INTRODUCTION

Name of work

Construction of restricted height RUBs on LC No. C-10 between GA-GVMR station, LC No. C-16 & LC No. C-18 between GVMR-NAC under ADEN/DNA section.

SIZE OF PRECAST RCC BOX:- 4m X 3.75m MIX DESIGN USED :-M-35

DETAILING OF RCC

Location Cut length No. of bar Diameter of bar

20mm 16mm 10mm

LC NO. 16RCC BOX NO. 01

8.10 16 20mm

a1

a2 8.10 8 16mm

b 4.80 15 16mm

c 8.10 8 16mm

d 4.80 15 20mm

e 4.55 16 16mm

f1 2.55 8*2=16 20mm

f2 2.55 8*2=16 20mm

g1 0.55 23*8=184 10mm

g2 0.55 22*8=176 10mm

g3 0.55 22*8*2=352 10mm

h 1.45 182+176=358 10mm

LC No. 16 BASE SLAB No.01

20mm 12mm

DETAILING OF RCC BASE SLAB

LOCATION CUT LENGTH NO. OF BAR DIAMETER OF BAR

5.40 X 1.53 1.43 36 X 2=72 12mm

1.53 10 X 2=20 12mm

6.55 1 X 2=2 20mm

1.08 8+9=17 12mm

LC No. 16

BASE SLAB No. 02

5.40 X 1.53 1.43 36 X 2=72 12mm

1.53 10 X 2=20 12mm

6.55 1 X 2=2 20mm

1.08 6+6=12 12mm

LC No. 16

BASE SLAB No. 02

5.40 X 2.30 2.20 36 X 2=72 12mm

5.45 15 X 2=30 12mm

6.55 2 X 2=4 20mm

1.08 6 X 3=18 12mm

DETAILING OF RCC BASE SLAB

LOCATION CUT LENGTH NO. OF BAR DIAMETER OF BAR

LC No. 16

BASE SLAB No. 04

5.40 X 1.53 1.43 36 X 2=72 12mm

5.43 10 X 2=20 12mm

6.55 1 X 2=2 20mm

1.08 7+7=14 12mm

LC No. 16

BASE SLAB No. 05

5.40 X 2.30 2.20 36 X 2=72 12mm

5.45 15 X 2=30 12mm

6.55 2 X 2=4 20mm

1.08 6 X 3=18 12mm

LC No. 16

BASE SLAB No. 06

5.40 X 1.53 1.43 36 X 2=72 12mm

5.43 10 X 2=20 12mm

6.55 1 X 2=2 20mm

1.08 6 + 6=12 12mm

CROSS SECTION OF RCC BOX

POSITION OF LIFTING HOOKS

CROSS SECTION OF PRE CAST BASE SLAB

MIX DESIGN

M-35

Design stipulation

• Characteristic compressive strength required= 35.0 N/mm2

• Maximum size of aggregate= 20 mm

• Type of cement= OPC 43 grade

• Exposure condition= Moderate

DESIGN STEPS

1. MATERIAL USED:-

Coarse aggregate:- 1 bag

Sand :- 1 bag

Cement:- 1 bag

2. TARGATE MEAN STRENGTH:-

For M-35

35+(1.65 X 6.0):- 44.90 N/mm2 (IS 10262:2009)

