HANDBOOK

-ON
BUILDING CONSTRUCTION PRACTICES
(Excluding Eiectrkai =Work)

.
As in the Original Standard, this Page is Intentionally Left Blank
 HANDBOOK
ON
BUILDING CONSTRUCTION PRACTICES
(Excluding Electrical Work)

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

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SP62(S & T,: 1997

FIRST PUBLISHED SEPTEMBER 1997

0 BUREAU OF INDIAN STANDARDS

KS 91.010.01

ISBN 81-7061-048-6

PRICE:Rs. 1080.00

Typeset by Paragon Enterprises, New Delhi 110002

Printed in India

at Central Electric Press, New Delhi 110028

Published by

Bureau of Indian Standards, New Delhi 110002

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 FOREWORD

Users of various civil engineering codes have been feeling the need for explanatory handbooks and other
compilations based on Indian Standards. The need has been further emphasized in view of the first publication
of the National Building Code of India in 1970 (which has since been revised in 1983) and its implementation.
The Expert Group set up in 1972 by the Department of Science and Technology, Government of India carried
out in-depth studies in various areas of civil engineering and construction practices. During the preparation of
the Fifth Five-Year Plan in 1975, the Group was assigned the task of producing a Science and Technology Plan
for research, development and extension work in the sectors of housing and construction technology. One of
the items of this plan was the formulation of design handbooks, explanatory handbooks and design aids based
on the National Building Code andrelated Indian Standards and other activities in the promotion of the National
Building Code. The Expert Group gave high priority to this itemand on the recommendation of the Department
of Science and Technology, the Planning Commission approved the following two projects which were assigned
to the Bureau of Indian Standards (erstwhile Indian Standards Institution):
a) Development programme on code implementation for building and civil engineering construction, and
b) Typification for industrial buildings.

A Special Committee for Implementation of Science and Technology Projects (SCIP) consisting of experts
connected with different aspects was set up in 1974 to advise the BIS Directorate General in identifying and for
guiding the development of the work. Under the first project, the Committee has identified several subjects for
preparing explanatory handbooks/compilations covering appropriate Indian Standards/ Codes and Specifica-
tions which include the following:

*Handbooks Published:
1. Design Aids for Reinforced Concrete to IS 456 : 1978 (SP 16 : 1980)
2. Handbook on Masonry Design and Construction (First Revision) (SP 20 : 1991)
3. Summaries of Indian Standards for Building Materials (SP 21 : 1983)
4. Explanatory Handbook on Codes of Earthquake Engineering (IS 1893 : 1975 and IS 4326 : 1976)
(SP 22 : 1982)
5. Handbook on Concrete Mixes (Based on Indian Standards) (SP 23 : 1982)
6. Explanatory Handbook on Indian Standard Code of Practice for Plain and Reinforced Concrete
(IS 456 : 1978) (SP 24 : 1983)
7. Handbook on Causes and Prevention of Cracks in Buildings (SP 25 : 1984)
8. Handbook on Functional Requirements of Industrial Buildings (Lighting and Ventilation) (SP 32 : 1986)
9. Handbook on Timber Engineering (SP 33 : 1986)
10. Handbook on Concrete Reinforcement and Detailing (SP 34 : 1987)
11. Handbook on Water Supply and Drainage with Special Emphasis on Plumbing (SP 35 : 1987)
12. Handbook on Typified Designs for Structures with Steel Roof Trusses (with and without Cranes) (Based
on IS Codes) (SP 38 : 1987)
13. Handbook on Structures with Steel Portal Frames (without Cranes) (SP 40 : 1987)
14. Handbook on Functional Requirements of Buildings (other than Industrial Buildings) (SP 41 : 1987)
15. Handbook on Structures with Reinforced Concrete Portal Frames (without Cranes) (SP-43 : 1987)
16. Handbook on Structures with Steel Lattice Portal Frames (without Cranes) (SP 47 : 1987)

Subjects Under Programme:

- Foundation of Buildings

“Handbooks published are available for sale from BIS Headquarters, and from all Branches and Regional Offices of BE.

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 - Construction Safety Practices
- Explanatory Handbook on IS 875 (Part 3) : 1987
- Fire Protection
- Form Work
- Tall Buildings

This Handbook has been written with a view to unifying the constructional practices being followed by various
organizations engaged in construction of residential, commercial and industrial buildings and is mainly based
on various Indian Standards published in the respective areas of construction. The Handbook provides
information regarding methods of construction of any particular element of the building using different materials
so that a designer/site engineer can choose the most appropriate material(s) and method(s) of construction as
per his needs. Besides, it is hoped that this Handbook would be of great help to students of Civil Engineering.

It may be noted that the Handbook does not form part of any Indian Standard on the subject and does not have
the status of an Indian Standard. Wherever, there is any dispute about the interpretation or opinion expressed
in this Handbook, the provisions of the codes only shall apply; the provisions of this Handbook should be
considered as only supplementary and informative.
The Handbook is based on the first draft prepared by Shri D. Ajitha Simha, former Deputy Director General of
Bureau of Indian Standards with Shri P. Krishnan, Director General CPWD (Retd) as the co-author. The draft
handbook was circulated for review to Structural Engineering Research Centre, Chennai; Central Building
Research Institute, Roorkee; Department of Science and Technology, New Delhi; Central Public Works
Department, New Delhi; Metallurgical and Engineering Consultants (India) Ltd, Ranchi; Planning Commission,
New Delhi; Engineers India Ltd, New Delhi; Hindustan Construction Co ~Ltd, Mumbai; Asia Foundation and
Construction Ltd, Mumbai; Cemindia Co Ltd, Mumbai; Engineer-in-Chief, Army Headquarters, New Delhi;
Housing and Urban Development Corporation, New Delhi; Howe India (Pvt) Ltd, New Delhi; National Institute
of Construction Management and Research, Mumbai; M/s Ansal Properties and Industries Ltd, New Delhi;
Building Material and Technology Promotion Council, New Delhi; Chief Engineer (R&B), Hyderabad; Public
Works Department, Itanagar; Road and Building Department, Gandhi Nagar; Public Works Department,
Mumbai; Chief Engineer (Blds, PWD, B&R), Chandigarh; Public Works Department, Shimla; Chief Engineer
(Communication and Buildings), Bangalore; Chief Engineer (Building and Local Works), Trivandrum; Public
Works Department, Patna; Public WorksDepartment, Calcutta; Public WorksDepartment (Buildings), Shillong;
Chief Engineer (Building Projects), Aizawal; Chief Engineer, Housing, Kohima; Works Department,
Bhubaneshwar; Public Works Department, Chennai; Public Works Department, Jaipur; Public Works Depart-
ment, Lucknow; Institution of Engineers, New Delhi; Garnmons India Ltd, Mumbai and views expressed were
taken into consideration while finalizing the Handbook.
 CONTENTS

Page

Introduction ix
,
Chapter 1 Construction Planning and Storage of Materials 1
,
Chapter 2 Earthwork 11

Chapter 3 Foundations 25

Chapter 4 Masonry 43

Chapter 5 Plain and Reinforced Concrete 91

Chapter 6 Anti-termite Measures 123

Chapter 7 Doors and Windows (Wood and Metal) 135

Chapter 8 Steel Construction 165

Chapter 9 Floors and Floor Coverings 177

Chapter 10 Wall and Ceiling Finishes and Coverings and Walling 239

Chapter I 1 Roofs and Rooting 277

Chapter 12 Damp-Proofing and Waterproofing 323

Chapter 13 Joints in Buildings (Control of Cracks in Buildings) 361

Chapter 14 Whitewashing, Colour Washing and Painting of Masonry, Concrete and 377
Plaster Surfaces (Calcareous Surfaces)

Chapter 15 Painting, Varnishing and Allied Finishes (Wood and Metals) 391

Chapter 16 Water Supply and Drainage 409

Chapter 17 Special Construction Procedures - Earthquake Effects, etc 433

Chapter 18 Demolition of Buildings 455

List of Referred Indian Standards 466 ‘_

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 COMPOSITION OF THE SPECIAL COMMITTEE FOR IMPLEMENTATION OF
SCIENCE & TECHNOLOGY PROJECTS (SCIP)

CHAIRMAN
PADMASHRIDR H. C. VISVESVARAYA
Vice-chancellor
University of Roorkee
Roorkee

MEMBERS REPRESENTING
DR T. V. S. R. APPARAO Structural Engineering Research Centre (CSIR), Madras
DIRECTOR Central Building Research Institute, Roorkee
SHRIV. RAO AIYAGARI Department of Science & Technology, New Delhi
DIRECTORGENERAL Central Public Works Department, New Delhi
ADDITIONALDIRECTORGENERAL (Alternate)
SHRIM. L. MEHTA Metallurgical and Engineering Consultants (India) Ltd,
Ranchi
SHRI S. K. DATTA (Alternate)
SHRIB. D. JETHRA Planning Commission, New Delhi
SHRI P. D. MAYEE (Alternate)

Secretaries
SHRI K.. K. SHARMA
Director (S & T), BIS
SHRIMATI NEETA SHARMA
Deputy Director (S & T), BIS

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 INTRODUCTION

The National Building Code of India, 1983 (NBC) covers all the aspects of buildings. These aspects include
building byelaws, development control rules, building materials and fire protection which are covered in Part
I to Part V; Part VI covers the design of buildings using the building materials. Part VII is a compendium ~of
Indian Standards on Construction Practices generally described as codes of good practices. Part VIII deals with
building services, Part IX with plumbing services and Part X, the last part, deals with signs and outdoor display
structures.
For implementation of the NBC, a broad decision was taken by all state governments and the central and public
sector departments to incorporate the appropriate parts of the NBC into the relevant technical documents, such
as, municipal building byelaws, PWD specifications, specifications of construction departments, etc.

Simultaneously it was felt that for easy understanding and implementation of various Parts of the NBC,
handbooks be brought out on various Parts/Sections as relevant. In the light of this, S & T project was launched
by BIS, the Bureau of Indian Standards to prepare such handbooks. This handbook on constructional practices
is one of them. Some handbooks have been already prepared and reference is made to them as found necessary.
This handbook has been on the anvil for some time now. The NBC has broadly classified buildings into 9 groups
based on use and occupancy; for convenience of this handbook, they have been grouped into three, namely,
residential, commercial and industrial buildings. Therefore, a study was made of available Indian Standards on
constructional practices of these three groups of buildings.

Within the BIS this work of standardization of the construction sector is spread over more than one technical
division. Departmental programmes of civil, mechanical, metallurgical, chemical, river valley had to be checked
up in this context.
Normally PWDs and other construction department largely cover the constructional practices relevant to
residential and to some extent office buildings. Constructional practices relevant to commercial buildings and
industrial buildings are not generally dealt with. Thus this handbook has a much wider coverage in dealing with
constructional practices for residential, commercial and industrial buildings, than normal departmental
specifications.

The approach to the handbook is to attempt to cover the ‘how’ of constructional practice with the ‘why’ of it.
The current departmental specifications generally specify as to how an item of work has to be done. They do
not explain the rationale for such specifications and therefore the user is not given enough information to decide,
for the same work, use of alternate or more appropriate specifications among others available in the country.
For example a number of specifications for flooring are available; the choice of any of them according to the
end use is not mentioned. Therefore the reasons or ‘why’ of a particular specification helps in choosing one of
the many specifications available for an appropriate end use. Such information, it is hoped, would lead to a
reasonably good decision on choice or selection of construction procedure in relation to its end use or
performance on site.

A holistic approach to buildings bring out the interrelationship among building materials, design and
construction of buildings using these materials. Therefore, construction practices have to be viewed inthe light
of quality of materials and appropriate designs. The BIS have already brought out a summary of Indian Standards
on building materials; handbooks on design; and handbooks on some services. This handbook would therefore
have to be looked at as filling a gap in the series of handbooks on the building as a whole. It is therefore felt
that a close co-ordination be established between the design of an item/element and its construction in the field
SO that the intention of the designer is fully understood in the field.

To demarcate the contents of the handbook into individual chapters, available PWD handbooks have been
studied; these include among others the CPWD specifications of 1991-92 and Tamil Nadu Building Practice
198311985. The main basis are the Indian Standards available up to March 1994. From a study of

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these, the chapters have been identified and arranged according to the sequence of construction as closely as
possible, namely, planning of work, collection of materials, earthwork and related termite treatment, founda-
tions, superstructure of masonry; wood, concrete and steel, flooring, wall finishes and roofing and then followed
by waterproofing and damp-proofing. Finishing of surfaces, such as, masonry, concrete and plaster are then
covered; finishes of wood and metal construction is also covered. Finally water supply and drainage systems
are covered. Emphasis is then laid on special construction procedure particularly for earthquake forces. The
last chapter deals with demolition of buildings.

For the use of materials not covered by Indian Standard Codes of Practice, the construction practices would be
based on the principles enumerated in each section. For example in painting, the preparation of surface and
application should be based partly on manufacturers recommendations and broadly on the principles of preparing
a clean, dry surface to receive the paint; the actual finishing should be preceeded by filling, staining where
applicable and sealing particularly with respect to wood surfaces. Similar procedure could be worked out for
other items of work using new materials, such as, for doors, roofing sheets and so on.

For economies in construction, planning of the entire work as covered in Chapter 1, is of importance. Crack
control in buildings as covered in Chapter 13 which could be of use in planning of buildings is also of great
importance.
,,
For specialized construction work reference has been made to ISS wherever available.

It is therefore reasonable to assume that careful planning and meticulous observance of all the constructional
practices elaborated herein would lead to ahigh quality building.

For ease of reading, each chapter is preceded by a table of contents. List of standards used and referred to are
given at the end of the handbook. A summary of each chapter is given below to indicate its broad coverage.

CHAPTER 1

Construction Planning and Storage of Materials

This chapter deals with the need for planning of construction before commencement of work. Attention is drawn
to the use of networking techniques like Programme Evaluation and Review Techniques (PERT) and Critical
Path Method (CPM) to draw up a sequence of operations in a given time frame taking into account various
elements of such operations. Such planning techniques are likely to help in proper monitoring of the work and
avoid time overruns and finish the project in time. That is why at the very beginning of this handbook this aspect
of planning has been brought in.
Stocking and storage of materials, before commencing the construction is an important activity as part of
planning. Safe storage and stacking would avoid hazards of breakage, etc. Details of storage of most of the
materials of construction are given.

The chapter is divided into two Parts; Part 1 deals with construction planning, and Part 2 deals with storage of
materials.

CHAPTER 2

Earthwork

Soils are classified for excavation work. Reference is also made to appropriate Indian Standard on soil
classification. Excavation for various end uses, different depths and different areas are described. Information
on excavation in soft soil, hard soil, soft rock and hard rock is given. Shoring and timbering details are
elaborated. Excavation in mud, water and foul positions is covered.

Immediately after excavation, the anti-termite treatment of soil for different situations, is elaborated. The site
preparation, chemicals to be used, etc, for treatment at various locations are given. Information on treatment of
masonry, concrete foundations, masonry up to ground level, etc, is given. Treatment of soils around pipes,
conduits, etc. is also given for protection against termites. Statutory authorities may be consulted in hazards
related to use of these chemicals.
CHAPTER 3

Foundations
This chapter covers the construction of shallow, deep, spread and strip foundations and pile foundations. Details
of different types of piles, namely cast in-situ, precast and timber piles are given; in this bored and driven piles
are elaborated. Reference is made to machine foundatians and special foundations.

Information on choice of foundations is given in Annex A. Guidelines for improvement of weak soils to carry
more loads are given in Annex B.

CHAPTER 4

Masonry
This chapter is divided into three parts, namely, mortars, brickwork and blockwork and stonework.

Part 1 deals with mortars. Types of mortars such as cement mortar, cement-lime mortar and lime mortars are
described in detail, such as, selection of mortars, preparation of mortars, etc. Emphasis is laid on the use of
composite mortars which have an edge over plain cement mortars. Optimum mortar mixes in relation to masonry
strengths are also indicated.

Part 2 deals with brick and block units, brickwork, blockwork and in-situ walls with soil cement.

Section 1 gives information on various types of bricks available in the country and some of their properties.
Information on various types of blocks made in the country is given. This could help in deciding on the type
of brick or block to be chosen for a given condition of loading so that economies can be achieved in
construction.

Section 2 deals with brickwork. Various types of bonds are illustrated and explained including the end uses.
Laying of brickwork for different components of building is indicated. Thickness ofjoints, preparatory work,
etc, are also covered.

Section 3 deals with blockwork. Careful consideration has to be given for avoidance of crack formation
due to structural movements of supporting structural elements. Remedial measures for such crack formation
are mentioned. Laying of blocks is dealt with in detail. Provisions for openings, roof and intersecting walls
are covered. The use of hollow, light weight and autoclaved concrete blocks is covered.

Section 4 deals with construction of walls in-situ with soil cement. The quality of soil, amount of cement
to be mixed depending on type of walls, etc, are covered. To carry roof loads through trusses, beams, etc,
bed blocks are recommended. Plastering with cement plaster is suggested. Mud plaster with addition of cut-
back bitumen is also provided. The building is limited to one storey only.

Part 3 deals with stone masonry. Types of stones and their properties such as durability, strength and sizes are
described. Preparatory work such as dressing, handling, etc, are detailed. Various types of stone masonry and
the general requirements of laying are covered; construction of these types of stone masonry is covered in detail
with illustrations.

CHAPTER 5

Plain and Reinforced Concrete

This chapter deals with plain and reinforced concrete work in buildings using cement; use of lime and lime
pozzolana concrete is also covered. Shotcreting of work is also dealt with.

Part 1 deals with the common requirements of plain and reinforced cement concrete. This includes materials
to be used, grades of concrete, production, transportation and mixing of concrete. Concreting under special
conditions, such as, hot weather, cold weather, underwater, in sea water and aggressive soils is also covered.
Reference is made to ready mixed concrete and non-destructive testing of concrete. Accelerated curing for
testing of concrete is also covered apart from determination of particle size and surface moisture on aggregate.

(4
Part 2 deals with additional requirements of reinforced concrete work over and above the general requirements
covered in Part I. Details of formwork, striking of formwork, etc, are dealt with. Placing of reinforcement,
welding of plain and deformed bars are also covered. Cover to reinforcement shall be as per drawings subject
to IS 456 : 1978.
Part 3 deals with the use of lime concrete and lime pozzolana mixture concrete.

Section 1 deals with lime concrete including materials, mixing and placing of concrete. Details of laying
lime concrete~in foundations, arches, etc, are covered.

Section 2 deals with laying of lime pozzolana mixture concrete.

Part 4 covers use of shotcreting methods when employed. Both dry mix and wet mix processes are covered.
Details of application of shotcrete for certain elements and locations are given.

CHAPTER 6

Anti-termite Measures
This chapter covers anti-termite measures by constructional means for new buildings and also the anti-termite
treatment of existing buildings. This chapter is brought in immediately after Chapters 3,4 and 5 dealing with
foundations, masonry and concrete to highlight the need to take these measures at the time of construction of
these items of work. The chemical methods of anti-termite treatment are already covered in Chapter 2 on
earthwork.

Design criteria, internal and external anti-termite measures and termite shields are dealt with in Part 1 dealing
with constructional measures.

Part 2 deals with post constructional methods for protection of existing buildings; including inspection of the
structure, elimination of termites andperventive measures. Statutory authorities may be consulted on the hazards
of use of chemicals.

CHAPTER 7

Doors and Windows (Wood and Metal)

Thischapter covers installation of doors and windows and ventilators made of wood, steel and aluminium; the
chapter is divided into two parts accordingly.

Part 1 dealing with wooden doors, etc. gives detailed information on classification of timber in the country for
construction and furniture making; in this portion all relevant information on various characteristics is given;
this would help in deciding on use of various species of timber for making of wooden doors, etc. Moisture
content is another important aspect governing woodwork and zoning of the country based on maximum
permissible moisture content is also given.
Installation of wooden frames, pressed steel frames, panelled shutters, ledged, braced and battened doors and
windows, battened and framed door and windows, timber panelled and glazed shutters; louvredshutters; glazing
and fittings are covered in some detail.

There are many hardware fittings and a number of figures are given to illustrate them; reference to Indian
Standards for both wood based products and builders hardware is given for ease of use.
Part 2 deals with the installation of steel and aluminium doors, windows and ventilators; details of installing
single and composite units are covered.

CHAPTER 8

Steel Construction
This chapter deals with the construction using hot rolled sections including tubular sections and cold formed
light gauge sections. For this purpose the chapter is divided into two Parts.

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 Fabrication of sections and their connections are the two major facets of steel construction. In each Part therefore
fabrication details such as straightening, machining, cutting, holing, etc, are dealt with.
In dealing with hot rolled sections use of rivets, bolts, high strength friction grip bolts and welding is elaborated.
Shop erection, site erection, shop painting and site painting are dealt with. Special precautions for members not
meeting at a joint, packing of materials, inspection, etc, are also dealt with.

, Special requirements of fabrication for design of hot rolled sections by plastic theory are mentioned.

For construction of tubular structures, use of rivets, close tolerance bolts and welding is dealt with. A list of
standards and handbooks relating to steel construction is given in Annex A.
Reference is made to good construction practice by resistance spot welding for cold formed light gauge sections.

CHAPTER 9

Floors and Floor Coverings

This chapter deals with floors and floor coverings extensively. For this purpose the chapter is divided into five
Parts.

Part 1 deals with brickfloors and details of their construction. It includes quality of bricks, preparatory work,
construction and finish.

Part 2 deals with laying of cement concrete floors. It includes in-situ concrete flooring, in-situ granolithic
flooring, in-situ terrazzo finish and cement concrete tiles.

Part 3 covers construction of industrial floor finishes including dairy floor finishes.

Part 4 deals with special floors and floor coverings. It includes magnesium oxychloride finish, rubber floors,
bitumen mastic floor finish, linoleum floors, epoxy resin floors, PVC floors, use of chemical resistant mortars
and parquet flooring.

Part 5 covers construction of timber floors using joists and planks.

CHAPTER 10

Wall and Ceiling Finishes and Coverings and Walling

This chapter is divided into two Parts. Part 1 deals with construction of wall finishes, ceiling finishes, wall
coverings and ceiling coverings. It covers the details of materials, preparatory work and construction of the
following finishes on walls and ceilings and their coverings.
- Lime plaster finish; cement and cement-lime plaster finish; external rendered finishes for different
backgrounds.
- Externalfacing and veneers using stone, cement concrete, tiles and mosaics, including the special
requirements of using devices like cramps to fix the veneers to the background wall.
- Wall coverings using various woodbased products, asbestos cement boards, etc, is dealt with.
Similarly ceiling coverings using different materials is also dealt with.
- Information on backgrounds with sulphate content is also given.

Part 2 deals with the construction of walls using reeds suitable for earthquake prone areas, gypsum light weight
partitions and the use of no fines in-situ concrete in walls and foundations.

CHAPTER 11

Roofs and Roofing

This chapter deals with various types of roofs and roofing. Roofing materials differ and for this purpose, the
chapter is divided into five Parts, namely, flat roofs, sloping roofs, shell roofs, thatched roofs and flat roof finish.

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Part 1 covers considerable amount of information on jack-arch type roof, Madras terrace, stone over joint
construction. Use of various types of precast roofing elements in combination with different types of blocks,
such as, hollow and solid made from concrete or clay materials are described. A careful study of these
combinations in flat roofs may lead to savings in cement and steel.

Part 2 covers use of wooden shingles in sloping roofs of hilly regions. Use of slates is also indicated. Use of
AC sheets both corrugated and semi-corrugated is extensively covered in the form of figures. Similarly use of
plain and corrugated galvanized steel sheets is also covered.

Part 3 is only an introduction to shell roofs; since it is a specialized job expert guidance both in design and
construction is needed.

Part 4 covers one of the traditional roof finishes, namely, use of mud Phuska which is economical as well as
a good insulating material easy to construct.

Part 5 deals with protection against hazards of fire of thatched roofing.

CHAPTER 12

Damp-Proofing and Waterproofing

This chapter covers in detail damp-proofing materials and damp-proofing of various elements of structures; it
also deals with waterproofing materials and their various uses in different elements of structures. Information
on use of water repelling agents is also given.
General details governing the preparation of surfaces to receive either damp-proofing treatment or waterproof-
ing application, to make these treatments effective, is of importance. These details are given in the beginning
of the chapter itself, applicable both to damp-proofing treatment and waterproofing treatment.

Part 1 deals with various materials for damp-proofing and their use. Normal, heavy and extra heavy treatments
are listed, as per conditions at site. The materials include, bitumen felt, bitumen mastic, etc.

Part 2 deals with various materials for waterproofing and their use. Normal, heavy and extra heavy treatments
are covered, as per conditions at site. The materials include bitumen felt, mastic, etc.
Precautions in the use of glass fibre tissue reinforced bitumen, polyethylene film, etc, are mentioned.

CHAPTER 13

Joints in Buildings (Control of Cracks in Buildings)

This chapter deals with various details of construction of joints to prevent initiation of cracks and their control.
That is why this chapter is also called control of cracks in buildings. Various types of joints are described; the
main joints are expansion and contraction joints. Some basic information on causes of cracking, namely,
moisture movement and thermal effects on building materials is given. Other aspects of long term creep of
materials, differential expansion/contraction of composite construction, like brick and plaster, are also covered.
Basic details, illustrative in nature of various types of joints and their locations in walls, roofs, floors and
junctions of such elements are also covered. The drawings are indicative of the principles involved in preventing
and controlling cracks in buildings. Attention is also drawn to an important handbook already published by BIS
on Causes and Prevention of Cracks in Buildings.

CHAPTER 14

Whitewashing, Colour Washing and Painting of Masonry, Concrete and Plaster

Surfaces (Calcareous Surfaces)
This chapter deals with whitewashing, colour washing and painting of calcareous surfaces like masonry,
concrete, plaster and asbestos cement surfaces. For convenience the chapter is split into two Parts; Part 1 deals
with whitewashing and colour washing and Part 2 deals with painting of calcareous surfaces.

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Emphasis is laid on preparation of surfaces to as dry a condition as possible and for painting to take care of
alkalinity of these surfaces. Painting of new and old surfaces are covered. Characteristics of calcareous surfaces
which have to be considered for painting have been listed. Schedules of painting of these surfaces like type of
paints for primer coat, undercoat and finishing coats are given. Problems of efflorescence, fungus growth,
suction, etc, are highlighted with some recommendations for treatment. Maintenance schedule of painting of
surfaces is also given. Some tests to determine fitness of plaster for painting through determination of dryness
of background before painting, alkalinity and efflorescence are given.

CHAPTER 15

Painting, Varnishing and Allied Finishes (Wood and Metals)

This chapter covers the painting of wood and wood based materials, ferrous and non-ferrous metals in buildings.
For convenience it is divided into three Parts.

Part 1 deals with finishing of wood and wood based materials and gives the general characteristics of timber
in relation to painting. It deals in detail with priming of timber joinery before painting followed by selection of
coating materials. Surface preparation of timber is important to ensure proper adhesion of paint. Details of
stopping, filling, staining and finishing are elaborated. Clear finishes, french polish, etc, are also covered. A
schedule of painting is listed in tabular form. Mention is also made of finishing wood based products similar
to solid wood. Some details regarding finishing of wood products with nitrocellulose and cold catalysed crystals
are given.
Part 2 covers the pretreatment of ferrous metals, either in factory or at site before final painting. Factory
pretreatment is recommended for durable results. The importance of preparing surface before treatment like
removal of oil, grease, rust, etc, is emphasized. A schedule of application of paints is given. Mention is also
made for maintenance painting.

Part 3 covers the pretreatment, preparation of surfaces and finish of non-ferrous metals in buildings.

CHAPTER 16

Water Supply and Drainage

This chapter is divided into three Parts dealing with water supply, drainage and plumbing system including that
in high altitude and/or sub-zero regions.

Part 1 on water supply deals with the piping system from the municipal water mains to the building and internal
distribution also. Appurtenant structures in relation to water supply are also covered. The basic principles of
supplying potable water, general requirements of pipe work, laying and jointing of pipes are elaborated.
Reference is made to testing, inspection, disinfection, storage tanks, etc.

Part 2 on drainage covers the conveyance of waste water, sewage, surface water and subsoil water. Laying of
pipes, pipe joints and disposal are dealt with; emphasis is laid on separation of storm water drainage and sullage.

Part 3 deals with special requirements of water supply and drainage of high altitudes and/or sub-zero
temperatures. The effects on physical, chemical and biological properties of wastes, equipment, etc, are brought
out and corresponding provisions given.

CHAPTER 17

Special Construction Procedures - Earthquake Effects, etc

This chapter deals with construction procedures for buildings when subjected to earthquake forces. Buildings
constructed with weaker materials and strengthening of earthen buildings are also covered. The general
requirements of design of course should be according to the basic code IS 1893 : 1984.

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Emphasis is laid on categorisation of buildings based on importance of the building, zone of seismic map of
India and the soil foundation factor. Special construction procedures are listed for each of the five categories
of buildings.

The general principles for earthquake resistance of buildings are enumerated. The main thrust of these principles
is to make the building rigid in both the horizontal directions through continuity of structural elements.

Details of such treatment are given for masonry and timber buildings. The ductility of joints in reinforced
concrete construction is covered by an Indian Standard to which reference is made. Use of precast elements
and their strengthening is also covered.

Some infonation on improving earthquake resistance of buildings using weaker building materials including
mud/earth is covered. Repair and seismic strengthening of buildings is mentioned giving reference to an Indian
Standard.

The title envisages covering construction for effects of blast and similar instantaneous forces on buildings.

CHAPTER 18

Demolition of Buildings
This chapter covers the safety requirements of the general public and the workers at site during demolition,
Emphasis is laid on planning of the work of demolition so as to avoid any accidents or damage to adjacent
structures. The need is therefore to consider sequence of demolition of elements of a structure starting from top
storey and working downwards.

Special requirements for demolition of masonry arches, precast elements, steel elements, beams, columns, etc.
are elaborated. Demoltion by hand, mechanical means or explosives is also mentioned. Protective equipment
for workers during demolition is listed. Continuous removal of debris throughout the operation is recommended
so as to avoid overloading of structures below the storey under demolition; chutes and openings for this purpose
are recommended.

In line with the National Building Code, the word Authority having jurisdiction, is used as merely Authority
in various chapters. The Authority always refers to the concerned department who has jurisdiction over the
matter or subject under jurisdiction.

(xvi)
 CHAPTER 1

CONSTRUCTION PLANNING AND STORAGE

OF MATERIALS
 CONTENTS

PART 1 CONSTRUCTION PLANNING 10 ROOFINGSHEETS

I GENERAL 11 BOARDS
2 CONSTRUCTIONPLANNING 12 PLASTICANDRUBBERSHEETS
2.1 Planning Techniques 13 GLASSSHEETS
2.2 Advantages
2.3 Networking Technique 14 ASBESTOSCEMENT,PIPESANDFITTINGS

PART 2 STORAGE OF MATERIALS 15 POLYETHYLENEPIPES

I GENERAL 16 UNPLASTICIZEDPVCPIPES

2 CEMENT 17 BITLJMEN,ROADTARANDASPHALT

3 LIME 18 WATER

-1BRICKS 19 FLATTILES

5 AGGKECATE 20 OILPAINTS

6 FLYASH 21 SANITARYAPPLIANCES

7 TIMBER 22 PILES

8 STEEL 23 OTHERMATERIALS

9 DOOR~,W!NDOWSANDVENTILATORS 24 SPECIALCONSIDERATIONS
25 ELECTRICALMATERIALS

.
 SP 62 (S & T) : 1997

CHAPTER 1

CONSTRUCTION PLANNING AND STORAGE OF

MATERIALS

PART 1 CONSTRUCTION PLANNING

1 GENERAL known as Network Techniques comprising of both

Programme Evaluation and Review Techniques
1.1 Planning and scheduling ofaconstruction project, (PERT) and Critical Path Method (CPM). Both are
be it a building, bridge, or drainage work, consists of modern techniques suitable for any organized activity;
defining all the tasks that must be performed and the basic aim being to tie up all loose ends involved in
laying them out in logical sequence necessary for the any project and put them in a proper sequence and time
completion of the project. There is a link between frame. These techniques can also be applied to con-
quality of preparation that goes into the formulation of struction industry.
a work plan and the efficiency of management and
contra1 in the execution and operation phases. This 2.2 Advantages
calls for effective co-ordination of the efforts of all the Networking overcomes some of the lacunae in Bar
participants and identification of the tasks which are Chart System. The advantages of it are as below.
likely to constrain the completion of project in time.
If not done, it might lead to time and cost overrun of 4 Results in a logical appreciation of the project
the project. Thus there is a need for application of from conception to completion.
modern and scientific techniques in the planning, b) Enables project completion to be forecast more
management and control of construction. This would accurately.
essentially mean a dedicated attempt to identify criti- c) Identifies critical activities that have great
cal tasks and then attempt at backward integration of bearing on the efficient progress of the con-
these, both in time and cost along with other non- struction project.
critical tasks. 4 Forecasts potential delays ahead of their actual
occurrence.
1.2 One of the conventional methods that have been e> Provides a slack to permit rescheduling of
in use for construction planning is the bar chart. .How- resources for efficient deployment.
ever, all the required information cannot be shown on f-l Identifies interdependent activities to focus on
a simple bar chart. For instance the chart cannot importance of co-ordination.
indicate the effect of some work being behind or ahead g) Provides an effective tool for management to
of schedule on the completion of project. This is locate slippages and plug them.
because the bar chart does not show the inter- h) Above all provides a basis for more dynamic
dependence of each item of work (activity) on the and quick reporting system to take corrective
other. It cannot also project the effect of delay action during different stages of construction.
(time overrun) in one item of work on another. It
2.3 Networking Technique
is this lack of knowledge of the inter-relationships
of various items of work that results in the lack of 2.3.1 Before launching on preparing a schedule the
co-ordination or appreciation of the sequential or following basic questions have to be answered:
logical role of each item of work to the total - What activity should precede the one that is
construction project. The bar chart also does not being considered?
identify those tasks which are critical to the completion
- What activity can follow this activity immedi-
of construction. Thus the attention to be paid to critical
ately?
areas of work gets diverted resulting in loss of time and
resources. -’ What activities can proceed concurrently?

2.3.2 Some of the ground rules to answer these three

2 CONSTRUCTION PLANNING
basic questions are:
2.1 Planning Techniques - No event can occur until every activity preced-
ing it has been completed;
Construction planning techniques have emerged in the
recent past abroad. These are being propagated in our - Similarly no activity, succeeding an event, can
country over a decade or more. These are commonly be started until that event has occurred;

3
SP 62@ & T): 1997

- Each activity must terminate in an event; tance of understanding and application of this techni-
- An event can occur twice; and que to construction. A considerable amount of litera-
ture has been generated on this and these may be
- Finally every activity must be completed to
referred to for any given project for preparation of
reach the end objective.
planning schedules.

2.4 The above introductory information is only to 2.5 One of the activities is to procure and store build-
indicate the practical aspect of the approach of Net- ing materials taking into account sequence of opera-
work techniques. The purpose in introducing at this tions. Some information on storage of materials is
stage in this very first chapter is to highlight the impor- given in Part 2 of this Chapter.

PART 2 STORAGE OF MATERIALS

1 GENERAL alround between the bags and external walls. In the

stacks, cement bags shall be kept close together to
1.1Materials shall be so stored as to prevent deteriora- reduce circulation of air as much as possible. Owing
tion or intrusion of foreign matter and to ensure the to pressure on the bottom layer of bags ‘warehouse
preservation of their quality and fitness for use in the pack’ is developed in these bags. This can be removed
work. Materials shall also be stored to protect against easily by rolling the bags when the cement is taken for
atmospheric agencies, fire and other hazards. use.
1.2 Materials like timber, coal, paints, etc, shall be The height of the stack shall be not more than 15 bags
stored in such a way that there may not be any fire to~prevent the possibility of lumping up under pressure.
hazards. Inflammable materials like kerosene, petrol, The width of the stack shall not be more than four bags
etc, shall be stored in accordance ~with the relevant length or 3 m. In stacks more than 8 bags high, the
rules and regulations in force prescribed by the cement bags shall be arranged alternately lengthwise
Authority, so as to ensure safety during storage (see and crosswise so as to tie the stacks together and
also IS 7969 : 1975). minimize the danger of toppling over. Cement bags
shall be stacked in a manner to facilitate their removal
Explosives like detonators shall be stored in accord- and use in the order in which they are received.
ance with the rules and regulations in force.
During the monsoon orwhen it is expected to be stored
Materials which are likely to be affected by subsidence for a long period, the stack shall be completely
of soil, like precast elements, large size timber sec- enclosed by a waterproofing membrane, such as,
tions, etc, shall be provided with unyielding supports. polyethylene sheet. Care shall be taken to see that the
membrane is not damaged any time during use.
In areas, likely to be affected by floods, the materials
shall be suitably stowcd to prevent their being washed Different types of cements shall be stored separately.
away or damaged by floods. Cement stored in drums may be arranged vertically
with closures on top. After partial use of cement in
During construction, stairways, passageways and
drums when it occurs, the closure should be firmly
gangways shall not be obstructed due to storage of
fastened to prevent ingress of moisture. A maximum
materials, tools or rubbish.
of 3 drums can be stacked in height.
2 CEMENT
3 LIME
Cement shall be stored at the work site in a building or
Quick lime deteriorates rapidly on exposure by taking
shed which is dry, leakproof and as moisture proof as
up moisture and carbon dioxide from atmosphere.
possible. The building shall have minimum number of
Therefore, it should be stacked as soon as possible
windows and close fitting doors which shall be kept
before deterioration sets in. If unavoidable, quicklime
closed as far as possible.
may be stored in compact heaps having only minimum
Cement stored in bags shall be stacked and shall be of exposed area. The heaps shall be stored on a
kept free from the possibility of any dampness or suitable platform and covered to avoid direct contact
moisture coming in contact with the bags. Cement with moisture/rain or being blown away by wind. In
bags shall be stored/stacked off the floor on wooden case it is stored in a covered shed, a minimum space
planks in such a way as to be clear above the floor by of 300 mm should be provided alround the heaps to
1SO mm to 200 mm and a space of 450 mm minimum avoid bulging of walls.

4
 SP 62 (S & T) : 1997

Hydrated lime is generally supplied in containers such shall be 50 bricks long and 10 bricks high, the bricks
as jute bags, lined polyethelene or HDPE woven bags being placed onedge. The width of each stack shall
lined with polyethylene or craft paper bags. It should be 6 to 8 bricks. Clear distance between adjacent
be stored in a building to protect lime from dampness stacks shall not be less than 0.8 m.
and to minimize warehouse deterioration.
Bricks of different types and class shall be stacked
Dry slaked lime should be stored on a platform suitably separately.
covered from rain and wind if it is to be used within a
few days. If required to be stored for longer periods 5 AGGREGATE
not exceeding 2 months it may be kept in a dry and
Aggregate shall be stored at site on a hard and dry level
closed godown.
patch of ground. If such a surface is not available, a
4 BRICKS platform of planks or of corrugated iron sheets, or a
floor of dry bricks, or a thin layer of lean concrete shall
Bricks shall not be dumped at site. They should be
be made so as to prevent the admixture of clay, dust,
stacked in regular tiers as and when they are unloaded
vegetable and other foreign matter.
to minimize breakage and defacement of bricks.
Stacks of fine and coarse aggregate-shall be kept in
In case of bricks made -from clay containing lime
separate stack piles, sufficiently removed from each
kanknrthe bricks in stack should be thoroughly soaked
other to prevent the materials at the edge of the piles
in water to prevent lime bursting.
getting intermixed. On a large job it is desirable to
Bricks shall be placed close to the site of work so that construct dividing walls to give each type of aggregate
least effort is required to unload and transport the its own compartment. Fine aggregate shall be stacked
bricks again by loading on pallets or barrows. Build- in place where loss due to the effect of wind is mini-
ing bricks shall -be loaded a pair at a lime unless mum.
palletized. Unloading of building bricks or handling
in any other way likely to damage the corners or edges Unless specified otherwise or.necessitated by site con-
or other parts of bricks shall not be permitted. ditions, stacking of aggregate should be carried out in
regular sizes.
Bricks shall be stacked on firm ground. For proper
inspection of quality and ease in counting, the stacks The suggested sizes of stacks are as follows:

Materials Size of Stuck (in m)

A
f \
Length Breadth Height

Soling stone 5.0 2.0 0.50

or 5.0 1.0 0.50

Coarse aggregate 2.0 2.0 0.50

or 5.0 5.0 1.oo

Fine aggregate 2.0 2.0 0.50

or 5.0 5.0 1.oo
or 5.0 1.0 0.50

6 FLY ASH in different lengths, and material of equal lengths shall

be piled together in layers with wooden battens, called
Fly ash shall be stored in such a manner as to permit
crossers, separating one layer from another. The
easy access and proper inspection and identification of
crossers shall be of sound wood, straight and uniform
each consignment. Fly ash in bulk quantities shall be
in thickness. In any layer, air space of about 25 mm
stored in a stack similar to fine aggregate as referred
shall be provided between adjacent members. The
to in 5, avoiding any inclusion of foreign matter. Fly
larger pieces shall be placed in the bottom layers and
ash in bags shall be stored in stack not more than 15
the shorter pieces in the upper layers, but one end of
bags high.
the stock including crossers shall be in true vertical
7 TIMBER alignment. The most suitable width and height of a
Timber shall be stored in stacks upon well treated and stack are recommended to. be about 1.5 m and 2 m.
even surfaced beams, sleepers or brick pillars as to be Distance between adjacent stacks is shown in Fig. 1.1.
above the ground level by at least 150 mm. The The stacks shall be protected from hot dry winds or
various members shall preferably be stored separately direct sun and rain. Heavy weights, such as metal rails

.
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L661: (A ‘8 S) Z9 dS
 ..-
r-
SP 62 (S & T) : 1997

All wooden frames and shutters shall be stored in dry 50 mm x 25 mm battens in such a way that it will give
andclean covered space away from any infestation and support to all the four edges and corners of the boards
dampness. The storage shall be preferably in well with intermediate battens placed at suitable intervals
ventilated dry rooms. The frames shall be stacked one to avoid warping.
over the other in vertical stacks with cross battens at
The boards shall be stacked in a solid block in a clear
regular distances to keep the stack vertical and straight.
vertical alignment. The top sheet of each stack shall
The cross battens should be of uniform thickness and
be suitably weighed down to prevent warping.
placed vertically one above the other. The door shut-
ters shall be stacked in the form of clean vertical stacks The boards shall be unloaded and stacked with utmost
one over the other and at least 80 mm above ground on care avoiding damage to corners and surface. In case
pallets or suitable beams or rafters. The top of the of decorative plywood and decorative boards the sur-
stack shall be covered by ~a protecting cover and faces of which are likely to get damaged by dragging
weighed down by means of scantlings or other suitable one over the other it is advisable thatthese boards are
weights. The shutter stack shall rest on hard and level lifted in pairs facing each other as far as possible.
ground.
12 PLASTIC AND RUBBER SHEETS
Separatestacks shall be built for each size, each grade
Plastic and rubber sheets have a tendency to break-
and each type of material. When materials of different
down during storage. These shall be stored according
sizes, grades and types are to be stacked together for
to manufacturers’ instructions.
want of space, the bigger size shall be stacked in the
lower portion of the stacks. Suitable pallets or separat- The coolest room available shall be utilized for the
ing battens shall be kept in between two types of storage of rubber and plastic sheets. The store rooms
material. where plastic and rubber sheets are stored shall be well
ventilated and kept as dark as possible. Though com-
If any wooden frame or shutter becomes wet during plete darkness is not necessary, direct light should not
transit, it shall be kept separate from undamaged be allowed to fall on the plastic and rubber sheets.
material. The wet material may be dried by stacking
in shade with battens in between adjacent boards with Contaminatian with vegetable and mineral oils,
free access of dry air generally following the guidance greases, organic solvents, acids and their fumes,
laid down in IS 1141 : 1993. alkalis, dust and grit, shall be prevented. When greasy
contamination occurs this shall Aberemoved immedi-
10 ROOFING SHEETS ately with petrol and the sheet thoroughly wiped dry
and dusted with French chalk.
Roofing sheets shall be stored in such a way as not to Rubber and plastic sheets shall be stored away from
damage them in any way. electric generators, motors, switchgear-and other such
electrical equipment as they produce harmful odour in
Asbestos cement sheets shall be stacked to a height of
their vicinity.
not more than one metre on a firm and level ground
with timber or other packing beneath them. If stacked Undue stretch and strain, kink, sharp bends or folds
in exposed position, they shall be protected from shall be avoided. In case of long storage, the sheets
damage by wind. shall be turned over periodically and treated with
French chalk, if necessary.
Asbestos cement sheets of the same variety and size
shall be stacked together. Damaged sheets shall not be 13 GLASS SHEETS
stacked with sound materials. All damaged sheets
shall be salvaged as early as possible. It is important that all sheets whether stored in crates
or not shall be kept dry. Suitable covered storage
11 BOARDS space shall be provided for the safe storage of glass
sheets. In removing glass sheets from crates great care
Gypsum boards shall be stored flat in a clean covered shall be taken to avoid damage to glass. The glass
and dry place. sheets shall be lifted and stored on its long edges and
shall be put into stacks not more than 25 panes, sup-
Boards shall not be stored in the open and exposed to
ported at two points by fillets of wood at 300 mm from
sun and rain, particularly if they are woodbased
each end. The first pane laid in each stack shall be so
boards, such as plywood, fibre board, particle board,
placed that its bottom edge is about 25 mm from the
block board, etc.
base of the wall or other support against which the
The boards shall be stacked on a flat dunnage, on top stack rests. The whole stack shall be as close and as
of which a wooden frame shall be constructed with upright as possible.

7
SP 62 (S & T) : 1997

14. ASBESTOS CEMENT, PIPES AND more than 1.5 m high. Avoid storing one pipe in
FITTINGS another.

The pipes shall be unloaded where they are required, Pipes of different sizes and classes should be stacked
when the trenches are ready to receive them. separately.

The pipes shall be stored on firm, level and clear On no account should pipes stored in a stressed or bent
ground and wedges shall be provided at the bottom condition. The ends of pipes should be protected from
layer to keep the stack stable. abrasion~particularly those specially prepared forjoint-
ing.
The stack should be in pyramid shape or the pipes be
arranged lengthwise and crosswise in alternate layers. In tropical conditions, pipes should be stored in shade.
The pyramid stack is advisable for smaller diameter In wintry conditions or cold weather the impact
pipes for conserving space in the store room. The strength of PVC is reduced making it brittle; therefore
height of the stack shall not exceed 1.5 m. more care shall be exercised in handling of the pipes.

Each stack shall contain only pipes of same class and If due to improper storage or handling, a pipe becomes
size, with consignment or batch number marked on it kinked, the damaged portion should be cut out com-
with particulars of suppliers wherever possible. pletely. Kinking is likely to occur in thin walled
pipes.
Cast iron detachable joints and fittings shall be stack-
ed under cover and separated from asbestos cement 17 BITUMEN, ROAD TAR AND ASPHALT
pipes and fittings.
All types of bitumen, road tar, asphalt, etc, in drums or
Rubber rings shall be kept clean, away from grease,
containers shall be stacked vertically on their bottoms
oil, heat and light.
up to 3 tiers. Leaky drums should be seggregated.
15 POLYETHYLENE PIPES Empty drums shall be stored in pyramidical stacks
neatly in rows.
Black polyethylene pipes are suitably protected from
ageing due to sunlight by the addition of appropriate 18 WATER
quantity and type of carbon black during manufacture.
Wherever water is to be stored for construction pur-
Therefore they may be stored even in the open; how-
poses, it shall be done in proper storage tanks to
ever, it is preferable that they are stored under cover.
prevent any organic impurities polluting the water.
Natural polyethylene pipes, however, shall be stored
under cover and protected from direct sun. 19 FLAT TILES

Pipe coils may be stored either on edge or stacked flat Flat tiles shall be stacked on well treated and hard
one on top of another, but in either case they should surface. Tiles shall be stacked at site in proper layers
not be allowed to come in contact with heat, such as, and tiers and they shall not be dumped in heaps.
through hot water or steam pipes. They should also In a stack, the tiles shall be so placed that the mould
be kept away from hot surfaces. surface of one faces another. The height of the stack
shall not be more than 1 m.
Straight lengths of pipes should be stored on horizontal
racks giving continuous support to prevent the pipe Tiles when supplied in packed boxes/crates shall be
getting a permanent set if allowed to sag. Storage of stored as such. They shall be opened only at the time
pipes in heated areas exceeding 27°C shall be avoided. of use.

16 UNPLASTICIZED PVC PIPES 20 OIL PAINTS

These pipes shall be given support at all times. Pipes All containers of paints, thinners and allied materials
should be stored on a reasonably flat surface free from shall preferably be stored on floors with sand cushions
stones and sharp projections so that the pipe is sup- in a separate room which is well ventilated and free
ported all along its length. Pipes should not be stored from excessive heat, sparks of flame and direct rays of
on racks. the sun. The containers of paint shall be kept covered
Pipes should not be stacked in large piles especially or properly fitted with lid and shall not be kept open
under warm temperature conditions as the bottom except when in use.
pipes may be distorted, thus creating problems in joint-
21 SANITARY APPLIANCES
ing. Socket and spigot pipes should be stacked in
layers with sockets placed at alternate ends of the All sanitary appliances shall be carefully stored under
stacks to avoid lopsided stacks. Stacks shall not be cover to protect from damage. When accepting and
 SP 62 (S & T) : 1997

storing appliances consideration shall be given to se- 23 OTHER MATERIALS

quence of removal from the store to the asssembly
positions. Proper stacking to assist the later stage will Small articles like screws, bolts, nuts, door and win-
be advantageous. As nearly all assemblage have need dow fittings, polishing stones, protective clothing,
for separating brackets, these shall be readily acces- spare parts of machinery, linings and packings, water
sible as they will be required at an early stage. supply and sanitary fittings, etc, shall be kept in a
suitable and properly protected store rooms. Valuable
22 PILES small material shall be kept under lock and key.

Pile shall be stored on firm ground free from liability 24 SPECIAL CONSIDERATIONS
to unequal subsidence of settlement under the weight
Material constantly in use shall be relatively nearer the
of the stack of piles. The piles shall be placed on
place of use.
timber supports which are truly level and spaced so as
to avoid undue bending in the piles. The supports shall Heavy units like precast concrete members shall be
be left around the piles to enable them to be lifted stacked near the hoist and the ramp.
without difficulty. The order of stacking shall be such
Materials which normally deteriorate during storage
that the older piles can be withdrawn for driving
shall be kept constantly moving, by replacing old
without disturbing the newer piles. Separate stacks
materials with new stocks.
shall be provided for different lengths of piles. When-
ever curing is needed during storage, arrangements Freshly arrived materials shall never be placed over
shall be made to enable the piles to be watered if the materials which had arrived earlier.
weather conditions so require. Fire extinguishers and fire buckets shall be provided
Care shall be taken at all stages of transportating, wherever necessary for safety.
lifting and handling of piles to see that they are not
25 ELECTRICAL MATERIALS
damaged or cracked during handling. During
transportation the piles shall be supported at ap- Storage of electrical materials such as, cables, conduc-
propriate lifting holes provided for the purpose. If tors, switch gear, etc, shall conform to National
Piles are Put down temporarily after being lifted, they Electric Code, 1983 [see &SO the supplementary
shall be placed on trestles or blocks located at the ‘Handbook on electrical installation .in buildings’
lifting points. (underpreparation)].

9
As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER 2

EARTHWORK
-_. -

CONTENTS

OF SOILS
CLASSIFICATION 10.3 Filling
GENERALPRECAUTIONS 11 SHORINGAND TIMBERING
SURFACEEXCAVATION 12 EXCAVATIONIN MUD, WATER OR FOUL POSITION
3. I General 13 FILLING IN TRENCHES,UNDER FLOURS,ETC
3.2 Setting Out and MakingProfiles
ROUGHEXCAVATION 14 SAND FILLING IN PLINTH
4.1 General 15 SURFACEDRESSING
4.2 Cutting
4.3 Filling 16 ANTI-TERMITETREATMENT
EXCAVATION OVERAREAIN SOFT/HARDSOIL (CHEMICAL TREATMENT)
5.1 General 16.1 General
5.2 Setting Out and Making Profiles 16.2 Site Preparation
5.3 Cutting 16.3 Treatment Beneath the Building
EXCAVATIONOVER AREA IN ORDINARY/HARD 16.4 Time of Application
ROCK 16.5 Treatment of Masonry Foundations and
6.1 General Basements
6.2 Blasting Operations 16.6 Treatment of RCC Foundations and Base-
6.3 Precautions During Blasting ments
16.7 Treatment of Top Surface of Plinth Filling
EXCAVATIONIN FOUNDATION TRENCHES OR 16.8 Treatment at Junction of the Wall and the
DRAINS (SOFT/HARDSOIL) Floor
EXCAVATION IN FOUNDATION TRENCHES OR 16.9 Treatment of Soil Along External Perimeter
DRAINS (ORDINARY ROCK) of the Building
16.10 Treatment of Soil Apron Along External
EXCAVATION IN FOUNDATION TRENCHES OR Perimeter of Building
DRAINS (HARD ROCK) 16.11 Treatment of Walls Retaining Soil Above
IO EXCAVATION IN TRENCHES FOR PIPES, CABLES, Ground Level
ETC, AND REFILLING 16.12 Treatment of Soil Surrounding Pipes,
10.1 General Conduits, etc
IO.2 Width of Trench 16.13 Treatment of Expansion Joints
-_..__ -

SP 62 (S & T) : 1997

CHAPTER 2

EARTHWORK
1 CLASSIFICATION OF SOILS 1.2 IS 1498 : 1970 may be seen for classification of
soils for general engineering purposes.
1.1 For the purpose of this chapter regarding
earthwork soils may be classified as below: 2 GENERAL PRECAUTIONS

4 Soft/Loose Soil - Generally any soil which Excavating shall not be carried out below foundation
yields to the ordinary application of pick and level of adjacent buildings, until underpinning, shor-
shovel or to a spade, rake or other ordinary ing, etc, is done. Adequate precautions shall be taken
digging tools, examples: to see that the excavation operations do not affect
I) Sand, gravel, loam, clay, mud, black adjacent buildings.
cotton soil.
Trenches and foundation pits shall be securely fenced
2) Vegetable or organic soil, turf, peat, soft
and posted with proper precautionary signs. They
shale or loose murrum.
shall be marked with red lights at night to avoid acci-
3) Mud concrete below ground level.
dents. Public safety shall be ensured at all times.
4) Any mixture of soils mentioned above.
2.1 Site Clearance
b) Hard/Dense Soil - Generally any soil which
requires the close application of picks or Before the earthwork is started, the site shall be cleared
jumpers or scarifiers and rippers to loosen the of vegetation, brushwood, trees, saplings, etc, of girth
same, examples: up to 30 cm measured at a height of 1 m above ground
1) Stiff heavy clay, hard shale or compact level and rubbish remained up to a distance of 50 m
murrum requiring grafting tool and/or outside the periphery of area under clearance. The
pick and shovel. roots of trees shall be removed to depth of at least 60
2) Shingle and river or nallah bed boulders. cm below ground level or 30 cm below foundation
3) Soling of roads, paths, etc, and hard core. level and the hollows filled up with earth, levelled and
4) Macadam surface of any description rammed.
(water bound, grouted tarmac, etc).
The trees of girth above 30 cm measured at a height of
5) Lime concrete, stone masonry in lime or 1 m above ground level shall be cut only after permis-
cement mortar below ground level.
sion of the Engineer-in-charge. The roots of trees shall
6) Soft conglomerate or soft laterite when the
be removed as specified in above para.
stone can be detached from matrix with
picks. Existing structures, such as, old buildings, culverts,
pipe line, sewers, etc, within the site, shall be dis-
cl Ordinary Rock (not requiring blasting, wedg- mantled; if necessary, with appropriate permission,
ing, or similar means) - This may be quarried
structures adjacent to the site may be dismantled.
or split with crow bars or picks, such as, lime-
stone, hard laterite, hard conglomerate and un- Archaeological monuments, structures, etc, should be
reinforced cement concrete below ground dealt with appropriately in consultation with the con-
level. cerned Authority, similarly felling of trees should be
NOTE - If required light blasting may be resortedto, for done in consultation with the concerned Authority.
loosening the materials, but this does not in any way entitle
the material to be classified as ‘Hard Rock’. 3 SURFACE EXCAVATION

4 Hard Rock (requiring blasting) -Any rock or 3.1 General

boulder for the excavation of which blasting is
required such as quartzite, granite, basalt, rein- Excavation exceeding 1.5 m width and IO m* on plan
forced cement concrete (reinforcement to be but not exceeding 30 cm in depth shall be called
cut through but not separated from concrete), ‘surface excavation’.
etc, below ground level. 3.2 Setting Out and Making Profiles
e) Hard Rock (blasting prohibited) - In hard A masonry pillar shall be erected at a suitable point in
rock where blasting is prohibited for any the area which would be visible from most points in
reason, excavation has to be carried out by the area to serve as a bench mark for the execution of
chiselling, wedging or any other agreed work. A typical construction of the bench mark is
method. shown in Fig. 2. I. This bench mark shall be connected

13

r L,.,.‘. .
SP 62 (S & T) : 1997

with a standard bench mark available in the vicinity. hill side cutting, etc, shall be described as rough
Necessary profiles, with pegs, bamboos and strings or excavation.
pillars, shall be made to show the correct formation
levels before the work is started. The profiles and 4.2 Cutting
Burjis shall be maintained during excavation.
The work shall be executed true to levels, slopes, shape
The ground levels shall be taken between 5 to 15 m and pattern as indicated in the drawings. During ex-
intervals in uniformly sloping ground and at closer cavation the natural drainage of the area shall be main-
intervals where local mounds, pits, undulations are met tained~to avoid water logging.
with. The ground levels shall be recorded in field
books and plotted on to appropriate scale. The plans Cutting shall be done from top to bottom. Under no
shall be signed by the Authority having jurisdiction circumstances shall, undermining or under cutting, be
before commencement of work to authenticate it. allowed. The sides of the excavation shall be dressed
or trimmed and bottom shall be levelled or graded and
4 ROUGH EXCAVATION rammed.

All cutting shall be done to the required levels. In case

4.1 General
it is taken deeper, it shall be brought to the required
Excavation not requiring dressing of sides and bottom levels by filling in with earth duly consolidated. How-
to exact levels, such as winning earth from borrow pits, ever in case of hard rock, where blasting operations are

MS hEMISPHERICAL
LL WELDED WITH PLATE

BRICK WORK IN I:4

+560------j
SECTIONAL ELEVATION

Alldimensionsin millimetres.

FIG. 2.1 TYPEDESIGNFORTEMPORARYSITEBENCHMARK

14

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___ - ._

SP 62 (S & T) : 1997

resorted to, cutting shall be left as it is and made up b) Excavation for basement, water tanks, etc;
during construction. and
4,3 Filling c> Excavation in trenches for foundations exceed-
ing 1.5 m in width and 10 m* on plan.
The earth from cutting shall be directly used for filling.
Excavation shall be carried out to the required depths
Filling of earth shall be done in regular horizontal
and profiles.
layers, each not exceeding 20 cm thick. The earth shall
be free of all roots, grass, rubbish; and lumps and clods 6.2 Blasting Operations
exceeding 8 cm in any direction shall be broken. Each
layer shall be consolidated by ramming. Watering of Where blasting operations are necessary as in hard
each layer may be done if required. The top surface of rock, prior permission shall be obtained from the
the finally finished area be neatly dressed. Authority. In ordinary rock, blasting operations shall
The finished formation levels, in case of filling, shall not be generally adopted.
be kept higher than the required levels, by making an
allowance of 10 percent of depth of filling for future 6.3 Precautions During Blasting
settlement in case of ordinary consolidated fills. The
During blasting operations proper precautions shall
allowance shall be 5 percent if consolidation is done
be taken for the safety of persons. Blasting operations
by machinery. No allowance shall be made if con-
solidation is done by heavy mechanical equipment shall not be done within 200 m of existing structures.
All operations shall conform to Rules and Regulations
under optimum moisture conditions.
of Indian Explosive Act, 1940 as amended from time
5 EXCAVATION OVER AREA IN SOFT/HARD to time. In addition precautions laid down in
SOIL IS 4081 : 1986 [see&o IS 5878 (Part 2/Set 1) : 19701.
5.1 General
7 $XCAVATION IN FOUNDATION
This shall include:
TRENCI-IJZS OR DRAINS (SOFT/HARD SOIL)
a) Excavation exceeding 1.5 m in width and
10 m* on plan and exceeding 30 cm in depth; 7.1 Excavation in trenches for foundations shall not
b) Excavation in basements, water tanks, etc; and exceed 1.5 m in width or 10 m* or plan to any depth
c) Excavatioriin trenches for foundations exceed- (excluding trehches for pipes, cables, etc).
ing 1.5 m width and 10 m* on plan.
7.2 The excavation operation shall include excavation
Excavation shall be carried out to the required depths and removal of the earth. The excavated earth shall be
and profiles. thrown at least at half the depth of excavation, clear of
5.2 !htth$ Out and Making Profiles (see 3.2) the edge of excavation. The earth shall be disposed off
as directed by the Authority.
3.3 Cutthg

In firm soils, the sides of the trench shall be kept While carrying out at the excavation work for drains,
vertical up to a depth of 2 m from the bottom. For care shall be taken to cut the sides and bottom to the
greater depth, the excavation profiles shall be widened required shape, slope and gradient. The surface shall
by allowing steps of 50 cm on either side after every be properly dressed. If the excavation is done to a
2 m from the bottom. Alternatively, the excavation greater depth than shown on drawings, the excess
may be done to give a side slope of 1:4. Where the soil depth shall be made good with stiff clay puddle at
is soft, loose or slushy, the width of steps shall be places where the drains are required to be pitched. The
suitably increased or side sloped or the soil shored up. excess depth shall be made good with~ordinary earth
The bed excavation shall be made to the correct level and properly watered and rammed where the drain is
or slope and consolidated by watering and ramming. not required to be pitched. The back filling with clay
Soft and weak spots shall be dug out and filled with puddle shall be done side by side as the pitching work
levellingconcrete. Excess depth, if any, also shall be proceeds. Brick pitched storm water drain shall be
mnde good with the same concrete. avoided as far as possible in filled up areas.

