beginning the standard test
cubes of the specified mix shall be
prepared by field units before un-
dertaking any concrete work in each
project.
(b) At least 18 standard cubes necesary
for formaion of one specimen of
specified mix. shall be cast by site
staff well in advance. From these 18
cubes any 3 cubes may be selected
at random to be tested for crushing
strt>'1.gthof 7 days. The crushing
strength obtained should satisfy the
specified strength for the mix as per
specification or agreemen!. If the
strength is satisfactory then the re-
maining cubes will form the stan-
dard'samples for calibration of re-
bound hammer. In case of failure,
the site staff should totall y reject the
samples and remove them also and
then make another set of samples by
fresh mixing or alternatively, out of
the remainiung 15 cubes, 3 cubes
will be tested on 28 days. If the 28
days' tests are found, satisfactory
then remaining 12 cubes will form
the standard sample for calibration
at 28 days' strength otherwise all
samples shall be rejected and whole
procedure repeated to form a fresh
specimen. All the results shall be
recorded in a register.
87
 ber'i.e. ±25% or otherwise whole'
procedure shall have to be repeated
and fresh specimen prepared.
These 8 cubes will form one stan-
dard sample in the beginning before
commencement of work and shall
be ;kept carefully for the visiting
officers who will calibrate their ham-
mers on these cubes.
(d) This calibration will be done by
field staff with their hammer and
then chart of calibration giving the
details of the average readings, date
& month' of casting, mix of the
- concrete etc. shall be prepared and
signed by Engineer-in-Charge and
will be duly preserved for future
reference as and when required
(C) Preserv~tion of cubes at site
Standard sample cubes cast shall be care-
fully, preserved at site under the safe
custody of AE or his representative for
making them available -together withthe
charts, to the officers of QCT NCfE or
any other senior departmental- officer,
during their inspection of the work. They
,will calibrate their hammer on these cubes
if required.
(D) Testing at site
(D-I) Testing equipments
(D-2) Testing will be done generally by
non-destructive methods like re-
bound ,hammers etc. Each field
Division/Sub Division/Unit will
purchase rebound hammers and
keep them in working order at
work site. The testing will be done
only by hammers which are duly,
calibrated.
(D- 3) The relative strength of actual field
work will be tested with reference
to strength of these standard cubes
and calibration charts of a hammer
for determining the rebound num-
ber on the field work. The hammer
will be used as per manufacturer's
guidelines at various locations cho-
sen at random. The number of
location/reading on each wall;
beam or column etc. shall not be
less than 12. All the readings
should be within the ±25% range
of values presribed in calibration
chart:r1ormally. However, reading
indicating good strength will be
t..
when it is at par with calibrated
value or between 100% & 125%
and very g~ if more than 125%.
Any value between 100% & 75%
of calibrated value shall be consid-
eredsatisfactory. Values from 75%
to 50% shall be considered for
payment at rates reduced on prorata
basis. The concrete indicating re-
bound number less than 50% of
calibrated value shall be rejected
and not paid for.
(E) Acceptance of Field tests and strength
If the relative strength of actual field
work is found satisfactory considering
the calibration charts with ' reference to '
.
the standard cube test kept at site, the
representative work will be considered
satisfactory. If the work is considered
below satisfactory, the same will be dealt
as stated in para D- 3 above.
(F) 7 days' strength in rare cases only
Normally cube crushing strength on'28
days' test shall form the basis of accep-
tance. However in rare cases of time
bound projects/urgent repairs 7 days' cube
test strength criteria may 1Je adopted on
similar lines using 7 days' standard test
cubes and calibration graphs/curves/charts
for 7 days' in lieu of 28 days' and testing
work done at 7 days'.
(G) Precautions
(G-1) The testing shall be done gener-
ally as per the guidelines of manu-
88
 '-

facturer of the apparatus & strictly (h) Stair-cases including waist or waistless
in accordance willi the procedure slab but excluding landing except in (i)
laid down in clause 6 of IS 13311 below.
(part 2): 1992 Indian Standard for
Non-Destructive Testing of con- (i) Spiral stair-case (including landing)
crete-Method of Test by Rebound (j) AJches, arch ribs, domes and vaults
Hammer.
(k) Olimneys and shafts
(0-2) The rebound ha.."llmers are influ-
enced by number of factors like (1) Well steining
type of cement aggregate, ,surface ,,(m) Vertkal and horizontal fins individually
conditions, moistllre content, age
or fonning box, louvers and facias.
of concrete & extent of calibration
of concrete etc. Hence care shall (n) Kerbs, steps and.the like.
be taken to compare the cement,
(0) String courses, bands, coping, bedplare.s,
aggregate etc. and tested under the·
anchor blocks, plain window sills a.nd the
similar surface conditions having like.
more or less same moisture con- ..
tent and age. However· effect of (p)" Mouldings as in cornices window sills
age' can be .ignored for concrete etc.
between 3 days & 3 months old.
(q) Shell, dome and folded plates.
5.4.H. Measurement
(I') Extnt for shuttering in circular work in
5.4.11.1 Dimensions shall be measured near· plan ...
est to a em except for the thickness of slab
5.4.11.3. Work under the following catergories
which shall be measured correct to 0.5 cm. The
shall be measured separately.
areas shall be worked out nearestto 0.01 sq. mt.
The cubical contents shall be worked out to (a) Rafts, footings, basis of columns etc. and
nearest 0.01 cubic metre. mass concrete.

S.4.n.2. Reinforced cement concrete whether (b) All other items

, upto floor two level
cast-in situ or precast 3hall be classified and
(c) From floor two level to floor threeJevel
measured separately as follows. and so on.
(a) Raft, footing, bases of columns etc. and (d) R.C.C. above roof leve.l shall be mea-
mass concrete.
sured along with R.C.C. work in floor
(b) Walls (any thickness) including attached just below.
pilasters, buttresses, plinth and string 5.4.11.4. No deduction shall be made for the
course, fillets etc.
following:
....
(c) Suspended floors, roofs, landings and
"

'. balconies. (a) Ends ofdis-similarmaterials (e.g. Joists,

beams, post griders; rafter:s, purlins
(d) Shelves trusses, corbels steps etc.), upto500sq cm
in cross-section.
(e) Chajjas
(b) Opening upto O.1.sqrn
(1) Lintel, beams and bressummers.

(i) Columns, pillars, piers, abutments, posts Note: In calculating area ,of openings
arid
-"
struts. upto 0.1 sqm the size of opening shall

7-4/CPWD/ND/92 89
 If
The the
Beams columns
actual
shall payment,
dimensions
measurement
be measured however,
decrease
shall
from
Whenever
exceed be
thethe
taken
more
faceto these charge
aresign
tolerance
not dimensions
following
apply.
de-clarification shall
specificed, be specified
limit
procedure
asstrength, final.
by permis-
the moreFor the
thanpurpose
for above, thethetoler-
measurements of shall
de-
\\-'here
The
Chajjas
For
Slabs
include the
volume
volume
the band
alongwith
acceptance
shall and
beoccupied
occupied
taken
of
thickness lintels
RCCits by
anyare
ofbyrunning
as bearing of the
reinforcement
water
members on
separate same
pipes,
wall
continu-
whose<'
lin- 5.4.12.
that
5.4.13.2.
tectural
described
5.4.13.
als
of
in case
being
(c)
(b)
When
specified Tolerances:
structural
5.4.13.1. concept
specified
and of
less
(a) " above
Rate
labour
The
On
actual
than
If
bers
tolerances
in safety
the
the
the does
rateexcept
involved
do
dimensions basisisnot
not
includes
average
specified
actual
innot the
drawings not
Subject
of in impaired
hamper,
forratethe toof
mandatory
exceed the
dimensions
dimensions
of the all
by the
cost
payable
compressive
strength or the
cost
but and
tole
of archi-
condition
maces
centring
operations
of
decrease
are
the
members lab
shall
materi-
ofRC.e. tests,
strength
upto
permitted,70%
the
designer.
plus be\!idesign
or ,
mem-
gsha dimensions,
dimensions
than
shall
actual
ment
neer-in-Charge
sible tolemance
shaH
payment.
purpose
given
Designer, the
be
and
ifbe ·are
dimensionsthe
tolerance
taken for
payment.
shall
after
ofmeasured decision
the
measurements.
innecessary.
para a, bbe exactly
oflimit
purpose
&decidedthe
consulations RCC as
Engineer-in-
specified,
the by
cforabove ofper design
measure-
members
the
shallWith
purpose Engi- ofminus
the
the
apply.
gas
in
as r. from
such
combined
from
in thebuilt
cavities
the
dimensions
chajjas,
and
ance
sign bottom
shuttering.
limit,
dimensionstheand
with
face to of
ofdesign
in RC.C.slab
holes.
lintel,
face
bearing
shall to
ofslab
the the
or
beam.
members
shall
dimensions
be taken bottom
beam, theofbe as (d)
beforshall
mea-
only
e.e

