A Study on the Construction Process of Seven Storied Residential Building.
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Study o n t he C onstruction Process of S uperstructure of a S even S toried R esidential Building Presented By- Md. Mahfuzur Rahman Jony Md. Khokan Mia Id# 14106020 Id# 14106028 Program: BSCE Program: BSCE IUBAT – International University of Business Agriculture and Technology 1 12/23/2017
CONTENTS Introduction Objectives Company o verview Company organogram and our project details Design specification Construction materials & equipment's Construction process of beam, slab, stair & column Problems & solution Recommendation Conclusion 2 12/23/2017
INTRODUCTION In this presentation we will try to present our 4 month’s practicum experience of the construction work of a seven storied residential building. We observed the construction process of super structural parts of a reinforced concrete building. Here we have focused on mainly column, stair, beam and slab construction process. 3 12/23/2017
OBJECTIVES To get knowledge about the structural drawing & design specification. To implement the structural drawing into construction site. To understand the construction and supervision work of column, stair, beam and slab . To learn about the estimating details of Super Structural work. To acquire knowledge about the steps involving construction process. To learn how to solve the rising problems and unexpected events . 4 12/23/2017
Company Overview Company Name: Tokyo Development Engineer’s Ltd. Office Address: House- 26, Road- 09, Sector-13 , Uttara , Dhaka- 1230 Phone : 02-550 89047, 550 88865 E-mail : [email protected] Web : www.tokyobd.com 5 12/23/2017
Company Organogram 6 12/23/2017
About Our Project Our project name : Tokyo Karim’s Garden Address : House #742, Road #23,Block-F, Bashundhara Residential Area. Property Details: Unit Size: 1650 sft . (Bedroom-3, Formal living, Family living, Dining, Bathroom-3) Building Facing: North facing Building Storied : ( GF+6) = 7 (Seven) Storied Residential Building. Structural Designer: Kawser Talukder B.Sc. Engg . (BUET) FIEB,RAJUK ENLISTED Fig: 3D View of Tokyo Karim’s Garden 7 12/23/2017
Typical Floor Plan 8 12/23/2017
9 Design Specification 12/23/2017
General: Design method followed is USD according to BNBC, 2006 and ACI Code 2008. Concrete: f’c = 3500 psi for columns, Cap f’c (specific strength) = Minimum 20 Mpa (3000 psi) for all other members. Minimum cement concrete ratio 1:1.5:3 for column and cap. Minimum cement concrete ratio 1:2:4 for other members. Concrete Aggregate: Fine aggregate: Local Sand of FM 1.2 & Sylhet Sand of FM 2.0 (minimum) Coarse Aggregate: 20 mm down well graded stone chips shall be used as coarse aggregate in column, Shear Wall and Cap and Brick Chips in other members. Steel Reinforcement: Reinforcement are 72 grade deformed bar having minimum fy = 500 Mpa (72,000 psi) Water: Portable water to be used in concrete mix Design Specification 10 12/23/2017
Design Specification (Continued) Lap Length: Bar type Bar Position Bar Size 10 12 16 20 25 Tension Top 450 600 750 900 1625 Bottom 400 475 650 800 1250 Compression 300 350 475 600 750 11 Clear Cover: Member Location of Condition Clear Cover Column Above ground Level 1.5” (40 mm) Beam Top Side & Bottom 1.5” (40 mm) Slab & Stair Top and Bottom 1” (25 mm) 12/23/2017