6 EXCAVATION OVER AREA IN 8 EXCAVATION IN FOUNDATION

ORDINARY/HARD ROCK TRENCHES OR DRAINS (ORDINARY ROCK)
6.1 General
8.1 Excavation not exceeding 1.5 m in width or 10 m*
This shall include:
on plan to any depth in trenches (excluding trenches
a) Excavation exceeding 1.5 m in width and 10 for pipes, cables, etc) shall be described as excavation
m* on plan and exceeding 30 cm depth; in trenches for foundations.

15
SP 62 (S & T) : 1997

8.2 Excavation in ordinary rock shall be carried out 10.3.1 Filling the trenches for pipes, cables, etc shall
by crow Pars, pick axes, or pneumatic drills. Blasting be commenced immediately after the joints of pipes,
operations are not generally required in this case. etc, are tested and passed. -Where the trenches are
excavated in soil, the filling shall be done with earth
9 EXCAVATION IN FOUNDATION
on the sides and top of pipes in layers not exceeding
TRENCHES OR DRAINS (HARD ROCK)
20 cm, watered, rammed and consolidated ensuring
9.1 Excavation not exceeding 1.5 m in width or 10 m2 that the pipes are not damaged.
on plan to any depth in trenches (excluding trenches
In case of excavation of trenches in rock the filling up
for pipes, cables, etc) shall be described as excavation
to a depth~of 30 cm above the crown of the pipe, shall
in trenches for foundation.
be done with fine material such as earth, murrum or
9.2 Excavation in hard rock shall be done by chisell- pulverized decomposed rock as available. The
ing, where blasting operations are prohibited or are not remaining depth shall be done with rock filling or
practicable. In trenches and drains, where blasting is boulders of size not exceeding 15 cm mixed with fine
not otherwise prohibited, excavation shall be carried material as available to fill up the voids; and then
out by blasting in the first instance and finally by watered, rammed and consolidated in layers not ex-
chiselling to obtain the correct section of the trench as ceeding 30 cm.
per drawings.
11 SHORING AND TIMBERING
10 EXCAVATION IN TRENCHES FOR PIPES,
CABLES, ETC, AND REFILLING 11.1 All trenches exceeding 2.0 m in depth shall be
securely shored and timbered as determined by the
10.1 General
Engineer-in-charge.
Excavation not exceeding 1.5 m in width or 10 m2 in NOTES
plan to any depth in trenches shall Abe described as
1 The above requirementsdo not apply in cases where the sides
trenches for pipes, cables, etc. Returning, filling and
of the trenches are sloped to within 1.5m of the bottom. The
ramming (after pipes and cables are laid) and removal slope that is provided for such purposes shall be inspected and
of surplus soil shaM form part of this work. declared as stable.

10.2 Width of Trench 2 Notwithstanding anything said above, it shall be understood

that the need for shoring is a matter which shall receive careful
a) For depth up to 1 m, fhe width of the trench consideration even in trenches less than 2.0 m of depth where
shall be arrived at by adding 25 cm to the there is a doubt as to the safety of work.
external diameter of the pipe (not socket),
cable, conduit, etc. When the pipe is laid on a 11.2 Where sides of trenches are sloped (see Note 1
concrete bed/cushioning layer, the width shall of 11.1) the vertical sides shall be shored and the
be pipe diameter plus 25 cm or the width of shoring shall extend at least 30 cm above the vertical
concrete bed/cushioning layer whichever is sides. When open spaced sheathing is provided, a toe
more. board shall be provided to prevent material rolling
b) For depths exceeding 1 m, an additional width down the slope and falling into the part of the trench
of 5 cm/m depth for each side of trench shall with vertical walls.
be taken to arrive at the width, that is, external 11.3 Shoring and timbering shall be carried out along
diameter of pipe + 25 cm + 2 x 5 cm. This shall
with the opening of a trench but when conditions
apply to the entire depth of trench.
permit protection of work, such as sheet piling may be
c) When more than one pipe, cable, conduit are done before the excavation commences.
laid, the diameter to be taken shall be the
horizontal distance from outside to outside of 11.4 Approved quality of SAL wood shall be used for
outermost pipe, cable, conduit, etc. shoring and timbering a trench. Any other structural
10.3 Filling material having strength not less than that of SAL may
be used for the purpose (see IS 883 : 1970). The
Normally excavated earth shall be used for filling. In
stress values of species for design of members shall be
case such earth contains deleterious salts, it shall not
taken as 2/3 of the values given in Table 2 of IS 883 :
be used. All clods of earth shall be broken or removed. 1970.
Where excavated material is mostly rock, the boulders
shall be broken into pieces not bigger than 15 cm in 11.5 Erection of Shoring and Timbering
any direction and be mixed with fine materials of
decomposed rock, murrum or earth as available so as Provisions detailed as in 11.5.1 to 11.5.4 shall be
to fill up the voids as far as possible; this shall be used followed while erecting shoring and timbering (see
for filling. Fig. 2.2).

16
 SP 62 (S & T) : 1997

CLOSE PLANKING AND STRUTTING

WITH VERTICAL POLING BOARD

ING BOARD 250x30

PLANKING AND STRUTTING FOR

SHALLOW WIDE EXCAVATION

rWALING

OPEN PLANKING AND STRUTTING CLOSE PLANKING AND STRUTTING

WITH LONGITUDINAL POLING BOARD

FIG. 2.2 CLOSE AND OPEN PLANKINGAND STRUI-I-ING

11.5.1 Sheathing supporting the pieces of sheathing next above it. The
The sheathing shall be placed against the side of the pieces of sheathing shall be firmly driven into the soil
trench so that the length of each piece of sheathing is and securely supported by wales and struts as the
vertical. The sheathing shall be held securely in place trench is made deeper.
against the wall of the trench by wales. Where the 11.5.2 Wales
trench is excavated in loose, sandy or soft soil or soil Wales shall be parallel to the bottom or proposed
which has been previously excavated or soil which is bottom of the trench. Each wale shall be supported on
under hydrostatic pressure, each piece of sheathing cleats spiked to the sheathing or by posts set on the
shall be driven into the bottom of the trench so as to be wale next below it and in the case of lowest wale on
firmly held in place. the bottom of the trench itself. Where necessary,
Where two or more pieces of sheathing are used one wedges may be provided between a wale and the
above the other, the sheathing shall be so arranged that sheathing it supports so that rightly uniform support is
the lower pieces of sheathing overlap the lowest wales given to all individual pieces of sheathing.

17
SP 62 (S & T) : 1997

11.5.3 Struts. In case of filling under floors, the finished level of the
filling shall be kept to the slope to be given to the floor.
Struts shall be horizontal and at right angles to the
wales or sheathing supported thereby. Struts shall be 14 SAND FILLING IN PLINTH
cut to the proper length required to fit in tightly be- 14.1 Sand shall conform to grading zone V or IV, and
tween the wales. Where necessary, the struts shall be it shall be free from dust, organic and foreign matter
held securely in place by wedges, driven between (see Chapter 4).
struts and the wales.
14.2 Sand filling shall be done in a manner similar to
11.5.4 Struts shall be placed on cleats spiked or bolted earth filling in plinths as specified in 13, except that
to posts supporting wales. consolidation shall be done by flooding with water.
The surface of the consolidated sand shall be dressed
11.6 Sizes and Spacing of Members to the level or slope required.
11.6.1 The sizes and spacing of sheathing, wales and 15 SURFACE DRESSING
struts used for shoring and timbering for different 15.1 Surface dressing shall include removal of
trenches shall be as given in Tables 2.1 to 2.4. Table vegetation, cutting and filling up to depth of 1.5cm and
2.1 for~hard soil, Table 2.2 for soil which may crack or
dressing the area.
crumble, Table 2.3 for loose sandy or soft soil which
has been previously excavated and Table 2.4 for soil 15.2 Dressing
under hydro-static pressure. Where the section of the High portions of groundshall be cut down and hollows
wale or strut is rectangular, the longer side shall be kept and depressions filled up to the required level with the
vertical. Where distinctly different types of strata en- excavated earth so as-to give an even, neat and tidy
countered, each strata shall be treated separately as is look to the site.
required by its characteristics.
16 ANTI-TERMITE TREATMENT
11.6.2 Where a wedge is used in shoring and timber- (CHEMICAL TREATMENT)
ing of a trench, the thick end of the wedge shall be at
16.1 General
least 5 cm wide.
Termites are divided into two types on the basis of their
11.7 Removal of timber members shall be done care- habitat, namely (a) Subterannean or ground-nesting
fully to prevent collapse of the trench. termites, and (b) Non-subterranean or wood-nesting
termites having no contact with soil. The former are
12 EXCAVATION IN MUD, WATER OR FOUL
more destructive. Treating the soil with chemicals
POSITION
beneath the building and around the foundation with a
12.1 When water is met with in excavation due to chemical soil insecticide is a good preveative measure.
stream flow, seepage, springs, rain or other reasons, The purpose of the treatment is to create a chemical
adequate measures shall be taken to bail out water by barrier between the ground and woodwork. Of course,
pumping or other means to keep the foundation trench timber used in the building shall be natural, durable,
dry. Excavation shall be done within shored and tim- heartwood, treated and seasoned.
bered area in a similar manner. Anti-termite treatment can also be given, through con-
structional measures, to existing buildings. These are
12.2 Trial pits shall be dug in the area where excava-
tion is required to be done. The steady water level in covered elsewhere (see Chapter 6).
the trial pits, before the pumping operation is started, 16.2 Site Preparation
shall be considered as the subsoil water level in that 16.2.1 Remove trees, stumps, logs or roots which may
area. be harbouring the termites.
13 FILLING IN TRENCHES, UNDER FLOORS, 16.2.2 On clays and other heavy soils where penetra-
ETC tion is likely to be slow and on sloping sites where run
13.1 Earth used for filling shall be free from stone, off of the treating solution is likely to occur, the surface
shingle or boulder not larger than 75 mm in any direc- of the soil should be scarified to a depth of at least
tion; it shall also be free from salts, organic matter or 75 mm.
other foreign matter. 16.2.3 On loose and porous or sandy soils where loss
of treating solution through piping or excessive per-
13.2 In trenches the space around the foundations,
colation is likely to occur, preliminary moistening to
pipes, drains, etc, shall be cleared of all debris, brick-
fill capillary spaces in the soil is recommended.
bats, etc. The filling shall be done in layers not exceed-
ing 20 cm in each layer. Each layer must be watered 16.2.4 All subfloor levelling and grading shall be
and rammed for consolidation. completed. All cuttings, trenches and excavations

18

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-w-___ ._.

SP 62 (S & T) : 1997

should be completed with backfilling in place. Bor- 16.2.5 All framework, levelling pegs, timber offcuts
rowed earth fill must be free from organic debris and or other builders’ debris should be removed from the
should be well compacted. area to be treated.

Table 2.1 Hard Soil

(Clause 11.6.1)

Item Depth Sheathing Wales Strut

No. Gf Trench

SHorTEln- S:ctionm Veal- Width of Width of

Cd ta1Spa- Trench Trench
cing, Spac- not more Between
MUX ing, Than 2 m 2 m and
MU 4m
m cmxcm In mix cm m cm x cm cmxcm m IT,
(1) (2) (3) (41 (5) (61 (7) (8) (9) ( I())

I Over 2 but not over 3 5x20 2 15X15 I .s 10 x 1s IOX 15 I.5 3

2 Over 3 but not over 5 5x20 .s 15x1s 3 10x 1s ISX IS I .s 3

3 Over 5 but not over 6.5 5x20 I 20x20 5 15x 1s ISX IS I.5 3

4 Over 6.5 but not over 8 5x I.5 W idth of 25x25 l.S 15x20 20x20 1.5 3
member

5 Over 8 but not over 10 8x20 Width of 20x30 1.5 20x20 20x25 1.s 3
member

Table 2.2 Soil which may Crack or Crumble

(Clause 11.61)

Item Depth Sheathing Wales Struts

No. of Trench h .
6
Section Spacing-
A
I 1
Section Horizon- Width of Width of
tal Spa- Cal Trench Trench Cal zontal
cing, Spac- not More Between
MUX iw, Than 2 m 2 m and
MUX 4m

In cmxcm m cm xcm m cmxcm cm X cm nl m

(1) (2) (3 (4) 0) (6) (7) (8) (9) Cl())

I Over I .S but 5x20 I.5 IOX IS I .s 10x10 - I.5 3

not over 2.5

2 Over 2.5 but 5 x 20 1 15x 1.5 I.5 IOX IO IS x IS I.5 3

not over 3
3 Over 3 but 5x20 0.5 1s x 20 .s IOX IS 15x IS I .s 3
not over 5
4 Over 5 but 8X15 Width of 20x2s 3 15x 1s 20x20 I .s 3
not over 6.5 member
5 Over 6.5 but 8X IS Width of 25x2s .s 1.x220 20x20 I .s 3
not over 8 member
6 Over 8 but 8X20 Width of 20x30 1.5 20x20 20x2s 1.S 3
not over IO member

19
SP 62 (S & T) : 1997

Table 2.3 -Loose Sandy or Soft Soil

(Clause 11.6.1)

Item Depth Sheathing Wales struts

No. of Trench A
, .
Section Spacing
- -
Section Horizon- Section Verti- Width
---YzF-
of Width of Hori-
tai Spa- Cd Trench Trench Cd zontal
cing, Spac- not More Between
Max- ing. Than2m 2mand
MUX 4m

m cmxcm m cmxcm m cmxcm cmxcm m m

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

I Over 1.5but 5x20 0.4 10x 15 I.5 IOX IO IOX 1s 1.5 3

not over 2.5

2 Over 2.5 but 5x I5 Width of 15x20 1 IOX I5 15 x I5 I 3

not over 3 member

3 Over 3 but 5x I5 Width of 20x20 I.5 15x I.5 I5 x I5 I.5 3

not over 5 member

4 Over 5 but 5x IS Width of 20x25 1.5 15x I5 15x20 I.5 3

not over 6.5 member

5 Over 6.5 but 8x20 Width of 20x25 I.5 IS x 20 20x20 I .s 3

not over 8 member

6 Over 8 but 8x20 Width of 25x25 1.5 20x20 20x20 1.5 3

not over 10 member

Table 2.4 Soil Under Hydro-Static Pressure

(Clause 11.6. I)

Item Depth Sheathing Wales struts

A
No. of Trench f I
Section Spacing
* A
c 1 t --
Section Horizon- Section Verti- Width of Width of Verti- Hori-
tal Spa- Cd Trench Trench cal zontal
cing. Spac- not More Between
MUX ing, Than 2 m 2 m and
MU 4m
m cmxcm “1 cm x cm m cmxcm cmxcm m m

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Over I .Sbut 5x I5 Width of 15x20 I.5 IOX IO I5 x I5 I.5 3

not over 2.5 member

Over 2.5 but 5x IS Width of 15x25 I IOX I5 15x I.5 I.5 3

not over 3 member

Over 3 but 8x20 Width of 25x25 1.25 15x IS 15x I5 1.25 3

not over 5 member

Over 5 but 8X20 Width of 25x30 1.25 20x20 20x20 I .25 3

not over 6.5 member

Over 6.5 but 10x20 Width of 25x35 20x20 20x25 I 3

not over 8 member

Over 8 but 10x20 Width of 35x35 20x25 25 x 25 I 3

not over 10 member

20
 SP 62 (S & T) : 1997

16.3 Treatment Beneath the Building chemical emulsion shall be directed towards the
For treating soils beneath a building, the following masonry surfaces in contact with the earth. All foun-
dations shall be fully surrounded by and in close con- ,
chemicals are effective:
tact with the chemicals treated soil barrier (see Fig._2.3
Ll> Heptachlor emulsifiable concentrate 0.5 and Fig. 2.4).
percent by weight (see IS 6439 : 1978); 16.6 Treatment of RCC Foundations and
b) Chlordane emulsifiable concentrate 1.O per-
Basements
cent by weight (see IS 2682 : 1984);
The treatment of masonry foundations was necessary
Cl Chlorpyrifos emulsifiable concentrate, 1.Oper-
because of the voids in joints through which the ter-
cent by weight (see IS 8944 : 1978).
mites are able to seekentry into the building. However
NOTES in RCC foundations there are no such voids for the
1 These chemicals are to be regarded as POISONS. They can
have adverse effect on health when absorbed through skin, termites to penetrate. It is therefore unnecessary to
inhaled as vapours or spraymists or swallowed. Therefore, they start the treatment of RCC foundations from the
most he safely handled [see Appendix B of IS 6313 (Part 2) : bottom. The treatment may be started at SO0 mm
19XIj. These chemicals should not be used where there is a risk below ground level except when the level is raised or
ol’ walls or other water supplies being contaminated. The
Authority concerned shall be consulted.
lowered by filling after the foundations have been cast.
In such a case the depth of soil level shall be deter-
2 Aldrin has heen banned by Government of India. Before use
mined from the new ground level. The soil in the
of these chemicals latest recommendations of Central Insecticide
Board and Registration Committee, Ministry of Agriculture, immediate contact with RCC shall be treated
Faridahad should be referred. with 7.5 l/m2 of the chemical. The other details are as
in Fig. 2.5.
16.3.1 Where there are mounds of termites within the
excavated area, these chemicals shall be poured into 16.7 Treatment of Top Surface of Plinth Filling
the mounds of several places after breaking them. The 16.7.1 The top surface of the consolidated earth
quantity used shall be related to the size of the mound. within plinth walls shall be treated with chemical
For a mound of about lcm3, 4 1 of the emulsion of one emulsion at the rate of 5 l/m2 of the surface before the
of the chemicals may be used, namely, sandbed or sub-grade is laid.’ If the. filled bed is
0.25 percent Heptachlor emulsifiable concentrate. rammed and the surface does not allow the emulsion
0.5 percent Chlordane emulsifiable concentrate. to seep through, holes up to SO mm to 75 mm deep at
150 mm centres both ways may be made with I2 mm
16.4 Time of Application
steel rod to facilitate saturation of the soil with chemi-
Soil treatment should start when foundation trenches cals.
and pits are ready to take mass concrete in foundations.
16.8 Treatment at Junction of the Wall and the
Treatment should not be carried out when it is raining
Floor
or when the soil is wet. This also applies to filled up
soil within the plinth area before laying the subgrade Special care shall be taken to establish continuity of
for the floor. the vertical chemical barrier on the inner wall surfaces
from ground level (or other level) up to the level of the
16.5 Treatment of Masonry Foundations and
filled earth surface. To do this, a small channel 30 mm
Basements
x 30 mm shall be made at all the junctions of wall 01
16.5.1 The bottom surface and sides (up to about columns with the floor (before laying sub-grade) and
30 cm) of the excavations made for necessary founda- rod holes made in the channel up to the ground level
tions and basements shall be treated with the chemical 150 mm apart; the rod shall be moved backward and
at the rate of 5 l/m2 of surface area. forward to break up the earth and then the chemical
16.5.2 After the masonry foundations and retaining emulsion be poured along the channel at a rate of
wall come up, the backfill in immediate contact with 7.5 l/m2 of the vertical wall or column. This would
the foundation shall be treated with the chemical at the perLmitthe soil to be soaked right down to the bottom.
rate of 7.5 l/m” of the vertical surface of the sub-struc- The soil should be tamped back into place after the
ture for each side. If water is used for ramming the operation.
earth fill, the chemical treatment shall be carried out 16.9 Treatment of Soil Along External Perimeter
after the ramming operation is done. For this rodding of the Building
of earth close to the wall at 15 cm centres shall be done After the building is complete, the earth along the
and working the rod backwards and forward parallel external perimeter of building shall be rodded at inter-
to the wall before applying the chemical emulsion. vals of 150 mm to a depth of 300 mm. The rod should
The earth fill is done in layers and the chemical treat- be moved backward and forward parallel to the wall
ment shall be carried out for each layer. After the to break up the earth and the chemical emulsion be
treatment the earth should be tamped in place. The poured along the water at the rate of 7.5 l/m2 of the

21
SP 62 (S & T) : 1997

vertical surfaces in contact with earth. After the treat- of termites through~voids in masonry, cracks, etc. The
ment the earth should be tamped back into place. If soil retained by the walls shall be treated with the
the earth outside the building is gradedthe treatment chemical emulsion at the rate of 7.5 l/m2 of the vertical
should be carried out on completion of grading. surface in contact with the soil. This barrier should be
In the event of the filling being more than 300 mm, the in continuation of the barrier upto the plinth level.
external perimeter treatment shall extend to the full 16.12 Treatment of Soil Surrounding Pipes,
depth of filling down to the ground level so as to ensure Conduits, etc
continuity of the chemical barrier. When pipes, conduits, enter the soil inside the area of
16.10 Treatment of Soil Apron Along External the foundations, the soil surrounding each point of
Perimeter of Building entry should be treated. For this the soil shall be
The top surface of the consolidated earth over which loosened for a distance of 150 mm and depth of 75 mm
the apron is to be laid shall be treated with chemical and then the treatment should be commenced at the
emulsion at the rate of 5 l/m2 of the surface before the same rate as the foundation soil. When the pipes enter
apron is laid. If the consolidated earth does not allow the soil external to the foundation they shall be similar-
the emulsion to seep through, holes up to 50 mm to ly treated for a distance of 300 mm unless they are clear
75 mm deepat 150 mm centres bothways may be made of the-walls by about 7.5 mm.
with 12 mm dia rod, on the surface to facilitate satura- 16.13 Treatment of Expansion Joints
tion of the soil with the chemical emulsion (see
Expansion joints at ground level are one of the worst
Fig. 2.4).
hazards for termite infestation. The soil beneath these
16.11 Treatment of Walls Retaining Soil Above joints should receive special attention when treatment
Ground Level under 16.6 for plinth filling is being carried out. This
Retaining walls like basement walls or outer wall treatment should be supplimented by treating the ex-
above the floor level retaining soil need to be protected pansion joint after the sub-grade has been laid, at the
by providing a chemical barrier so as to prevent entry rate of 2 litres per linear me&e.

/- FLOOR FINISH

/A’:..‘_:‘;1 L PLINTH FILLING

Stages of Treatment
A = Bottom and sides oftrenches
B = Backfillin immediatecontactwithmasonryfoundation
C = Junctionof wall andfloor
D = Topsurfaceof plinthfilling
E = External perimeter of building

FIG. 2.3 TREATMENTFORMASONRYFOUNDATIONSWITHOUTAPRON

22

.
 SP 62 (S & T) : 1997

ED/
ETC.

GR

Stages of Treatment
A = Bottom and sidesof trenches
B = Backfillin immediatecontactwith masonryfoundation
C = Junctionof wall and floor
D = Top surface of plinth filling
E= External perimeter of building
F = Soil below apron

FIG. 2.4 TREATMENTFORMASONRYFOUNDATIONS.WITH APRON ALONG EXTERNALPERIMETER

23
SP 62 (S & T) : 1997

r FLOOR FINISH
FLOOR BASE
CONCRETE
I

SAND 6ED/
SOLING ETC.

GROUND LEVEL

PLINTH FILLING

Stages of Treatment
A = Backfill in immediate contact with RCC foundation
B = Junction of wall and floor
C = Top surface of plinth filling
D = Externalperimeterof building
FIG. 2.5 TREATMENTFORRCC FOUNDATIONS

24
 CHAPTER3

FOUNDATIONS

.
 CONTENTS

1 GENERAL 3.5 Cast in-situ Piles

1. I Pre-construction 3.6 Timber Piles
1.2 Drainage 3.7 Load Test on Piles
1.3 Setting Out 4 MACHINEFOUNDATIONS
1.4 Protection of Excavation
4. I General
2 TYPESOF FOUNDATIONS 4.2 Criteria for Construction
2.1 Shallow Foundations 5 MISCELLANEOUS
2.2 Deep Foundations
2.3 Foundations for Special Structures 6 SPECIALSTRUCTURES

3 CONSTRUCTION
OFFOUNDATIONS ANNEXA-INFORMATIONONCHOICEAND CHARAC-
TERISTICS
OFCERTAIN TYPESOFFOUNDATIONS
3.1 Shallow Foundations
3.2 Pile Foundatiops ANNEXB-GUIDELINESFORGROUNDIMPROVEMENT
3.3 Under-Reamed Foundations FOR FOUNDATIONSIN WEAK SOILS
3.4 Precast Piles

.
 SP 62 (S & T) : 1997

CHAPTER 3

FOUNDATIONS
1 GENERAL Alternatively, the bottom of the excavation
shall be protected immediately by 8 cm thick
1.1 Pre-construction
layer of cement concrete not leaner than mix
After the excavation is done, as per Chapter 2, con- 15: 10; the foundation concrete should then be
struction of foundations should be undertaken. How- placed on this. Or in order to obtain a dry hard
ever, certain pre-construction activities should be bottom, the last stretch of excavation of about
completed before commencement of work. These are 10 cm shall be removed just before concreting.
described below. d) The refilling of excavation shall be done with
care so as not to disturb the just constructed
1.2 Drainage
foundation. The backfill should be carried out
If the site of the building is such that water would drain evenly on both sides of the wall. The fill shall
towards it, land may be dressed or drains laid to divert be compacted in layers not exceeding 20 cm
the water away from the site. thick, with sprinkling of just enough water
necessary for proper compaction.
1.3 Setting Out
2 TYPES OF FOUNDATIONS
1.3.1 Generally the site shall be levelled before the
layout of foundations are set out. In case of sloping 2.1 Shallow Foundations
terrain, care shall be taken to ensure that the dimen- These cover such types of foundations in which load
sions should be set out with theodolites in case of transfer is primarily through shear reistance to the soil
important and intricate structures where the length of and are normally laid to a depth of 3 m.
site exceeds 16 m. In other cases these should be set
out by measurement of sides. In rectangular or square 2.1.1 The various types of shallow foundations are as
setting out, diagonals shall be checked to ensure under:
accuracy. a) Spread or Pad (see IS 1080 : 1986),
The setting out of wall shall be facilitated by per- b) Strip (see IS 1080 : 1986),
manent row of pillars, parallel to and at a suitable c) Raft [see IS 2950 (Part I) : 198 I], and
distance beyond the periphery of the building. The d) Ring land Shell (see IS 11089 : 1984 and IS
pillars shall be located at junctions of cross walls with 9456 : 1980).
the peripheral line of pillars. The centre lines of the 2.2 Deep Foundations
cross walls shall be extended and permanently con-
These foundations ark generally in the form of piles,
nected to the tops of corresponding pillars.
caissons, diaphragm walls, used separately or in com-
The datum lines parallel to and at a known distance bination to transmit the loads to a deeper load bearing
fixed from the centre lines of external walls, should strata. The transfer of load may be through friction,
also bepermanently set on the rows of pillars to serve end bearing or a combination of both.
as checks on the accuracy of the work as it proceeds.
2.2.1 The various types of deep foundations are as ‘.
The tops of pillars shall be at the same level and under:
preferably at plinth or floor level. The pillars shall be a) Pile Foundations
of sizes not less than one brick wide and shall be 1) Driven cast in-situ - see IS 29 11 (Part
embedded sufficiently deep into the ground so that l/Set 1) : 1979
they are not disturbed. 2) Bored cast in-situ - see IS 2911 (Part
l/Set 2) : 1979
1.4 Protection of Excavation
3) Driven precast - see IS 291 l(Part l/Set
Protection of excavation during construction 3) : 1979
of shoring, timbering, ~dewatering operations, 4) Bored precast - see IS 291 l(Part l/Set
etc, shall be ensured. 4) : 1984
b) After excavation, the bottom of the trench shall 5) Timber - see IS 291 l(Part 2) : 1980
be cleared of loose soil and rubbish and shall 6) Under-reamed - see IS 2911 (Part 3) :
a
be levelled, where necessary. 1980
cl Excavations, in clay or other soils, that are b) Diaphram Walls - see IS 9556 : 1980
likely to be effected by exposure of atmos- c) Combined Foundations-Two or more of the
phere, shall be concreted as soon they are dug. above.

27
SP 62 (S & T) : 1997

2.3 Foundations for Special Structures b) Steel--Reinforcement steel shall conform to

IS 432 (Part 1) : 1982; or IS 1786 : 1985; OI
These include foundations for machines, towers, etc.
IS 2062 : 1992.
2.3.1 Machine foundations are subject to vibrations.
For under-reamed bored compaction piles, the
Manufacturer’s instructions, if any, may be followed.
reinforcement cage shall be prepared by weld-
Indian Standards cover machinery foundations for
ing the hoop bars to withstand the stresses
Reciprocating type [see IS 2974 (Part 1) : 19821;
during compaction process.
Impact type [see IS 2974 (Part 2) : 19801; Rotary type
[see IS 2974 (Part 3) : 1992 and IS 2974 (Part 4) :
cl Concrete

19791; Impact type (other than Hammer) [see IS 2974

1) Consistency of concrete for cast in-situ
piles shall be suitable to the method of
(Part 5) : 19871.
installation of piles.
Tower foundations are covered by IS 4091 : 1979 for 2) Concrete shall be so designed or chosen as
steel towers and by IS 11233 : 1985 for Radar, Anten- to have a homogeneous mix.
na? Microwave and TV towers. 3) Slump of concrete shall range between
3 CONSTRUCTION OF FOUNDATIONS 100 mm and 150 mm for concreting in
water-free unlined bore holes. For con-
3.1 Shallow Foundations creting by tremie, a slump of 150 mm to
In shallow foundations, generally, masonry and/or 200 mm shall be used.
concrete, plain and reinforced, are used. The proce- 4) In case of tremie concreting ~of piles of
dure for masonry and concrete foundations shall be the smaller diameter and depth up to IO m, the
same as described in masonry and concrete work (see minimum cement content should be 350
Chapters 4 and 5). kg/m” of concrete. For piles of larger
diameter and/or deeper piles, the mini-
3.2 Pile Foundations
mum cement content should be 400 kg/m’
Under-reamed piles, though listed under deep founda- of concrete.
tions also are used for foundations up to 3 m depth.
In case the piles are subsequently exposed to water or
3.3 Under-Reamed Foundations in case piling is done under water or drilling mud is
Under-reamed piles are of bored cast in-situ and bored used in methods other than tremie, 10 percent extra
compaction concrete types having one or more bulbs cement shall be used over and above that required for
formed by suitably enlarging the bore hole of the pile the grade of concrete at specified slump.
stem. With the provision of bulbs, substantial bearing
For making concrete, aggregate as described in
or anchorage is available.
IS 456 : 1978 shall be used. For tremie concreting;
These piles find application in widely varying situa- aggregates having nominal size more than 20 mm
tions in different types of soils where foundations are should not be used.
recluired to be taken to a certain depth in view of
For bored compaction piles Rapid Hardening Cement
considerations like the need
to IS 8041:1990 shall not~be used.
a ) to avoid the undesirable effect of seasonal
3.3.2 Equipment
moisture content changes as in expansive soils;
b) to reach firm strata; Normally the equipment required for manual opera-
c) to obtain adequate capacity for downward, up- tions are:
ward and lateral loads and moments; and a) auger;
d) to take the foundations below scour level. b) under-reamer;
c) boring guide; and
Under-reamed piles may also be used in situations
d) accesories.
where vibration and noise caused during construction
of piles are to be avoided. For piles of deeper and larger size greater than 30 cm
and a portable tripod hoist with manually operated
The provision of bulbs is of advantage in under-
winch is required.
reamed piles to resist uplift as they can be used as
anchors; increased bearing surface also becomes avail- For piles in high ground water table and unstable soil
able. conditions, boring and under-reaming shall be carried
3.3.1 Materials out using suitable equipment. Tremie pipe shall ‘be
used for concreting.
a) Cement-The cement used shall conform to
the requirements of IS 269 : 1989 or IS 455 : For compact piles, the additional equipment required
1989 or IS 804 1 : 1990 or IS 6909 : 1990 or IS are drop weight for driving the core assembly and pipe
1489 (Parts 1 and2) : 199 1; or IS 12269 : 1987. or solid core.

28
 SP 62 (S & T) : 1997

3.3.3 Construction bore hole. Care shall be taken that soil is not
scrapped from sides if rodding is done for
a) Bore holes may be made by earth augers. In
compaction. Vibrators shall not be used.
:ase of manual boring, an auger bohng guide
<hall be used to keep the bores vertical or at the If the subsoil water level is confined to the
lesired inclination and in position. After the bucket length portion at the toe, the seepage is
bore is made to the required depth, enlarging low and the water should be bailed out before
of the bore shall be carried out by means of an commencing concreting.
under-reaming tool. In case the pile bore is stabilized with drilling
b) Drilling mud may be used for boring and mud or by maintaining water head-within the
under-reaming in a site with high water table. bore hole, the bottom of bore hole shall be
Benronite may be used. carefully cleaned by flushing it with fresh drill-
Cl To avoid irregular shape and widening of bore ing mud and the pile bore be checked before
hole in a very loose strata at top, a casing pipe concreting.
of suitable length may be temporarily used. Concreting shall be done by the tremie method.
4 For better under-reamed piles, the reinforce- The tremie should have a valve at the bottom
ment cage should be placed guiding it by a and lowered with the valve closed at the start
chute or any other means. and filled up with concrete. The valve is then
e) In order to achieve proper under-reamed bulb, opened to permit concrete which permits the
the depth of bore hole should be checked upward displacement of drilling mud. The
before starting under-reaming. It should.also pouring should be continuous and the tremie is
be checked during under-reaming; any extra gradually lifted up such that the pipe opening
soil at the bottom of bore hole shall be removed remains always in the concrete. In the final
by auger before re-inserting the under-reaming stage the quantity of concrete shall be enough
tool. so that on the final withdrawal some concrete
The completion of the desired under-reamed spills on the ground (see Notes I to 5).
bulb is ascertained by vertical movement of the
NOTES
handle and when no further soil is cut.
S> In multi-under-reamed piles, the boring is first 1 All tremie tubes should be cleaned hefore and after
completed to the depth required for the first ttse.

(top) bulb only and after completing under- 2 The tremie pipe should always penetrate well into the
reaming bulb, the boring is extended further concrete with an adequate margin of safety against
withdrawal of the pipe.
down to the second bulb and so on.
h) The piles shall be installed as correctly as pos- 3 The tremie method shall not be changed for a given
sible, both at the correct location and truly pile, to prevent the laitance from being entrapped in the
pile.
vertical (or at the specified batter). Piles shall
not deviate by more than 75 mm or one quarter 4 In the case of withdrawal of a pile accidentally or to
remove a choke, the tremie may be reintroduced in a
the stem diameter whichever is less; for piles
manner to prevent fragmentation of laitance or scmlt
of diameter more than 600 mm, the deviation lying on the top of the concrete deposited already in the
may be 75 mm or 10 percent of the stem bore.
diameter. 5 In the exceptional case of interruption of concreting
j> Concreting shall be done as soon as possible which can he resumed in one or two hours, the tremie
after completing the bore. The bore hole full shall not be taken out of concrete. Instead it shall be
of drilling mud should be concreted between raised or lowered slowly, from time to time, to prevent
the concrete around the tremie from setting. Concreting
12 to 24 h depending on the stability of the
should be resumed by introducing a little richer mix of
hole. concrete with a slump of about 200 mm for easy displace-
k) The method of concreting should be such that ment of the partly set concrete. If the concreting cannot
the entire volume of the pile bore is filled up be resumed before the final set of concrete, the pile may
be rejected or used with modifications.
without formation of voids and/or mixing of
soil and drilling fluid in the concrete. For plac- m>In inclined piles, concreting should be done
through a chute or by tremie method.
ing concrete in pile bores, funnel should be
used.
4 A bored compaction pile is one in which the
compaction of surrounding ground as well as
In the empty bore holes for under-reamed piles fresh concrete in the bore is simultaneously
a small quantity of concrete is poured to give accomplished. In under-reamed bore compac-
about a 100 mm layer of concrete at the bottom. tion piles, the pile shall be filled up with con-
Reinforcement is lowered next and positioned crete, without placing reinforcement.
correctly. The concrete is poured to fill the Immediately, the core assembly shall be driven

29
SP 62 (S & T) : 1997

and extra concrete shall be poured in simul- binding wire, the free ends of which should be
taneously to keep the level of concrete up to turned into the interior of the pile. The lon-
ground level. If a hollow driving pump is used gitudinal bars may be held apart by temporary
in core assembly, the pipe shall be withdrawn or permanent spreader forks not more than
after filling it with fresh concrete. 1.5 m apart. The reinforcement shall be check-
In these compaction piles it shall be ensured ed for tightness and position immediately
that concreting should be done uninterrupted- before concreting.
ly. Accidental withdrawal should be com- After casting the piles, they shall be stored as
pletely avoided. described in Chapter 1.
Bored precast piles shall be .constructed by
P) The top of the concrete pile shall be brought
above the cut-off level to permit removal of all suitable choice of boring and installation tech-
laitance and weak concrete before capping and niques depending on detailed information
to ensure good concrete at the cut-off level for about the subsoil conditions. The bottom end
proper embedment into the pile cap. of the pile shall have proper arrangements for
cleaning and grouting.
9) Where cut-off level is less than 1.5 m below
working level, concrete shall be cast to mini- Piles shall be installed as vertically as possible
mum of 300 mm above cut-off level, for every according to the drawings, or to the specified
excess of 0.3 m over 1.5 m, additional of batter. The deviation from specified alignment
50 mm shall be cast over and above 300 mm. shall be as permitted for under-reamed piles in
When tremie method is employed, it shall be 3.3.
cast to the piling platform level to permit over- g) Cement and sand (1 : 2) grout mixed with water
flow of concrete for visual inspection or to a in a high speed colloidal mixer is fed to the pile
minimum of 1 m above cut-off level. with grout pump of suitable capacity to the
central duct through a manifold. Temporary
When the cut-off level is below the ground
casing used here shall be removed in stages
water level, there is a need to maintain a pres-
with the rise of level of grout. The grout should
sure on the unset concrete equal to or greater
be levelled off at the top. The strength of the
than the water-pressure and a length of extra
grout shall be at least equal to the strength of
concrete above the cut-off level may be per-
the surrounding soil.
mitted to provide this.
When defective piles are formed, they shall be h) Where a pile is to have another length cast on
r) to it before or during placing, the longitudinal
removed or left in place whichever is con-
reinforcement should be welded with full
venient, without effecting the performance of
penetration butt welding, after the concrete at
adjacent piles or the cap as a whole.
the top of the pile should be cut-off to expose
Any deviation beyond permissible limits from not less than 200 mm of the bars. Bars may be
the designed location, alignment or load lapped if it is not possible to undertake butt
capacity of any pile shall be noted and adequate welding with an overlap of 40 times the dia of
measures be taken well before the concreting bar.
of the pile cap and plinth beam.
3.4.2 Driven Precast Piles
The pile should project 50 mm into the cap
concrete. Driven precast piles transmit the load of the structure
by resistance developed either at the tip or by end
3.4 Precast Piles bearing or along the shaft by friction or by both. They
3.4.1 Bored Precut Piles are cast in a yard and subsequently driven into the
ground with or without jetting. These piles find wide
Bored precast concrete piles are constructed in a cast- application for structures, such as, wharves, jetties, etc,
ing yard and subsequently lowered into prebored holes or where conditions are unfavourable for use of cast
and the space grouted. in-situ piles.
a) As far as possible, in-situ extensions shall be a ) Pile foundations shall be designed in such a
avoided. way that the load of supports can be transmitted
b) The casting yard should be well drained. to the soil without any soil failure and without
c> As far as possible, longitudinal reinforcement causing settlement as may result in structural
shall be in one length. In case joints are damage. It shall withstand all loads (vertical,
needed, they should be staggered. axial, or otherwise) and moments to be trans-
4 The hoops and links for reinforcement shall fit mitted to the soil.
tightly against the longitudinal bars and be b) When working near existing structures care
bound to them by welding or by tying with shall be taken to avoid damage to such struc-

30
 SP 62 (S & T) : 1997

tures. In case of deep excavations adjacent to 3) Single or double-acting hammer - A

piles, proper shoring or other suitable arrange- hammer operated by steam or compressed
ments be provided against lateral movement of air;
soil stratum or releasing the confined soil 4) Kentledge - Dead weight used for apply-
stress. [For guidance, see IS 2974 (Part 1) : ing a test load to a pile; and
1982 for effect of vibrations due to reciprocat- 5) Pile rig - A fabricated movable steel
ing machines.] frame.
c> The casting yard for all concrete piles shall be c) Construction
so arranged that they can be lifted directly into 1) Concrete - The minimum slump should
the piling area. The yard shall have a well be 100 mm when the concrete in the pile
drained surface to prevent excessive or uneven is not compacted, and shall not in any case
settlement during manufacturing and curing. be more than 180 mm.
As far as possible longitudional reinforcement 2) Control of alignment - Piles shall be
shall be in one length. In case joints are needed installed as accurately as possible accord-
they shall be buttwelded and staggered. ing to the drawings. Permitted deviations
e) The hoops and links reinforcement shall fit shall be as per 3.3.3.
tightly against the longitudional bar and bound 3) Sequence of piling - In a pile group, the
to them by mild steel wire or by welding. The sequence of installation of piles shall nor-
bars may be held apart by spreader forks not mally be from centre to the periphery of
more than 1.5 m apart. The reinforcement the group.
shall be checked for tightness and position No adjacent pile should be driven until the
before concreting. concrete in the pile under construction has set;
After casting the piles, it shall be cured and otherwise the pile may be damaged. The
stored as described in Chapter 1. damage is greater in piles driven in compact
The piles may be driven by any type of ham- soils than in loose soils.
mer, provided they penetrate to the prescribed
In loose sandy soils compaction will increase
depth or attain the specific resistance without
as the piles are driven. Thereforethe order of
being damaged. Any change in the rate of
installing such a pile should be so chosenas to
penetration which cannot be ascribed to nor-
avoid creating a compacted block in the
mal changes in the nature of the ground should
ground, which would prevent further piles
be noted and cause ascertained if possible
being driven.
before driving is continued.
h) The head of the precast pile should be protected Similarprecautions should~be taken in stiff clayey soils
with packing of resilient material. and compact sand layers; this can be done by driving
j) Piles should be installed as accurately as pos- the piles from centre outwards.
sible in a pile group. The sequence of installa-
However in very soft soils, the driving of piles should
tion of ~piles shall be from centre to the
be from outside to centre, so that soil is prevented from
periphery of the group or one side to the other.
floating out during driving of piles.
W For details of manufacture of piles, pile driv-
ing, etc, reference may be made to IS 2911 The casing may be jetted out by means of water
(Part l/Set 3) : 1979. without impairing the bearing capacity of the pile,
3.5 Cast in-situ Piles stability of the soil and safety of adjoining structure.

3.5.1 Cast in-situ driven piles transmit load to the soil The cut-off level, formation of latiance, etc shall be
by resistance developed by the toe of the pile or by end dealt with as in 3.3.3.
bearing or by friction along their surface or by both.
Defective piles shall be dealt with as in 3.3.3.
a) Materials - (see in 3.3.1)
b) Equipment - Among the commonly used 3.5.2 Bored Piles
plants, tools and accessories, the suitability
The bored cast in-situ piles, of less than 2 500 mm
depends on subsoil conditions, manner of
transmit the load to soil by resistance developed either
operation, etc. Some commonly used equip-
at the tip by end bearing or along the shaft by friction
ment are:
or by both.
1) Dolly - A cushion of hardwood or
suitable material placed on top of the a) Bored cast in-situ piles may be driven by
casing to receive hammer blows; suitable choice of installation techniques; the
2) Drop hummer - Hammer (ram or manner of soil stabilization, that is, using of
monkey) raised by a winch and allowed to casing and/or use of drilling mud; manner of
fall under gravity; concreting, etc. Sufficient information on sub-

31
SP 62 (S & T) : 1997

I __._ I:*:-_- 1_ -_-_._r:_, I_ .__.J_&___-t__ .L_ A-.-__ __r.__l _I___-..-.:_-- :_ Al__ --.__ -42 c-...
SUll c;uIIuItIuIls 1s css~llllal LO prcumx1111ne Lilt: tru1n ilClUa1 uc3su valluIls 111 Lilt: cast: Ul ICW

details of installation techniques. piles cast initially. If the quantity is found to

b) Piles shall be installed as accurately as possible be considerably less, special investigations
as per drawings. Great care shall be taken in shall be conducted and appropriate measures
installing single pile or a group of two piles. taken.
Any deviation from designed location, align-
3.6 Timber Piles
~ment or load capacity of anypile shall be noted
and adequate measures taken well before the Timberpiles find extensive use for compaction of soils
,fin,,.~t;+,, “I
L”llL.l5LLII&
,C the Ala
L11L p”G
n-n nnrl ,.l:nth
Lap a11u yrllrrrl
I.\,,,-
“LXIIII. and also L... ,..,,,...L..,
I”, sup~“‘rUlg “,. ..,,11
a5 WC“ aa _” p’“LeLL”1g
,..,.*,,*:..,. ..,.. +-..
W‘lLeI-
c) A minimum length of I m of temporary casing front structures. The choice of use of timber piles shall
shall be inserted in each bored~pile. Additional be mainly governed by the site conditions, particularly
length of temporary casing may be used water table conditions. They are comparatively light
depending on the conditions of strata, ground for their strength and are easily handled. However,
water level, etc. Drilling mud of suitable con- they will not withstand as hard driving as steel or
~i&=nr~, .,,UJ he
OLULV’,“, m~.r “I IIEPFJ inat~arl ,f
“Lll.8 I,*Ub”U” “1 tsvmnnrcan,
cv”‘y”.Y’J n;1nr T;mha.
cn”,.rP*P tJJllti.7.
b”.lnrLti hoc tn ha ralnrtd t.~n-caf,,llx,onA
-A,ll,"Ul IILL.L" vu .Y~-l~b,l"Urcl,"‘u.,J LtInCI

casings to stabilize sides of holes. For marine treated as durability andperformance would consider-
locations, the piles may be formed with per- ably depend upon the quality of the material and
manent casing (liner). freedom from natural defects.
4 In case the bored pile is stabilized by drilling
mud or by maintaining water heads in the hole, 3.6.1 Class of Piles
the bottom of the hole shall be cleaned careful- Depending upon the use, piles shall be classified as
ly before concreting work is taken up. Flush-
Class A and Class B.
ing of holes hefnre
--_-_- concretinp
- ----------=
wit_h frer;h

drilling fluid/mud is preferred. a>Class A - For railway and highway bridges,

e) The specific gravity of the drilling mud shall trestles, docks and warehouses. The butt
be consistent. For this periodic samples shall diameter or sides of square shall not be less
be taken and tested. Concreting shall not be than 30 cm.
taken up when the specific gravity is more than b) Class B - For foundation work other than
1.2. specified in Class A and temporary work. Piles
Concreting shall be done by tremie method in used for compaction of ground shall not be less
all such cases. The slurry should be main- than 100 mm in diameter or side in case of
tained at 1.5 m above ground water level if square piles.
casing is not used. 3.6.2 Timber Species
f) Concreting may be done by tremie method or
by the use of specially designed underwater The species of timber shall conform to IS 3629 : 1986.
placer to permit deposition of concrete in suc- The length of the individual pile shall be specified
~PCC~VP
“““Ul u lavera
‘C’J“I” rxrithmxt
.
nermittinn the
.v I...“YI y”‘L#“‘L”n~ %.I” rnnrretn
““IIWAW.Y lmanth A. 4”
,“,,6L” L Wl VI,,
c-m fnr 13 m
I”, I& 11. lnntr ad A
‘“I.& ..>I” A MI
-11, rm
“1,. +n;rr
A”, lrnothc
&,d.‘&. . . .I
to fall through free water. above 12 m. In case of round piles, the ratio of
.g) Convenience of installation may be taken into heartwood diameter to the pile butt diameter shall not
account while determining the sequence of be less than 0.8. Both the ends shall be sawn at right
piling in a group. angles to the length of the pile and surface shall be
h) The top of concrete in a pile shall be brought made flush by trimming the knots and limbs.
above cut-off level to permit removal of The timber shall be treated as per IS 401 : 1982 on
laitance and weak concrete before capping and timber preservation.
to ensure good concrete at the cut-off level for
3.6.3 Control of Pile Driving
proper embedment into the pile cap.
j) In case defective piles are formed, they shall The piles in each bent of a pile shall be selected
be removed or left in place whicheveris con- for uniformity in size to facilitate placing of
venient affecting the performance of the ad- bracing members.
jacent piles or the cap as a whole. Additional b) The pile tip shall be pointed (unless driving is
piles shall replace them. in wholly soft strata) in the form of truncated
k) ‘Pneumatic tools shall not be used for chipping cone or a pyramid having the end 25 cm2 to
until seven days after pile casting. Manual 40 cn? in area and the length shall be 11 to 2
chipping of pile top may be permitted after 3 times the diameter or side of a square.
days of casting the pile.
m) After concreting the actual quantity of concrete
c>If the driving is to be done in hard material such
as stiff clay, gravels, etc, metal shoes of
shall be compared with the average obtained
approved design shall be attached to the tip.

32
 SP 62 (S & T) : 1997

4 To prevent splitting and reduce brooming, the 3.6.4 Hundlir~g of’ Piles
read of the pile should be hooped with a
a ) Care shall be taken to see that the piles are
suitable ring or wrapped with wires. The heads
sufficient number of points, properly located to
)f piles shall be further protected by the
prevent damage due to excessive bending.
Errovision of cushion blocks.
b) Treated piles shall be handled with hemp OI
e) I f the piles are required to be formed from two manila rope slings or other means of support
rr more lengths, the butting surfaces shall be
that will not damage the surface of the wood.
:ut square to ensure contact over the whole
c) Dropping, brushing, breaking of fibres and
:ross section of the pile. A thin steel plate
penetrating the surface shall be avoided.
Ilaced between the butting surfaces will
.educe the tendency to brooming. d) Sharp pointed tools shall not be used for
handling or turning them in leads.
The pieces should also be secured with steel
e) Minor abrasions of the surface of treated piles
ubes or steel tlats. Splices in the middle of the below cut-off level in the portions which are to
Gle should be avoided. If it is necessary to remain permanently under water shall be
obtain increase in size and length of pile by permitted.
Glding up sections, the joints should be stag- 1) Surface of treated piles below cut-off shall not
:ered and the timber members connected by be disturbed by boring holes or driving nails to
neans of bolts or screws. support temporary material or stagping.
Tiles shall be installed as accurately as possible
according to drawings. 3.7 Load Test onPiles
[n a pile group, the sequence of installation of Shall be done as prescribed in IS 29~11 (Part 4) : 1985.
piles shall normally be from centre to
periphery of the group or from one side to the 4 MACHINE FOUNDATIONS
other. Adjacent piles shall not be damaged 4.1 General
when driving a pile; the danger is greater in
compact soils than in loose soils. Machine foundations are specialized structures,
according to typeof machines, namely, rotary, impact,
Driving piles in loose sand tends to compact
reciprocating, etc. However, a few criteria for con-
the sand which in turn increases the skin fric-
struction are listed below.
tion for friction piles. Therefore the order of
installing of such a pile group should avoid 4.2 Criteria for Construction
creating a compact block of sand pile into
4.2.1 Concrete
which further piles cannot be driven.
Similar precautions have to be taken in case The-concrete used shall be controlled concrete. The
piles have to be driven into stiff clay or com- grade of concrete shall be between M 15 to M 20 for
pact sand layers. This may be overcome by block foundations and M 20 for formed foundations.
driving piles from the centre to the periphery A slump of 50 mm to 80 mm is allowable. The
or by beginning at a selected edge or working concrete used shall be of plastic consistency without
across the group. In case of very soft soils, excessive water. The water cement ratio shall not
driving may have to proceed from outside to exceed 0.45 which shall be maintained throughout the
inside, so that soil is retained from flowing and concreting of foundation.
during operation. 4.2.2 Continuous concreting shall be done as far as
h) Jetting of cases by means of water shall be possible for the entire block, leaving provisions for
carried out if required in such a manner as not grouting.
to impair the bearing capacity of piles already
in place, the stability of the soil or the safety or 4.2.3 All areas under and adjacent to the foundation
any adjacent buildings. shall be well cleaned prior to pouring of concrete. The
j> Defective piles shall either be removed or left surfaces except the pockets for grout, shall be made
in place as is convenient without affecting the rough so as to secure good bond with fresh cement.
performance of the adjacent piles or the cap as Cement grout with non-shrinkable additive shall be
a whole. Additional piles shall be provided to used where structurally required.
replace the defective piles.
4.2.4 All elements of foundation shall be provided
k) Any sudden change in the rate of penetration
both at top and bottom by two way reinforcement.
which cannot be ascribed to the nature of
Reinforcement shall be provided along the surface in
ground shall be noted and its cause ascer-
case of block foundations. The amount of reinforce-
tained, if possible, before driving is con-
ment shall vary between 25 to 50 kg/m’ of concrete as
tinued.
the case may be. The minimum dia shall be 12 mm

33
SP 62(S &T): 1997

and maximum shall be 20 mm in order to take care of and covered by a rich layer of 1: 2 cement grout
shrinkage. Concrete cover shall be 75 mm at bottom, 20 mm thick, concrete should be placed not
SO mm on sides and 40 mm on top. later than 2 h after the grout is laid.

4.2.5 The tlnished surface of the foundation shall be 5 MISCELLANEOUS

leveiied before installing the machine. 5.1 For field testing of soils reference may be made to
SP 36 (Part 2) : 1988.
4.2.6 The foundation bolts shall be properly anchored.
5.2 Some information on choice and characteristics of
4.2.7 Construction joints should be avoided. If foundations is given in Annex A. Information on
needed the plane of the joint shall be horizontal. improvement of weak soils to carry more load is given
in Annex B.
The requirements of a construction joint are:
6 SPECIAL STRUCTURES
a1 Embed dowels of 12 mm to 16 mm dia at
60 mm centres to a depth of at least 30 cm 6.1 Requirements of foundations for special struc-
depth; and tures shall be as per design and drawings and any
b) Before laying fresh concrete, the previously requirements specified. By and large IS 456: 1978 may
laid surfaces shall be cleaned and roughened be followed.

ANNEX A
(Clause 5.2)
INFORMATION ON CHOICE AND CHARACTERISTICS ~OF CERTAIN
TYPES OF FOUNDATIONS

A-l GENERAL A-2.2 These foundations could be used for medium

high structures of residential and commercial occupan-
A-l.1 The design of foundation, superstructure and
cy with uniform distribution of loads.
the characteristics of the soil are inter-related. In order
to obtain mnximum’economy, the supporting soil, A-3 RING FOUNDATION
foundation and the superstructure should be studied as A-3.1 Ring foundation is a substructure supporting an
a whole. The gee-technical aspects of the soil deter- arrangement of columns or walls and transmitting
mines the type and design of foundation; whereas the loads to the soil by means of a continuous Slab.
materials and properties of these materials determine Generally, these foundations could be used for tail
the design of superstructure. In effect it may appear structures, such as, silos, chimneys, water tanks, etc,
that an inelastic foundation should support a super- which have a non-uniform distributed loads.
structure constructed out of elastic materials.
A-3.2 For fairly small and uniform column spacing
The general aim of foundation choice and design is to and when the supporting soil is not too compressible,
ensure that the loading intensity imposed on the soil a flat concrete slab of uniform thickness is most
does not exceed the safe bearing capacity of the soil. suitable. Under the effect of dead load, the soil is
In addition the materials of foundation, such as, subjected to uniform pressure; but under live loads like
masonry, concrete, etc, should not be stressed for more wind or earthquake the pressure on the soil is non-
than the limits specified in appropriate codes govern- uniform.
ing the structural design of such elements. The
If there is sufficient bending due to lateral loads it is
construction procedures should enable the aim of
more economical to adopt a annular raft. Annular
design in office to be realised in the field.
circular slab with a ring beam type of raft is likely to
A-2 SPREAD FOUNDATIONS be more economical for large column spacing.

A-2.1 In spread foundations transfer of load is A-4 RAFT FOUNDATION

primarily through shear resistance of the bearing soil A-4.1 Raft foundation is a substructure supporting an
and they are normally laid to a depth of 3 m. arrangement of columns or walls in a row and trans-
Strip foundations provide continuous and longitudinal mitting the loads to the soil by means of a continuous
bearing of loads, such as, wall elements, beams and the slab with or without openings or depressions. The
like. The soil bearing capacity is limited for choice of foundations are useful where the soil has low bearing
such foundation. capacity.

34
 SP 62 (S & T) : 1997

A-4.2 A raft (mat) foundation slab of uniform thick- They are also useful where artesian conditions exist or
ness is suitable for fairly small and uniform column where local obstructions are encountered above the
spacing and when the supporting soil is not too com- foundation level. They also can be protected by
pressible. appropriate coatings.
The slab may be thickened for heavily loaded columns A-5.3 Driven Cast in-situ Concrete Pile
to provide adequate strength for shear and negative
moment. Driven cast in-situ piles are formed by driving a casing
A slab and beam type of raft is likely to be more and filling it in the hole with plain or reinforced con-
economical for large column and unequal spacing of crete. The casing may be temporary or permanent.
columns; particularly when the supporting soil is com- The concrete may be rammed, vibrated or just poured.
pressible. These piles find wide application where the pile re-
quired is taken to a greater depth to find adequate
For heavy structures, provision of cellular raft or rigid bearing strata or to develop adequate skin friction; and
frames consisting of slabs and basement walls may be also when the length of individual piles cannot be
considered. pre-determined.
A-5 PILE FOUNDATION
A-5.4 Bored Cast in-situ and Driven Precast Pile
A-5.1 The load transfer mechanism from a pile to the
surrounding soil is cgmplicated and has not yet been Their application is similar to A-5.3 and A-5.2 respec-
fully determined, altliough application of pile founda- tively.
tion has been in vogue for many decades.
Broadly speaking, piles transfer axial load either by A-5.5 Under-Reamed-Piles
friction along its shaft and/or subsequently by end
Under-reamed piles find wide application under the
bearing.
following conditions:
Construction of pile foundations requires careful
choice of piling system, depending on the subsoil 4 When the site consists of expansive soils, like
black cotton soil, the bulb provides additional
conditions, the load characteristics, limitations of total
anchorage against uplift due to swelling pres-
settlement, differential settlement, etc. It requires
sure impart from the increased bearing.
careful control of alignment, position and depth and
involves specialized skill and experience.
b) In filled or otherwise weak strata overlying
firm strata, enlarged base in the form of under-
A-5.2 Bored Precast Concrete Pile reamed bulb provides larger bearing area and
These piles find wide application in chemically agres- therefore piles of greater bearing capacity can
sive soils and in high ground water conditions. These be constructed.
piles are protected even in such conditions because c) In loose to medium pervious sandy and silty
they are made by using dense, vibrated matured con- strata, the process of compaction increases the
Crete. bearing capacity of the pile.

ANNEX B
(Clause 5.2)
GUIDELINES FOR GROUND IMPROVEMENT FOR
FOUNDATIONS IN WEAK SOILS

B-l GENERAL B-2 METHODS

B-l.1 In poor and weak subsoils, the design of con- B-2.1 Need
ventional shallow foundations for structures may The need for ground improvement should be estab-
present problems with respect to both size of founda- lished by collection of soil data. If the bearing capacity
tion and control of settlements. Traditionally pile is less than that specified in IS 6403: 198 I for shallow
foundations have been employed at very high costs. A foundations than the need for ground improvement
recent approach is to improve the soil itself to the arises; also if the settlements exceed those specified
extent that would result in adequate bearing capacity by IS 8009 (Part 1) : 1976 and IS 8009 (Part 2) : I980
and settlements within acceptable limits. for shallow and deep foundations. Soils subject to

35
SP 62 (S & T) : 1997

liquefaction particularly during earthquakes under B-2.4 Injection and Grouting

high water table conditions also need strengthening. a ) Injecting of chemicals, lime, cement, etc, into
B-2.2 SOIL DENSIFICATION subsoils to improve subsoil by formation of
bonds between soil particles. Mechanical
a) Soil structure improvement from in a loose to compression of subsoil~is also achieved under
medium dense or dense state is by application certain conditions provided grout is pumped in
of shock and vibration. This technique, is ap- under high pressure.
plicable only to cohesionless soils under high
water table conditions. b) This method is suitable for sands as well as fine
grained soils.
b) Vibroflotation, vibrocompaction, compaction
piles, blasting and dynamic consolidation are B-2.5 Soil Reinforcement
some of the methods suitable to undertake this
a) Reinforcement introduced into the soil mass
treatment. causes marked improvement in stiffness and
9-2.3 Preconsolidation consequently load carrying capacity and
stability of soil mass. Reinforcement may be in
a > Increase in shear strength with substan- the dense granular materials like stone chips.
tially reduced values of settlement result by These are used primarily to increase load bear-
expulsion of water from the pores of the soil ing capacity of the soil mass.
causing consolidation. This consolidation is
achieved by subjecting it to a preload. Preload b) Reinforcements may be in the form of horizon-
tal or vertical membranes. These membranes
can be soil itself or any suitable material.
serve significantly to increase the capacity of
b) Preloading is generally carried at in stages the soil to withstand tensile, shear and com-
to allow gradual build up of strength en- ~pression loads and contribute towards stability
abling it to safely support further stages of of mass.
preload.
B-2.6 Other Methods
c) For poorly draining soils precompression is
accelerated by provision of vertical drainage in Other methods include heating and drying and by
soils. fusion at high temperatures; replacement of poor sub-
soil by competent fill. However, these have certain
d) Removal of water from pore spaces can also be
limitations.
done by application of electric current to sub-
soil. This process is known as ‘Electra B-3 CWOICE OF METHOD
Osmosis.’
B-3.1 For more information on soil improvement
e> This technique is applicable to fine ground techniques, choice, etc, is given in IS 13094 : 1992.
soils such as silts and clays. Subsoils requiring Table 3.1 may be taken as a guide for selection of the
high secondary consolidation characteristics various methods along with principles applicable to
may not be amenable to improvement by the various soil conditions, equipments required, results
preload method. likely to be activised and limitations.

