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- Authors : M. Sankaraiah, E. Rambabu, C. Eswara Reddy
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- Volume & Issue : Volume 02, Issue 01 (January 2013)
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Quality Management and Practices in Mechanised Construction of Multi-Storeyed Buildings
M. Sankaraiah 1, E. Rambabu 2, C. Eswara Reddy 3
1 Research Scholar, Dept. of Mechanical Engg, S. V. U. College of Engg.,Tirupati-517502, India.
2 General Manager, A. P. Rajiv Swagruha Corpn. Ltd., Jawahar Nagar, Hyderabad, India
3 Professor of Mech. Engg., Sri Venkateswara University,Tirupati – 517502, India.
ABSTRACT
Mechanical Handling and Material Handling go together as that of hand-in glove in the modern construction of the Dams, Roads, Bridges, Buildings, Over Head Water Tanks, Towers, High- rise buildings having many stories, etc.
An attempt is made in this paper discusses the Quality Management and Practices on Reinforced Cement Concrete(RCC) where the Mechanical Handling equipment like Concrete Batching Plant (CBP) and Transit Concrete Mixer (TCM) are involved in the construction of multistoried buildings / High-rise buildings due to difficulties in the manual handling and time constraint.
The Cement Concrete (CC) is prepared in the CBP and transmitted to the Pre-casting yard by TCM for casting of RCC columns and RCC beams.
The compressive strength of CC is measured with samples (cubes) at different types of water curing methods. The duration for reaching required strength are found. The differences of compressive strength are studied and found that the continuous water curing has maintained for a period of 28 days so as to gain the compressive strength of 34 K/mm2 as per the code IS 456:2000 of the Buerow of Indian Standards.
Key words: Quality, RCC, Material handling, Mechanical handling, Compressive strength,,
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INTRODUCTION
Quality Management and practices are the collection, analysis and interpretation of data for use in quality control activities. Quality control is the use of techniques and activities to achieve sustain and improve the quality of product. Time saving, Cost saving and Reputation saving are the main objectives for the Project Planning and Construction Projects. Concrete Batching Plant (CBP) are being used in Constructions and they play a key role particularly in the construction of multi storeyed buildings / commercial complex in thick populated urban areas. The additional area required for yards of raw materials, installation of concrete plants and go-downs mat not be available in such areas. Therefore, mixing of concrete has to be maintained at separate locations away from the construction area. The M30 grade CC of required design is prepared in CBP by mechanical process and controls. The ready mix CC is collected and transported to the required place of work though TCM. The TCM having collecting drum which is revolving continuously upto the end of the delivery of CC so as to maintain in the uniform standards. The ready mix CC is used in
Pre-casting yard for casting of RCC hollow columns and RCC beams as per the required sizes with reinforcement as per bar bending schedule.
This paper investigates the Quality Management and Practices on Compressive strength of CC in different water curing methods and durations on the same Cubes(samples). The water curing has to maintained for a period of 28 days so as to gain the compressive strength of 34 N/sqmm as per the BIS codes, The gaining of compressive strength and Quality management of CC by Mechanical handling and material handling processes is found at better performance. This is the representation of strength coming in to the particular RCC components.
-
LITERATURE SURVEY
Quality has nine different dimensions such as Performance, Features, Conformance, Reliability, Durability, Service, Response, Aesthetics and Reputation [1]. The history of Q.C is undoubtedly as old as industry itself. During the middle ages, quality is a large extent controlled by the long periods of training required by the guides. Such training has instilled pride in workers for quality of a product.
The concept of specialization of labour was introduced during the Industrial revolution [2]. As a result, a worker no longer made the entire production, only a portion. Such change has brought about a decline in workmanship(3). Since, most products manufactured during the early period were not complicated and hence quality was not greatly affected. In fact increase in production, leads to decrease in cost. Thus, satisfying the customer expectation as for as cost is involved. But, products have became more complicated and jobs more specialized. Therefore, has it become necessary to inspect products after manufacture.