90
 in the same proportion as actual average com-
pressive strength bears to the specified com-
pressive strength.
Example:
1. Average compressive strength is 80% of
specified strength. Rate payable shall be
80% of agreement rate
2. In case average compressive strength is
less than 70% of the specified strength,
the work represented by the sample shall
be rejected.
3. However, on the basis ofmandatory field
tests, where they prevail, the rates of the
work represented by samples showing
actual compressive strength less than
specified strength shall be worked out as
per para 5.4.10.5 (D-3) above. In addi-
tion, Engineer-in-charge may order for
addition'al tests (see Appendix 'c' on
page 108) to be carried out at the cost of
contractor to ascertain if the portion of
structure where in concrete represented
by the samples has been used, can be
retained on the basis of these tests. Engi-
neer-in-charge may take further remedial
measures as necessary to retain the struc-
ture at the risk and cost of the contractor.
5.4.13.3 Where throating or plaster drip or
moulding is not reuired·to be provided in RCC
chajjas, deduction for not providing throating
- or plaster drip or moulding shall be made from
the item ofR.e. e. in chajjas. The measurement
for deduction item shall be made in running
metres correct to a cm of the edge of chajja.
5.4.13.4. No extra payment for richer mix
which projects into any member from another
member during concreting of junctions of beams
arid columns etc. will be made except to the·
extent structurally considered necessary and
when so indicated in the structural drawings.
The payments for work done under items of
different mixes shall be limited strictly to what .
is indicated in the structural drawings.
91
5.5 .. Encasing Rolled Steel Sections
5.5.1. Before concrete work is started, the
Engineer-in-charge shall check that all rolled
steel sections to be encased, have been erected
truly in position. The sections shall be unpainted
and shall be wire brushed to remove the loose
rust/scales etc. Where so specificed,
ungalvanised metal, having mesh or perfora-
tions large enough to permit the free passage of
12.5 mm nominal size aggregate through them,
shall be wrapped round the section to be en-
cased in concrete and paid for separately.
5.5.2. Wrapping
5.5.2.1. In case of columns, the wrapping shall
be alTanged as illustrated in Fig: 27 to pass
through the centre of the concrete covering.
The wrapping of the entire length of the col-
umns be carried out in stages and no stage shall
cover more than 1.5 metre of height of col-
umns. Successive wrappings shall be carried
out only afterthe immediate adjacent wrapping
has been encased in concrete. The surface and
edges of the flanges of the steel columns shall
have a concrete cover of not less than 50 mm.
The wrappings of successive stages shall ~
tied together.
5.5.2.2. In the case of beams and grillages, the
wire mesh or expanded metal shall be wrapped
round the lower flange of the beam as illus-.
trated in Fig 28 and the wrapping shall be
suspended by wire hangers 5 mm diameter
placed at about 1.2 metres centres. The surfaces
and edges of the steel sections shall have a
concrete cover ·of not less than 5Omm. The
wrapping shall pass through the centre of the
concrete covering at the edges and soffits of the
flanges.
5.5.3. Form work shall be as prescribed in
5.2
5.5.4. Concreting: Concrete shall consist of
a mix of 1:2:4 (1 cement: 2 coarse sand :4
graded stone aggregate of 12.5 mm nominal
siz~) unless a richer mix is specified. The mix
shall be poured solidly around the steel sec-
tions and around the wrapping by vibrating the
concrete into position. Consistency of con-
crete, placing of concrete and its compaction,
curing, finishing and strength of concrete shall
be as described in 5.4.
5.5.5. Measurements: The length shall be
measured correct to one cm and other dimen-
sions correct to 0.5 em. The cement concrete
shall be measured as per gross dimensions of
the encasing exclusive of the thickness of plas-
ter. No deduction shall be made for the volume
of steel sections, expanded metal, mesh or any
other reinforcement used therein. However, in
case of boxed stanchions or girders, the boxed
portion only shall be deducted.
Fabric reinforcement such as expanded metal
shall be measured separately in square metres
stating the mesh and size of strands.
The description shall include the bending of the .
fabric as necessary, Raking or circular cutting
,and waste shall be included in the description.
5.5.6. Rate: The rate shall include the cost of
materials and labour required for all the opera-
tions described above except the cost of fabric
reinforcement. The cost of providing and erect-
ing steel section and wire hangers shall be paid·
for separately.
5.6. PRECAST REINFORCED CON-
CRETE
5.6.1. General requirements: Precast rein-
forced concrete units such as columns. fencing
posts, door and window frames, lintels, chajjas,
copings, sills, shelves, slabs, louvers etc. shall
be of grade ormix as specified and cast in forms
ot moulds. The fonnsJmoulds shall be of fibre
glass or of steel sections for better finish.
Provision shall be made in the forms and
moulds to accommodate fixing devices such as
nibs, clips, hooks, bolts and forming of notches
and holes. The contractor may precast the units
on a cement or steel platform which shall be
adequately oiled provided the surface finish is
of the same standard as obtained in the forms.
Each unit shall be cast in one operation.
·92
5.6.2. Concrete used for precasting the units
should be well proportioned, mixed, placed
and thoroughly compacted by vibrations or
tamping to give. a dense concrete free from
voids and honeycombing.
5.6.3. Precast articles shall have a dense sur-
face finish showing no coarse aggregate and
shall have no cracks or creyices likely to assist
in disintegration of concrete or rusting of steel
or other defects that would interfere with the
proper placing of the units. All angles of the
precast units with the exception of the angles
resulting from the splayed or chamfered faces
shall be true right angles. The arises shall be'
clean and sharp except those specified or shown
to be rounded. The wearing surface shall be
true to the lines. On being fractured, the interior
of the units should present a clean homoge-
neous appearance.
5.6.4. The longitudinal reinforcemwtshall
have a minimum cover of 12 mm or twice the
diameter of the main bar, whichever is more,
unless otherwise directed ~in respect of all
.items except fencing posts or electric posts
where the minimum cover shall be 25 mm:
5.6.5. 'Curing
After having been cast in the mould or form the.
concrete shall be adequately prot\::cted during
setting in the first stages of hardening from
shocks and frol1l,harmful effects of frost, sun-
shine, drying winds and cold. The concrete
shall be cured at least for 7 days from the date
of casting.
5.6.6. The precast articles shall be matured
for 28 days before erection or being built in so
that the concrete shall have sufficient strength
to prevent damage to units when first hand1ed.
5.6.7. Marking :Pr~cast units shall be clearly
marked to indicate the top of. member and its
location and orientation in the structure.
5.6.8. Precast units shall be stored, trans-
ported and placediil position in such a manner
that they will not be overstressed or damaged.
 5.7 PRECAST CEMENT CONCRETE
JALI
5.7.0. The jail shall be of cement concrete
1:2:4 (1 cement :2 coarse sand: 4 stone aggre-
gate 6 mm nominal size) reinforced with 1.6
mm thick mild steel wire, unless otherwise
specified.
5.7.1 Fixing: The jali shall be setin position
true to plumb and level before the joints sills
and soffits of the openings are plastered. It shall
then be properly grouted with cement mortar
1:3 (lcement:3 coarse sand) and rechecked for
levels. Finally the jambs, sills and soffits shall
be plastered embedding the jali lmiformly on
all sides.
5.7.2. Measurements The jail shall be mea-
sured for its gross superficial area. The length
and breadth shall be measured correct to a cm.
The thickness shall not be less than that speci-
fied.
5.7.3 Rate: The rate shall be inclusive of
materials and labour involved in all the opera-
tions described above except plastering of
jambs, sills and soffits, which will be paid for
under rel~vant items of plastering.
5.8' DESIGN MIX CONCRETE
5.8.0 Definition: Design mix concrete is.
that concrete in which the design of mix Le the
- determination ofpr<?portionsof cement, aggre-
gate & water is arrived as to have target mean
strength for specified grade of concrete.
5.8.1. Materials:
5.8.1.1. Cement (:One of the following types
of Cement as sp¢cified shall be used:
1. Ordinary Portland Cement 33 grade
conforming to IS 269-1989.
2. Ordinary Portland Cement 43 grade
conforrriing to IS 8112-1987.
3. Ordinary Portland Cement 53 grade
conforming to IS 12269-1987.
4. Rapid hardening Portland Cement Con-
forming to IS 8041-1990.
5. Blast Furnace slag cement conforming to
IS 455-1989.
However for severe condition~ of sulphate
content in sub soil water, special literature on
use of sulphate resisting cement may be re-
ferred to. For supply and storage para 3.1.2.1.
and 3.1.2.2. shall be applicable.
5.8.1.2 Coarse Aggregate
This shall be as specified in para 4.1.2 i/c
subparas.
5.8.1.3.Fine Aggregate: This shall be of
grading zone I, II or III as specified under para
3.1.4 ilc sub paras.
5.8.1.4. Water: It shall conform to the require-
ment as l~d down in IS 456-1978 para 4.3 and
para 5.1.1 of this chapter.

It will be designed based on the principles

given in I.S. 456-1978 and SP 23-1982" Hand-
book for design mix concrete".
In order to ensure that not' more than the
specified proportion of test results are likely to
fall'below the characteristic strength, the con·
crete mix has to be designed 'forhigher average
compressive strength and this higher average
compressive strength for a specified grade of
concr~te is defmed a target mean strength:

93
5.8.1.5. Grades of concrete 5.8.3.2. Minimum cement content required in
Reinforced cement concrete to ensure durabil-
The compressive strength of various grades of
ity under specified conditions of exposure, will
designation concrete shall be as given below: be in accordance with I.S. 456-1978. However
it shall nOtbe less than 300 Kgs/m 3 of concrete
Grades Designation Comprssive Specified for 33 grade cement.
strength on characterstic
15cm compressive 5.8.3.3. (a) Standard Deviation of concrete for
Cubes strength at
min at 7 days 28 days. each grade shall depend upon the degree of
(N/mm2) (N/mm2) quality control expected to be excercised at
site. As per IS 10262-1982 the values of stan-
M 15 25
20
30
15
35 20.0
23.5
10.0
17.0
13.5
dard deviation for various grades of concrete
for different degree of control shall be as speci-
fied in table V.

Table V

Grade of Standard Deviation for different

Note:ln the designation of a concrete mix letter M
degree of control
refer to the mix and the number to the specified
concrete In N/mm2
characterestic compressive strength of 15 cm- cube
at 28 days expressed in N/mm2• 5.6
7.7
7.0
4.5
6.3
4.6
3.5
6.0
6.7
5.3 4.3
5.0
5.7
2.5
3.6
FairGood
Very Good

5.8.2. Scope: M25 M30

M35
M20
M15 procedure described be-
The
low for design mix is for concrete upto grade
M-35 which are generally used for reinforced
concrete structure. Minimum grade of concrete
for design mix will be M 20 normally. How-
ever in cases of projects having some parts of
M15 also in addition'to M 20 to M35 grade,
then design mix concrete will cover M-15
grade as an exception only.

5~8.3. Data for Mix Design.: Tne following (b) Degree of quality control expected under
basic data are required to' be specified for different site conditions are described in
design of concrete mix. table VI.

(1) Characteristic compressive strength of

concrete at 28 days'. .Table VI

(2) Degree of workability desired.

(3) Limitation on water cement ratio and Degree of Condition of Production of

minimum cement content to ensure ad- control concrete
equate durability.

(4) Type and maximum size of aggregate to

be used. Very Good: Fresh cement from signle source
and regular tests, weighbatching
(5) Standard deviation of compressive
of allmaterials, aggregates grad-
strength of concrete:

94
 ing and moisture content, control
of water added, frequent supervi-
sion, regular workability and
strength tests and field labora-
tory facilities.
such case value oft will be 1.65 and
equation will reduce to Tck = fck
+ 1.65 s
5.8.3.5. Selection of proportions

Good: Since different cement, aggregate of different

Carefully stored cement and pe-
riodic test, weighbatching of all
materials, controlled water,
graded aggregate supplied, occa-
sional grading and moisture tests,
periodic check of workability and
strength, intermittem supervision
and experienced workers.
Pair: Proper storage of cement, vol-
ume batching of all aggregates
maximum size, grading surface texture shape,
produce concrete of different compressive
strength for the same free water cement ratio,
the relationship between strength and free wa-
ter cement ratio con'esponding to 28 days'
strength of cement of various grades is given in
Fig~l of IS 10262- 1982and is reporduced
below in chart 1.
28 OA~ 5fREtlGTH
\E5T~t? ACCORDING
a TO
c.f'.)\EI-\T
"/

allowing for bulking of sand, I. 5: 403) - \ 1 6 g,

weighbatching of cement, water A"" 3\ ''1- 3&" h tV1"M"'}-(?>2C;-375;:~ f

content controlled by inspection (..,l.)
~,,g-4/·7 rdJnJ?t(37!'_42'71'-~!CY
of mix and occasional supervi- 17.::.

sion and tes~s. ., C=41·H·(,·6 t1!-»>,,;'-(42S-41, t+J1c.Z)

9' "'<;.0- 5I,1jN/"""'Y47§-~25 "j/o.;'