36
 Table 3.1 Soil Improvement Methods
(Clause B-3.1)

Summary of Soil Improvement Methods

Method Principle Most Suituble Soil Maximum Special Mate- Special Equipment Properties of Special Advantages Relative
Conditions/Types Effective Treat- rials Required Required Treated Material and Limitations Cost
ment Depth

Blasting Shock waves ‘and Saturated, clean sands : >30m Explosives backfill to Jetting or drilling machine Can obtain relative Rapid, inexpensive, Low
vibrations cause li- partly saturated sands plug drill holes, hole densities to 7080, can treat any size areas :
quefaction and dis- and silts (collapsible casings may get variable variable properties, no
placement with loess) after flooding density time de- improvement near sur-
settlement to higher pendent strength face, dangerous
density gain

Vibratory Densification by Saturated or dry clean 20 m (ineffective None Vibratory pile driver and Can obtain relative Rapid, simple, good Moderate
Probe vibration; liquefaction sand above 3-4 m 750 mm dia, open steel densities of up to underwater, soft un-
induced settlement depth) pipe 80. Ineffective in derlayers may damp
under overburden some sands vibrations, difficult to
penetrate, stiff over-
layers, not good in
partly saturated soils

Vibrocom- Densification by Cohesionless soils 30m Granular backfill, Vibroflot, crane, pumps Can obtain high Useful in saturated and Moderate
paction vibration and compac- with less than 20 fines water supply relative densities, partly saturated soils,
tion of backfill good uniformity uniformity
material

Zompaction Densification by dis- Loose sandy soils: >20 m Pile material (often Pile driver, special sand Can obtain high Useful in soils with Moderate
‘iles placement of pile partly saturated clayey sand or soil plus ce- pile equipment densities, good fines, uniform corn- ‘to high
volume and by vibra- soils, loess ment mixture) uniformity pactioh, easy to check
tion during driving results, slow, limited
improvement in upper
I-2m

heavy Tamp- Repeated application Cohesionless soils, 30m None Tampers of up to 200 tons, Can obtain good Simple, rapid, suitable Low
ng (Dynamic of high intensity im- waste fills, partly high capacity crane improvement and for some soils with
Consolidation) pacts at surface saturated soils reasbnable unifor- fines; usable above
mity and below water, re-
quires control, must be
away from existing
structures

-
 Table 3.1~Continued

Summary of Soil Improvement Methods

Method Principle Most Suitable Soil Maximum Special Mate- Special Equipment Propekies qf Special Advantages Relalive
Conditions/Types Effective Treat- rials Required Required Treated Material and Limitations Cost
ment Depth

Particulate Penetration grouting- Medium to coarse sand Unlimited Grout, water Mixers, tanks, pumps, Impervious, high Low cost grouts, high Lowest of
Grouting till soil pores with soil, and gravel hoses strength with strength; limited to the grout
cement and/ or clay cement grout, coarse grained soils systems
eliminate liquefac- hard to evaluate
tion danger

Chemical Solutions of two or Medium silts and Unlimited Grout, water Mixers, tanks, pumps, Impervious, low to Low viscosity control- High to
Grouting more chemicals react coarser hoses high strength lable gel time, good very high
in soil pores to form a eliminate liquefac- water shut-off; high
gel or a solid tion danger cost, hard to evaluate
B
5 precipitate
I
3
8
B Pressure Lime slurry injected to Expansive clays Unlimited, but Lime, water surfactant Slurry tanks, agitators, Lime encapsulated Only effective in nar- Competi-
e Injected Lime shallow depths under 2-3 m usually pumps, hoses zones formed by row range of soil con- tive with
9 high pressure channels resulting ditions other solu
P from cracks, roof tions to ex
9 holes, hydraulic pansive
fracture soil
problems

Displacement Highly viscous grout Soft, tine grained soils; Unlimited, but a Soil, cement water Batching equipment, high Grout bulbs within Good for correction of Low
Grout acts as radial hydraulic foundation soils with few m usually pressure pumps, hoses compressed soil differential settle- material
jack when pumped in large voids or cavities matrix ments filling large high injec-
under high pressure voids; careful control tion
requited

Electro- Stabilizing chemical Saturated silts; silty Unknown Chemical stabilizer DC power supply, anodes Increased strength, Existing soil and struc- Bxpensive
, kinetic Injec- moved into soil by clays (clean sands in colloidal void tillers cathodes reduced comptes- tures not subjected td
tion electroosmosis or col- case of colloid injec- sibility, reduced high pressures; no
loids into pores by tion) liquefaction poten- good in soil with high
electrophorasis tial conductivity
Jet Grouting High speed jets at Sands, silts. clays Water. stabilizing Special jet nozzle, pumps. Solidifiedcolumns Useful in soil that can’t
depth excavate, inject, chemicals pipes and hoses and walls be permeation
and mix stabilizer with grouted, precision in
soil to form columns or locating treated zones
panels

Preloading Load is applied suffi- Normally con- Earth fill or other Earth moving equipment. Reduced water Easy, theory well Low
with/ without ciently in advance of solidated soft clays, material for loading large water, tanks or content and void developed, unifor- (moderate
Drain construction so that silts, organic deposits, the site; said or gravel vacuum drainage systems ratio increased mity; requires long if vertical
compression of soft completed sanitary for drainage blanket sometimes used; settle- strength time (vertical drains drains are
soils is completed landfills ment markers, can be used to reduced required)
prior to development piezometers consolidation time)
of the site

Surcharge Fill in excess of that Normally con- Earth fill or other Earth moving equipment; Reduced water Faster than preloading Moderate
Fills required permanently solidated soft clays, material for loading settlement markers, content, void ratio without surcharge,
is aIjplied to richieve a silts, organic deposits, the site; sand or gravel piezometers and compres- theory well developed
given amount of settle- completed sanitary for drainage blanket sibility; increased extra material
ment in a shorter time; landfills strength handling; can use ver-
excess fill then tical drains to reduce
removed consolidation time

Electro- DC current causes Normally con- Anodes (usually rebars DC power supply, wiring, Reduced water No fill loading re- High
Osmosis water flow from anode solidated silts and silty or aluminium) metering systems content and com- quired, be used in con-
towards cathode where clays cathodes (well points pressibility. in- fined area. relatively
it is removed or rebars) creased strength, fast; non-uniform
electrochemical properties between
hardening electrodes; no good in
highly conductive
soils
 Table 3.1-Concluded
_ --
Summary of Soil Improvement Methods

Methocl Principle Most Suitable Soil Maximum Speck1 Mote- Special Equipment Properties oj Special Advuntages Relative
Conditions/Types IYffective Treot- rials Required Required Treated btuteriul and Limitations Cost
ment Depth

Remove and Foundation soil ex- hr-organic soils IOm Admixture stabilizers Excavating mixing and Increased strength Uniform, controlled High
Replace cavated, improved by compaction equipment and stiffness, foundation soil when
drying or admixture dewatering system reduced compres- replaced; may require
and recompacted sibility large area dewatering

b
B
E Structural Structural fills dis- Use over soft clays or - Sand, gravel fly ash, Mixing and compaction Soft subgrade High strength, good Low to
2 Fills tributes loads to under- organic soils marsh bottom ash, slag, ex- equipment protected by struc- load distribution to un- high
lying soft soils deposits panded aggregate, tural load bearing derlying soft soils
clam shell or oyster till
shell, incinerator ash

Mix-in-Place Lime, cement or as- All Soft or loose >20m Cement lime asphalt, Drill rig. rotary cutting and Solidified soil Uses native soil, Modente
Piles and phalt introduced inorganic soils or chemical stabilizer mixing head, additive pro- piles or walls of reduced lateral support to high
Walls through rotating auger portioning equipment relatively high requirements during
or Special in-place strength excavation; difficult
mixer quality control

-
Heating Drying at low Fine-grained soils, 15m Fuel Fuel tanks, burners, Reduced water Can obtain irreversible High
temperatures’ altera- especially partly blowers content, plasticity, improvements in
tion of clays at inter- saturated clays and water sensitivity; properties: can intro-
1 mediate temperatures silts loess
: increased strength duce stabilizers with
(400-600 “C); fusion at hot gases
2
l high temperatures
(>I 000 “C)

Freezing Freeze soft, wet All soils Several m Refrigerant Refrigeration system Increased strength No good in flowing High
ground to increase its and stiffness, ground water, tem-
strength and stiffness reduced per- porary
meability
 Vibro Re- Hole jetted into soft. Soft clays and alluvial 20 m Gravel or crushed Vibroflot. crane or Increased bearing Faster than Moderat
placement fine-grained soil and deposits rock backfill vibrocat. water capacity. reduced precompression, to high
Stone and backfilled with dense- settlements avoids dewatering re-
Stand ly compacted gravel or quired for remove and
Columns sand replace; limited bear-
ing capacity

B
t$ Root Piles, Inclusions used to All soils - Reinforcingbars, Drilling and grouting Reinforced zone In-situ reinforcement Moderatr
s Soils Nailing carry tension, shear, cement grout equipment behaves as a for soils that can’t be to high
& compression coherent mass grouted or mixed-in
.E place with admixtures
d

Strips and Horizontal tensile Cohesiohless soils Can construct Metal or plastic strips, Excavating, earth han- ‘Self-supporting Economical, earth Low to
Membranes strips, membranes earth structures to geo-textiles dling, and compaction earth structures, structures coherent, moderate
buried in soil under heights of several equipment increased bearing can tolerate deforma-
embankments, gravel tons of m capacity. reduced tions; increased allow-
base courses and foot- deformations able bearing pressure
ings

P
As in the Original Standard, this Page is Intentionally Left Blank
CHAPTER 4

MASONRY

.
 CQNTENTS

1 GENERAL 4 SUMMARYOF PROPERTIES

OF MASONRY UNITS

PART 1 MORTARS ANNEX C SAMPLING AND TESTING OF COMMON

BURNTCLAY BRICKS
1 TYPEOF MORTARS
Section 2 Construction Practices -
1.1 General Brickwork
1.2 Cement Mortars
1.3 Lime Mortars 1 GENERAL
1.4 Cement-Lime Mortars
1.1 Introduction
1.5 Mix Proportions 1.2 Setting Out
2 SELECTION
OF MORTARS
2 TYPESOFBONDS
2.1 Cement Mortar
2.1 General
2.2 Composite Mortar English Bond
2.2
2.3 Lime Based Mortars Double Flemish Bond
2.3
2.4 Optimum Mortar Mixes Single Flemish Bond
2.4
3 PREPARATION
OFMORTARS 2.5 Garden Wall Bond
2.6 American Bond
3.1 Materials 2.1 Stretcher Bond
3.2 Slaking of Lime 2.8 Header Bond
3.3 Preparationof Mortars 2.9 Other Bonds
ANNEX A SIEVEANALYSIS 3 THICKNESS
OFJOINT

ANNEX B F~ELUTESTFORSILTCONTENT 3.1 General

3.2 Finishing of Joints
PART 2 BRICKWORK AND BLQCKWORK
3.3 Mortars
Section 1 Brick and Block Units
4 PREPARATORY
WORK
1 GENERAL 4.1 Scaffolding
4.2 Soaking of Bricks
1.1 Introduction
1.2 Types of Bricks 5 LAYINGOFBRICKWORK

2 BRICKS 5.1 General

5.2 Walls
2.1 General 5.3 Plasters
2.2 Information on Bricks 5.4 Openings
2.3 Classification of Bricks 5.5 Partitions
2.4 Size of Bricks 5.6 Half Brick Masonry
2.5 Sand Lime Bricks 5.7 Arches
2.6 References 5.8 Brick Tile Work
5.9 Honey Comb Brickwork
3 BLOCKS
5.10 Brickwork in Openings
3.1 General 5.11 Parapets and Copings
3.2 Types of Blocks 5.12 Cavity Walls
3.3 Concrete Blocks 5.13 Curing
3.4 Lime Based Blocks 5.14 Service Installation
3.5 Soil Based Blocks 5.15 Moulding and Cornices
5.16 Jointing Old Brickwork with New Brickwork PART 3 STONEWORK

Section 3 Construction Practice - 1 GENERAL

Blockwork I .I Introduction
1 GENERAL 1.2 Types of Stones

1.1 Introduction 2 PROPERTIES

OF STONES

MORTAR 2.1 Strength

2.2 Durability
2.1 Hollow Concrete Blocks 2.3 >~zes
2.2 Light Weight Blocks
MORTARS
CONCRETE
SELECTION
OF STONE
THICKNESS
PREPARATORY
WORK
LATERALSUPPORT
5.1 Dressing of Stone
AVOIDANCEOFCRACKFORMATION 5.2 Scaffolding
6.1 General 5.3 Handling
6.2 Bonded Beams and Studs Used on 5.4 Tools
Structural Members 5.5 Wetting

PREPARATORY
WORK 6 TYPESOFMASONRY

7.1 Wetting of Blocks 7 RANDOM RUBBLE

7.2 Scaffolding 7.1 Uncoursed
8 LAYINGOF CONCRETEBLOCKS 7.2 Brought to Courses

8.1 First Course 8 SQUAREDRUBBLE

8.2 Construction 8.1 Uncoursed
8.3 Closure Block
8.2 Brought to Courses
9 PROVISIONFORDOOR AND WINDOW FRAMES 9 POLYGONALRUBBLEMATCHING
10 PROVISION
FORROOF
! 0 PLAINASHLAR
11 INTERSECTING
WALL 11 LAYINGOF STONES- GENERALREQUIREMENTS
12 RENDERINGS
AND OTHERFINISHES
12 LAYINGOFDIFFERENT
TYPESOF MASONRY
Section 4 In-situ Walls with Soil Cement
12.1 General
1 GENERAL 12.2 Random Rubble (Uncoursed and Brought
to Course)
2 SOIL
12.3 Coursed Rubble Masonry-First Sort
3 WALL CONSTRU(XION 12.4 Coursed Rubble Masonry-Second Sort
12.5 Plain Ashlar Masonry
3.1 Preparationof Soil
12.6 Ashlar Sunk or Moulded
3.2 Compaction
12.7 Ashlar Rock Faced
3.3 Curing
12.8 Ashlar Rough Tooled
3.4 Joints
12.9 Ashlar Chamfered
3.5 Fixing Frames
12.10 Ashlar Block in Course
3.6 Bearing of Roof
12.11 Ashlar Masonry for Special Works
3.7 Lintels
12.12 Laterite Stone Masonry
3.8 Parapet
12.13 Stone Veneering
3.9 Plastering

4 PREPARATION
OF MUD PLASTER
As in the Original Standard, this Page is Intentionally Left Blank
:,
L-. .-

SP 62 (S & T) : 1997

CHAPTER 4

MASONRY
1 GENERAL Part 1 Mortars
Part 2 Brickwork and Blockwork
1.1 The chapter on masonry will cover the fol-
Part 3 Stonework
lowing:

PART 1 MORTARS

1 TYPE OF MORTARS Mortar with workability will hang from trowel and
spread easily. Good water retentivity will -enable
1.1 General
mortar to develop good bond with masonry units.
Mortars for use in masonry work are many. Mortar
Masonry in lime mortar has b,:tter resistance to rain
strength ingeneral shall not be greater than that of the
penetration and is less liable to cracking; but its
masonry units; nor greater than necessary in any
strength is less than that of cement mortar.
application.
1.4 Cement-Lime Mortars
IS 22SO : 1981 covers the requirements of various
mortars. Mortars could be classified as cement mor- These have good qualities of cement as well as that of
tars, lime mortars, and cement-lime mortars. The main lime; that is, medium strength alongwith good
characteristics of these mortars are as under. workability and good water retentivity, freedom from
cracks and good resistance against penetration. Com-
1.2 Cement Mortars
monly adopted proportions are (cement, lime and
These consist of cement and sand, varying in propor- sand) 1:1:6, l:2:9 and 1:3:12. Mix proportion of
tions from I:8 to 1:3; the strength and workability binder to sand (cement plus lime) is kept as 1:3. This
improving with the increase in proportion of cement. gives a very dense mortar, since voids of sandare fully
filled.
Mortars richer than 1:3 are not used in masonry be-
cause of high shrinkage and no appreciable gain in the 1.5 Mix Proportions
strength of masonry.
The mix proportions and compressive strength of some
Mortars leaner than 15 tend to become harsh and of the commonly used mortars are given in Table 4.1.
unworkable. 2 SELECTION OF MORTARS
1.3 Lime Mortars 2.1 Cement Mortar
These consist of intimate mixtures of lime as a binder Cement mortar is needed, when
and sand, burnt~claylSURKHI, cinder as fine aggregate
in the proportion of I:2 or 1:3. a) masonry units of high strength are used,
b) early strength is necessary, and
As a general rule lime mortars gain strength slowly and c) in wet condition, as in foundation below plinth
have low ultimate strength. Mortars using hydraulic level where a dense mortar being less pervious
lime gain somewhat better strength than those using can better resist the effect of soluble salts.
fat lime. Lime mortars using fat lime do not harden at
all in wet locations, Properties of mortar using semi- 2.2 Composite Mortar
hydraulic &me is intermediate betwen those of Unnecessarily strong mortar, concentrate the effect of
hydraulic lime and fat lime mortars. any differential movement of masonry in a fewer and
wider cracks; whereas a weak mortar (mortar having
When only fat lime is used, it is necessary to use some
more lime and less cement) will accommodate move-
pozzolanic material, such as, burnt clay/SURKHI or
ments and cracks are distributed. Thus, when strong
cinder to improve the strength of the mortar.
mortars (cement mortar) are not required from
The main advantage of lime mortar lies in its good strength, wet locations, or other considerations, it is
workability, good water retentivity and low shrinkage. preferable to use composite mortars.’

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SP 62 (S & T) : 1997

Table 4.1 Mix Proportion and Strength of Commonly Used

Mortars for niasonry
(Clause 4.1)
__
SI Mix Minihtum Mortar
No. h Compressive
/ . Type
Cement Lime Sand Strength
N/mm*
(1) (2) (3) (4) (5) (6)
I 1 o-1/4c 3 10 HI

2(a) I 0 4 1.5 H2

2(b) I 1/2C 4.5 6 -

3(a) I 0 5 5 h41

3(b) I IC 6 3 -

4(a) I 0 6 3 -

4(b) I 2c 9 2 M2

4(c) 0 IA 2-3 2 -

5(a) I 0 8 0.7 Ll

5(b) 1 3c 12 0.7 -

6 0 IBorC 2-3 0.5 L2

NOTES

1 A, 8, C denote eminently hydraulic lime, semi-hydraulic lime, and fat lime respectively, as stipulated in IS 712 : 1984.

2 When using plain cement sand mortars SI No. 2(a). 3(a), 4(a) and 5(a) it is desirable to include a plasticizer in the mix to improve
workability. if sand used is too coarse and graded,

3 For mortar at SI No. 6, if lime is used, part of sand should be replaced by some pozzolanic material, for example, burnt clay or fly
ash, in order to obtain the requisite strength.

4 Strengths of mortar may vary appreciably, depending on nngularity, grading and fineness of sand. Quantity of sand in the mix may
therefore be varied where found necessary to attain the desired strength.

5 In this Table, classificafion of types of mortar as HI, H2, etc. is only for convenience in reference to design calculations. It is different
from IS 2250: 198 I,

6 Though compressive strength of composite mortars H2, Ml and M2 is less than cement to mortan, the masonry strength may not be
significantly affected.

7 Other mortar mixes may also be permitted where necessary as in blockwork,

2.3 Lime Based Mortar Mortar Type

Brick Strength Mortar Mix
Lime based mortars give higher ratio of masonry kg/m2 (N/nm2)
strength to mortar strength as compared to non-lime 150-249 I:0 :4 H2
based mortar. This is because masonry with lime (15 to24.9) 1: 1/2c:+
abased mortars have higher strength and this is more
important in masonry failure. 250 (25) 1:o-1/4c:3 Hl
and above
2.4 Optimum Mortar Mixes
3 PREPARATION OF MORTARS
From considerations of maximum strength of brick-
3.1 Materials
work for various strengths of bricks, optimum mortar
mixes are as below: 3.1-l Water

Brick Strength Mortar Mix Mortar Type Water used shall be clean and reasonably free from
kg/cm2 (N/mm2) injurious or deleterious materials, such as, oils, acids,
alkalies, salts, etc. Potable water is generally con-
c 50 (5) 1:0 :6 M2 sidered satisfactory. As a guide the following con-
1:2C:9 centrations represent the maximum permissible limits
0: lA:2-3 of deleterious materials in water.
50 to 149 1:o :5 Ml a) Limits of acidity - To neutralize 200 ml
(5 to 14.9) I:lC:6 sample of water, using phenolpthalein as an

48

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.

I
 SP 62 (S & T) : 1997

indicator, it should not require more than 2 ml the form of paste and used before it dries up. This is
of 0.1 normal NaOH. comparable to Class C lime. It may be used for mortar
Limits of alkalinity - To neutralize 200 ml and plaster work, but not for white washing.
sample of water, using methyl orange as an 3.1.3.2 Hydrated lime
indicator, it should not require more than 10 ml
of 0. I normal HCI. It shall be in the form of dry fine powder produced by
Permissible limits of solids shall not exceed as treating quick lime in any suitable form with sufficient
given below: water so as to produce a completely hydrated but dry
Organic 200 mg/l and sound product. It shall be brought from approved
Inorganic 3 000 mg/l manufacturers and shall be used within 3 to 4 months
Sulphates (as S04) 500 mg/l from the date of manufacture.
Chlorides (as Cl) 2 000 mg/l 3.1.4 Lime Pozzolana Mixture
Suspended matter 2 000 mg/l It shall conform to IS 4098 : 1983. Only LP 40 type
The pH value of water shall generally be not
lime pozzolana mixture shall be used. Class C lime
less than 6. shall be ground with burnt clay pozzolana to IS 1344 :
Sea water is not recommended, because of 1981 to obtain the mixture; burnt clay pozzolan; with
presence of harmful salts in sea water. Under a minimum lime reactivity of 80, 60, 40 kg/cm- shall
unavoidable circumstances sea water may be be used.
used for under sea constructions.
3.1.5 Firte Aggregate
3.12 Cement
Aggregate most of which passes 4.75 mm IS sieve is
Cement shall conform to any of the following:
known as fine aggregate. The aggregate shall conform
a) 13 Grade ordinary Portland cement conform-
to the requirements of IS 383 : 1970. It shall not
ing to IS 269 : 1989,
contain harmful organic impurities in such form or
b) Portland slag cement conforming to IS 455 : 1989, quantities to affect adversely the strength of mortar.
cl Portland pozzolana cement conforming to
Fine aggregate, when used in places using reinforce-
IS 1489 (Parts 1 and 2) : 1991,
ment, shall not contain any material acidic in character
4 Rapid hardening Portland cement conforming
which is likely to attack reinforcement.
to IS 8041 : 1990,
e) Hydrophobic Portland cement conforming to Fine aggregate shall be either sand or crushed stone
IS 8043 : 1991, dust. Sand is of two types, namely, coarse and fine
0 43 Grade ordinary Portland cement conform- sand.
ing to IS 8 112 : 1989, 3.1.5.1 Fine sand
g) 53 Grade ordinary Portland cement conform-
ing to IS 12269 : 1987, and This shall be natural river sand. Its grading, ai per
Annex A, shall be within the limits of Grading Zone
h) -Low heat Portland cement conforming to
IS 12600 : 1989. IV (see Table 4.2). When the grading falls outside the
High alumina cement conforming to IS 6452 : 1989 percentage limits prescribed for sieves other than
may be used under special circumstances as permitted 600 micron, 300 micron and I50 micron IS sieves by
by the Authority; simimlarly supersulphated cement not more than 5 percent it shall be regarded as falling
conforming to IS 6909 : 1990 may also be used in within the zone. This 5 percent can be split up among
special cases. Specialist literature may be consulted the different sieves; for example, it could be one per-
for use of these types of cements. cent for each of the three sieves and 2 percent on
another.
3.1.3 Lime
Lime shall conform to IS 7 12 : 1984. Building lime The maximum quantity of silt as determined by
shall be classified as follows: Annex B, shall not exceed 8 percent.

Class A -Eminently hydraulic lime used for struc- 3.1.5.2 Stone dust
tural purposes. This shall be obtained by crushing hard stones. Its
Class B - Semi-hydraulic lime for masonry purpose. grading, as per Annex A, shall be within the limit of
Class C -Fat lime used for finishing coat; it can be Grading Zone III (see Table 4.2). When the grading
used for masonry mortar with addition of falls outside the percentage limits prescribed for sieves
pozzolanic material. other than 600 micron and 300 micron IS sieves by not
Class D -Magnesium lime used for finishing coat. more than 5 percent and on 150 micron sieve by nut
Class E - Kankar lime used for mortar. more than 20 percent, it shall be regarded falling within
3.1.3.1 Carbide lime the limits of this zone. The 5 percent can be split up;
Carbide lime is obtained as a by-product in the for example, it could be one percent in each of the three
manufacture of acetylene. It shall be procured fresh in sieves and 2 percent on another.

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SP 62 (S & T) : 1997

Table 4.2 Grading of Fine Aggregates

(Clauses3.1.5.1,3.1.5.2,3.1.5.3and3.1.5.4)

IS Sieve Percentage Passing for

Designation / h
\
Grading Grading Grading Gmding
Zone I Zone II Zone III Zone IV
IO mm 100 100 100 100
4.1.5 mm 90-100 90-100 90-IO0 9%IO0
2.36 mm 60-95 75-100 85 100 95.100
I. 18 mm 30-70 5s.90 75-100 90. IO0
600micron I s-34 35-59 60-79 X0- IO0
300 micron s-20 8-30 12-40 I s-50
150micron O-10 O-10 o-to O-IS

The maximum quantity of silt, as per Annex B shall strength, hardening, durability of mortar. The maxi-
not exceed 8 percent. mum quantities of impurities, such as, clay, fine silt,
fine dust and organic impurities, taken together shall
3.1.5.3 Marble dust
not exceed 5 percent by weight. The particle size of
This shall be obtained by crushing marble. Its grading, SURKHZ for use in lime mortars shall be as below:
as per Annex A, shall be within the limits of Grading
IS Sieve Designation Percentage P@$ng
Zone IV (see Table 4.2). When the grading falls
(by Weight)
outside the percentage limits prescribed for the sieves
other than 600 micron, 300 micron and 150 micron IS 4.75 mm 100
sieves by not more than 5 percent, it shall be regarded 2.36 mm 90- 100
as falling within the zone. This 5 percent can be split 1.18 mm 70- 100
up; for example, one percent on each of the three sieves 600 micron 40- 100
and 2 percent on the other. 300 micron 5-70
150 micron O-15
The maximum quantity of silt, as per Annex B, shall
not exceed 8 percent.
3.1.7 Calcined Clay Aggregate
3.1.5.4 Coarse sand
This shall conform to IS 1344:1981. It shall be ob-
This shall be either river sand or pit sand. It shall be tained by calcining processed clay at a suitable
clean, sharp, strong, angular and composed of hard temperature and grinding the resultant product to re-
silicious material. Its grading as determined by Annex A, quired fineness. The average 7 day strength of three
shall be within the limits of Grading Zone III (see cubes of size 7 cm shall not be less than 40 kg/cm2.
Table 4.2). When the grading falls outside the percent- The cubes shall be prepared with a mix of one part of
age limits prescribed for the sieves other than hydrated lime, 2 parts of pozzolana (blended intimate-
600 micron, 300 micron and 150 micron IS sieves by ly) and 3 parts of standard sand.
not more than 5 percent, it shall be regarded as falling
within the zone. This 5 percent can be split up; for The strength of cement cube prepared with 4 parts of
example, one percent on each of the three sieves and ordinary cement (Grade 33), one part of pozzolana
2 percent on another. (blended intimately) and three parts of standard sand
shall be as follows:
The maximum quantity of silt, as per Annex B shall
not exceed 8 percent. a) Abe at 28 days - not less than 80 percent of
the strength of corresponding plain cement
3.1.5.5 Sand for masonry mortars should generally mortar cube, prepared with one part cement
conform to IS 2116 : 1980. and three parts of standard sand and cured for
28 days.
3.1.6 Broken Brick Aggregate
b) At 90 days - not less than the age at 28 days.
Broken brick aggregate (SURKHI) shall be made by
3.1.8 Cinder
grinding underburnt or overburnt broken bricks. It
shall conform to 1s 3 182 : 1986; and shall not contain Cinder for mortar shall conform IS 2686 : 1977.
any harmful impurities, such as, iron, pyrites, salts, These shall-be obtained from furnace of steam boilers
coal, mica, shale or similar laminated or other using coal fuel only. Cinder from brick klins should
materials in such form or quantity to adversely affecl not be used. Cinder shall be free from clay dirt, wood

50

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 SP 62 (S & T) : 1997

ashes and other deleterious materials. It shall pass The stirring may be stopped 5 min after the boiling has
through IS sieve 3.35 mm with at least 50 percent of it stopped. As the mix thickens more water shall be
passing through IS sieve 1.70 mm. The allowable added.
percentage of unburnt carbon, for use in mortars, shall The mix shall then be allowed to pass through IS Sieve
be up to 20 percent and acid soluble sulphate
3.55 mm and flow into a tank at the lower level where
(expressed as SOS) shall be one percent.
it shall kept standing for 72 h before use. Water will
3.1.9 Fly Ash evaporate partly and the surplus water at top shall be
Fly ash to be used as pozzolana for mortars shall removed, leaving lime putty in the form of paste.
conform to IS 38 12 : 198 1. It shall be free from any Lime putty shall be kept wet till it iscompletely used.
contamination of bottom ash, grit or small pieces of It can be stored for a fortnight without getting spoilt.
pebbles. This fly ash can be used as part replacement
of fine aggregate in mortar and concrete. With a view 3.3 Preparation of Mortars
to improve the grading, the recommended extent of
replacement is upto 20 percent. As already mentioned in 1.1 mortars shall be prepared
and tested as for IS 2250 : 198 1, except mud mortar.
3.1.10 Soils
Some important points to be noted are given below.
Soils for making mud,mortar shall have suitable plas-
ticity. The soil shall be free from vegetable roots, 3.3.1 Cement Mortar
stone gravel greater than 2 mm in particle size, Kankar,
coarse~sand and harmful and efforescent salts. Soil Mixing shall be done in a mechanical mixer. If done
shall not be collected from locality affected by white by hand, the operation shall be carried out on a clean
ants. waterlight platform. It shall be used as soon as possible
after mixing and before it has begun to set, in any case
The plasticity index of the soil shall be between 6 and within 2 h, after water is added to the dry mixture.
10. For large and important projects it shall be between Mortar unused for more than 2 h shall be rejected.
12 and 15. The sulphate content shall not extend 0.1
percent. Coarse materials, coarser than 3.55 mm, shall 3.3.2 Cement Lime Mortar
not exceed 10 percent~by weight (see IS 13077: 199 I).
It shall be used as soon as possible after mixing and
3.1.11 Properties of Materials within 2 h. Mortars unused for more than 2 h shall be
The chemical and physical properties of materials rejected. For class B lime, lime putty and sand can be
referred to in 3.1 and its subparas shall be as listed in kept for 72 h for preparation of cement lime mortar.
SP 21 : 1983. The original Indian Standard Specifica-
Cement fly ash mortar shall also conform to require-
tions may also be referred to.
ment as mentioned herein.
3.2 Slaking~of Lime
Slaking of lime shall conform to IS 1635 : 1992. 3.3.3 Lime Mortar
3.2.1 Pla@orm Lime mortar shall be used as soon as possible after
Lime, before slaking, shall be quite fresh and generally mixing and grinding. As a rule the mortar should be
in the form of lumps. Slaking shall be carried out on used the day it is made. If Class A is present as an
a masonry platform by sprinkling water gradually till ingredient, the mortar shall be used within 4 h after
lime is slaked and reduced to powdery form. Slaked mixing or grinding. Lime mortar with Class B lime
lime shall be screened through IS Sieve 3.35 mm and shall be used within 36 h; the same applies to use of
the residue retained on the sieve shall be rejected. Class C lime; with pozzolana lime mortar with Class
Slaked lime shall then be run to putty before use in C lime and shall be used within 72 h. time mortars
mortar. shall be kept damp with wet sack or other means and
3.2.2 Preparation of Lime Putty shall not be allowed to dry.

Three sufficiently large slaking vessels or tanks shall Similar precautions shall be taken for mortars with
be made; one 50 cm deep at a higher level, the remain- pozzolana mixture as mentioned herein.
ing 80 cm deep at a lower level such the contents of 3.3.4 Mud Mortar
upper tank flow into the next by gravity.
Soil as chosen in 3.1.10 shall be broken up into fine
The upper tank shall be filled with water to half the powdery form and then shall be mixed with clean
depth; sufficient quick lime be added gradually to fill water and matured at least for 2 days. The mortar shall
up the tank to half of water depth. Lime shall be added then be trodden with man’s feet and spades, turning
to water and not water to lime. over and over again to make it a homogeneous mass
The mix shall be stirred continuously ensuring that of working consistency.
lime does not get exposed above water. Reference may also be made to IS 13077 : 1991.

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SP 62 (S & T) : 1997

ANNEX A
(Clauses 3.1.5.1,3.1.5.2,3.1.5.3and 3.1.5.4)
SIEVE ANALYSIS

A-l EQUIPMENT A-2 SAMPLE

Perforated plate sieves of designation 10 mm,4.75 mm The weight of the sample available shall not be less
and fine mesh sieves of designation 2.36 mm, than the weight as given below. The sample for siev-
I. 18 mm, 600 micron, 300 micron and I50 micron ing shall be prepared from the larger sample by
shall be used. quartering or by sample divider.

Pm-tide Size, 60 50 40 25 20 16 12.5 10 6.3 4.75 2.36

50 35 15 5 2 2 I 0.5 0.2 0.2 0.1

A-3 SIEVlNG A-4 REPORT

The sample shall be brought to air-dry condition before The results shall be calculated and reported as:
sieving. The sieves shall be clean before use. Sieving a > Cumulative percentage by weight of the total
shall be done on successive sieves starting from the sample passing each sieve to the nearest whole
largest. Light brushing is permitted on-finer sieves. number; or
b) Percentage by weight of the total sample pass-
On completion of sieving, the material retained on ing one sieve and retained on the next small
each sieve shall be weighed. sieve to nearest 0.1 percent.

ANNEX B
(CZauses3.1.5.1,3.1.5.2,3.1.5.3and3.1.5.4)
FIELD TEST FOR SILT CONTENT

B-l PROCEDURE ensuring that some sidewise shaking is also done.

Allow the mix to settle for 3 h.
A sample of sand to be tested shall be placed without
drying in a 200 ml measuring cylinder. The volume
The height of the silt layer visible above the sand shatl
of sand shall fill up to 100 ml mark.
be expressed as percentage of the height of sand below.
Clean water shall be added up to 150 ml mark. One
tea spoon of salt shall be dissolved in a half litre of Sand containing more silt than permitted shall be
water before adding. Shake the mixture vigorously, washed as to bring the silt content to acceptable levels.

52
 SP 62 (S & T) : 1997

PART 2 BRICKWORK AND BLOCKWORK

Section 1 Brick and Block-Units

1 GENERAL bricks. For semi-mechanized process of manufacture

1.1 Introduction of common burntclay building bricks, reference may
be made to IS 11650 : 1991.
There are several types of masonry units, such as, clay
bricks, concrete blocks, lime based blocks, stones, etc. 2.2 Information on Bricks
Therefore the choice of masonry unit becomes
relevant. Generally, the choice is governed by local The following information of availability, strength, etc.
availability; compressive strength; durability; imper- of different types of bricks in the country would be of use.
meability in heavy monsoon areas; fire resistance;
a) Strength of Bricks - Strength of bricks in
cost; ease of construction; etc.
India varies from region to region depending
Generally brick has the advantage over stone as it lends upon the nature of available soil and technique
itself to easy construction and requires less labour for adopted for moulding and burning. Some re-
laying. Thus the first choice is any place would be search has been done for manufacture of bricks
brick if it is available at reasonable cost, has required of improved quality from inferior soils, such
strength and isof good quality. as, black cotton and moorum, which ordinarily
give bricks of very low strength.
Stone masonry, because of practical limitations of
dressing to shape and size, usually has to be thicker According to some survey done, the average strength
and results in unnecessary extra cost. In hills and of bricks ~manufactured in India, employing common-
certain plains, where soil is unsuitable for brick burn- ly known methods for moulding and burning, is as
ing, and stone is locally available, the choice naturally given below:
is on stone. However if the type and quality of stone Delhi, Punjab and 70- 100 kgf/cm2 (7- 10 N/mm2)
is unsuitable for dressing and shaping, recourse may Haryana
be taken to using blocks particularly when the con- Uttar Pradesh 100-200 kgf/cm2 ( 1O-20 N/mm2)
struction is not more than two storeys high. For ex- Madhya Pradesh 35-50 kgf/cm2 (3.5-5 N/mm2)
ample, precast stone masonry work to IS 12440: 1988 Maharashtra 50 kgf/cm2 (5 N/mm2)
may be considered. With these blocks, the thickness Gujarat 30- 100 kgf/cm2(3- 10 N/mm2)
of walls could be kept within economical limits. Rajasthan 30 kgf/cm2 (3 N/mm2)
West Bengal 100-200 kgf/cm2 (1 O-20 N/mm’)
In places where brick and stone of suitable~quality is
Andhra Pradesh 30 kgf/cm (3 N/mm2)
not available, and concrete blocks cannot be manufac-
Assam 35 kgf/cm2 (3.5 N/mm2)
tured at reasonable cost, sand lime bricks could be
considered. However the cost of equipment for sand In some cities like Delhi, Calcutta and Madras,
lime bricks is high and hence these bricks have not yet machine made bricks have become available,
become popular. with high compressive strengths ranging from
175-250 kgf/cm2 (17.5-25 N/mm2).
1.2 Types of Bricks
b) Strength ofMasonry -Apart from strength of
The following Indian Standards cover various bricks: bricks and grade of mortar, as a general rule,
a) IS 1077 : 1992; IS 2180 : 1988; IS 2222 : 1991; the strength of masonry depends on surface char-
IS2691: 1988;IS3952: 1988;IS6165: 1992 acteristics and uniformity of size and shape of
for clay bricks. units, Units which are true in shape andsize, can
b) IS 4139 : 1989 for calcium silicate (sand lime) be laid with thinner mortar joints, thereby result-
bricks. ing in higher strength. Therefore, for the same
c) IS 12894 : 1990 for sand lime bricks and fly brick strength, higher masonry strength can be
ash lime bricks. obtained by better shaped bricks with true edges.
For this very reason, ashlar stone masonry, with
2 BRICKS uses accurately dressed and shaped stones, is
much stronger (nearly double) than ordinary
2.1 General coarsed stone masonry.

Bricks shall be handmade or machine moulded. Ref- 2.3 Classification of Bricks

erence may be made to IS 2117 : 1991 for guide on
manufacture of handmade commonburntclay building Common burnt clay bricks are classified on the basis

53
SP 62 (S & T) : 1997

of compressive strength as given below:

Class Designation 35 30 25 20 17.5 15 12.5 10 7.5 5 3.5

Average Compressive Strengths

N/mm* 35 30 25 20 17.5 15 12.5 10 7.5 5 3.5
kgf/cm* 350 300 250 200 175 150 125 100 75 50 35

IS 2180 : 1988 covers burnt clay bricks of higher 2.5.2 Sizes

strength 40 and above, for heavy duty.
Sand lime bricks shall have the same size as clay bricks
The bricks shall be free from cracks and flaws and to IS 1077 : 1992.
nodules of free lime. They shall have smooth rectan-
gular faces with sharp corners and shall be uniform in 2.5.3 The physical properties, sampling, etc shall be
colour. Tolerance on brick dimensions shall be f 3 as per IS 4139 : 1989.
percent for designation 100 and above ; zk8 percent for 2.6 References
lower designations.
For information on other bricks, refer to SP 20 : 1991.
The requirements of bricks to IS 1077 : 1992 are These include bricks to IS 2222 : 1990, IS 3952 : 1988
summarized in SP 21 : 1983. Sampling and testing and brick shapes to IS 6165 : 1992. Also for informa-
shall be as per IS 5454 : 1978 and IS 3495 : 1992 tion on IS 12894 : 1990 for fly ash lime bricks refer to
respectively. However sampling and tests for proper- SP 20 : 1991.
ties of bricks are given in Annex C.
3 BLOCKS
2.4 Size of Bricks
Bricks shall have the following dimensions: 3. I General

Length Width Height Blocks have several advantages, such as, durability,
mm mm mm strength, structural stability, fire resistance, sound ab-
sorption, heat insulation, etc. They are also economi-
Modular bricks 190 90 90
cal because of the following reasons:
190 90 40
Non-modular bricks 230 110 70 a) The units are relatively large and true in size
230 110 30 and shape. This ensures rapid construction so
that more wall is laid per man than in other
For obtaining proper bond between modular and non- types of wall construction.
modular bricks the following size of bricks may also b) Fewer joints result in considerable saving in
be used: mortar as compared to normal masonry con-
struction; it also increases the strength of
Length Width Height
masonry [see 2.2 (b)].
mm mm mm
c) The true plane surfaces obtained obviate
70 110 I/3 length
necessity to plaster for unimportant buildings
of brick
situated in low rainfall areas; even when plaster
2.5 Sand Lime Bricks is used for any reason, the quantity required for
Sand limebricks, also called ‘Calcium Silicate’ bricks satisfactory coverage is significantly small.
consist essentially of an intimate mixture of siliceous 3.2 Types of Blocks
sand or crushed siliceous rock and lime combined by
action of saturated steam under pressure. Coloured Concrete blocks may be solid or hollow. The follow-
sand lime bricks also can be made by adding fast ing Indian Standards covers various types of blocks:
pigments to the raw mix before pressure casting. Concrete masonry units: IS 2185 (Part 1) :
2.5.1 Classes 1979 Hollow and solid concrete blocks; IS
2185 (Part 2) : 1983 Hollow and solid light
Sand lime bricks shall be of 4 classes as givenbelow:
weight concrete blocks; and IS 2185 (Part 3) :
1984 Autoclaved cellular aerated concrete
Class Average Comp;essive Strength
blocks.
N/mm (k&/cm )
b) Lime based blocks: IS 3115 : 1992.
Class 75 7.5 to 10.0 (75 to 100)
Class 100 10.0 to 15.0 (100 to 150)
c> Soil based blocks: IS 1725 : 1982.

Class 150 3.3 Concrete Blocks

15.0 to 20.0 (150 to 200)
Class 200 20.0 and above (200 and above). They shall be handmade or machine made.

54
 SP 62 (S & T) : 1997

3.3.1 Manufacture Height: 200 mm or 100 mm.

4 Materials- Cement shall conform to either of For other dimensional details see IS 2185 (Part I) :
the following: 1979.
IS 269 : 1989; IS 455 : 1989; IS 1489 (Parts 1
3.3.3 Classification of Blocks
and 2) : 1991; IS 6452 : 1989; IS 6909 : 1990;
IS8112: 1989;IS8041: 199O;IS8042: 1989; a) Hollow (open and closed cavity) concrete
IS 8043 : 1991; IS 12269 : 1987; IS 12600 : blocks - Hollow blocks shall conform to the
1989. following three grades:
Aggregates shall conform to IS 383 : 1970. 1) Grade A - Load bearing units with a
Fly ash conforming to IS 3812 : 198 1 may be minimum block density of I 500 kgf/m”.
used as a replacement for fine aggregate up to Average compressive strength shall be
20 percent. 3.5,4.5,5.5 and 7.0N/mm2 (or 35,45,55
and 70 kgf/cm2). The thickness of face
Water used in the manufacture of blocks shall
shell and web shall not be less than 25 mm.
be free from harmful matter and shall not cause
efflorescence. It shall conform to the require- 2) Grude B - Load bearing units wit? a
ments laid down in IS 456 : 1978. block density between I 000 kgf/m- to
1 500 kgf/m . The average compressive
Admixtures may be added and they shall be
strength shall be 2.0 3.0 and 5.0 N/mm2
either:
(20, 30 or 50 kgf/cm’).
I) Accelerating, water reducing and air
entraining admixtures conforming to 3)Grade C - Non-load bearing units with
IS 9103 : 1979; or block density between 1 000 kgf/m3 to
2) Waterproofing agents conforming to 1 500 kgf/m3. The average compressive
IS 2645 : 1975. strength shall be not less than 1.5 N/mm”
(1.5 kgf/cm2).
b) Concrete Mix - The concrcte mix used for
blocks shall not be richer than one cement to b) Solid concrete blocks - Load bearing units
six combined aggregates (by volume). Com- with a block density not less than 1 800 kgf/m3.
bined aggregates shall be graded as near as The average compressive strength shall be
possible to IS 383 : 1970. The fineness between 4.0 to 5.0 N/mm2 (40 to 50 kgf/cm2).
modulus of combined aggregate shall be be-
tween 3.6 and 4. 3.3.4 The physical properties, sampling criteria for
cl Hand Moulding - For hand moulding com- conformity and testing shall be as per IS 2185 (Part 1) :
paction is done manually. Concrete mix 1979 or SP 2 1 : 1983 which summarizes properiies of
should be of sufficient consistency to enable various masonry elements. Some important properties
demoulding immediately after casting. The are:
consistency should be such that it may be a) Water absorption - not more than 10 percent
cohere when compressedby hand without free by mass;
water being visible. b) Drying shrinkage - not more than 0.1 percent;
4 Machine Moulding - In machine moulding, and
the web markings on the units give a good c) Moisutre movement - not more than 0.09
indication as to whether proper consistency of percent.
concrete has been used.
3.4 Lime Based Blocks
e) Curing - The blocks shall be cured in water
for 14 days. Steam curing also may be adopted
3.4.1 Manufacture
instead of curing in water. The blocks shall
then be dried for 28 days before using on work. Several individual process of manufacture are avail-
The blocks shall be stacked with voids able.
horizontal to permit free flow ofair. They shall
a) Materials - Lime shall conform to IS 712 :
be allowed to complete their initial shrinkage 1984. Cement shall be as per IS 269 : 1989 or
before using on site. IS 455 : 1989 or IS 1489 (Parts 1 and 2) : 199 1.
3.3.2 Sizes Burnt clay pozzolana shall conform to
IS 1344 : 1981. Lime pozzolana mixture to
The nominal dimensions are as below:
IS4098: 1983andflyashtoIS3812: 1981.
Length: 400 mm, 500 mm or 600 mm. Aggregate shall be as per IS 383 : 1970; or
Width: 50 mm, 75 mm, 100 mm. 150 mm, IS 3068 : 1986; or IS 2686 : 1977. Water shall
200 mm, 250 mm, or 300 mm. be as per IS 456 : 1978.
SP 62 (S & T) : 1997

b) Sizes - The sizes of blocks shall be as below: 29cmx19cmx9cm.

Length: 390 mm. 3.5.5 The physical properties, sampling, testing, etc,
Width: 100 mm, 200 mm, 300 mm. shall be as perIS 1725 : 1982 or SP 21 : 1983 which
Height: 90 mm, 190 mm. summarizes properties of various masonry elements.
Some important properties are:
3.4.2 For other physical properties, sampling, tests,
etc, see IS 3115 : 1992 or SP 21 : 1983 which sum- a) Compressive stren th - Not less than
5
marizes properties of various masonry elements. 2 N/mm2 (20 kgf/cm ) for Class 20. Not less
Some important properties are: than 3 N/mm* (30 kgf/cm2) for Class 30.
b) Water-absorption-Not more than 15 percent.
a>Bulk density - not less than 1 000 kgf/m3;
c) Weathering - Not more than 5 percent.
b) Compressive strength - not less than 3.5
N/mm* (35 kgf/cm*); 4 SUMMARY OF PROPERTIES OF MASONRY
c) Drying shrinkage-not more than 0.1 percent; UNITS
and
4 Moisture movement - not more than 0.05 4.1 So far several masonry units have been covered,
percent. For the purpose of design it would.be useful to have a
look at the compressive strengths of these masonry
3.5 Soil Based Blocks
units since this is an important characteristic for choice
3.5.1 General of unit (see Table 4.3).
Experience has shown that most soils can be satisfac-
4.2 From this it is clear that in building construction,
torily stablized with cement-lime. It is, however,
high strength masonry units and lower strength units
necessary to conduct comprehensive tests on soils in a
are also available. For load-bearing construction, so
laboratory in order to determine optimum require-
far buildings up to 6 storeys have gone up. In many
ments to give the specified properties. Soil based
places abroad, even 14 storeys have been built only
blocks can generally be used in low cost structures;
with masonry.
they can substitute bricks except in case of isolated
heavy load bearing columns, piers, etc. This is possible by combining vertically high strength
3.5.2 Manufacture bricks in lower storeys (heavier loads) and lighter
masonry units (blocks) in upper storeys.
Soil based blocks shall be manufactured from a mix-
ture of suitable soil and cement, thoroughly mixed That is why, this aspect should be decided at planning
preferably in a mechanical mixer. The mixture is cast and design stages, so that, higher buildings can be done
into blocks. with masonry units only; thus load bearing masonry
35.3 Classification construction is possible. Very light blocks can be used
for partition, tiller walls, etc, as non-load bearing
The blocks shall be of two classes, class 20 and
elements.
class 35.
3.5.4 Sizes Thus an attempt on these lines would result in savings
in construction. As already mentioned there is a need
The sizes of soil based blocks shall be : to correlate strength of mortar with the masomy unit
19cmx9cmx9cmor and finally arrive at an ascending order of load bearing
19cmx9cmx4cmor capacity.

Table 4.3 Compressive Strength of Masonry Units

(Clause 4.1)

IS No. Compressive Strength N/mm’ (kgflcm’)

2180 : 1988 45 (450). 40 (GO)

1077 : 1992 35 (350). 30 (3OO),25 (250), 20 (200), 17.5 (175), 15 (150), 12.5 (125). 10 (100).
7.5 (75), 5.0 (50), 3.5 (35)

4139 : 1989 20 (200), 15 (150). 10 (loo), 7.5 (75)

2185 (Part 1) A979 7.0 (70), 5.5 (55), 5.0 (50), 4.5 (45). 3.5 (35), 3.0 (30), 2.0 (20). 1.5 (15)

2222 : 1991 7.0 (70). Min

3115 : 1992 and 3952 : 1988 3.5 (35)

1725 : 1982 3.0 (30), 2.0 (20)

.
 SP 62 (S & T) : 1997

ANNEX C
(Clause 2.3)
SAMPLING i$ND TESTING OF COMMON BURNT CLAY BRICKS

Cd CHFCKING QF TOLE&jNCES be as follows:

Cc1.I Twenty vqhole bricks shall be selected at ran-
Brick Lot Size Sample Size
dom. 411 the blisters, loose particles of clay and small
projections shall be removed. These shall then be Class 100 More than 20 Bricks
arranged upon a level surface as in Fig. 4.1 in contact 50 000 bricks
with each other and in a straight line. Class 75,50,35 More than 20 Bricks
100 000 bricks
The total length of the assembled bricks shall be
measured with a steel tape or other suitable inexten-
sible measuring device sufficiently longto measure the C-2.2 The sampling shall be at random and the
whole row at one stretch. If for any reason it is samples shall be stored in a dry place until the tests are
impracticable to measure the bricks in one row of 20 done.
bricks, it may be divided into two rows of 10 bricks C-3 TESTS
each and shall be‘measured seperately to the nearest C-3.1 Compressive Strength
millimetre. Both dimensions shall be added.
Five bricks shall be tested. The average compressive
C-l.2 The dimensions of 20 bricks when measured as strength shall be as per class designation. The com-
above shall be within the following limits: pressive strength of individual brick shall not less than
Length: 372 to 388 cm (380 + 8 cm) 20 percent, of the specified value.
Width: 176to 184cm (180f4cm) C-3.1.1 The bricks shall be immersed in water for
Height: 176 to 184 cm (180 f 4 cm) 24 h at 27°C + 2°C. The surplus water shall be allowed
(for 9 cm thick bricks) to drain. The frog of the bricks should be filled with
76 to 84 cm (8044cm) 1:3 cement mortar, flush to the surface and shall be
(for 4 cm thick bricks) cured under the jute bags for 24 h; the bricks shall then
C-2 SAMPLING AND CRITERIA FOR be immersed in water for 72 h. The bricks after
CONFORMITY removal shall be wiped clean.

C-2.1 The sample size for all the tests prescribed shall C-3.1.2 The brick shall be placed with flat faces
horizontal with the frog with mortar upside. Loads

A MEASUREMENT OF LENGTH

B MEASUREMENT OF WIDTH

C MEASUREMENT OF HEIGHT

FIG.4.1 MEASUREMENTOFTOLERANCESOFCOMMONBUILDINGBRICKS

57
SP 62 (S & T) : 1997

shall be applied at a uniform rate of 140 kgf/cm2 pet Then they shall be immersed in water at 27 + 2°C for
minute, after placing a plywood sheet or similar 24 h. After removal they shall be wiped clean and shall
uniform surface on the upper side. be weighed again, W2.
C-4.3 The difference between the two weights as a
C-3.1.3 Average of five results of compressive
percentage of the weight WI shall be recorded and the
strength shall be reported. The compressive strength
average of five bricks shall be reported as the moisture
is load at failure of brick divided by surface area of
absorption.
brick, expressed as kgf/cm*. ,
C-5 EFFLORESCENCE
If any value exceeds the specified value, this may be C-5.1 Five bricks shall be tested for efflorescence. A
taken into account in reporting the results. shallow dish with distilled water may be arranged.
The bricks on end are immersed in the water in the dish
C-4 WATER ABSORPTION to a height of 2.5 cm. The brick should be allowed to
absorb the whole water. Again pour some water and
C-4.1 Water absorption by brick shall not exceed 20 allow it to evaporate as before.
percent by weight up to class 12.5 and 15 percent by
weight for higher classes. The brick shall be examined after the second evapora-
tion.
C-4.2 Five bricks shall be tested for water absorption. C-S.2 Check for efflorescence. The efflorescence
The bricks shall be dried in_a+oven at 110°C to 115°C shall be ‘nil’ to ‘moderate’. For ‘nil’ there is no per-
till they attain constant weight. .Then they shall be ceptible deposit of efflorescence. For ‘slight’ there is
allowed to cool at room temperature. Oven drying no more than 10 percent of area of the brick covered
may take 48 h and cooling another 4 h on an average. with a thin deposit of salts. For ‘moderate’ a heavy
deposit covering up to 50 percent of the area of the
The cooled bricks shall be weighed, WI. bricksurface but not accompanied by flaking.

Section 2 Construction Practices - Bridwork

1 GENERAL 1.2.3 Setting out of walls shall be done by permanent

rows of pillars, parallel to and at a fixed distance from
1.1 Introduction the building. The pillars shall be located at junctions
of cross walls. The centre lines of cross walls shall be
BrIckwork is in a way a specialized craft where dif-
extended and permanently marked on plastered tops of
ferent types of bricks have been tried, different types
corresponding pillars. The datum line shall be marked
of bonds evolved with various types of mortars and a
on corresponding rows of pillars to serve as a check
number of construction details for improving the per- ‘.
~for accuracy of work as it proceeds. The tops of the
formance of the brickwork that have emerged. The
pillars shall be uniform in size say 30 cm2 in plan, and
performance of brickwork includes strength,
shall be bedded in ground deeply so that they are not
durability, waterproofing, thermal insulation, fire
disturbed.
resistance, etc.
1.2.4 Appropriate bench harks be located at con-
1.2 Setting Out
venient points linked to standard bench mark available
1.2.1 In case of sloping terrain, care shall be taken to neear the site.
ensure that the dimension on plan are set out correctly 2 TYPES OF BONDS
in one or more horizontal planes, after clearing the site.
2.1 General
1.2.2 The building lines shall be set out with steel
The primary.object of a bond is to give strength to
tapes. Setting out of angles shall be with theodolite in
masonry. In brickwork, the cross joints in any course
case of important and intricate buildings where the
shall not be nearer than a quarter of a brick length from
length is more than 16 m. In other cases they may be
those in the course below it. The types of bonds
set out by measurement of sides. In rectangular or
generally in use, their characteristics, situations of use
square setting out, the diagonals shall be checked to
ensure accuracy. are described below.

58
 SP 62 (S & T) : 1997

2.2 English Bond (see Fig. 4.2) length of bricks, a queen closer is introduced next to
The bricks in the facing are laid in alternate courses of the quoin header in alternate courses, the intervening
headers and stretchers. The header course is com- ones commencing with a stretcher, and every header
menced with a quoin header followed by a queen will obtain a location that is central with respect to the
closure and continued with successive headers. The stretcher above or below.
stretcher course is formed by stretchers having a The appearance on the face may be considered as more
minimum lap of one quarter their length over the uniform than in English bond. It requires less number
header. The bond contributes substantially to the of facing bricks than English bond and hence may be
strength of brickwork and may be particularly suitable more economical where brickwork is faced with spe-
for carrying heavy loads. cial facing bricks and exposed to view.
2.3 Double Flemish Bond (see Fig. 4.3) Though considered inferior to English bond in strength
The courses both in the facing and backing are formed this bond may be-suitable for single-brick thick walls
with alternating stretcher and headers. In order to in normal house construction, provided a strong mortar
obtain the lap, which is equal to one-quarter of the such as cement mortar is used.

F1ci.4.3 DOUBLEFLEMISHBOND
SP 62 (S & T) : 1997

2.4 Single Flemish Bond (see Fig. 4.4) Flemish garden wall bond consists of alternate courses
composed of one header to three or five stretchers in
This facilitates the facing of wall to be in Flemish bond
series throughout the length of these courses.
and the backing in English bond.This will entail the
use of snap headers. One brick thick walls are easier to construct with these
bonds than with pure Flemish or English bonds and
This attempts to combine practically the better ap-
save facing bricks considerably in the case of exposed
pearance of Flemish bond with the better strength of
work.
English bond. However increase in strength over
Double Flemish bond is doubtful. 2.6 American Bond (also Known as Common
2.5 Garden Wall Bond (see -Fig. 4.5 and 4.6) Bond) (see Fig. 4.7)

English garden wall bond consists of a header course It consists of one header course to a numberof stretcher
with the necessary queen closure next to quoin header courses.
to three or sometimes even five stretcher courses run-
ning in series with overlap of half-brick between This is for general use. It is commonly adopted in
stretcher over stretcher. America.

FIG.4.4 SINGLEFLEMISHBOND

v /COURSE ‘C’

FIG.4.5 ENGLISHGARDENWALLBOND

60
 SP 62 (S & T) : 1997

2.7 Stretcher Bond (see Fig. 4.8) 2.8 Header Bond (see Fig. 4.9)
In this bond all the courses are stretcher courses and The facing of this bond has all the courses as headers
the overlap is usually half brick and is obtained by only and the overlap, which is half the width of the
commencing each alternate course with a half-bat. brick, is obtained by introducing a three quarter bat in
With a slight variation at the quoin the overlap may be each alternate course at quoins.
varied to 314 or 1I4 brick and the bond is then known
as ‘Raking Stretcher Bond’. This bond is used for walls curved in plan for better
alignment; and preferably in foundation footings of
This is generally used in l/2 brick thick leaves of cavity brick masonry for better transverse distribution.
walls.

F~4.6 FLEMISHGARDENWALLBOND

FIG.~.~ AMERICANBOND

61
SP 62 (S & T) : 1997

2.9 Other Bonds 3 THICKNESS OF JOINT

The bonds covered from 2.2 to 2.8 are based on the 3.1 (&nerd
traditional 225 mm x 112.5 mm x 75 mm brick. These
are also suitable for modular bricks. Other bonds, such The thickness of bed joints shall be such that four
as, Monk Bond, Dutch Bond, English~Cross Bond are courses and three joints taken consecutively shall
in vogue for special conditions. They give different measure as follows:
artistic appearance.
SLATE CLOSURE TO JAM6
f

F!!EsEE PLAN OF COURSE ‘8’

-PLAN OF COURSE ‘A’

I 1 I I I I I I
ELEVATION
NOTE-Use of stretcher bond in cavity wall construction is illustrated here.
FIG.~.~STRETCHERBOND

~PLAN OF COURSE ‘A’

ELEVATION
FIG.4.9 I~EADERBOND

62’

.
 SP 62 (S & T) : 1997

a) In the case oj’traditional brick- Equal to four 3.3 Mortars

times the actual thickness of brick + 3 cm.
b) In the case of modular brick to IS 1037 : 1992 Mortars shall be any one described in Table 4.1 of Part
with thickness of 39 cm the maximum thick- 1 of this Chapter. The strength of mortar should match
ness of joint shall be 10 mm. strength of brick (see 2.4 of Part I for optimum mix).

3.2 Finishing of Joints 4 PREPARATORY W-ORK

3.2.1 The face joints of brickwor!< may be tinished by
‘jointing’ or ‘pointing’. 4.1 Scaffolding

3.2.2 In jointing, either the face joints of the mortar Single scaffolding shall not be used on important
shall be worked out while green to give a finished works, since subsequent filling up of the putlog holes
surface flush with the face of the brickwork; or the and rendering of their surfaLe would give an unsightly
joints shall be squarely raked out to a depth of I cm appearance. Another disadvantage with single scaf-
while the mortar is still green for subsequent plaster- folding is that the workmen are apt to support them on
ing. The faces of the brickwork shall be cleaned with window and similar openings, thereby spoiling frames
wire brush so as to remove any splashes of mortar and shutters.
during the course of raising brickwork.
4.1.1 Where single scaffolding is adopted, the placing
3.2.3 In pointing, the joints shall squarely be raked out of the poles, which are to rest on the brickwork under
to a depth of 15 mm, while the mortar is green and the construction, shall be so adjusted to affect only one of
raked joints shall be well brushed to remove dust and the headers at the point of support at various courses.
loose particles and well wetted; the joints shall then be
4.1.2 Scaffolding shall be designed to withstand the
tilled with mortar to give the required finish. Some
finishes are ‘flush’, ‘weathered’, ‘tucked’, ‘ruled’, etc loads coming on it. They should conform to IS 3696
(Part 1) : 1987, IS 4014 (Part 2) : 1967.
(see Fig. 4.10).
Pointing will offer facilities for introducing in the face 4.1.3 Scaffolding for exposed brickwork or tile work
joints a mortar specially prepared with regard to com- shall be double scaffolding, having two sets of vertical
position, colour, etc. supports. For all other brickworks in buildings, single
scaffolding may be permitted subject to provision of
4.1 and 4.1.1. For such scaffolding, holes for scaffold-
ing shall not be allowed in pillars/columns less than
1 m width; holes also shall not be permitted immedi-
ately near skew backs of arches. The holes left in the
masonry works shall be filled and made good before
plastering.

4.2 Soaking of Bricks

4.2.1 Bricks shall be soaked in water before use for a

period that is sufficient for the water to just penetrate
the whole depth of bricks.

The period of soaking may generally be at least 6 h. ..

The period of soaking may easily be determined by
field test at site. The bricks are soaked in water for
different periods and then broken to find the extent of
water penetration. The least period that corresponds
to complete soaking will be one allowed for. If the
bricks are soaked for the required time in water that is
c
frequently changed, the soluble salts in the brick will
-be bleached out and subsequent efflorescence reduced.

Wetting of bricks assists in removing the dirt, sand and

dust from them. Further, it prevents the suction of
water from wet mortar, as otherwise mortar is likely to
dry out soon and crumble before attaining strength.
Also the bricks shall not be too wet at the time of use,
FIG. 4.10 DIFFERENTTYPES OF POINTINGFINISHES as they are likely to slip on the wet mortar bed and there
FORBRICK WORK will be difficulty in ensuring plumbness of the wall.