The issues of improving production performance with shortening construction time, reducing costs, etc. are the topics for researchers since a long time due to the urban growth. In realizing the goal of adequate shelter for all, the utilization of local materials as well as agro- industrial wastes could made a crucial contribution. In India, the shortage of traditional materials in which cement claims a share of 17 million tons, brick 54,898 millions, timber 13.34 million cubic meter, steel 2.70 million tons sand aggregate for concrete 286 million tons [4]. Many projects of building materials based on imported technologies closed down with colossal financial losses as they proved to be highly energy intensive and incompatible with the physical properties of local materials. Therefore, it is necessary to develop technology for construction of multi storeyed buildings from local resources which could provide sustained housing growth [5].
The productivity investigation as well as the analysis of planning and scheduling techniques are studied in [6,]. The effect of managerial action on the objectives of reducing time, cost and improving quality are investigated in [7]. The technological improvements, refers to using different materials, tools and / or equipment and to adopt new construction methods [8]. Pre-fabrication, being one of the greatest technological improvements in construction, the industrialization has long been recognized as the major way to achieve a quantum leap in productivity improvements in the Building Industry.
Accordingly, the multi storeyed building construction in Hyderabad is taken as a Case Study the construction of ground Floor [2].
Therefore, the Quality Controle and Management [9) on compressive strength of RCC components have to be compared with International Standards [10]. Therefore, Mechanical handling and Material handling of preparation of RCC is taken up for the Research pertaing high rise Building constructions..
-
METHODOLOGY
The methodology consists of curing and monitoring of M30 grade CC samples used in RCC works. The process flow chart for monitoring and measurement of incoming material from quality control laboratory is shown in Figure : – 1.
Input
Process
Input
Process
Material Specification as per contract
Material Specification as per contract
Inspect
Reject
Reject
Material as NO
Receive Sample & Lots of incoming material
Receive Sample & Lots of incoming material
per PO, QAP, IS, IRC, MORT
& H
Quality Plans, IS, MORTH & H,
IRC
Quality Plans, IS, MORTH & H,
IRC
YES
Record inspection results
Output QC-01-R-01
Record inspection results
Output QC-01-R-01
Figure 1.Process flow chart for monitoring and measurement of incoming material
The process of monitoring and measurement of quality control are explained below.
The C of M30 grade is designed as per the requirement. The raw materials such as River sand, Robo sand, 12.50mm HBG metal, 20mm HBG metal are collected from various places , tested to required standards and ready stocked at the convenient place (Back side) of the CBP. The mini water tank is located at the top of the mixing chamber with automatic gate valve system and Cement through pipe from the bunkers with hydraulic system. The CC of 0.50 cum is prepared at one cycle of duration and loaded in TCM by chain conveyor system. The CBP is controlled by electrical motors, wire ropes, conveyors and hydraulic systems.
Stage 1.
The CC of M30 grade is collected and transported by TCM for casting RCC footings, RCC columns, RCC beams, Grade slab etc. in multistoreyed buildings of G+14 floors, 17 blocks in the construction site. The samples of CC are collected and filled in the Iron moulds of size 150 mm x 150 mm x 150 mm. The cubes prepared are places under water for curing. The compressive strength of cubes are tested after 7th day and 28th day as per the guidelines of IS 456:2000 of Buerow of Indian Standards. The results are tabulated in the Table No. 1.
Stage 2.
For further analysis, the similar type of cubes of 18 No. are prepared at the columns location and another 18 cubes at beams location.
The cubes are de-moulded after minimum setting time of 30 minutes and numbered for sub division into 4 groups as shown in Figure -. 2.
Group I : BCW (B-type Columns under Water curing) : RCC cubes are immersed in water pond for 28 days and kept out side without water curing upto 63 days.
Group II : BCS (B-type Columns under Water curing) : RCC cubes placed for water curing at the yard by mechanically(sprinkling) for 28 days and kept out side without water curing upto 63 days.
Group III : BBCW (B-type Beams under Water curing) : RCC cubes are immersed in water upto 63 days.
Group VI : BBCS( B-type Beams under Water curing) : RCC cubes placed for water curing at the yard by mechanically(sprinkling) up to 63 days.
