PROJECT TRAINING REPORT

NAME OF THE PROJECT:

CONSTRUCTION OF G+9 NEW HOSTEL BUILDING AT

N. R. S. MEDICAL COLLEGE & HOSPITAL, KOLKATA

SUBJECT: LAYING OF ROOF SLAB AND STAIRCASE

TRAINING UNDER: PUBLIC WORKS DEPARTMENT, GOVT. OF WEST BENGAL

TRAINING PERIOD: 26-12-2017 TO 15-01-2018

SUBMITTED BY: SHOUBHIK SAHA

ROOF SLAB

The design of a roof slab consists of thickness of slab, size of bars, spacing
of bars, hooks, cranks and laps of bars, minimum cover of concrete etc. The
mix of concrete for the slab is usually by volume and is of proportion 1:2:4 (
cement, sand and aggregate)

Due to the loading conditions the slab is subjected to possible or sagging

bending movement on the bottom surface at the centre of the span and
negative or hogging bending moment at top near supports. To resist these
moments main reinforcement is provided at bottom surface along the
direction of span to resist positive bending moment.

Depending upon the span, an RCC slab may be designed as either one way
reinforced slab or two way reinforced slab. The slab which is supported on two
opposite supports is called as one way slab. This slab is considered to be
supported on two longer opposite sides. When the ratio between the length
and breadth of the room over which the slab is provided is more than 2. One
way slab consists of main reinforcement spanning between the supports with
distribution of reinforcement at right angles to it. Two way slab is said to be
spanning in two directions, when the length to breadth ratio falls below 2. In
such case, main reinforcement is provided in both directions in the form of a
mesh.

The overall thickness of slab is usually kept 10 cm though the minimum

thickness can be 7.5 cm. The minimum area of reinforcement per unit width
of a slab shall not be less than 0.15%. of the gross cross sectional area of
concrete. But due to other limitations, it becomes necessary to provide higher
percentage of steel in the slab.

Spacing of bars of main reinforcement shall not be more than 3 times the
effective depth of slab and that for the distribution bars not more than five
times the effective depth. Spacing of not more than 20 cm diameter for main
bars and not more than 40 cm for distribution bars is usually provided.

Bars smaller than 6 mm diameter or greater than 18 mm are not used for
slabs. 10 mm or 12 mm plain M.S. bars or 8 mm or 10 mm tor-steel bars are
generally used. They are provided at the bottom of the slab allowing minimum
cover of 25 mm of concrete.

In addition to bars along the main direction, provided at the bottom, bars
along the longer span are also placed on top of the main bars and at right
angles to them. These are called ‘ distribution’ bars or ‘temperature
reinforcement’ or ‘ transverse bars’. The distribution bars function to resist
cracks due to variation of temperature and shrinkage stresses. They also assist
in distribution of loads. The area of such reinforcement is usually 20 % of that
of main reinforcement. Plain M.S. bars of 6 mm diameter are usually used for
this purpose.

In all buildings, slabs covers the full width of the wall over which walls are
raised. This creates partially fixed conditions for the slab. In such cases, every
alternate bar is bent up. This arrangement is economical as compared to
providing additional bars at the top. The main bottom bar is cranked at one-
fifth of the span at either end and taken up.

Main and distribution bars are tied together with black mild steel wire of 16
gauge by providing a cross and twisting the ends. If smaller diameter of wire
is used, double strands of wire shall be provided in place of single strand.
About 5 kg. of binding wire is required for tying 1 tonne of reinforcing bars.

Considering a 2.5 M or 8’0” wide verandah by way of example, the thickness

of slab is 10 cm. Main bars are 10 mm plain M.S. or 8 mm tor-steel and are
placed at 20 cm centre at bottom of the slab along the short span allowing a
cover of 25 mm. Every alternate bar is cranked up to 0.5 M from the edge of
wall and at both ends 6 mm plain M.S. bars are used as distribution bars and
are placed at 30 cm centres at the top of the bottom bars. For the cranked
bars near the supports at the top of the slab distribution bars of same size
and same spacing are provided below the top bars.

Two-Way Slab

In providing steel for a two-way slab, the bars in both directions shall be of
the same diameter and of the same kind i.e. either plain or tor-steel. The
bottommost layer will be along the shorter span. Same size bars along the
longer span shall be placed on top of these bars and at right angles to them.
No extra distribution bars are necessary. Cranking of alternate bars shall be
done at 1/5th span from support on all the four sides and cranked bars taken
to the top which come at the top of slabs over the supports allowing usual
cover.

If the slab of one room continues over the adjacent room the portion of the
slab over the common intermediate support needs top reinforcement. The
bars in the middle portions in short span direction will be at the bottom
whereas those over the intermediate supports will be at the top. The spacing
of a given size of bar in all these positions depends upon the lengths of spans
and upon the loading conditions and is determined by design considerations.

It is desirable for sake of convenience of workmen and the supervisor to adopt

the same spacing for the bottom bars at the midsection of the slab as that of
the top bars over intermediate supports. Every alternate bottom bar when
cranked up at 1/5th of the span serves as the top bar over supports which
should be extended upto a distance equivalent to 1/4th of the adjacent span.
When the cranking of bottom bars in two adjacent spans is done in a staggered
manner, the spacing of top bars at supports becomes the same as that of the
bottom bars at the mid-span.

Shear stress in concrete is generally small and bond stress within allowable
limits. Stirrups are not used in slabs whether it is reinforced one way or both
ways.
Thickness of the slab is decided based on span to depth ratio specified in
IS456-2000. Minimum reinforcement is 0.12% for HYSD bars and 0.15% for
mild steel bars. The diameter of bar generally used in slabs are: 6 mm, 8
mm, 10 mm, 12mm and 16mm.

