6 Quality saves cost , improves excellence. J Unsafe Menu, Accident venue. Placing [Degree of | Slump (am) aot a lanai 5 ° acing gree ol P conditions yet Conditions | Workability 1. Blinding ery Low |Determination concrete, lof compacting Beams, Medium Shallow factor will be walls, sections and more { columns, Pavements appropriate slipform using pavers. than slump (see work IS 1199) & its value suggested Pumped is 0.75 to 0.80 concrete 2. Mass Low 25-75 Trench fill, | High 700 -150, concrete, In - situ Lightly | piling reinforced in slabs,beams, Tremie Devermination | of flow is walls, columns, concrete more floors, hand Very High — Tenants workability canal lining (See 1S 9103) and strip footings 3. Heavily Medium] 50-100 reinforced sections in slabs10! 5. Check for Visual Inspection MATERIAL ‘QUALITY ASPECTS Reinforcement Check for defects such as rust, oil, grease, mud coated paint [Sand Clay & organic material WORK INSTRUCTIONS EARTHWORK IN EXCAVATION & BACK FILLING Divert/Support/Protect all electrical cables, telephone cables, water lines, sewer lines etc, if existing, before starting excavation work. Brick Colour, Spots Wooden Doors /__| Crack / Warpage 7 Flush Doors Factory| Damage / Made Lamination bulging Steel Doors 7 Free from dents Barricade the excavated trench/pit properly and provide the red lamp for safety at night wherever necessary. Provide sufficient number of ladders/ steps in trench/pit for emergency escape route. Windows & Ventilators, Glass Fice from waviness [Natural Stones Free from impurities Granite/ Marble/ | & Cracks Kotah, Inter Iocking Paver | Colour & Pattern Blocks Structural Steel Free from cracks, surface flaws, rough & imperfect edges, free from excessive rust, scaling & pitting, warping If required provide gangway with handrails across open trenches. Do not stack the excavated muck within 600 mm from the edge of excavation and ensure that the height of the stacks does not exceed 1 M. Take precautions to avoid rolling down of muck from the stack into the pits/ trench Quality has to be caused, not controlled. Communication, Example, and Participation fare the three legs of the platform for Pride. a. ee ee ee aFORM WORK Discard damaged shuttering boards and weak supporting members. Oil the shuttering boards after cleaning the adherent materials. Before fixing formwork ensure that the concrete construction joints are well prepared and cleaned. Provide shuttering, maintain line, level and accurate dimension of the structure as given in the drawing. Check rigidity of the lateral arid bottom support. Provide bearing plates of sufficient area below the vertical props & clamps with horizontal bracing with regular interval. Check the level of the completed formwork to avoid reverse slope It is hard to find a company that failed hecause its expenses were too low. 15. Seal the gaps of shuttering boards by packing jute or any other materials. Strip the shuttering boards after the time mentioned below: Walls, columns, vertical sides of ‘beams and sides of foundation - 20 to 48 hours. Slabs (props left under) - 3 days Beams bottom (props left under) - 7 days Removal of props of slabs: Spanning upto 4.5 m - 7 days Spanning over 4.5 m - 14 days. Removal of props for beams ‘Spanning upto 6 m - 14 days Spanning over 6 m - 21 days. N.B.: For de-shuttering slab bottom, start removing the formwork from the centre and proceed toward supports Eliminating what is not wanted or needed is profitable in itself,BRICK MASONRY WORK Use only well burnt bricks Soak the bricks thoroughly for an hour, Check to ensure thorough soaking by breaking a few bricks. Use non absorbent platform for mixing of mortar Use screened sand Mix the mortar till it attains uniform colour/ consistency Keep 8 to 10 mm thickness of mortar in the joints between the bricks and pack it proper: Use English bond for brickwork Keep the frog of the bricks up