5.8.3.4. Target strength
!: :0 S'I,$--Vb'4t-I/,.,,,,t72S--,75I(j';j,
f ==5'6,4-<::1:3
~J..,",Y'i75-t.2' Y-J/0
for Mix Design: . f - RELATIDII &TweEt-)
CHAJ'f

oL J I I I I I I H<,\;~WATt::R..
Ct'-!'\.fATIQ ANP
o,3C> 0'35 O,4D bA? o,~o 0.55 0.'0 0.<:;; cow:.. 5WtNGT.f1 fOR.1:>lff[;-
The target mean strength for a specified grade WATt:1< CEI"ENT RATIO .RENT cj'Ot.I\. S\R.G~H1S.
of concrete depends upon the quality control (a) The free water cement ratio selected from
(expressed by standard deviation) and accepted Chart 1 above should be checked against
proportion of results of the strength tests below the limiting water cement ratio for re-
the characteristic strength (Fck) and is given by quirement of durability as given in IS
456-1978 and the lower of the two values
relation, Tck = fck + t.S
is to be adopted.
Tck - target mean compressive strength at (b) Estimate of Air Control
28 da~s
The amount of entrapped air for normal
fck - Characteristic compressive strength
mix (non air entrained) concrete a~per IS
at 28 days 10262 - 1982 is given in table VII.
s - Standard Deviation
Table VII
t a statistical figure depending upon
the accepted proportion of low test Nominal miximum Entrapped air as
results and number of tests.
size of Aggregate precentage of volume
of concrete
Note: According to IS 456-1978 & IS
1343~ 1980 the characteristic 10mm 3.0
Strength is defined as that value 20mm 2.0
below which not more than 5 % (1 in 40mm
1.0 '.:;
20) results are expected to fall. In

95
(c) Selection of water content and fine to
total aggregate ratio -Based on experi-
ence, emperical relationship have been
established between quantity of water per
unit volume of concrete and ratio of fine
aggregate to total aggregate by absolute
volume for desired workability. The esti-
mated values for concrete upto M 35
grade are given in table VIII.

absolute
30
35
Sand
total %volume
165
40 aggregate
as208
186 Table
Water
age
per of vrn
content
cubic
by metreinofkgs

A) The values given in table VIII are based iv) Workability corresponding to com-
on the following conditions: pacting factor of 0.8

i) Crushed coarse aggregate conform- B) For other conditions of workability, wa-

ingtolS 383-1970 and para 4. 1.2 of ter cement ratio, grading of fine aggre-
this specification. gate and for round aggregate, certain
ii) Fine aggregate consisting of natural adjustment in quantities of mixing water
sand conforming to grading zone II and fine to total aggregate ratio as given
of IS 383-1970 and para 3.1.4 of in table VIII are to be made as per IS
this specifications. 10262-1982. These are explained in Table
IX below.
iii) Water cement ratio (by mass) of 0.6
and
Table IX

Change in conditions Adjustment required in

stipulated for TabieVIII water content Percentage of fines to
total aggregate

(a) For sand conforming to

grading Zone I & III of
IS 383-1970 o + 1.5% for Zone I
-1.5% for Zone III
(b) Increase or decrease in the value
of compacting factor by 0.1
For increase +3.0% o
For decrease --3.0%
(c) For each 0.05increase or decrease
in free water - cement ratio
For increase o + 1.0%
For decrease o -1.0%
(d) For rounded aggregates -15 kg/m3 -7%

96
 C) Comparison of consistency measure-
ment by various methods-

Workability Slump Compacting factor

description mm

Extremely dry

Very Stiff 0.70-

Stiff 0-25 0.75

Stiff Plastic 25-50 0.85

Plastic 75-100 0.90

Flowing 150-175 0.95

5.8.3.6 Calculation of aggregate Content aggregate and coarse aggregate)

With the quantities of water and cement per Sfa,Sca = Specific gravities· of saturated sur-
unit volume of concrete and ratio of fine to total face dry fine aggregate and coarse
aggregate content per unit volume of concrete aggregate respectively.
to be calculated from the following equations
5.8.3.7 Calculation of Batch Masses
1
The masses of various ingredients for concrete
for design mix of a parti~ular batch size may be
. v=[+['C~ 1
+ -;- x fa]
Sfax 1000 calculated as described above.

5.8.4 Production of controlled concrete

v=E+~+_l
Sc 1-P
x~J
Sca
x_I 1000 The calculated mix proportion shall be checked
by means oftrial batches. Quantities of materals
v = absolute volume· of fresh concrete
worked out in accordance with para 5.8.3.1 to
which is equal to gross volume (m 3) 5.8.3.6 described above shall be termed as trial
minus the volume of entrapped air. mix no. 1. The quantities of materials for each
w trial mix shall be sufficient for atleast three
mass of water (kg) per m3 of con-
crete 150mm size cube concrete specimens and con-
crete required to carry out workability test
c =
= mass of cement (kg) per m3 of con- according to IS 1199-1959.
crete
Fa,Ca = '5.8.4.1 Workability of Trial.Mix No.1 shall be
pSc ratio of fine aggregate to total ag- measured. The mix shall be carefully observed
gregate by absolute volume for freedom from segregation and bleeding and
its finishing properties. If the measured work-
specific gravity of cement ability of Trial Mix No. 1 is different from the
stipulated value, the water content shall be
aggregate (kg) per m3 of concrete
adjusted according to Table X corresponding
respectively (total masses of fine
to the required change in compacting factor.

97
 ·With this adjustment in water content, the mix
proportions shall be recalculated keeping the
free water-cement ratio at the preselected value
which will comprise Trial mix No.2. In addi-
tion, two more Trial Mixes NO.3 and 4 shall be
made with the water content same as Trial Mix
No.2 and varying the free water cement ratio
. by (+) 10 percent and (-) 10 percent of the
preselected value. Forthese two additional trial
Mixes No.3 and 4, the mix proportions are to be
recalculated for the altered condition of free
water-cement ratio with suitable adjustments
in accordance with Table X.
5.8.4.2 Fresh trial mixes are to be made for
different types and brands of cement, alternative
source of aggregates, maximum size and grad-
ing of aggregates.
5.8.5 Batching
In proportioning concrete,the quantity of both
cement and aggregate should be determined by
mass. Cement shall be used on the basis of
mass & should be weighed separately from the
aggregate. Water should be etthermeasured by
volume in caliberated tanks or weighed. Any
solid admixture that may be added, may be
measured by mass,liquid and paste admixture
by volume or mass. Batching plant where used
should conform to IS 4925-1968. All measur-
ing equipment should be maintained in a clean
serviceable condition and their accuracy peri-
odicall y checked.
Table X
Surface Water Carried by Aggregate
(Clause 5.8.4.1)
Aggregate
Vey wet sand
5.0
2.5 sand
Moderately_wet
Moist sand 1.25-2.5
Moist gravel to crushed
rock
Except where it can be shown to the satisfac-
tion of Engineer -in-charge that supply of prop-
erly graded aggregate ofunifonn quality can be
maintained over the period of work, the grad-
ing of aggregate should be controlled by ob-
taining the coarse aggregate in different sizes
and blending them in the right proportions
when required, the different sizes being stocked
in separate stock piles. The material should be
stock-piled for several hours preferably a day
before use. The grading of coarse and fine
aggregate should be checked as frequently as
possible, the frequency for a given job being
determined by Engineer- in -Charge to ensure
that the specified grading is maintained.
It is important to maintain the water-cement
ratio.constant at its correct value. To this end,
determination of moisture contents in both fine
and coarse aggregate shall be made as fre-
quently as possible, the frequency for a given
job being determined by the Engineer -in-
Charge according to weather conditions. The
amount of the water to be added shall be
adjusted to compensate for any observed
variations in the moisture contents. For the
determination of moisture content in the aggre-
gates, I~ 2386 (part III) -1963 may be referred
to.To allow for the variation in mass of aggre-
gate due to variation in their moisture content, .
suitable adjustments in the masses of aggre-
gates shall also be made.!n the absence of exact
data, only in the case of nominal mixes,the
amount of surface water may be estimated from
the values given in the Table X.
approximate Quantity of Surface Water
percent by Mass 11m3
7.5 20-40
40
80
120
98
5.8.6 Mixing
Concrete shall be mixed in a mechanical mixer.
'The mixer should comply with IS 1791-1968.1t
shall be fitted withhoppe.r. The mixing shall be
continuous until there is uniform distribution
of the material & the mass is uniform in colour
and consistency. If there is segregation after
unloading from the mixer, the concrete should
be remixed. The mixing time shal,l not be less
than 2 minutes.
5.8.7 Laying
It shall be done as specified under para 4. 2.4 of
this specification.
5.8.8 Curing
It shall be done as specified under para 4.3.4 of
this specification.
5.8.9 Approval of Design Mix
The preliminary test for approval of design mix
shall consists ofthree sets of separate tests and
each set of test shall be conducted on six
specimens. Not more than one set of six
specimem shall be made on any particular day.
Of the six specimens of each set, three shall be
tested at seven days and remaining three at 28
days. The preliminary tests at seven days are
intended only to indicate the strength to be
attained at 28 days.
5.8.10 Work Strength Test
Work strength test shall be conducted in accor-
dance with IS 516-1959 on random sampling.
Each test shall be conducted on ten specimen,
five of which shall be tested at 7 days and
remaining five at 28 days. Not less than one
work test consisting of tests on 10 cubes sh<!ll
be carried out for every 30 cubic metre of
concrete or less as per the lot size as specified
below.
Lot Size
Concrete under acceptance shall be notionillly
divided into lots for the purpose of sampling,
before commencement of work. The delimita-
99
tion of lots shall be determined by the follow-
ing :-
1) No individual lot shall be more than 30
m3in volume
2) Atleast one cube forming an item of the
sample representiIig the lot shall be taken
from the concrete of same grade and mix
proportions cast in any day.
3) Different grades or mixes of concrete
shall be divided into separate lots.
4) Concrete of a lot shall be used in the same
identifiable unit of the structure.
5.8.11 Standard of Acceptance
a) The average strength of group of cubes
cast for each day shall not be less than the
specified work cube strength. 20 percent
of cubes cast for each day may have
values less than the specified strength
provided that the lowest value is not less
than 85% of the specified strength.
b) Concrete strength less than specified may
as a special case be accepted in a member
with the approval of Engineer-in-charge
provided that the maximum stress in the
member under the maximum design live
load does not exceed the permissible safe
stress appropriate to the lower strength of
the concrete.
c) Concrete which does not meet the strength
requirements as specified but has a
strength greater than that of the lowest
value of 85 % may, at the discretion of the
I
designer, be accepted as being structur-
ally adequate without further testing.
d) Concrete of each grade shall be assessed
separately.
e) Concrete shall be assessed daily for com-
pliance.
t) Concrete is liable to be rejected if it is
porous or honey combed, its placirlg has
been interrupted without providing a
 proper construction joint, the reinforce- 5.8.12 An example illustrating the mix de-
ment has been displaced beyond the~tol- sign for concrete mix M 20 grade is given
erances specified, or construction toler- below.
ances have not seen met. However, the
hardened concrete may be accepted after
carrying out suitable remedial measures
5.8.12.1 Designstipulta,ion
to, the satisfaction of the Engineer-in-
'charge.

a) Characteristic compressive '

strength requjred in the field at
f8 days 20 N/mm2

b) M~ximum sizes of aggregate 20 MM (angular

crushed)

c) Degree of workability 0.9 compacting

factor (slump
75mm)

d) Good
Degree of quality cont,rol

e) '.Type of exposure Mild

5.8.12.2 Test Data of Material

a) Cement.used:- ordinary portland cement stisfying the requirements of Is 269-1989.

b) specific gravity of cement 3.15

c) Speciic gravity of

1) Coarse aggregate 2.60

2 _Hne aggregate-(natural sand) 2.60

d) Water absorptiqn of

1) Coarse aggregate 0.5 percent

2) Fine aggregate 1.0 percent

e) Free Surface moisture of

1) Coarse aggregate Nil (absorbed moisture

also nil)

2) Fine aggregate 2.0 percent

100
 5.8.12.3 Sieve analysis

a) Co~se aggregate

IS sieve Analaysis 40
Combined
28.5
3.7
40%
100.
100%100
IT
of 71.20
IT
coarse 60
060% 3.7 I
fraction
Percentage of different
on sizes
mm

20

10

4.75

2.36

The grading of combined fraction I & II in the 4.6, therefore with a tolerance factor of 1.65 the
ratio of 60 & 40 conform to table, 1 described value of target mean' strength for specified
above. characteristic cube strength=20+ 1.65x4.6=27.6
, N/mm2 :
b) Fine a~gregate
5.8.12.5 Selectionof water cement ratio
IS Sieve sizes Fine aggregate (percent .
r" .~

passing) From chart 1, the free water cement ratio re-

quired for target mean strength of 27.6 N/mm2
4.75 100
is 0.50. This is lower than the maximum value
2.36 mm 100
.of 0.6~ presrcibed for mild exposure.
1.18mm 93
5.8.12.6 Selection of water and sand
600 micron 60 content
300 micron 12
From table VIII for 20 mm nominal maximum
150 mcicron 2 size aggregate and sand conforming to grading
zone II water content as per cum of concrete is
The sand confonns to grading zone III
186 kg' and sand content percentage of tot~
aggregate by absolute volume is equal to 35%.
5.8.12.4 Target mean strengt~ ;,; For change in,value 'of water cement ratio
As described earlier for degree of qualitycon-' compacting factor, and sand belonging to zone
trol 'good' the value of standard deviation is III the following adjustment is required.