Construction Materials Materials: Cement Fine Aggregate Fig: Seven Rings Special Cement Fig: Local Sand Fig: Sylhet Sand FM Practical Design Specification Sylhet 3.0 2.0 12 12/23/2017
Construction Materials (Cont.) Fig: Brick Chips Fig: Stone Chips Fig: Reinforcement bar Materials: BSI Rod (72 Grade) 20 mm down graded Stone-Column 20 mm down brick Chips- slab, stair 13 12/23/2017
Main Equipment's Fig: Mixer Machine Fig: Bar Cutter Fig: Vibrator Fig: Crane 14 12/23/2017
Field Test of Cement Fig: Checking Hard Lumps Fig: Checking Temperature Fig: Checking Manufacturing Date Name of the Test Practical Standard Adulteration Test No hard Lumps No hard Lumps Temperature Test Cool Cool Manufacturing Date It should used within 90 days It was used within 90 days 15 Table: comparison between practical and standard 12/23/2017
Field Test of Aggregate Fig: Colour Check Fig: Earthy Substance Check Fig: Salt Test Name of Test practical Standard Salt Test No salty Taste No salty Taste Silt Test No Earthy Sub. No Earthy Sub. Color check Golden Yellow Golden Yellow 16 12/23/2017
Angular size Test : Field Test of Aggregate(continued) Large size ¾ inch 60%, Medium size ½ inches 30% Small size ¼ inch 10% Fig: Checking Angular Size 17 12/23/2017
Field Test of Bricks Fig: Tee Test Fig: Hardness Test Fig: Soundness Test Name of Test Practical Standard Hardness Test No Mark on Surface No Mark on Surface Soundness Test Metallic Sound Metallic Sound Tee Test Broken Remain Unbroken 18 12/23/2017
Field Test of Bricks (continued) Fig: Checking Brick Size Practical Standard 9.5”x4.5”x2.75” 9.5”x4.5”x2.75” 19 12/23/2017
SL Sieve Size (mm) Retain(gm) Retained Weight Percentage Cumulative (%) 1 4.75 7 0.70 0.70 2 2.36 17 1.71 2.41 3 1.18 89 8.93 11.34 4 0.600 750 75.23 86.57 5 0.300 130 13.03 99.60 6 0.150 4 0.40 100 7 pan 0.00 100 Lab Test Practical FM Design Specification FM 3.00 2.0 Fineness Modulus (FM) = Summation of cumulative (%) \ 100 = (0.70 + 2.41 + 11.34 + 86.57 + 99.60 + 100) \ 100 =3.006 = 3.00 20 Lab Test of Fine Aggregate: Fig: Sieve Analysis of Fine Aggregate 12/23/2017
Concrete Mixing Ratio is 1:1.5:3 Load = 171.44 K N Cylinder Test Name of Test Practical Design Specification Concrete compressive strength 3165 psi for 21 days 3150 psi for 21 days 22 12/23/2017
We have observed the following construction process: Construction of column. Construction of stair. Construction of beam. Construction of slab. Construction Process 24 12/23/2017
25 Construction of Column 12/23/2017
Total 14 Columns Five Types of Column(C-1 to C-5) & We observed C-2 Type Construction of Column 26 Column Layout plan : 12/23/2017
We observed the entire columns but as we are going to explained C-2 type column. The column size is 12”X18”. 6-20mm & 4-16mm bar are used is this column in 3 th Floor. Construction of Column 27 Column Schedule : 12/23/2017
The following works are followed at the time of column construction : Kicker making. Reinforcement bar placing. Shuttering. Casting. Curing. Construction of Column 28 12/23/2017
Construction of Column 29 Fig: Kicker Making and Checking Kicker Making: 12/23/2017
Construction of Column Fig: Column Ties Fig: Placing tie on Column Fig: Tie Binding 30 Reinforcement Bar Placing: 12/23/2017