63
SP 62 (S & T) : 1997

Proper adhesion of the bricks will not be possible if the 51.2 Brickwork shall be built in uniform layers.
bricks are too wet. Corners and other advanced work shall be raked back.
No part of a wall may rise more than 1 m high above
4.2.2 When bricks are soaked, they shall be removed
the general construction level to avoid unequal settle-
from the tank sufficiently early so that at the time of
ment. If unavoidable the work shall be raked back at
laying they are skin dry. Soaking by spraying of water
an angle not exceeding 45’ and not toothed.
may also be permitted if~found satisfactory.
Toothing may be done where ~future extensions are
4.2;3 Bricks required for masonry with mud mortar or
contemplated.
fat lime mortar shall not be soaked.
5.1.3 Vertical joints in alternate courses shall come
5 LAYING OF BRICKWORK
directly over the other. Thickness of brick course shall
5. I General be kept uniform. Both faces of the wall shall be kept
in proper parallel planes.
Bricks shall be laid on a full bed of mortar. When
laying, the bricks shall be slightly pressed so that the 5.2 Walib
mortar can get into all the pores of the brick surface to
&2J All qttoins shall be accurately constructed and
ensure proper adhesion. Cross joints and wall joints
the height of the courses checked with storey rods as
shall be properly flushed and packed with mortar SO
the work progresses. In general quoin bticks shall be
that no hollow spaces are left. Properly filled joints
~headers and stretchers in alternate courses, the bond
ensure maximum strength and ix?Sb4taHO2 to pe&!tf%
being estnbiished by placing a quoin closer next to the
tion of moisture which takes place mainly through the
queen hettdet .
joints.
5.2,2 Acute and obtuse quoins shall be bonded, where
In case of thick walls (two brick thick and over), the
pructlcable in the sume way as square quoins. Obtuse
joints shall be grouted at every course in addition to
quoins shall be formed with squints showing a three-
bedding and flushing with another.
quarter brick on one face nnd a quarter brick on the
In case of traditional bricks, the courses at top of plinth other,
and sills, at the top of the wall just below roof slab or
5.3 Plasters
floor slab and at the top of the parapet, may be laid with
bricks on edge. These shall be so set out as to avoid a broken bond.
The bricks at corners and perpends shall be properly
keyed into position by using cut bricks. A typical
5.4.1 The depths of reveals and rebates shall, where
arrangement is shown in Fig. 4.11.
practicable conform to standat-d brick sizes to avoid
cutting of bricks and thereby weakening the work.
5.4.2 The arrangement of bond at quoins, at jambs of
openings shall be symmetrical.
5.5 Partitions
For half brick partitions to be keyed into main walls,
indents shall be left in the latter.
L 5.6 Half Brick Masonry
70
- Work shall be done as in 5.1 except that all bricks shall
70 be laid with stretchers.
-
5.6.1 For the case of half-brick wall water tanks or
60 long length of half brickwalls, reinforcement may be
T provided from structural considerations. Two bars of
6 mm shall be provided at every third course or as per
drawings. Half the mortar joint must be first laid, then
FIG. 4.11 A TYPICAL ARRANGEMENTOF place the reinforcement followed by the rest~ofmortar,
CUT-BRICKS IN A CORNER so that the bar is fully embedded inmortar. Reinforce-
ment shall be straight.
51.1 Bricks with frogs shall be laid with frog-down
if the frog is 2 cm deep; if 1 cm deep, they may be used 5.7 Arches
either frog-down or up. The courses shall be aligned 5.7.1 General requirements of 5.1 shall be followed
and care shall be taken to keep the perpends. as applicable.

64
 SP 62 (S & T) : 1997

Both plain and gauged arches are covered. In plain arch. The sequence of easing the shuttering shall be
arches, uncut bricks shall be used. In gauged arches carefully worked out. The shuttering shall be struck
moulded bricks shall be used. between 24 to 48 h of the completion of the arch. This
shall be done after the sprandrel has been filled in and
Bricks forming skewbacks shall be dressed or cut so
the arch loaded.
as to give proper radial bearing to the end voussoirs.
Defects in dressing up bricks shall not be covered by 5.8 Brick Tile Work
extra use of mortar, nor use of chips be permitted.

The bricks of the spandrel wall at their junctions with It shall be done in the same way as brickwork as in 5.1.
extrados of arch shall be cut to fit the curvature of the
5.9 Honey Comb Brickwork
arch.

5.7.2 Circular Arches The honey comb brickwork shall be done with
specified class of brick, laid in specified mortar. All
They shall be either (a) plain arches and shall be built joints and edges shall be struck flush to give an even
with half brick concentric rings with break joints, or surface. The thickness shall be half-brick only, unless
(b) gauged arches with bricks cut to or moujded to otherwise specified. Openings shall be equal and
proper shape. The arch work shall be carried out from alternate with half-brick laid with a bearing of 2 cm on
both ends and keyed in the centre, The bricks shall be either side.
flush with mortar and well pressed into their positions
as to squeeze out a part of their mortar and leave the 5.10 Brickwork in Openings
joints thin and compact. All joints shall be full of
mortar and thickness of joints shall not be less than Openings shall be of such size and so spaced in walls
5 mm and not more than 15 mm. as to reduce the cutting of bricks to minimum. The
width of openings shall, as far as possible, be a multiple
After the arch is completed, the haunches shall be
of width of brick.
loaded by filling upmsprandrels up to the crown level
of the arch. Care shall be taken to load the haunches In the external walls, it is desirable to rebate the sills,
on two sides of the sprandrels. jambs and heads of openings so as to form a barrier for
rainwater. The sill may be sloped slightly to allow the
When the arch face has to be pointed, the face bricks
rain water to drain off.
shall be cut to proper shape or moulded as to have
joints not more than 5 mm thick. These shall be laid
5.11 Parapets and Copings
to the full depth of the arch. The voussoirs shall break
joints to the full depth of the arch. 511.1 The parapets and copings shall be of thickness
5.7.3 Flat Arches such that their~base covers the junction of roof slab and
wall which shall be further effectively treated against
These shall be gauged arches of cut brick or moulded possible leakage of rain water. Normally a cement
brick to proper shape. The extrados shall be kept lime mortar ‘gola’ or fillet is done (see SP 25 : 1984)
horizontal and the intrados shall be given a slight Fig. 4.12.
camber of 1 in 100 of the span. The centre of the arch
from which joints shall radiate shall be determined by 511.2 Coping may be of stone, concrete, brick or
the point of intersection of the two lines drawn from terraccota; it is throated underside of the projection.
the ends of the arch at the springing level and at 60’ to The top of the coping shall be slightly sloped to allow
horizontal. water to drain off.
In flat arches, bricks shall be laid with radial joints to
the full depth of the arch and voussoirs breaking joints 5.12 Cavity Walls
with each other. The arch work shall be carried out
from both the ends simultaneously and keyed in the 512.1 In building cavity walls of half-brick thick-
centre. The thickness ofjoints shall not exceed 15 mm. ness, only stretcher bond shall be used, unless purpose
made snap headers are available. When header bricks
5.7.4 Centering and Shuttering are cut and used, they are either likely to protrude into
The centering and shuttering for the arches shall~be got the cavity and form a ledger for mortar droppings to
approved by the Authority. It shall carry the dead-and collect or they may be so short as to weaken the
live loads without any appreciable deflection. structure. The cavity shall not be less than 5 cm.

The shuttering shall be tightened with hardwood The outer and inner leaves shall be tied by means of
wedges or sand boxes, so that the shuttering can be wall ties. The wall ties shall preferably be bedded with
eased out without any jerks being transmitted to the a slight fall towards the exterior part of the wall.

65
SP 62 (S & T) : 1997

CONCRETE FILLET

ONE COURSE OF BRICK TILES

CHASED INTO PARAPET
r
PROTECTIVE COVER (MUD. flC)

tilTH ‘MASTIt FIRST COURSE OF PARAPET

COMPOUND MASONRY IS THICKER THAN
THE WALL BY % BRICK

hCC SLAB CEILING PLASTER

12 mm WIDE GROOVE IN PLASTER

YA3 L SLIP JOINT AT SUPPORT OF RCC‘SiAB

SECTION

Flc. 4.12 CONSTRUCTIONALDETAIL OF BEARINGOF RCC ROOF SLAB OVERA MASONRY WA.LL

5.12.2 At the base of the cavity wall, the foundations 5.12.5 The thicker leaf shall be arranged on the inside.
and basement shall be solidly constructed up to The materials of leaves may be different masonry,
300 mm above the ground level. The air cavity shall concrete, etc. Wall ties, binding them together shall
begin not be less than 200 mm below the upper floor not be placed more than four brick-lengths apart
surface of the ground floor and the cavity shall be horizontally and not more than five brick-heights
continued without interruption to the roof. vertically staggered. Additional ties shall be used near
openings. A minimum of 5 ties/m2 of surface area of
The cavity shall be ventilated by air slots below the
the wall shall be provided.
eaves level of the roof to the extent of 50 cm2 for every
20 m* of the wall. Ties may be of mildsteel, flat iron or round bars
suitably sloped towards the exterior wall so as to
5.12.3 Precautions prevent water from flowing into the innerleaf. Ties
may be given a protective coating from corrosion.
The following precautions shall be taken:
5.12.6 Efforts shall be rnade to prevent mortar drop-
a>Parapets - If the top of a hollow wall ends
ping into cavity and remove the same in the event
with a parapet, the cavity shall be carried to the
full height of the wall or stopped at the roof mortar were to be dropped.
flashing level; 5.13 Curing
b) Euves - If a roof projects over the top of the
wall, the cavity shall be closed at the top; and The wall shall be cured at least for 7 days except
c> Party walls - In a hollow party wall, the top brickwork of mud mortar.
of a cavity wall shall be closed just above the
uppermost ceiling level and the courses over 5.14 Service Installation
shall be continued as in solid brickwork. A
Provision for service installations shall be made during
sound insulation material shall be interposed
construction itself.
between the hollow wall and solid brickwork.
5.15 Moulding and Cornices
5.12.4 At the points where the two ieaves of party wall
come into contact, for example at windows and doors, 5.15.1 Cornices
they shall be separated by a water tight membrane.
Cornices shall not ordinarily project by more than
Above lintels of doors and windows, a damp-proof 150 mm to 200 mm and this projection shall be
membrane shall be inserted sloping downwards and obtained by projecting each brick course by not more
outwards. At solid jambs, a vertical damp-proof than one-fourth of brick length. Metal clamps shall be
course shall be inserted. used for cornices longer in length.

66
 SP 62 (S & T)~: 1997

US,2 CorOelling 5.16 Jointing Old Brickwork with New

Corbelling shall be brought roughly to shape by Brickwork
plastering with specified mortar. When the mortar is
The old brickwork shall be proper cleaned of dust,
green, the mouldings shall be finished stra’ight and
loose mortar, etc. Bricks of the same size shall be used.
trace with the help of metal template. The mouldings
The surfaces of old work shall be thoroughly wetted
and cornices shall be cured for seven days. They shall
before commencing the work.
be protected during construction from sun and rain.

Section 3 Construction Practice - Blockwork

1 GENERAL 2.2 Light Weight Blocks

1.1 Inttoduction Light weight blocks shall be embedded with a mortar
Blocks are either hollow or solid. Generally they are mix, the strength of which is lower than mix for
of light weight compared to bricks. Concrete blocks making blocks, to avoid formation of cracks. A 1:2:9
to IS 2185 (Part i) : 1979 may be used for both load cement, lime, sand mortar may generally be used; for
bearing and non-load bearing walls. The wall thick- high intensity of load it shall be 1:1:6. Autoclaved
ness will vary. blocks shall be embedded in mortar as specified in
Table 4.4.
For high thermal insulation, cavity walls having inner
leaf of light weight concrete blocks to IS 2185 (Part 3 CONCRETE
2) : 1983 may be used. Each leaf of cavity shall not be
3.1 Concrete used for filling hollow concrete block
less than 100 mm.
masonry when reinforced shall be 1 cement, 2; sand
Autoclave cellular concrete blocks to IS 2185 (Part 3) : and 3 coarse aggregate of size ranging from 4.75 mm
1984 shall not be used for foundations and for masonry to 10 mm. The water cement ratio shall not exceed 0.6.
below damp-proof course. When cells exceed, 100 mm on the narrower side, the
2 MORTAR proportion of mix shall be 1 cement, 2; sand, 3icoarse
2.1 Hollow Concrete Blocks aggregate for reinforced concrete and 1:3:6 for plain
concrete.
Hollow concrete blocks shall be embedded with a
mortar which is relatively weaker than the mix used 4 THICKNESS
for making blocks in order to avoid formation of
cracks. A rich or strong mortar tends to make a wall 4.1 For load bearing masonry built with hollow con-
too rigid thus localizing the effects of movements due crete blocks, the thickness of walls shall not be less
to ~temperature and moisture variations, resulting in than the values as obtained from IS 1905:1987.
cracking of blocks. The recommended proportion of 4.2 Light weight block in load bearing masonry for
mortar measured by volume is given in Table 4.4. external walls in framed construction shall not be less
than 200 mm. However, if they are suitably braced by
Table 4.4 Mix Proportions of Mortar for Hollow lateral or vertical supports, the thickness can be
Concrete Blocks 100 mm. Non-load bearing hollow block walls shall
(Clauses 2. I and 2.2) be not less than 100 mm.
Sl Type of Work Normal Masonry Reinforced Masonry 4.3 Autoclaved block walls in framed construction
No. (Cement:Lime:Sand) (CementSand) shall also be as per 4.2, except that for load bearing
1. Normal work I: 1:9to10 1 :7to8 work, the minimum thickness shall be 200 mm; how-
2. Exposed to severe I : 1:6to7 1 :4tos ever it can be reduced to 150 mm if properly braced.
conditions; high
intensity of loads; 5 LATERAL SUPPORT
plasters; heavily
loaded lintels and Walls made of blocks shall have vertical or horizontal
beams
lateral supports at right angles to the face of the wall.
3. Partitions of 10 cm I : 1:7to8 I :5to6
Cross walls, plasters or buttress walls shall provide the
NOTE - All mortars shall have a slump of 75 mm.
lateral support.
SP 62 (S & T) : 1997

6 AVOIDANCE OF CRACK FORMATION

6.1 General
-MASONRY
The major cracks in the walls or partitions in a structure
constructed with blocks, whether they are of hollow of
cellular types can be prevented. The preventive
measures to be undertaken are covered in 6.1.1
to 6.1.5.

6.1.1 Structurul Movements

Cracks may arise from alterations in length, curvature

or orientation due to load settlement, thermal expan-
sion or changes in moisture content.
\OPENlNG
In the case of framed structures, erection of partitions
and panel walls shall be delayed wherever possible
until the frame has taken up, as much as possible, any
deformation occurring due to structural movements.
Floor deformation and movement- The floor
upon which a partition is built may deflect BOND BEAM
/-
under load brought on it after the partition is
built. Such deflections tend to create a non- 98mm BARS.2 No.
continuous bearing for the block leading to -r Y--

cracks in the partition. This can be avoided by !L

embedding wires of 3 mm diameter of mild
steel or galvanized steel or welded wire mesh L@ 6 mm STIRRUPS
strip in bed joints in cement mortar I:2 after e @ 175 mm WC
every 900~mm to I 200 mm height.
Ceiling deflection and movement - A ceiling
above a partition wall may deflect under loads
applied after its erection or through thermal or
other movements. To avoid cracking as a
result of such deflection, the partition wall
shall be separated from the ceiling by a gap or
by a layer of resilient material or lean mortar. H 480mm
When this cannot be done as in the case of wx H -j 1200Ill,,?

plastered finishes, the risk of cracking may be FIG.4.13 NOMINALREINFORCEDCONCRETE

reduced By forming a cut between the ceiling BONDBEAMATSILLLEVEL
plaster and the wall plaster.
Defection or movement of structural abut- 6.1.2 Control of Wall Movements Accompanying
rnents-The wails, columns or other structural Temperature and Moisture Changes
elements against which the wall or partition Cracking in concrete masonry walls is often due to
abut, may deflect or move because of load, tensile stresses which develop when wall movements
settlement, shrinkage or thermal effects. accompanying temperature and moisture change are
In order to avoid cracking of w:!lls or partitions restained by other elements of the’building or when
as a result of such movements, a slip joint shall concrete masonry places restraint on the movement of
be provided where possible, preferably packed adjoining elements.
with a resilient mortar or lean mortar. a) There are three methods of controlling crack-
Cracks in partition walls may occur at corners ing in concrete masonry structures:
of door and window frames at lintel level or sill 1) Specifying a limit on the moisture content
level. It may therefore be desirable to provide of masonary units at the time of delivery
a nominal reinforced concrete band beam (see and construction;
Fig. 4.13) at sill level and vertical reinforced 2) Incorporating steel reinforcement either in
concrete stud at either side of vertical members the form of nominal bond beams (see
of frames which may in addition provide 6.1.3) or horizontal joint reinforcement
sufficient anchorage for hold fast. (see 6.1.4); and

68
 SP 62 (S & T) : 1997

3) Providing control joints to accommodate mix. In walls exposed to action of weather. the
the movement of masonry (see 6.1.5). For reinforcement shall have a mortar cover of not
control joints (see Chapter 13). less than 15 mm.
In all concrete masonry construction, it is essential to d) Notwithstanding the above, location of joint
employ only moisture controlled units. Their use, reinforcement shall be as follows:
combined with the provision of control joints is 1) Place the joint reinforcement in the first
generally adequate to prevent cracking in concrete and second bed joints immediately above
masonry walls. and below wall openings;

However, bond beams or joint reinforcement, or both

2) It shall not extend less than 600 mm
beyond the openings to end of the panel
in different locations as considered suitable may also
whichever is smaller;
be used in addition to the above.
3) Place joint reinforcement wtthm two or
6.1.3 Nominal Bond Beams three courses immediately below the top
Bond beams, the use of which as structural members of the wall;
have been referred to in 6.2, shall also serve as a means 4) Joint reinforcement shall not be located
to crack control. Norma1 bond beams shall be built in closer to a bond beam than 600 mm; and
the same manner as the structural bond beams with a 5) Joint reinforcement shall be interrupted at
minimum reinforcement of two 8 mm dia mild steel control joints.
bars or two 6 mm dia high strength deformed bars.
Their value for this purpose is due to increased strength Table 4.5 Recommended Length to Height
and stiffness they provide to a masonry wall. As a Ratios for Concrete Block Masonry
means of crack control, the area of influence of bond (Clause 6.1.3)
beam shall generally be assumed to be extend 600 mm
Sl Wall Panel Vertical Spacing of Joint Reinforcement
above and below its location in the wall. In walls No.
without openings, they shall be placed at 1 200 mm ri)00mm
apart and may be of any length up to a maximum of 1. Length of panel (L) 18m 15 m 12m
18 m (see Table 4.5). irrespective of
height (H), MIX
Nominal bond beams shall be discontinuous at control
2. Ratio L/H,Max
joints, but practice here varies depending on the struc- 2.75 2.50
a) 200 mm thick wall 3.0
tural requirements. Dummy joints shall be formed b) 300 mm thick wall 2.25 2.00 I .75
when a bond beam is continuous at a control joint.
NOTES
6.1.4 Joint Reinforcement 1 When bond beams spaced at I 200 mm are used in place of joint
reinforcement, control joints shall be spaced at I8 m.
Horizontal joint reinforcement serves much the same
2 Where reinforcement has not been provided, the ratio L lHof wall
purpose as bond beams in crack control. It increases panel shall conform to IS 1905 : 1987.
stresses to cracking. Due to closer spacing adopted,
joint reinforcement may be more effective in crack 6.1.5 Control Joints
control than bond beams. Control joints are employed to reduce restraint by
a>Joint reinforcement shall be preferably accommodating movement of masonry wall or move-
be fabricated from galvanized steel to ment of structural elements adjacent to the wall, and
IS 280 : 1978 and shall consist of two or more thus to control cracking. They are in fact vertical
smooth or deformed longitudinal wires 3 mm separations built into the wall at locations where crack-
dia or larger weld connected with 2.8 mm dia ing is likely due to excessive horizontal stresses. The
or larger cross wires. The out-to-out spacing spacing along the wall length depends upon:
of longitudinal wires shall be 30 mm less than a) expected movements of the wall and other
the width of masonry units. Cross wires shall elements;
be welded at a pacing of 150 mm for smooth b) resistance of the wall to horizontal stresses; and
wires and 400 mm for deformed wires. Where c) the extent and location in the wall of doors,
splice in wires is necessary, it shall be lapped windows, recesses, chases and other causes of
to a length of at least 300 mm. stress concentration.
b) The reinforcement shall be embedded in
horizontal joints at intervals of 900mm to Some typical methods of control joints are shown in
1 200 mm depending on panel length, height Fig. 4.14 and Fig. 4.15.
and the number and type of wall openings. 6.2 Bonded Beams and Studs Used on Structural
Table 4.5 gives, general guidance in this regard. Members
c) Joint reinforcement shall be used in conjunc- 6.2.1 Reinforced concrete structural bond beams may
tion with cement mortar not weaker than 1 : 2 be used in concrete block masonry to meet the

69
SP 62 (S & T) : 1997

ON EXPOSED FACE OF WALL.

RAKE OUT MORTAR TO 20 mm
ALTERNATE AND FILL WITH CAULKING
COURSESA COMPOUND\

LC~NTROL GAULKING COMPOUND

JOINT OR MORTAR ON
UNEXPOSED WALL
METHOD A
ON EXPOSED FACE OF WA&RAKE
ALTERNATE OUT MORTAR TO 20 mm AND FILL
WITH CAULKING COHPO

5 mm WIRES GREASED LKING COMPOUND

AND LAID IN EVERY OR MORTAR. ON
OTHER COURSE UNEXPOSED WALL
METHOD B
ALTERNATE ON EXPOSED FACE OF WAl_L.RAKE
OUT MORTAR TO 20 mm AND FILL

JAMB BLOCK

mm WIRES GREASED
AND LAID IN EVERY OR MORTAR ON
OTHER COURSE tiNEXPOSED WALL

METHbD C

FIG.4.14 CONTROL JOINTSINCONCRETE BLOCKMASONRYCONSTRUCTION

ON EXPOSED FACE OF WALL,RAKE

MORTAR TO 20 mm AND FILL
WITH CAULKING COMPOUNO

L/5 mm WIRES BENT IN \ L CAULKING COMPOUND

FORM OF Ll, GREASED OR MORTAR ON
AND LAID IN EVERY UNEXPOSED WALL
OTHER COURSE ALTERNATE COURSES

METHOD A

FIG.4.15 PLASTERSWITHCONTROLJOINTSINCONCRETEBLOCKMASONRYCONSTRUCTION-C~~~~~~~~

70
 SP 62 (S & T) : 1997

WITH CAULKING CO~MPOUND

L 5 mm WIRES BENT tN
FORM OF U, GREASED CAULKlNG COMPOUND
AND LAtD IN EVERY OR MORTAR ON
OTHER COURSE i
UNEXPOSED WALL

h4ETHOD 8

ON EXPOSED FACE OF WALL,RAKE

OUT MORTAR TO 20 mm AND FILL
WITH CAULKING COMPOUND

/r;ALTERNATE COURSES

bmm WIRES GREASED ‘%AULKlNG COMPOUND

AND LA10 IN EVERY OR MORTAR ON
OTHER COURSE UNEXPOSED WALL

METHOD C

FACE OF WALL,RAKE
UT MORTAR TO 20 mm AND’FILL
WITH CAULKING COMPOUND

NATE COURSES

6 mm WIRES GREASED L CAULKING COMPOUND

AND LAID IN EVERY OR MORTAR ON
OTHliR COURSE UNEXPOSED WALL

METHOD Cl
SP 62 (S & T) : 1997

ON EXPOSED FACE OF WALL,RAKE

OUT MORTAR TO 20 mm AND FILL
WITH CAULKING COMPOUND

/-qAQ_TERNATE COURSES

CAULKING COMPOUND OR
MORTAR ON UNEXPOSED WALL

METHOD E
ON EXPOSED FACE OF WALL,RAKE
OUT MORTAR TO 20 mm AND FILL
WITH CAULKING COMPOUND

LTERNATE COURSES

&AULKING COMPOUND
OR MORTAR ON
UNEXPOSED WALL

METHOD F
FIG.4.15 PLASTERSWITHCONTROLJOINTSINCONCRETEBLOCKMASONRYCONSTRUCTION- Concluded

requirements of unusual stress conditions. Examples 6.2.3 Bond beams may be provided at any of the
are as below: following locations depending on the conditions
described in 6.2.1.
a) In buildings in earth-quake regions;
a) At floor level;
b) In buildings in areas where severe wind storms
b) At top of all door and window openings (in
occur;
which case they serve as lintels over them);
c) In buildings in areas where unfavourable soil
c) Below the sill in all window openings; and
movements and soil subsidence occur; and
d) At plinth level.
d) In buildings where walls are subjected to
excessive vibration or to heavy loads. 6.2.4 Apart from the horizontal bond beams, vertical
reinforced concrete studs may also be provided at
In all such cases, it is necessary to provide n-ore than corners, at wall openings and at regular intervals
nominal stability for all types of masonry walls. between wall openings. The studs shall be tied in
with bond beams.
6.2.2 Bond beams, shall be built integrally with block
Non-structural use of bond beams is already covered
masonry or with special U-shaped lintel blocks slung
in 6.1.3.
together with reinforcing steel placed in the core of
hollow of blocks filled with M 15 concrete. The rein- 7 PREPA-RATORY WORK
forcement shall conform to IS 456 : 1978; but in no
7.1 Wetting of Blocks
case shall be less than two 12 mm dia mild steel bars.
The beams are discontinuous at control joints; but the The blocks need not be wetted before or during the
joints should be designed to transfer forces along the laying of the blocks. In case the climatic conditions so
wall. require, the top and sides of the blocks may be slightly

72

.
 SP62(S&T):1997

moistured so as to prevent absorp&n of water from 8.2.3 To ensure satisfactory bond, mortar shall not be
the mortar and ensure development of the required spread too far ahead of actual laying of the block as it
bond with the mortar. will stiffen and lose its plasticity.
7.2 Scaffolding As each block is laid, excess mortar extruding from the
joints shall be cut off with a trowel and thrown back
Scaffolding shall be on the same lines as brickwork,
on the mortar board to be reworked into fresh mortar.
suitably modified where necessary.
If the work is proceeding rapidly, the extruded mortar
8 LAYING OF CONCRETE BLOCKS
cut from the joints may be applied to vertical face
8.1 First Course shells of the blocks just laid. It’ there be any delay long
The first course of concrete block shall be laid with enough for the mortar to stiffen or? the block, the
great care, making sure that it is properly levelled, mortar shall be removed to the mortar board and
aligned and plumbed, to assist in obtaining a straight reworked. Dead mortar that has been picked up from
and truly vertical wall. the scaffold or from the floor shall not be used.
8.3 Closure Block
Before laying the first course, the alignment of the wall
shall be marked on the d.p.c. The blocks for this course When installing a closure block, all edges of the open-
shall be laid dry, that is, without mortar along a string ings and all four edges of the closure block shall be
stretched between properly located corners of the wall buttered with mortar.
in order to determine the correct position of blocks The closure block shall be carefully lowered into
including those of the cross walls jointing it and also place. If any mortar falls leaving an open joint, the
ad.just their spacing. closure block shall be removed, fresh mortar applied
When the blocks are in proper position, the two corner and the operation repeated.
blocks shall be removed, a mortar bed spread and these 9 PROVISION FOR DOOR AND WINDOW
blocks relaid back in place truly level and plumb. The FRAMES
string shall then be stretched tightly along the faces of 9.1 Door and window frames shall be attached to the
two corner blocks and the faces of the intermediate surrounding masonry either by conventional method
blocks adjusted to coincide with the line. Thereafter or by 200 mm flooring nails with screwed lends fixed
each block shall be removed and relaid over a bed of directly into the block, after the frame has been edged
mortar. After every three or four blocks are laid the into the opening at every nailing position. The number
correct alignment and verticality be checked. of nails depends on the~dimensions of the frames. The
8.2 Construction nails shall be spaced at a maximum of 400 mm apart
and the first nail shall not be farther than 200 mm from
The construction of walls may be started either at the
the corner.
corners first or started from one end preceding to the
other end. Frames may be attached to the masonry by holdfasts
anchored in the vertical reinforced concrete studs
If the corners are built first, they shall be built four or
provided to the frames (see 6.2).
tive courses higher than the centre of the wall. As each
course is laid at the centre, it shall be checked for 10 PROVISION FOR ROOF
alignment and level and for being plumb. 10.1 The top of the roof course shall be finished
smooth with a thin layer of 1:3 cement mortar and
Each block shall be carefully checked for alignment
covered with a coat of crude oil or craft paper or oil
with a straight-edge to make sure that the faces of the
paper to ensure free movement of the roof.
blocks are in the same plane.
11 INTERSECTING WALL
8.2.1 Each course, in building the corners, shall be
11.1 Load Bearing Walls
stepped back by a half-block and the horizontal spac-
ing of block shall be checked by placing a mason’s When two load bearing walls intersect and courses are
level diagonally across the corners of the blocks. to be laid up at the same time, a true masonry bond
between 50 percent of the units at the intersection is
A storey rod or course pole, suitably marked provides necessary. When such walls are laid up seperately,
an accurate method of finding the top of the masonry pockets with maximum 200 mm vertical spacings shall
for each course. be left in the first wall laid. The corresponding course
8.2.2 When filling in the wall between corners, a of the second wall shall be built into these pockets.
mason’s line shall be stretched from corner to corner 11.2 For non-load bearing walls same bonding
for each course and the top outside edge shall be laid -methods as for load bearing walls may be used.
true to this line. The manner of handling or gripping 12 RENDERINGS AND OTHER FINISHES
the block shall be such as to position the block properly
12.1 All finishes shall be as described in Chapter IO
with minimum adjustment. on wall finishes as the case may be.

13
SP 62 (S & T) : 1997

Section 4 In-Situ Walls with Soil Cement

1 GENERAL NOTE - Sand content is the fraction of sand of the soil that
passes 425 micron and is retained on 75 micron IS sieve. More
1.1 This type of in-situ construction with soil cement than half the material is smaller than 75 micron by mass.

shall be limited to single storey construction with a 2.2 Soil shall be prepared as per IS 21 10 : 1980.
wall height not exceeding 3.2 m and a minimum wall
Cement shall be mixed in proportions as given below:
thickness of 300 mm for load bearing and 200 mm for
non-load bearing walls. a) For construction of walls 2.5 to 3.5 percent by
mass of dry soil depending on the density to be
1.2 The procedure described herein may also be obtained.
followed for rammed in-situ wall construction with
b) For construction of walls below plinth level
unstabilized soil, provided the surfaces of the wall are and for copings. 5 to 7.5 percent by mass of dry
protected by a waterproof mud plaster (see 4). soil, so that the crushing strength of blocks
2 SOIL mate shall not be less than 1.4 N/mm2
(14 kg/cm2) for dry condition.
2.1 Raw soil used for soil cement shall be’free from
deleterious contents, such as organic matter of For calculation purposes the unit weight of dry soil
vegetable origin, mica. etc. Black cotton soil may not shall be taken as 1 300 kg/m3. Properties of soil
be used from economy considerations. cement shall be as in IS 2110 : 1980.

Soil shall conform to the following requirements: 2.3 Preparatory Work

Sand content, percent by mass 35, Min 2.3.1 Shuttering

Plasticity index. percent 8.5 to 10.5 Any timber planks suitable in local practice may be
Total soluble salts, percent by mass 1, MU used for shuttering. The planks shall be not less than
Sodium salts, percent by mass O.l,/t4ax 200 mm in width and 50 mm in thickness. A typical
Liquid limit, percent 27, Max arrangement is shown in Fig. 4.16.

WOOOEN Pl ANK

MS ANGLES
LOxLOx6mm

END PLANK FOR

CASTING WALL
MS ANGLE AT CORNER NEAR AN OPENING
5Ox50r6mm

4.16A 4.168
NOTE-If the thickness of wall is greater than 300 mm the shuttering details will have to be suitably modified.
All dimensions in millimetres.
FIG. 4.16 TYPICAL DETAILS OF SHUTTERING FOR 300 mm THICK WALL

74
 SP 62 (S & T) : 1997

The shuttering shall generally be in lengths ranging 3.6 Bearing of Roof

from 1.8 m to 3.3 m. The height of the shuttering for
one lift shall be about 600 mmclear for casting the wall Where light roof framework is to rest on the wall, the
plus 200 mm for holding on to the portion of the portion of the wall directly below it shall be built with
compacted wall below in the previous lift. bricks laid in cement mortar 1:6 for a depth of 150 mm;
or bricks made out of 7.5 percent soil cement.
The shuttering may be lifted immediately after first lift
is well compacted and the shuttering for next lift Beams shall rest on cement concrete bed plates.
arranged. Trusses or flat roofs shall rest on brick bearing course
to a depth of 150 mm laid in cement mortar 1:6.
3 WALL CONSTRUCTION
3.7 Lintels
3.1 Preparatiou of Soil
Reinforced brick or cement concrete lintels may be
After the shuttering is erected, the moist stabilized soil used. The space above the lintels shall be filled either
shall be poured into the shuttering in layers of 75 mm with soil cement rammed in-situ, or precast soil ce-
at a time. The layer shall be uniform in depth. To ment blocks laid in cement in mortar mix 1:6.
control this depth, templates may be used.
3.8 Parapet
3.2 Compaction
The parapet shall be of brickwork. A drip course shall
Compaction shall be done by iron rammers. Compac- be provided to drain rain water from parapet and away
tion shall be started at the side and worked inwards. from the lower portions of the walls on to the roof
Ramming of the sides shall be evenly distributed to surface. The plaster finish of the roof shall be con-
* avoid tilting of the shuttering. Verticality of the shut!- tinued from the roof surface right up to the drip course
tering shall be checked as compaction proceeds. in the parapet.
3.3 Curing
3.9 Plastering
The walls shall be cured for 15 days after removal of
shuttering. Curing shall be done by slight sprinkling Cement plaster of mix not leaner than 1:5 shall be used.
of water at regular intervals. It shall be applied after drying the wall for four weeks
at least. The wall surface shall be given a neat cement
3.4 Joints wash before applying plaster.

Vertical joints shall be provided at a spacing of not 4 PREPARATION OF MUD PLASTER

more than 2 m apart. Vertical joint shall be staggered.
Fig. 4.17 gives details of joint. 4.1 Add cutback bitumen to IS 217 : 1988, grade
80/100 to mud with BHUSA which is allowed to rot for
Horizontal joints shall be formed by finishing smooth
a week. About 60 kg of BHUSA should be added to a
the rammed surface at the end of each lift.
cubic metre of mud. Bitumen should be around
3.5 Fixing Frames 40 kg/m3 of soil used.

Frames for door and windows shall be fixed by iron 4.2 Surfaces to be plastered shall be moistened before
holdfasts inserted in the wall before-hand. application of mud plaster.

I-.
/1O-f
4.17A Section of Plank Used for
Making Vertical Joint
1LO

‘i
c--t-
120

4.176 Plan of Vertical Tongue and

Groove Joint

Alldimensions
in millimetres.
FIG. 4.17 TYPICALDETAILSOF~CONSTRUCTION
JOINTIN IN-SITUSOIL
CEMENTWALLS OF 300 mmTHICKNESS

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SP 62 (S & T) : 1997

PART 3 STONEWORK

1 GENERAL flaws, sandholes, ve,ins, patches of soft or loose

1.1 Introduction materials, etc. The stone should not contain crypt0
crystalline silica or chert, mica or any other deleterious
Use of stone masonry work is~practised from earlier
materials, like iron oxide, organic impurities, etc.
days and natural building stone is available extensively
Petrog’raphic examination of stones may bedone as per
in many parts of the country. The types of stone
IS 1123 : 1975 which helps in identifying natural
masonry construction depends on local factors, such
building stones.
as, physical characteristics of the stone, climatic con-
ditions, workmanship, etc. Certain broad principles of 2.3 Sizes
laying, bonding, breaking of joints and finish should Normally stones used in stone masonry work shall be
be complied with in order that masonry develops as described below:
adequate strength and presents a neat appearance.
1.2 Types of Stones Length Breadth Height
The following Indian Standards on different types of mm mm mm
stones used for stone masonry: a) Ashlar masonry 597 297 297
based on 3 mm joint 697 347 347
a) IS 1127 : 1970 for Natural building stones.
thickness 1 797 397 397
b) IS 1128 : 1974 for Lime stone (slab and tiles).
c) IS 33 16 : I974 for Structural granite. b)Block in course 394 194 194
d) IS I 130 : 1969 for-Marble (blocks, slabs, tiles). based on 6 mm joint 494 244 244
e) IS 3622 : 1977 for Sandstone (slabs and tiles). thickness 1
f) IS 12440 : 1988 for Precast concrete stone c) Squared rubble, Length - 90, 140 mm in
masonry blocks. based on 10 mm increments of 50 mm
g) IS 3620 : 1979 for Laterite stone brick. joint thic-kness Breadth - 90, 140,290 mm
in increments of 50 mm
2 PROPERTIES OF STONES
d)Random rubble May be any shape and size
2.1 Strength but not less than 150 mm in
The strength of building stones shall be adequate to any direction
carry the loads imposed. For ashlar and coursed rubble Dimension of other natural stones for sills, lintels,
masonry, the strength shall be worked as in IS 1905 : arches, domes,coping stones andother stones, such as,
1987, taking into account appropriate crushing lime stone, structural granite, laterite, marble, etc, are
strength of stones as given in Table 4.6. summarized in SP 21 : 1983.

Table 4.6 Crushing Strength of Stones Other ~physical properties like water absorption,
(Clause 2.1) transverse strength, durability, etc, as applicable to
different types of stones are also covered in SP 21 :
Type of Stone Minimum Crushing Strength
1983. If not covered by SP 2 1 : 1983 for other stones,
N/mm2 (kgf/cm’)
Granite 100 (1 000) reference may be made to the appropriate Indian
Basalt 40 (400) Standards.
Limestone 20 (200)
(except very soft stone) 3 MORTARS
Sandstone 30 (300) Mortars shall conform to IS 2250 : 198 1.
Marble so (500)
Laterite 3 (30) 4 SELECTION OF STONE
4.1 In selection of stone, the situation where it is to be
2.2 Durability
used shall be considered. Table 4.7 gives the recom-
Stone shall be free from defects like cavities, cracks, mended use of common types of stones.

Table 4.7 Recommended Use of Common Types of Stones

(Clause 4.1)
Type of Stone Use
I. Dense stone like granite, gneiss a) Masonry work submerged in water
b) Masonry below plivth level or in contact with soil
2. Granite. quart&e Masonry work exposed to smoke or chemical fumes
3. Sandstone Fire resistant masonry
4. Soft stone like marble, sandstone For carved ornamental work, arches, veneers, etc

76

.
 SP 62 (S & T) : 1997

5 PREPARATORY WORK Scaffolding shal! conform to IS 3696 (Part 1) : 1987.

5.1 Dressing of Stone 5.3 Handling

The dressing of stones shall be as specified for in- The use of grips in the tops of stones is preferable to
dividual types of masonry work; it shall also conform any method of holding the stone at the end because it
to the general requirements of dressing of stone enables the stone to be set in final position before the
covered in IS 1129 : 1972. tackle is released. Due care shall be taken to protect
the work done against any danger during handling.
5.2 Scaffolding
Various methods of handling for lifting of stone is
52.1 Single scaffolding, except as in 52.2, having shown in Fig. 4.18.
one set of vertical supports shall be used and the other
end of the horizontal scaffolding member shall rest in 5.4 Tools
a hole provided in the masnry. The holes shall not be
left in pillars under I m in height or immediately near Tools, such as, plumb bob and line, straight edges,
the skew backs and arches. Planks should be laid over masons square, spirit level and trowel as described in
the horizontal pieces. The holes in masonry shall be IS 1630 : 1984 and various types of mason’s hammer
made good before plastering. and chisels as in IS 1129 : 1972 shall be used.

5.5 Wetting
Double scaffolding having two vertical supports shall
be provided for pillars less than 1 m wide or for a Stones shall be sufficiently wetted before laying to
building having more than two storeys. prevent absorption of water from mortar.

rSHACKLE

TRINGS

RECTANGULAR
STEEL PIECE

CHAIN LEWIS
THREE-LEGGED LEWIS
WEDGE - SHAPED
CENTRAL PIECE
r WEDGE -SHAPED
STEEL PIECE

LEWI,S
MODlFlED THREE -
LEGGED LEWIS

FIG. 4.18 TYPICAL DETAILSOF LIFTINGAPPLIANCESOF STONES

77
SP 62 (S & T) : 1997

6 TYPES OF MASONRY 8 SQUARED RUBBLE

6.1 The following types of masonry are dealt with: 8.1 Uncoursed (see Fig. 4.21)
a) Random rubble masonry - Uncoursed and In this type, the stones are roughly squared as risers or
brought to courses; jumpers and stretches with varying heights, and are
b) Squared rubble; laid uncoursed.
c) Ashlar, plain;
d) Ashlar, punched; 8.2 Brought to Courses (see Fig. 4.22)
e) Special ashlar; and
1) Stone veneering. The stones are similar to those used for uncoursed
rubble but the worked is levelled up to courses of
7 RANDOM RUBBLE varying depth from 300 mm to 900 mm according to
7.1 Uncoursed (see Fig. 4.19) the the type of stone used. ..

This type of masonry is constructed of stones as they 8.3 Coursed (First and Second Sort) (see Fig. 4.23)
come from the quarry. Coursed masonry is built in courses which may vary
in height from 100 mm to 300 mm but the stones in
Blocks of all shapes and sizes are selected more or less any one course are roughly squared to the same height.
at random, and placed in position to obtain a good The faces of the stones may be pitched to give a
bond while restricting the cutting of stones to the rockface appearance or may be dressed smooth. A
removal of inconvenient corners with a scabbling or variant of this type of masonry may be formed by the
spalling hammer. introduction of pinnings, that is, similar stones in the
7.2 Brought to Courses (see Fig. 4.20) same courses, at intervals, producing a chequered
effect.
This masonry is similar to uncoursed random rubble
except that the work is roughly levelled up to courses 9 POLYGONAL RUBBLE MATCHING (see
at intervals varying from 300 mm to 900 mm, accord- Fig. 4.24)
ing to the locality and type of stone used.
9.1 Stone with no pronounced stratification is roughly
The course heights usually correspond with the heights hammer pitched into irregular shapes, and bedded to
of quoin and joint stones. show face joints running irregularly in all directions.

SECTION XX

FIG.4.19 RANDOMRUBBLEUNCOURSEDMASONRY

SECTION XX

FIG.4.20 RANDOMRUBBLEMASONRYBROUGHTTOCOURSES

78

* ..,I -- ,I.) ,_ ti *,. . ..., . /,... ^,,S

4
 SP 62 (S & T) : 1997

SECTION XX

FIG. 4.2 1 SQUAREDRUBBLEUNCOURSEDMASONRY

SECTION XX

FIG. 4.22 SQUAREDRUBBLEMASONRYBROUGHTTO COURSES

[-COPING

-BOND
STONE

I-X SECTION XX

FIG. 4.23 SQUAREDRUBBLE COURSEDMASONRY

10 PLAIN ASHLAR
10.1 Every stone shall be cut to required size and
shape; and chisel dressed on all beds and joints so as
to be free from bushing.

Dressing of exposed face of stone shall be done to suit

the type of ashlar masonry to be adopted, namely, plain
ashlar, sunk or moulded ashlar, punched or tooled
ashlar, rock-faced ashlar or block-in-course ashlar.
Bond stones (see 12.1) shall be provided between
1.5 m to I .8 m apart in every course. Heights of stones
shall be such that masonry has regular courses. In
width it shall be at least twice the height.
11 LAYING OF STONES - GENERAL
REQUIREMENTS
FIG. 4.24 POLYGONALRUBBLE WALLING 11.1 In all types of masonry the particulars given
below shall be compiled with.

79
SP 62 (S & T) : 1997

11.2 The stone should be laid so that the pressure is 11.5 Where there is break in the masonry work, the
always perpendicular to the bed. The courses shall be masonry shall be raked in sufficiently long steps for
built perpendicular to the pressure’ which the masonry facilitating jointing of old and new work. The stepping
will bear. In case of battered walls, the base stone and of the raking shall not be more than 45°C to the
the plane courses shall be at right angles to the batter. horizontal. Walls and pillars shall be carried up truly
plumb as to the specified batter.
11.3 In the case of coursed rubble masonry, if the
heights of the courses vary, the largest stone shall be 11.6 Fixing of Frames
placed in the lowest course; the thickness of courses
shall also decrease gradually to the top. Vertical joints Where door or window frames fixed in the openings,
shall be staggered as far as possible. Bell shaped bond holdfasts may be used (see Fig. 4.25).
stones or headers shall not be used. All the necessary
chases for joggles, dowels and cramps should be 11.7 Bearing of Floors, Roofs and Joists
ft>rmed in the stones before hand.
Corbels or brackets shall be provided for resting of
11.4 Sufficient transverse bonds should be provided joists. Beams carrying heavy loads shall be supported
by the use of bond stone extended from the front to~the
by templates of concrete or stone.
back of the wall and from outside wall to the interior
of thick wall and in the latter case bond stones shall be 11.8 Jointing and Pointing
overlap each other in their arrangement.
All joints shall be full of mortar. Pointing may be
At all angular junctions, the stones at each alternate
avoided. If unavoidable, raking is done and types of
course shall be well bonded into the respective courses
pointing shall be as per Fig. 4.10 for brickwork.
of adjacent wall.

DOOR FRAME

NUT AND

HOLDFAST--/

CONCRETE BLOCK

F1~4.25 POSITIONOFHOLDFASTSTODOORFRAME

80
 SP 62 (S & T) : 1997

The use of chips shall be restricted to filling of

Ail green work shall be protected suitably from rain, the interstices between adjacent stones in
hearting and shall not exceed 20 percent of the
atid dust, etc; All faces shall be kept moist for seven
days, The top of the masonry shall be flooded with masonry.
water: When masonry is interrupted, it shall be raked
12 LAYING OF DIFFERENT TYPES OF to 45OC for continuing later on.
fl Bond Stones - Bond stones shall be provided
MABONWY
in walls up to 600 mm thick; in case of thicker
i&i General
walls two or more bond stones shall be
C&t&al details of laying shalt be as per 11. provided overlapping each other by at least
1%9 ib-mdam Rubble (Unraursed aad Brought to 150 mm, in a line from face to back. Bond
Cmme) stones or through stones run right through the
thickness of masonry.
Normally stones shall be small enough to be
lifted by hand. The length of stone shall not In case of highly absorbent bond stones, such
exceed three times the height; and breadth on as, porous lime stone, sand stone, etc, the bond
the bnae shdli not exceed three fourth the thick- stone should extend only about two-third into
ness of waif not lew than 150 mm. The height the wall. Through stones in such cases may
of stone fray be tip to 300 mm. give rise to dampness. Therefore for all such
Stone shall be hammer dressed on the face, thickwalls, a set of two or more bond stones
sides and beds to enable it to Abe in close overlapping each other by at least 150 mm shall
proximity with the neighbouring stone. The be provided.
bushing In the face shall not project more than When bond stones of suitable length are not
40 mm ofl the exposed face, and 10 mm on a available, cement concrete blocks of 1 : 3 : 6
face to be plastered, cement, sand, 20 mm graded aggregate mix
Bond shall be obtained by fitting closely the shall be used.
adjacent stones and by using a bond stone. At least one~bond stone for every 0.5 rn’~of the
Face stones shall extend beyond the bond well
wall surface shall be provided. All the bond
into the backing, These shall be arranged to stones shall be suitably marked.
break joints and to avoid long vertical lines as Quoins shall be selected stones neatly dressed
much as possible.
g)
with hammer or chisel to form the required
The hearting or interior of the wall shall consist angle and laid as stretcher and headeralter-
of rubble stones which may be of any shape,
nately.
but shall not pass through a circular ring of
150 mm inner diameter. Thickness of stone in
h) Face joints, shall not be more than 20 mm
thick. When pointing or plastering is not re-
any direction shall not be lesser than 100 mm. quired to be done, the joints shall be struck
Every stone shall be carefully fitted to the
flush and finished at the time of laying. Other-
adjacent stone so as to form a neat and close wise, the joints shall be raked back to a mini-
joint. They shall be carefully laid, hammered
mum depth of 20 mm by raking tool while the
down with a wooden mallet into proper posi- mortar is green.
tion and solidly bedded in mortar; chips and
spawls of stone may be used wherever neces- 12.3 Coursed Rubble Masonry - First Sort
sary, to avoid thick mortar joints. It shall be
ensured that there are no hollow spaces left a) Faces shall be hammer dressed on all beds, so
anywhere in the masonry, as to give them approximately rectangular
The hearting shall be laid nearly level with block shape. These shall be squared on all
facing and backing, except that about 1 m joints and beds. The bed joints shall be rough
intervals, vertical ‘plumb’ projecting about chisel dressed for at least 80 mm back from the
150 mm to 200 mm shall be firmly embedded face and for at least 40 mm for side joints so
to form a bond between successive courses. that no portion of the dressed surface is more
than 6 mm away from a straight edge placed on
Stones may be brought to level courses at it. The bushing on the face shall not project
plinth, window sill and roof level. Levelling
more than 40 mm as an exposed face and
for this purpose shall be done with a mix of one
10 mm on face to be plastered. The hammer
part of mortar and two parts of graded
dressed stone shall have a rough tooling for a
aggregate 20 mm size.
minimum width of 25 mm along the edges of
Chips shall not be used ~below the heartening the face of the stone, when stone work is
to bring these up to the level of face stones. exposed.

81
SP 62 (S & T) : 1997

b) All courses shall be laid truly horizontal and all two stones shall not be used in the height of a
vertical joints shall be truly vertical. The height course.
of each course shall be not less than 150 mm c) Face joints shall not be more than 20 mm thick.
and not more than 300 mm. When plastering or pointing is not required to
Face stones shall be laid alternate headers and be done, the joints shall be struck flush and
stretchers. No pinning shall be allowed on the finished at the time of laying. Otherwise joints
face. No face stone shall be less in breadth than shall be raked to a minimum depth of 20 mm
its height and at least one-third of the stones by raking tool during the progress of work,
shall tail into the work not less than twice their when the mortar is green.
height.
12.3 Plain Ashlar Masonry (see %ig. 4.26)
c>Hearting or the interior filling of the wall shall
consist of stones carefully laid on their proper a) Every stone shall be cut to the required size and
beds in mortar. Chips and spawls of stone may shape, so as to be free from any waviness and
be used where necessary to avoid thick bed to give truly vertical and horizontal joints.
joints of mortar and at the same time ensuring In exposed masonry, the faces are to remain
that no hollow spaces are left anywhere in the exposed in the final position and the adjoining
masonry. The chips shall not be used below faces to a depth of 6 mm shall be fine chisel
the hearting stone to bring these up to the level dressed so that when checked with a straight
of face stones. The use of chips shall be edge, no point varies from it by more than
restricted to the filling of the interstices be- 1 mm. The top and bottom faces, that are to
tween the adjacent stones in hearting and these form bed joints, shall be chisel dressed so that
shall not exceed 10 percent of quantity of stone the variation from a 60 cm straight edge at no
masonry. point exceeds 3 mm. Faces, which are to form
The masonry shall be carried on continuously; the vertical joints, should be chisel dressed so
but when breaks are unavoidable, the joints that variation at any point with straight edge
shall be raked by at an angle not steeper than does not exceed 6 mm. Any vertical face
45°C. Toothing shall not be allowed. which hasto come against backing of masonry
shall be dressed such that variation from the
4 Bond stones shall be the same as in 12.1; bond straight edge does not exceed 10 mm.
stones shall be inserted 1.5 m to 1.8 m apart, in
every course. All angles and edges of masonry that are to be
exposed in the tinal position shall be true,
e) Quoins shall be of the same height as the
square and free from chippings.
course in which they occur. These shall be at
least 4.50 mm long and shall be laid stretchers A sample of dressed stone shall be prepared for
and headers alternately. These shall be laid approval of the Authority.
square on the beds, which shall be roughly b) in case of ashlar work wihout backing of brick
chisel dressed to a depth of at least 100 mm. In work or coursed rubble masonry, face stone
case ~of exposed work, these stones have a shall be laid headers and stretchers alternately
minimum of 25 mm wide chisel drafts at four unless otherwise specified, the headers shall be
edges; all the edges shall be in the same plane. arranged to come as nearly as possible in the
f-1 Face joints shall not be more than 10 mm thick. middle of stretchers above and below. Stone
When plastering or pointing is not required to shall be laid out in regular courses of not less
be done, the joints shall be struck flush and than 150 mm in height and all courses shall be
finished at the time of laying. Otherwise the of the same height unless otherwise specified.
joints shall be raked to a minimum depth of For ashlar work with backing of brick work or
20 mm by raking tool during work when the coursed rubble masonry,. face stone shall be
mortar is still green. laid in alternate courses of headers and
stretchers, unless otherwise directed. Face
12.4 Coursed Rubble Masonry - Second Sort stone and bond stone courses shall break joint
on the face for at least half the height of the
a ) Dressing shall be as in 11 except but no portion
standard course and the bond be carefully
of dressed surface shall exceed 10 mm from a
maintained through out. All the connected
straight edge placed on it.
masonry in the structure shall be carried up
b) Laying shall be as in 11 except that the use of nearly at the uniform level through out; but
chips shall not exceed 15 percent of the quan- where breaks are unavoidable, the joint shall
tity of stone masonry. The stone in each course be made in good long steps so as to prevent
need not be of the same height, but more than cracks developing between new and old work.

82
 SP 62 (S & T) : 1997

When necessary, jib crane or other mechanical or bushing shall project more than 75 mm from plane
appliances shall be used to hoist heavy pieces of drafts.
of stones, to place these in correct position;
care shall be taken to see that corners of stones 12.8 Ashlar Rough Tooled (see Fig. 4.29)
are not damaged, Stone shall be covered with
gunny bag hefore a chain or rope for tying is a>The dressing of the stone shall be similar to
passed over it and shall be handled carefully. plain ashlar as in 12.4 except that the face
No piece which has been damaged shall be exposed to view shall have a fine chisel draft
used in the work. 25 mm wide round the edges and shall be rough
tooled between the draft such that the dressed
Cl joint8 shall Hd be more than 5 mm thick. Face
surface shall not deviate more than 3 mm from
joints shall be tmiform throughout and a
the straight edge placed over it.
unifotm recesb of 20 mm depth from face shall
be ieft with the help of a st%elplate during the b) Other requirements shall be as in 12.5.
progress of Work.
12.9 Ashlar Chamfered (see Fig. 4.30)
d) All exposed joints shall be pointed with mortar
as specified, The~pointing when finished shall
be sunk from atone face by 5 mm or as a>The dressing shall be as in 12.5 except that the
levelled off to 45°C for a depth of about 25 mm
specified, The depth of mortar in pointing
or more as specified.
work shall fiat be less than 15 mm,
b) Other requirements shall be as per 12.5.
126 Ashiar &it& 6t l%ulded (see Fig. 4.27)
12.10 Ashlar Block in Course (see Fig. 4.31)
The faces shall then be gauged, cut, grooved, rebated,
sunk d plain maulded as required. For this purpose a a) The stones are dressed all squared and laid to
full site layout of the mouiding_shtlll be prepared on fine joints; the faces being usually hammer
platforms for which sheet tempiates shall be cut and dressed. The stones selected may be larger size
the stone dressed to the templates to a uniform and fine than plain ashlar.
finish. The dressed surface shd not be mare than
3 mm from the straight edge placed on it. b) The other requirements are as in 12.5; except
that the courses vary between 200-250 mm in
All visible angles and edges shall be true and free from thickness. This type of masonry is therefore
clippings. The joints, 6 mm from the face shall also be superior to coursed rubble masonry.
fine tooled so that a straight edge placed on it is in
contact with-every point. It shall be finest surface that 12.11 Ashlar Masonry for Special Works
can be given to a sfdHIwith the chisel and without
rubbing. Other requirements shall be as in 12.5 a) Special works include arch dome, circular
moulded works, moulded and carved columns,
12.7 Ashiar Rack Faced (see Pig, 4.28) etc.

Dressing shall be as per 12,s; except that the exposed b) The dressing of the stone shall be as in 12.5
except giving the appropriate shape to the
faces of the stone betweeh the drafts shall be left rough
stones as required in each specialized work.
as the stone corners frotn fhe quarry; but no rock face

FIG.4.26 PLAINASHLAR

83
SP 62 (S & T) : 1997

12.12 Laterite Stone Masonry

a) Lateritestone should be compact in texture. It

may be mottled with streaks of brown, red and
yellow colours. It should not contain white
clay or lithomarge or an appreciable number
of deep sinuosities. Blocks should be obtained
from a good ferrugenous variety of laterite
which hardens on exposure after it is quarried.
b) Stones should be dressed immediately after
FIG. 4.27 SUNKOR MOULDED quarrying into regular rectangular blocks, so
that all faces are free from waviness and edges
are straight and square. Blocks may be cut to
size either manually or by machine; for good
quality work machine cut blocks may be used.
Stone blocks after dressing shall be exposed to
atmosphere for a period of 3 months before use
in masonry. The stone, on exposure changes its
nature and improves in compreLive strength.
c) Blocks are laid in masonry in regular horizon-
tal courses, breaking bond of vertical joints in
every course to the extent of half the height of
blocks. When the thickness of a masonry ele-
ment is more than the breadth, these should be
laid as headers and stretchers as in English
Bond.
d) Joint thickness shall not be more than 10 mm.
FIG. 4.28 ROCKOR QUARRYFACED
Faces may be plastered, pointed or finished
flush. Joints should be raked to a depth of
15 mm for pointing, while the mortar is green.
e) Other requirements should be as in 12.5 as
applicable.

12.13 Stone Veneering

a) Lime stone and sand stone -Dressing shall be

as per 12.5; except that the top, bottom and
vertical sides which are to form joints shall be
chisel dressed so that variation from a straight-
edge at no point exceeds 5 mm. Dressing at the
back should not be done so as to~ensure good
grip work for the backing. All the angles and
edges that are to remain exposed in final posi-
tion should be from-chippings.
b) Marble slabs - Marble slabs should be cut to
the required size and shape and chisel dressed
FIG. 4.29 ROUGHTOOLEDOR PUNCHED on all beds and joints so as to be free from any
waviness and to give truly vertical and
horizontal, radial and circular joints as re-
quired. The exposed faces and joints 12 mm
from the face should be fine tooled such that
straight edge laid along the face of the slab is
in contact, with every point on it. The~surfaces
shall then be rubbed smooth. Beyond the
depth of 12 mm from the face, the joints should
be dressed with a slight spray so that joints are
V-shaped, being thin at face and wide at the
FIG. 4.30 CHAMFERED back. Back surface in contact with the backing
shall not be dressed.

84
 SP 62 (S & T) : 1997

SECTION XX

FIG. 4.31 BLOCK-INCOURSE ASHLAR MASONRY

c) Slabs should be anchored to be backing by supports shall be at vertical intervals not more
means of cramps (of bronze, gun metal or other than 3;5 m apart and also over the head of all
non-corradible metal). Cramps may be of openings. Such supports shall also be provided
25 mm x 6 mm and 30 mm long; they may be when there is a transition from thin facings to
provided as shown in Fig. 4.32. The cramps thick facings above.
shall be spaced not more than 600 mm apart. Alternatively, cramps may be used to hold
Alternatively the slab may be secured to the units position. The pins, cramps and dowels
backing by means of stone dowels 100 mm x shall be laid in cement mortar 1 : 2. The types
50 mm x 25 mm as per shape indicated in of cramps are shown in Fig. 4.35.
Fig. 4.33; the adjoining stone secured to each 4 As far as possible the backing shall be carried
other by means of gun metal cramps or copper out simultaneously with the face work. In case
pins of specified size. Cramps may be attached of reinforced cement concrete backing, the
to its sides and/or top and bottom (see Fig. lining shall be secured after the concrete has
4.34). The actual number of cramps and their been cured. The cramps shall be laid in posi-
sections shall however be as per design to carry tion in concrete while laying.
the loads [see IS 4101(Part 1) : 19671. e> All joints shall be full of mortar specified.
When cramps are used to hold units in position Special care shall be taken to see that the
only, the facings shall be provided with a con- grounding for veneer work is full of mortar.
tinuous support on which the stones rest, as the The thickness of joints shall be as small as
support being in the form of a projection from possible and not more than 5 mm.
or recess into the concrete slab as beam. These

85
SP 62 (S & T) : 1997

I-
L

tP T0
LGUN METAL CRAMP

FEXPOSED FACES AND

L FACE- JOINTS

SECTIONAL ELEVATION
MORTAR
AT PQ / .