3. WATER CEMENT RATIO (W/C):-

W/C taken based on trails % experience is :- 0.43

4. CALCULATION OF CEMENT CONTENT:-

Water content :- 186.0 liter

Cement content :- 186.0/0.43=432.55 kg/m3

5. PROPORTION OF COARSE AND FINE AGGREGATE (Based on volume ) :-

For concrete volume of C.A.= 0.62

Volume of F.A.= 1-0.62=0.38

DESIGN MIX CALCULATION

A. Volume of concrete 1 m3 1 m3

B. Volume of cement (432.55/3.15)x(1/1000) 0.137m

C. Volume of water (186.0/1.0)x(1/1000) 0.186m3

D. Volume of plasticizer NIL NIL

E. Volume of all in aggregate [A-(B+C+D)] 0.677m3

F. Mass of coarse aggregate 0.677x0.62x2.682x103 1125.74kg

G. Mass of fine aggregate 0.677x0.38x2.560x103 658.58kg

H. Correction for water absorption for C.A. 1125.74x(1.02/100) 11.48kg

I. Correction for water absorption for F.A. 658.58x(2.12/100) 13.96kg

J. Total water 186+11.48+13.96 211.44kg

TRIAL MIXES DETAILS PER m3

TRIAL MIX NO. 1 2 3

W/C Ratio 0.45 0.43 0.41

Cement 413.33kg 432.55kg 453.65kg

Send(F.A.) 650.23kg 644.62kg 637.94kg

Aggregate(C.A.) 1123.78kg 1114.26kg 1102.71kg

Water 211.66kg 211.44kg 211.18kg

Slump 44mm 52mm 66mm

Compressive strength water 28 days

43.14 N/mm2 45.68N/mm2 47.52N/mm2

RECOMMENDATION

Per m3 by weight:-

FREE WATER CEMENT SAND AGGREAGATE

211.44kg 432.55kg 644.62kg 1114.26kg

By Ratio:-

FREE W/C CEMENT SAND AGGREAGATE

0.488 1.0 1.490 2.576

COMPRESSION TEST ON CC CUBES (3 NOS.)

7 Days strength result

Description of the CC Cubes

Actual Compressive Strength (in N/mm2)

Average Compressive Strength

(in N/mm2)

15X15X15 cm 34.94 35.56

35.79

35.96

28 Days strength result

Description of the CC Cubes

Actual Compressive Strength (in N/mm2)

Average Compressive Strength

(in N/mm2)

15X15X15 cm 37.31 38.82

38.69

40.45

CALCULATION (for 3 days)

1 st CASE :- 1000kN = 100 tons

1kN = 1000 N x reading

= 1000 x 770

For 150 x 150mm = (77x10000)/22500 = 34.94 N/mm2

2nd CASE:-1000kN = 100 tons

1kN = 1000 N x reading

= 1000 x 790

For 150 x 150mm = (79x10000)/22500 = 35.79 N/mm2

3rd CASE:- 1000kN = 100 tons

1kN = 1000 N x reading

= 1000 x 800

For 150 x 150mm = (80x10000)/22500 = 35.96 N/mm2

Average Compressive Strength= (34.94+35.79+35.96)/3

= 35.56 N/mm2

CALCULATION (for 28 days)

1 st CASE : 1000kN = 100 tons

1kN = 1000 N x reading

= 1000 x 840

For 150 x 150mm = (84x10000)/22500 = 37.31 N/mm2

2nd CASE: 1000kN = 100 tons

1kN= 1000 N x reading

= 1000 x 870

For 150 x 150mm = (87x10000)/22500 = 38.69 N/mm2

3rd CASE:1000kN = 100 tons

1kN = 1000 N x reading

= 1000 x 900

For 150 x 150mm = (90x10000)/22500 = 40.45 N/mm2

Average Compressive Strength = (37.31+38.69+40.45)/3

= 38.82 N/mm2

RESULT & DISCUSSION FOR CEMENT

TEST SAMPLE REF

SPECIFIED REQUIREMENTS RESULT OBTAINED AS PER IS 8112

Rock strong

OPC 43 Grade Cement

PHYSICAL TEST

Specific Gravity 3.15 --------

Initial setting Time 132.0 min >30 min

Final setting Time 214.0 min <600mm

Fineness 3.40% <10%

Soundness 1.0 mm <10 mm

Compressive strength

(a) At 72 + - 1h 28.22 N.mm2 >23.0 N/mm2

(b) At 168 + - 2h 37.95 N/mm2 >33.0 N/mm2

(c) At 672 + - 4h 48.40 N/mm2 >43.0 N/mm2

RESULT & DISCUSSION FOR AGGREGATE (20mm)