The RCC cubes of Group I (9No) are designated BCW1 to BCW9 with date of casting and completely immersed in the water pond as shown in Fig.ure -3.
The RCC cubes of Group II (9No) are designated BCS1 to BCS9 with date of casting and placed over the Pre-casting Columns n the yard. The water sprinkling device is fixed for spreading over the surfaces of cubes.
The RCC cubes of Group III (9No) are designated BBCW1 toBBCW9 with date of casting and completely immersed in the water pond at separate location.
The RCC cubes of Group IV (9No) are designated BBCS1 to BBCS9 with date of casting and placed over the surface of the Beams at the yard. The water sprinkling device is fixed for spreading over the surfaces of cubes.
After 7 days of curing time, the No.1 cube of individual Groups (4) are being tested their compressive strength in Compression Testing Machine as shown in Figure 5.
The specifications of the Compressive testing machine is shown Figure 5.: Sl.No. : Electrical & Digital HT 1654/A
Capacity : 200 KN
Proving Ring : Span: 0 2000 div.
Dial Gauge : 1 div = 0.002 mm = 10 KN
Dial Gauge Sl No and make : K 0430, Baker
Simultaneously, the other cubes of No.2,3,4,5,6,7,8,9 of individual groups are tested on 14,21,28,35,42,49,56,63 day respectively. The results are tabulated in the Tables 2 to 5 respectively.
-
RESULTS AND DISCUSSIONS
The minimum compressive strength of CC cubes of M 30 grade for 28 days = 34.00 N/mm2.
The target compressive strength of CC M30 grade cubes for 28 days = 38.30 N/mm2 .
The standard Division for the samples are found by using the following formulas.
(A) From the Table 1.
n 2
xi x
s i 1
n 1
Sx = Standard deviation of average values.
Xi = Observed value
x = Average of Xi
n = Number of observation value Sr= Standard deviation of the Ranges
Ri= Observed ranges R= Average of Ri
n= number of ranges
-
From the Table 1.
X=38.98 n=25 Sx=0.299
R=0.568 N=25 Sr=0.299
-
From table 6.
n 2
xi x
s i 1
n 1
0.79
s 3 = 0.510
-
From Table . 7
n 2
xi x
s i 1
n 1
0.048
s = 0.126
3
-
Determine the trail central line and control charts.
The central lines for the x and R charts are obtained using formulas
g g
xi Ri
x i 1
g
and R
i 1
g
Where x = average of the observations
xi = value of the ith sample
g = number of samples
R = average of the sample ranges Ri = range of the ith sample
Trial control limits of the charts are established at + standard deviations from the central value as shown by the formulas.
UCLx
x 3 x
; UCLR
R 3 R
LCLx
g
x
x 3 x
; LCLR
g
R
R 3 R
X i 1
g
; R i 1
g
UCLx=38.98+3×0.299 = 39.877
LCLx=38.98-3×0.299 = 38.083
UCLr = 0.568+3×0.299 = 1.465 LCLr = 0.568-3×0.299 = -0.329
Figure 2: CC cube Figure 3: CC cubes under water
Figure 4 : Compressive Testing Machine Figure 5: CC cube under Compression
Table : -1 Compressive strength of M30 grade CC under wter curing period of 28 days
S.No.