I
SECllONAL ‘ELEVAlION ’

FULL SIZE DETAIL ‘A’ /-“‘ORTAR

/@J 6,75 mm
LONG COPPER
PIN

I
SECTIONAL PLAN
FULL SIZE DETAIL A

FIG. 4.32 TYPICALDETAILSOFFIXINGSTONEVENEERWORK FACINGUSINGGUN METAL

CRAMPSANDCOPPERPINS

86
 SP 62 (S & T) : 1997

GUN METAL CRAMP

STONE VENEER

SECTIONAL PLAN
I

u FAC E JOINTS L GUN METAL CRAMP

SECTIONAL ELEVATION AT PQ

SECTIONAL ELEVATION
(FULL SIZE DETAILS AT’A’)

N METAL CRAMP

SECTIONAL PLAN
(FULL SIZE DETAILS AT ‘A’)-

FIG. 4.33 TYPICAL DETAILSOF FIXING STONEVENEER WORK USING STONEDOWELS AND
GUN METAL CRAMPS

87
SP 62 (S & T) : 1997

BRICK WORK BACKING

VENEERING -.__~.A.. “”

UT GUN METAL CRAMP

FIG. 4.34 TYPICAL DETAILSOF FIXING STONEFACING SHOWINGUSE OF GUN METAL CRAMPS
 SE’ 62 (S & T) : 1997

BACKING WALL WASHER

/ f

F
/ GUN-METAL CRAMP

FIG. 4.35 TYPESOFCRAMPSFORSTONEFACINGS

As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER 5

PLAIN AND REINFORCED CONCRETE

 CONTENTS

PART 1 COMMON REQUIREMENTS FOR 8.2 Centrally Mixed Concrete

PLAIN AND REINFORCED CEMENT 8.3 Truck Mixed Concrete
CONCRETE 9 NON-DESTRUCTIVE
TESTS
1 GENERAL ANNEX A PARTICLE SIZE ‘PINDSHAPE OF COARSE
2 MATERIALS AGGREGATE

2.1 Cement ANNEX B TEST FORSURFACEMOISTURE

2.2 Aggregates ANNEX C ACCELERATEDCURING FOR DETERMINA-
2.3 Water TIONOFCOMPRESSIVE
STRENGTHOFCONCRETE
2.4 Admixtures
2.5 Pozzolanas PART 2 REQUIREMENTS OF REINFORCED
2.4 Reinforcement CONCRETE

3 GRAD= OF CEMENTCONCRETE 1 GENERAL

3.1 General 2 FORMWORK
3.2 Design Mix Concrete
3.3 Nomfnal Mix Concrete 2.1 General
2.2 Materials of Formwork
4 PRODIKTIONAND.CONTROL
OFCONCRETE 2.3 Reinforcement
4.1 General PART 3 LIME AND LIME POZZOLANA
4.2 Batching MIXTURE CONCRETE
5 MIXING Section 1 Lime Concrete
5.1 General
1 GENERAL
5.2 Machine Mixing
5.3 Hand Mixing 2 MATERIALS
6 TRANSPORTING,
PLACING,COMPACTING
AND
2.1 Lime
CURING
2.2 Cement
6. I Transporting 2.3 Pozzolana
6.2 Placing 2.4 Coarse Aggregate
6.3 Compaction 2.5 Fine Aggregate
6.4 Construction Joints 2.6 Water
6.5 Curing
3 PROPERTIES
OFLIMECONCRETE
6.6 Supervision
3.1 Workability
UNDERSPECIALCONDITIONS
7 CONCRETING
3.2 Rate of Hardening and Setting Time
7.1 ~Workin Extreme Weather Conditions 3.3 Strength
7.2 Hot Weather Concreting
4 MIXING
7.3 Cold Weather Concreting
7.4 Under-Water Concreting 4.1 General
7.5 Concrete in Sea-Water 4.2 Hand Mixing
7.6 Concrete in Aggressive Soils and Water 4.3 Machine Mixing
8 READYMIXED CONCRETE 5 LAYING OF LIME CONCRETE
8.1 General 5.1 General
 5.2 In Foundations and Under Floors 2 MATERIALS
5.3 In Haunches of Arches 3 MIXING
Section 2 Lime Pozzolana Mixture 4 LAYING
Concrete

1 ~GENERAL

PART 4 SHOTCRETE

I GENERAL 7 APPLICATIONOF SHOTCRETE

2 MATERIALS 7.1 Surface Preparation

7.2 Formwork
3 SHOTCRETINGPROW% 7.3 Reinforcement
3.1 "I*LI~IU1
r-4...3rnl
7.4 _A!ign_mentContro!
3.2 Dry-Mix Process 7.5 Placing of Shotcrete
3.3 Wet-Mix Process 7.6 Rebound
7.7 Preparation for Succeeding Layers
4 PROPORTIESOF SHOTCRETE 7.8 Construction Joints
5 PRE-CONSTRUCTIONTESTING 7.9 Finishing
7. I 0 Suspension of Work
6 -h’bXlNG 7. I 1 Curing
6.1 Dry-Mix Process
6.2 Wet-Mix Process
As in the Original Standard, this Page is Intentionally Left Blank
 SP 62 (S & T) : 1997

CHAPTER 5

PLAIN AND REINFORCED CONCRETE

PART Ilhaan”r\LI L)l!cn, Ilc)el”e~l-rc CAl3 n, Alhl fiNIn “elrler\anen
run ruwv HIYY nciiw-wnbcu
4
I ~~VIIVIUIY n~bw~n,c~vici~ I3

CEMENT CONCRETE

1 GENERAL is placed. The resistance of concrete to weathering,

chemical attack, abrasion, frost and fire depends la;-
1.1 Concrete mix proportions shall be selected to en-
gely upon the quality and constituent materials. Sus-
sure that the workability of fresh concrete is suitable
t&the rnnA;t;nnr nfh.znrllinn .znA Y‘UtiU16,
nl,w.inn rnth~t oftar
ceptibility of corrosion of steel is governed by the
1”I CLlVU”LIU‘CI”.ILI
“I ,XL.,U”‘,6U,.U U”~CL,clL
U&l”&
cover provided and the preamibility of concrete.
completion it surrounds all reinforcements and com-
pletely fills the formwork. When concrete is har- One of the main characteristics influencing durability of
dened, it shall have the required strength, durability any concrete is its permeability. With strong and dense
andsurface finish. aggregates, a suitably low permeability is achieved; by
having a sufficiently low water-cement ratio, by ensur-
1.2 The strength of concrete depends on the mix
ing as thorough a compaction as possible and by achiev-
proportions of cement, aggregates, and water. Con-
ing sufficient hydration ofcement through proper curing
crete mixes can be designed and this is called ‘Design
methods. Therefore, for given aggregates, the cement
Mix’; otherwise ‘Nominal Mix’ is generally adopted.
content should be sufficient to provide adequate
Design mix concrete is preferred to nominal mix. If
workability with low water-cement ratio so that concrete
design mix cannot be used for any reason, nominal
can be completely compacted with the means available.
mixes may be used; however this is likely to increase
The cube-crushing strength alone is not a reliable guide
cement content than by design mix.
to the quality and durability of concrete; it must also
1.3 The durability of concrete depends on its resis- have ai adequate cement- content and a low water
tance to deterioration and the environment in which it cement ratio as indicated below:

Exposure Plain Concrete Reinforced Concrete

A c
F \ f \
Minimum Maximum Minimum Maximum
Cement Water Cement Water
Content Cement Ratio Content Cement Ratio
i
kg/m3 kg/m’
II\ I_\ IT)\ I”\ ,r\
1’1 (L,J (3) (4) (3)

Mild - For example, completely protected against 220 0.7 250 0.65
weather, or aggressive conditions, except for a brief
period of exposure to normal weather conditions during
construction
Moderate -For example, sheltered from heavy and 250 0.6 290 0.55
wind driven rain and against freezing, whilst saturated
with water; buried concrete in soil and concrete con-
tinuously under water
Severe - For example, exposed to sea water, alternate 310 0.5 360 0.45
wetting and drying and to freezing whilst wet, subject to
heavy condensation of water or corrosive fumes
NOTES

1 When the maximumwater-cementratio can be strictly controlled, the cement content may be reduced by 10 percent.

2 The minimum cement content is based on 20 mm aggregate. For 40 mm aggregate, it should be reduced by about IO percent:
for 12.5 mm aggregate, it should be increased by about IO percent.

2 MATERIALS b) IS 804 1 : 1990 Rapid hardening Portland

2.1 Cement cement;
c) IS 455 : 1989 Portland slag cement;
Any of the following cements may be used as required.
d) IS 1489 (Parts 1 & 2) : 199 1 Portland poz-
a) IS 269 : 1989 Ordinary Portland cement, 33 _-1...- .~~ ..~I
zolana cement;
grade;

95
SP 62 (S & T) : 1997

e) IS 8112 : 1989 43 ~Grade ordinary Portland ful effects may be used for secondary members; but
cement; such aggregates should not contain more than 1 per-
f) IS 8043 : 1991 Hydrophobic Portland cement; cent of sulphates and should not absorb more than
g) IS 269 : 1987 53 Grade ordinary Portland (0 percent of their own mass of water.
cement;
h) IS 12600 : 1989 Low heat Portland cement; 2.2.3 Heavy weight aggregates or light weight ag-
j) IS 6452 : 1989 High alumina cement and gregates such as bloated clay aggregates may also be
IS 6909 : 1991. Supersulphated cement may be used provided sufficient data on the properties of con-
..rPrl
u3cIu
fiml., ..n,-Ic.,-‘..,‘ao;nl n:..,wIm"tnnr.‘a"
"rrlJ "Ll"c.l qAA&lL Lll\r"IIIJLaIILb"a*
crete made with them is avai!ab!e.

2.1.1 Recommended Uses of These Cemertts 2.2,4 Fly ash conforrtting to IS 38 12 : 1981 may be
The type of cement selected shall be suitable for the used as part repiacement up to 20 percent of fine
intended use. Some guidelines are as below: aggregate. It shah be ensured that cement is thoroughly
intermixed with fly ash.
a) Ordinary portland cement may be used for
most of the works; it has a ‘28 days strength of 2.15 Aggregates sh0uid be free from deieterious
33 MPa (33 kg/cm2). materials, such as, iron pyrites, coal, mica, slate, clay,
alkali, soft fragments, sea shell8 and tither organic
b) Grade 43 ordinary portland cement can be used impurities. IS 383 : 1970 gives lithlts of such
in works where grade 33 is used and where the
deleterious impurities passing 75 mlcroti IS sieve.
spaces are longer.

c>For higher strength requirements of works or Aggregates containing reactive silica, such as, chert
for specialized works, such as, prestressed and chacendony shall not be used.
concrete work, higher grades of cement such
as 53 grade ordinary portland cement may be Soft lime stone, soft sand stone or other porous or weak
used. aggregates shall not be usedfor concrete in sea water.

4 Rapid hardening portland cement gains

Inadequate washing of aggregates leaves clay or dust
strength more rapidly at early ages, but has a
films over the surface of the aggregates; this prevents
strength comparable to ordinary portland ce-
adhesion of cement to aggregate and results in weak
ment. Therefore, it can be used where early
concrete.
strength is required.

e) Slag cement has a low heat of hydration and 2.2.6 The following tests in the field may be done
has better resistance to soils and water contain- based on IS 2386’(Parts 1 to 8) : 1963.
ing excessive amounts of sulphates as well as
a) Particle size and shape (see Annex A).
to acidic waters. Therefore it may be used for
b) Determination of surface moisture (see
marine works. However manufacturers’
Annex B).
recommendations should be followed.

f) Pozzolana cement produces less heaton hydra- 2.2.7 Grading and Sizes
tion and offers greater resistance to the attack
of agressive waters than ordinary portland ce- 2.2.7.1 Grading
ment. It is useful in marine structures and mass
concrete work. It does not develop strength in 4 Fine aggregate is defined as aggregate mainly
early ages. It can be used in works where passing 4.75 mm IS sieve and coarse aggregate
ordinary portland cement is used. as that mainiy retained on this sieve.
b) Fine aggregates are divided into four zones
S) The other special cements shall be used as per (see Chapter 4, Part 1 on mortars also). Most
manufacturers’ recommendations. of the natural sands found in the country have
gradings corresponding to one or the other of
2.2 Aggregates
these zones.
2.2.1 Coarse and fine aggregates obtained from Typical good sands fall in Zone II grading.
natural sources shall conform to IS 383 : 1970. The However, finer or coarser sand may be used
aggregates may be tested as per IS 2386 (Parts 1 to 8) : with suitable adjustments in the ratio of quan-
1963. tities of coarse to fine aggregates.
2.2.2 Other aggregates such as slag and crushed over- Very fine sands as included in Zone IV grading
burnt brick or tile, which may be found suitable with should not be used except when the concrete is
regard to strength, durability and freedom from harm- closely controlled by the use of design mixes.

96

/. .
 SP 62 (S & T) : 1997

With nominal mix concrete, it is not advisable Table 5.1 Graded Aggregate
to use Zone IV sand under any circumstance, (Clause 2.2.7. I)
and to avoid use of Zone I, if a lean concrete
IS Sieve Percentage Passing~for Normal Size of Aggregate
mix is desired. Designation A
I
c) Grading of coarse aggregate shall be controlled mm 40 mm 20 mm 16mm 12.5 mm
by obtaining, the aggregates in different sizes 80 100
and blending them in right proportions when 40 95-100 100
required, the different sizes being stacked in 20 30-70 95 100 100 100
separate stock piles. 16 - 90-100 -
Graded aggregate shall conform to the require- 12.5 - ‘XI-IO0

ments in Tables 5.1,5.2,5.3 and 5.4. IO IO-35 2.5-55 30-70 40-85

4.15 o-s o- IO O-10 O-IO
dj Aii-in-aggregates shaii conform to require- 2.36 - - -
ments in Table 5.5. If combined aggregates are
available they need not be separated into fine
and coarse aggregates; but necessary adjust- Table 5.2 Single Sized Aggregate (Ungraded)
ment may be made in grading by addition of (Clause 2.2.7. I)
single size aggregates.
IS Sieve Percentage Passing for Normal Size of Aggregate
2.2.7.2 Size Desig- h
\
nation f
a ) The nominal maximum size of coarse ag- mm 63 mm 40 mm 20 mm I6 mm 12.5 mm IO mm
gregate should be as large as possible within 80 100 - - -
limits specified but in no case greater than one- 63 85-100 100 - - - -

fourths of the minimum thickness of the mem- 40 O-30 85-100 100 -

bers, provided that the concrete can be placed 20 o-s O-20 85-100 100 - -

without difficulty to fill all corners of the form 16 - - - 8.5-100 100 -

12.5 - - - - 8%100 100
and to surround all reinforcement. For (light) o_5 ^ ^^ ^ ^^ ^ _ ,._ .^^
i0 0-j u-20 U-Xl u-4> KS- ItJO
reinforced concrete work, aggregates having a
4.15 - - o-s o-s O-IO O-20
nominal size of 20 mm are generally con-
2.36 - - - - - o-s
sidered satisfactory.
Plums above 160 mm and up to any reasonable
size may be used in plain concrete work up to Table 5.3 Making Single Sized to Graded
a maximum limit of 20 percent by volume of Aggregate
concrete when specifically permitted. The (Clause 2.2.7.1)
plums shall be distributed evenly and shall not
P,.-,.-_4
L51115111h,,....:..“,
I.“IIIIII~E Dmr,r
I ‘lxID,.F
“I cx”“lr.
6x”,,rx~&‘C~“.L
U.I,RLC
O.&C A,.“m”n+‘.‘c.
L”
be cioser than i60 mm from the surface.
Concrete Size of be Mixed to Get Graded Aggrepte
Mix Graded (by Volume)
b) For heavily reinforced concrete members, as in A
.
Aggregate r
the case of ribs of main beams, the nominal
Required SO mm 40 mm 20 mm 125 mm IO mm
maximum size of aggregate should usually be
1:6: 12 63 9 3 -
restricted to 5 mm less than the minimum clear
40 9 3 --
distance between the main bars or 5 mm less _ .^
1:5: 10 63 7.5 - 2.5
than the minimum cover to reinforcement
40 - 7.5 2.5
whichever is smaller.
I :4:8 63 6 - 2 --
Where reinforcement is widely spaced as in
40 6 2
solid slabs, limitations on the size of the ag-
l:3:6 63 4,s I.5 - -
gregate may not be so important and the 40 - 4.5 I.5 - -
nominal maximum size may sometimes be as 20 - 4.5 - 1,s
great or greater than the minimum cover. l:2:4 40 2.5 I - 0.5

c? Coarse and fine aggregates shall preferably be 20 - - 3 I

batched separately, specially for design mix 12.5 - 3 I

l:l.S:3 20 - - 2 I
concrete.
NOTE - Proportions indicated arc by volume. If single sized
d) The largest possible size, properly graded, aggregate specified is not available, the volume of single sized
should be used in order to reduce the water aggregates shall be varied with a view to obtain the graded
demand. For high compressive strengths of aggregate. ,
concrete, it is usually economical.

97
*ul._-. _ .._”

SP 62 (S & T) : 1997

Table 5.4 Grading of Fine Aggregates 2.3.1 In case of doubt regarding development of
(Clause 2.2.7.1) strength, the suitability of water for making concrete
shall be ascertained by compressive strength and initial
IS Sieve Percentage Passing for setting time tests as specified in 2.3.1.2 and 2.3.1.3.
Designation A
f I
Grading Grading Grading Grading 2.3.1.1 The sample of water taken shall represent the
Zone I Zone II Zone 111 Zone IV water proposed to be used for concreting, due account
10 mm 100 100 100 100 being paid to seasonal variation. The sample shall not
4.15 mm 90- 100 90- 100 90-100 90- IO0 receive any treatment before testing other than that
2.36 mm 60-95 75-100 85-100 95-100
envisaged in regular supply of water proposed for use
1.18 mm 30-70 55-90 75-100 90-100
in concrete. The sample shall be stored in a clean
600 micron 15-34 35-59 60-79 80-100
container previously rinsed out with similar water.
300 micron S-20 8-30 12-40 IS-50
I50 micron O-10 O-IO O-10 O-IS 2.3.1.2 The average 28 days compressive strength of
at least three 15 cm concrete cubes prepared with the
NOTE - For crushed stone sands, the possible limit on 150
micron IS sieve is increased to 20 percent. This does not affect water proposed to be used, shall not be less than 90
5 percent allowance permitted to other sieves. percent of the average strength of three similar con-
crete cubes prepared with distilled water. The cubes
shall be prepared, cured and tested as per IS 516 :
Table 5.5 All-in-Aggregate Grading 1959.
(Clause 2.2.7.1)
2.3J.3 The initial settinob time
. . . . . ., nf
-_ tpct
._“. hlnrk
“.“_.. .ma&
. . ..-- with
IS Sieve Percentage Passing for All-in-Aggregate of the appropriate cement and the water proposed to be
Designation used shall not differ by more than + 30 min from initial
r40
Size ‘ Size
setting time of control test block prepared with the
80 mm 100 - same cement and distilled water. The test blocks shall
40 mm 95-100 95-100 be prepared and tested in accordance with IS 4031
20 mm 45-75 95-100 (Part 1) : 1988.
4.75 mm 25-45 30-50
2.3.2 ThepH value of water shall generally be not less
600 micron 8-30 IO-35
150 micron O-6 O-6 than 6.
2.3.3 Sea Water
2.3 Water
Mixing and curing of concrete with sea water is. not
Water used for mixing and curing shall be clean and recommended because of presence of harmful salts in
free from injurious amountsofoils, acids, alkalis, salts, the sea water. Under unavoidable circumstances, sea
sugar, organic materials or other substances, that may water may be used for mixing or curing in plain con-
be deleterious to concrete or steel. Potable water is crete or such reinforced concrete constructions which
generally considered satisfactory for mixing concrete. are permanently under sea water.
The following concentrations, as a guide, represent the
maximum permissible values: 2.3.4 Water found satisfactory for mixing is also
suitable for curing of concrete. However, water
4 To neutralize 200 ml sample of water, using
phenolphthalein as an indicator; it should not should not produce any objectionable stain or unsight-
require more than 2 ml of 0.1 normal NaOH. The ly deposit on the concrete surface. The presence of
details of the test are as given in IS 3025 : 1964. tannic acid or iron compounds is objectionable.
bj To neutraiize ‘200 mi sampie of water, using 2.4 Admixtures
methyl orange as an indicator; it should not
Admixtures are added to the concrete mix before or
require more than 10 ml of 0.1 normal HCI.
during mixing, in order to modify one or more of the
Details of test are as given in IS 3025 ~: 1964.
properties of concrete. Use of admixtures should be
Permissible limits for solids, when tested in
correlated to the type of cement and aggregates to be
accordance with IS 3025 : 1964, shall be as
-:..__ L-1-.... used and to the conditions expected at the site.
g;lvtX, IJCIVW.
Qrganic 200 mg/l, Max Admixtures should be used only on the basis of
Inorganic 3 000 mg/l, Max approval by the Authority.
Sulphates (as S04) 500 mg/l, Max 2.4.1 Types of Admixtures
2 000 mg/l for plain
Chlorides (as Cl) concrete work and a>Accelerating admixtures- These are added to
1 000 mg/l for reinforced hasten the_rate of early strength development,
concrete work which would facilitate early removal of
Suspended matter 2 000 mg/l. Max formwork: or reduce the required period of

98
 SP 62 (S & T) : 1097

curing or concreting in cold weather or in 2.6 Reinforcement

emergency repairs.
Reinforcement shall be any of the following:
Common acceleraters are calcium chloride, a) Mild steel and medium tensile steel bars to
flourosilicates and triethanolamine; but IS 432 (Part 1) : 1982.
chloride content in concrete shall be carefully b) High strength deformed bars and wires to
checked [see 2.3 (c)l. IS 1786: 1985.
c) Hard drawn steel wire fabric to IS 1566 : 1982.
b) Retarding admixtures - These admixtures
tend to slow down the rate of setting of cement. d) Rolled steel made from structural steel to
They are useful in hot weather concreting; for IS 2062 : 1992.
avoiding cold joints in mass concrete works 2.6.1 Hard drawn steel wire fabrics are occasionally
and for special treatment of concrete surfaces. used for floor slabs, for secondary reinforcement in
Common retarders are starches, cellulose developing fire resistance and in some precast concrete
products, sugars and hydroxyl-carboxylic products like pipes.
acids and their salts.
2.6.2 All reinforcement shall be free from loose mill
Water-reducing or platicizing admixtures - scales, loose rust and coats of paints, oil, mud or other
These admixtures allow greater workability to coatings which may destroy or reduce bond.
be achieved for a given water-cement ratio; or
for the same workability reduces water con- However, some indications are available to show that
tent. When used in sufficient quantities, these rust firmly adhering to steel may not be harmful; and
admixtures function as-set-retarders. on the contrary it may increase bond with concrete.
Therefore, it may not be necessary in all cases for bars
The basic ingredients of water-reducing ad-
to be cleaned or wiped before using in concrete con-
mixture are either ligno-sulphonate or poly-
struction.
hydroxy compounds.
3 GRADES OF CEMENT CONCRETE
4 Air-entraining admixtures - These are used
to intentionally entrain a controlled quantity of 3.1 General
air in the concrete, without altering the setting Grades of cement concrete shall be as given in
or hardening of concrete significantly. Their Table 5.6
use improves durability, water tightness and
workability. Table 5.6 Grades of Cement Concrete
Commonly used air-entraining agents are (%/awes 3.1, 3.2and 3.3.1)
animal and vegetable oils and fats: natural
wood resins and their sodium salts; and alkali Grade Specified Characteristic
Designation Compressive Strength at
salts of sulphated and sulphonated organic
28 Days
compounds. I . 1
N/ITli-l12 (kg/cm*)

2.4.2 All admixtures should be used taking into M 10 IO 100

account manufacturer’s instructions. Use of two or M 15 15 IS0

more admixtures may be considered after ascertaining M 20 20 200

their compatibility. M 25 25 250

M 30 30 300
2.4.3 All admixtures shall be tested as per IS 9103 : M 35 35 3.50
1979. M 40 40 400

NOTES
2.5 Pozzolanas
1 Grades lower than M IS shall not be used in reinforced
Pozzalanas may be used in any of the following ways: concrete.
a) As an ingredient of cement, that is, portland 2 M 5 and M 7.5 grades of concrete may be used for leean
pozzalana cement; concrete bases and simple foundations for masonry walls.
b) As part replacement of ordinary portland
cement; 3.2 Design Mix Concrete
c) As fine aggregate; and
d) As an admixture. The mix design shall produce concrete having reduced
workability (consistency) and strength not less than
2.5.1 Fly ash conforming to IS 3812 : 1981 or burnt that of the appropriate values given in Table 5.6. The
clay pozzolana conforming to IS I344 : I98 1 may be procedure given in IS 10262 : 1982 for mix design
used as an admixture for concrete. may be followed. Reference may also be made to
SP 23 (S&T) : 1982.

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SP 62 (S & T) : 1997

Workability is used to cover a variety of characteristics those specified for the grade in the nominal mix of
such as cohesiveness, mobility, compactability, and concrete, it shall not be placed in a higher grade.
tinishability of concrete. IS 456 : 1978 stipulates that
3.3.3 Accelerated curing and testing is given in
workability of concrete can be controlled by direct
Annex C.
measurement of water content; and checking it at
frequent intervals by the method prescribed 4 PRODUCTION AND CONTROL OF
in IS I199 : 1959. CONCRETE

Three methods of test to assess workability are slump 4.1 General

test, compacting factor test and vee-bee test. Each of To avoid confusion and error in batching, practicable
them measures only a particular aspect of it. Out of consideration should be given to using the smallest
the three, slump test is most widely used. practicable number of different concrete mixes.
A competent person shall supervise all stages of
3.3 Nominal Mix Concrete
production of concrete. Preparation of test specimens
Nominal mix concrete may be used for concrete of and site test shall be properly supervised.
grades M 5, M 7.5, M 10, M 15 and M 20. The
4.2 Batching
proportions of materials used for concrete of grades
M.5. M7.5, M IO, M 15 and M20shallbeasin a) For guidance, in proportioning concrete, the
Table 5.7. quantity of both cement and aggregates should
be determined by mass [see ulso 4.2(f) for
3.3.1 The cement content of the mix specified in Table
volume batching].
5.6 for any nominal mix shall be proportionately in-
creased if the quantity of water in a mix has to be b) Water should be either measured by volume in
calibrated tanks or weighed.
increased to overcome the difficulties of placement
and compaction, so that the water-cement ratio as
c) Any solid admixture to be added, may be
measured by mass; liquid and paste admixtures
specified is not exceeded.
by volume or mass.
NOTE - In case of vibrated concrete, the limits specified may
4 Batching plant where used should conform to
suitably be reduced to avoid segregation.
IS 4925: 1968 for concrete batching and
3.3.2 If nominal mix concrete made in accordance mixing plant. All measuring equipment
with the proportion given for a particular grade does should be cleaned and be in a serviceablecon-
not yield the specified strength, such concrete shall be dition and their accuracy periodically checked.
classified as belonging to the appropriate lower grade. e) Grading of aggregate should be controlled by
However, if the strength results of test are higher than obtaining coarse aggregate in different sizes

Table 5.7 Proportions for Nominal Mix of Concrete

(Clause 3.3)

Grade of Total Quantity of Dry Aggregate Proportion of Fine Aggregate Quantity of Water per
Concrete by Mass per 50 kg of Cement to Coarse Aggregate 50 kg of Cement,
(as 9um of Fine and Coarse (by Mass) Max in Litres
Aggregates), in kg, MUX
MS 800 Generally 1:2. Subject to an 60
upper limit of 1:1.Sand a
lower limit of 1:2.5
M 7.S 625 -do- 4s
M 10 480 -do- 34
M 1.5 3.50 -do- 32
M 20 250 -do- 30

NOTES
1 The proportions of the fine to coarse aggregates should be adjusted from upper limit to tower limit progressively as the grading of
the fine aggregates becomes finer and the maximum size of coarse aggregate becomes larger. Graded coarse aggregate (see Table 5. I)
shall be used.

kjianznfe : For an average grading of fine aggregate (that is, Zone II of IS 383: 1970, Table 4). the proportions shall be I : I .S , I :2 and
I:25 for maximum size of aggregates 10 mm. 20 mm and 40 mm respectively.
2 This table envisages batching by weight. Volume batching when done the nominal mixes would roughly be 1:3:6, l:2:S and 1:0.5:3
for M IO, M IS and M 20 respectively.
3 For underwater concreting the quantity of coarse aggregate, either by volume or mass, shall not be less than 1.5 times nor more than
twice that of the fine aggregate.

100
 SP~62 (S & T) : 1997

and blending them in right proportions when materials and the mass is uniform in colour and con-
required; the different-sizes being stacked in sistency. If there is seggregation after unloading, the
separate stock ~piles. The material shall be concrete should be remixed.
stock piled preferably a day before use. 4 For guidance, mixing time may be 1; to 2 min;
The grading of coarse and fine aggregate shall for hydrophobic cement it may be taken as
be checked as frequently as possible, frequen- 23 to 3 min.
cy being decided by the Authority. b) In exceptional cases hand mixing may be done
f) In case uniformity of materials used for con- as approved by the Authority. Hand mixing
crete has been established over a period of may be done for work done in cases, such as,
time, the proportioning may be done by remote areas, break down of mechanical
volume batching, provided periodical checks mixer, or when quantity of work is small sub-
are made on mass/volume relationship of the ject to additional 10 percent extra cement.
material. When weigh batching is not prac- When hand mixing is permitted it shall be done
ticable, the quantities of fine and coarse on a water-tight platform and care shall be
aggregate (not cement) may be determined by taken to ensure that mixing is continued until
volume. If fine aggregate is moist and volume concrete is uniform in colour and consistency.
batching is adopted, allowance shall be made cl Stone aggregate shall be washed with water to
for bulking in accordance with IS 2386 remove dirt, dust or any other foreign matter.
(Part 3) : 1963. Brick aggregates shall be well soaked with
8) It is important to maintain water-cement ratio water for a minimum period of 2 h.
constant at its correct value. To this end, there- 5.2 Machine Mixing
fore determination of moisture content in both
The mixing drum shall be flushed clean with water.
coarse and fine aggregates frequently as pos-
Measured quantity of dry coarse aggregate shall be
sible is necessary. The amount of water added
first placed in the hopper. This shall be followed with
should be adjusted to compensate for any
placing of measured quantities of fine aggregate and
observed variation in moisture contents.
then cement. In case damp sand is used add half the
To allow for variation in mass of aggregate due to quantity of the coarse aggregate, then followed by
variation in moisture content, suitable adjustments in cement and sand, finally add the balance of coarse
masses of aggregates shall also be made. In the absence aggregate.
of exact data, in the case of nominal mixes only, the
The dry materials shall be mixed for at least four turns
amount of surface water may be estimated from the
of the drum, after which the correct quantity of water
values given in Table 5.8.
shall be added gradually while the drum is in motion
Table 5.8 Surface Water Carried by Aggregate to ensure even distribution of the dry materials.. The
(Clause 4.2) total quantity of the water shall be introduced before
25 percent of the mixing time has elapsed. The com-
Aggregate Approximate Quantity of plete content of the mixed concrete shall be removed
Surface Water
I from the drum before recharging.
Percent by Mass - II”,” ’
(1) (2) (3 When the mixer is idle for more than 20 min, the drum
Very wet sand 1.5 120 shall be flushed clean again.
Moderately wet sand 5.0 80 5.3 Hand Mixing
Moist sand 2.5 40
Hand mixing shall be done in a smooth, clean and
Moist gravel ‘) I .25 to 2.5 20-40
or crushed rock water-tight platform of suitable size in the following
‘) Coarser aggregate, less the water it will carry. manner:

a ) Measured quantity of sand shall be spread

h) No substitution of materials work or alterations evenly.
in the established proportions, except as per- b) Cement shall be dumped on the sand and dis-
mitted in 4.2 (f) and (g) shall be made without tributed evenly.
additional tests to show quality and strength of c) The sand and cement shall be intimately mixed
concrete. with spade, turning the mixture over and over
5 MIXING until it is of even colour throughout and free
from streaks.
5.1 General
d) The sand cement mixture shall be spread out
Concrete shall be mixed in a mechanical mixer con- and measured quantity of coarse aggregate
forming to IS 1791 : 1985. The mixing shall be shall be spread on top. Alternatively, the
continued until there is uniform distribution of measured quantity of coarse aggregate shall be

101
SP 62 (S & T) : 1997

spread out and the sand and cement mixture 6.2 Placing
shall be spread on its top.
This shall be mixed at least three times by The concrete shall be deposited as nearly practicable
shovel1 ing and turning over from centre to side, in its final position to avoid rehandling. Concrete shall
then back to centre. be placed and compacted before setting commences
A hollow shall be made in the middle of the and should not be subsequently disturbed. Methods of
mixed pile. placing should be such as to avoid segregation. Care
Three-fourths the quantity of the total quantity should be taken to avoid displacement of reinforce-
of water required shall be added while the ment or movement of formwork (see 2 of Part 2). The
material is turned in towards the centre with a layers of concrete shall be so placed that the bottom
spade. The remaining water shall be added by layer does not finally set before the top layer is placed.
a water can slowly turning the whole mixture 6.2.1 During cold weather, concreting shall not be
over and over until a uniform colour and con-
done when the temperature falls below 4S”C. The
sistency is obtained throughout the pile. concrete placed shall be protected against frost by
The slump as given in Table 5.9 shall be suitable covering. Concrete damaged by frost shall be
adopted for different kinds of works. removed and work redone. During hot weather,
The mixing platform shall be washed at the end precautions shall be taken to see that the temperature
of the day. of wet concrete does not exceed 38°C (see 7).

Table 5.9 Slump 6.3 Compaction

(Clause 5.3)
Concrete should be thoroughly compacted and fully
worked around the reinforcement, around embedded
Placing Slump, mm
Conditions
fixtures and into corners of the formwork.
A
cDegrce of Vnlues of ’
6.3.1 The use of mechanical vibrators to IS 2505 :
Workability Workability
1980, IS 2506 : 1985, IS 2514 : 1963 and IS 4656 :
(1) (2) (3 1968 for compacting concrete is recommended. Over
Concreting of Very low 2040 seconds, vee-hce time vibration or vibration of very wet mixes is harmful and
shallow sections 01
should be avoided; under vibration is harmful.
wiih vibration 0.75-0.80. compacting factor

Concreting of Low IO-S seconds. vee-bee time The vibrator should penetrate rapidly to the bottom of
lightly reinforced Or the layer and at least 15 cm into the preceding layer, if
sections with 0.X0-0.85. compacting factor there is any. It should be held (generally 5 to
vibration
15 s) until the compaction is considered adequate and
Concreting of Medium S-2 seconds, vee-bee time then withdrawn slowly at the rate of about 8 cm/s.
lightly reinforced Or

sections without 0.85-0.92. compacting factor Whenever vibration has to be applied externally, the
vibration, or heavily 01‘
design of formwork and the disposition of vibrators
reinforced section 25-75 mm, slump for 26 mm”
with vihrnlion aggregate
should receive special consideration to ensure efficient
compaction and to avoid surface blemishes.
Concreting of High Above 0.92, compacting factor
heavily reinforced 01
6.4 Construction Joints
sections without 75-125 mm, slump for 20 mm ‘I
vibration aggregate
Concreting shall be carried out continuously up to
” For smaller aggregare the values will he lower construction joints, the position and arrangement
of which shall be indicated by the designer (see
6 TRANSPORTING, PLACING, Chapter 13).
COMPACTING AND CURING
6.4.1 When work has to be resumed on a surface
6.1 Transporting
which has hardened, such surface shall be roughened.
Concrete shall be transported from the mixer to the It shall then be swept clean and thoroughly wetted. For
formwork as rapidly as possible which will prevent vertical joints, neat cement slurry shall be applied on
segregation of or loss of any of the ingredients and the surface before it is dry. For horizontal joints, the
maintaining the required workability. surface be covered with a layer of mortar about IO mm
During hot or cold weather, concrete shall be to 15 mm thick composed of cement and sand in the
transported in deep containers. Other suitable same ratio as the cement and sand in the concrete mix.
methods to reduce the loss of water by evaporation in This layer of cement slurry or mortar shall be freshly
hot weather and heat loss in cold weather may also be mixed and applied immediately before placing
adopted. concrete.

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SP 62 (S & T) : 1997

6.4.2 When the concrete has not fully hardened, all 7.2 Hot Weather Concreting
laitanceshallbe removed by scrubbing the wet surface The climatic factors affecting concrete in hot weather
with wire or bristle, care being taken to avoid dislodge- are high ambient temperature above 40°C and reduced
ment of particles of aggregate. The surface shall be relative humidity, the effects of which may be consid-
thoroughly wetted and all free water removed. The erably pronounced with increase in wind velocity. The
surface shall then be coated with neat cement slurry. effects of hot~weather are most critical during periods
On this surface, a layer of concrete-not exceeding of rising temperature, fall in relative humidity or both.
150 mm thick shall first be placed and shall be well They may occur at any time of the year in warm
rammed against old work, particular attention being tropical or arid climates and generally occur during
paid to corners and close spots; work thereafter shall summer season in other climates. Precautionary
proceed in the normal way. measures required on a calm humid day will be less
6.5 Curing strict than those required on a dry, windy day, even if
air temperatures are identical.
6.51 Moist Curing
Damage to concrete caused by hot weather can never
After the concrete has begun to harden, that is, 1 to
be fully alleviated since improvisations at site are
2 h after laying curing shall be started. Exposed sur- rarely successful; easily preventive measures may be
faces shall be kept continuously in a damp or wet applied with the emphasis on materials, advanced
condition by ponding or by covering with layer of planning and co-ordination of all phases of work.
sacks, canvas, hessian or similar materials and kept
constantly wet for at least seven days from the date of 7.2.1 @beets of Hot Weather on Concrete
placing of concrete. a) Accelerated setting - High temperature in-
creases the rate of setting of concrete. The
6.5.2 Membrane Curing
duration of time during which the concrete can
Approved curing compounds may also be used with be handled is reduced. Quick stiffening may
the approval of Authority. Such compounds may be necessiate considerable retempering by addi-
applied to all the surfaces of concrete as soon as tion of water. It may also result in cold joints.
possible after it has set [see SP 24 (S&T) : 19831. b) Reduction in strength - High temperature
results in increase of the quantity of mixing
6.53 Over foundation concrete, masonry work may
water to maintain the workability -with conse-
be started after 48 h of its laying, but the curing of
quent reduction in strength.
cement concrete shall be continued along with the
masonry work for a minimum period~of 7 days at least. cl Increased tendency to crack - Either before
or after hardening, plastic shrinkage may form
6.5.4 When concrete is used as a sub-grade for floor- in the partially hardened concrete due to rapid
ing, the flooring may be commenced before the curing evaporation of water. Cracks may be
period of sub-grade is over but the curing of sub-grade developed in hardened concrete either by in-
shall be continued along with the top layer of tlooring creasing drying shrinkage resulting from
for a minimum period of 7 days. greater mixing water used or by cooling of the
concrete from its elevated temperature.
6.6 Supervision
4 Rapid evaporation of water during curing
It is exceedingly difficult and costly to alter concrete period - It is difficult to retain moisture for
once placed. Hence, constant and strict supervision of hydration and maintain reasonably uniform
all items of the construction is necessary during the temperature conditions during the curing
progress of work, including the transporting and period.
mixing of concrete. Supervision is also of extreme e) Difficulty in control of air content in air-
importance to check the reinforcement and its placing entrained concrete - It is difficult to control
before being covered. air content in air-entrained concrete. This adds
to the difficulty of controlling workability. For
Before any important operation, such as concreting or
a given amount of air-entraining agent, hot
stripping of the formwork is started, adequate notice
concrete will entrain less air than concrete at
shall be given to the construction supervisor.
normal temperatures.
7 CONCRETING UNDER SPECIAL
Procedures to minimize these effects are given in 7.2.2
CONDITIONS
to 7.2.6.
7.1 Work in Extreme Weather Conditions 7.2.2 Temperature Control of Concrete Ingredients
During hot or cold weather the concreting should be The most direct approach to keep concrete tempera-
done as per IS 7861 (Part 1) : 1975 for hot westher and ture down is by controlling the temperature of its
IS 7861 (Part 2) : 198 1 for cold weather. ingredients. The contribution of each ingredient to the

103
SP 62 (S & T) : 1997

temperature of concrete is a function of the tempera- of mixing water. It must be ensured that the
ture, specific heat, and quantity used ofthat ingredient. ice melts by the time mixing is completed.
The aggregates and mixing water exert the most
c) Cement --Temperature has a direct effect on
pronounced effect on temperature of concrete. Thus,
the hydration of cement. Higher the tempera-
in hot weather all available means shall be used for
ture of concrete, higher the rate of hydration,
maintaining these materials at as low temperature as
the rate of stiffening and generally it results in
possible.
increased water demand; and therefore results
a) Aggregates - Any one of the procedures or a in reduced strength and plastic shrinkage.
combination of the procedures given below Temperature has a definite effect on setting
may be used for lowering the temperature of time depending on cement composition. How-
aggregates. ever, a change in temperature of cement,
1) Shading stock piles from direct rays of the produces significantly less change in the
sun. temperature of fresh concrete than the other
2) Sprinkling of the stock piles of coarse ingredients. Cements shall preferably not be
aggregate with water and keep them used at temperatures in excess of 77°C.
moist; this is effective when relative
7.2.3 Proportioning of Concrete Mix Materials and
humidity is low.
Mix Design
3) Successive layers of coarse aggregate
should be sprinkled with water as the stock The quantity of cement used in a mix affects the rate
pile is built up. of increase in temperature.
4) If cold water is available heavy spraying
a) Therefore cement content may be the least and
on coarse aggregate immediately before
cements with lower heat of hydration shall be
use may also be done to have a direct
preferred.
cooling action.
b) Admixtures which reduce water demand or
3 Coarse aggregates may be cooled by cir-
culating refrigerated air through pipes or retard setting may be used.
other suitable methods. 7.2.4 Temperature ef Concrete as Placed
b) Water - Mixing water has the greatest effect In hot weather, ingredients of concrete should be
on temperature of concrete, since it has a cooled to the extent necessary to maintain the tempera-
specific heat of about 4.5 to 5 times that of ture of concrete at the time of placing to below 38°C.
cement and aggregate. The temperature of Temperature of the concrete may be ascertained from
water is easier to control than that of other a sample of the mix or by calculations.
ingredients. Even though water used is small 7.2.5 Production and Delivery
in quantity compared to cement and aggregate, a>Temperature of aggregates, water and cement
the use of cold mixing water will bring about a shall be maintained at the lowest practical
moderate reduction in concrete placing levels so that the temperature of concrete is
temperatures. below 4O”C, at the time of placement.
For example, for a nominal mix concrete of b) Mixing time shall be held to the minimum
336 kg cement, 170 kg water and I 850 kg of which will ensure adequate quality and unifor-
aggregate per cubic metre of concrete, a change mity, because the concrete gets warmed up due
of 2°C in water temperature will bring a change to mixing, by the air and by the sun. The effect
of 0S”C in the temperature of concrete. of mixer surface exposed to the hot sun must
Efforts shall be made to obtain cold water, and be minimized by painting and keeping the
to keep it cold by protecting pipes, water mixer drum yellow or white and spraying it
storage tanks, etc. Tanks or trucks used for with cold water.
transporting water shall be insulated and/or c> Cement hydration, temperature, loss of
coloured and maintained white or yellow. workability and loss of entrained air, all these
Under certain circumstances, reduction in will increase with the passage of time after
water temperature may be most economically mixing. Therefore the period of time between
obtained by mechanical refrigeration or mixing and delivery shall be kept to a mini-
mixing with crushed ice. Use of ice as a part mum.
of mixing water is highly effective in control- Co-ordination of delivery of concrete with the
ling concrete temperature, since on melting rate of placement should be ensured.
alone, it takes up heat at the rate of 80 kcal/kg. 7.2.6 Placement, Protection and Curing
To take advantage of this, the ice should be a) Forms, reinforcement and sub-grade shall be
incorporated directly into the concrete as part sprinkled with cold water just prior to place-

104
 SP 62 (S & T) : 1997

nent of concrete; area around the work may be essential to keep concrete temperature above a mini-
tept cool. mum value before it isplaced in the formwork.
b) when temperature conditions are critical, con- 7.3.1 Effects of Cold Weather Concreting
(:rete placement may be restricted to evenings
3r night when temperatures are lower and a>Delayed setting - Development of concrete
:vaporation is less. strength is retarded at temperatures below 5°C
c> Speedy placement of concrete, with the help of compared to strength development at normal
adequate personnel is necessary. temperatures.
4 Finishing of flat surfaces shall be done promptly. The hardening period thus increases.
e) Concrete layers shall be thin enough and in b) Free&g of concrete at early uges - When
area small enough so that time interval be- concrete is exposed to freezing temperature,
tween consecutive placements is reduced; there is a risk of loss of strength and other
vibration should ensure complete union with qualities irreparably; permeability may in-
adjacent portions. crease and durability may be impaired.
f) tf, cold joints tend to form or if surfaces dry c> Freezing and thawing qf concrete - Quality
and set too rapidly, or if plastic shrinkage of concrete may also be impaired, if the con-
cracks tend to appear, the concrete shall be kept crete after final set is subjected to repeated
moist by means of fog sprays, wet burlap, freezing and thawing.
cotton mats, or other means. Fog sprays have 4 Stress due to temperature d@rntials - Large
been found to be particularly effective in temperature differentials within concrete may
preventing plastic shrinkage cracks when other promote cracking and harm durabilty; such
means have failed. differentials can occur when the insulation is
g) Concrete when delivered by truck or other- removed from the formwork.
wise, shall reach the forms at a temperature not e> Cold weather conditons, for assessing the
higher than 40°C. effect’s on concrete can be divided into three
h) When the concrete has attained some degree of categories as below:
hardening sufficient to withstand surface I) When temperature is below 5°C but does
damage, roughly 12 h after mixing, moist not fall below freezing point,
curing shall commence. 2) When frost occurs at night only and is not
Actual duration of curing will depend. on the severe, and
mix proportions, size of member, environment, 3) When there is a severe frost day and night.
etc; in any case it shall not be less than 10 days. Precautions to be taken in each case of (e) are
Continuous curing shall be arranged. given in Table 5.10.
j> Reliance should not be placed on forms for
protection during hot weather. All formwork Table 5.10 Precautionary Measures for
shall be kept completely and continuously Cold Weather Concreting
moist prior to and during removal of (Clause 7.3.1)
formwork. Condition Precautions to be Taken
k) Wind breakers shall be provided to protect new a) At low temperature 1) Keep formwork in position longer or
concrete work since wind causes more use rapid hardening cement
evaporation as compared to still-air; sometimes 2) Cover the top of the concrete with
insulating material
as high as 4 times depending on wind speed. 3) Insulate steel formwork
On hardened concrete and on flat surfaces in I) Make sure that the concrete is
particular, curing water shall not be much delivered to the point ofplacingat not
less then 5 “C
cooler than the concrete because of the pos-
b) Where there is All the precautions as in (a) plus:
sibilities of thermal stress and resultant crack- frost at night I) Insulate all formwork
ing. Attempt may be made to reduce rate of 2) Make sure that the concrete is not
drying by avoiding air circulation after curing. placed against frozen sub-grade or

n> Proper records should be maintained so that against reinforcement

covered with snow or ice
or forms

any changes that are needed may be done 3) Place concrete quickly and insulate
during construction. c) When there is Take all precautions at (a) and (b) plus:
frost day and night I) Heat the water and if necessary the
7.3 Coid Weather Concreting aggregate
2) Make sure that the concrete is
. The production of concrete in cold weather introduces delivered for placing at not less than
lO”C, or make sure that the concrete
special problems, such as, in setting and hardening of is delivered for placing at not less
concrete, damage to concrete in plastic state when than 5 “C, place quickly and provide
exposed to low temperature, etc. It is, therefore, continuous heating to concrete

105
SP 62 (S & T) : 1997

7.3.2 Temperature Control of Concrete Ingredients

The most direct approach to keeping concrete tempera-
ture up is by controlling temperature ofits ingredients.
The contribution of each ingredient to the temperature
of concrete is a function of specific heat and quantity
used for that ingredient. Aggregates and mixing water
have the most pronounced effect on temperature of
concrete.
a) Aggregates - Heating of aggregates shall be
such that frozen lumps, ice and snow are
eliminated and at the same time over-heating
is avoided. At no point shall the aggregate
temperature exceed 100°C.
The average temperature of aggregate for an
individual batch shall not exceed 65°C. The
heating of aggregates to higher temperatures is
rarely necessary if mixing water is at 60°C.
1) If the coarse aggregate is dry and free of
frost and ice lumps, adequate tempera-
tures of fresh concrete can be obtained
by increasing the temperature of sand
only, which will seldom have to be higher
than about 4O”C, if mixing water is at 60°C. 0 5 10 IS 20 25
2) Steam embedded in pipes is recom- lEMPERA?URE OF CONCRETE;C

mended for heating aggregates; but for

small jobs aggregates may be heated with
the help of steel drums embedded in heaps
of aggregate and filled with fire. When
steam pipes are used for heating ag-
gregates, the exposed surfaces of the ag-
gregates shall be covered with tarpaulins to
maintain uniform distribution of heat and to
prevent formation of frozen crusts.
b) Water - The required temperature of mixing
water to produce specified concrete is shown
in Fig. 5.1; uniform heating of water should be
WMPERAWRE OF CONCRElE.;C -
ensured. To avoid possibility of flash set when
either aggregate or water is heated to a Moisturecontentof aggregate:
Damp(4%in fine, 1%in coarse)-------
temperature in excess of 40°C, water and Wet(8%in fine, 2%in coarse)-------
aggregate shall be mixed together in a mixer Temperature of aggregated and contained moisture = 1°C
first in such a way that the high temperature of Temperature of cement = 5°C
one or other is reduced before cement is added.
FIG. 5.1 OF MIXING
REQUIREDTEMPERATURE
The heated water shall come into direct contact
WATERTO PRODUCEHEATEDCONCRETE
with aggregate first and not cement.
I) Water having temperature up to boiling 7.3.3 Proportioning of Concrete Mix Materials and
point may be used provided the aggregate Concrete Mix Design
is cold enough to reduce the temperature
of mixing water and aggregate appreci- 4 With the winter conditions prevailing in our
ably below 40°C. In fact this temperature country, concreting can be achieved mainly
shall not~normally exceed 25°C. by conserving heat of hydration of cement
2) If effectiveness of air-entraining admix- with insulating materials and insulating
tures is lost due to hot water, the admixture formwork.
may be added to the batch only after the b) Air-entrainment is necessary where alternate
water temperature is reduced. thawing and freezing is anticipated. 1

c) Cement - During winter concreting, it is c> Development of strength in a short period is

preferable to use rapid hardening Portland ce- desirable; for this additional quantities cement,
ment conforming to IS 8041 : 1990. ordinary or rapid hardening cement may be

106
 SP 62 (S & T) : 1997

added or proper admixture in right proportions. may be thawed deep enough to ensure that it
This results in saving du,e to shorter duration of will not freeze back up to the concrete; or it
protection, earlier removal of formwork, etc. majl be covered with dry granular material.
Cement which gives earlier and higher heat of Arrangements shall be made to cover and in-
hydration is preferred. The cement content in sulate newly placed concrete well in advance.
the mix shall preferably be not less than
300 kg/m”. b) All concrete surfaces shall be covered as soon
as the concrete has been placed; clean straw
4 Admixture to be used may be calcium chloride;
blankets about 50 mm thick, sacks, tarpaulins,
however it cannot be used under certain condi-
expanded polystyrene, plastic sheeting,
tions listed below; also the stipulated chloride
waterproof paper in conjunction with an air
content as per IS 456 : 1978 should be adhered
gap may be used. Insulating materials may be
to. The conditions are:
used as a protective material for formwork
I ) When sulphate resistant cement is used,
also.
2) When there are cracks in concrete,
3) When they are exposed to alternate drying c>Water curing is not necessary during freezing
and wetting, or-near freezing conditions.
4) When the concrete cover is small, and On removal of formwork and insulation the
5) When the concrete is permeable. member shall be immediately covered with
Chlorides lead to corrosion of reinforcement plastic sheet or tarpaulins properly taped and
and hence every care shall be taken to restrict made wind-tight. On no account shall such
its content in concrete; for using it as an admix- concrete, released from insulated formwork,
ture if need be, specialists may be consulted. be saturated with cold water.
e> Air-entraining agents, if proper amounts are Low pressure wet steam provides the best
used, increase the resistance of hardened con- means of both cheating enclosures and moist
crete to freezing and thaw~ing and also im- curing of concrete. Later on liquid-membrane
proves workability of concrete. forming compounds may be followed on con-
7.3.4 Temperature of Concrete as Placed crete surfaces with heated enclosures.
In cold weather, curing is not so important, as
4 When ~placing concrete at or near freezing
temperature, precautions shall be taken to en- the protection offered by formwork. There-
sure that concrete at that time of placing has a fore, forms may not be removed until the end
temperature of at least 5’C and the tempera- of minimum period of protection or even later.
ture of concrete after having placed and com- Table 5.11 gives the minimum time for struc-
pacted is maintained at above 20°C until it tural concrete for stripping of formwork; the
hardens thoroughly. time for removal of formwork fo; sides of
beams, columns and walls shall be not less than
b) The temperature of concrete mix may be as-
sessed by calculation or by taking a sample of those in Table 5.12.
the mix and measuring its temperature by a
metal clad thermometer. - Table 5.11 Stripping Time for-Structural
Concrete
7.3.5 Production and Delivery (Clause 7.3.6)
a ) The concrete shall be delivered at not less than
5°C. Stripping Time
b) Suitable precautions be taken during produc-
Walls, columns and vertical 24 to 48 h as may be
tion of concrete against the weather for both faces of all structural members decided
machines and materials.
c) It is necessary to place the concrete quickly and b) Beam soffits (props left under) I days

cover the top of-the concrete with an insulating c) Removal of propsunder slabs:
material. i) Spanning up to 43 m 7 days
ii) Spanning over 4.5 m 14 days
7.3.6 Placement, Protection and Curing
d) Slabs (props left under) 3 days
a) Before any concrete is placed all ice, snow and
frost shall be completely removed and the e) Removal of props under
beams and arches:
temperature of all surfaces to be in contact with i) Spanning up to 6 m I4 days
concrete be raised to the temperature of con- ii) Spanning over 6 m 21 days
crete to be placed.
When concrete has to be placed over per- For other cements, the stripping time recommended
manently frozenground, sub-grade material above may be modified.

107
L.,.-

SP 62 (S & T) : 1997

Table 5.12 Recommended Minimum Stripping limestone, soft sandstone, or other porous weak
Time for Formwork when Member is Carrying aggregate shall not be used.
Its Own Weight
7.53 No construction joints should be within 600 mm
(Clause 7.3.6)
below low water-level or within 600 mm of the upper
Beam Slabs Beam Removal Removsl
and lower planes of wave action. When unusually
Sides Sonits of Pr00s or PWDS severe conditions or abrasion are anticipated, such
lo Slabs to Beams
Oays bYS Days Days Days parts of the work shall be protected by bituminous or
silica-flouride coatings or stone facing be added with
I. Ordinary Cold weather 5 7 14 14 28
Portland Air temperature
bitumen.
cement about 3°C
7.5.4 Reinforcement in reinforced concrete structures
concrete
shall be protected from saline atmosphere during
Normal weather I 3f 7 7 14 storage and fabrication.
Air temperature
7.5.5 Precast members well cured and hardened may
about 16°C
be given preference; they shall be free from sharp
2. Rapid Cold weather I 4 8 8 16 corners, crazing, cracks or other defects; they shall
hardening Air temperature
Portland about 3°C
have trowel smooth finish; plastering should be
cement avoided.
concrete
7.6 Concrete in Aggressive Soils and Water
Normal weather 1 2 4 4 8
Air temperature 7.6.1 Destructive action of aggressive waters on con-
about 16°C crete is progressive.

The rate of deterioration which varies with alkali

7.4 Under-Water Concreting
resisting property of cement used decreases as the
7.4.1 Prior approval of Authority is necessary for the concrete is made stronger and more impermeable; and
method to be used for under-water concreting. increases as the salt content of water increases.

7.4.2 The concrete shall contain at least 10 percent When even a part of the structure is in contact or
more cement than that requiredfor the same mix in the exposed to aggressive soils and waters, evaporation
dry condition, the quantity of extra cement varying may cause serious concentration of salts leading to
with conditions of placing. deterioration even if the original salt content of soil or
water is not high.
The volume or mass of the coarse aggregate shall be
between one and a half times to twice that of fine 7.6.2 Where alkali contents are concentrated or may
aggregate. become high Portland cement is not recommended; if
used the ground water may be lowered by drainage so
The slump shall be between 100 mm to l80 mm.
that it will not come into contact with concrete. Addi-
7.4.3 Cofferdams or forms should be sufficiently tight tional protection may be obtained by the use of a
to ensure still water or in any case to restrict the flow chemically resisting stone facing or a layer of plaster
to less than 3 m/min in the space to be concreted; the of Paris covered with suitable fabric such as jute
forms should also prevent loss of mortar through the thoroughly impregnated with bituminous material.
walls. Dewatering shall not be done while concrete is
being placed or unit1 24 h thereafter. 8 READY MIXED CONCRETE

7.4.4 Concrete shall be deposited in any of the ways; 8.1 General

by tremie, by drop bottom bucket or by bags or grout-
ing. To minimize formation of laitance, concrete The use of ready mixed concrete, mixed elsewhere and
should not be disturbed while being placed. supplied to a site is coming into vogue. Ready mixed
concrete may be of two types, namely, centrally mixed
7.5 Concrete in Sea-Water
concrete and truck mixed concrete.
7.5.1 Concrete in sea-water or exposed directly along
the seacoast shall be at least M 15 Grade for plain 8.2 Centrally Mixed Concrete
concrete and M 20 for reinforced concrete. Use of slag
or pozzolana cement is advantageous under such con- Concrete produced by cbmpletely mixing cement, ag-
ditions. gregates, admixtures, if any, and water at a stationary
central mixing plant and delivered in containers fitted
7.5.2 Densest possible concrete is to be obtained by with agitating devices, except that the concrete, if so
proper design of the mix; slag, broken brick, soft desired, may be transported without being agitated.

108
 SP 62 (S & T) : 1997

8.3 Truck Mixed Concrete 8.4 IS 4926 : 1976 covers requirements of ready
mixed concrete.
Concrete produced by completely mixing the in-
gredients except water of concrete in a truck mounted 9 NON-DESTRUCTIVE TESTS
mixer at the batching plant; and water and admixtures
9.1 Non-destructive tests are covered in IS 133 11
being added and mixing being done entirely in the
(Parts 1 & 2) : 1992 by ultrasonic pulse velocity and
truck mixer either during the journey or on arrival at
by rebound hammer. .Rapid determination of com-
site. No water shall be added to the aggregate and
pressive strength is covered by IS 9013 : 1978 (see
cement until the mixing commences.
Annex C).

ANNEX A
(Clause 2.2.6)
PARTICLE SIZE AND SHAPE OF COARSE AGGREGATE

A-l GENERAL Table 5.13 Maximum Weight on Sieves

(Clause A.l.1)
A-l.1 The sieves shall not be overloaded. Therefore
care must be taken to ensure that the maximum loads IS Sieve Maximum Weight for
on sieves are not exceeded at the time of completion Designation r \
of seiving (see Table 5.13). 45 cm dia Sieve 30 cm dia Sieve

A-2 SIEVING kg kg
SOmm 10 4.5
A-2.1 The sample will require several operations on 40 mm 8 3.5
each sieve. Each sieve shall be separately shaken over 31Sor25mm 6 2.5
a clean tray or reciever until no more than a trace 20 mm 4 2
passes, but in any case for not less than 2 min. Material 16 or 12.5 mm 3 I.S
should not be forced through the apertures but hand 10mm 2 I.0
placing is permitted. A little brush shall be used with 6.5 mm 1.5 0.75
fine sieves. 4.15 mm I.0 0.50

A-3 RESULT 3.35 mm 0.30

A-3.1 The cumulative weight passing each sieve shall

be calculated as a percentage of total sample weight to
the nearest whole number.

ANNEX B
(Clause 2.2.6)
TEST FOR SURFACE MOISTURE

B-l PROCEDURE Weigh again (W2).

B-l.1 Take a test sample of wet aggregate and weigh Continue heating thereafter until all the moisture is
it (WI). Place it in a frying pan and gently apply heat evaporated and weigh the dry sample (W3).
while stirring with a glass rod until the surface mois-
B-l.2 Surface moisture = ((WI - W2)lW3) x 100
ture disappears. This is apparent when its shining
expressed as percentage of dry aggregate.
appearance disappears and the aggregate looks dull.
SP 62 (S & T) : 1997

ANNEX C
(Clause 3.3.3)
ACCELARATED CURING FOR DETERMINATION OF COMPRESSIVE
STRENGTH OF CONCRETE

C-l GENERAL immersion in a curing tank. The time between the

addition of water to the ingredients and immersion of
C-l.1 The compressive strength of concrete is ex-
the test specimens in the curing tank shall be between
pressed as its 28 days strength. The procedure requires
1; h to 3; h.
28 days moist curing before testing, which is too long
a period to be of any value either for construction C-2.3 The specimens in their moulds shall be gently
control or for applying timely corrective action. If lowered into the curing tank and shall be totally im-
after 28 days, the quality of concrete is suspect, it mersed at 55 + 2°C for a period of not less than 19 h
would have hardened by that time and might have been and 50 min. The specimens shall then be removed
buried by subsequent construction. Therefore the re- from the water, marked for identification, removed
placement of that concrete is difficult and imprac- from the moulds and immersed in cooling tank at
ticable. On the other hand if the concrete is found to 27 + 2°C before completion of 20 h and 10 min from
be too strong than necessary, cement is wasted due to the start of immersion in the curing tank. They shall
uneconomical mix proportioning. Hence the standard remain in the cooling tank for at least 1 h.
28 days strength is not feasible for quality control.
C-3 ACCELERATED CURING BY BOILING
C-l.2 Thus, there is a need for a rapid test which can
WATER METHOD
give results while the concrete is still green so that it
can be either removed or modified. A period of 24 h C-3.1 Test specimens in mould shall be stored in a
would help in this, that is the test result should be place free from vibration, in moist air of at least 90
available in a day’s time so that corrective actions can percent relative humidity and at a temperature of
be taken successfully. With the assistance of ac- 27 f 2°C for 23 h +15 min from the time of addition
celerated curing techniques, it is now possible to test of water to the ingredients.
the compressive strength of concrete within a short
period and thereby it is possible to estimate whether C-3.2 The specimens shall be gently lowered into a
the concrete is likely to reach the28 days strength. curing tank and shall remain totally immersed for a
period of 3; h + 5 min. The temperature of the water
C-l.3 This is fairly reliable and fast method for
in the curing tank shall be at boiling point (1OO’C) at
evaluating controlled concrete in the field by
sea level. The temperature of the water shall not drop
accelerated curing. Two methods of curing are warm
by more than 30°C after the specimens are placed and
watermethod and boiling water method. Appropriate
shall return to boiling within 15 min. In confined
correlation curves are available to estimate the quality
places, the temperature of water may be kept just
of concrete at normal ages. Methods of test proposed
below the boiling point to avoid excessive evapora-
are readily applicable to the site-testing and to give
tion.
results of reasonably low variability.
C-3.3 After curing for 3$ h + 5 min in the curing tank,
C-l.4 High pressure steam curing is also used as in
accelerated-curing method, but has some inherent the specimen shall be removed from the boiling water,
limitations for application. However this may be used removed from the moulds and~cooled by the immers-
for internal quality control purposes under special ing in cooling tank at 27 + 2’C for a period not less
circumstances. than 1 h.

C-l.5 For detailed information refer to IS 9013 : 1978. C-4 TESTING

C-2 ACCELERATED CURING BY WARM
C-4.1 The specimens shall be tested in accordance
WATER METHOD
with IS 516 : 1959.
C-2.1 Test specimens, shall be made according to
C-4.2 The warm water method specimens shall be
IS 5 16 : I959 if correlation curves have to be drawn.
tested while still wet, not more than 2 h from the time
If it is for control purposes sampling shall be done as
of immersion in the cooling tank.
per IS I199 : 1959.