SIEVE SIZE RESULT OBTAINED

20.0 mm

AS PER IS PARAMETER

GRADING PASSING%

(a) 40.0mm 100.0 (100.0)%

(b) 20.0mm 97.85 (95-100)%

(C) 10.0mm 41.26 (25-55)%

(D) 4.75mm 3.64 (0-10)%

Specific Gravity 2.682 ------------

Water Absorption 1.02 ------------

Flakiness Index 13.20 ------------

Impact Value 18.62 ------------

Abrasion Value 20.14 ------------

Free Surface Moisture NIL ------------

RESULT & DISCUSSION FOR SAND

SPECIFIED REQUIREMENT RESULT OBTAINED AS PER IS 383-1970 PARAMETER

GRADATION PASSING%

(a) 10.0mm 100.0% (100.0)%

(b) 4.75mm 95.12% (90-100)%

(c) 2.36mm 82.26% (75-100)%

(d) 1.18mm 63.15% (55-90)%

(e)600micron 42.20% (35-59)%

(f) 300micron 17.42% (8-30)%

(g) 150micron 3.81% (0-10)%

Specific Gravity 2.560% -----------

Water absorption 3.20% -----------

Silt content 1.70% ------------

Free Moisture Surface 1.08%

RESULT AND DISCUSSION FOR STEEL BAR

RESULT AND DISCUSSION FOR 43 GRADE CEMENT

Sl.No Particular Requirement of IS:8112-1989 Test result

1 CHEMICAL REQUIREMENTS 0.66 To 1.02 0.930

(CaO-0.7 SO3)/

(2.8 SiO2+1.2 Al2O3+0.65Fe2O3)

2 Al2O3/Fe2O3 0.66 min 1.37

3 Insoluble Residue(% by mass) 3.0% max 1.58

4 Magnesia(% by mass) 6.0% max 1.98

5 Sulphuric Anhydrite(% by mass) 3.0% max 2.48

6 Total loss on ignition(%) 5.0% max 1.47

7 Total Chloride(%) 0.10% max 0.01

RESULT AND DISCUSSION FOR 43 GRADE CEMENT (Cont..)

Order No.

Nominal Size

(mm)

Lot. No.

Qty. Chemical

Analysis

2% Proof Stress (N/mm2)

Tensile Strength (N/mm2)

Elongation

Total elongation

Bending Test

Rebend Test

Grade

838 FP BAR 10

S11-0279

3.54 C% S% P% 521 630 20.0 0.00 OK OK Fe 500

.22 .040 .046

838 FP BAR 16

S11-0247

3.47 .22 .042 .040 534 619 9.246 0.00 OK OK Fe 500

838 FP BAR 20

S11-0249

4.96 .19 .038 .040 519 646 20.00 0.00 OK OK Fe 500

Sl No.

Particular Requirement of IS:8112-1989 Test result

1. PHYSICAL REQUIREMENTS Not less than 225 m2/kg 332

Fineness (m2/kg)

2 Soundness: Lechatlier Expansion (mm)

10.0 max 1.00

Auto-clave (%) 0.8 max 0.080

3 Setting time (minutes)

initial 30 min 125

final 600 max 175

4 Compressive strength

3 days 23 Min 30.5

7 days 33 min 40.5

28 days 43 min 51.0

5 Temperature during Testing (25-29) 0c 27

RESULT AND DISCUSSION FOR 33 GRADE CEMENT

Sl.No Particular Requirement of IS:1489 (part I) -1991

Test result

1 CHEMICAL REQUIREMENTS I.R.= X + 4(100-X)/100

Where X=% of Pozzolona used

32.60

Insoluble Residue(% by mass)

2 Magnesia(% by mass) 6.0% max 1.48

3 Sulphuric Anhydrite (% by mass) 3.0% max 2.55

4 Total loss on ignition(%) 5.0% max 1.29

5 Total Chloride(%) 0.05% max 0.01

Sl No.