10mm@ 4”c/c spacing is at the end section for tie binding. 10mm@ 8”c/c spacing at the mid section for tie binding. 25” Provide as lapping length for 16 mm bar Construction of Column Fig: 4” c/c Spacing Fig: 8” c/c Spacing Fig: Checking Lapping Length 31 Checking Bar Arrangement: 12/23/2017
Main Bar: 6-20 Ø & 4-16Ø bar Used. Tie Bar: 19-10Ø bar Used Construction of Column Fig: Column Main Bar & Tie Spacing Fig: Cross Section(C-2) 32 Details of Column (C-2): 12/23/2017
Construction of Column Fig: Cleaning Shutter Fig: Fixing Shutter Fig: Completed Shuttering Fig: Checking Vertical Alignment at bottom, mid and top section 33 Column Shuttering & Checking: 12/23/2017
Mixing by Mixer Machine Mixing Ratio- 1: 1.5 : 3 Using Vibrator Cement Grout Spread cement, Sylhet Sand & Stone Water-Cement Ratio: 0.40 4′-4″ column casted Construction of Column Fig: Column Casting Fig: Using Vibrator 34 Column Casting: 12/23/2017
Remove the nuts by the screw Then De-Shutter the Column Curing by Hose Pipe Fig: Column De-Shuttering Fig: Column Curing 35 12/23/2017 Construction of Column Curing of Column
Number of Column: 1 NO Height of the column: 8.25 ft. Column Dimension: 1.0×1.5 ft. Or (12”X18”) Total Volume: (1×1.5×8.25) = 12.40 cu. ft. Dry Volume: 12.40 ×1.5 =18.56 cu. ft. Mixing Ratio = 1:1.5:3 Water/Cement ratio = 0.4 Concrete Calculation: Cement = (Dry Volume x Cement ratio)/Summations of ratio Sand = (Dry Volume x Sand ratio)/Summations of ratio Stone = (Dry Volume x Stone ratio)/Summations of ratio So, Cement = 3.0 bags Sand = 5.0 cu. ft. Stone = 11 cu. ft. Reinforcement Calculation: 20mm & 16mm bar = 1 × ((6×10×.75) + (4×10×.48)) = 64.2 kg. 10mm bar = 1×19×7×.19 = 25.27 kg . 36 Sample Estimation for C-2 Cement Sand Stone 3.0 bags 5.0 cu. ft. 11 cu. ft. Main Bar Tie Bar 64.2 kg 25.27 kg 12/23/2017
37 Concrete Details of A ll Column Column Name No . of Column Size of Column Cement Sand Stone C-1 2 12”X15” 3.0 bags 5.0 cu. ft 11 cu. ft. C-2 1 12”X18” 13 bags 23 cu. ft 46 cu. ft. C-3 6 12”X20” 18 bags 34.0 cu. ft. 68 cu. ft. C-4 4 12”X20” 3.0 bags 5.0 cu. ft 11 cu. ft. C-5 1 12”X18” 5.0 bags 9.0 cu. ft. 17 cu. ft.
12/23/2017 38 Materials Estimated Actual Cement 42 bags 41 bags Sand 76 cu. ft. 78 cu. ft Stone 153 cu. ft. 154 cu. ft. Concrete Details of All Column Comparison between Estimated vs Actual Materials:
39 Reinforcement Details of All Column Column Name No . of Column Tie Bar Size of Column Reinforcement of Column Main bar Weight Tie bar Weight C-1 2 19-10 Ø 12”X15” 4-20mm + 4-16mm 99 kg 38 kg C-2 1 19-10 Ø 12”X18” 6-20mm + 4-16mm 64 kg 26 kg C-3 6 19-10 Ø 12”X20” 6-25mm + 6-20mm 443 kg 159 kg C-4 4 19-10 Ø 12”X20” 6-25mm + 6-20mm 461 kg 159 kg C-5 1 19-10 Ø 12”X18” 10-20mm 90 kg 26 kg
40 Reinforcement Details of All Column Column Name Estimated Main bar (kg) Used Main Bar C-1 99 101 C-2 64 65 C-3 443 450 C-4 461 467 C-5 90 92 Comparison between Estimated vs Actual Reinforcements:
Working Schedule of Column 41 12/23/2017
42 Construction of Stair 12/23/2017
The following works are followed at the time of stair construction: Shuttering of stair. Reinforcement bar placing. Shuttering of treads and risers. Casting of stair. Curing of stair. Construction of Stair 43 12/23/2017