while laying, Don't raise the brickwork more than a metre height in a day Satisfy the customer, first, last, and always 11. Check the top level of the brickwork done after the day's work with reference to datum fixed at G.L. or P.L. on both ends of the wall 2. Do the adjustment of level, if required, with more or less mortar thickness, before proceeding with further laying. Rake the joints on both faces neatly after the day's work while it is green Before starting the work, wet the previous day's work. Provide step back construction joints. Check and ensure verticality of brickwork by checking plumb at suitable intervals Ensure vertical joints line. Improving quality requires an overall culture change, not just a new dietPAINTING WITH FLAT OIL PAINT Clean the surface of dust, dirt, grease, oil, loose scale ete. Fill up the depressions, cavities, cracks, etc. with cement mortar 1:1, Do not apply this paint on wet surface. If required, apply a priming coat with cement primer, Apply interior or exterior quality paint depending on the surface to be painted. Get the brush to be used, approved by the Engineer, Ensure the finished surface free from brush marks. N.B.: Each coat shall consist of 4 brush strokes 2 horizontal and 2 vertical both in opposite direction, ‘A leader has to be a reflection of the soul of the organization. WHITE WASHING & COLOUR WASHING Cover all doors, windows, fittings, furniture, and equipment etc., before starting the job. Repair all holes, depressions, cracks etc., with cement mortar 1:1 or lime putty. Clean the surface properly before starting the job Use lime of approved quality only. Stake the lime and add it to sufficient quantity of water in drum/vat etc. Stir the lime solution thoroughly in the drum/vat and strain the mixture through clean and coarsé cloth. Add gum/glue @3.90 kg per cubic metre of strained lime mixture or add synthetic resin as prescribed In case of white wash, add ultramarine blue powder of approved quality and quantity. Barricade the danger zones,In case of colour washing, add required quantity of approved brand of coloring pigment to the limewater solution Do not use blue in the colour wash. Use jute brush or approved quality brash to apply lime wash. . Apply the subsequent coat when the previous coat is dry. Apply the final coat in such a way that no brush mark remains In case of new surface apply a coat of lime wash before application of colour washing. GENERAL : On completion of the job, clean all the doors, windows, fittings, furniture floor etc., properly, N.B. i) Each coat shall consist of 4 brush strokes 2 horizontal and 2 vertical both in opposite direction. Stir the solution continuously while application to keep the colour uniform. Don't worry, your safety belt, will protect you “i You eee! Serax Remit: “ DISTEMPER, Clean the surface thoroughly by removing dust, dirt, oil grease and loose scale ete Repair the damaged surface as needed, Use the brush approved by the Engineer. Do not apply distemper on damp surface. Apply primer, if required, on approval of Engineer. Apply the number of coats as specified Allow the surface to dry Ion checking, the distemper comes out with the touch of fingers, apply additional coat without any extra cost. Each coat shall consist of 4 brush strokes 2 horizontal and 2 vertical both in opposite direction Safety Ever, Accident Never.a. 42 C) Water Bound Mecadam Keep the size of the stone metal for W.B.M. 50 to 20 mm with specified grading Screen the stone metal before use to remove the oversize and undersize Particles. Keep the thickness of the compacted W.B.M. as specified in the order specification /drawing. Keep the thickness of the loose ballast 25% more than the required compacted thickness Lay W.B.M. in single layer, when the compacted thickness is 115 mm. Lay W.B.M. in 2 layers, when the compacted thickness is more than 115 mm, but upto 150 mm. Continue