Particular Requirement of IS:8112-1989 Test result

1. PHYSICAL REQUIREMENTS Not less than 300 m2/kg 359

Fineness (m2/kg)

2 Soundness Lechatlier Expansion (mm)

10.0 max 1.00

Auto-clave (%) 0.8 max 0.072

3 Setting time (minutes) initial 30 min 155

final 600 max 205

4 Compressive strength 3 days 16 Min 34.5

7 days 22 min 40.5

28 days 33 min 46.5

5 Temperature during Testing (25-29) 0c 27

FOR NIGHT BLOCK WORKING

Sl.No Description Quantity

1 Electric generator of 10 kV 1 no. + 1 spare

2 500 Watt hallozen & electric wire etc. 15 no. hallozen and Electric wire for connection

3 Electrician and helper As per requirement

MACHINARY REQUIRED FOR LOUNCHING IN TRAFFIC BLOCK

Sl.No Description Quantity.

1 Crane of 80-100 MT capacity with 2 operator on each crane and 10 skilled labour

2 no. + 1 spare

2 Excavator Tata Hitachi or similar with operator 2 nos.

3 JCB with tools & operator 2 nos.

4 Dumper with hydraulic lift system 6 nos.

5 Gas cutting equipment 2 no. + 1 spare

TENDER CONDITION FOR SUPPLY OF CEMENT BY CONTRACTOR

Supply of cement by contractor at the rate for relevant NS item will be governed by the following condition:-

Cement for use in the works shall be procured by the contractor from the main procedures.

Cement older than 3 months from the date of manufacture shall not be accepted.

Cement bags perfectly in paper bags packing should bear the following markings:-

1. Manufacture’s name.

2. Registered Trade Mark of manufacture, if any.

3. Type of cement.

4. Weight of each bag in kg. or No. of bags/tons.

5. Date of manufacture.

Quality test certified for cement as per IS:4031 shall be furnished by the contractor.

Railway may also take samples during course of execution of works.

Frequency of testing shall be as prescribed by the relevant IS code.

Following test shall be carried out:-

1. fineness

2. compressive strength

3. initial and final setting time

4. consistency

5. soundness

In case the sample tested do not pass the quality test conduced ,the entire batch of cement supply shall be rejected and return to the contractor.

For storage of cement, the contractor shall have to construct a temporary godown of adequate capacity.

It will be obligatory on the part of the contractor to weight the truck of cement in the presence of inspector in charge and supply an original copy of weight slip along with consignment.

The inspector in charge will verify the quantity of cement brought to the sight of work and returned one verified weight slip to the contractor after the same is stacked inside the cement godown under his supervision.

The record of cement brought to the site of work, daily consumption, daily opening balance and closing balance shall be maintained at site jointly by the inspector in charge of work and contractor or his authorized representative.

The contractor shall make the cement godown available for inspection along with contractor record to the site engineer or his representative as and when required.

The contractor shall ensure that after completion of the work of the contract for any reason what so ever, the temporary cement godown shall be dismantled.

All disentailed material/debris shall be removed and the clear site shall be handed over back to railway.

All the released material shall be the property of the contractor and no payment shall be made by the railways.

The final bill and earnest money/security deposits shall not be released unless the godown is dismantled and the site is cleared.

Tolerance requirement for cement

Cement supplied at one time will be taken as a batch.

The number of batches taken for the sample from each bags shall be as under:

Sl.No Batch size Sample size

1 100 to 150 20

2 151 to 280 32

3 281 to 500 50

4 501 to 1200 80

5 1201 to 3200 125

6 3201 to above 200

The bags in sample shall be selected as random.

The specified net mass(50 kg) shall be not more than 5% of the bags in the sample.

In case of truck load of 10 to 25 tons, the overall tolerance on net mass of cement shall be -0.5 to +0.5%.

Any batch of cement not conforming to above tolerance will be rejected.

The consumption of cement on work shall be assessed on the basis of cement constants per unit quantity of various items of work.

In case of design mix of concrete of specified strength where the cement is to be used by weight by where specially ordered in the NS item rate or tender condition, a verification of +1%(max) will be allowed in the consumption of cement.

Staking of cement in the godown shall be done on a layer of wooden sleepers, so as to avoid contact of cement bags with the floor.

Cement shall be stored in such a manner as to permit easy access for proper inspection.

Cement should be stacked not more than 10 layers height.

The stacks of cement bags shall be covered with Tarpaulin during monsoons so as to avoid the possibility of deterioration of cement by moisture in the atmosphere.