101
 water=191.6 kgs
change in condition Adjustment required in
water content percentage in cement=191.6/0.5=383 kglm3
percent total
aggregate' Thus Cement content is adequate ,for mild
for decrease in water exposure condition as as per IS 456-1978 as
described in table below.
cement ratio by (0.6-0.5)
i.e. 0.10 0 -2
5.8.12.8 Determination of coarse and fine
for increase in compacting aggregate content.
factor by (0.9-0.8)
i.e.0.l0 +3 0 From table VII for specified maximum size of
for sand conforming aggregate of 20 mm, the amount of entrapped
grading zone III 0 -1.5 air in the wet concrete is 2 percent. Taking this
into account and applying equations given in
+3' -3.5 'para 5.8.3.6

Therefore the required water content = 0.98 m3 = (191.6+38313.15+ 1/0.315. fa/2.60) x

1/1000
186+186/100x3=186+3.58=191.6 kglm3 and and
required sand content=35-3.5=31.5 percent
0.98 m3= ( 191.6 + 383/3.15 + 1/0.685.ca/2.60) x
1/1000
5.8.12.7 Determination ,
of cement Content

Water-Cement ratio = 0.5 or fa =546 kglm3 and ca=1187 kg/m3

The mix proportion now works out:

Water Cement Fine aggregate Coarse Aggregate

191.6 383 kg 546kg 1187 kg
or 0.5 1 1.42 3.0

For 50 kg cement, the quantity of materials are 2) Extra quantity of water to be added for
worked out as below absorption in case of coarse aggregate at
0.5 % by mass
a) Cement =50 kg , =154.5/l00x0.5=0.77 kg
b) Sand =71 kg 3) Quantity of water to be deducted for free
moisture In sand at 2% by mass=
c) Coarse Aggregate =154.5 kg
(-) 171.0/100x2=(-) 1.42 kg
fraction I - 92.7
fraction II - 61.8 Therefore actual quantity of water =

d) water 25.00 +0.77-1.42=24.35 kg

1) For water cement ratio of 0.5 quantity Actual quantiy of sand required after allowing
=25.0 kg ./ for mass of free moisture =71.0+ 1.42=72.42
kg

102
Actual Quantity of Coarse Aggregate
Fraction I=92.7-(O.6xO.77)=92.24
Fraction II=61.8-(OAxO.77) =61.49
Therefore the actual quaL ?':: of different
constituent required for mix are
Water=24.3;; kg
Cement=50 kg
Sand =72.42 kg,
Coarse aggregate Fraction 1=92.42 kg
Fraction H=61.49 kg
5.8.13 Measurements: shall be done is
accondance with Para 5.4.11 and its sub-paras
5.8.14 Tolerance: Para 5.4.12 shall apply.
5.8.15 Rate: Para 5.4.13 shall apply with the
exception regarding limitations for actual aver-
age compressive strength beingles than speci-
fied strength which shall be governed by para
5.8.11 for acceptance and proratat rates worked
out accordingly.
5.9.0 Precast reinforced concrete door and
window frames
5.9.1 Manufacture of precast reinforced con-
crete door and window frames is describes!
here. These willconfonn to IS 6523: 1983inall
respects unless otherwise specified. Frames
shall be manufactured in an approved factory
with all necessary - arrangements for fixing
hinges or hinges fixed at position as specified
with hole for receiving tower bolt, sliding bolt
etc. as specified.
5.9.2 Shape and dimensions
5.9.2.1 Precast reinforced concrete door and
window frames shall be 60 x 100 mm or 70
x75mm in cross section for single shutter and
60x 120 mm for double shutter door, cross
section generally conforming to fig. 29 & 30.
Where specified, suitable groo~e for receiving
wall plaster shall be provided.
103
,
5.9.2.2 The over all sizes (width and height)
shall be as per drawing or as specified.
5.9.3 Materials
5.9.3.1 The materials used for manufacturing
of the 'frames shall comply with standards
given in table I of IS 6523-1983
5.9.3.2 Aggregate
The aggregate used shalll be of well graded
mixture of clean coarse and nne aggregates.
The nominal size of coarse aggregae shall not
exceed 10 mm.
5.9.3.3 Concrete
Mix of concrete shall be as specified or as
directed by the Engineer-ill-Charge. But the
mix shall not be weaker than M 20 controlled
mix or 1:1 1/2:3 (1 cement: 11/2 coarse sand: 3,
stone aggregate 10 mm nominal size by vol.
mix) and shall be suitable for producing a dense
concrete without voids after proper vibration.
5.9.3.4 Reinforcement
There shall be a minimum of three bars of 6 mm
dia or equivalent as shown ?1 fig ..29 .. The
longitudinal reinforcement for each vertical or
horizontal member shall be one piece and shall
be firmly held by 3 mm dia ties spaced at not
more than 300 mm centre to centre.
The longitudinal reinforcement shall have a,
maximum cover of 12 mm or twice the diam-
eter of main bar, whichever is higher.
5.9.4 Casting
The entire frame may be cast complete in one
piece or each of the vertical and horizontal
members of the frame may be cast separately to
be assembeled into the complete frame at site.
When the frame is cast in separate parts, one of
the reinforcing bars of the vertical members of
the frame shall be kept projecting so as to
te~on into the corresponding hole in the hori-
zontal member. The holes in the horizontal
member for taking the projecting reinforce-
ment from the vertical members shall be sligtl y
larger than the bar diameter to faciliate easy
insertion of the projecting bar. Mter assembly
at site, the holes 'shall be grouted. with cement
slurry of 1 cement : 2 coarse sand.
5.9.5 Mould
The mould for casting shall preferably be of
steel to ensure better surface finish of the cast
frame. Provision shall be made inthe mould to
accomodate fixing devices for hinges and the
hold fasts. Wh~re specified, suitable rebates
may also be provided to act as plaster groove.
5.9.6 ,Protection & curing
After casting in moulds, during setting and in
first stage of hardening the concrete shall be
protected from shocks, running or surface wa-
ter and the harmful effect of frost, sunshine
<irving winds and cold. The concrete shall be
•• _i- •
cured for atleast 7 days unless special curing
methods are adopted which shall conform to IS
6523-1983.
The frames shall be matured before testing or
despatch for.the following periodS:
Type of cement used
Ordinary portland cement,
portland blast furnace slag cement
portland pozzolana cement
Rapid hardening cement(to be used
with approval
of Engineer~in- Incharge)
Theframes after maturing shall have sufficient
strengtll to prevent damage wh~n h<l!1dled.
5.9.7 Arrangem~nts for fi~ing of hinges to
frames: Suitable ammgements forfi,xing hinges
shall be provided in the frame by one of the
following methods as directed-(Ref. Figure
30)
a) Hardwood fixture
Hardwood blocks of well seasoned teak
or other suitable timber 150 mm long, 45
to 50 mm x 30 to 40 mm in cross secti()l1,
one block for each of the hinge, shall be
fixed in pOsition with 6 mm mild steel
bolts, nuts and washers, after the frame
has been cast, cured, and matured. After
tightening the nuts, the bolt heads and the
nuts shall be suitably covered with hard
wood fillets, finished flush with concrete
surfaces of the frame.
b) Hinge directly attached to frame. L Type
flap hinge may be attached directly to~
fr<;unewith the help of 6 mm dia, mild
steel bolts & nuts.
c) Hinge welded to frame.
The hinge may be wel¢ed to 3 mp:1 thick
mild steel flat embedded in a frame.
5.9.S Arrangements for Door and Win-
dow Fixhlres
Suitable arrangements shaH be.PJovide9 in the
frame for receiving tower bolts, sliding bolts
and other door and window fixtures as indi-
cated.
5.9.9 Fast.ners
5.9.9.1 Amangements for fixing the frames
with hold fasts or metalic fastners shall be
Period
provided in vertical members \of ,frames as
specified. In case of door frame, there will be 3
Nos. hold fasts and in case of window, there
will be 2 Nos. hold fasts on each vertical
28 'days
members in contact with the opening where the
frame is to be fixed. Holes to accomodate 10
mm dia bolts to be fixed to hold fasts and the
14 days
nuts shall be lei} at appropriate locations.
5.9.10. Erection.
5.9.10.1 Whena three piece frame is used,
the vertical members shall be held in position
with top member placed over them, the w~ole
frame plumbed and firmly supported till the
concrete around the hold fasts in the masonry
has properly set and hardened. Cement and
, coarse sand mortar slumy 1:2 shall be used ~
grouting the joints between the vertical and
horizontal members of door frame. In case
where four members are used, the bottom mem- .
ber shaH be first placed in position and other
erected on this base.
104
 APPENDIX -A
WORK TEST FOR CO~CRETE-
MANDA TORY LAB TEST
(Clause 5.4.9.1)
, -
A-O One sample (consisting of six cubes
lSx15x15 cm shall be taken for every
20cum or part thereof of concr,ete work
ignoring any part less than Scum or as
often as,considered ne,cessary by the En-'
gL'1eer-in-Charg~. The test of concrete
cubes shall be carried out in accordance
with the procedure ~ described below. A
register of cubes shall be maintained at '
the site of work in appendix D, .page
110The casting of cubes, concrete used
for cubes and all otherincidentalcharges,
such as curing, carriage, to the testing
laboratory Shall be borne by the contrac-
tors. The testing fee for the ~ubes, if any,
shall be borne,by the department.
\
A-I Test procedure -
A-I.1 Mould'
The mould shall be of size 15 cm x 15 cm
xIS for the maximum nominal size of
aggegate riot exceding40mm. For con-
crete with aggregate size more than 40
mm, size of mould shall be specified by
the Engineer-in-charge, keeping in view
th~ fact that the length of siz~ of !U0uld
should be about four times the size of
aggregate.
Th~ moulds for test specimens shall be
made of non-absorbent material and shall
be substantially strong enough to hold
their form during the moulding of test'
speciniens. They shall not very from the
standard- dimensions by more than one
percent. The moulds shall be so con-
structed that tliere'is no leakage of water
.from the test specimen during moulding. -
All the cube mould~" for particular site
should, prior to use, be checked for accu-
8-4/CPWD/ND/92::
racy in dimensions 'and geomatric form
and s~chJest should at least be made once
a year.
Each mould shall be provided with a base
plate having a plane sutface and made of
non absorbent rpaterial. ,This plate shall
be large enough in illameterto support the
moulds properly without leakage. Glass
plates not less than 6.5 mm thick or plain
metal not leSSthan 12 mm thick shall be
used for this purpose. A similar plate
. shall be p~ovided for covering the top
surface of the test specimen when moul-
ded.
NOTE: Satisfactory moulds can be made
from masJ:tYle or, steel castings.
rolled metal plastes or galvanised .
iron.
.. ,"}
A-1.2 Sample of concrete
Samples of concrete, for test specimen
shall be taken at the tfnxer or in the case
.' of ready mixed concrete fr6~ the trans-
portation vehicle discliarge or as directed
by Engineer-in-charge. Such ~amples
shall be obtained by repeatedly passing a
scoop or pail through the discharge stream
o(concrete. The saItJ.pliflg operation
should be spread over evenly to the entire
discharging operation/The sifuples thus
"obtained sha11.betransported to the place
of moulding of the specimen. To counter-
act segregation, the concrete shall be
mixed with a shovel until itis uniform in
appearance. The location in the work of
the batch ofconcrety thus sarripled shall
be noted for further reference. In case of
paving concr,ete" samples shall ~ taken
from the batch immediately after deposi-
tion of the subgrade. At ~east five samples
shall be taken from different,portion of
the pile an~ these",samplys shall be thor-
oughly mixed before being used to f<?rm
the test specimen. 11u~"sampling shall be
spread as everily as possible throught out
the day. When wide change$ occur during
105
 concretfug, 'addtional;mh.pies: shall be
":taken if so desifed by; the Engineet-in-
charge.
A-1.3 :PreRaratlon of Test Specimens
The interior surfaces of the mould and
base plate shall be lightly oiled before the
concrete is placed fu the mould. The
samples of ~ncreteobtcpned'as described
under the testspecimen shall be immedi-
ately moulded by one of the following
methOds-as iridicated below:-
When the job concrete is compacted by
manual metbogs; the test specimen shan
be moulded 1;>YI>lacing, thefresh~ncrete
in the mould in three layers, ,each. ap-
proxiffiately one t!U[d of the volume of ~
·the mould. In plac~g each' scoopful of.
concrete the scoop shall be moved around
the top edge of the It1.ouldas the concrete
there slides from i~, inordedo ensure a.
uniform distribution of concrete,;within
,the moUld~>Eachlayer shall be rOdded 35
,tiffie~With "i 6mm rod, 60 cm in length,
bullet pointed at the lower end. The strokes
shall;c~ j1iStrib~~~
~"'-; / iP.,uniform:'matmer
~ ca,fIi~d out in such a m~er
- ~-,.:~~
,"
.. '--' .,;--
over the cfus'"ssection of the mould and.
·"shallperterate irltojmderlying.layer ..The
,bOttomlayershall.be
~ ..•.. i:~.' ;-' ,,' fOdded
. ,. ". throughout
i!Sd~p~YAfter the t§p ,!,,~~, Jayer'has
-'-,' "'''''''''
>--. ~- - ..•• -~".-
rodded, the surface of the concrete shall
be,struck ~off'Yith a jrowerand covered
wiih a glass plate at leas(6~5 nun thick or
a machin~' plate. We wholeTprocess,of
rllouldfug shall be cMried outin sheh ama
;,nnet as £<1' p@Clud~ the.:ch,8I!ge of the
~,,water cement ratio ofth~ cd~crete,by loss
'of~ater either By ie#!lgefw!Il'tfie bot-
tom;to? o~ei'flbwfrom ,the t6pibf the
,';"~iDofua~~~<
',~, ~.,
- When thejob concrete is placed by vibra-.
tion aI!d the consistency of the concrete is
~- the ".te§t
such fbat; '. specimens cannot be
..•.
properly ,lJloU1<ied, by"-handrodd!ng~as'
pesri!>esd 'aooye; ~~'specimens shall be
vibraied to give aeompaction correspond-
ing.to that of the joMzoncrete. The fresh
"coi}cre1eshall'~<pl<}ced in mould.in two
layers, each approximately half the vol-
um~,of the mould. fu placing e~chJcobp; ,'.
ful of concrete the scoop shall be moved
around the· top edge of the mould as the
concret~ there ~1ides from it, in order to
ensure a symmetrical distribution of con-
crete wifu.i!1the mould. Either internal or
extemalv~brators may be usedThe vibra-
tion ofeachl~yershallnot be continued
longer than is pecessary' to ..secure' the
.- required density. Interiial vibrators 'shall
,--,- be of appropriate size and shallJ>enetrate
only the layer tore oompactedtIn com-
p~ct.ipg th~ first layer~ the.vibrators shall
not be allowed to rest on the bottom of the
. ,..,.., .. , -.: .• ". c· ,
I1!0uld., IiIplacing the concrete for the top
,:.q ,
layer' the' ..mould shalH:>e·filled to the
- -
extent' that there willb~ no mortar loss
'during vibraq.on: A:ft:ervibratirig the sec-
ondlayerenough"co~crete shall be added
to bring level abOve the top of the mould.
The surface 'Ofthe ,~--;.."
Concrete shall then be
;.;
stI'Uckoff with a trowel and covered With
a glass or steel plate"as s~cified above.
The whole process pf moulding shall be
as t9 pre-
...,~-
clude the alteration of water-cement ratio
-
.. of the concrete by:loss of water, either by
',>, - "'
c"'leakag~{from the",bot!0m. or over flow
~n.. ' from the top of the mould."
«~ , ~_ ,,~":';t,.:f
A-1.~ Cut1ng,an4sioI:iig~.,of tesJ specimen
," In"'o;a;i'to 5~!1~~~-~~;;onably uniform
" tel!,lpe~tUre and ,m9ispl,re condipons dur-
ing the first 24 hours for cU,r.ingthe speci-
men and to protect them from damage,
/ moUldsshall be covered with wet straw or
~ ;guriny s'aJ19ng",,~fl placed in~ .~torage
,~;.,.,.~ bo~ so~nsti:uc~d3!ld kept on tl1e work
>..site t4~~its airtem~rature ~tIen cbntain-
ing' concrete. specjmens' shall (Cmain
/l-2°'C ,to 33° C .. Ot:l]erc,suitapl~.nieans
which provide s~~h a temperature and
,',moiswr(copditjons may ~used~
" 106
 "-