Date of Casting
Date of Testing
Compressive strength N/mm2
(Xi-X)
(Xi-X)2
Ri
(Ri-R)
(Ri-R)2
1
2
3
4
5
6
7
8
9
1
03.01.2011
31.01.2011
38.96
-0.02
0.0004
0.59
0.022
0.0005
2
04.01.2011
01.02.2011
39.55
0.57
0.3249
0
-0.568
0.3226
3
05.01.2011
02.02.2011
38.51
-0.47
0.2209
1.04
0.472
0.2228
4
06.01.2011
03.02.2011
38.96
-0.02
0.0004
0.59
0.022
0.0005
5
07.01.2011
04.02.2011
39.11
0.13
0.0169
0.44
-0.128
0.0164
6
08.01.2011
05.02.2011
39.25
0.27
0.0729
0.30
-0.268
0.0718
7
10.01.2011
07.02.2011
38.96
-0.02
0.0004
0.59
0.022
0.0005
8
11.01.2011
08.02.2011
38.66
-0.32
0.1024
0.89
0.322
0.1037
9
12.01.2011
09.02.2011
38.95
-0.03
0.0009
0.60
0.032
0.0010
10
13.01.2011
10.02.2011
38.96
-0.02
00004
0.59
0.022
0.0005
11
14.01.2011
11.02.2011
39.55
0.57
0.3249
0.00
-0.568
0.3226
12
17.01.2011
14.02.2011
38.96
-0.02
0.0004
0.59
0.022
0.0005
13
18.01.2011
15.02.2011
38.66
-0.32
0.1024
0.89
0.322
0.1037
14
19.01.2011
16.02.2011
38.66
-0.32
0.1024
0.89
0.322
0.1037
15
20.01.2011
17.02.2011
38.96
-0.02
0.0004
0.59
0.022
0.0005
16
21.01.2011
18.02.2011
39.41
0.43
0.1849
0.14
00.428
0.1832
17
22.01.2011
19.02.2011
38.96
-0.02
0.0004
0.59
0.022
0.0005
18
24.01.2011
21.02.2011
39.11
0.13
0.0169
0.44
-0.128
0.0164
19
25.01.2011
22.02.2011
39.25
0.27
0.0729
0.30
-0.268
0.0718
20
27.01.2011
24.02.2011
39.11
0.13
0.0169
0.44
-0.128
0.0164
21
28.01.2011
25.02.2011
39.26
0.28
0.0784
0.29
-0.278
0.0772
22
29.01.2011
26.02.2011
38.66
-0.32
0.1024
0.89
0.322
0.1037
23
31.01.2011
28.02.2011
38.96
-0.02
0.0004
0.59
0.022
0.0005
24
01.02.2011
01.03.2011
38.36
-0.62
0.3844
1.19
0.622
0.386
25
02.02.2011
02.03.2011
38.81
-0.17
0.0289
0.74
0.172
0.029
Table- 2 Compressive strength of CC cubes which are immersed in water pond in 28 days and kept outside without water upto 63 days.
S.N
o
Cube ID NO.
Location
Date of Casting
Date of testing
Curing Duration in days
Weight of the Cube inKgs
Load in Tones
Compressive strength in N/mm2
1
2
3
4
5
6
7
8
9
1
BCW1
Pre-casting yard
03.03.11
10.03.11
7
8.17
620
27.56
2
BCW2
-do-
03.03.11
17.03.11
14
8.21
640
28.44
3
BCW3
-do-
03.03.11
24.03.11
21
8.24
680
30.22
4
BCW4
-do-
03.03.11
31.03.11
28
8.25
800
35.56
5
BCW5
-do-
03.03.11
07.04.11
35
8.20
820
36.44
6
BCW6
-do-
03.03.11
14.04.11
42
8.14
840
37.33
7
BCW7
-do-
03.03.11
21.04.11
49
8.28
880
39.11
8
BCW8
-do-
03.03.11
28.04.11
56
8.32
880
39.11
9
BCW9
-do-
03.03.11
05.05.11
63
8.22
880
39.11
Table: 3 Compressive strength of CC cubes which are in water curing at the yard by mechanical(sprinkling) in 28 days and without water upto 63 days.
S.N
o
Cube ID NO.