C-2.2 The test specimens shall be left to stand undis- C-4.3 Inthe boiling water method, the age at the time
turbed in their moulds in a place free from vibration at of test subsequent to removal of moulds and cooling
a temperature of 27 + ~2°C for at least 1h, prior to shall be 28; h f 15 min.

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 SP 62 (S & T) : 1997

C-5 INTERPRETATION OF RESULTS C-S.2 Correlation curves shall be developed for a set
of given materials for normal curing and accelerated
C-5.1 Since the strength requirements in existing curing for reasonable projection of strength at any age.
specifications are not based on accelerated curing,
results from this method, in checking the compliance Figures 5.2 and 5.3 indicate one such typical~correla-
of specified strength at later stages shall be applied tion curves for the two methods, namely, warm water
with great care. method and boiling water method.

ACCELERATED STRENGTH Nd-I?,

FIG. 5.2 TYPICALRELATION BETWEENACCELERATEDAND 2%DAYS

COMPRESSIVESTRENGTHOF CONCRETE(WARM WATER METHOD)

ACCELERATED STRENGTH Nlmfr?-R,,

FIG. 5.3 TYPICALRELATION BETWEEN ACCELERATEDAND 28-DAYS

COMPRESSIVESTRENGTHOF CONCRETE(BOILING WATER METHOD)
SP 62 (S & T) : 1997

PART 2 REQUIREMENTS OF REINFORCED CONCRETE

1 GENERAL usage, such as, erection of forms, fixing of steel, pour-

ing concrete, etc.
1.1 All the common requirements of Part 1 apply to
reinforced concrete work also. These include 2.2.2 Propping and Centering
materials, grades of concrete; production and control
of concrete; mixing, transporting, placing, compacting 4 Props for centering may be of steel, timber
posts or ballies; brick masonry may also be
and curing; and concreting under special conditions,
used as props. Ballies shall rest squarely on
as described in detail in Part 1.
wooden base plates or any other load bearing
1.2 This Part will deal with requirements of reinforced material. Wedges or other devices may be
concrete work in addition to those given in Part 1. used below the props to ensure tight fitting
2 FORMWORK again to formwork.
b) Props for upper storeys may rest on the floor
2.1 General below. Formwork and concreting of upper
The requirements of formwork for reinforced concrete floors shall not be done until concrete of lower
apply to plain concrete work except for information floor has set for 14 days.
relating to reinforcement. Formwork shall include all Before concreting is done props and wedges
temporary or permanent forms or moulds required for should be checked for alignment.
forming the concrete which is cast in-situ. Together
2.2.3 Shuttering
with all temporary construction required for their sup-
port. Shuttering material shall have smooth, and even sur-
Formwork shall be of rigid construction true to shape face and the joints shall not permit leakage of cement
and dimensions shown in drawings. It shall be able grout. Timber when used shall be seasoned and free
enough to withstand dead, wind and live woods, etc, from loose knots, splits, etc; nails shall not be project-
[as per IS 875 (Parts 1 to 5) : 19871 as applicable. It ing from timber pieces. Steel plates when used should
shall also be designed to resist forces generated during have no projections of bolts and nuts. Fixing devices,
construction, namely, those due to-ramming, vibration if any shall be properly provided for (see IS 1946 :
of concrete and other incidental loads imposed on it. 1961).
The species of timber and design shall be according to All surfaces of shuttering, in contact with concrete,
IS 883 : 1970 and SP 33 (S&T) : I986. shall be treated with a non-staining mineral oil or other
It shall be made sufficiently rigid by use ties and approved material to prevent adhesion with concrete
braces. Screw jacks or wedges shall be used when and protect reinforcement also. Suitable camber shall
required to take up any settlement in the formwork be givenfor horizontal members.
either before or during the placing of concrete. 2.2.4 Special formwork, where necessary, may be
used, for example for tall structures.
Forms shall be removable in sections in desired se-
quence, without disturbing other sections or damaging 2.2.5 Stripping
the surfaces of concrete. All formwork should be easy The formwork shall be so removed as not to damage,
to strip after connecting; care shall be taken to see that the concrete. In slab and beam construction, sides of
no piece is keyed into the concrete. beams shall be stripped first and then the underside of
the slab and lastly the underside of the beam.
Details of formwork should be carefully worked out
and approved by the -Authority. The completed Under no circumstances shall formwork be stripped
formwork shall be inspected before placing reinforce- until concrete attains a strength at least twice the stress
ment in position. to which concrete may be subjected at the time of
removal of formwork. When possible, formwork shall
2.2 Materials of Formwork
be left in place longer as it would assist the curing.
2.2.1 Formwork may be timber, plywood, steel or any
For ordinary Portland cement, forms may be stripped
other material. IS 4990 : 1981 may be used for
after the expiry of the periods as specified in
plywood shuttering.
Table 5.11.
Timber used for formwork shall be easily workable,
with nails without splitting and of light weight. It shall Where the shape of element is such that formwork has
be stiff and strong enough to avoid undue deflection re-entrant angles, the formwork shall be removed as
when loaded; it shall not warp when exposed to sun soon as possible after the concrete has set to avoid
and rain or wetted during concreting. It shall not be shrinkage cracking due to restraint imposed by the stiff
soft and shall withstand easily the normal forces of formwork.

IL2
 SP 62 (S & T) : 1997

2.3 Reinforcement - for effective depth more than 200 mm,

+ 15 mm.
2.3.1 Straightening, Cutting nnd Bending c) Cover shall not be reduced by more than one-
third of specified cover or 5 mm whichever is
Reinforcement may be bent and fixed in accordance
less.
with the procedure indicated in IS 2502 : 1963; and
shall not be straightened in a manner injurious to the 2.3.2 Welded Join.ts or Mechanical Connections
material. Cold twisted barsshall be bent cold. All bars
shall be placed and maintained in the position shown Welded joints or mechanical connections in reinforce-
on drawings. Crossing bars should not be tack welded ment may be used; but tests shall be need to prove that
for assembly of reinforcement. Annealed steel wire the joints are of full strength of bars connected. For
(0.9 mm dia or over) may be used for tying crossing welding of mild steel plain and deformed bars refer to
bars. IS 275 1 : 1979 [see also SP (S&T) 34 : 1987 on
2.3.1.1 Tolerance on formwork and placing of rein- concrete reinfol~cementl.
forcement
When reinforcement are bent aside at construction
a) Formwork tolerance shall be as follows:
joints and afterwards bent back to their original posi-
- deviation from specified dimensions of tions, care should be taken to ensure that at no time is
cross sections of beams and columns, - 6 the radius of the bend less than 4 bar diameter for plain
mm to 12 mm. mild steel and 6 bar diameters for deformed bars. Care
- deviation-from dimensions of footings, in also shall be exercised that when bending the bars back
plan - 12 mm to 50 mm eccentricity 0.02 the concrete around the bar is not damaged.
times the width of footing in the direction
of footing but not more than 50 mm; thick- 2.3.3 Cover
ness f 0.05 times the specified thickness.
Cover to reinforcement shall be as per drawings sub-
b) Reinforcement tolerance
ject to requirements of IS 456 : 1978.
- for effective depth 200 mm or less,
* 10 mm;

PART 3 LIME AND LIME POZZOLANA MIXTURE CONCRETE

Section 1 -Lime Concrete

1 GENERAL moisture variations. It undergoes negligible volume

change~after setting and initial shrinkage.
1.1 Lime concrete, inspite of its low strength, may be
used in several situations in construction such as in 1.3 For detailed information refer to IS 254 1 : 199 1.
well foundations for moderately tall buildings, under
floor finishes, for filling haunches over masonry arch 2 MATERIALS
work and for roof terracing work.
2.1 Lime

1.2 Lime concrete is found to have many desirable Lime for use in lime concrete shall conform to
properties and advantages for use in construction. IS 712 : 1984.
Properly prepared, compacted and laid, lime concrete
2.2 Cement
is durable under normal exposures. Lime concrete
possesses considerable resistance for sulphate attack Cement shall conform to the requirements of 33 grade
and can be used in foundations and in areas in which ordinary Portland cement to IS 269 : 1989.
soil contains considerable quantities of soluble sul-
2.3 Pozzolana
phate or where subsoil water table is high. The effect
of temperature fluctuations on the volume change is Burnt clay pozzolana shall conform to IS 1344 : 198 I.
negligible in lime concrete compared to that due to Fly ash shall conform to IS 38 12 : 1981.

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SP 62 (S & T) : 1997

2.4 Coarse Aggregate 4 MIXING

Coarse aggregate for use in lime concrete shall be 4.1 General

either natural stone aggregate conforming to IS 383 :
1970 or broken brick (burnt clay) aggregate conform- Lime concrete may be hand mixed or machine mixed.
ing to IS 3068 : 1986 or cinder aggregate to IS 2686 : For large quantities of concrete, machine mixing is
1977 depending on the situation of use (see Table desirable.
5.14). 4.2 Hand Mixing
2.5 Fine Aggregate
The aggregates should be thoroughly washed and
Sand for use in lime concrete shall conform to IS 383 : drained before use. Mixing shall be,done on a clean
1970. Brick aggregate shall conform to IS 3 182 : water-tight platform.
1986. Fly ash shall conform to IS 38 12 : 1981. The coarse aggregate shall be stacked on the platform.
Lime shall then be evenly spread over it, in the
2.6 Water
specified proportion, and thoroughly mixed. Water in
Water used for mixing and curing shall be clean and just sufficient quantity shall be applied with a
free from injurious amount of deleterious matter. Sea sprinkler. Mixing shall be done by turning the mix
water shall not be used. Potable water is considered over and over until all particles of aggregate are
satisfactory. covered with mortar and concrete of uniform
appearance and consistency is obtained.
3 PROPERTIES OF LIME CONCRETE
4.3 Machine Mixing
3.1 Workability Clean dry coarse aggregate shall be ~first laid into a
mechanical mixer. Lime mortar is then fed into the
Satisfactory workability of lime concrete is obtained
mixer. The contents shall then be mixed well. Re-
by using the proportions recommended in Table 5.14.
quired quantity of water shall then be added. Mixing
Workability of lime concrete can be increased further
shall be continued until there is a uniform distribution
by increasing the proportion of lime mortar, within the
of materials. Final adjustment of water, to obtain con-
limits specified in Table 5.14. Lime concrete with a
crete of required consistency, may be added if~neces-
slump of SO-75 mm will be generally found to be
sary and continue mixing.
satisfactory.
5 LAY-ING OF LIME CONCRETE
3.2 Rate of Hardening and Setting Time
5.1 General
3.2.1 Hardening

Only that amount of concrete shall be mixed which can

Hardening of lime concrete is slow compared to
be laid in 2 h after mixing. Laying and compaction
cement concrete. Therefore for structural load bearing
of concrete shall be completed within 4 h of adding
lime concrete, it should be allowed to harden for a
water.
period of seven days before further work is undertaken.
3.2.2 Setting time of lime concrete depends on the 5.2 In Foundations and Under Floors
class of lime used in the preparation of the mortar. For
a) The soil sub-grade shall be thoroughly wetted
Class A lime initial set may occur in 2 to 3 h. Final set
and rammed before the concrete is laid.
does not occur in less than lo-12 h. Placing of lime
b) Concrete shall be laid, and not thrown, in layers
concrete shall be done before the initial set has
not thicker than 150 mm, when consolidated.
occurred.
c) Each layer shall be thoroughly rammed and
3.3 Strength consolidated before succeeding layers are
placed. Where joints in the same layer are
The process of strength development in lime concrete unavoidable each layer shall be sloped at an
is slow and may extend over years. The strength again angle of 30’ and made~to ensure proper bond
depends on the class of lime used and the aggregate; with the new concrete. The surface of each
proportion and quality of pozzolana used in the completed layer shall be cleaned and
preparation of concrete. The compressive strength, for roughened by wire brushing or other means
mixes shown in Table 5.14, shall not be less than before the next layer is laid. Where vertical
1 N/mm2 (10 kg/cm2) at 28 days, and for transverse joints occur, they shall be at least 600 mm
strength it shall not be less than 0.2 N/mm2 (2 kg/cm2) apart.
at 90 days. The compressive strength is expected to d) Vibrators may be used for uniform and good
rise to 1.2 N/mm2 (12 kg/cm2) in 90 days. compaction.

114
 ASP62 (S & T) : 1997

Table 5.14 Recommended Mixes for Use in Lime Concrete

(Clauses 2.4, 3.1 and 3.3)

SI Situations Type of Mortar Class of Lime” Type of Maximum Proportion of Remarks

No. (All Proportions as in IS 712 : Coarse Size of Mortar to
by Volume) 1984 Aggregate Coarse Coarse Aggre-
Aggregate gate (by
Volume)

(1) (2) (3) (4) (5) (6) (7) (8)

i) In founda- 1lime, 2 fine A Stone or 50 ml-0 40 to 50 parts of Normally suitable

tions aggregates broken brick mortar to 100 parts for buildings not
I lime, 1pozzo- B, C, D. E -do- 50 mm of aggregate more than three
lanic material. depending upon storeys high and in
I fine aggregate the grading of ag- places with dry sub-
gregate grade that is subsoil
3 lime, I cement, B, C, D. E -do- SO mm
! water level not
I2 fine aggregate
within 25 m of foun-
dation level

ii) Base con- I lime, 2 fine A Stone or SO mm 40 to 50 parts of Suitable for dry and
crete under aggregate broken brick mortar to 100 parts tolerably wet sub-
floor finishes I lime, 1pozzo- B, C. D, E -do- 50 mm of aggregate grades
on ground Ianic materials, depending upon
I fine aggregate the grading of ag-
3 lime, 1 cement, -do- gregate
B, C, D, E 50 mm
12 fine aggregate

iii) Levelling 1 lime, 2 fine A Broken brick 20 to 25 40 to 50 parts -

course or aggregate 01’ of mortar to
cushioning I lime, I pozzo- B. C, D. B cinder 100 parts of
layer under lanic material, aggregate
floor I fine aggregate

2 lime, I cement, B,C,D,E - - - -

12 tine aggregate

iv) Filling over I lime. I pozzo- B, C, D, E Broken brick 25 mm 45 parts of mortar -

haunces of lanic~material, to100partsofI:2
masonry 1 fine aggregate aggregate
arch work

NOTE - For details of fine aggregate, see 2.5.

‘) When lime is used as putty, the proportioning shall take into account only the equivalent quantity of dry slaked lime.

e) Care shall be taken to ensure that segregation Curing may be done by using wet hessian, gunny bags,
of aggregate and mortar does not take place etc and watering frequently. No brickwork or
when laying concrete. masonary shall be started at least for 7 days after laying
f-l No water shall be added during ramming. of concrete foundation.
s) Mixing and ramming shall go on uninterrup-
5.3 In Haunches of Arches
tedly. When not practicable, break joints as in
(e) above, may be provided. a) Each layer of concrete shall not be more than
h) The completed work shall be cured for a period 100 mm when compacted.
of not less than 10 days. b) Curing shall be done for at least 21 days as
described in 5.2.

Section 2 Lime Pozzolana Mixture Concrete

1 GENERAL shrinkage. Well compacted lime pozzolana concrete
1.1 Lime pozzolana concrete is used in building and is less permeable than cement concrete.
road constructions. The dry shrinkage values of this
concrete are low. Compared to cement concrete, it has 1.2 Lime pozzolana concrete conforming to
also a low volume change after setting and -initial IS 4098 : 1983 is used as a levelling course in

115
SP 62 (S & T) : 1997

foundation, footing under~masonry walls and columns, 3 MIXING

ordinary base concrete under floor, filling haunches in
masonary arches, roof finish, making blocks, etc. 3.1 Both hand mixing and machine mixing are per-
mitted (see Section 1)
1.3 For more information refer to IS 5817 : 1992.
2 MATERIALS 4 LAYING

2.1 Lime pozzolana mixture shall conform to 4.1 The methods of laying lime pozzolana concrete
IS 4098 : 1983. are similar to lime concrete laying as per Section 1.
2.2 Fine and coarse aggregate and water shall be as in 4.2 In Roof Finish
Section 1.
Shall be as per IS 3036 : 1992.
2.3 Recommended mixes with lime pozzolana mix-
ture are given in Table 5.15.

PART 4 SHOTCRETE

1 GENERAL 2.1.1 Aggregates

1.1 Shotcrete is mortar or concrete conveyed through
a) Fine aggregate (sand) - Sand for concrete
a hose and pneumatically projected at high velocity on shall comply with the requirements of
to a surface. The force of jet impinging on the surface IS 383 : 1970 and graded evenly from fine to
compacts the material. Generally a relatively dry mix- coarse as per Zone II and Zone III grading.
ture is used, and so the material is capable of support- Sand failing to satisfy this grading may how-
ing itself without sagging or sloughing, even for ever be used if pre-construction testing gives
vertical and overhead applications. good results (see 5). Further sand for finish or
1.2 Shotcrete is generally referred to as gunite, flash coats may be finer from the above grad-
pneumatically applied mortar or concrete, sprayed ing. However, the use of finer sands results in
concrete, airblown mortar and concrete, etc. How- greater drying shrinkage, and coarse sands in
ever, the term ‘shotcrete’ will be used throughout this more rebound.
part as the term is~accepted internationally. b) Coarse aggregate - Coarse aggregates, when
used, shall comply with IS 383 : 1970. It shall
1.3 Shotcrete is suitable for a variety of new construc-
conform to one of the gradings given in Table
tion and repair work, but its properties are to a great
5.16.
extent dependent on the conditions under which it is
placed, the capability of the particular equipment 3 SHOTCRETING PROCESS
selected and in particular on the competence~of the
operating staff. Shotcrete can be either plain or rein- 3.1 General
forced.
The two basic processes are:
1.4 Shotcrete is done by two processes, namely, dry-
a) Dry-mix process, and
mix process and wet-mix process. Pnetlmatically con-
b) Wet-mix procqss.
veyed shotcrete in which most of the mixing water is
added at the nozzle is dry-mix process. Shotcrete 3.2 Dry-Mix Process
wherein all the ingredients, including mixing water,
are mixed in the equipment before introduction into In this process, a mixture of cement and moist sand is
the delivery hose in wet-mix process; the shotcrete mix conveyed through the delivery hose to a nozzle where
may be conveyed pneumatically or moved by dis- most of the mixing water is added, under pressure (see
placement. Fig. 5.4). The process consists of the following steps:
2 MATERIALS a) The cement and moist sand are thoroughly
2.1 Cement, aggregates, water, admixtures and rein- mixed;
forcement are as per Part I except as mentioned b) The cement-sand mixture is fed with a special
in 2.1.1. mechanical feeder or gun;

116
 ‘fable 5.15 Recommended Mixes with Lime-Pozzolaha Mixture
(Clause 2.3 of Part 3 Section 2)
Sl No. Situation Grade of Coarse Mix by Mass Mix by Volume 28 Days Strength, Min
Lime- Aggregatk / A %
Poizalana , Lime- Fine Coarse zE-G---- coarse Compressive Flexural
Pozzo- Aggre- Aggre- Pozzo- Aggre- Aggregate MPa MPa
lana gate gate lana gate
Mixture Mixture
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

1. Levelling course under foundations, foot- LP-20 Crushed stone 1 4 8 1 2.25 4.5 1 0.2
iligs under masonry walls and columns,
Brick aggregate 1 3 6 1 1.75 4.0 1 0.2
ordinary base concrete under floors, filling
of haunches over masonry arches and roof LP-7 Crushed stonC 1 3 6 1 1.75 3.5 1 0.2
finish
Brick aggregate 1 2.5 5 1 1.5 3.0 1 0.2
Type 1 Crushed stone 1 8 16 1 4.5 9 1 0.2
Brick aggregate 1 6.8 12 1 4.0 8 1 0.2
Type 2 Crushed stone 1 5.2 10 1 3.0 6 1 0.2
Brick aaaregate 1 4.2 8 1 2.5 5 1 0.2
Type 3 Crushed stone 1 3.4 7 1 2.0 4 1 0.2
Brick aggregate 1 2.5 5 1 1.5 3 1 0.2

2. Rbad bases air-field bases and improved LP-40 Crushed stone 1 2.33 5 1 1.25 3.0 4 0.6
base concrete under floor
LP-20 do 1 1.33 3 1 1.25 1.75 4 0.6
Type 1 do 1 3.72 6.66 1 2.0 4 4 0.6
Type 2 do 1 2.66 2.60 1 1.5 3 4 0.6

3. Bonded under lays, building blocks and LP-40 Crushed stone 1 2 4 1 1.12 2.25 7 0.9
paving blocks
LP-20 do 1 1 2 1 0.50 1.12 7 0.9
Type1 do 1 1 3.60 1 1.0 2.0 7 0.9
G
Type 2 do 1 1 2.64 1 0.5 1.5 7 0.9
E
NOTES G
n 1 The aggregate grading for the lime-pozzolana concrete should, in the absence of special mix design procedure generally conform to the grading given in IS 383 : 1970. Ro
2 The volumetric proportioning is based on the assumption that a 36 kg bag of LP mixture would be 0.042 5 m3 by volumC. 5
..
3 For water requirement, the compaction factor should be kept b.85 _+0.02 for all the mixes.
5
4

i. .
 Table 516 Coarse Aggregates
(Chse2.1.1)

IS Sieve Percentage Passing for Single-Sized Aggregate of Percentage Passing for Graded
Designation Nominal Size Aggregate of Nominal Size
h h
#- I / %
63 mm 40 mm 20mm 16mm 12.5 mm 10mm 40 mm 20 mm 16 mm 12.5 mm

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (10

80 mm 100 - - - - - 100 - -

63 mm 85 td 100 100 - - - -

40 mm oto30 k5 to 100 100 - - - 95 to 100 100 - -

20 mm 0 to 5 oto20 85 to 100 100 - - 30 to 70 9s to 100 100 100

16 mm - - - 85 to 100 100 - - 90 to 100 -

12.5 mm - - - - 85 to 100 100 - - - 90 to 100

IOmm 0 to 5 0 to 5 oto20 oto30 oto45 85 to 100 10tcs3.5 25 to 55 30 to 70 40 to 85

c
oc
4.15 mm - - 0 to 5 oto5 oto 10 oto20 0 to 5 Oto 10 oto10 oto 10

2.36 mm - - - - - 0 to 5 - - - -
 SP 62 (S & T) : 1997

C) The mixture is forced into the delivery hose by e) The mortar or concrete is jetted from the nozzle
a feed wheel or a distributor; at high velqcity on to the area to be shotcreted.
d) The mixed material is carried in suspension of 3.4 Shotcrete may be produced by either of the
compressed air through the delivery hose to a processes for normal constructional requirements.
nozzle, which is filled inside with a perforated However, difference in cost of equipment, main-
manifold through which water is introduced tenance and operational features may make one or the
under pressure and intimately mixed with other other method more attractive for a particular
ingredients; and application.
4 The mortar is jetted from the nozzle at high
velocity on to the surface to be shotcreted. 4 PROPERTIES OF SHOTCRETE

3.3 Wet-Mix Process 4.1 Shotcrete, if properly applied, is a structurally

adequate and durable materid capable of excellent
In this process, all the ingredients including water are bond with concrete, masonary, steel, and other
mixed before they enter the delivery hose. It consists materials. However, these favourable properties of
of the following steps: sound shotcrete are contingent on properplanning and
supervision, and on the skill and continuous attention
4 All the ingredients, including mixing water, by the operating staff.
are thoroughly mixed;
b) The mortar or concrete is introduced into the 4.2 The water cement ratio for shotcrete in place
chamber of the delivery equipment; normally falls within a range of 0.35 to 0.50 by mass
c) The mixture is forced into the delivery hose which is somewhat lower than for most conventional
and conveyed by compressed air or other concrete mixes. In general, the physical-properties of
means to a nozzle; sand shotcrete in place are comparable to those of
d) Additional air is injected at the nozzle to in- conventional mortar or concrete of the same composi-
crease the velocity and improve the shooting tion. Most reported values for 28 days strength are in
pattern; and the range of 20 to 50 N/mm2 (200 kg/cm2 to

CEMENT AGGREGATE

YY MIXER

Y WATEI 9 !SUPPLY

AIR CONVEYED
DRY MIX
I PRESSURISED
WATER

WATER CONTROL
VALVE d

MIX SPRAY ED
FROM NOZZLE

FIG. 5.4 DIAGRAMATICREPRESENTATION

OFGUNITEPROCESS
SP 62(S & T): 1997

500 kg/cm2). It is recommended that strength higher be large enough to obtain all test specimens needed,
than 25 N/mm2 (250 kg/cm2) be specified only for the and also to indicate what quality and uniformity may
most carefully executed shotcrete jobs. be expected in the structure. Generally, the size of the
panel shall be not less than 75 cm x 75 cm. The
4.3 The drying shrinkage of shotcrete depends, some-
thickness shall be the same as in the structure, except
what on the mix proportions used, but generally falls
that it shall normally be not less than 7.5 cm.
within the range of 0.06 to 0.08 percent. This is-rather
higher than most low slump conventional concrete, 5.6 Cubes or cores shall be taken from the panels for
which is generally placed in heavier sections using testing. The cores shall have a minimum diameter of
larger aggregates and leaner mixes. It will tend to give 7.5 cm and length diameter ratio of at least one if
more shrinkage, cracking and may require a closer possible. The specimens shall be tested in compres-
joint spacing. The durability of shotcrete is good. sion at the age of 7 or 28 days or both.

4.4 Shotcrete offers advantages over conventional 5.7 The cut surfaces of the specimens shall be careful-
concrete in a variety of new construction and repair ly examined and additional surfaces shall be exposed
works. It is frequently more economical because of by saving and breaking of the panel when it is con-
lesser forming requirements and because it requires sidered necesary to check the soundness and unifor-
only a small portable plant for manufacture and place- mity of the material. All cut and broken surfaces shall
ment. be dense and free from laminations and sand pockets.

5 PRE-CONSTRUCTION TESTING 6 MIXING

5.1 Testing shall be done prior to the commencement 6.1 Dry-Mix Process
of the work in order to check the operation of equip-
ment, skill of the operating staff and the quality of
a>Batching by mass is preferred.
b) The moisture content of the sand shall general-
shotcrete. The procedure is detailed in 5.2 to 5.7. ly be within 5 to 6 percent 10 permit flow at a
5.2 Test panels shall be fabricated, simulating actual uniform rate.
job conditions, by the operating staff using theequip- c) The mixing equipment shall be capable of
ment, materials and mix proportions proposed for the thoroughly mixing the sand and cement in
job. sufficient quantity to maintain continuity of
placing. The mixing time shall be not less than
5.3 For the dry-mix process, the amount of water a minute in a drum type mixer. The mixer shall
added at the nozzle is adjusted so that the inplace be thoroughly cleaned to prevent accumula-
shotcrete appears to be adequately compacted and tions of batched materials.
neither sags nor shows excessive rebound. Where
4 Supply of clean dry air under pressure should be
justified by the size and importance of the job or lack ensured through an air compressor. The air pres-
of previous experience with the materials, it may be sure should be uniformly steady (non-pulsating).
advisable to test two or three mixes, generally within The operating pressure shall drive the material
the range of 1 part of cement to 3 to 4; parts of sand, from the delivery equipment into the hose.
before deciding on the final mix proportions. 4 For length of hose up to 30 m, the operating
pressure shall be 0.3 N/mm2 (3 kg/cm2) or
5.4 The procedure for wet-mix process is similar to
more; for each additional 15 m length of hose
the dry-mix process (see 5.3), except that the entire
pressure maI be increased by 0.035 N/mm’
concrete mix is premixed to give a workability judged
(0.35 kg/cm ) and the same increase allowed
to be appropriate for the work, before it is introduced
for each 7.5 m ~that the nozzle is raised before
to the chamber of delivery equipment. Tests on more
the gun.
than one~mix design are usually recommended where
Water under pressure shall be supplied; the
it is desired to include coarse aggregate in the mix.
water pressure shall be sufficiently greater than
Normally 20 to 40 percent of coarse aggregate is first
the operating air pressure at the discharie
tried with subsequent mixes adjusted to reflect the
nozzle. Water pressure shall also be steady
results of the first trial.
and non-pulsating.
5.5 The panels are fabricated by gunning on to a back
form of plywood. A separate panel shall be fabricated 6.2 Wet-Mix Process
for each mix design being considered, and also for each
gunning position to be encountered in the structure, a) Batching by mass is preferred. Aggregates
that is, slab, vertical and overhead sections. At least may be batched by volume of periodic checks
part of the panel shall contain the same reinforcement are made to ensure that the masses are main-
as the structure, to show whether sound shotcrete is tained within the required tolerance. Water
obtained behind the reinforcing rods, The panel shall may be batchedeither by volume or mass.

120

.
 SP 62 (S & T) : 1997

b) The mixing time will depend on the mix being from each position of the nozzle. ?ivoid build-
used and the efficiency of the mixer. ing up on the front face of the bar.
c> The other details are as per~dry-mix. b) The first layer shall completely embed the bar
for walls, columns and beams, beginning at the
7 APPLICATION OF SHOTCRETE
bottom.
7.1 Surface Preparation
7.6 Rebound
Shotcrete shall not be placed on any surface
which is frozen, spongy or where there is free- a) Rebound is aggregate and cement paste which
water. ricochets off the surface during the application
b) Surfaces shall be kept damp for several hours of shotcrete. Rebound may be as below:
before shotcreting. Sutiace Percentage of Rebound
cl In case of repairs, all existing deteriorated con-
Floors or slabs 5-15
crete shall be removed. The final cut surface
Sloping and vertical walls 15-30
shall be examined to make sure that it is sound
Overhead work 25-50
and perfectly shaped; all edges shall be
tapered. The surface shall be cleaned of all b) Rebound shall not be worked back into the
loose and foreign materials. concrete; it shall not be included in later
4 Exposed reinforcement shall be free of rust, batches.
scales, etc.
7.7 Preparation for Succeeding Layers
7.2 Formwork
Forms may be plywood sheeting or other material, true The earlier layer shall be allowed to take initial set
to line and dimension. They shall be so constructed as before the second layer is commenced. Then laitance,
to permit the escape of air and rebound during gunning loose material and rebound shall be removed. The
operations. Forms shall be~oiled and dampened just surface shall be thoroughly sounded with a hammer for
before gunning. Short removable bulkheads may be drummy areas resulting from rebounding pockets or
used at intersections. lack of bond. Drummy areas shall be cut off and
replaced with succeeding layers. Surfaces to be shot
Appropriate scaffolding shall be erected to permit shall be damp.
suitable positions for holding the nozzle.
7.3 Reinforcement 7.8 Construction Joints

4 Reinforcement shall be so placed as to cause Construction joints shall generally follow the prin-
least interference to gunning operations. ciples as laid down in Part 1.
b) Minimum clearance may be 12 mm to 50 mm
between formwork and reinforcement for mor- 7.9 Finishing
tar work and concrete mix respectively.
c> Clear spacing between bars shall be not less The natural gun finish is preferred both from structural
than 65 mm. and durability considerations. Finishing may be dif-
4 As far as possible, bars shall be so arranged as ficult for dry-mix work.
to permit shooting from the opposite side.
7.10 Suspension of Work
e) Lapped reinforcing bars shall not be tied . ‘,
together; they shall be separated by at least a) The work shall be suspended when exposure to
50 mm. high wind, breezing or rain is likely.
fl For repair work, existing work may be fixed b) When work is stopped, the shotcrete shall be
with reinforcement by nails. sloped off to a thin edge and then the work
g) All detailing shall be as per IS 456 : 1978. resumed after cleaning the surface.
7.4 Alignment Control
7.11. Curing
Adequate ground wires shall be installed to ensure
thickness and surface planes of shotcrete build up. The surfaces shall be kept continuously wet for at least
7.5 Placing of Shotcrete 7 days.
a) Shotcrete may be built up in layers. Shotcrete 7.12 For more details reference may be made to
t shall be forced behind bars. When bars are IS 9012 : 1978 on recommended practice for shotcret-
closely spaced more than one bar may be shot ing.

121
As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER 6

ANTI-TERMITE MEASURES
 CONTENTS

1 GENERAL 5 TERMITESHIELDS
PART 1 CONSTRUCTIONAL MEASURES 5.1 Installation
5.2 Termite Caps
1 GENERAL
PART 2 TREATMENT IN EXISTING
2 PRELIMINARY
WORK BUILDINGS
2.1 Presence of Termites
2.2 Clearance of Site 1 GENERAL
2.3 Elimination of Moisture 2 POSTCONSTRUCTION TREATMENT
2.4 Foundation and Sub-base of Ground Floor 2.1 Inspection
2.5 Selection of Timber 2.2 Extermination of Termites in Buildings
3 DESIGNCRITERIA 2.3 Preventive Measures

4 INTERNALANDEXTERNAL
ANTI-TERMITE 3 INSPECTION
MEASURES I
ANNEX A GUIDE FORTERMITE
DETECTION
4.1 Construction Methods
 SP62(S & T): 1997

CHAPTER 6

ANTI-TERMITE MEASURES
1 GENERAL This chapter will deal with (a) Anti-termite measures
through constructional means; and (b) Anti-termite
1.1 In Chapter 2 on earth work the anti-termite treat-
ment of soil by chemical methods has been dealt with. treatment of existing buildings.

-PART 1 CONSTRUCTIONAL MEASURES

1 GENERAL a stump or other piece of timber near the site. If the

soil is covered by soil rich in decaying matter, the top
1.1 Termite control in buildings is very important as
layer of the soil (about 50- 100 mm) shall be removed.
damage likely to be caused by the termites is huge.
The soil shall be graded to maintain drainage around
Termites attack both cellulosic and non-cellulosic
the building.
materials. They also damage materials of organic
origin with a cellulosic base. Wood, rubber, leather, 2.3 Elimination of Moisture
plastic, neoprene as well as lead coating used for
covering underground cables are damaged by termites. Drainage shall be ensured so that water does not ac-
1.2 There are two types of termites, namely, subter- cumulate or stagnate around the building. Access of
ranean or ground nesting termites and non subter- water to the underside of the ground floor shall be
ranean termites or wood nesting which have no contact prevented through proper construction measures, such
with soil. The subterranean termites cause most as, construction of concrete apron around the building.
damage in buildings.
2.4 Foundation and Sub-base of Ground Floor
1.3 Prevention of possible invasion by subterranean
termites from the ground to the building through ex- a>Every effort should be made to avoid voids in
ternal entry or internal attackfrom under floors should the construction of foundations.
be undertaken. This can be done either by preventive- b) The earth and sand filling around the founda-
cum-detection methods, for example, masonry groove tions and in sub-base shall be fully rammed so
or termite shield orstring course and cement concrete asto prevent any subsidence in soil.
apron floor; or by internal preventive methods, such c> Where jointless sub-base is not .possible,
as, by providing a solid floor. The constructional precautions may be taken to prevent crack
methods given in this part are based on actual trials in formation and the joints are sealed.
the field but modifications due to local conditions have 4 If concreting of sub-base has to be resumed on
to be made. a surface which has hardened, such surfaces
shall be roughened, swept clean, thoroughly
2 PRELIMINARY WORK
wetted and covered with a 15 mm layer or
2.1 Presence of Termites mortar composed of cement and sand in the
same ratio as in the concrete mix. This layer of
The presence of termites at the site may be determined
mortar shall be freshly mixed and laid imme- .”
either by experience of local inhabitants or by stake
diately before placing of concrete. When con-
test as described below.
crete has not fully hardened, all laitance shall
A member of stakes 50 mm x 50 mm of timber species be removed by scrubbing the wet surface with
which are suspectible to termites, such as, chir, kail, wire or bristle ~brushes, care being taken to
mango, etc, should be buried at least 150 mm into the avoid dislodgement of particles of aggregates.
ground spaced at 1 m centre-to-centre at the proposed The surface shall be wetted and all free water
site. After 3-4 months, the stakes may be taken out and removed and then coated with neat cement
infestation of termites observed. Termites, if present, grout. The first layer of concrete to be laid shall
will damage the stakes. not be more than 150 mm in thickness and shall
be well rammed against old work, particular
2.2 Clearance of Site
attention being paid to corners and close spots.
Care shall be taken to see that all wooden debris, roots,
2.5 Selection of Timber
leaves, stumps and other organic matters are not ac-
cumulated or buried near the foundation or under floor Seasoned timber which is naturally durable in
of the building. Typically termite nests are formed in heartwood and which is treated to withstand the attack

125
SP 62 (S & T) : I997

of subterranean termites should be used in the building the brick on edge masonry for getting offset space for
(see IS 401 : 1982 and IS 1141 : 1993, onpreservation coarse sand layer (see Fig. 6.2).
and treatment of timber). 4.1.3 The dry brick for the anti-termite groove shall
3 DESIGN CRITERIA be taken out and cement concrete (1:3:6) sub-floor
shall be laid casting an anti-termite groove in position.
Anti-termite measures through construction
In case of internal protection walls, the cement concrete
will be effective if both external and internal
sub-floor shall be laid on either side over dry bricks to
protection are adequately provided. The exter-
sufficient extent for getting staggered vertical joints over
nal protection refers to prevention of termite
the joint of plinth wall and earth filling (see Fig. 6.3).
access on surrounding area of the building.
4.1.4 Superstructure masonry shall be raised over the
The internal protection refers to the access
cement concrete sub-floor and overhead jobs com-
from soil under the floor area.
pleted (see Fig. 6.4).
b) For external protection, provision of metal
shields or masonry grooves around the 4.1.5 The dry brick for coarse sand filling shall be
periphery of the building and cement concrete removed and graded sand (of size 3 mm to 5 mm) layer
apron around the building are recommended. at least 100 mm thick shall be compacted over the earth
To be effective the shape of the metal barrier filling (see Fig. 6.5).
shall be properly maintained. 4.1.6 Cement concrete (1:3:6 mix) sub-floor at least
For internal protection the concrete sub-base 75 mm thick shall be laid over the sand filling. Mason-
shall be extended under the walls so that the ry finish may be provided to the cement concrete
entire plinth area is fully covered without any sub-floor (see Fig. 6.6).
break. In case of depressed floors like 4.1.7 Dry brick provided for apron floor (see Fig. 6.1)
liftwells, bathrooms, garrage pits, etc, the sub- shall be taken out and 600 mm wide formation of earth
base should be continuous. in 1:30 slope shall be made. lover the formation
4 The concrete flooring shall be laid over a layer 75 mm thick lime concrete (1:3:6 mix) shall be laid
of coarse sand (larger than 3 mm) as the sand (see Fig. 6.7).
layer checks soil moisture rising up. 4.1.8 Over the 75 mm thick lime concrete bed at least
e) Termites do not generally penetrate masonry 25 mm thick cement concrete topping ( 1:2:4) shall be
or concrete in which there are no voids. laid and 12 mm thick cement plaster shall be applied
Masonry with lime mortar mix leaner than on the plinth (see Fig. 6.8).
I : 3 shall not be used to be in contact with soils.
4.1.9 The finished construction, incorporating the
If the floor construction gives rise to vertical
stages mentioned in 4.1.1 to 4.1.8, appears as in Fig. 6.9.
joints between the floor and the plinth masonry,
the joints may be filled with heavy grade coaltar 4.1.10 The finished construction for stone masonry
pitch to IS 216 : 1961 to minimize the tendency incorporating the stages mentioned in 4.1.1 to 4.1.8,
of termites to infiltrate through these joints. would be as in Fig. 6.9 without plaster.

4 INTERNAL AND EXTERNAL ANTI- 5 TERMITE SHIELDS

TERMITE MEASURES 5.1 Installation
4.1 Construction Methods Termite shields may be installed around the periphery
The construction methods specified in 4.1.1 to 4.1.8 of a building where infestation is high. Provision of
may be adopted for protection against subterranean metal shields takes care of external protection only.
termites originating both internally from within and The visible termites tunnels on the shields should be
externally from the area surrounding the building. destroyed periodically. However, termite metallic
Stagewise details are given. shield in residential areas may be hazardous for
people; so it may be advantageously used for
4.1.1 Earth, free from roots, dead leaves, or other warehouses, godowns, etc. Metallic sheets may be
organic matter, shall be placed and compacted in suc- made out of galvanized sheets, aluminium sheets, etc.
cessive horizontal layers of loose material not more The sheet should be embedded~in the sub-floor proper-
than 200 mm thick. Dry brick shall be inserted at least ly with about SOmmprojection bent downword around
50 mm in brick masonry for providing apron floor 45’C~(see Fig. 6.10). The free edge also may be turned
around the periphery (see Fig. 6.1). downwards as termites can negotiate on straight edge.
4.1.2 Brick on edge in cement mortar shall be laid on General protective measures shall be attempted for door
the plinth wall. Dry brick shall be placed on the inner entrances as it is not practicable to install metal shields.
side of the plinth wall for getting anticipated offset 5.2 Termite Caps
space for coarse sand and on the otherside for installing Inverted caps may be used in pipelines outside walls
anti-termite masonry groove. In the case of inter- to prevent migration of termites and they should be
mediate walls, dry bricks are placed on either side of properly mounted.

126
 SP 62 (S 8r T) : 1997

DRY BRICK FOR

APRON FLOOR

Alldimensions in millimetres.
FIG.6.1 ANTI-TERMITECONSTRUCTION-STAGE 1
BRHZK ON EDGEIN
CEMENT MORTAR

DRY BRICK FOR

ANTI-TERMITE GROOVE

All dimensions in millimetres.

FIG.6.2 ANTI-TERMITECONSTRUCTION-STAGE 2

DENSE CEMENT CONCRETE [1:3:6)

SUBFLOOR CARPET LAID CASTING
.-DRY FIRICK
_..._.. / -ANT-TERMITE GROOVE IN POSITION
\-‘-- 1
THICK
_r 12mm
CEMENT PLASTER

DETAIL AT A

All dimensions
in millimetres.
FIG.6.3 ANTI-TERMITECONSTRUCTION-STAGE 3

127

.
SP 62 (S & T) : 1997

SUPERSTRUCTURE

dimensions in millimetres.
All
FIG.6.4 ANTI-TERMITECONSTRUCTION-STAGES

DRY BRICKS TAKEN OUT

AND 100 mm THICK SAND
LAYER LAID AND COMPACTED
7

FIG.6.5ANTI-TERMITECONSTRUCTION-
STAGES

128
 SP 62 (S & T) : 1997

COMPLETED 75mm THICK

DENSE CEMENT CONCRETE

F1ci.6.6 ANTI-TERMITECONSTRUCTION-STAGES

~6oo-------t-1r25
t GL

\-DRY BRICK TmAKE-N

OUT AND
.IMECONCRETE BED [1:3:6)
.AID FOR APRON FLOOR

AI1dimensions
inmillimetres.
Fa6.7 ANTI-TERMITECONSTRUCTION-STAGE 7

129
SP 62 (S & T) : 1997

12mm THICK CEMENT

PLASTER

25 mm -THICK CEMENT
CONCRETE 4 1: 2: 61 TOPPlNG

FIG. 6.8 ANTI-TERMITE CON$TRUCTION - STAGE 8

SUPERSTRUCTURE

FLOOR
75mm THICK CEMENT
CONCRETE SUBFLOOR

FILLING-j \
I ///l=y r BRICK ON EDGE

75
Y-
100

12 mm THICK CEMENT
~PLASTER

r25

!’
L50
FILLING
LIME CONCRETE APRON

CEMENT CONCRETE TOPPING

All dimensions in miliimetres.

FIG. 6.9 ANTI-TERMITE CONSTRUCTION - FINAL RECOMMENDATIONS

130

.:
 SP 62 (S & T) : 1997

DETAIL Al A

ANTI -TERMITE SHIELD

ALROUND THE PERIPHERY
OF THE BUILDING ~EXCEPT
AT EN1 RANCE

PRQN FLOOR

Alldimensions in millimetres.
FIG.6.10 TERMITESHIELDATPLINTHLEVEL

PART 2 TREATMENT IN EXISTING BUILDtNGS

1 GENERAL 2.2 Extermination of Termites in Buildings

1.1 Chapter 2 covered preventive chemical treatment After making a study of the infestation in the building
against termites in the soil. Part 1, dealt with the next step~to eliminate the termites located inside
constructional means of preventing termite attack. the building. This shall be carried out in a thorough
This part deals with treatment after attack in existing manner, seeking the termites in their hideouts, such as,
buildings. ceilings, behind wooden panelling, inside electrical
battens, conduits, switchboards and similar locations.
2 POST CONSTRUCTION TREATMENT Recourse may be taken to inject chemicals as already
2.1 Inspection mentioned in Chapter 2 along with the recommended
concentrations; every precaution shall be taken while
Before undertaking any type of treatment, a thorogh using chemicals to protect the operators. All traces of
inspection shall be made of the infestation in the build- termite tubes shall be removed so that any fresh infes-
ing with a view to determine the extent to which it has tation which might occur at a later date may be easily
spread and the routes of entry of the termites into the detected. The chemicals to be used Heptachlor 0.5
building. A study of the structure of foundation land percent emulsifiable concentrate, I .O percent Chlor-
the ground floor helps in finding out the routes of entry dane emulsifiable concentrate and 1.O percent Chlor-
of termites from the-soil and also in deciding on the pyrifos emulsifiable concentrate. The Authority
mode of treatment. For guidance, information on concerned with the use of pesticides should be con-
detection of termites is given in Annex A. sulted on the hazards in using these chemicals.

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SP 62 (S & T) : 1997

2.3 Preventive Measures a>At the junction of the floor and walls as a result
of shrinkage of the concrete;
2.3.1 Soil Treatment
b) On the floor surface owing to construction
defects; and
The object of soil treatment is to establish chemical
cl At expansion joints in the floor.
(toxic) barrier between termites in the soil and the
building to be protected. Basically~it consists of treat- The method of the dealing with these locations is to
ing the soil adjacent to or under the building with a apply chemical treatment within the plinth wherever
chemical toxicant which kills or repels termites. such cracks occur. The chemical should be pumped
Water emulsions of any one of the chemicals men- through holes drilled at regular intervals to a
tioned in 2.2 shall be used in soil treatment and applied reasonable depth, until refusal, subject to maximum of
uniformly at the prescribed rate. one litre/hole. The holes shall then be sealed.

2.3.1.1 Treatment along outside offoundations 2.3.1.3 Treatment of voids in masonry

a) The soil in contact with the external wall of the The movement of termites through the masonry walls
building shall be treated with the chemical may be arrested by squirting chemical emulsion
emulsion at the rate of 7.5 l/m* of the vertical through holes drilled in the wall at plinth level. The
surface of the substructure to a depth of holes shall be drilled at a downward slope of around
300 mm. 45’C. This treatment shall also be done to internal
b) To facilitate this treatment a.shal1o.w channel walls in contact with soil. Additional holes may also
shall be excavated along and close to the wall be drilled as needed, such as, wall corners, under door
face. and window frames, etc. The treatment holes shall
c) The chemical emulsion shall be directed then be sealed.
towards the exposed wall at the rat6 of 1.75
litres per running metre of the channel (see 2.3.1.4 Treatment at points of contact with woodwork
Note).
All existing work, infested with termites, shall be
NOTE - 7.5 l/m2 for a depth of 0.3 m means 2.27 litres treated by spraying at points of contact with masonry
per running metre.
with chemical emulsion in holes drilled at an inclina-
4 For uniform disposal of the chemical, rodding
tion of around 45’C, the rate shall be around half-a-
may be done at every 150 mm intervals.
litre per hole.
e) The balance of the chemical (2.27- 1.75 l/m)
shall be used to treat the backfill returned to the 2.3.2 Treatment of Woodwork
channel.
4 ~Woodwork which has been damaged beyond
f) If there is a concrete apron around the wall,’ repair shall be replaced after appropriate treat-
instead of excavating a channel,~holes shall be
ment.
made in the apron 800 mm apart and deep
enough to reach the soil below and then the
b) Infestld woodwork, which can be used, shall
be protected with chemical treatment squirted
chemical solution be pumped at the rate of
through inclined holes drilled into the wood-
about 2.25 litres per running metre.
work up to the core, on the unaffected side of
d The treatment mentioned here applies to
the frame. If need be, the woodwork may be
masonry foundations.
painted with one or two coats of chemicals.
In the case of RCC foundation, the soil (backfill) in
contact with the column sides and plinth beams along 2.3.3 Treatment of Electrical Fixtures
the external perimeter of the building shall be treated
Wherever possible, the inside of the enclosures of
with the chemical solution at the rate of 7.5 l/m* of
electrical fixtures shall be treated liberally with chlor-
vertical surfaces of the structure. Details of the treat-
dane powder.
ment shall be as above.

2.3.1.2 Treatment of soil under floors 3 INSPECTION

The points where termites are likely to seek entry 3.1 Periodic inspection of the work/installations par-
through the tloor are the cracks at the following loca- ticularly during humid and hot seasons would be help-
tions: ful.

132
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SP 62 (S ‘& T) : 1997

ANNEX A
(Clause 2.1)
GUIDE FOR TERMITE -DETECTION

A-l PROCEDURE A-l.3 The signs of presence of termites is through the

tell tale tubes. Termites travel in these and are~sup-
A-l.1 Bright light is essential for termite detection. A
posed to eataway woodwork leaving the film of paint
bright hand-held electric bulb (in a fixture) or a torch
on the surface, making it difficult to locate the termite.
would be necessary.
Woodwork sheuld be tapped to check hollow sound
A-l.2 Portions of the building in contact with or ad- which would indicate termite attack. The new tubes
jacent to soil should be inspected. Damp locations, of termites are moist; the old ones are dry and break
such as, bathrooms, etc, shall also be inspected. Points easily. These must be gouged out with a knife to
where woodwork is embedded in the floor, in par- destroy the termites.
titular, shall be examined.
As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER 7

DOORS AND WINDOWS (WOOD AND METAL)

 CONTENTS

1 ~GENERAL 9 LEDGED AND BATTENEDAND LEDGED, BRACED

ANDBATTENEDDOORAND WINDOW SHUTTERS
PART 1 TIMBER DOORS, WINDOWS AND
VENTILATORS 10 BATTENEDAND FRAMED DOOR AND WINDOW
SHUTTERS
1 GENERAL
11 TIMBERPANELLEDAND GLAZEDSHUTTERS
2 CLASSIFICATIONOF TIMBER
12 LOUVREDSHUTTERS
2.1 Zonal Distribution
2.2 Information on Timber 13 FITTINGS
2.3 Moisture Content
14 GLAZING
3 WOOD PANELPRODUCTS
14.1 General
4 DOORSAND WINDOWS 14.2 PatentGlazing
14.3 Materials
4.1 Frames
14.4 Glazing
4.2 Shutters
4.3 Hardware ANNEX A LIST OF INDIANSTANDARDSON BUILDERS
4.4 Paints and Varnishes HARDWARE
4.5 ~Glass
PART 2 METAL DOORS, WINDOWS AND
5 INSTALLATION
OFWOODEN FRAMES VENTILATORS (STEEL AND ALUMINIUM)

5.1 Prepared Openings 1 GENERAL

5.2 Installation of-Frames
2 INSTALLATION
5.3 Precautions
2.1 General
6 INSTALLATION
OFPRESSEDSTEELFRAMES
2.2 Type of Openings
6.1 General 2.3 Installation~of Single Units
6.2 Components 2.4 Installation of Composite Units
6.3 Installation 2.5 Hardware

7 INSTALLATION
OFPANELLEDSHUTTERS 3 GLAZING

8 JOINERY
4 OTHERSHUTTERS
 SP 62 (S & T) : 1997

CHAPTER 7

DOORS AND WINDOWS (WOOD AND METAL)

1 GENERAL metal (steel and aluminium) are dealt with. Part I
deals with timber doors and windows. Part 2 deals
In this chapter doors and windows made of wood and with metal doors and windows.

PART 1 TIMBER DOORS, WINDOWS AND VENTILATORS

1 GENERAL 2 CLASSIFICATION OF TIMBER

1.1 Timber generally used in buildings are either of 2.1 Zonal Distribution
solid timber or panel products like plywood, particle
board, etc. The major use is in door and window IS 399 : 1963 details the zonal distribution of common
frames and their shutters, furniture and the like. It commercial and timber of India, classified according
is also used in structures specially in hilly regions to their various end uses and gives information on
where timber is abundantly available and other com- availability and on some of the other properties of
mon building materials like brick are not easy to come these timbers. The uses, include:
by. a) Constructional purposes, including building
1.2 India has around two hundred species of commer- construction, piles, bridges, poles, railway
cial timber grown in different parts of the country. For sleepers, etc; and
quite sometime timber was transported over long dis- b) Furniture and cabinet making.
tances for some specific services even when species India is divided into five zones for convenience in
suitable for the purpose would be secured from nearby tabulating the information on timber. The zones are:
sources. The reason apparently appears to be the misT
Zone I - Jammu & Kashmir, Punjab, H.imachal
conception that in timber there are primary species
Pradesh, Uttar Pradesh, Haryana and
(teak) and secondary species. No such classification
Rajasthan.
exists and it is a misnomer. All species can be used,
only each species has different end use. Some species Zone2 - Assam, Manipur, Tripura, West Bengal,
are even stronger in cumulative properties than teak. Bihar, Orissa, Mizoram, Arunachal
IS 399: 1963 classifies commercial timber and their Pradesh, Nagaland, Sikkim, Bhutan,
distribution in India along with different end uses. Andamans.
Therefore it is necessary to check locally available Zone 3 - Madhya Pradesh, Vidharbha areas of
timber for building purposes before specifying the Maharashtra and north east part of
species for woodwork. Andhra Pradesh (Godavari Delta area).

1.3 Moisture content is an important requirement for Zone 4 - Maharashtra (except Vidharbha area),
use of timber in woodwork. Moisture content affects Gujarat, and north west part of Kar-
its workability, size, etc. The moisture content of nataka.
timber changes from season to season depending on Zone 5 - Tamil Nadu, Pondicherry, Andhra
atmospheric humidity. The application of a finish Pradesh (except Godavari Delta area),
(paint or varnish) reduces the change in moisture con- Kerala and Karnataka (except north west
tent with changes in humidity in the atmosphere. part).
IS 287 : 1993 governs the recommendations for max-
imum permissible moisture content for timber used for 2.2 Information on Timber
different purposes.
Tables in IS 399 : 1963 give information on the
1.4 For actual end use seasoning and treatment of following aspects of timbers available in these zones.
timber are necessary. Seasoning will help in the con-
trol of moisture and it should be done as per IS 1141 : a) Availability - Availability of commercial
1993; and preservation as per IS 40 I : 1982. timber is categorized under three classes as

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SP 62 (S & T) : 1997

given below: 2.3 Moisture Content

X - Most common, 1400 cu.m and more per For the purpose of classification the country is divided
year into four zones as under:
Y - Common, 350 - 1 400 cu.m per year Zone 1 - Average annual relative humidity less
Z - Lesscommon, bElow 350cu.mperyear. than 40 percent
b) Mass per cubic metrc -The average mass per Zone2 - Average annual relative humidity be-
cubic metre at 12 percent moisture content for tween 40-50 percent
all timbers. Zone3 - Average annual relative humidity be-
cl Durability - The figures of durability are tween 50-67 percent
based on grave yard tests carried out on
Zone4 - Average annual relative humidity above
60 cm x 5 cm x 5 cm specimens and are
67 percent.
categorized as below:
For these zones see Map of India in IS 287 : 1993.
High - Timber having, an average life
of 120 months and over 2.3.1 Maximum permissible moisture content of dif-
ferent end uses are given in IS 287 : 1993. For
Moderate - Timbers having an average life
construction, furniture, etc, purposes Table 7.1 gives the
between 60 to 120 months
recommended values of~maximum moisture content.
Low - Timber having an average life
less than 60 months. Table 7.1 Permissible Moisture Content of
4 Treatability - Treatability, reflecting the Timber
resistance offered by the heartwood to the (Clause 2.3.1)
penetration of preserative fluid under pressure
of 10. 5 kg/cm2 is classified as below: Sl Use Moisture Content, MUX
h
No. / \
a - Heartwood easily treatable Zone I Zone 2 Zone 3 Zone 4
b - Heartwood treatable, but complete i) Beams and rafters 12 14 17 20
penetration of preservative not always ii) Doors and windows
obtained a) 50 mm and above in 10 12 14 16
thickness
c - Heartwood only partially treatable
b) Thinner than 50 mm 8 10 12 14
d - Heartwood refractory to treatment iii) Flooring strips 8 10 10 12
e - Heartwood very refractory to treatment, iv) Furniture and cabinet 10 12 14 15
v) Timber for further con-
penetration being practically nil from
v&on, pasts, poles, etc 20 percent in all zones
side or end
Compressive strength coejjfkient - The com- NOTE - The moisture content is determined within a depth of
e)
12 mm from the surface excluding 30 cm from each end, by a
pressive strength coefficient is arrived at by
moisture meter.
grouping the various important mechanical
properties of timber that may come into play 3 WOOD PANEL PRODUCTS
for any particular use and giving due 3.1 Types
weightage to the relative important of these
There are several types of wood panel products which
properties.
can be used in wood work for buildings. These are
2.2.1 The Handbook SP 33 (S & T) : 1986 covers the covered by the following Indian Standards:
engineering aspects of use of timber.
IS No. Title
2.2.2 Timber species be identified by using 303 : 1989 PJywood for general purposes
IS 4970: 1973 keys for identification of commercial 1328 : 1982 Veneered decorative plywood
timbers; around 50 cards are available for identifying 1658 : 1977 Fibre hardboards
1659 : 1990 Block boards
species.
3087 : 1985 Wood particle board (medium density)
2.2.3 Timber may be graded on the~basis of defects as 3097 : 1980 Veneered particle~boards
per IS 6534 : 197 1 which gives guidelines of grading 3129 : 1985 Particle board (low density)
and inspection of timber. 3348 : 1965 Fibre insulation boards
3478 : 1966 Particle boards (high density)
2.2.4 Since publication of IS 399 : 1963 further work 5509 : 1980 Fire retardant plywood
has been done in identifying species of timber suitable 5539 : 1969 Preservative treated plywood
for doors and window shutters and frames; and for 7316 : 1974 Decorative plywood using plurarity of
furniture and cabinets. These are covered in IS 12896 : veneers for decorative faces
1990 for shutters and frames and IS 13622 : 1993 for 6701 : 1983 Structural plywood
furniture and cabinets. Thus additional species have Properti-es of these panel products are summarized
been brought in for these~end uses. in SP 21 (S &T) : 1983.