with battens to avoidwatping. The , d) The load ~ be _applied 'axially

.box should=be well painted ;nm.de:. witout shoc~ atJhe rate of approxi-
and outside,and should be prPvided~ mately 140 kg.sq em per minute.
with a hirtged cOverand padl~k. The total load indicated by the test-
ing machiiie at failure of test.sped':
The t,est,spegmen shall be ~mdv¥ from' men sh,allbe recorded and the writ
the moulds at the. end of 24 hours and cOmpressive strength.is calculated
_,", stored ill a moist,condition at a tempera- in kg per sq em using the area com-
ture within 24°· cto 300 c until the:timeof puted from the meitsured dimen-
test. If. storage, in water is desired, a sions of the test specimen. The type
saturated lime solution shall be used. of ~failure and appear.ance of the
concrete shall be noted
A-1.5 Te,sting

"The specin?-~nsshall6e"tested in~accor-

dance with' piqsedure as"described be- APPENDIX B
low: "
(Clause $,.5.9.1)
" -~ &
a) TIu~tests shall ~ made. at ~ age o( .'
B-1 REBOuND HAMMER TEST.,:
concr~~eccorrCSI'2IldiIig..,to
'tJIat for
which the stre,ngtl,ts"ajes~cified;
~ANbATORYnELDTES~
•. ,,,_, ,.. ., -c. ':- ~ ~_.:.~ _ ._,_

b)' , Comp~ssion tests shan 00. made If a rebound hammer.~is reght8rty used. by
. i1!1mediately,uponremoval' of the trairle<lperSgnnelin accordai1cewith proce-
dure desribci1in IS 13311 (part II) -1992 and a
concrete test s~en f~ the.
curing rOOlnte. the test spCcimen cOntinuouslymamtained iD.dividualcharts are
shall ~ loaded !P'd~p condition. kept showing a large number otrea~gs and -
the relation ,betWeenthe readings and strength
The <fil!1ensio~()f ~e ~st,speci- of cOncretecubeS madef1'Om the same batch of
m~ns ~hallbe ni~asu~d in mm ac-
curate)o 0.5 mm. concrete, such charts may be used in Conjunc-
tion with hammer' readings to obtain ~ ap.-
c) The me,talbea~g plate~ ~fthe Jest- proximate indicatioo:of the ~~ of COn-
iI!gmachi.Qesnall be placed ~&'n~ crete dn a structure or element. I.f~alj.bratioll
tact~th t!J:eends of t!J.etest specj-
-~ ....•. ""':0: -.' " • .,..,.- ',- -- ..•.
charts are available frotn manufactUrers,it ca,I,1
inenS,'Cushonmgmaterialsshallnot ,. ~ .. _. -'~, _.~ 'S .1 : be used;~When ma1dn~,.rebound ~mer testS
be used. Inthe case of cu):?es,thetest
~ -;;. • ': .'" .. , ",c"';; each result shouJ4 be th~ av~rage of at least 12
,'s~(;i.m~!lsh.@"be placed mthe readings. ReadiDgsshpu!d not be t,*en within
. machinem S\i'Cldi ttIanner
~»
",~
__
that the ;,.- lr-",. -,.-:' 20 mm of the edge o! concrete mem~rs and it
IQadis apj>liedtosid~s
OC,' , ~_~-!.
of the s~ci-~'
,~_ ','-: ..• ':..1'
may ~ neacessarytodistingUish between read-
.mens as cast; An adjustable bearing
- .. C';;'.- .,'*'.;- .;: -;;:.,_ n •• ~ ,"" ings iaken,on a trowel¢, Jace and those on a
, block shall"be.used)o:trarismit the "- ":;, ••_'f.;.~,, ,:.."- ,- .c-' :_~
moulded~'face;,tWhen making thetest~ on a
load to the test specimen. The size precast units, special ;care should,be taken to
of thebearingbl~ok shaIl.~bethe bed~th~m finnlyagairist the impact of the
·same.or,slight!Y·I~rgerJhai1that of hammer:'- .
test sPecimen. The upper or lower
'- .~:<-~;j::- '," -" -~'" .~ ,~

,section of the bearingq~O(;kshallbe

k~pLin moti()n'asJh~:hea~,ofth~.
testingma,£hineis 6!oughtt~ ~beai~
ing on the test specimen.