Cement brought to the site from godown in excess of the requirement calculated based on the cement factors shall be taken back by the contractor on completion of the work after written approval of ADEN/XEN on proper documents.

Payment as per relevant NS item will be made on the basis of quantity of cement actually consumed and the quantity calculated as per cement factors for various items.

Cement actually consumed on works shall normally match the quantity calculated as per cement factors for various items.

Empty cement bags will be the property of contractor.

SPECIAL CONDITION OF CONTRACT

The contractors shall satisfactorily maintain the work completed by him/them for the following period from the date of completion certificate.

Sl.No. Description of work Maintenance period

1 Earth work & supply of material NIL

2 Repair and maintenance work 03 months

3 New works(except earth work) 06 months

SUPPLY OF WATER:-

As regards the supply of water the condition as laid down on the relevant chapters & annexure of the standard schedule of rates of 1996 shall apply except the right of the travelling water tanks shall be bond by the railways.

For the plants and machineries for the use of contract the contractor will be required to pay such higher charges as stipulated in the northern railway schedule of rates or may be fixed by the divisional engineer.

For mixing cement concrete where it is required to be done by the mechanical mixers by the Railway, the contractor will be debited to Rs150/mixer for each working day at site inclusive at crew staff.

SOURCES OF BUILDING MATERIALS:-

Stones patties ashlar will be obtained from fedoras and quarries or equivalent stone lime will be obtained from goton .

All other building materials will be obtained from the nearest sources after obtaining the approved of the quality by the engineer.

In case of location where it is not possible to get the material by road or working in between the section the assistance may be offered by the Railway by way of display and labor.

RECORD BOOKS

Following records are maintained in project :-

1. Site order book.

2. Cement register.

3. Steel register.

4. Cube testing register.

5. Material passing register.

6. Sieve analysis register.

1. SITE ORDER BOOK: - It is used to instruct the work agency and is required at site.

PERFORMA

Sl.No Date Description of instruction to agency

Action taken by agency

Signature of agency Signature of officers of department

2. CEMENT REGISTER: - It is used for day to day consumption of cement

PERFORMA:

Sl.No Date Cement received at site

Cement used

Cement balance

Signature of agency

Signature of officers of department

Description of works

3. STEEL REGISTER:- It is maintained for records of steel as hidden measurement.

PERFORMA:

Sl.No. Date Location Shape of bar

Cut length of bar

No. of bar

Dia of bar

(mm)

Total length

Wt per meter

Total weight

Signature of contractor

4. CUBE TESTING REGISTER:- It is used for checking compressive strength of cube for 7 days & 28 days.

PERFORMA:

Sl.No

Date of casting

Location

Cube no.

Mix used

7 Days testing 28 Days testing Signature of contractor

Date of testing

Strength (N/mm2)

Avg. strength

N/mm2

Date of testing

Strength N/mm2

Avg. strength N/mm2

PLANNING OF WORK

Where Railway bank height about 2 to 3 meters from original ground level, where RUB proposed.

Estimate sends to head quarter for proposed RUB work.

Estimate sanction for RUB by competent authority.

Tender invite for RUB work by Head quarter office.

Work sanctioned for RUB.

Working drawing & detailed drawing received from Head quarter for sanction of work.

Mix designed prepared, which is used in work.

Materials checked at site before use.

Segments casting work starts before shuttering & steel reinforcement

Casting of segment RCC box & base slab near level crossing where RUB site proposed as per mix concrete design.

Curing work start 24 hours after casting and up to 28 days completely.

Cube testing result taken after 7 days & 28 days after casting.

Preparation of launching of RUB box.

Drainage system to be provided for removing of rain water.

Height gauge to be provided both sides of bridge 20m away bridge.

1 in 20 slopes is provided in a ramp.

REFERENCES

1. IS 383-1970:- Specification for coarse and fine aggregate from natural source for concrete.

2. IS 2386-1963:- Methods of test of aggregate for concrete.

3. IS 456-2000:- Code of practice for plan and reinforced concrete.

4. IS 10262-2009:- Recommended guidelines for concrete mix design.

5. Sp 23:- Hand work on concrete mixes.