Location
Date of Casting
Date of testing
Curing Duration in days
Weight of the Cube inKgs
Load in Tones
Compressive strength in N/mm2
1
2
3
4
5
6
7
8
9
1
BCS1
Pre-casting yard
03.03.11
10.03.11
7
8.16
600
26.67
2
BCS2
-do-
03.03.11
17.03.11
14
8.24
620
27.56
3
BCS3
-do-
03.03.11
24.03.11
21
8.20
680
30.22
4
BCS4
-do-
03.03.11
31.03.11
28
8.18
780
34.67
5
BCS5
-do-
03.03.11
07.04.11
35
8.22
800
35.56
6
BCS6
-do-
03.03.11
14.04.11
42
8.23
810
36.00
7
BCS7
-do-
03.03.11
21.04.11
49
8.20
840
37.33
8
BCS8
-do-
03.03.11
28.04.11
56
8.30
860
38.22
9
BCS9
-do-
03.03.11
05.05.11
63
8.24
880
39.11
Table: 4 Compressive strength of CC cubes which are immersed in water pond upto 63 days.
S.N
o
Cube ID NO.
Location
Date of Casting
Date of testing
Duration in days
Weight of the Cube inKgs
Load in Tones
Compressive strength in N/mm2
1
2
3
4
5
6
7
8
9
1
BBCW1
Pre-casting yard
03.03.11
10.03.11
7
8.21
610
27.11
2
BBCW2
-do-
03.03.11
17.03.11
14
8.24
650
28.89
3
BBCW3
-do-
03.03.11
24.03.11
21
8.22
720
32.00
4
BBCW4
-do-
03.03.11
31.03.11
28
8.20
800
35.56
5
BBCW5
-do-
03.03.11
07.04.11
35
8.20
820
36.44
6
BBCW6
-do-
03.03.11
14.04.11
42
8.22
860
38.22
7
BBCW7
-do-
03.03.11
21.04.11
49
8.21
870
38.67
8
BBCW8
-do-
03.03.11
28.04.11
56
8.30
880
39.11
9
BBCW9
-do-
03.03.11
05.05.11
63
8.28
880
39.11
Table: 5 Compressive strength of CC cubes which are in water curingat the yard mechanically(sprinkling) upto 63 days.
S.
No.
Cube ID NO.
Location
Date of Casting
Date of testing
Duration in days
Weight of the Cube in Kgs
Load in Tones
Compressiv e strength in N/mm2
1
2
3
4
5
6
7
8
9
1
BBCS1
Pre-casting yard
03.03.11
10.03.11
7
8.24
620
27.56
2
BBCS2
-do-
03.03.11
17.03.11
14
8.22
640
28.44
3
BBCS3
-do-
03.03.11
24.03.11
21
8.26
680
30.22
4
BBCS4
-do-
03.03.11
31.03.11
28
8.28
780
34.67
5
BBCS5
-do-
03.03.11
07.04.11
35
8.20
820
36.44
6
BBCS6
-do-
03.03.11
14.04.11
42
8.25
830
36.89
7
BBCS7
-do-
03.03.11
21.04.11
49
8.26
860
38.22
8
BBCS8
-do-
03.03.11
28.04.11
56
8.30
880
39.11
9
BBCS9
-do-
03.03.11
05.05.11
63
8.25
880
39.11
Table: 6 Compressive strength of CC cubes after curing of 28 days.
S.No.
Cube ID No.
Stress N/mm2
Xi-X
(Xi-X)2
1
BCW4
35.56
0.45
0.202
2
BCS4
34.67
-0.44
0.193
3
BBCW4
35.56
0.45
0.202
4
BBCS4
34.67
-0.44
0.193
Total
140.46
0.02
0.790
Table: 7 Compressive strength of CC cubes after curing of 42 days.
S.No.
Cube ID No.
Stress N/mm2
Xi-X
(Xi-X)2
1
BCW4
37.33
0.45
0.202
2
BCS4
36.00
-0.44
0.193
3
BBCW4
38.22
0.45
0.202
4
BBCS4
36.89
-0.44
0.193
Total
148.44
0.00
0048
X-Chart Samples
R-Chart Samples
-
-
CONCLUSIONS
The compressive strength of M30 grade CC is vary in different water curing methods. It is found that the water curing in water pond is getting more values than the other methods.
FURTHER WORK
Line balance techniques will be studied .
ACKNOWLEDGEMENT
The authors expresses their sense of gratitude for the help and cooperation extended by A. P. Rajiv Swagruha Corporation Limited, Jawahar Nagar, Hyderabad, India.
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