107
 APPENDIX-C
ADDITIONAL TESTS FOR
CONCRETE
(Clause 5.4.9.2)
c-o In case th~ concrete fails when tested as
per the method presribed in Appendix A,
one or more of the foll~iwing check tests
may be carried out at the discretion of
Engineer-in-charge to satisfy the strength
of the concrete laid. All testing expendi-
ture shall be borne by the contractor. The
nuinber of additional tests to be carried
out shall be determined by the Engineer-
in-charge. He shall be the fip.al authority
for interpreting the results of additional
tests and shall decid~ upon the accep-
tance or otherwise. His decision in this
regard shall be final and binding. For the
purpose of payment, the Hammering test
results only shall be the criteria. Some of
the tests are outlined below:-
-C-l '.CUTTING CORES - for normal design procedures. / Where
This method involves drilling and testing
cores from the concrete for determination
of compressive strength. In suitable cir-
cumstances' the compressive strength of
the concrete in the structure may be
assessed by drilling cores from the con-
crete and testing. The procedure used
shall comply with the requirements ofIS
1199-1959 and IS 516-1959.
The points from which cores shall .be
taken shall be representative of the whole
concrete and at least three cores shall be
obtained and tested. If the average of the
strength of all cores cut from the structure
is less than the specified strength, the
concrete represented by the cores shall be
liable to rejection and shall be rejected if
a static load test (c-4) either cannot be
carried out or is not permitted by the
Engineer-in-charge.
108
C-2 ULTRASONIC TEST
If an ultrasonic apparatus is· regularly
used by tniined personnel in accordance
with IS 13311(part I) -1992 and'
continuosly maintained individual charts
are Kept showing a large number of read-
ings & the relation between the reading
and strength of cubes made from the same
batch of concrete, such c!1arts may be
used to obtain approximate indications of
the strength of concrete in the structures.
'In cases of suspected lack of compaction
or low cube strength the results obtained
from the ultrasonic test results on adja~
cent acceptable sections of the structures
may be used for the purpose of assessing
the strength of concrete in the suspected
portion.
. C-3 LOAD TESTS ON INDIVIDUAL PRE-
CAST UNITS
The load tests described in this clause are
intended as check on the quality of the
units and should not be used as substitute
members require special testing, such
spe~ial testing procedures shall be in ac-
cordance with the specification. Testloads
shall be applied and removedincremently.
C-3.1 Non-destructive Tests
The unit sha}1be supported atits designed
points of support and loaded for five
minutes with a load equal to the sum of
the· characteristic dead load plus one and
a quarter time the characteristic imposed
load. The defleaction is th~n recorded.
The maxinium deflection after applica-
tion of the load shall be in accordance
with the requirements defined by the En-
gineer-in-charge. The recovery is mea-
sured .five minutes after the removal of
the load and the load then r.eimposed: The
percentage recovery after the second load-
ing shall be not less than that after the first
loading nor less than 90% of the deflec-
tion recorded during the second loading.
 --
At notime during the tests, shall the unit
show any 'sign of weakness or faulty
construction as defined by the Engineer-
in-charge in the light of reasonable inter-
pretation of relevant data.
C-3.2 Destructive Tests
.. ,The unit is40aded while supporfed at its
design poiilt of support and must not fail
at its design load for collapse, wi~ 15
minutes of time when the test load
beacomes operative. A deflection e)(ceed-
ing· 1/40 of the test span is regarded as
failure of the unit. /
·C-3.3 Special Tests
For very large units or units not readily
amenable to the above test e.g. colUIims~
the precast parts of composite beams and
members designed for continuity or fix-
ity, the testing arrangement shall be agreed
upon before such units are cast.
C-4 LOAD TESTS OF STRUCfURES OR
PARTS OF STRUCTURES
The test described in this clause are in-
tended as a check where there is a doubt
regarding structural strength. Test loads
are to be applied and removedincremently.
C-4.l Age at Tests
The test is to be carried Fissoon as pos-
sible after the expiry of 28 days from the
time of placing of the concrete., When the
test is for a reason other than the quality
of concrete in the structure being in doubt,
the test may be carried out earlier, pro~
vided that the· concrete has already
reached its specified characteristic
strength.,
C-4.2 Test Load
The test loads to be applied for the limit
.
states of deflection and local damage are
the appropriate design loads i.e. the char-
acteristic dead and superimposed loadS.
109
When the limit state of collapse is being
considered the test load'shall be equal to
the sum of characteristic dead load plus
. one and a quarter times the characteristic
imposed load and shall be maintained for
a period of 24 hours. In any of the test
temporary supports of sufficient strength
to take the whole load shall be placed in
position underneath but not in contact
with the member being tested. Sufficient
precautions must be taken to safeguard
persons in the vicinity of the structure.
C-4.3 Measurements during Tests
Measurements of deflection and crack
width shall be taken imme~ately after
application of the load and, in the case of
24h sustained load test, at the end of 24h
loaded period, after removal of the load
and after 24h recovery period. Sufficient
measurements shall be taken to enable
side effects to be taken in account. Tem--
perature and weather contitions shall be
recorded during the tests.
C-4.4 Assessm~nt of Results
In assessing the strength of a structure or
a part of the structure following a loading
test, the possible effects of variation in
temperature and humuditi during the
period of the test shall be considered.
The following requirements shall be met:
a) The maximum width of any crack
measured immediately on applica-
tion of the test load for local dam-
age, is to be not more than 213 of the
value of the"'approriate limit state
requirement·
..,
b) Formembers spanning between two
supports the deflection measured
immediately on application of the
.test lo~d for deflectioI} is ~o be not
more than 1/500 of the effective
span. Limits shall be agreeed upon
before testing cantilevered po~ons
of structUres.
 c) If, maximum deflection in mm 5' in ~lause (a) a reinforced concrete
s~own~uring 24 h .under load is structure does not show a recovery
leSs than 40L2/D where L is effec- of at least 75 percent of the maxi-
tive span in ill~ D is 9verall depth t;num deflection 'showndUrlng the
ofconstruciioo in. rom, ~t is not 24 h under l()~d, the loading should
~ssary for the recovery to be' be repeated. The structure should be
" me<1Sin-ed and the require~ent (d) considered to have failed to pass the
does not apply, and test if the recovery after second load-
ing is not atleast75 percent of the
d) If within 24 hours of the'removal
,.,- ~ of maximum deflection shown during
test' load Jor collapse as calculated ,the second loading.-

"
APPENDIX-D

REGISTER OF WORK TEST OF CONCRETE

. (Clause A-O of appendix A)

a) Name of work, Concrete mix, Compn;ssive strength

(By volume) .' , in kg/cm2 on 7 days

b) Name of contractor 1:1:2 210

c) : Agreement No
d) Sample No. 1:1 1/2:3 175
e) Identification mark

t) Portion of work and quantity

represented by sample 1:2:4 140

g) Date and time of c'asting ,cube

h) " Proportion of mi.x

7Days' Test (C!. 5.4.10.3.)

1. "Due date of test cube No.

2. " Actual,date of test

3. ~ MfuIDmumstre~~
b) Maxinium Strength
•
c) Average strength of three cubes

d) ,Difference between 3 a & 3b

~ e) Difference in % age in tepns pf average strength -
i.e 3b-3a
--,- .... x 100 =
3c

. 110
 ,4. ~Pecified compresssive strength of concrete mix used -
'5 a) If 3 (e) is more than 30% Sample is not acceptable, then 28 days'
,strength test shall be carried out. '

b) If 3 (e) is equal to or less

than 30% than proceede as below:

i) Difference between column 4

i.e. specified compo strength &
column 3 (c) i.e. actual average is
higher, it will be denoted
(+) and (-) if it is less.

ii) Difference in Column ~ (b) (i) in . 3(c)-(4) x 100%

, terms' of % age of specified strength 4

ill) If the difference in col5 (b) ,(i) is Acceptable & Strength is

+ve and the'same in terms of % age, considered in order /'
of specified strength (4) i,e. value of ,
co1. 5 (b) (ii) is with in (+ 15% range)

JE . AE/AEE ' BE

REGISTER OF WORK TEST OF CONC,RETE

, a) Name of work Concrete Mix compressive strength

(by volume) . in kg/cm on 28 days

b) Identification
Name ofof
Agreement
Sample
Proportion
Portion
Date and No. Nomark
contractor
of
time mi,x
work
ofand quantity
casting cube 1:1:2 315
represented by sample
e)
d)
f)
g)
c)
h)

1:1 1/2:3, 265

1:2:4 210

28 Days' Test (C!. 5.4.10.4)

1. Due date of test Cube No.

-
2. Actual date of test

3. Actualcomp. strength of cubes

. (MiD No. of cubes to be tested-tl1reC)

-111 - .
 a) Minimum Strength

b) _Maximum Strength

c) Average Strength of three cubes

d) Specified compressive strength of concrete mix used

e) 70% of specified strength Le. 10%- of 3 - (d)

- ..
--' - --"
_.~._. -- ~._- .. --' --~~'-- . --.,
f) 130% of spcified strength i.e. 130% of3(d)

4. If 3any
(c)
3(c) ~= more
is<
(b)test 3(f)
3(e)-
value
3(d) and
and>
but <3(a)
exceeds
thai13 33(f)
(f)
(e) 3 (f)
~3(e) value of3 (c) shall be compressive streIigth
of sample.
.
.
.
. tm mayor~er further investigation

It should be restricted to 3(1) for computa-

1ion of strength.

Strength is in oider and concrete accepted

at full rates.

Concrete may be accepted at reduced rates

in accordance with para 5.4.13.2

Worle represented by this sample shall be

rejected and action taken as prescribed in
clause 5.4.1004

112
TYPICAL SET UP OF STEEL
WALL FORM WORK CHAPTER - R.C.C.
(FORM WORK)
CLAUSE - 5'2,], 6
FIGURE - 1.

.
. . "
o "

SINGLE SJDED WALL FORM (ADJUSTABLE)'

FIG. 1A

..'
:'0' .
0'
...
. '.
•

~.. : ...

"!'
----
.. ',.,
..

,FI G.-1 B DOUBLE SIDED' WAll FORM

All members' are of 5 t eel. . 1~
 WALL FORM
..CHAP TER-RoC. C.
(FORM WORK 1
CLAU SE ~ 5, ·2-9·6·
FIG UR E - 2 .

CLIPS

ADJUSTABLE CURVED WALL FORM (DOUBLE ,SIDED 1

FIG.,-2'
All MEMBERS ARE OF STEEL.

II -

114
 TV F?~IC AL FI~fINGDE,TA IbS
- - elF WA=LL TIES - CHAPTER - R.C.C.
(FORM WORK)
CLAUSE -5'2-3 .. ' 2
COILJIE
FI GURE - 3 .
lEN6! ~
75 LONG~e.0LT ~:_ CONES
,-.1 - •....

WASHER -

SOLDIER -

WALL TIE' FOR TWO SIDED SHtJ,TTERING

ALL MEM BERS ARE OF STEEL

WALL TUBES
- C H AN NE L SOULDIER 2· 5M: LONG
WALl FORM PANELS
A-ASSEM8.LY-CLIP
B-,~RIDGE. cLIP
s- SINGL£ cLIP
U1
-['--,.
.--
•...:
C •• 1750"- .. I .".

0"1125
E"1250 ..
F_"137S,'
~,,:2t5pO_

..
100
EL EV ATiON

~OSITION' OF WALL TIES &- WALING TU8tS

(SMUTTERING FOR 1ST POUR Sf:lOULD 8E •
~ ;". - t "'- .~,' .••.•
PRORERLY STRUT-TED BY RAKERS)

,c~~t;,:;,
EG~~I ~(;OA~~~~
~~ F:IG. 3 ~fiJ
-
!
115 ~- .. '!:""
"-~.
"-.
--
.,.,. -.,
"
 TYPICAL STANDAR[) UNITS OF
FORM WORK (CENTRING 8; SHUTTERING)
. Cl A US E - 5. 2 . 3
FIG - I..