Stair total length 14.5′ & width 8′ Stair has Two Flight Each Flight has 8 Steps Each step height 6″ & wide 10 ″ 44 12/23/2017 Construction of Stair Stair Plan:
First timber planks fixed. Runner attached with timber planks. Bamboo props Support the Runner. Fig: Stair Shuttering and using Jute Fabric 12/23/2017 45 Construction of Stair Shuttering of Stair:
Main Bar: 12mm@ 6” c/c Binder Bar: 10mm@ 6” c/c Extra Top bar length L/4 12mm@ 6” c/c in Landing & 2-16mm bar in Landing 46 12/23/2017 Construction of Stair Reinforcement Details:
47 Construction of Stair Fig: Reinforcement bar placing Reinforcement Bar placing & Checking: Fig: Checking
Fig: M aking Riser & Tread Fig: C hecking Tread Fig: C hecking Riser 48 12/23/2017 Construction of Stair Making & Checking Riser &Tread:
Fig: P ouring water Fig: Casting of Stair Fig: Using Vibrator Fig: Complete Casted Stair Fig: using Trowel 49 12/23/2017 Construction of Stair Casting of Stair:
Fig: Curing of Stair Curing Start at Next day Spreading Water by hose pipe 2-3 times on a day 50 12/23/2017 Construction of Stair Curing of Stair:
12/23/2017 52 Estimation of Stair Reinforcement calculation: Cement Sand Brick chips 13 bags 33 cft 65 cft Main bar length = 4+3.5+9 = 16.5 ft. Number of bar = 8 and 12mm@6”. So, weight of main bar = 0.27 ×8×16.5 = 35.64 kg×2 = 71.28 kg Binder bar length = 3.83 ft. Number of binder = 33 and 10mm@6”. So, weight of binder bar = 0.19×18×3.83 = 13.10 kg×2 = 26.2 kg Extra top length = 7 ft. Number of bar = 8 and 12mm@6”. So, weight of top bar = 0.27 × 7 ×8 = 15.12 kg×2 = 30.24 kg Extra top length = 6.5 ft. Number of bar = 8 and 12mm@6”. So, weight of top bar length = 0.27×6.5×8 = 14.04 kg×2 = 28.08 kg Binder bar length = 3.83 ft. Number of binder = 6 and 10mm@6” So, weight of binder bar = 0.19×3.83×6 = 4.37 kg×4 = 17.48 kg
Working Schedule of Stair 53 12/23/2017
12/23/2017 54 Construction of Beam & Slab
Construction of Beam & Slab The following works are followed at the time of beam & slab construction : Shuttering Reinforcement bar placing Casting Curing 55 12/23/2017
Fig: Bottom shutter of Beam Fig: All side shutter of Beam 12/23/2017 56 First timber planks fixed. Runner attached with timber planks. Bamboo props Support the Runner. Shuttering of Beam : Construction of Beam & Slab
Fig: Runner placing on Slab Fig: Wooden plank placing on Slab Fig: Runner supported by bamboo Props Fig: Steel Sheet Placing on Slab 12/23/2017 57 Construction of Beam & Slab Shuttering of Slab :
12/23/2017 58 Comparison Required Used Bamboo Props 241 233 Wooden Runner 51 50 Steel Sheet 54 57 Construction of Beam & Slab Calculation Shuttering Materials of Beam & Slab:
Construction of Beam & Slab 12/23/2017 59 Beam Layout Plan: Total 14 Beams. Classify (FB-1 to FB-14) Here I am going to explain FB-1
Fig: Reinforcement details of beam (FB- 1) 12/23/2017 60 Construction of Beam & Slab Reinforcement Details of Beam: Top Bar: 2-20 mm Ext Top Bar: 1- 20mm Bottom Bar: 2-16mm Ext Bottom Bar:1-16mm Stirrup: 63-10 mm
Fig: Keep the Stirrup on Marked Place Fig: Placement of S tirrup Fig: Fixing Bottom & Top bar Fig: Stirrup Binding 12/23/2017 61 Construction of Beam & Slab Reinforcement Bar Placing:
Fig: Extra top & bottom bar placement 12/23/2017 62 Construction of Beam & Slab Reinforcement Bar Placing:
Fig: Checking stirrup spacing at end section Fig: Checking stirrup spacing at mid section Fig: Checking clear cover of beam 12/23/2017 63 Checking Reinforcement Bar Arrangement : Construction of Beam & Slab
12/23/2017 64 Concrete Calculation: Beam size = 10″ x 21″ L= 38.42 ft Volume = .83 x 1.75 × 38.42 = 55.81 cft Dry volume = 1.5 × 55.81 = 83.72 cft Ratio = 1:2:4 Cement = (83.72 × 1) / 7 = 11.96 x .8= 14.96 bags Sand = (83.72 × 2)/ 7 = 23.92 cft Brick chips = (83.72 ×4) /7 = 47.48 cft Reinforcement Calculation: Total length for straight bar = L + 2×hook+ lapping = 38.42+2× (6/12) = 39.42 ft Main Bar: 2-20mm& 2-16mm =2×.75 ×39.42+2×.48×39.42 = 96.97 kg. Extra Top bar length: 33.08 ft. Extra Bottom length: 8.00 ft. Extra Bar: 1-20mm & 1-16mm = 1×33.08×.75 + 1×8.00×.48 = 28.65 kg. Tie bar Length: 5.17 ft. Total Number of Tie: 63 NOS Tie bar: 10mm = 63×5.17×.19 = 61.88 kg.
12/23/2017 65 Name of Beam Main Bar Weight Extra Bar Weight Tie Bar Weight FB-1 (12”x20”) 96.97 kg. 28.65 kg. 61.88 kg. FB-2(10”X20”) 35.7 kg 00 kg 16.15 kg FB-3(10”X21”) 94.91 kg 19.29 kg 32.42 kg FB-4(10”X10”) 27 kg 6 kg 10.6 kg FB-5(10”X10”) 31.26 kg 16.11 kg 17.76 kg FB-6(10”X10”) 19.5 kg 00 kg 10.75 kg FB-7(10”X21”) 49.29 kg 16.53 kg 41.26 kg FB-8(10”X15”) 48.24 kg 11.38 kg 30.11 kg FB-9(7”X15”) 46.5 kg 00 kg 21.62 kg FB-10(10”X20”)(7”X20”) 96.75 kg 36.64 kg 51.87 kg FB-11(10”X12”) 35.49 kg 16.25 kg 15.33 kg FB-12(10”X20”) 96.75 kg 29.25 kg 79.8 kg FB-13(10”X20”) 62.01 kg 14.75 kg 30.4 kg FB-14(10”X15”) 40.26 kg 9.32 kg 20.58 kg
Fig : Bottom s lab reinforcement 12/23/2017 68 Construction of Beam & Slab Reinforcement Details of Bottom Slab: Main Bar: 10 mm Binder: 10 mm
Fig: Checking c\c distance reinforcement of slab Fig: Checking lapping length of bottom slab reinforcement Fig: Checking 1 ʺ clear cover on bottom slab reinforcement Fig: Bottom s lab r einforcement placement Fig: After placing bottom s lab r einforcement 12/23/2017 69 Construction of Beam & Slab Reinforcement placing on Bottom Slab & Checking:
Fig : Top s lab reinforcement 12/23/2017 70 Construction of Beam & Slab Reinforcement Details of Top Slab : Main Bar: 10mm & 12 mm Binder: 10 mm
Fig: Concrete block for maintain clear cover Fig: Top slab r einforcement placement 12/23/2017 71 Construction of Beam & Slab Reinforcement Bar Placing on Top Slab :
Fig: Checking 3 ʺ clear cover on top slab reinforcement Fig: Checking extra top bar length Fig: Checking top bar spacing 12/23/2017 72 Construction of Beam & Slab Checking Top Slab Reinforcement Bar Placement:
Fig: Concrete mixing in mixer machine Fig: Using crane for pulling up the concrete Fig: Concrete place on Slab Fig: Casting the beam 12/23/2017 73 Construction of Beam & Slab Casting of Beam & Slab :
Fig: Using vibrator for compaction Fig: Using steel runner for leveling Fig: Placement of U-bar Fig: checking depth of slab 12/23/2017 74 Construction of Beam & Slab Casting of Beam & Slab:
12/23/2017 75 Construction of Beam & Slab Casting of Beam & Slab :
Fig: Making Pond for Curing Fig: Curing the Slab 12/23/2017 76 Construction of Beam & Slab Curing of Beam & Slab :
12/23/2017 78 Span Bottom bar Weight Top bar Weight Span-1 42 kg 40 kg Span-2 87 kg 84 kg Span-3 83 kg 53 kg Span-4 64 kg 48 kg Span-5 219 kg 104 kg Span-6 175 kg 101 kg Span-7 80 kg 55 kg