The maximum diameter of bar used in slab should not exceed 1/8 of the
total thickness of slab. Maximum spacing of main bar is restricted to 3 times
effective depth or 300 mm whichever is less. For distribution bars the
maximum spacing is specified as 5 times the effective depth or 450 mm
whichever is less.

Minimum clear cover to reinforcements in slab depends on the durability

criteria and this is specified in IS 456-200. Generally, 15mm to 20mm cover
is provided for the main reinforcements. Alternate main bars can be cranked
near support or could be bent at 1800 at the edge and then extended at the
top inside the slab as shown in Fig.1. Curtailment and cranking of bars and
is shown in Fig. 2.
 MATERIALS AND MACHINERY USED

 Batching plant:

A concrete plant, also known as a batch plant or batching plant or a concrete

batching plant, is equipment that combines various ingredients to form concrete.
Some of these inputs include water, air, admixtures, sand, aggregate (rocks,
gravel, etc.), fly ash, silica fume, slag, and cement.
 Transit mixer

Transit mixer is a piece of equipment that is used for transporting concrete/

mortar or ready mix material from a concrete batching plant directly to the site
where it is to be utilized. Transit mixer is loaded with dry material and water. The
interior of the transit drum is fitted with a spiral blade. Spiral blade is able to
move in two directions. During clockwise movement drum is charged with
concrete and in counter clockwise direction concrete discharge out from the
transit drum. Concrete mixing drum ensures the liquid state of materials through
rotation of the drum about its own axis.
 Concrete pump

A concrete pump is a system designed to deliver concrete through pipes.

While pumping can be used in almost all construction sites, it is especially
useful in projects where space for equipment is limited. The pump can be
placed out of the way and still pour concrete through a pipeline to the spot it
is needed.

The pump, depending on the manufacturer and model, generally consists of

a receiving hopper, two concrete pumping cylinders, and a valve system
controlling the flow of the concrete from the hopper to the pipeline. One
cylinder receives from the hopper while the other dispenses to the pipe. The
pipeline is made up of both steel lengths of pipe and heavy duty flexible
hose.
 Vibrators

A concrete vibrator is a construction tool typically used on concrete pouring

sites. These machines and an assortment of attachments are designed for
multiple applications built by a variety of manufacturers. The vibrators are used
to ensure that the pour is free of air bubbles and are even. This is so that the
concrete remains strong and has a smooth finish even after removal of the form
work. It is not exactly necessary for small jobs but it can be essential for large
load bearing projects.
 Chute and CI Pipes
 SCOPE OF THE WORK

 Marking the slab

 Form work for slab

 Placing the reinforcement

 Placing the concrete

FORMWORK (SHUTTERING)

Formwork (shuttering) in concrete construction is used as a mould for a

structure in which fresh concrete is poured only to harden subsequently.
Types of concrete formwork construction depends on formwork material and
type of structural element.

A good formwork should satisfy the following requirements:

1. It should be strong enough to withstand all types of dead and live loads.

2. It should be rigidly constructed and efficiently propped and braced both

horizontally and vertically, so as to retain its shape.

3. The joints in the formwork should be tight against leakage of cement

grout.

4. Construction of formwork should permit removal of various parts in

desired sequences without damage to the concrete.

5. The material of the formwork should be cheap, easily available and should
be suitable for reuse.

6. The formwork should be set accurately to the desired line and levels
should have plane surface.

7. It should be as light as possible.

8. The material of the formwork should not warp or get distorted when
exposed to the elements.

9. It should rest on firm base.

REINFORCEMENT

It shall be as per BBS prepared according to approved drawing. The R/F shifting
and binding shall be started as soon as shuttering is completed. R/F binding
shall continue as formwork and shuttering work is progresses.
CONCRETING

Construction joint
The construction joint shall be pre decided and fixed prior to start of the
concreting. It is planned to have two construction joints for main building as
decided. In case of major break down of the Batching plant, the additional
Construction joint may be left. The location of the construction joint shall be
at the one-third span. Construction joint shall be straight and have profile of
‘L’ shape so that successive layer of concrete shall be perfectly bonded with
previous laid layer.

Preparation of construction joint shall include roughening, removing all

laitance adhering to the joint and application of thick slurry before start of the
new concrete.

Production and placement of concrete.

Stock of material shall be sufficient to start the concrete. It shall be ensured
by stores/purchase depart that concreting is not stopped on account of
materials.

All plant and machinery are checked and made in working conditions.

Concrete of grade M-25 shall be produced from our batching plant and directly
pumped to the location of concrete placement through the pipeline. The
pouring sequence shall be from grid A towards construction joint. Since the
grade of concrete for column is M-40 and surrounding concrete is M-25,
sufficient offset around column shall be casted with M-40. The offset
dimensions shall be provided by PMC.

Proper walkways/platforms shall be arranged so that the supports of the

pipeline and manpower are not directly stand on reinforcement.

Sufficient carpenters along with supervisor shall inspect the behaviour of

supports below the slab during the casting. Extra Props shall be stocked below
slab to provide additional supports in case of any failure of supports.
CURING

The curing shall be started immediately after thumb set of the concrete laid.
Hessian clothe /Plastic shall be covered over the set concrete to reduce
moisture evaporation from the concrete during hardening and thus to
minimize shrinkage crazy cracks. These cracks are inheriting property of the
concrete specially appears during casting of flat surfaces.

Final curing shall be done by ponding and stacking water for minimum
period of 7 days.