DETAilS AT 0

II§
1'12 90Ft 9f II "§I
. 0III 0 JI~I,

I=";-----!-. t ';==:1
! KNOCK
'J"",-_- IJ _1d\l... + ,'
DROP
TO
o
C>

C>

DROP HEAD ADJ. STIRRUP HEAD

C D

t U'I,'+ U-L
0f-
3 M ,2 M 2·I.M 1·2 M
E - VERTICAL S
ALL MEMBERS ARE OFS TEEl
(IN DIFFERENT HEIGHT!)
AL,~ DIMEN SrONS ARE IN /M tv!
DRAWING NOT TO SCALE FIG.-'
116
 CI=tAPTER - R.C.C.
TYPICAL COM~ONENTS OF (FORM WORK)
CLAUSE-5'2')'2
FORM WO~·K FIGURE-5

'\
ANG LE TRA NSOME TU8ULARTRANSOMI DIAGONAL
. \ LEDGER/HANDRAIL

A B

HOP-UP 8RACKET ANGL E TIE AD JUSTARLE. BASE

i;.

'.. I:dI

H
GII
II
oI.COLLAR-
F I .~.I 1CUP
~I LOCK GRIP
-1-"~~/"~
I L FiXED SASE PLATE
 TYPICAL ARRANGEMEN'T
COLUMN FORM ,WORK CHAPTER.;. Re.C.C.
(FORM - WORK)
C LA'u SE - 5·2·3·2
FIG. '- 6.
I
CORNER ANGLE BRACKET

,
" .

• I;

FOUR SIDES ADJU 5 TABLE COLUMN, FORM

'CORNER ANGLE
BRACKET

EXTERNAL CORNER ANGLE'

TWO . FORM-;"~'"

ALL 'MEMBERS ARE"6F STEEL

118
 . CHAPTER -R.C.C.
(FORM WORK)
CLAUSE - 5,2,,),2
FIGURE - 7.

TYPI CAL COLUMN SHUTTERIN9

FIG. - 7

ALL MEMBERS ARE OF STEEL

 TYPICAL DETAIL ,;OF BEAM
HEAD AND STIFFNER CHAPTER - R .C.C.
(FORM WORK)
FIGURE - 8.
CLAUSE - 5·2·3·3

I£AM HEAD 0
BEAM HEAD CD

ASSEMBLY OF BEAM
HEAD OVER PROP

l 5 TIFFN ER

1 VARYJ~ WIDTH t
'- ~ J~MM
~MM S TIFFNER

FLOOR FORMS PLAN OF FLOOR (SLAB) FORMS

(OUT OF 14 GAUGE M.S.SHEET)
(A DJUS TER
AVAILABLE
FLOOR FORMS
.IN VARDUS SIZES)
®
®

ALL MEMBERS ARE OF STEEL.

FIGURE ..,8
120
 TYPICAL DETAILS OF MULTI.
STAGE SHUTTERING
CHAPTER - R .C.C:
SUSPENDED FLOOR/.iSlAB TO BE CAS T (FORM WORK)
...,
- -- - - - - -- -
----- CLAUSE - 5·2'3·2

. ---- - --IN G- - - - STEEL- -

o.lS
BEAM -CENTR-
SHUTT ERING -- -r HEIGHT ~ 3.5 Nt FIG. - 9.
HEAD

.·········m---·-- ~----.-. 1
PRO P5
VERT IC

tEIGHT'\< 3.5 M

SUSPENDED FLOOR -MULTI STAGE SHUTTERING

( VERTICA L SECTION)

FIG.-9A
A LL MEMBERS ARE OF STEEL

VERTICALS

-·DIGONAlS

\
\

121
9-4!CPWDIND/92
DETAILS OF EXPAN'SI0N JOINTS
( INVAAIOUS lOCATIONS) CHAPTER - R.C.C.
CLAUSE- 5,',5
F! G U R E - 10 &11.

JOINTS

•• 'Ot' •••• 4 ,

GROOVE AT'R.C.C.-MASONRY JUNCTION

FIG ..-10 EXPANSION JOINTS IN lONG SUN SHADE

R.C.C. COPING'
CRAFT PAPE.R OR
'BITUMEN PAINTlNG- BITUMEN PAIN TIN G
BRICK TILE rLi ME TERRACING MUD PHUSKA I
BITUMEN FlllE R
·C£.lING PLASTER
R .C.C. BEAM
R.¢~~.;SLAa _',
M ET',1!iiiCRA
'''''.0;,;;/.'.' .:-"" OLE

A. C. SHEET -RAWl' PLUG & SCR''EWS'WITH OVAL

SHAPEP SLOT & WASHER
'RAWL PlU G & SCREWS

DE TAl LS OF RAISED TYPE EXPANSION JOINT AT ROOF

FIG ... 11
122
 EXPANSION JOINTS (C ONTO.)
CHAPTER .R.C.C.
, CLAUSE - 5-4,5
FIGURE -12 T014.

25M~,1 THICI< TO MATCH

.THE FLOOR FINISH & LAID OVER A .cOAT
OF HOT BITUMtN
FILLED WITH J GIN T FILLER
:..1---,--,-12
~R.C.c. TIl.£
MMT .(,.AP
PRECAS
.•..

',8 .•

R.C.C .SL AB
METAL CRADLE FILLED UP
If:

"'.'.I
- -.:'
. ~PLASTER
L~_~ITH
R .C C. BI T UM EN
BEAM FI LL EH ( ABOVE)
A.C. SHEET -RAWl PLUGS &. SCREWS WITH
RAWl PLUG & SCREWS- OVAL SHAPP EO SLOT & WASH ER

FIG; 12 TYPICAL DETAilS

c.c.

25M M GAP

\
\
MASONRY TO BE CONSTRUCTED BRICK WALL
AFT ER PLACINGCANTILE VER SL A B PLASTER
R.C.C. CANTILEVER SLAB
.. I D~BEDoED IN MASONRY AT
C.C .GOLA -
ONE END, FREE AT THE OTHER END
. FLOOR FINISH SKIRTING
MUD PHUSKA

R .C.C. SL.h. B
BIT U MEN FI LLER
METAL CRADLE
R.C.C. BE.6.M

FIG
...• 14 TYPICAL DETAILS ---,.."
OF ·EXPANSION 25 M~~ GAP
JOINT
AT ROOF t FLOOR JUNCTION
123
 EXPAN SION JOIN TS (CaNTO.)
CHAPTER - R. C.C.
A. TWIN\BEAM WITH TWIN COLUMNS
CLAUSE - 5, 4·5
Twin beams FI G UR [ - 15 TO 18

Twin
col umns

o
[ •.---- -f
- - --
-' --- - -- ---- ----
- - ---- - - ----- -- - c --
---
.•. J
cradlt
t'50
for
'beamCopper D
External lace

I
Twin beams Twin columns
A.J

PLAN

L1QQ f
.'
8'~ ..: ....•.
,.
.-A ".
I
: lM~d laid 10
fuska
sl<:pe

12 mm open joint in .•. :/:1~

::.,.;~" R.C.C.
_BeamR.C.C.',b
floor stagger e d from
upansion
wit" bitumen
joint filled
FIG.-15
tiliJ~
"
. C· ··E·.·,
<.'..'. . :~
~':"::
Plast er

Q1,P2~ tGap 12 D-¥.25

SECTION A-A ON flOOR SEC A-A ON ROOF
B. SLAB & T:BEAM CONSTRUCTION OF LONG LENGTH
( T- Beam changed inlo rectangular beam 10 prav ide inlermediate expansion joint)

5mm •• pans! on
joint fill.d
with bit umen -=!. .. Flooring
.~. ~::..;
I iller .... ' J.R.c.c. Slab
Situmen lelt Unfilled gap
12mm expansion joint j T - 8 ea m ."
-ular
R.C.C.beam
Rectang.\ .•·'. :":.
'.
filled with bitu men Iiller
or impregnated fibre board

o
FIG. - 16

C: LONe; VERAN DAH SLAB D. LONG WATER -RESERVOIR SLAB

1ll2006-13OOO • t 12000-13000 }
12 -~2
KEY PLAN PLAN

FIG. - 17 FIG.-18
Butl joinli.floor & slab
.~.. -

Bilumen lelt ~ .. : ':'.;.'.:':

..... ' ..•
R.C.C. Sab
$Fborin~
Ceiling plasler r~":·:-·.~:....
' •. ~:~~.'.
..'" .' " . ....•..... ~:':-':::~':'~j
: ...•• ~arln
R.C.C.
PlasterSlab
lilling
6mm
PART SEC. A- A SECTION A-A

A' Hot bitumen painting @ 1·7 k.g./ sqm.

BBifumen filler.
CRawl plugs t, 50mm screws @ 300 mmclc.
D Asbestos sheet 150mm wide or P. V.C. sheet.
E Rawl plugs & scr'ews with oval shaped slot
•• washers @ 300 mm c/c. Drawing not to scale.
F Copper cradle. 124 All dimensions ar e in mm.
EX PANS10N JOINTS (CONTO.)
CHAPTER - R .C.C.
CLAUSE - 5'4,5
Ft GURE - 1CJ TO 22 .

-200 M MASSES TOS CEMEN T FLA T

R AWL PLUG .& SCREW W ITII SHEET OR ALUMINIUM PLATE
OR SIMILAR MATERIAL
OVAL SHAPPED SLOT &, WASHER
1 2 MM GA P RAWL PLUG & SCREW

R. C .C . COLUM N
INSIDE 25 MM GAP

FIG. _19PLAS TER

TYPICAL DE TAl L OF EX PANSION JOIN 1. COVERING
ON OUTER FACE OF C OLU MN S (PL AN)

STEEL OR AlUMIr'JIUM ANGLE

FIXEO WfTHRAWL PLUG &,

SO MM SCREW Ia) 300 MM ~Ic..:\\ BRICK

12MM GAP \:, WORK

; , ,...
..
.
-
t- -
..':.,. '.JOINT
.~ FILLER PlAS TER
..
,~ • .J,
'- c.t:" 1\ I

EX PAND EX 25MM GAP

R.C.C. COLUMN
BOARD

JG COMPOUND
COLUM N FIG.2QTYP'CAL DETAILS OF
TYPICAL DETAILS Of EXPANSION EXPANSION JOINTS.~T
CORNER COLUMN
JOINT ~T ISOLATED TWIN COLUMNS
REINFORCE

FIG. 21
PV.C.WATER •.
••
S Tor! BAR •..

.•. - " ........•

JOINT FILLER
DISCONTfNUTY'lN BOTH'
CONCRETE' & STEEL
FIG.22 EXPANSION JOINT SUBJECTED
TO WATER PRESSURE

(FOR WATER TANK S )

125
 EXPANSION JOINTS ( CONTD~)
CHAPTER - R.C.t.
@ 12MM E)(~ANSION JOINTS FILLE.D WITH BITUMEN CLAUSE - 5·4,5
FILLER ORIMPREGNATEDR8RE BOARD· FIGURE - 23 .
(96MM CEMENT PLASTER 1!J (1C;:3F. SAND) FINISHED
WITH A FLOATING COAT OF NEAT CEMENT AND A
THICK COA.T OF LIME WASH OR LAID WITH KRAFT PAPER.