Working Schedule of Beam & Slab 12/23/2017 79
Total length for straight bar = L + 2×hook+ lapping = 38.42+2× (6/12) = 39.42 ft Main Bar: 2-20mm& 2-16mm = 2×.75 ×39.42+2×.48×39.42 = 96.97 kg. Extra Top bar length: 33.08 ft. Extra Bottom length: 8.00 ft. Extra Bar: 1-20mm & 1-16mm = 1×33.08×.75 + 1×8.00×.48 = 28.65 kg. Tie bar Length: 5.17 ft. Total Number of Tie: 63 NOS Tie bar: 10mm = 63×5.17×.19 = 61.88 kg. Beam size = 10″ x 21″ , L= 38.42 ft Volume = .83 x 1.75 × 38.42 = 55.81 cft Dry volume = 1.5 × 55.81 = 83.72 cft Ratio = 1:2:4 Cement = (83.72 × 1) / 7 = 11.96 x .8 = 14.96 bags Sand = (83.72 × 2)/ 7 = 23.92 cft Brick chips = (83.72 ×4) /7 = 47.48 cft 80 Sample Estimation of FB-1 12/23/2017
Problem-1: During the column casting, liquid of concrete mix came out from the form of column due to leakage in formwork or improper shuttering of column. Solution : We alert the labor about the leakage on the column Shutter and said to used jute tap properly which can protect the leakage on shutter. Problem and Solution Fig: Leakage of formwork 12/23/2017 81
Problem-2: Column C-3, after removing the shuttering there are honeycomb on the column which can occur due to improper vibration. Problem and Solution (Continued) Fig: Honeycomb in column 12/23/2017 82 Solution : We suggest the labor to fill the honeycomb by cement paste. Then they filled the place by cement paste and make plain by rubbing the jute tap. Fig: Using cement paste in honeycomb
Problem-3: In beam FB-2, Stirrup spacing is changed and being some transverse during the placement of beam. Problem and Solution (Continued) Fig : Changed spacing in stirrup Solution : We inform the labor about it and then they rebind the ties maintaining the correct spacing. 12/23/2017 83
Problem-4 : Safety should be the first condition in construction work. Wearing helmet and pant is safer than lungi and free head. Problem and Solution (Continued) Solution: We talk with them and make aware about the safety but they don‘t take any measure. Most of the time, they work unsafely. When we said about the safety, they replied that they would be habituated in this condition. Fig: Working without safety 12/23/2017 84
During our practicum period we are face some problems and our recommendation are: There are no working schedule in the construction site. Company should have work schedule for every project . Maintain work schedule properly can save cost. The management should aware of the safety. A little training and care can prevent accidents in the project . Company should need to do some test like slump test, cylinder test etc. Some test like this can ensure the strength able construction. Recommendation 12/23/2017 85
We have supervised beam, slab, stair & column construction work. After supervising our construction site, We have learned about beam, slab, stair & column construction and achieved practical experience. We have also learned construction management. It was an awesome experience dealing with different types of people at construction site. It seems to me that the practical knowledge is the most essential to be an efficient engineer. I tried to give my full afford as trainee engineers . Overall the internship program laid sound foundation for us to start our career. Conclusions 12/23/2017 86