138

.
 SP 62 (S & T) : 1997

4 DOORS AND WINDOWS c) Selection of hardware shall depend on

economy desired and climatic conditions, such
4.1 Frames as, exposure to sea wind in coastal areas, etc.
d) The material of the hardware may be mild
Quite often doors which are factory made have to be steel, brass, oxidized iron. anodized
adjusted with regard to dimensions of openings. aluminium, etc.
Therefore, co-ordination among dimensions of shut-
ters would be of great use. For larger benefit modular 4.4 Paints and Varnishes
co-ordination is desirable. Installation practices have White lead primer paint, aluminium or other primer,
to be suitably adjusted so as to achieve satisfactory wood filing putty, ready mixed paints, varnishes.
work within the tolerances specified. polishes and all other materials shall conform to
relevant Indian Standards (see Chapter IS).
4.1.1 Timber frames for doors and windows shall
conform to IS 402 1 : 1983. For permatrent door frames 4.5 Glass
Group I Timber shall be used (see IS 12896 : 1990). Sheet glass used for glazing shall conform to
For temporary frames Group II and III can be used. IS 2835 : 1987 or IS 2553 (Part I) : 1990 or IS 5437 :
Same species shall be used for rails and stiles; solid 1969. Other glasses like frosted glass, coloured glass,
wood panels may be of any other specie. Steel door etc, may also be used (see 14 for glazing).
frames to receive wooden shutters shall conform to
IS4351 : 1976. 5 INSTALLATION OF WOODEN FRAMES

5.1 Prepared Openings

4.2 Shutters
Installation into prepared openings shall be preferred
Shutters can be of several kinds as below: (see 5.3); the advantage being that the frame is less
liable to distortion and moisture changes.
Timber panelled and glazed shutters shall con-
form to IS 1003 (Part 1) : 1991 for doors and 5.2 Installation of Frames
to IS 1003 (Part 2) : 1983 for windows.
Door frame shall be installed at the required place and
Wooden flush door shutters shall conform to each door frame shall be provided with three holdfasts
IS 2191 (Part 1) : 1983 with plywood face on either side; one each at top and bottom 30 cm away
panels (cellular and hollow core) and to IS from the edge and one in the middle. Masonry or
2 19 1 (Part 2) : 1983 for particle board and hard concrete in the wall shall be built after installation of
board face panels (cellular and hollow core). doors so that holdfasts and pins at the bottom are
Wooden flush door shutters shall conform to anchored into them. Before construction of masonry,
IS 2202 (Part 1) : 1991 plywood face panels the outside of frames coming in contact with masonry
(solid core); and to IS 2202 (Part 2) : 1983 for shall be given a thick coat of coal tar or other water
particle board face panels and hard board face proofing paint. Suitable arrangements shall be made
panels (solid core). to hold the frames in rectangular shape during con-
cl Wooden sliding doors shall conform to struction. Usually one cross batten at the middle and
IS 4962 : 1968. one cross batten at the bottom (no sill for the door) and
two cross battens diagonally will be necessary to hold
4 Ledged, Braced and Battened Doors shall con-
form to IS 6198 : 1992. the frame in rectangular shape.
Window frames shall be installed in the same manner
4.3 Hardware as door frames, except that at least two holdfasts shall
be provided. The size of the opening shall be checked.
Door and window hardware shall meet the require-
ments of relevant Indian Standards (see 13). To ensure that the units are set at the appropriate levels
a datum line for the sill of the door, window or ven-
4 Each wooden door shutter shall have a mini- tilator shall be taken from a fixed point on the watl or
mum of three hinges and two fastenings like from the finishes of the floor or ceiling.
tower bolt, hasp and staple, mortice lock, etc.
Alternatively, in a prepared opening, the fixing of the
Floor stoppers, handles, hydraulic door
door frame may be flush or rebated as per drawings.
closers, kick plate, etc, are optional.
The clearence between the frame and opening shall be
b) Each window shutter shall have a minimum of kept depending on whether the opening is externally
three hinges and one fastening like tower bolt rendered or fair faced. The frame shall be checked
and one handle for opening and closing. Ad- before fixing in the positions that the same is square
ditional fastenings or tower bolts may be op- and in the proper position. The holdfast openings and
tional. the bottom pin shall be grouted. Plastering of the sides

139
SP 62 (S & T) : 1997

shall be done and allowed to dry before the door size and quality. The size of openings and the door
window or ventilator shutters are fixed. frames shall be checked along with the verticality of
the side frames, level position of the tloor and the wall.
5.3 Precautions
Adjustment any, if necessary, shall be done before the
Precautions shall be taken to fix the door frame so as installation of the shutters. The shutter shall be
to take care of the final floor level and also the follow- installed only after the walls have dried.
ing points: 7.2 Any defects in storage should be rectified, unless
a) Whether the shutters are inside opening or otherwise specified door shutters shall be fixed to the
outside opening,~and frames with 100 mm (or appropriate) long hinges. In
b) Whether the frames are for exterior use or driving screws in hard timbers, pilot holes be driven
interior use. before fixing the screws. The door shutters shall be
checked again after installation.
6 INSTALLATION OF PRESSED STEEL
FRAMES 7.3 All fixtures shall then be fixed on the shutters and
checked for preference.
6.1 General
7.4 Glazed panels, where required, should be fixed
Each door frame shall consist of hinge jamb, lock making sure that the correct size of glass panels are
jamb, head and if required angle thresh hold. The used.
whole shall be welded or rigidly fixed together by 7.5 Flush doors, when used in bathrooms, shall be
mechanical means. Where no threshold is required, protected at the bottom (inside) with 15 cm high-sheet
temporary base tie shall be screwed to the feet of the of aluminium or plastic.
frames in order to form a rigid unit.
7.6 Where combination of doors, windows and ven-
6.2 Components tilators is desired, care shall be taken that the symmetry
of combination both as to dimension, colour and fix-
Base ties, fittings, such as, hinges, fixing lugs, mortar
guards, lock-strike plate and sheet absorbers shall be ture is preserved.
as per IS 435 I : 1976. 7.7 Wooden doors, shutters, etc, shall be finished as
given in Chapter 15 on finishes.
6.3 Installation
8 JOINERY
Pressed steel door frames are ideally suited for built-in;
while fixing the following instructions shall be fol- 8.1 Joinery work may be started immediately after
lowed: commencement of building work. All pieces shall be
accurately cut and planed smooth to full dimensions
1) Place the door in position at correct height from without any patching or plugging of any kind.
the finished floor level.
Rebates, rounding and moulding as shown in drawings
2) Plumb to ensure that the frame is upright,
shall be made before assembling. The thickness of
square and free from twists.
stiles and rails shall~be as specified for the shutters.
3) Pressed steel door frames are liable to develop
bow in heights or sag in the width either during 8.2 All members of door shutters shall be straight
fixing or during subsequent building work. To without any warp or bow and shall have smooth well
aovid this fix temporary struts across the width, planed faces at right angles to each other. The corners
preventing sides bulging inwards by weight of and edges of panels shall be finished as shown in _““.. ,.,__&

wall or partitions. drawings and these shall be feather tongued into stiles
4) Build the walls up solid or each side and grout and rails. Sash bars shall have mitered joints with
each course so as-to make solid contact with stiles. Stiles and rails shall be properly and accurately
the frame leaving no voids. mortised and tenoned. Rails which are more than
5) Three lugs shall be provided on each jamb and 180 mm in width shall have two tenons. Stiles and rails
the lugs shall not be placed more than 75 cm of shutters shall be made out of one piece only. The
apart. tenons shall pass through the stiles for at least three-
6) Do not remove temporary struts till brickwork fourths of the width of the stile. When assembling a
is set. leaf, stiles shall be left projecting as a horn. The stiles
7) In case screwed base tie is provided, leave it in and rails shall have I2 mm groove in panelled portion
position until floor is laid when it shall be for the panel to fit in.
removed.
8.3 The depth of rebate in frames for housing the
7 INSTALLATION OF PANELLED SHUTTERS shutters shall in all cases be 1.25 cm and the rebate in
7.1 Before installation of shutters, it shall be ascer- shutters for closing in double shutter door or window
tained that the shutters, hardware, etc, are of the right shall be not less than 2 cm. In the case of double leaved

140
 SP 62 (S & T) : 1997

shutters, the meeting of the styles shall be rebated side only. The other side being supported by the rebate
20 mm. The rebate shall be splayed. from the stiles. For external doors and windows the
beading shall be fixed on the outside.
8.4 The joints shall be pressed and secured by bamboo
hardwood pins of about 6 mm diameter. The horn of 8.9 For fixing glazing, the glass shall be embedded in
the stiles shall be sawn off. putty and secured to the rebate by wooden beads of
suitable size and shape. Wash leather, ribbon velvet,
8.5 The finished work shall have a tolerance of + I mm
rubber flannel, felt, absestos or other similar material
in thickness and f 2 mm in width of stiles and rails.
may be used in place of putty for internal glazing. The
8.6 The contact surfaces of tenon and mortise joints material shall be fitted either as a beading on one side
shall be treated before putting together with bulk type or in such a manner that~it covers all parts of the glass
synthetic resin additive. The shutters shall not be which will be covered by beading (see also 14).
painted, oiled or otherwise treated, before these are
fixed in position. Mounting and glazing bars shall be If glazing compound or putty are not to be used
sub-tenoned to the maximum depth which the size of recourse may be taken to patent glazing as per IS 10439 :
the member would permit or to a depth of 25 mm 1983. The term ‘patent glazing’ is applied to those
whichever is greater. The thickness of each tenon shall forms of glazing that rely on their efficiency upon
be approximately one-third of the finished thickness of some means of collecting and removing water in chan-
the members and the width of each tenon shall not nels or grooves incorporated in the glazing bar as
exceed five times the thickness. distinct from putty or other glazing compounds. For
more details refer to IS 10439 : 1983.
8.7 Beading for panels- may be provided on one or
both sides for fixing wooden panel products. 8.10 Wooden cleats and blocks, for fixing locks,.shall
8.8 For fixing glass and absestos panels, beadings be provided as decided by the Authority.
with grooves shall be provided; where beading is
provided without grooves, the beading shall be on one 8.11 Figures 7 to 7.4 give typical details of joinery.

7.1A Single Tenon in Top Rail ?.I B Haunched Single Tenon in

Top Rail

7.1C Double Tenon in Lock Rail 7.1 D Hazle Tenon in

BottomRail

FIG. 7. I TYPICAL~LLUSTKATIONS OF TENONAND HAUNCHEDTENONINJOINERY

141
SP 62 (S & T) : 1997

7.2A Single-Haunched Tenon on a Top Rail

7.2B Middle or Lock Rail with Pair of Single Tenon

and Haunch in Centre

7.2D Stub Tenon on a

Munting (it does not go
Through the Rail)

7.2C Pair of Single-Haunched

Tenon on Bottom Rail

FIG.7.2 TYPICALILLUSTRATIONSOFTENONANDHAUNCHEDTENONINJOINERY(ALTERNATEFIGURE)

142
 SP 62 (S & T) : 1997

FIG. 7.3 COMMON METHODSOF JOINTINGPANELS WITH STILESAND RAILS WITH/WITHOUTBEAIIING

pqp pFjg
7.4A Splayed Type 7.48 Square Type

NOTE- t= Thickness
of shutter
FIG. 7.4 MEETINGOF STILESFORDOUBLE-LEAVED DOOR SHUTTERS

9 LEDGED AND BATTENED AND LEDGED, with minimum 12 mm rebated joints. The finished
BRACED AND BATTENED DOOR AND work with a tolerance of +I mm in thickness and
WINDOW SHUTTERS &2 mm in width of battens, ledges, etc. The ends of
battens shall be feather tongued into styles and rails
9.1 Timber specified for ledges, bracing and battens which shall be provided with a 12 mm grove to fit
should be used and sawn in the direction of grains. battens.
Sawing shall be fully straight and square. The timber
shall be planed smooth and accurate to the full dimen- 9.3 The battens shall be fixed together by 25 mm thick
sions, rebated, roundings and mouldings as in draw- ledges and braces to the inside face of door shutters
ings, before assembly. Patching and plugging shall not with screws. The ledge shall be 175 mm wide and
be permitted except as provided. The thickness of the brace 125 mm wide unless otherwise specified. The
doors shall be the thickness of battens only and not the braces shall incline down towards the side on which
Lombined thickness of battens and braces. the door is hung as shown in Fig. 7.5. Edges and ends
of ledges and braces shall be chamfered. Tee hinges
9.2 Planks shall be 20 mm thick unless otherwise
shall be provided in ledges only. The finished work
specified and of uniform width of 75 mm to 100 mm.
shall be with a tolerance of I!I~ mm in thickness and
These shall be planed and made smooth and provided + 2 mm in width of battens ledges etc.

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SP 62 (S & T) : 1997

T,G AND V JOINTED

FRAME7 BRACE7 BATTENS

j--4Jb’ERALL WIDTH OF DOOR+

WIDTH OF OPENING

SECTION XX
r-LINTEL

/HEAD
*-I

,-TO! LEDGE

STRAP OR HINGE

X
I,

r-MIDDLE LEDGE

- SLIDING
BOLT

BATTENS
-?

BRACE \

-BOTTOM LEDGE

-BARREL BOLT

SECTION YY

FIG. 7.5 LEDGED,BRACEDANDBATTENEDTIMBERDOOR SHUTTER

1.
10 BATTENED AND FRAMED DOOR AND a) Timber for frames shall be as in 4.
WINDOW SHUTTERS b) Panels shall be made of any listed in 3.
c) Glazing shall conform to IS 2835 : 1987 or
10.1 These shall be made on the same lines as ledged,
IS 2553 (Part 1) : 1990.
battened, braced shutters as shown in Figs. 7.1 to 7.4.
d) Joinery as given in Figs. 7.1 to 7.4.
11 TIMBER PANELLED AND GLAZED 12 LOUVRED SHUTTERS
SHUTTERS
12.1 Timber and frames shall be as in 4.
11.1 These shutters shall be-made in the same way as 12.2 Venetian panels shall be 12 mm thick unless
in 9 exceptas below: otherwise specified. The Venetian shall slope down

144
 SP 62 (S & T) : 1997

towards the outside at an angle as shown in drawings and corners and other defects. Screw holes shall be
and shall be fixed in the stiles. The Venetians shall smooth and free from sharp edges, flaws or other
overlap each other by about half of their width. They defects. Screw holes shall be countersunk to suit the
may be fixed or movable. A tolerance of fl mm on head of wood screws. Screws used for fittings shall be
thickness and 5 2 mm on width of the finished work is of the same metal and finished as the fittings. How-
permissible. ever, chromium plated brass screws may be used for
12.3 The louvers may also be fixed to frames in fixing aluminium fittings. Screws shall be driven
grooves of minimum I .25 cm depth. Venetian blades home with screw driver and not hammered in. Recess
shall slope down towards the outside at an angle of 45’ shall be cut to the exact size and depth of counter
or specified otherwise, the overlap shall be about half sinking or hinges.
the width. Fittings shall be truly vertical or horizontal and in
proper position as shown in drawings.
13 FITTINGS (HARDWARE)
13.2 Figures 7.6 to 7.17 illustrate some of these
13.1 Fittings shall conform to requirements of Indian hardware. The requirements of these hardware are
Standards listed in Annex A. Fittings may be of steel, summarized in SP 2 1 (S & T) : 1983; for hardware not
brass or aluminium or as specified. These shall be well covered here reference may be made to relevant Indian
made, reasonably smooth and free from sharp edges Standards given in Annex A.

--IF

t
CRANKEO UNCRANK ED

FIG. 7.6 MILD STEETBUTT HINGES(MEDIUM)

I t Ll U

KNUCKLE -X4 TAFpLEipE0

FIG. 7.7 BUTT HINGES(ALUMINIUMALLOY, CAST BRASSOR EXTRUDEDBRASS)

145
SP 62 (S & T) : 1997

CSK HOLE
I

t R6

KNUCKLE-/
I

I- min- I!’ 7 min.

3
t

C @7- .

J-Y@==
I
-+ 7 min.

FIG.7.8 PARLIAMENT HINGES

I I I

A--+-C--l
7.9A MildSteel Tee Hinges
(Light,
MediumandHeavy) L.. L”

Nominul B II h 1.1
Size
40 40 k 1 75+2 2szkI 20+ 1
30 30+ I 7Sf2 2s + I Is+ I
All dimeosionsm millimetres.
7.9B Continuous (Piano) Hinges
FIG.7.9 TYPICAL~LLUSTRATIONSOFHINGES
146 b

I .’

.
 SP 62 (S & ‘I’) : 1997

SPOT WELDED

c 1 BOLT (ALTERNATIVE

SECTION XX

BACK PLATE -4 b-3.15 -A-

CSK HOLE
.
FOR DESIGNATION
No.9 CSK WOOD SCREW
CLIP
STAPLE

NOTE - Shapes of parts are only illustrative but the dimensions and the minimum requirements, wherespecified,arebinding.

All dimensionsin millimetrs.

FIG. 7.10 MILD STEEL SLIDINGDOOR BOLT, CLIPOR BOLT TYPE

SCREW v
HOLES PRES LSED

16 mm
+ +

44
F-d-- F-h--
PRING AND BALL CAST OR
EXTRUDED

FIG. 7.11 BARRELL TOWER BOLTS

147
SP 62 (S & T) : 1997

I
‘G
\

T7
\ A

!
KNOB
\

m-B-4

TYPE I TYPE 2
NOTE I - Number and position of screw holes are illustrative and shall conform to the requirements given in IS 5 I87 : 1972.
NOTE 2 -The shapes of the component parts are only illustrative and are not intended to limit the design. Movement of the bolt may
be either by means of a knob or a lever.

FIG.7.12FLUSH BOLTS

148
 SP 62 (S & T) : 1997

ll
II

ttt-ii-t-

DISC I INDICATING BOLT

GUIDE AND LOCK PLATE 6mm ROUND HEAD NUT

3 mm THICN imm ROUND HEAD SHUTTER7 \ WITH SQ. SEAT
I
I

I I ^.
LGUIDE__..AND
ML UCK
STOP
I IRON
SCREW
LDOOR FRAME

‘-OPEN POSITION .10 mm DIA BOLT IN LOCKING-POSITION

PULL BOLT LOCK

F1c.7.13 BOLTANDPULLBOLTLOCK
SP 62 (S & T) : 199’7

/-KNOB

NIGHT LATCH

FLOOR DOOR STOPPER -CAST TYPE

FIG. 7.14 NIGHT LATCH AND FLOOR DOOR STOPPER

ADJUSTING ARM CONCENTRIC

,- SkiAFT
/- RATCHET-

STUB TOOTH
PINION GEAR

BACK PI ATE

’ ,REGULATING SCREW4
-“..,r , .._.“&

7.15A Typical Illustration of a Door Closer (Hydraulically Regulated)

7.156 Typical Door Handles (Type 1)

FIG. 7.15 TYPICAL ILLUSTRATIONSOF DOOR HANDLES - Cmtinued

150
 SP62~(S& Tj~: 1997

7.15C Typical Door Handles (Type 2)

8
SECTION AT XV

7.15D Typical Door Handle (Type 3)

NOTE - Variousdimensionsshall conformto requirementsgiven in IS 208 : 1987.
FIG. 7.15TYPICAL ILLUSTRATIONSOF DOORIHANDLES- Concluded

r4’1fl MAIN WIRE I

7.16A Ventilator Chain with Eyeand Staple

All dimensions in millimetres.

FIG. 7.16 STAYS - Continued

151
SP 62 (S t& T) : 1997

I (80mm TO
G-73 ----+ Lc
WEB
l--30--+

I_- ___._-
BG K ET
All dimensions in millimetres.
7.168 Window Stay

-H--i k-----l
900’
I \ >ooo

L__Ip., , l-4
B \,

----_--

t
D
D

_F
1 loo0

t1.5 mm
WROX.

7.16C Gate and Shutter Hooks and Eyes

FIG. 7.16 STAYS - Concluded

+--F--A

----“m+

STAPLE (MILD STEEL)

D+I-5 mm
HASP -IP
(MILD STEEL BRASS OR
ALUMINIUM ALLOY 1

STAPLE
(BRASS OR ALUMINIUM ALlDY)

FIG. 7.17 MILD STEELOKBRASS OR ALUMINIUM ALLOY HASPS AND STAPLES (SAFETY TYPE)

152
 SP 62 (S & T) : 1997

14 GLAZING 14.4.1 Rebates and Grooves

14.1 General . Rebates shall be rigid and true. The rebates shall be as
f0110’ws:
Glazing is an important item in building construction
- 6 mm for small panes.
and glass has to be selected to cater to several require-
ments, such as. in multistoreyed buildings, industrial - 8 mm for normal panes.
structures, etc. Therefore fixing of glass is a special- - 10 mm at tops and sides and 12 mm at bottom
ized operation and has to be done carefully; otherwise for large windows, such as, shop windows.
it w~ill lead to hazards of broken glass. Besides the - 16 mm deep for double or multiple glazed seal
types of glass and exposure conditions have to be taken
units, un!ess otherwise advised by the
into account.
manufacturer.
14.2 Patent Glazing - A wider rebate is required for bent glass than
for flat glass; rebate for flat glass without beads
As already mentioned, it is covered by IS 10439 :
1983. shall be enough to accommodate the back
putty, the glass and front putty stripped at an
14.3 Materials angle.
a) The glass shall conform to: - For glazing with beads rebates shall be wide
I) IS 2835 : 1977 for sheet glass. enough to accommodate glass and beads and
2) IS 2553 : 1990 for safety glass. to allow a minimum clearance of 1.5 mm at
3) IS 5431: 1969 for wired and figured glass. both-back and front of the glass.
b) Glazing compound shall conform to: - Rebates and grooves shall be clean and un-
1) IS-419 :-1967 for putty. obstructed before glazing.
2) IS 11433 (Part 1) : 1985, IS 11433 (Part 2)
: 1986 for polysulphide based sealants. 14.4.2 Location of Glass in Frame (see Fig. 7. IS)
3) Compounds for glazing in concrete, stone,
a) The’glass shall rest on two blocks to locate the
brick or asbestos cement are needed to be pane properly within the surround. In case of
sealed to prevent absorption of oil from small panes, the blocks may not be necessary,
the glazing compound, unless the com-
when glazing in side-hung windows or door,
pound has been specifically formulated; the glass shall be located by blocks so that it
resistance to alkali is important. A non-
bears on the bottom of the surround at a point
setting compound may be used, provided near the hinge but is not brought into contact
it is pointed.
with surround and does not suffer und& stress.
4) Non-setting compunds are needed for use
with colour and heat absorbing glasses b) When glazing in horizontal hung sashes, which
which will become hot in sunshine and may turn through about 180°, additional
which are therefore liable to expand and blocks shall be placed between the top edge of
contract much more than ordinary glass. glass and the surround to prevent movement of
The fact that non-setting compounds are the glass when the sash is inverted. When the
easily finger marked make it undesirable panes are more than 90 mm high, the glass shall
to use them without beads except in rela- be located at two pivoting points by blocks of
tively inaccessible situations. suitable material, like chloroprene.
c) The design criteria like thickness, durability,
14.4.3 Preparation of Rebates and Grooves in Wood
fire resistance, thermal expansion and contrac-
tion, light transmission and heat insulation, a) Rebates or grooves should be primed to
sound insulation are to be satisfied as per prevent ,excessive absorption of oil from the
IS 3548 : 1988 on glazing practice. putty. If a shellac varnish or gloss paint is used,
14.4 Glazing the wood may be completely sealed and setting
of putty unduly delayed.
The size of glass shall allow for a clearance between
the edge of glass and surround as specified below: b) Absorbent hardwood frames that are not to be
painted should either be primed with a medium
For wood or metal surrounds Y 2.5 mm composed of equal parts of exterior varnish and
For stone or brick - 3.0 mm white spirit and glazed with linseed oil putty;
The clearance may be increased, provided the depth of or be completely sealed with a coat of un-
the rebate or groove is sufficient to provide not less thinned exterior quality varnish and glazed
than 1.5 mm cover to the glass. with a metal casement putty (which will need
to be painted); or with a non-setting compound.

153
SP 62 (S & T) : 1997

c) When completely non absorbent hardwoods, 14.4.5 Glazing with Beads

such as, teak frames are used, metal-casement
putty shall be used. This method should be used for windoy and door
panes where the combined height and width exceed the
4 If the wooden frame has been treated with a maximum shown in Fig. 7.19; glazing in unpainted
preservative, preparation of rebates and
hardwood frames and framed shopfronts for double
grooves shall be made as per instructions of the and multiple glazing units as defined in 14.4.9.and
manufacturer of glazing compound.
wherever a non-setting compound is used in a position
e) In case of stone, concrete, brick or other where it is liable to be disturbed.
materials, the rebates or grooves should be
sealed with an alkali resisting sealer and 14.4.6 Glazing with Compound into Rebates
allowed to dry before glazing. The compound
shall be metal-casement putty. a) Sufficient compound should be applied to the
rebate so that, when the glass has been pressed
14.4.4 Glazing with Compound into the rebate, a bed of the compound (known
as back putty) not less than 1.5 mm thick will
This method is suitable for window or door panes remain between the glass and rebate; there
where the combined height and width do not exceed shall be a surplus of compound squeezed out
the maximum shown in Fig. 7.19 for appropriate above the rebate which would be stripped at an
exposure grading. angle as in Fig. 7.18 B and not undercut to
prevent water accumulating.

I
TIGHT
SIZE

7.18A Glazing Rebate

GLASS

FRONT
PUTTY.

7.188 Glazing withCompound c

FIG. 7.18 TYPICAL ILLUSTRATIONSSHOWING GLAZING DETAILS

154
 SP 62 (S & T) : 1997

LENGTH OF SHORTER SlBE(mm) v;?OOO

1750

1500

1'250

-11000

750

500

PLATE SHEET WIND

THICKNESS PRESSURE
(mm) ( N/m2)
“‘Weight ofglass in kg/m2approximatelyequalto 2.6 times the thicknessin millimetres. Nomogram for determiningthickness of window
panes for various wind.pressures.(Modulus of ruptureof sheet glass taken CC+ 38 N/mm’ and of plate glass as 19 N/mm’ after making
allowance for variability of strength.)

FIG. 7.19 NOMOGRAM FOR DETERMINING THICKNESS OF GLASS PLATE AND SHEET~FORWINDOW PANES

b) The glass should be secured by springs or pound against the glass and wood beads should also be
spring clips spaced not more than 350 mm bedded against the rebate.
apart measured around the perimeter of the
pane, and afterwords fronted with the com- a>Care should be taken to see that no voids are
left between the glass and the bead. For outside
pound to form a triangular fillet stopping
glazing, hollow beads are undesirable unless
1.5 mm short of the sight line so that the edge
they can be completely filled.
of the compound may be sealed against the
b) With non-setting compound and where there is
glass by-painting, without encroaching over the
a risk of glazing compound being dislodged by
sight line.
pressure, front and back distance pieces (to
14.4.7 Glazing with Compound into Grooves maintain face clearances) should be used. Dis-
The glass should be pressed into the glazing com- tance pieces should be completely embedded
pounds previously placed in the groove. The space in the compound.
between the glass and sides of the groove should be c> Beads should be secured to the wooden frame
filled with the compound which should then be with either panel pins or screws and to metal
stopped at an angle and not undercut (see Fig. 7.18 C). frames in the way providea for in the-frame. In
securing wooden frames, an adequate number of
14.4.8 Glazing with Beads Alongwith Compound
pins or screws for fixing the beads should be used
Sufficient compound should be applied to the rebate as to prevent flexing or movement of beads.
so that when the glass has been pressed into the rebate, 4 The external glazing should as far as possible
a bed of compound (known as back putty) not less than be fixed from outside with beads as stated in
1.5 mm thick will remain between the glass and the 14.4.5.
rebate. There should also be a surplus of compound e> Where it is not possible to fix the glass from
squeezed out above the rebate which should be outside, especially in a multistoreyed build-
stripped at an angle not undercut, to prevent water ings, it may befixed from inside with sealing
accumulating. Bends should be bedded with the com- compound as shown in Fig. 7.20.

155

d
SP 62 (S & T) : 1997

other. However carefully such glazing is done,

it may be necessary to open the cavity at fre-
quent intervals for the purpose of cleaning.

cl One window frame of sash single-glazed

provided with clip to permit attachment of
second glass - This system involves no
serious cleaning problems since the slipped-
OUTSIDE
on panes can be quickly detached. Their main
I BEAD* use is on existing windows which cannot other-
I /II/ /-
wise be modified.

4 Double or multiple factory made hermetically

sealed units - Problems of cleaning of inner
surfaces do not arise. Adequate~rebate shall be
‘?ALING COMPOUND provided in accordance with manufacturer’s
SECTION AA instruction.
CLEAR ANC
14.4.10Double Glazing other than Factory Made Units

To minimize the entry of moist air from the interior of

the building or penetration of rain from outside into the
cavity, the glazing shou!d be done carefully. When
opening sashes are provided, it is essential that they
should fit closely. A small breathing hole should be
provided from the bottom of the cavity to the outside
* Can be fixed prior to or after placing the glass pane as per site to ensure that such breathing vents are kept clear of
conditions.
paint or other obstructions.

FIG. 7.20 INSIDE GLAZING

Where separate panes are glazed in one sash, it is
preferable to use preformed strip of compound for the
Figured glasses are used to avoid direct sunrays back putty in glazing the second pane, in order to
and to get diffused-light. This can be achieved provide full~back putty with a neat finish. Usually it is
advantageously by placing rough surface of the better to glaze the outer pane first.
glass facing outside. As the surface of the glass
from inside is smooth, it will facilitate in past- 14.4.11 Factory-Made Double or Multiple Sealed
ing colour plastic film on the inside surface, Units
whenever required. In that case, it will be
difficult to clean the rough surface of the When ordering factory-made units or multiple units
glass outside, but it can be cleaned by a water the following points may be taken into account:
jet.
a) Both tight size and glazing size (see Fig 7.18)
14.4.9 Double and Multiple Glazing should be specified and not the glazing size. ---“W-b

The problems connected with application of double b) Sealed unitsshould be checked in the opening
for sedge clearance consistent with the
and multiple glazing are briefly as follows:
manufacturers’ recommendations. It is essen-
Two separate window frames, each single- tial to follow any recommendation given by the
glazed--These are preferable for sound in- manufacturer concerning the correct edge to be
sulation. To avoid problems of dirt and glazed at the bottom. Units should be posi-
moisture in the air space, means of access to tioned in the compound approximately one
the cavity should be provided. quarter of the total length from each end. The
width of the blocks should be not less than the
One window frame carrying two sashes
IA’

thickness of the sealed units and their thickness

coupled together, each separately glazed,
should be such as to positioh the units centrally
The glazing may be in separate rebated, one
in the opening. The thickness of glazing com-
inside glazed and the other outside glazed; or
pound between the glass and the back of the
in single wide rebates with spacing beads. The
rebate, and between the glass and bead should
former method has the advantage that either
be about 1 mm.
pane can be replaced without disturbing the

156
 SP 62 (S & T) : 1997

Special techniques of glazing are required to 14.4.12 Louvred Glazing

protect the seal and reference shall be made to
This type of fixed glass louvres are recommended for
the manufacturer of glazing units.
toilets, stores, etc, where permanent ventilation is
A non-setting glass compound having good required.
adhesion to glass and frame should be used.
All absorbent rebates and beads should be a) Louvred glazing (horizontal) - Glass strips
with rounded edges are inserted frpm outside
treated with a sealer (priming is not suffi-
into the grooves placed one above the other.
cient).
The grooves shall be angular preferably at 45’
Glazing with beads should always be used. on the frame. The grooves shall overlap each
Hollow beads are not recommended. other by at least 20 mm (see Fig 7.2 I).

Where there is a risk of the glazing being b) Luuvred glazing (vertical) - Glass strips are
dislodged by pressure, front and back distance placed angularly and vertically, and inserted as
pieces should be used to maintain face described in 14.4.l2 (a).
clearance.

FRAME

GROOVE

20 mm

OUTSIDE

NOTE-The depthof groovemaybe thricethe thicknessof glassand widthof the groovemnybe I to 1S mm morethan the maximum
thicknessof glass.

FIG. 7.21 FIXED GLAZED LOUVEREDWINDOW

157
SP 62 (S & T) : 1997

ANNEX A
(Clauses 13.1 and 13.2)
LIST OF INDIAN STANDARDS ON BUILDERS HARDWARE

IS No. Title IS -No. Title

204 Tower bolts (ferrous metals) 5187 : 1972 Flush bolts

(Part 1) : 1991 5899 : 1970 Bathroom latches
204 Tower bolts (non-ferrous metals) 5930 : 1970 Mortice latch
(Part 2) : 1992 6315 : 1992 Floor springs (hydraulically regu-
20.5 : 1992 Non-ferrous metal bull hinges lated) for heavy doors
206 : 1992 Tee and strap hinges 6318 : 1971 Plastic window~stays and fasteners
208 : 1987 Door handles 6343 : 1982 Door closers (pneumatically regu-
281 : 1991 Mild steel sliding door bolts for use lated) for light doors weighing up~to
with padlocks 40 kg
362 : 1991 Parliament hinges 6607 : 1972 Rebated mortice locks
363 : 1993 Hasps and staples 7196 : 1974 Holdfast
364 : 1993 Fanlight catch 7197: 1974 Double action floor springs
452 : 1973 Doorsprings, rat-tail type (without oil check) for heavy doors
453 : 1993 Double acting spring hinges 7534 : 1985 Sliding locking bolts for use with
729 : 1979 Drawer locks, cupboard locks and padlocks
box locks 7540 : 1974 Mortice dead locks
1019: 1974 Rim latches 8756 : 1978 Mortice ball catches for use wooden
1341 : 1992 Steel butt hinges almirah
1823 : 1980 Floor door stoppers 8760: 1978 Mortice sliding door locks, with
1837: 1966 Fanlight pivots lever mechanism
2209 : 1976 Mortice locks (vertical type) 9106: 1979 Rising butt hinges
2681 : 1993 Non-ferrous metal sliding door 9131 : 1979 Rim locks
bolts for use with padlocks 9460 : 1980 Flush drop handles for drawer
3564: 1986 Door closer (hydraulically regulated) 9899: 1981 Hat, coat and wardrobe hooks
3818 : 1992 Continuous (piano) hinges 10019 : 1981 Mild steel stays and fasteners
3828 : 1966 Ventilator chains 10342 : 1982 Curtain rail system
3843 : 1985 Steel back flap hinges 12817 : 1989 Stainless steel butt hinges
3847 : 1992 Mortice night latches 12867 : 1989 PVC hand rail covers
4992 : 1975 Door handles for mortice lock (ver-
tical type)

158
-.._ ._

SP 62 (S & T) : 1997

PART 2 METAL DOORS, WINDOWS AND VENTCLATORS (STEEL AND ALUMINIUM)

1 GENERAL 2.2 Type of Opening:

1.1 The dimensions and other details of steel Metal doors windows and ventilators may be required
doors, windows and ventilators shall conform to to be fixed to either masonry openings (including
IS 1038 : 1983. The hot rolled steel sections shall brick, concrete, stone and marble) or timber openings
conform to IS 7452 : 1990. Fire check doors or steel work openings.
shall confirm to IS 3614 (Part l) : 1966 and IS 3614
(Part 2) : 1992.
4 Masonry openings - Masonry openings may
either be rebated or flush and in either case,
1.2 Fixing of aluminium doors, windows and ventila- they may have either external rendering ap-
tions is also covered in this Part. plied or be ‘fair-faced’ (that is, without exter-
nal rendering). It is usual for stone or marble
2 INSTALLATION masonry to be fair-faced.

2.1 General b) Timber openings-Timber openings are in-

variably rebated.
Fixing and glazing of metal doors, windows and ven-
tilators refer to securing them in structural or masonry
c>Steelwork openings-Steelwork openings
vary in detailed design but shall be so designed
surrounds and securing glass to the metal frame. The that the outer frame of the door, window or
method adopted should be such that movement of the ventilator frame sections overlap a steel sur-
structure to which the securing is done does not trans- face either externally or internally.
mit strain to the metallic units. Special requirements
of manufacturer shall be taken care of while installing 2.2.1 Size of Openings
fire check doors.
The overall size of both flush and rebated openings to
Every installation presents its own problems and dif- which the units have to be fixed shall allow a clearance
ferent surround details may require different techni- between the frame and opening and the amount of
ques. Further, doors, large composite windows, bay clearance depends on whether the opening is external-
windows are rather complicated, to install and ly rendered or fair-faced.
whereever special windows are being fixed, a careful
study of the drawings and specialized training and skill
a>Flush openings-Rendered flush openings
shall allow a clearance between frame and
are called for. A trained titter in metal window fixing opening equal to thickness of rendering (see
knows how to make adjustments to bring window out Fig. 7.22 A and Fig. 7.22 B). Fair-faced flush
of wind ‘and to take out any twist or bend in the openings shall allow a clearance of 3 mm be-
section. tween frame and opening (see Fig. 7.23).

I-
WIOTH OF OPENING

rb25cm RENDERING

WlDtH OF VENTILATOR-

GLASS

CEMENT MORTAR

7.22A

FIG. 7.22 MASONRY OPENINGSFLUSH WITHRENDERING- Continued

SP 62 (S & T) : 1997

rGLASS

7.228
FK. 7.22 MASONRY OPENINGSFLUSHWITHRENDERING- Concluded
WIDTH OF OPENING -

WIDTH bF WINDOW -

CEMENT MORTAR

FIG. 7.23 MASONRYOPENINGS

FLUSHWITHOUTRENDERING

b) Rebated openings flange of the frame. The depth of rebate

Fair-faced masonry openings and timber shall therefore be adjusted accordingly
openings shall allow a clearance of 3 mm (seeFig. 7.26).
between the opening and the inner flange 3) Steelwork openings shall be designed to
of the frame as well as between the open- allow the outer flange of the window
ing and the outer flange of the frames. The frame section to overlap the steel surface
depth of rebate shall therefore be equal to by 10 mm (see Fig. 7.27A).
the distance between the inner and outer ~_
flanges of the frame of the unit. The rebate The size of the Indian Standard units both for building
shall be 12.5 mm in the case of general and industrial purposes are designed for modular open-
building and industrial windows (see Figs. ings which are larger by 12.5 mm allround than these
7.24 and 7.25). units. This gap of 12.5 mm is for fixing those units. In
2) Rendered masonry openings shall allow a case of masonry the gap is filled with mastic cement
clearance~of 3 mm between opening and and plaster after the unit is in position. In the case of
the inner flange of the frame and a steel and timber openings, extra steel or timber fillets
clearance equal to the thickness of render- will be necessary to cover this gap of 12.5 mm (see
ing between the opening and the outer Fig. 7.27B).

160
 SP 62 (S & T) : 1997

wcoT_n OF OPENING -

t- pmm(f)
WIOTH OC WINDOW-

FIG. 7.24 MASONRY OPENINGS REEATEDWITHOUTRENDERING

WSUTW OF OPENING-

+ WIOTH OF WINOOW-’

~WOOOEN OR-METAL
BEAO

PLASTER

FIG. 7.25 MASONRY OPENINGS REBATEDWITHOUTRENDERING

k-WlblH OF OPENtNG _

WlOtM OF OOOR-

FIG. 7.26 MASONRY OPENINGSREBATEDWITH RENDERING

2.3 Installation of Single Units done to the unit during subsequent building
work. Placing of scaffolding on frames or glaz-
a) The units shall be fixed into prepared open-
ing bass shall on no account be done.
ings.They shall not be ‘built-in’ as the walls go
up as this practice often results in brickwork b) The size of the opening shall be checked and
being brought right up to the frame with no cleaned of all obstructions. Suitable markings
clearance allowed and usually distorts the units may be done to fix the unit in the proper posi-
and increases the likelyhood of damage being tion, including the fixing hole positions. In case

i
I 161
SP 62 (S & T) : 1997

WIDTH OF WINDOW -

Y
ROLLED STEEL
ANGLE

WIDTH OF STEEL_
WORK OPENING
7.27A

m /--ROLLED STEEL
ANGLE

k 7 ~000 OR
lMRDBLOCK

L l9mm

MASTIC

7.278

FIG. 7.27 DETAILS OF FIXINGWINDOW TO STEELWORK !I

(
of masonry, hales for fixing lugs shall be cut In concrete, dressed stone and marble sur-
5 cm2 and 5 cm to 1D cm deep or to fix raw rounds, the units shall be fixed with legs.
plugs.
Wood surrounds are generally rebated and
c>The units shall be checked to ensure that they mastic be applied to the sill of the opening and
are square and working satisfactorily before units placed on it, and screwed on to the open-
fixing. ings. In case of steel openings, special clips _Y”._
may be used to fix the unit.
4 The units shall then be put in position and the
lugs screwed on tight. h) In case of aluminium frames, the surfaces shall
be anchored in direct contact with the sur-
i
e) When fixing to flush surrounds without render- rounds afid shall be protected with two coats of
ing the 3 mm gap shall be pointed with mastic alkali-resistant paints, to avoid chemical attack
on the outside before the internal plaster and from the materials of surround. 1
rendering; the plaster and rendering shall be
2.4 Installation of Composite Units 1
applied to the surrounds after the lugs have
firmly set. When fixing to rebated sorrounds a) Composite units shall follow the procedures I
I-
without rendering the frame shall be bedded in described in 2.3 and in addition shall conform
mastic. When fixing to rebated surrounds with to the following.
rendering, after bedding in mastic, plaster shall r
b) Mullions and transome of composite units
be applied from outside.

162
 SP 62 (S & T) : 1997

shall be bedded in mastic to ensure weather 3 GLAZING

tightness. Mastic shall be applied to channels
3.1 The procedures laid down in 14 of Part 1 may be
of the outside frame sections before assembly.
followed to the extent applicable.
c>If their is a cross joint
of mullion and transome,
4 OTHER SHUTTERS
the shorter coupling unit shall run through un-
broken. 4.1 Steel rolling shutters shall conform to IS 6248 :
1979
4 Mullions normally project 2.5 cm at head and
sill into the surround; transomes also project 4.2 Steel collapsible gates shall conform to IS 10521 :
2.5 cm into surround where appropriate they 1983.
shall be cut. 4.3 Steel sliding shutters shall conform to IS 10451 :
2.5 Hardware 1983.
4.4 Installation of these shutters shall be as per prin-
Hardware shall be fixed as late as possible just before
ciples laid in 2 except as required during installation
the final coat of paint is applied.
to suit local conditions.

163
As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER8

STEELCONSTBUCTION
 CONTENTS

PART 1 USE OF HOT ROLLED SECTIONS 4 CONNECTIONS

1 GENERAL 4.1 General

4.2 Rivets, Close Tolerance Bolts, High Strength
2 MATERIALS
Friction Grip Fasteners, Black Bolts and
2.1 Structural Steel Welding
2.2 Rivets 4.3 Composite Connections
2.3 Welding Consumables 4.4 Members Meeting at a Joint
2.4 Steel Castings 4.5 Bearing Brackets
2.5 Bolts and Nuts 4.6 Gussets
2.6 Washers 4.7 Lug Angles
2.7 Cement Concrete 4.8 Pitch of Rivets
-2.8 Hot Rolled 4.9 Pitch of Bolts

3 FABRICATIONAND ERECTION 5 FABRICATIONAND CONNECTIONSFORDEZXN BY

3.1 General PLASTIC THEORY
3.2 Fabrication Procedures 5.1 Fabrication
3.3 Assembly 5.2 Connections
3.4 Riveting
3.5 Bolting 6 FABRICATION AND CONNECTIONS FOR TUBULAR
3.6 Welding STRUCTURES
3.7 Machining of Butts, Caps and Bases
3.8 Solid Round Steel Columns 6.1 General
3.9 Painting 6.2 Materials
3.10 Marking 6.3 Fabrication
3.11 Shop Assembly 6.4 Connections
3.12 Packing ANNEX A LIST OF INDIAN STANDARDSAND HAND-
3.13 Inspection and Testing BOOKS RELEVANT TO STEEL CONSTRUCTION
3.14 Site Erection
3.15 Field Connections PART 2 USE OF COLD FORMED SECTIONS
3.16 Painting after Erection
1 GENERAL
3.17 Bedding of Stanchion Bases and Bearings of
Beams and Girders on Stone, Brick or Con- 2 MATERIALS
Crete (Plain or Reinforced)
 SP 62 (S & T) : 1997

CHAPTER 8

STEEL CONSTRUCTION

PART 1 USE OF H-OT ROLLED SECTIONS

1 GENERAL 2.4 Steel Castings

-1.1 This Part covers use of hot rolled steel sections Steel castings shall conform to grade 23-45 of
including tubes in general building construction, in IS 1030 : 1989.
particular fabrication practices and connections. The 2.5 Bolts and Nuts
requirements do not completely cover those of bridges,
chimneys and other special steel structures. This is line Bolts and-nuts shall conform to IS 1363 (Parts 1,2,3) :
1992, IS 1364 (Parts 1,2,3) : 1992, IS 1367(Part 3) :
with the design codes, one for general building con-
struction and others for individual structures depend- 1991, and IS 3640 : 1982 as appropriate.
ing loads, service conditions, etc. 2.6 Washers

1.2 There are three basic methods of connecting steel Washers shall conform to IS 5369 : 1975, IS 5370 :
members through rivets, bolts and welding. Thus, the 1969, IS 5374 : 1975 and IS 6610 : 1972, as
fabrication practices differ. In addition high strength appropriate.
grip bolts are being used in construction which reduces 2.7 Cement Concrete
noise during fabrication on site, and is based on the
Cement concrete used in association with structural
principle of friction through grip.
steel shall conform to IS 456 : 1978.
2 MATERIALS 2.8 Hot Rolled
2.1 Structural Steel Hot rolled sections shall conform to Indian Standards
Structural steel shall conform to IS 1977 : 1975, IS listed in Annex A. It also lists other relevant Indian
2062 : 1992 and IS 8500 : 1992 and any other struc- Standards and Handbooks_prepared so far in relation
tural steel as specified with minimum guaranteed yield to steel construction.
point. 3 -FABRICATION AND ERECTION
NOTE - IS 226 and IS 961 have been superseded by IS 2062 3.1 General
and IS 8500 respectively.
As much fabrication work as is reasonably practicable
2.2 Rivets shall be completed in the shops where steel work is
fabricated. Tolerances for fabrieation of steel struc-
Rivets shall conform to IS 1929 : 1982 and IS 2155 : tures shall conform to IS 7215 : 1974. Tolerances for
1982 as appropriate. High tensile steel rivet bars shall erection of steel structures shall conform to IS 12843 :
conform to IS 1149 : 1982. Hot rolled rivet bars shall 1989. For general guidance on fabrication by welding
conform to IS 1148 : 1982. reference may be made to IS 9595 : 1980.

3.1.1 Minimum Thickness of Metal - Corrosion

2.2.1 Friction Grip Bolts
Protection
High tensile diction grip bolts shall conform to IS 3757 : a> Steel work exposed to weather- Where steel-
1985; high tensile friction grip nuts shall conform to work is directly exposed to weather and is fully
IS 6623 : 1985 and high tensile friction grip washers accessible for cleaning and repainting, the
shall conform to IS 6649 : 1985. thickness shall be not less than 6 mm; and
where steel is exposed to the weather and is~not
2.3 Welding Consumables accessible for cleaning and painting, the thick-
ness shall not be less than 8 mm. This shall not
Covered electrodes shall conform to IS 814 : 199 1, or
apply to hot rolled sections covered by Indian
IS 1278 : 1972. Barewire electrodes for submerged arc
Standards.
welding shall conform to IS 7280 : 1974. Combination
of wire and flux shall satisfy IS 3613 : 1974. Filler b) Steel work not directly exposed to the
rods and bare electrodes for gas shielded metal arc weather - The thickness of steel work not
welding shall conform to IS 6419 : 1971 and to directly exposed to the weather shall be not less
IS 6560 : 1972 as appropriate. than 6 mm. The thickness of steel in secondary

167
SP 62 (S & T) : 1997

members shall be not less than 4.5 mm. For stanchion and girder tlanges shall, where
hot rolled sections to Indian Standards the possible, be drilled after the members are
mean thickness of flange be considered and not assembled and tightly clamped or bolted
the web thickness. together. Punching may be permitted
before assembly, provided the holes are
c) These requirements of3.1.1 (a) and (b) do not
punched 3 mm less in diameter than the
apply to light structural work or to sealed box
required size and reamed after assembly
section or to steel work in which special
to the full diameter. The thickness of
provision against corrosion has been made;
material punched shall not be greater than
also in case of steelwork exposed to highly
16 mm. For dynamically loaded struc-
corrosive industrial fumes or vapour or slaine
tures, punching shall be avoided.
atmosphere. the minimum~thickness shall be as
agreed to between the customer and designer.
2) When holes are drilled in one operation
through two or more separable parts, these
3.2 Fabrication Procedures parts, when so specified, shall be
separated after drilling and the burrs
4 Straightening - All material shall be straight removed.
and, if necessary, before being worked shall be
3) Holes in connecting angles and plates
straightened and/or flattened by pressure, un-
other than splices, also in roof members
less required to be curve linear and shall be free
and light framing, may be punched full
ft-om twists.
size through material not over 12 mm
b) Clearances - The erection clearance of thick, except when required for close
cleated ends of members connecting steel to tolerance bolts or barred bolts.
steel should preferably be not greaterthan 4) Matching holes for rivets and black bolts
2.0 mm at each end. The erection clearance at shall register with each other so that a
ends ofbeams without webcleats should be not gauge of 1.5 mm or 2.0 mm (as the case
more than 3 mm at each end, but where, for may-be depending on the diameter of rivet
practical purposes, greater clearance is neces- or bolt is less than or more than 25 mm)
sary, suitably designed seatings should be less in diameter than the diameter of the
provided. hole will pass freely through the as-
Where black bolts are used, the diameter of sembled members in the direction at right
holes, shall be generally 1.5 mm more than the angle to such members. Finished holes
diameter of permanent bolts, and 3 mm more shall be not more than 1.5 mm or 2.0 mm
than diameter of erection bolts. (as the case may be) in diameter larger
than the diameter of the rivet or black bolt
c) Cutting passing through them, unless otherwise
1) Cutting may be effected by shearing, crop- specified.
ping or sawing. Gas cutting by mechani- 5) Holes for turned and fitted bolts shall be
cally controlled torch may be permitted drilled to a diameter equal to the nominal
for mild steel only. Gas cutting of high diameter of the shank or barrel subject to
tensile steel may also be permitted H8 tolerance specified in IS 9 19 (Part I ) :
provided special care is taken to leave 1993. Parts to be connected with close
sufficient metal to be removed by machin- tolerance or barrel bolts shall preferably
ing sothat all metal that has been hardened be tightly held together through all the
by flame is removed. Hand flame cutting thickness at one operation and sub-
may be permitted subject to approval by sequently reamed to size. All holes not
the Authority. drilled through all the thickness in one
2) Except where material is to be subsequently operation shall be drilled to a smaller size
joined by welding, no loads shall be trans- and reamed out after assembly. Where
mitted into metal through a gas cut surface. this is not practicable, the parts shall be
3) Shearing, cropping and gas cutting, shall drilled and reamed seperately through
be clean, reasonably square, and free from hard bushed steel jigs.
any distortions, and should the Authority 6) Holes for rivets or bolts shall not be
find it necessary, the edges shall be ground formed by gas cutting process.
afterwards.
3.3 Assembly
4 Holding
I) Holes through more than one thickness of The component parts shall be assembled and aligned
material for members, such as, compound in such a manner that they are neither twisted nor

168
 SP 62 (S & T) : 1997

otherwise damaged, and shall be so prepared that the 3.7 Machining of Butts, Caps and Bases
specified cambers, if any, are provided.
1) Column splices and butt joints of struts and
3.4 Riveting compression members depending on contact
for stress transmission shall be accurately
1) Rivets shall be heated uniformly throughout machined and close butted over the whole sec-
their length without burning or excessive scal- tion with a clearance not exceeding 0.2 mm
ing, and shall be of sufficient length to provide
locally at any place. In column caps and bases,
a head of standard dimensions. They shall, the ends of shafts together with attached gus-
when driven, completely fill the holes, and if sets, angles, channels, etc, after riveting
countersunk, the countersigning shall be fully together should be accurately machined so that
filled by the rivet; any protrusion of the parts connected butt over entire surfaces of
countersunk head being dressed off flush, if contact. Care should be taken that these gus-
required. sets, connecting angles or channels, are fixed
2) Riveted members shall have all parts firmly with such accuracy that they are not reduced in
drawn and held together before and during thickness by machining more than 2.0 mm.
riveting, and special care shall be taken in this
2) Where sufficient gussets and rivets or welds
respect for all single riveted connections. For are provided to transmit the entire loading, the
multiple riveted connections, a service bolt
column ends need not be tnachined, the design
shall be provided in every third or fourth hole. of column members should cover this.
3) Wherever practicable, machine riveting shall
3) Ends of all b&ring stiffness shall be machined
be carried out by using machines of the steady or ground to fit tightly both at top and bottom.
pressure type.
4) Slab bases and caps, except when cut from
4) All loose, burned or otherwise defective rivets material with true surfaces, shall be accurately
shall be cut out and replaced before the struc-
machined over the bearing surfaces and shall
ture is loaded, and special care shall be taken be in effective contact with the end of the
to inspect all single riveted connections.
stanchion. A bearing surface which is to be
5) Special care shall be taken in heating and driv- grouted direct to a foundation need not be
ing long rivets.
machined if such face is true and parallel to the
3.5 Bolting upper face.
5) To facilitate grouting, holes shall be provided
I) Where necessary, washers shall be tapered or where necessary in stanchion bases for the
otherwise suitably shaped to give the heads and escape of air.
nuts of bolts a satisfactory bearing.
2) The threaded portion of each bolt shall project 3.8 Solid Round Steel Columns
through the nut by at least one thread.
3) In all cases where full bearing area of the bolt 1) Solid round steel columns with shouldered
ends shall be provided with slab caps and bases
is to be developed, the bolt shall be provided
machined to fit the shoulder, and shall be tight-
with a washer of sufficient thickness under the
ly shrunk or welded in position.
nut to avoid any threaded portion of the belt
being within the thickness of the parts bolted 2) The tolerance between the reduced end of the
shaft and the hole in case of slabs welded in
together.
position, shall not exceed 0.25 mm.
3.6 Welding 3) Where slabs are welded in position, the
reduced end of the shaft shall be kept just
1) Welding shall be in accordance with IS 816 : sufficiently short to accommodate a fillet weld
1969, IS 819 : 1957, IS 1024 : 1979, IS 1261 : around the hole without weld metal being
1959, IS 1323 : 1982 and IS 9595 : 1980 as proud of the slab. Alternatively, the caps and
appropriate. bases may be directly welded to the column
2) For welding any particular type of joint, without bearing or shouldering. All bearing
welders shall give evidence acceptable to the surfaces of slabs intended for metal-to-metal
Authority of having satisfactorily completed contact shall be machined perpendicular to the
appropriate tests as described in any of the shaft.
. Indian Standards, namely, IS 817 (Part 1) :
1992, IS 1393 : 1961, IS 7307 (Part 1) : 1974, 3.9 Painting ‘i
IS 7310 (Part 1) : 1974 and IS 7318 (Part 1) :
1974 as appropriate. Painting shall be done as prescribed in IS 1477 (Parts : . 1
1 and 2) : 1971 (see also Chapter 15). L

169
SP 62 (S & T) : 1997

1) All surfaces to -be painted, oiled or otherwise manufacturers’ works which are concerned
treated shall be dry and thoroughly cleaned to with the fabrication of steelwork and shall be
remove all loose scale and loose rust. afforded all reasonable facilities to satisfy that
2) Shop contact surfaces need not be painted un- the fabriction is being undertaken in accord-
less specified. If so specified, they shall be ance with the specifications.
brought together while the paint is still-wet. 2) Unless specified otherwise, inspection prior to
3) Surfaces not in contact, but inaccessible after despatch shall not interfere with the operation
shop assembly shall receive the full specified of the work.
protective treatment before assembly. This
3.14 Site Erection
does not apply to the interior of hollow sections
(see IS 3502 : 1981). 1) Plant and Equipment - The suitability and
4) /Chequered plates (see IS 3502 : 1981) shall be capacity of all plant and equipment used for
painted but the details of painting shall be erection shall be to the satisfaction of the
specified by the Authority. Authority.
5) In case the surfaces are to be welded, the steel 2) Storing and Handling - All structural steel
shall not be painted or metal coated within a should be so stored and handled at the site that
suitable distance of any edges to be welded, if the members are not subject to excessive
the paint specified or metal coating would be stresses and damage.
harmful to the welders or impair the quality of 3) Setting Out-The positioning and levelling of
welds. all steelwork, the plumbing of stanchions and
6) Welds and adjacent parent metal shall not be the placing of every part of the structure with
painted prior to de-slugging, inspection and accuracy shall be in accordance with approved
approval. drawings and to the satisfaction of Authority.
7) Parts to be encased in concrete shall not be 4) Security during Erection - Safety precaution
painted or oiled. during erection shall conform to IS 7205 :
1974. During erection, the steelwork shall be
3.10 Marking
securely botled or otherwise fastened and,
Each piece of steelwork shall be distinctly marked when necessary, temporarily braced to provide
before delivery, and bear such other marks as in for all load to be carried by the structure during
accordance with a marking diagram as well facilitate erection including those due to erection equip-
erection. ment and its operation.

3.11 Shop Assembly No, riveting, permanent bolting or welding

should be done until proper alignment has been
1) The steelwork shall temporarily shop as- obtained.
sembled complete or as arranged with the
Authority so that accuracy of fit may be check- 3.15 Field Connections
ed before despatch. The parts shall be shop All field assembly by bolts, rivets and welding shall
assembled with sufficient numbers of parallel be executed in accordance with the requirements for
drifts to bring and keep the parts in place. shop fabrication excepting such as manifestly apply to
2) In case of parts drilled or punched, through shop conditions only. Where the steel has been
steel jigs with bushes resulting in all similar delivered painted, the paint shall be removed -before
parts being interchangeable the steelwork~may field welding, for a distance of 50 mm at least on either
be shop erected in such position as arranged side of the joint.
with the Authority.
3.16 Painting after Erection
3.12 Packing
1) Before painting of such steel which is
All projecting plates or bars and all ends of members delivered unpainted is commenced, all sur-
at joints shall be stiffened, all straight bars and plates faces to be painted shall be dry and thoroughly
shall~be bundled, all screwed ends and machined sur- cleaned from all loose scale and rust.
faces shall be suitably packed; and all rivets, bolts, 21 The specified protective treatment shall be
nuts, washers and small loose parts shall be packed completed after erection. All rivet and bolt
separately in cases so as to prevent damage or distor- heads and site welds after de-slugging shall be
tion during transit. cleaned. Damaged or deteriorated paint sur-
3.13 Inspection and Testing faces shall be first made good with the same
type of paint as the shop coat. Where
1) The Authority shall have free access at all specified, surfaces which will be in contact
reasonable times to those parts of the after site assembly shall receive a coat of paint

170
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SP 62 (S & T) : 1997

(in addition to any shop priming) and shall be be used provided that due allowance is made for any
brou~ght together while paint is still wet. slippage.
3) Where the steel has received a metal coating in 4.3 Composite Connections
the shop, this coating shall be completed on site
so as to be continuous over any welds and site In any connection which takes a force directly trans-
rivets and bolts; but subject to the approval of ferred to it and which is made with more than one type
Authority, protection may be completed by of fastening, only rivets and turned and fitted bolts may
painting on site. Bolts which have been gal- be considered as acting together to share the load. In
vanized or similarly treated are exempted from all other connections sufficient number of one type of
this requirement. fastening shall be provided to transfer the entire load
4) Surfaces which will be inaccessible after site for which the connection is designed.
assembly shall receive the full specified treat-
4.4 Members Meeting at a Joint
ment~before assembly.
5) Site painting should not be done in frostly or For triangulated frames designed on the assumption of
foggy weather, or when humidity is such as to pin jointed connections, members meeting at a joint,
cause condensation on the surfaces to be shall, where practicable, have their centroidal axes
painted. meeting at a point; and wherever practicable the centre
of resistance of a connection shall be on the line of
3.17 Bedding of Stanchion Bases and Bearings of
action of the load so asto avoid eccentricity moment
Beams and Girders on Stone, Brick or Concrete
on the connections.
(Plain or Reinforced)
1) However, where eccentricity of members or if
1) Bedding shall be carried out with cement,
connection is present, the members and the
grout, or mortar or with cement concrete as in
connections shall provide adequate resistance
IS 456 : 1978.
to the induced bending moments.
2) For multistoreyed buildings, this operation 2) Where the design is based on non-intersecting
shall not be carried out until a sufficient num-
members at a joint all stresses arising from
ber of bottom lengths of stanchions have been
eccentricity shall be calculated and this stress
properly lined, levelled and plumbed and
within limits specified.
sufficient floor beams are in position.
3) Whatever method is employed, the operation 4.5 Bearing Brackets
shall not be carried out, until the steelwork has
Wherever applicable, connections of beams to
been finally levelled and plumbed, the
columns shall include a bottom bracket and top cleat.
stanchion bases being supported meanwhile by
Where web cleats are not provided, the bottom bracket
steel wedges; and immediately before grout-
shall be capable of carrying the whole of the load.
ing, the space under the steel shall be thorough-
ly cleaned. 4.6 Gussets
4) Bedding of structure shall be carried out with Gusset plates shall be designed to resist the shear,
grout or mortar which shall be of adequate direct and flexural stresses~acting on the weakest or
strength and shall completely fill the space to critical section. Re-entrant cuts shall be avoided as far
be grouted and shall either be placed under as practicable.
pressure or by ramming against fixed supports.
4.7 Lug Angles
4 CONNECTIONS
Lug angles connecting achannel shafied member, shall
4.1 General as far as possible, be disposed symmetrically with
respect to the section of the member.
As much of the work of fabrication as in reasonably
practicable shall be completed in the shops where the 1) In case of angle members, the lug angles and
steel work is fabricated. their connections to gusset or other supporting
member shall be capable of developing a
4.2 Rivets, Close Tolerance Bolts, High Strength
strength not less than 20 percent in excess of
Friction Grip Fasteners, Black Bolts and Welding
the force in the outstanding leg of the angle and
Where a connection is subject to impact or vibration the attachment of the lug angle to the angle
or to reversal of stress (unless such reversal is solely number shall becapable of developing 40 per-
due to wind) or where for some special reasonsuch as cent in excess of that force.
continuity in rigid framing or precision in alignment 2) In the case of channel numbers and the like, the
of machinery, rivets or close tolerance bolts, high lug angles and their connections to the gusset
strength friction grip fasteners or welding shall be or other supporting member shall be capable of
used. In all other cases bolts in clearance holes may developing a strength of not less than 10 per-
SP 62 (S & T) : 1997

cent in excess of the force not accounted for by When two or more parts are connected
direct connection of the member, and the together, a line of rivets or bolts shall be
attachment of the lug angles to the member provided at a distance of not more than (37 mm
shall be capable of developing 20 percent in + 4 t) the nearest edge. In case of work not
excess of that force. exposed to weather, this may be increased to
3) Inno case shall fewer than two bolts or rivets 12 t.
be used for attaching the lug angle to the gusset 4) Tacking Rivets - Tacking rivets not subject to
or other supporting member. calculated stress shall be used, in case the
4) The effective connection of the lug angle shall, maximum distances specified in 4.8 (2) is ex-
as far as possible terminate at the end of the ceeded. The pitch of tacking rivets in line shall
member connected, and the fastening of the lug not exceed 33 t or 300 mm whichever is less.
angle to the member shall preferably start in When the plates are exposed to weather, the
advance of the direct connection of the mem- pitch in line shall not exceed 16 t or 200 mm,
ber to the gusset or other supporting member. whichever is less. In both cases, the lines of
tacking rivets shall not be apart at a distance
4.8 Pitch of Rivets
greater than the pitches.
1) Minimum Pitch - The distance between In tension members composed of two angles,
centre of rivets shall not be less than 2.5 times flats, channels or tees in contact back-to-back
the nominal diameter of the rivet. or seperated back-to-back by a distance not
2) Maximum Pitch - The maximum pitch for more than the aggregate thickness of the con-
any two adjacent rivets shall not exceed 32 t nected parts, tackng rivets shall be at a pitch
where t is the thickness of the thinner outside not exceeding 1 000 mm.
plate or 300 mm.
For compression members as above, the pitch
In tension members the distance between any shall not exceed 600 mm.
two adjacent rivets, in a line lying in the direc-
4.9 Pitch of Bolts
tion of stress, shall not exceed 16 t or 200 mm;
and 12 t or 200 mm for compression members. They shall be as for rivets including edge distances and
In case of butting compression members, the tacking bolts.
distance shall not exceed 4.5 times the 5 FABRICATION AND CbNNECTIONS FOR
diameter of the rivets for a distance from the DESIGN BY PLASTIC THEORY
abutting faces equal to 1.5 times the width of 5.1 Fabrication
the member.
All the requirements of fabrication as per 3 shall apply
The distance between centres of any two con- for fabrication for design of steel structures by_ _
plastic
secutive rivets in a line adjacent and parallel to theory subject to the following:
an edge of an outside plate shall not exceed
( 100 mm + 4 t) or 200 mm; whichever is less a ) The use of sheared edges shall be avoided in
in compression or tension members. locations subject to plastic hinge rotation at
factored loading. Ifvsed they shall be finished
When rivets are staggered at equal intervals
smooth by grinding, chipping or planning.
and the gauge does not exceed 7.5 mm, the
distances specified herein between centres of b) In locations subject to plastic hinge rotation at
rivets, may be increased by 50 percent. factored loading, holes or rivets or bolts in the
3) Edge Distances - The minimum edge distance tension area shall be sub-punched and reamed
from the centre of any hole to the edge of the plate or drilled full size.
shall be not less than as given below:
5.2 Connections
Din of DiLstalzce to Distance to Rolled.
Hole Sheared or Hand Muchine Flume Cut, 4 All connections which are essential to the con-
Flame Cut Edge Sawn or Planed Edge tinuity, assumed as the basis of design analysis
mm mm mm shall be capable of resisting the moments,
13.5 and below I9 17 shears and axial loads to which they would be
IS.5 2s 22 subjected by either full or factored loading.
17.5 29 2s b) Corner connections (haunches), tapered or
19.5 32 29 curved for architectural reasons shall be so
21.5 32 29
proportioned that the full bending strength of
23.5 38 32
25.5 44
the section adjacent to the connection may be
38
29.0 51 44 developed.
32.0 57 51 c> Stiffeners shall be used, as required, to
35.0
.________ 57 51 preserve the flange continuity of interrupted

172
 SP 62 (S & T) : 1997

members at theirjunctions with other members posed to weather. In case some other metallic
in a continuous frame. Such stiffeners shall be corrosion protecting material is used, such as
placed irrpairs on opposite sides of the web of aluminium painting, the renewal of coating
the member which extends continuously may be done after longer intervals.
through the joint.
6.3 Fabrication
6 FABRICATION AND CONNECTIONS FOR
TUBULAR STRUCTURES 4 As mentioned in 6.1, provisions of 1 to 5 apply
to construction using tubes also. Where weld-
6.1 General
ing is adopted provisions of IS 8 16 : 1969 shall
The use of tubular steel in structural work would result apply, as appropriate.
in considerable savings, particularly in case of roof
trusses, latticed girders and compression members in b) The component parts of the structure shall be
assembled in such a manner that they are
general. This clause on fabrication and connections
neither twisted nor otherwise damaged and be
for tubular structures is complimentary to the
so prepared that the specified cambers, if any,
provisions of 1 to 5. Requirements which are of
are maintained.
special application to construction using steel tubes
are included here. c) Straightening - All material before assembly
6.2 Materials shall be straightened, if necessary, unless’
otherwise required to be a curvilinear form and
a) Steel tubes shall be hot roiled finished tubes shall be free from twist.
conforming to IS 1161 : 1979. Tubes made by
other than hot finishing processes or which d) Bolting
have been subjected to cold working, shall be 1) Washers shall be specially shaped where
regarded as hot finished, if they have sub- necessary, or other means used, to give the
sequently been heat-treated and are supplied in nuts and the heads of bolts a satisfactory
normalized conditions. bearing.
2) In all cases where the full bearing area of
NOTE - Grade ERW YSt 22 tubes specifiedin IS I 16 I :
the bolt is to be developed, the threaded
I979 with a carbon content less than 0.30 percent, may be
considered as hot finished for this purpose. portion of the bolt shall not be within the
thickness of the parts bolted together, and
b) Electrodes used for welding of steel tubes shall washers of appropriate thickness shall be
conform to IS 814 : 1991. provided to allow the nut to be completely
Minimum Thickness tightened.
1) For tubular steelwork painted with one
~priming coat of red oxide and zinc e) Cut Edges-Edges should be dressed to a neat
chromate paint after fabrication and peri- and workman like finish and be free from dis-
odically repainted and maintained tortion where parts are to be in contact metal-
regularly, the wall thickness of tubes used to-metal.
for construction exposed to weather shall Caps and Bases,for Columns - The ends of
be not less than 4 mm (see 2); for con- all tubes for columns, transmitting loads
struction not exposed to weather, it shall through the ends, shall be true and square to the
be not less than 3.2 mm and; where struc- axis of the tube and should be provided with a
tures are not readily accessib!e for main- cap or base accurately fitted to the end of the
tainance, the minimum thickness shall be tube and screwed, welded or shrunk on. The
5 mm. cap or base plate shoul‘d be true and square to
2) Steel tubes used for construction exposed the axis of the columns.
to weather shall be not less than 3.2 mm
thick and for construction not exposed to g) Sealing of Tubes - When the end of a tube is
weather shall be not less than 2.6 mm thick not automatically sealed by virtue of its con-
provided that in each case the tube is ap- nection by welding to another member, the
plied with: end shall be properly and completely sealed.
- one coat of zinc primer conforming to Before sealing, the inside of the~tube should-be
IS IO4 : 1979, followed by a coat of paint dry and free from loose scale.
conforming to IS 2074 : 1992; or
h) Flattened Ends-In tubular construction, the
- two coats of paint conforming to IS 123 : ends of tubes may be flattened or otherwise
1962.
formed to provide for welded, riveted or bolted
This painting schedule should be reviewed connections, provided that the methods
after every two years in the case of tubes ex- adopted for such flattening do not injure the

173
SP 62 (S & T) : 1997

material. The change of section shall be welding. When butt weld running throughout
gradual. is not employed, a fillet running throughout
should be used where the diamter of the branch
j) Oiling and Painting - If not galvanized, all
tube is less than one-third of the diameter of the
tubes shall, unless otherwise specified, be
main tube. The combined fillet-butt weld
painted or oiled or otherwise protectively
should be used when the diameter of the branch
coated before exposure to the weather. If they
tube is equal to or greater than one-third of the
are to be painted with any special require-
diameter of the main tube.
ments, this shall be arranged. Reference may
3) A weld connecting the end of one tube to
also be made to Chapter 15.
the surface of another, with axes of tubes
6.4 Connections intersecting at an angle less than 30°, shall
be permitted only if adequate efficiency of
General - Connections in structures using
the junctions has been demonstrated.
steel tubes shall be provided by welding, rivet-
ing or bolting. Wherever possible, connec- 4) Connections where the axes of the two
tubes do not intersect - A weld connect-
tions between tubes shall be made directly tube
to tube without gusset plates and other attach- ing the end of one tube to the surface of
ments. Each tube may be flattened as specified another, where the axes of the tubes do not
in 6.3 (h) or otherwise formed to provide for intersect, shall be subject to the provision
of 6.4 (c) (2) and (3) provided that no part
welded, riveted or bolted connections. When
loads are required to be carried from one tube of the curve of intersection of the eccentric
to another or are required to be distributed tube with the main tube lies outside the
between tubes, diaphragms which may be curve of intersection of the corresponding
tubular, designed with sufficient stiffness to largest permissible eccentric tube with the
distribute the load between tubes, shall be main tube (see Fig. 8.1).
used.