FLOORING/MUD
PH USKA WITH TILES 50
GAPTO100
AT UNFILLED
TOP. / ,/BUTT
FLOORJOINT IN THE
STAGGERED '
FROM EXPANSION JOINTS

§)
R CC SLAB

BED
PlAT E

A. END WALL WITH RooFI B. BEAM

'SUSPENDED flOOR SLAB

FLOORING/MUD PHUSKA
- 81TUMEN FEL T
WIT H TILES.
25 TO 1.0 UNFlLL ED
GAP A T TO P

<-

D. INTERMEDIATE WALL WITH FLOOR SLAB

C. END WALL WITH RCX?F/
SUSPEf\UED FLOOR SLAB

BRICK LAID WIT H

VERTICAL J(iINT
IN MORT AR

E" INTERMED!AT E
, 'V" - PLASTER
WALL WITH ROOF SLAB
t:~~
MEt:L\L SHEET 25MM GA"P
-FL:AT ASBESTOS
'(Q HOT BITUMEN PAINTING @17 K·G.f SQM.IN CASE CEMENT SHEET OR
OF ROOF SLAB/ BEAM.- , ANY OTHER EQUALLY
© HOT 'BITUMEN 'PAlNTING @1·7K·G./ SQM.,8ELOW SUITABlE MATERIAL
BRICK WALL ONLY ON SUSPENDED FLOOR, 150MM WIDE
F, EXPANSION JOINT USING·
BEAM{ SLAB. JOINT FILLER AND SEALING
DRAWING NOr TO SCALE. COMPOUND
ALL DIMENSIONS ARE IN M~-1.
 EX PAN SION
CHAPTER - R.C.C.
C LA USE - 5, 4 . 5
FIG. - 24-25.

PRE CAS T SL.ABI TILE 5--

BITUMEN
FLOORING

RUBBERISEO
---,

PAD-l r--
~_- -SHEET METAL FLASHINf1
j-RECTANGULAR
I , - --I ,FLAT.
BAR
BAR SET IN FORMS
I
II>
, .~C]=D::J
..
.. '
•••• 1 "II' , .' • lit'
~' ~
. ----' . .. ~ .. _JI/":r-
-6- -__-~ '~I ~..",,'"
•• -
· //( .. ;' 1,4 •••.• ~ •••.
11 I
"~.,t':J ~ .0#< •

MASTIC-·-----'II >~;. -,,.,...., ';,".

'41"

=r.--t=q .
••• " ",' ' •• ' ." 1 ,,to _ II L'-'- R .C ,c. Pl.ASTER
CEILING 5l A8

Rt.,WL

FI Go24
PLUG
GAP, =t &
'~_.~
SCREW)
Ji.

~!§.t:1I~ ..._,;~EPARAT ION AT

T --- - RAWl PLUG WITH
SHAPPED
A.C. SHEET GA.P
SLOT

FLOOR LEVEL
OVAL

· ----"R.C.C. COPING , .

BITUMEN PAINTING .

...
,,;,
(/''. ~~
.....
• ', :.,..-: ~ •• '4< •• _~

•
.'C.C.
• .'• GOLA'*
- ••
' ••.•
••• /7/ / / -L.'
'/Y'" .. ' ....rBRICK
- .
,y-
•••• •••
TilES

...
~."
r-'-'
••

...
<t •••
... ~ ' ...

R.C.C. BEAM-
II ..
.f-'-....
· . • ",
.
''',

' ..
.
.. ; -.c
,;
;'
.':..'
' ... ~

~.,.,.:.,.

•••••• ~
t-flLLED
METAL UP WITH
,. LR.C.C.SLAB
. L_CEILING PlA.STER,

OLE BITUMENfiLLER
CR/.•.

•• ••

RAWl PLUG
GAP-8, - S;fEWS IL.A. C.'--RAWL
SHEET'" PLUG WITH OVALSHAPPEi:; SLOT

FIG..25 ~J:ISMIC SEPARATION JOINTS DETAIL AT )~Q£f

127
 CON STRUCTION JOINTS
CHAPTER - R.C.C.
CLAU SE - 5'~' ~
FIGURE - 2.&.

A .. PROHIBITED
(CLAU
"...•....
~.;'ot,-.;

JOINT.
SE -5'4'4'3)
., '.; .•.• :, •..•"' • CD
- -. - -I!!--::;.ti':~·\>r~.::_·\:~;
- - _(2)- ....::..•.•.
.::.;...:,.~:·~.::.;'I.::..)-2 .• ~·a..'L

IN SLAB
<D '~~,,:@
.". ;', .~.:. :.,. :---. '.. .'.~
E. JOINT' IN BEAM
"'T
OR SLAB
.

, <DJ.l~g4~~
.' =" ="~"-~p{Cl/~rrnING
. ;JfSASE LEAN aN
F. JOINT IN FLOORING FOR WATER RE.SERVOIRS

B. JOINT 'IN SLAB

(STOP BOARD SLOTTED TO
TAKE HORIZONTAL REINFffiCEMENT.)

C, . STOP - BOARD PLAN

H. JOINT IN MONOLITHIC R.C.C,
SLAB AND BEAM CONS T.

\!.J "., ••· •.1

'f'E,r';''''';.iliu
• -:- .'~
---_:_:~1R.C.C.
7" I ~ ~SECONDARY 8EAM
. ':MAlN BEAM SLAB

D. KEY ED JOINTS IN WALLS H. SECTION A - A

(WITH 5 TO P - BOARD FI TrED
WIT H 25 X 25 CHAM FER PIECE
AND SLOTTED TO TAKE HORIZONTAL BARS.)

CD RtPRESENTS FIRST. PLACING OF CONCRETE.

<l) REPRESENTS SUBSEQUENT PLACING OF C~CRETE '.

DRAWING NOT TO SCALE.

ALL DIMENSIONS ARE IN. MM.

FIG. -26
128
 ENCASING ROLLED STEEL SECTION
CHAPTER- R .C.C,
CLAUSE-S'S'2
FIG, 27 - 28

f-- "
".·, •.,
,·,",. ...;~, I~.'.,,.
" .:
• r . , ,,.f-:-
••
\'
."
. ,,, ,
<JV
-f.,-.'•-Y••"...•.•~~=~
' ,' ,
~.
.'..''10)0-
," - ~ ,. •-'////0
,- , • ,., .,.LAP
• . NOT
t" LESS THAN 100

EXPANDED METAL
OF UNGAlVANIZED R.S. JOIST
WIRE MESH

FIG. 27 STEEL COLUMN

5 DfA WIRE HANGER AT 1200 C/c

, . "'-," . ~ ,.
;,
RC,C, SLAB
.
,
• -'
.•.
... "
•

- ..
-- .. " • ..
..
,. • .
• t?777// ~ ~
.•
: ,. ',' UNGALVANIZED WIRE MESH
),,: .. .•\--+-{EXPANDED METAL OR

~5j,251.

"FIG. 2 8 STEEL
, BEAM .WITH SLAB
NORMALLY CEMENT CONCRETE 1:2:1. (1 CEMENT:
2 COARSE SAND: 4 GRADED S TONE AGGREGATE
12,5 NOMINAL S,IZE) SHALL BE USED.

DRAWING NOT TO SCALE

ALL i DIMENSIONS ARE IN MM

129
R. C.Co· DOOR .& WINDOW' FRAMES
CHAPTER· R.C,C.
CLAUSE·5·9·2 «.
5,9,3,4
FIGURE - 29.

MILD CAOLKED ~(.1CEMENT:

. 2 COARSE SAND)
~CEMENT MORTAR;:2 .
HORN DETAIL
AT X

NOTE: Insteod of bolts for hdd fas t

m.s. rod 10 mm ~ may be .
HINGE embedded in concrete &. the
FOR .,projec1ed pieces 'may, be
STOPPER

~Il'- HINGE bent after casting. '"

iii, FOR
1:1 . SHUTTER
~ BOLT
t.n

-MILD STEtL ANGLE IRON OR

OPT laNAI. ONl Y- A NY OTHER EQUALLY SUITABLE
IN 'AS £ OF~k PIE . ARRAN GErvlEN T
FRAME
All dimensions 01 mm.

". ._PRECAS T RE INFORCED' CONCRETE

3 mm d> m.s. wi re
ties@>300 mm clc
25

oN

I..()

=--
---~
2 nos. m.s.· 0 L10rnmfi
.... "i
bolt
..
'I! ., XS···mm N.,..•;
".:.'~.v~r j.a.s
~ats:30'·
size .'V_
___ It '70rarn. In''
Q 19- _ ,
h"do fast.
I Co, ,

'~120 f t
GROOVE
. WA L L PlAS
FOR J
TER
~bNGE.
R = 30,35 OR40 MM DEPEN DING UPON
THE. THICKNESS OF SHUTTER
E!..!L ·',29 ( C )ALTER NA TlVE D ET AI LS OF PR E·
CAS T REINFORCED CONCRETE DOOR ~
R 30, 35 OR L.OMM
= DEPENDiNG UPON . WINDOW /FRAME .SHOWING ARRANGEMENT
THE THICKNESS OF SHLJTTER j fOR· REINFORCEMENT , HOlDFASTS & HINGES.
FIG.- 29(b) CROSS SECTION OF PRECAST -
REINFORCED CONCRETE DOOR AND '
WINDOW' FRAME SHOWING REINFORCEMENT

CONCRETE DOOR AND WINDOW . F~AME

,130
 DOOR & WINDOW FRAMES
CHAPTER - R. C.e:
CLAUSE - 5·9·2
- I·h·Ice~ 5S t 0 FiGURE;.. 30 .
sui t the size
of rebate(See
R in fig1~)
Wall fate

6mm $
b oM ---.
'-....
...
.•..
-......••. ~
::,:,
...
#
v
~!
~60
R.c.e. Fram-~· .:..: r

Hing e--'
/1~60 /l"
FIG. 30th) HINGE FIXED ON
T IMBER FRAM~

+~Q
b mm 11
boll

FIG .30{el~_6IL~
HINGE FIXED ON TIMBER FRAfv'£ HINGE FIXED GroutedJ \-Nut
(DOUBLE SHUTTER R.e.c. FRAME) DRECTLY ON FIc;3cmHINGE FIXED DIREqLY ON R.C.c. FRAME
FIG. 30(c) R.C.e. FRAME
ARRANGEMENTS FOR FIXING HINGES TO PRFCAST ARRANGEMENTS FOR FIXING HINGES TO
REINFORCED C(]\ICRETE DOOR 8. WINDOW FRAMES . PRECAS T R.C. DOOR 8. WIf'UOW FRAMES

6mm 4Jbars ~3 mm $ stirrups' 75

:~+~
20--~---~---:-~;
u_
30 I ~- -__-__ ~
-----;--1
- L
,-
80
- .
.
Hole to 2~H~"I
receive
-::
.•
tow~r
:
I
I,
-1--
r~,.--=t
I
1
_J
,

T-1-'-1
11 110 + bol t
_
6mm $ bars
:I
I
~
III :,I
I
o
'-25
20
::-5
6mm thick m.5 .pllate
Gmm¢1bars'

FIG. 30{g) ~ETHOD OF flXlNG ,TOWER BOLTS

TO R.C.C. FRAMES
AI! dimensions in mm.
13f
 NOTES

132
/
NOTES

133