the dry rolling till interlocking of the stone metal is complete and there is no sign of further compaction. Mix the moorum and sand in 2 (moorum) 21 (sand) proportion by volume. When job is loved, work makes life sweet 43 Use only the absolutely dry moorum and sand. Atfirst, spread the small quantity of this mixture on the rolled surface and broom to allow the mixture to enter into the interstices of the dry rolled suriace. . Spread 25 mm thick layer of moorum sand mixture after the interstices are filled up. . Provide earthen bund on both sides of the road, . Flood the prepared surface with suficient water before rolling, Roll the surface with 8 to 10 tonnes roller untill moorum slurry flows with the movement of the roller wheel. Allow the surface to dry for 7 dyas before laying permix carpet. Premix Carpet Work Use the stone chips of specified size and grade for premix carpet work. Screen the stone chips if found mixed " Malke failure your teaches, not your undertaker.44 Mixin proper proportion, if different sizes of aggregates are brought at site. Measure the aggregates by volume and asphalt by weight. Heat the asphalt to a temperature of 163° to 177° centrigrade before use. Make thermometer available at site to ‘measure the tempreature of the asphalt. Heat the aggregates before mixing with asphalt. Surface P: Finishing etc, If the premix carpet work is done on W.B.M. surface, scrub the surface Properly to remove the moorum sand mixture from the surface and to expose the interstices of the stone metal up to 12mm. Provide bricks on edge on either side of Tew W.B.M. before the premix cerpet is laid. If the premix carpet work is done on the old premix surface, rough the surface by hacking followed by sweeping to make the surface rough and free from dust/ dirt. aration, Spreading, Direction creates time. Apply tack coat before laying premix. Spread the aggregates mixed with asphalt on the prepared surface to such a thickness so that after compaction it gains the specified thickness. Roll the premix carpet with 8 to 10 tonnes power roller when the mixture | is in plastic state. Do the rolling from edge to centre. Provide sand blindage at the top finished surface and sweep it to spread it properly. List of Tools, Tackles and Plants Required for W.B.M. Work and Premix Carpet Work 8 to 10 tonnes power roller. Drums for storing water for using during wet rolling. ‘Metallic scraper for scraping the mixture |] of moorum sand from the rolled surface Culture is the widening of the mind and of the spiritao Brooms for cleaning the W.B.M Surface, Templet for checking the road profile. Steel plate or Hot Mix Plant for heating stone chips and for mixing stone chips with hot asphalt Drums for heating asphalt. Thermometer for measuring tempreature of hot asphalt. Wheel-barrow for carrying mixed materials. Spade, shovel etc. for various requirements. Caution Boards etc. for safety during execution PILING WORK Mark the pile group, cut the trial trench up to two meter depth and relocate if any underground service lines pass through pile group. Mark the pile point as per drawing, by Griving 10-12 dia 300 longrod and encase with concrete, approx. 200 dia x 150 deep. Ensure the following accessories / equipments are available before starting the pile boring. a) Bailer & Chisel Bottom casing pipe & Head casing pipe. Sufficient No. of casing pipe. Sufficient No. of tremmie pipe and hopper. Welding machine & welding set Reinferment cage for the pile as mentioned in drawing.Do the boring with bailer. If you meet obstructions like concrete, hard fused slag etc. change to chisel, break the obstruction and continue boring with bailer. Continue boring till you meet the specified strata. Get the sample approved by client engineer. Do the socketing in hard rock to the depth as specified in the drawing & terminate the pile. If boring dose not progress in hard rock or rate of progress is very slow, terminate the pile at that level, though the specified depth in hard rock is not reached. Clean the borehole thoroughly and remove all loose rock / earth by bailer. . Prepare the reinforcement cage as per following : a) Provide main reinforcement & helical as per drawing and calculate from pile termitate level / COL. 49 Keep outer dia of helical as pile diameter less 100mm. c) Tack weld helical with main rod at frequent intervals. d) Weld the over lap of all main rods to suitable lenght at site. e) Insert the circular cover block size 40mm dia with 10mm dia center hole while preparing cage @ 1m c/c. Lower the cage carefully, ensure that top level of cage is as per drawing. . Lower the tremmie pipe and fix upto 600mm above boring bottom. Ensure that concrete freely flows into tremmie pipe. . Withdraw the tremmie and casing progressively during concrete, During withdrawal of casing, always ensure that no gap forms between bottom of casing and top of concrete. Finish the concrete at 2.5m above pile COL.Tr. 18. so & Withdraw all casing pipes after finishing |} the concrete. Fill up the empty bore hole with pile muck. Note : - If the boring / chiseling is not |} progressing due to obstruction, open excavation to be done to remove the obstruction OR pile location to be abandoned. STRUCTURAL FABRICATION Ensure steel section are available as per drawings withiout any defect. Clean the surface of all-steel sections & straighten the same before use. Ensure the required qualities of electrodes are available. Do the layout / marking as per marking plan get it checked before cutting / drilling. Ensure gas cut edges made smooth Ensure electrodes are preheated as required. 51 Make the rigidly leveled platform for forming the structure. Preheat the plates of thickness 25mm & above before welding. Ensure locking the free ends using spindles/jigs & fixture before welding. Form the structures as per drawings by assembling the pieces and do tack weld. Check the structres once again as per drawing and take clearance from client's Engineer. . Carry out the welding as per the welding procedure specification (WPS). . Ensure the dimension of structures after welding and rectify for warpage if any ? Carry out NDT as required Grind the welding and remove the scales ‘Apply one coat of red oxide primer, STRUCTURAL ERECTION Ensure avialibility of adequate capacity of crane with required boom lenght.‘Check the foundation bolt and shaearkey as per drawing and make protocol. Keep the packing plates in proper level Erect the column structure on foundation resting on packing plates. Check the verticality of column and tighten the nuts. Erect the tie members between the columns and do tack weld. Ensure the members are erected as per drawings Check verticality, lines & levels of all members. Weld all structural connecting / joints as per WPS. Carry out NDT if required. Grind all the joints before painting. ‘Take final clearance for painting. ‘Thickness of paint to be checked with elcometre as per drawing as required, FINAL MESSAGE If the above mentioned processes are executed effectively, Continual Improvement and Customer Delight could be achieved. Being an ISO certified company it shall be the endeavour of all employees to maintain a high degree of execution and documentation so as to maintain the awarded licences by BIS. (ae Mr.N.RADHAKRISHNAN ‘Just being honest is not enough. ‘the essential ingredient is executive integrity.ANGLES Sis Unit Wt. Sie 200 x 200x 20] 60.0) 200x200x16] 48.5) 150X150X20] 44.1 160X150X18| 35.8] 150X150X12| 27.3 130X130x12] 235 130x130X10] 19.7] nox 10x12 | 19.6) 10x 10x10] 185} 110 10X8 13.4) soox100x12| 177] tox 10x10] 149) sooxtooxs | 124 300 X 100 X6 92 80X90X8 90X90 X6 7X 75X 10 75X75 X8 75X 75X68 65 X 65X10 65x65x8 65x 65x6 65X05X 5 50X 50X68 40X 40X6 40X40 5 35X 35X6 35 X35X5 RAILS (CR) Size Wim. (Kg) CR80 CR 100 CR 120 64.20 89.00 118.00 Bro aie fr a 250K 125 200 X 100 17X90 150 X 80 125X75 100 75 50X75, 150 76 12565 125 X 66 100 X 50 75X40 41x32HEXAGONAL NUTS PLATE Wt. (kg-/sqm.) Unit We (kg/each) | Size Unit We (ko/each) The (ae) ‘Ghead. Plate WS. Plate 10 R 18 20 24 27 0.002 | 30 0.005 | 32 oor | 36 0.018 | 40 o.o32 | 42 0.081 | 50 0.105 | 63 0.159 | 80 100 222 0.265 0.350 0.435 0.605 0.920 2.700 3.500 7.500 GALVANIZED PLAIN SHEETS Gauge Size mm WIKKGSOM) 10 12 16 20 25 30 32 40 50. 35.20 61.10 68.80 84.60 100.30 13170 163.10 a7.10 54.95 62.80 78.50 94.20 125.60 387.00 196.25 235.50 251.20 314.00 392.50 ‘200 X 2500) 800 X 2600 800 X 1800 800 X 2500 800 X 2500 12.84 10.19 a2 8.66 5.32 LLED BLACK SHEETS ‘Size (mm) WiK@SGM) 3.15 mm 2.58 mm 2.00 mm 4.60 mm 4.25 mm 4.00 mm 0.80 mm 0.63 mm 24.78 19.60 15.70 12.55 8.80 7.85 6.30 4:95, PIPE (MEDIUM)Wt. (kg-/m.) MS. 288 4.85 5.10 573 6.57 8.47 12.10 16.20 19.20 21.00WEIGHT OF M. S. CEMENT CONSUMPTION DATA Round ‘Square Description Cement in kglunit O22 0.99 0.62 0.89 1.58 2.87 3.85 4.83 5.55 6.31 7.99 9.86 10.87 12.48 15.41 19.94 22.20 24.47 27.68 30.21 39.46 61.65 96.33 0.28 0.50 0.78 1.13 2.01 3.14 4.91 6.15 7.07 8.04 10.17 12.26 13.85 15.90 19.62 21.62 28.26 31.16 35.24 38.47 50.24 78.50 122.66 PoC 1 :4 :8 eo 1 8 6 ROG 1 :2 34 RCC 1 :1% 33 RG i 2 A. R. masonry in 1: 6 om Rough Stone work in 1:6 cm Brick work in 1; 3 om Brick work in 1: 4m Brick work in 1: 5 om Brick work in 1: 6 em Brick work in 1: 8 om Brick thin wal in 1: 4 em Brick flat paving in 1: 6 em Brick on edge paving 1: 6 om 170.0/ms 221.0/m? 318.0/m' 400.0/m? 560.0/m? 85.0/m? 85.0/m? 123.0/m* 96.0/m* 82.0/m* 68.0/m? 53.0/m? 9.5/m? 2.75/m? 5,00/m?A= ores. CEMENT CONSUMPTION DATA Awst Cement nig! | Asst oo rae Aal e070 MR miata ge tate 40mm thk DPC in 1:1% :3 om ees Roof water profing treatment 30.0/m? a Awad Parapet vertical water proofing 21.0/m* aes Neat cement punning 2.69/m? ben | ota mat dimension a is ma 6 mm thk. Plaster 1:4 cm (ceiling) 3.09/m* sured ight angies to tir 10 mm thk. Plaster 1:4 em(ceiling) | 4.71/m? 12mm thk. Plaster 1:4.0m 5.65/m? nade 8 EST 12 mm thk. Plaster 1:6 cm 3.98/m? Z/ a eek oe 15 mm thk. Plaster 1:4.m 5.90/m? +b4c), then 15mm hk. Plaster 1:6 cm 4.50/m? Acuieangied Tangle 20 mm thk. Plaster 1:4 em 7.86/m? 20 mm thk. Plaster 1:6.m 5.00/m? teas 20 mm thk. Plaster 1:3 cm 10.12/m? } a ee: 25 mm thk. Plaster 1:4 cm 42.11/m? il \ = ape 25 mm thk. Plaster 1:3 em aeiaiaicease Teaperiim Az area, Aza Acjpc Asana andble ct WSeda-bee), nen Ax \Sia=a)s=8X8=6) Vided Into Iwo triangles as indie ested. The area ol sach of nese triangles Is compuied, fang the results adced te lind the area of ihe trapezium, Reyuar Polygon A = s100. 1m = number ol sides. B= 160° a a, C = circumference, Aw mrt 3.14167 = 0.78540" Cm 2nr = 6.2832 = 9.14160 mC 46.2092 aVA + 51496 =0.5644R mC 43.1416 wR + 07854 =112e4 Length of arc for centre angle of 1 degree = 0,008727 6 Length of arc for centre angle ol n degrees = 0.008727 ndx 4 rl Cube Nout ipa) [Mie Naw cibaee 2 Frustum of Pyramid V = volume ya (2ate)boh 6 ‘ane Ae Pyramid, Vevolume; V= 1/2hxaron of base the base is 8 roguinr polygan, wih 7 aidan, and # wlongit of feradius of creumscribod circa, al RSI Cylinder Ve volume, 8 = avon of cylindrica! surineo Ve3.1418 n=0.7054 on 8 = 0.7032 shed 1416 da Total arva of cylindrical surtace ‘and end surlaces Aw 6.2692 « (r+h) 3146 d[!s +n] 2 — ‘Square Prism | | | FETAL col wares mere satis ar tee ssrna nen 13100 WO +8 Hollow Cylinder Vevolime Veaiaren (Ae) = 0.7084» (OF 22.1410 nr (2R-1) 23.1418 nt (O=0)a of conical auriace ae, Aa BIEPD jour oh r soz010 oh Aw asare rere Te-n—o| lerdce! 9.1418 re = 1.8708 00 salto he [Fay 4 2 Cone ae Ba ence Sere cs Lozeie note Dee) Raine Bond = 1.5708 3 (D+ a) Ror sole Frustum of Cone ees air va volume | A= area of surlace, vad 228" 4.1008 # 3 = 0.5200 1 Aw anite nat = 12.5064 saiiso 357 = 0.6204 V0 "Vew aes