Eccentricity of Members - Tubes meeting at

a point shall, wheverever practicable, have
their gravity axes meeting at a point so as to
avoid eccentricity. Wherever practicable, the
centre of resistance of the connection shall lie
on the line of action of the load so as to aovid
TYl’E I Butt Weld
eccentricity of the connection.
e,, = +(D~-D~
Welded Connections
I! A weld connecting two tubes end-to-end
shall be full penetration butt weld. The
effective throat thickness of the weld shall
be taken as thickness of the thinner part
joined.
2) A weld connecting the end of one tube
(branch tube) to the surface of another
tube (main tube) with their axes at an angle
of not less than 30” shall be of the follow-
ing type:
- butt weld throughout,
- fillet weld throughout, and
- fillet-butt weld, the weld being a fillet
weld in one part and a butt weld in another
with a continuous change from the one
form to another form in the intervening TYPE m Filfrt-6utt Weld
portions. Go, =f (DICDCJ
A butt weld throughout may be used whatever enhl = +C+-D$
the ratio of the diameters of the tubes joined, NOTE - Dottedcircle shows curve of intersection of largest
provided complete penetration is secured permissiblenon-eccentrictube with main. Solid circle indicates
either by the use of backing material, or by curve of intersection of eccentric branch.
depositing a sealing run of metal on the back FIG. 8.1 DIAGRAM SHOWING LIMITS OF
of the joint, or by some special method of ECCENTRICITYFOR TUBE CONNECTIONS

174
 SP 62 (S & T) : 1997

5) Connections of tubes with flattened diameter of the flattened tube for this pur-
ends - Where the end of the branch tube pose shall be measured in a plane perpen-
is flattened to an elliptical shape, the dicular to the axis of the main tube.
provisions of 6.4 (c) shall apply and the

ANNEX A
(Clause 2.8)
LIST OF INDIAN STANDARDS AND HANDBOOKS RELEVANT TO STEEL CONSTRUCTION

A-l HOT ROLLED STEEL SECTIONS IS No. Title

IS No. Title 806 : 1968 Use of steel tubes in general building

construction
808: 1989 Beam, column, channel and angle
sections 4000 : 1992 Assembly of structural joints using
high tensile bolts
1161 : 1979 Steel tubes
1730 : 1989 Dimensions of steel plates, sheets, HANDBOOKFOR STRUCTURAL ENGINEERS
strips and flats for general engineer-
ing purposes SP 6 (17 : 1964 Steel sections
1732 : 1989 Dimensions of round and square SP 6 (2) : 1962 Steel beams and plate girders
steel bars for general engineering SP 6 (3) : 1962 Steel columns and struts
purposes
SP 6 (4) : 1969 High strength friction grip bolts
1852: 1985 Rolling and cutting tolerances for
SP 6 (6) : 1972 Plastic theory
hot rolled steel products
3443 : 1980 Crane rail sections A-3 WELDING CODES/HANDBOOKS
3954: 1991 Channel sections for general en-
gineering purposes IS No. Title

12778 : 1989 Parallel flange beam and column 10801 : 1984 Recommended procedures for heat
sections - Dimensions treatment of welded fabrication

12779: 1989 Rolling and cutting tolerances for 11991 : 1986 Recommended practice for flash butt
parallel flange beam and column welding of tubes, rods and other sec-
sections tions in carbon and alloy steels
SP 6 (7) : 1972 Simple welded girders
A-2 DESIGN CODES AND HANDBOOKS IS1 handbook for manual metal arc
welding for welders.
IS No. Title
SP 12: 1975 Handbook for gas welders
800 : 1984 Use of steel in general building
construction
SP 62 (S & T) : 1997

PART 2 USE OF COLD FORMED SECTIONS

1 GENERAL 2 MATERIALS

1.1 The design of cold formed sections is covered by 2.1 Cold formed gauge sections shall conform to
IS 801 : 1975. The fabrication is largely by resistance IS 811 : 1988.
spot welding and by site bolting. This is because of 2.2 Design code using cold formed sections shall con-
extremely thin sections used in cold forming. IS 819 : form to IS 801: 1975. SP 6 (5) : 1980 is the handbook
1957 for resistance spot welding of light assemblies in for cold formed light gauge sections.
mild steel covers the fabrication practices of cold
formed sections.

176
 CHAPTER 9

FLOORSANDFLOORCOVERINGS
 CONTENTS

1 GENERAL 3 IN-SITUTERRAZZO
FLOORFINISH
PART 1 BRICK FLOORS 3.1 General
3.2 Materials
1 GENERAL
3.3 General Construction
2 BURNTCLAYBRICKFLOORING 3.4 Preparatory Work
2.1 General 3.5 Spreading the Under layer
2.2 Preparatory Work 3.6 Laying Terrazzo Topping
2.3 Bedding 3.1 Curing
2.4 Laying of Bricks 3.8 Grinding
2.5 Dry Brick Paving 3.9 Laying Terrazzo Skirtings and Dados
3.10 Maintenance
3 REINFORCED
BRICKANDBRICKCONCRETE
FLOORS
4 CEMENTCONCRETE
FLOORING
TILES
3.1 General
3.2 Preparatory Work 4.1 General
3.3 Construction of RB and RBC Roof or Floor 4.2 Materials
3.4 Laying of Bricks and-Reinforcement 4.3 Preparatory Work
3.5 Curing 4.4 Bedding
3.6 Removal of Formwork 4.5 Laying of Tiles
3.7 Finishing 4.6 Grinding and Polishing
4.7 Laying of Rough Tiles
PART 2 CEMENT CONCRETE FLOORS
4.8 Tolerance in slaying
1 IN-SITUCONCRETE
FLOORING 4.9 Skirting, Dado Work and Staircase -Tread
Work
1.1 General
4.10 Maintenance
1.2 Materials
1.3 Types of Floor Finishes ANNEXA SURFACE
TREATMENT
TO CEMENT
1.4 Mix Proportions CONCRETE
EOOR TOPPING
1.5 Durability
PART 3 INDUSTRIAL FLOOR FINISHES
1.6 Resistance to Attack by Chemical Reagents
1.7 Slipperiness 1 GENERAL
1.8 Surface Hardening Solutions
1.9 Size 0f~Panels 2 TYPESOFINDUSTRIAL
FLOORFINISHES
1.10 Protection against~Dampness
1.11 Finish over Stairs 2.1 Types
1.12 2.2 Considerations for Selection of Floor Finish
Laying of Concrete Flooring on Ground
1.13 2.3 Properties of Floor Finishes
Laying of Bonded Construction (Type II)
1.14 2.4 Recommendations for Floor Finish for In-
Laying of Floor Topping on Suspended Slabs
dustrial Buildings
2 IN-SITU
GRANOLITHIC
CONCRETE
FORFLOOR 2.5 Bedding and Jointing of Materials
TOPPING
3 DAIRYFLOORFINISH=
2.1 General
2.2 Materials 3.1 General
2.3 Preparatory Work 3.2 FloorFinishes for Different Sections of Dairy
2.4 Laying of Floor over Base Concrete Floors
2.5 Laying of Floor Topping on Suspended Slab 3.3 Waterproofing Membrane for Dairy Floors
2.6 Curing 3.4 Drainage in Dairies
2.7 Maintenance 3.5 Maintenance of Dairy Floor
 SP 62 (S & T) : 1997

FORLPG
BITUMENMASTICFLOORING 9.2 Mortar
9.3 Storage
4.1 General 9.4 Mixing
4.2 Thickness 9.5 Application
4.3 Preparatory Work 9.6 Acid-Curing
4.4 Laying 9.7 Chemical Resistance of Silicate Type Mortars
PART 4 SPECIAL FLOORS AND FLOOR 10 RESINTYPECHEMICAL
RESISTANT
MORTAR
COVERINGS
10.1 Material
GENERAL
10.2 Storage
MAGNESIUM
OXYCHLORIDE
COMPOSITION
FLOORS 10.3 Safety Precautions
10.4 Mixing
2.1 General
10.5 Handling
2.2 Types Application
10.6
2.3 Materials
10.7 Acid-Curing
2.4 Properties of Magnesium Oxychloride Floors Chemical Resistance of Resin Type Mortars
10.8
2.5 Application
2.6 Testing 11 SULPHURTYPECHEMICAL
RESISTANT
MORTAR
2.7 Maintenance
2.8 Protection of Metal Work 11.1 Material
I 1.2 Storage
3 BITUMENMASTICFLOORING 11.3 Safety Precautions
3.1 General 11.4 Melting and Pouring
3.2 Materials 11.5 Application
3.3 Preparatory Work 11.6 Chemical Resistance of Sulphur Type Mor-
3.4 Laying tars

4 RUBBERFLOORS 12 PARQUET
FLOORING
4.1 General 12.1 General
4.2 Preparatory Work 12.2 Materials
4.3 Laying and Fixing of Rubber Flooring 12.3 Classes of Mosaic Parquet Flooring
12.4 Parquet Floor Patterns
5 LINOLEUM
FLOORS
12.5 Wood Block Flooring Patterns
5.1 General 12.6 Mosaic Parquet Panel
5.2 Materials 12.7 Dimensions
5.3 Preparatory Work 12.8 Fabrication and Laying
5.4 Laying
ANNEXB SPECIESOF TIMBERRECOMMENDED FOR
6 EPOXYRESINFLOORTOPPINGS SLATS,FLOORBOARDSAND PARQUETFLOORS
6.1 General
PART 5 TIMBER FLOORS
6.2 Materials
6.3 Types of Epoxy Resin Toppings 1 GENERAL
6.4 Preparatory Work
6.5 Laying 2 MATERIALS
6.6 Maintenance
3 TYPESOFTIMBERFLOORS
7 FLEXIBLEPVC SHEETANDTILE FLOORING
4 CONSTRUCTION
7.1 General
7.2 Materials 4.1 Single Joisted Timber Floor
7.3 Preparatory Work 4.2 Double Joisted Timber Floor
7.4 Laying 4.3 Triple Joisted Timber Floor
4.4 Solid Timber Floors
8 CHEMICAL
RESISTANT
MORTARS 4.5 Purpose-Made Floors
9 SILICATETYPECHEMICAL
RESISTANT
MORTAR
5 TIMBERFLOORBOARDS
9.1 Material
As in the Original Standard, this Page is Intentionally Left Blank
 SP 62 (S & T) : 1997

CHAPTER 9

FLOORS AND FLOOR COVERINGS

1 GENERAL Part 3 Industrial floor finishes
1.1 For the purpose of this Handbook floors and floor Part 4 Special floors and floor coverings
coverings are grouped as under: Part 5 Timber floors
Part 1 Brick floors Indian Standards available for different floor and floor
coverings are IS 5766 : 1970 and IS 13074 : 199 1.
Part 2 Cement concrete floors

PART 1 BRICK FLOORS

1 GENERAL of cement per square metre so as to get a good

bond between sub-grade and flooring.
1.1 In this Part construction of the floors are con-
sidered: b) The sub-grade shall be provided with the slope
required for the flooring for proper drainage.
a) Burnt clay brick flooring to IS 5766 : 1970.
Where sub-grade is not provided, the earth
b) Reinforced brick and RBC floors and roofs to
below shall be properly sloped, watered,
IS 10440 : 1983.
rammed and compacted. Before laying the
2 BURNT CLAY BRICK FLOORING floor it shall be moistened.

2.1 General c) To prevent subsidence a layer of sand 75 mm

thick may be provided under the base concrete.
The usefulness of burnt clay bricks as flooring material
is their wearing quality and facility for quick installa- 2.3 Bedding
tion. Generally, common burnt clay bricks to IS 1077 :
1992 can be used for low cost temporary sheds, court Before the concrete sub-grade is finally set, lime mor-
yards, footpaths, etc. Heavy duty bricks conforming tar or lime cement mortar not less than 10 mm thick
to IS 2180 : 1988 and IS 3583 : 1988 could be used for shall be spread evenly over the base concrete.. The
locations of floors subject to heavy wear and tear, such proportions of mortar shall be as given below:
as, stores, godowns and platforms. Generally, bricks Heavy dutyfloors - 1:4 (cement mortar) or 1: 1:6
laid on edge give better performance than when laid (cement lime mortar)
flat.
Light dutyfloors - 1:6 (cement mortar) or 1:2:9
.
(cement lime mortar)
2.2 Preparatory Work
2.4 Laying of Bricks
2.2.1 Base Concrete

Heavy duty floors shall be provided with base con-

a>Soaking - To reduce excessive suction, the
bricks shall be soaked in clean water, before
crete; light duty floors may also be provided with base laying, and then allowed to drain until they are
concrete. The concrete used shall generally be lime
surface dry.
concrete with brick or stone aggregates prepared as
described in Chapter 5. Lean cement concrete mix b) The bricks shall be laid in plain, diagonal,
1:5:10 may also be used. For heavy duty floors the herring bone, or other suitable patterns. The
base concrete shall be 150 mm thick, for light duty brick shall either be laid flat or on edge; laying
floors, base concrete, when provided, shall be 75 mm on edge is preferred. Broken bricks shall not
thick. be used in flooring except for closing line.

a) Limeconcrete sub-gradeshall be allowed to set c) Bricks shall be laid on the mortar bed by gentle
for seven days. If the sub-grade is of lean topping. The inside faces of bricks shall be
cement concrete, flooring work shall be com- smeared with mortar before the next brick is
menced within 48 h; if not the surface of the laid and pressed against it. On completion of
sub-grade shall be roughened with steel wire a portion of flooring, the vertical joints shall be
brushes, wetted by sprinkling water and fully filled with mortar from top. The surface
smeared with a coat of cement slurry at 2.75 kg of the flooring shall be checked frequently for

181
SP 62 (S & T) : 1997

trueness and slope. In case of flat brick floor- 3.2.3 Details of corrosion protection are as below:
ing, bricks shall be laid with frog down, when
laid flat in plain courses, the units shall be a>Quality of concrete mix, should be higher than
M 15.
bonded to break joints at half the length~of the
bricks. b) Cover to reinforcement as specified in\
IS 456 : 1978 subject to severe conditions.of
4 All joints shall be full of mortar; the thickness exposure.
of joints shall be 8 to 10 mm. The joints shall
be flush pointed after being raked out 10 mm c>Protective coatings may be as follows:
deep while the mortar is still green. The raked 1) Cement-sand-asphaltkoaltar pitch mix-
joints, after cleaning, shall be wetted and filled ture coating - A dry mixture of cement,
with I:3 cement mortar. molten asphalt or coaltar pitch and dry
sand in the ratio of 1: I:3 by mass should
The flooring shall be cured at least for 7 days
be applied on the steel surface to a thick-
after completion. In case of cement lime mor-
ness of 6 mm and surface should be
tar, curing shall commence 2 days after laying
finished by flaming.
and continued for 7 days.
2) Cement-sand-mortar with neat cement
2.5 Dry Brick Paving finish - 1:3 cement mortar to a thickness
of 6 mm shall be applied. The surface
The bricks without soaking in water, shall be laid dry, should be finished with a neat cement
flat or on edge on 12 mm thick mud mortar laid to slurry finish with a2: 1 water cement ratio.
required slope on the sub-grade. The mud mortar shall 3) Empty resin/mortar rendering may also be
be made of soil free from vegetable roots, gravel, and applied in existing structures.
coarse sand; the plasticity index shall be between 9 to 41 Steel reinforcement may be coated with
12 percent and it shall be prepared as in Chapter 4. cement slurry to inhibit corrosion.
After laying the bricks, the joints shall be filled with
fine sand. Reinforcement shall be free from rust; heavy
rust shall be removed by brushing or by de-
3 REINFORCED BRICK AND BRICK rusting jellies.
CONCRETE FLOORS
3.3 Construction of RB and RBC Roof or Floor
3.1 General 3.3.1 Centering shall be erected to support the RB
Reinforced brick and brick concrete floors are widely floor or roof from below. The centering shall be
smooth, clean and to correct alignment. The top sur-
adopted, particularly in north India. This type of con-
struction consists of laying high strength bricks direct- face of the formwork shall be given an upward camber
ly over the formwork with reinforcements in between of 1 mm for every 150 mm of span subject to a
the joints and filling up the joints with concrete. This maximum of 30 mm to allow for initial settlement.
type of construction has been found to be strong, Before laying the slab, the formwork and the supports
durable and it also facilitates quick construction. shall be checked to prevent undue sag and to ensure
However, in this type of construction, reinforcement overall safety and stability of the formwork.
deteriorates due to corrosion, unless otherw~ise 3.3.2 All main and distribution bars shall be placed in
protected. the position in Fig. 9.1 and shall be completely em-
bedded in concrete. They shall be rigidly secured
3.2 Preparatory Work against any displacement and arrangement shall be
made to ensure proper cover to reinforcement. Splices
3.2.1 Bricks shall be kept immersed in water for 4 to
6 h and removed about 15-20 min before they are in adjacent bars shall be staggered. Horizontal spacing
of bars shall not be more than 3 times the effective
used so that their skin is dry when concrete is
poured. depth or 450 mm whichever is smaller. The pitch of
the distribution bars shall be not more than 5 times the
effective depth or 450 mm whichever is smaller. The
3.2.2 Reinforcement shall be so placed, that they do
reinforcement in either direction shall not be less than
not touch bricks at any point. A minimum cover of
0.20 percent of the cross section of slab for mild steel
25 mm shall beprovided all round the reinforcement.
and 0.16 percent for deformed bars.
Corrosion of reinforcement shall be prevented by
taking measures recommended in IS 9077 : 1979 3.3.3 The bricks, as prepared in 3.2.1 shall be laid as
which deals with corrosion protection of reinforce- shown in Fig. 9.1 with cement mortar 1:3. Preferably
ment in RB and BBC construction. In general two bars a minimum spacing of 60 mm in between bricks should
shall not be used in the same joint. be maintained for preventing corrosion.

182
 SP 62 (S & T) : 1997

DISTRIBLITION
/- REINFORCEMENT OEPTH OF SLAB7

MAIN REINFORCEMENT

l 9.1 A Cross Section of RB Slab

9.1 B Cross Section of RBC Slab

FIG 9.1 TYPICALRB ANDRBC SLAB

3.4 Laying of Bricks and Reinforcement 3.5 Curing

The brickwork shall be kept wet by means of wet straw

a) The bricks~for single brick thickness of floor or
or wet sand or merely be sprinkling water gently over
roof shall be laid directly on the forms without
the surface for about 24 oh after finishing. The slab
bedding of any kind. After one or two bricks
shall then be watered profusely for a period of at least
has been laid the next row is similarly laid
10 days.
providing the gap for concrete joint. Cement
concrete shall be poured into the joints after the 3.6 Removal of Formwork
placement of reinforcement. The concrete The formwork shall not be removed before 14 days
shall be fluid enough to run freely around the after laying.
reinforcing bars and fill the joints completely.
3.7 Finishing
The joints shall be puddled sufficiently with a
trowel or a sharp ended 16 mm bar to allow free The completed floor nor roof shall be finished with
flow of concrete. a waterproofing course of lime concrete (sea
Chapter 12) or mudphusku with tiles (see-chapter 11).
b) If a slab of two courses of bricks is laid, a fresh The ceiling shall be rendered or plastered, after drying,
layer of concrete shall be placed over the first with cement mortar (1:3) or lime mortar (1:2) as
course to make the middle horizontal joints and specified. Theplaster may be in a single coat of 12 mm
screeded properly to the desired thickness of thick and shall~be done in accordance with IS 1661 :
the joint. The top course is laid in the same 1972 (see Chapter 4). The finished surface of the floor
manner as the first course. or roof shall be cured with water for a period of not
less than 3 weeks.

PART 2 CEMENT CONCRETE FLOORS

1 IN-SITU CONCRETE FLOORING properties and facility of easy cleaning and main-
1.1 General tenance which make it suitable for use in houses,
offices, schools, hospitals and light industrial build-
In-situ cement concrete flooring consists essentially of ings. Depending on the loading conditions and degree
rich cement concrete, and possesses good wearing
of wear resistance needed, the floor finish has to be laid
SP 62 (S & T) : 1997

in various thicknesses; and careful selection of mix cal floor finish (Type I) with good wearing quality (see
proportion, panel sizes and number of layers has to Figs. 9.2 and 9.4).
made. Also the laying operations have to ensure proper
bonding of the finish to the base or sub floor. 1.3.2 Bonded Floor Finish (Types II, III, V and VI)

1.2 Materials In case of bonded construction, where floor finish is

laid separately over a set and hardened base, the
4 Cement shall conform to IS 269 : 1989, or to topping has to be laid to greater thickness, care shall
IS455: 19890rtoIS 1489(Parts I &2): 1991; be taken to ensure a good bond~between the topping
or any other as specified. and base; otherwise it may lead to cracking, curling
and warping of the floor finish. The higher thickness
b) Aggregates shall conformto IS 383 : 1970. The adds to the dead weight of slab (see Figs. 9.3.9.5 and
aggregate crushing value, tested as per IS 2386
9.6)
(Part 4) : 1963 shall not exceed 30 percent.
Graded coarse aggregate shall be as per 4 The advantage of this type of bonded finish is
Chapter 4. The coarse aggregate shall generally that it is not damaged since it is done after all
be of the following sizes: the work of base and structural slab is done
much in advance. Close tolerances can be
Sl No. Material Size of Aggregate maintained and levels of finished floor can be
controlled. This type of finish is also suitable
i) Base concrete (lean Graded from 40 mm and
cement concrete or below to be laid on old concrete.
lime concrete)
b) Where very dense and smooth surface is
ii) Cement concrete Graded from 16 mm and desired, the topping can be laid in two layers
topping ofthickness below (finsihes Types III and VI). The underlayer
40 mm and above consisting of a leaner mix is first laid seperately
iii) Cement concrete Graded from 12.5 mm and on the hardened base; and the wearing layer of
topping of thickness below very stiff and richer mix, but of thickness
25 mm smaller than the underlayer, is bonded to the
iv) Underlayer of cement -Graded from 12.5 mm green concrete of underlayer and finished
concrete topping in and below smooth.
two layers
Grading of fine aggregate shall be as per Chapter 4.
c>In case of bonded finish on structural slabs
where it is not possible to obtain proper levels
within the thickness of topping, a cushioning
c) Water shall be clean and free from oil, and layer of about 50 to 75 mm thick lime concrete
alkali organic or vegetable matter. Generally is laid and well compacted over the structural
potable water is suitable. In case of doubt slab. Lime concrete layer may also be neces-
about, quality of water, it shall be tested as sary to obtain a level surface over structural
described in Chapter 5. floors other than that of concrete or for embed-
ding fixtures like pipes, etc. This will however
d) Dividing strips shall be as per 3.2 (0.
add dead weight to the structure.
1.3 Types of Floor Finishes

Types of floor finish shall be as given in Table 9.1, r BASE CONCRETE

depending on the expected load, wear of the floor and CEMENT CONCRETE TO+PING
LAID MONOLlTHlCALLY WITH
whether the top is monolithic with base or laid THE BASE CONC-RETE
separately on a set and hardened base. In either case r20
special precaution is necessary to ensure bond between
topping and the base.

1.3.1 Monolithic Floor Finish (Finishes Type I and

NSOLIDATEC 1 GROUND’ ’
Type IV)
LSAND FILLING

In case of monolithic construction even a small thick- 9.2A Without Hard Core Sub-Base
ness of topping is sufficient because of strength im-
parted to it by the base concrete and such type of finish All dimensionsin millimetres.
is quite suitable as a moderately strong and economi- F~9.2 MONOLITHICFLOOR FINISH
(OVERGROUND)- Continued

184
 SP 62 (S & T) : 1997’

CEMENT CONCRETE TOPPING SOFT MOORUM. OR

LAID MONOLITHICALLY WITH CINDER OR SAND
THE BASE CONCRETE1 I- BASE -20
HARD CORE OF DRY BRICK OR STONE BALLAST
BASE CONCRETE
CEMENT CONCRETE TOPPING LA10
MONOLITHICALLY WITCH THE BASE CONfRETE

25

~CONSOLIDATED GROUND

ED

9.2B With Hard Core Sub-Base 9.2C Sub-Base for Regions Having
Expansive Soil
All dimensions in rmllimetres.
Concluded
FIG.~.~MONOLITHICFLOORFINISH(OVERGROUND)-

WEARING LAYER OF
CEMENT CONCRETE
MIX 12 TO 3 FINISHED
MONOLITHICALL WITH
WITH UNDER-LAYER

L CONSOUDATEOGFIQUND
BAND nWuQ BAND FILLINU

B4!3EcoNCRm
BABE COFlCRrn

9.3A Tapping Laid in Single Layer 9.38 Topping Laid in Two Layers

FIG.9.3 BONDED,FLOORFINISHOVERGROUND

CEMENT CONCRETE TOPPING

FINISHED MONOLITHtCALLY
WITH THE STRUCTURAL SLAB 1

15mm

* LSTRUCTURAL SLAB

FIG.9.4 FLOOR FINISHLAIDMONOLITHICALLYWITHTHESTRUCTURALSLAB

185
SP 62 (S & T) : 1997

r-WEARING LAYER OF CEMENT

CONCRETE MIX 1:2 TO 3
CEMENT CONCRETE
‘FINISHED MONOLITHICALLY
WITH UNDER-LAYER
ToPPlNG -7-l

LSTRUCTURAL SLAB--l ’ LUNDER-LAYER OF

CEbiENT CONCRETE
MIX 1:3:6

9.5A Topping Laid in Single Layer 9.5B Topping Laid in Two Layers

FIG. 9.5 BONDEDFLOOR FINISHOVER STRUCTURALSLAB

CEMENT CONCRETE TOPPING

LIME CONCRETE
CUSHIONING LAYER
r 25

75

LSTRUCTURAL SLAB

9.6A Topping Laid in Single Layer

CEMENT CONCRETE TOPPING

UNDER-LAYER Of
CEMENT CONCRETE

75

LSTRUCTIJRAL SLAB
1 LIME C~ONCRETE
CUSHIONING LAYER

9.6B Topping Laid in Two Layers z

All dimensions
in nlillimetres.
*
:
FIG 9.6 FLOORFINISHONSTRUCTURALSLABLAIDOVER CUSHIONINGLAYEROF'LIMECONCRETE

B
L

:
186
 SP 62 (S & T) : 1997

1.4 Mix Proportions nesium silica-flouride or zinc silica-flouride or

proprietary materials consisting mainly of one or more
Mix proportions of base concrete and the topping for of these compounds.These treatments are likely to
different types of floors shall be as specified in need renewals at intervals of one year. Manufacturers
Table 9.1. The topping finish mix of 1:2:4 is being advice should be followed when proprietary materials
replaced by 1:2.5:3.5 mix since this gives a much are used. The treatment may be given as described in
better workability and finish. Annex A.

1.5 Durability 1.9 Size of Panels

Concrete floors possess good durability and resistance Floor finish shall be divided into panels so as to reduce
to abrasion and wear depending upon the following the risk of cracking. The size of the panel is governed
factors: by the thickness of floor finish, the type of construc-
tion (monolithic or bonded), local conditions of
a>Choice of Aggregate - Hard tough aggregate
temperature, humidity and the season in which the
is essential for good durability as well as
flooring is laid. For floor finish laid in hot and dry
abrasion resistance.
climates or in exposed situations, the size of the panels
b) Water-Cement Ratio - The lower the water for floor finish shall be smaller than those laid in less
cement ratio the greater the durability and wear exposed situations or in cold and humid climates. The
resistance provided the flooring is fully com- size of panels for monolithic floor finish can be larger
pacted. than that of bonded floor finish. Generally no
dimension of a panel shall exceed 4 m in case of
cl Density of Flooring - Durability increases
monolithic floor finish and 2 m in case of bonded
with density of finish. The staining of floor
floor finish. The length of the panel shall not exceed
surface that may result from absorption of oils
1; times its breadth. Dividing strips may be used to
is, reduced by increasing the density of floor
finish. form panels.

4 Curing - Adequate curing is very essential to a>The joints of floor finish shall extend through
ensure good wear resistance. the border and skirtings. If the skirting is
laid monolithic with the flooring, a border of
1.6 Resistance to Attack by Chemical Reagents about 300 mm width must be provided alround
the floor. The width of the border provided
Concrete flooring is slowly attacked by acids, around the floor when the skirting is not
vegetable oils, sugar solution and various other agents; monolithic with floor finish shall not exceed
prolonged exposure to these reagents will bring about 450 mm.
gradual deterioration. b) Construction joints between bays of the floor
finish should be placed over any joints in the
1.7 Slipperiness base concrete.
The slipperiness of concrete surface depends mainly
1.10 Protection against Dampness
upon the surface treatment, highly polished type of -“QIw*
floor finish is likely to be slippery. A trowel finished
The layer of sand provided under the base concrete will
floor is reasonably non-slip. Non-slip surfaces may be
generally serve w a damp-proof course under normal
obtained by trowel finish or by providing non-slip
conditions. However in more severe conditions,
inserts. Floor finishes over ramps, stairs and other
damp-proofing as described in Chapter 12 shall be
similar situations, specially if they are liable to get wet,
provided.
shall be finished in chequered pattern to make them
non-slip.
1.11 Finisb~over Stairs
1.8 Surface Hardening Solutions I
For risers 6 mm thick mortar finish~will be sufficient, n
It is not necessary, generally, to ~apply any further 10 mm thickness may be provided when the-surface
treatment to the cement concrete floor topping but of structural concrete is uneven. At treads, the thick-
. dusting may be reduced by application of one of the ness shall be not less than 20 mm for monolithic type
surface hardening solutions of sodium silicate, mag- of construction and 40 mm for bonded construction.

187
SP 62 (S & T) : 1997

Table 9.1 Recommended Specifications for Different Types of Concrete Floors

(Clauses 1.3, 1.4 and-1.14.3)
Type Sub-base Base Concrete Topping
. fl \
c Minimum Mix Proportion Minimum Mix Proportion
Thickness, (by volume) Thickness, (by volume)
mm mm
(1) (2) (3) (4) (5) (6)
A. Cement concrete flooring laid over ground
1 T-horoughly consolidated 100 Cement concrete 20 Cement concrete I:2 to
ground covered with 100 to 1:4:8 (stone aggregate 3 (fine aggregate)
150 mmtiell rammed preferably 40 mm and below)
coarse sand
I A. 100 mm thick hard core of well 100 do 20 Cement concrete 1:2:4
consolidated dry brick or stone (coarse aggregate 12.5mm
aggregate blended with and below)
MOORUM or coarse sand, laid
over well rammed sand filling of
100 mm thick
I B. Stone -ballast (40 mm graded 100 do 20 Cement concrete 1:2 to 3
aggregate) mixed with locally (fine aggregate)
available yellow or red soil or
soft MOORUMin 1:l proportion
shall be compacted to about
300 mm thickness and throughly
saturated with water
II Thoroughly consolidated IdO Cement concrete 25 Cementconcrete 1:2.5:3.5
ground covered with 100 to 1:5:10 (aggregate size (coarse aggregate 12.5
150 mm well rammed (preferab- 40 mm-and below) mm and below)
ly coarse) sand
III do 100 do Underlayer, Underlayer cement con-
25 crete 1:3:6 (coarse ag-
gregate 12.5 mm and
below)
Wearing Wearing layer cement
layer, 15 concrete I:2 to 3 (fine
aggregate)
B. Floor topping laid over structural slabs
IV - - - 15 Cement concrete 1:2 to~3
(fine aggregate)
V - - - 25 Cemcntconcmte 1:2.5:3.5
&oarszaggregate 12.5 mm
and below)
VI Underlayer, Under layer cement con-
25 crete 1:3:6 (coarse ag-
gregate 12.5 mm and
below)
Wearing Wearing layer-cement
layer, 15 concrete 1:2 to 3 (stone
aggregate 4.75 mm and
below)
VII - 50-75 Lime concrete Same as for
Type V or VI
NOTES
1 In regions having expansive soils, the sub-base shall be laid as given in Type I B for bothType II and Type III flooring.
2 For Type I, the cement concrete topping shall be laid monolithic with the base concrete. For Type I A, in places such as garages,
where wheeled traffic comes into contact with the flooring, the sub-base shall have a hard core over the well rammed sand filling. For
Type I B, in regions having expansive soils, Note 1 will apply.
3 For Type III, underlayer shall be laid seperately over specially prepared surface of set and hardened base concrete. The wearing layer
shall then be laid over the green-surface and finished/monolithic with it.
4 For Type VII, a cushioning layer of lime concrete shall be laid over the prepared surface of structural slab. Lime concrete shall be
prepared as in Chapter 5.

1.12 Laying of Concrete%looring on Ground left anywhere in the whole area. This shall be
covered with clean sand well consolidated to a
1.12.1 Preparation of Sub-base
thickness of not less than 100 mm.
a) The ground or earth filling shall be thoroughly
b) In cases where wheeled traffic comes into con-
compacted so that there are no loose pockets
tact with sub-base, as in garages, the sub-base
 SP 62 (S & T) : 1997

shall consist of well compacted sand layer of 1.12.4 Sequence of Building Up

100 mm thick and an additional 100 mm thick
The base concrete and topping shall be laid in alternate
well compacted hard core of dry brick or stone
panels if screed stips are used; the intermediate panels
ballast 40 mm in size blended with Moorum or
being filled after one or two days depending on atmos-
coarse sand.
pheric conditions. But if glass or metallic strips are
c>In the case of expansive soils, after preparing used for effective separation of panels, the base con-
as per Table 9.1, a further cover of 200 mm crete may be laid in all panels simultaneously.
thick layer~of soft MOORUM or cinder or sand
1.13 Laying of Bonded Construction (Type II)
be laid and compacted properly before laying
the base concrete. 1.13.1 Preparation of sub-base shall be as in 1.12.1.

1.12.2 Luying of the Base 1.13.2 Laying of Base Concrete

The area shall be divided into suitable panels (see 1.9). The base concrete may be deposited over the whole
This shall be done by fixing screed strips, the depth of area at a stretch. Before placing the concrete in the
which shall be equal to combined thickness of the base sub-base, the whole area shall be properly w,etted and
concrete and the topping. The screed strips may be rammed. The concrete so placed shall be thoroughly
tamped and the surface finished level with the top
coated with a thick coat lime wash so as to prevent
them sticking to the concrete deposited in the panels. edges of the forms. The surface of the base concrete
Before placing the base concrete, the sub-base shall be shall be left rough~to receive the topping. Two or three
properly wetted. The concrete so placed shall be hours after the concrete is laid, the surface shall be
thoroughly tamped and surface screeded uniformly brushed with a hard brush to remove any laitance or
below the finished grade of flooring to accomodate the scum and swept clean so that the coarse aggregate is
required thickness of topping. Any slope desired in the exposed.
floor finish shall be given in the base concrete. The 1.13.3 Laying of Topping
surface shall be kept rough to receive the topping.
The surface of base concrete shall be thoroughly
1.12.3 Laying the Topping cleaned by scrubbing with a coir or steel wire brush.
Where the concrete is hardened so that roughening of
On the clean green surface of the base concrete, the the surface by wire is not possible, the entire surface
topping shall be laid as soon as possible but not later shall be roughened by chipping and hacking. The
than 2 to 3h of laying the base concrete, depending surface shall be soaked with water, before laying the
on the atmospheric conditions. The base concrete topping, at least for 12 h and surplus water shall be
shall be still green, but sufficiently firm to enable removed by mopping immediately before laying the
workmen to walk over it by placing planks on its topping.
surface.

4 The concrete mix for topping shall be

a>The screed strips shall be fixed over the base
concrete dividing into suitable panels; the
deposited on the base concrete, thoroughly screed strips shall be so arranged that joints, if
compacted to the finished thickness. If water any, in the base concrete shall coincide with the
or laitance rises to the top when consolidat- joints in the topping. Neat cement slurry shall
ing, the concrete should be scraped and be thoroughly brushed into the prepared sur-
replaced by a fresh mix; the excess water in no face of the base concrete. The topping shall
case be absorbed by spreading dry cement. then be laid, very thoroughly tamped, struck-
The topping should be floated with a wooden off level and surface floated with a float. Any
float to render the surface even and shall be inequalities in the surface shall be made good
finished~smooth as in 1.12.3 (b), after slight immediately. The finish shall be laid in alter-
hardening. nate panels as described for monolithic con-
b) Finishing the surface - Finishing operations struction.
shall start after the compaction of concrete and
b) Finishing the surface - The surface shall be
shall be completed in a period of 6 h finished as given in 1.12.3.
depending on the temperature and atmos-
pheric conditions. The surface shall be 1.13.4 L.uying the Topping in Two Layers
trowelled (about three times) to produce a Where the topping is to be laid in two layers to obtain
uniform or hard surface. The trowellings shall
very smooth and dense finish (Type III), the sub-base,
be done at proper intervals; the final trowelling
base concrete and underlayer shall be as described in
shall be done before the concrete has become
1.13.1 to 1.13.3 with the exception that the topping
too hard.
shall not be finished smooth with a trowel but left

189
SP 62 (S & T) : 1997

rough after tamping it and levelling it with screed water overnight and wiped clean. On the clean
board. damp surface of sub-floor, lime concrete shall then be
The top 15 mm thick wearing layer of I:2 to 3 concrete evenly spread between forms, throughly tamped and
mix of consistency stiffer than underlayer concrete levelled.
shall then be laid immediately over the rough but green The clean surface shall be covered with a thin layer of
surface of underlayer, thoroughly tamped struck-off neat cementslurry and then the topping shall be laid
level and the surface floated with a wooden float. Any either in single or two layers.
unevenness in the surface shall be made good imme-
1.14.4 Curing
diately. The surface shall then be finished smooth as
in 1.12.3. The surface shall be cured for 15 days and no traffic
shall be allowed during this period; traffic shall be
1.14 Laying of Floor Topping on Suspended Slabs
allowed only after 28 days.
1.14.1 Floor Topping Laid Monolithically with
Structural/Suspended Slab (Type IV) 2 IN-SZ1’U GRANOLITHIC CONCRETE FOR
FLOOR TOPPING
4 The framework of structural slab shall be
erected to the finished thickness of floor finish. 2.1 General
The concrete shall be deposited in the
a) Granolithic concrete floor topping is adopted
framework and surface finished below the top
for heavy engineering factories, workshops,
edge of the form to accommodatethe required
garages, warehouses, etc, where the floor is
thickness of the topping; any required slope
subject to heavy loads and severe abrasion
shall be given~in the structural concrete and any
combined with impact. The granolithic con-
laitance or scum shall be brushed away from
Crete essentially consists of rich concrete made
the surface of concrete when it is still green.
with specially selected aggregate of high hard-
The surface shall be left rough to receive the
ness, surface texture and particle shape suitable
topping.
for use as a wearing finish to the floors. Al-
b) On the green surface of structural concrete, though plain concrete laid as per 1 of this Part
topping shall be placed immediately after the would be satisfactory for many purposes,
concrete has stiffened to allow the workmen to granolithic concrete is chosen because of its
walk over it by placing planks. high abrasion resistance and used for floor
Laitance and foreign matter if any shall be removed. toppings wherever abrasion combined with
The topping shall be laid and thoroughly compacted impact is likely to be severe.
and screeded to the finished grade. The topping shall b) The base doncrete shall be laid as per 1 of this
be floated with a wooden float to render the surface Part and here only the laying of granolithic
even. It shall be finished as in 1.12.3. topping is described as a supplement to 1 of this
1.14.2 Floor Topping Laid Directly over the Hardened Part.
StructuraVSuspended Slab (Type V and Type VI)
c) There are two methods of laying in-situ
a> Preparation of surface-When the topping is granolithic concrete floor topping. The topping
to be laid separately but directly over the slab shall be laid within 3 h of the laying of the base,
without any cushioning layer, the structural that is, monolithically with the base concrete;
concrete shall be brushed thoroughly with a or alternatively shall be laid anytime after the
coir or steel wire brush and swept clean to base has begun to harden, in such a way as to
expose the coarse aggregate and leave the produce the maximum possible bond between
surface rough. the base and topping, that is, it shall be laid
separately from the base. In ground floors it is
b) Laying topping - The surface of concrete advisable to lay the granolithic concrete top-
shall be thoroughly cleaned. Where concrete ping monolithically with base concrete. In the
has hardened, the entire surface shall be case of bonded construction extreme care shall
roughened by chipping or hacking. The rest of be taken to ensure no breaking of bond be-
the operations shall be as in 1.13.3. tween the base and topping.
1.14.3 Floor Topping Laid over Cushioning Layer of
_ 4 Floor finish to be laid depends on nature of use
Lime Concrete (see Table 9.1)
and performance expected ~of the topping.
1.14.3.1 Preparation of sub-floor - Before laying Therefore the thickness, selection of mix
lime concrete, the surface shall be thoroughly cleaned proportions, pane1 sizes and the type of con-
by scrubbing with steel wire brushes and soaked with struction shall be carefully decided.

190
 SP 62 (S ‘& T) : 1997

2.2 Materials -Where expansion joints are necessary in the

walls and roof of a building, there should be
a>Cement to IS 269 : 1989 or IS 455 : 1989 or IS
corresponding joints in the floor. The floor
1489 [Parts 1 & 2) : 199 1: or any other cement
as specified. finish should not be allowed to cover the joint
filler of the expansion joint in the base con-
b) Aggregates -The aggregates shall consist of
one or more of the following groups : crete; either joint filler should be extended
through the full thickness of the base concrete
i) Granite, ii) Basalt, iii) Trap, and iv)
and finish or the space above it should be filled
Quartzite.
with a suitable sealing compound.
The aggregates shall conform to IS 383 : 1970 and the
crushing value when determined as per IS 2386 c) Protection against Dampness - Protection
against dampness shall beas given in 1.10.
(Part 4) : 1963 shall not exceed 30 percent. The grading
of the aggregates for granolithic concrete shall con- 2.4 Laying of Floor over Base Concrete
form to Table 9.2 for coarse aggregate and Table 9.3 2.4.1 Floor Topping Laid Monolithically with the
for fine aggregate. Base Concrete (see Table 9.4)
On clean green surface of the base concrete laid in
Table 9.2 Coarse Aggregate
(Clause 2.2) accordance with 1 of this Part, the topping shall be
placed in position as soon as possible but generally not
ISSieve Designation Percentage by Mass Passing
later than 2 to 3 h of laying base concrete, depending
IS Sieves
12.5 mm 90- 100 upon the temperature and atmospheric conditions. The
IO mm 40% base concrete at the time of laying the topping shall be
4.75 mm O-IO still green but sufficiently firm to enable the workmen
2.36 mm -
to walk over it by placing planks on its surface. The
granolithic mix (I : 1:2) shall be deposited on the base
Table 9.3 Fine Aggregate concrete in the screed strips already laid and
(Clause 2.2) thoroughly compacted to the finished thickness. The
ISSieve Designation Percentage by Mass Passing surface shall be tested to detect any undulation in the
IS Sieves surface, if any, and shall be made good immediately.
’ Gmding Grading ’ The topping shall be floated with a wooden float to
Zone 1 Zone 2
render the surface even and after the surface is slightly
10 mm 100 100 hardened it shall be finished smooth as descrbed in
4.75 mm 90-100 90-100
2.36 mm 60-95 75-100
1.12.3.
1.18 mm 30-70 55-90 2.4.2 Floor Topping Laid Separately on Hhrdened
600 micron 15-34 3%s9
Base Concrete (see Table 9.4)
300 micron S-20 8-30
1SO micron O-10 O-IO Before the operation of laying the topping is started,
Admixtures - Integral additions are not nor-
the surface of the base concrete shall be thoroughly
cl
mally required; but may be advantageous in cleaned of all dirt, loose particles, laitance, etc. by
certain circumstances. scrubbing with coir or steel wire brush, where the
concrete is hardened, the surface shall be roughened
4 Abrasives - Metallic or non-metallic by chipping or hacking. The surface shall be wetted
materials of high abrasion resistance may be with water for several hours and surplus water shall
incorporated in the floor topping mix to in- be removed immediately before topping is laid.
crease the abrasive resistance of floor topping. A neat cement slurry shall be thoroughly brushed into
the prepared surface of base concrete before laying the
e>Surface Hardening Solutions - These solu-
granolithic topping. The screed strips shall be so
tions, as described in Annex A of this Part may
be used. arranged that the joints, if any, in the base concrete
shall coincide with the joints in the topping. The top-
2.3 Preparatory Work
ping shall be tested for eveness, floated as in 2.4.1 and
a) Mix Proportions - The mix proportion for finished smooth as in 1.12.3.
granolithic concrete floor topping for different
types of floor finishes shall be I: lc2 (by 2.5 Laying of Floor Topping on Suspended Slab
volume)
2.5.1 Floor Topping Laid Monolithically with the
b) Joints - Construction joints between bays of Suspended Slab {see Table 9.4)
the floor finish need only be plain untreated
vertical butt joints and shquld be placed over The framework for the suspended slab shall be erected
any joints in the base. to the full thickness of the floor finish. Structural

191
-..

SP 62 (S & T) : 1997

concrete shall be deposited in the forms thoroughly shall be brushed with a layer of neat cement slurry. The
consolidated and surface finished below the top edge granolithic concrete shall be laid and finished smooth
of the form to accomodate the required thickness of the as in 2.4.
topping. Any slope required in the floor finish shall be NOTE-Where lime and good quality of bricks are not avail-
given in the structural concrete itself when it is still able 1:4:8 cement concrete may be used.
green. The surface shall be finished smooth but rough
enough to provide an adequate bond for the topping. Table 9.4 Different Types of Granolithic
On the green surface of the structural concrete, Concrete Floor Topping
granolithic concrete (1: 1:2) shall be placed in position (Clauses 2.4 and 2.5)
immediately after the structural concrete has stiffened SI Type of Topping Thickness Remarks
enough (but is still plastic) to allow workmen to tread No. of Granolithic
over it by placing planks. Laitance and foreign matter, Concrete Floor
Topping
if any, shall be removed and then granolithic concrete inmm,Min
placed in position. The topping shall be thoroughly
A. Floor Topping Laid over Base Concrete on Ground
compacted and screeded to the finished grade. The
i) Floor topping laid 20 Granolithic concrete
topping shall be floated with a float to render the floor topping shall be
monolithically with
surface even. The mix for the structural concrete as base concrete laid monolithic with
well as the topping shall be as stiff as possible consis- base concrete
tent with workability so as to prevent accumulation of ii) Floor topping laid 40 Granolithic concrete
excess of water or laitance on the surface. After the separately on floor topping shall be
surface is hardened it shall be finished smooth as in hardened based laid over separately
concrete prepared surface of set
1.12.3. and hardened base con-
NOTES crete

B. Floor Topping Laid over Suspended Slabs

1 In the monolithic method of construction, the granolithic
topping may be regarded as contributingto the structural strength iii) Floor topping laid 20 Granolithic cculcrete
of the suspended slab. monolithically with topping shall be laid and
suspended slab finished monolithic
2 The monolithic construction of granolithic concrete floor with the suspended slab
topping presents certain difficulties in construction due to ac-
tivities, such as plastering of walls and ceilings, fixing ofjoinery, iv) Floor topping laid 40 The granolithic topping
movement of scaffoldings, ladders, etc, which are likely to over hardened shall be laid separately
damage the floor finish. suspended slab over the specially
prepared surface of set
2.5.2 Floor Topping Laid over the Hardened and hardened concrete
Suspended Slab (see Table 9.4) v) Floor topping laid 40 Cushioning layer of
over cushioning layer lime concrete of 40 to
The surface of the base concrete shall Abethoroughly 50 mm thickness shall
brushed with a coir or steel wire brush to remove any be spread over the
scum or laitance before the topping is laid; the surface prepared surface of
suspended slab. Top-
shall be swept clean to expose coarse aggregate. ping shall be laid as in
Where the concrete is hardened, the surface shall be Sl No. (iv)
roughened by chipping or hacking. The surface shall
be wetted with water for several hours and surplus 2.6 Curing
removed by mopping immediately before the topping The surface shall be kept moist ,at least for 10 days; no
is laid. traffic shall be permitted on the surface during this
A neat cement slurry shall be thoroughly brushed into period.
the surface as per 2.4 before depositing the topping. 2.7 Maintenance
The surface shall be tested for uneveness and made
good immediately. The top surface shall be finished Except for oil and grease, frequent washing of the
smooth. surface with water may be sufficient to maintain the
floor finish in a clean condition. Grease stains may be
2.5.3 Floor Topping Laid over Cushioning Layer (see
removed by means of sodium metasilicate, caustic
Table 9.4)
soda, some phosphates or other proprietary materials. I
The surface of the suspended slab shall be prepared as b
in 2.5.2. Lime concrete (see Note) shall be spread 3 IN-SITU TERRAZZO FLOOR FINISH
evenly thoroughly tamped and levelled. Lime concrete
3.1 General 1
shall be prepared as per Chapter 5. .
The surface of lime concrete shall be prepared as In-situ terrazzo is a popular floor finish in residential
described~in 2.4 before laying the topping. The surface and public buildings preferred for its decorative and
 SP 62 (S & T) : 1997

wearing properties and facility for e.asy cleaning. It can TERRAZZO TOPPING
also be used in skirting and dados. Use of cement UNDERLAYER
concrete flooring tiles is covered in 4.
rCUSHlONlNG LAYER
3.2 Materials
a>Aggregates used in terrazzo topping shall be
marble aggregates with size varying from
1 mm to 25 mm. Marble powder used in
terrazzo topping shall pass through IS Sieve L STRUGTURAL SLAB

300. Aggregate for terrazzo underlayer as well

FIG. 9.8 TERRAZZOFINISHON STRUCTURALSLAB
as the base concrte shall conform to IS 383 :
1970. 3.3.2 The thickness of base concrete shall be not less
b) Cement - Cement shall conform to IS 269 : than 100 mm and of cushioning layer not less than
1989, or IS 455 : 1989, IS 1489 (Parts 1 & 2) : 75 mm. The combined thickness of underlayer and
199 1, or any other cement as specified. topping for flooring and dada/skirting shall not be less
c>White Cement - It shall conform to IS 8042 : than 30 mm and 20 mm respectively. The thickness of
1989. terrazzo topping shall be not less than the following
depending upon the size of chips used :
4 Pigments - The pigments shall be of per-
manent colour and shall conform to the Size of Chips Minimum Thickness
requirements mentioned~in Table 9.5. mm mm
Water - Water for use in terrazzo work shall 1 to 2
6
be as described in Chapter 5. 2 to 41
Dividing Strips - The material for dividing 4 to 7 9
strips shall be such that it has similar resistance 7to 10 12
to wear as the flooring. The dividing strips may Where chips of larger size than 10 mm are used, the
be aluminium, brass, copper, glass, plastic or minimum thickness of topping shall be not less than
similar materials. Aluminium dividing strips one and one-third times the maximum size of chips.
should have a protective coating of bitumen. 3.3.3 Mix Proportions
The thickness of strip shall not be less than
1.5 mm and width not less than 25 mm for a) The underlayer shall be of cement concrete
flooring. mix 1:2:4 by volume, the maximum size of
aggregate shall not exceed 10 mm.
3.3 General Construction b) The mix for terrazzo topping shall consist of
3.3.1 The terrazzo finish normally consists of the top- cement with or without pigments, marble pow-
ping and an underlayer and is laid over a layer of base der, marble aggregates and water. The propor-
concrete or cushioning layer. The arrangement of ter- tions of cement and marble powder shall be
razzo finish laid directly over the ground shall be as three parts of cement and one part of powder
various layers shown in Fig 9.7 and when laid on by mass. For every part of cement marble
structural slab, the arrangement shall be as shown in powder mix, the proportion of aggregates shall
Fig 9.8. The sub-base shall be well consolidated layer be as follows depending on the size of
of earth or preferably sand. The cushioning layer shall aggregates:
preferably be lime concrete. The base concrete -shall Size of Aggregates Proportion of Aggregate of
be lean cement concrete of 1:5: 10 mix or lime con- mm Binder Mix Parts
crete.
lto7 \ One and three-fourths
7to 15
One and one-half
15 to22 r’
TERRAZZO TOPPING
The aggregates may be of required colour or may be a

Ir
UNDERLAYER mix of aggregates of different colours in the required
proportions. The proportions of cement shall be in-
n--BASE CONCRETE
clusive of any pigments added to cement. The propor-
tions in which pigments are mixed with cement or
white cement to obtain different colours for the binder
shall be as specified in Table 9.5.
kUB -BASE
3.3.4 Size of Panels

FIG. 9.7 TERRAZZOFINISHOVER GROUND a) While laying the floor the joints in tlooring
shall always coincide with the expansion

193
SP 62 (S & T) : 1997

joints, if any, in the structural slab so that any b) Where different coloured chips are used, they
movement of the base will be in the joint in the shall be first well mixed in required propor-
flooring instead of forming uncontrolled tions of various colours and sizes.
cracks. c> Coloured cement may be procured as ready
mixed material or mixed at site; in the latter
b) Differential shrinkage or expansion between
case the pigment and cement in the required
terrazzo and the sub-floor may cause cracks in
proportions shall be mixed thoroughly and
the flooring and floor joints shall be formed so
sieved before further mixing with marble
that the positions of such cracks are controlled.
powder and aggregates.
The floor both while laying the underlayer and
later on the topping shall be divided into panels
4 The coloured cement shall be thoroughly
mixed in dry state with marble powder. The
not exceeding 2 m2 so as to reduce the risk
binder so obtained and the mix of chips shall
of cracking. The joints shall beso located that
then be mixed dry together as given in 3.3.3.
the longer dimension of any panel does not
exceed 2 m. The panel shall preferably be e) While mixing the aggregates, care shall be
taken notto get the materials into a heap, as this
separated by means of dividing strips. How-
would result in the coarsest chips falling to the
ever where butt joints are provided, the bays
edge of the heap and cement working to the
shall be laid alternately allowing for an interval
centre at the bottom. The material shall be kept,
of at least 24 h between the laying of adjacent
as far as possible, in an even layer during
bays.
mixing.
After the materials have been thoroughly
Table 9.5 Cement Pigment Proportion for
mixed in the dry state, water shall be added in
Various Colours of Matrix in Terrazzo Work
small quantities, preferably in a fine spray,
(Clauses 3.2,3.3.3 and 4.2.5)
while the materials are being mixed until the
All proportions by mass.
proper consistency is obtained. The mixture
Colour -Pigment to Proportion Proportion Proportion shah be plastic but not so wet that it will flow;
be Used of Pigment of Cement of White
Cement a rough indication for the addition of proper
quantity of water in the mix is that it shall be
(1) (2) (3) (4) 6)
capable of being moulded when squeezed in
Red Red oxide of iron 1 15-20 Nil
(see IS 44 : 1969) hand without water flowing out. A high water
Black Carbon black 1 25-40 Nil
cement ratio will produce a mixture with a high
(see IS 40 : 1971) dry shrinkage.
Bottle
Green
Green chromium oxide
(see IS 54 : 1975)
1 15-30 Nil s> Machine mixing may preferably be used but
the common type of concrete mixer is not as
Pink Red oxide 1 Nil 100-300 suitable for terrazzo work as the mixer special-
(see IS 44 : 1969)
ly made for this purpose, in which segregation
Cream Yellow oxide of iron 1 Nil 100-400 is prevented by~blades with a lifting as well as
(see IS 44 : 1969)
rotating movement. Only constant work justi-
Yellow Yellow oxide of iron 1 Nil 25-75
(see IS 44 : 1969) fies the installation of such special machines.
Light Green chromium oxide 1 Nil 50-150 h) The mix shall be used in the work within half
Green (see IS 54 : 1975) an hourof the addition of water during prepara-
French - Nil 1 to2 1 tion.
Grey
3.5 Spreading the Underlayer
Fawn Yellow oxide of iron 1 6 4
(see IS 44 : 1969) 3.5.1 Dividing strips, including the stips required for
3.4 Preparatory Work decorative design, shall be fixed on the base to the
exact surface level of floor so as to divide the surface
3.4.1 Mixing of Materials
of base into the required arrangement of panels.
a) Mixing of materials is of great importance, for 3.5.2 Where the dividing strips are not used, the
if this is not done thoroughly the work will not screed strips shall be fixed on the base, properly
have a uniform appearance. If done manually levelled to the correct height to suit the thickness of
the mixing shall preferably be done in a trough floor.
or a tub. With a view to avoid variation in
3.53 The base shall be cleaned of all~dirt, laitance, or
colour the complete quantities of cement and
loose material and then well wetted with water without
pigment required for one operation shall be
forming any water pools on the surface. It shall then
mixed at the begining of work and stored
be smeared with cement slurry just before spreading
properly.
of underlayer.

194
 SP 62 (S & T) : 1997

3.5.4 After application of cement slurry, the under- stencils or framework shall be rectified with a large
layer shall be spread and levelled with a screeding trowel, care being taken to consolidate terrazzo to
board. The slightly rough surface left by the screeding avoid damage to the edges of the design.
board will form a satisfactory key for the terrazzo.
3.7 Curing
3.6 Laying Terrazzo Topping
The surface shall be left dry for air-curing for a dura-
3.61 Terrazzo topping shall be laid while the under- tion of 12 to 18 h depending on the atmospheric
layer is still plastic, but has hardened to provent cement conditions. It shall then be cured by allowing water to
from rising to the surface which is, normally, achieved stand in pools over it for a period of not less than 4
between 18 to 24 h after the underlayer has been laid. days. Precautions shall be taken to prevent the floor
A cement slurry preferably of the same colour as the from being subjected to extreme temperature.
topping shall-be brushed orrto the surface immediately
before laying is commenced. If possible, the entire 3.8 Grinding
work of laying the topping shall be completed at one
3.8.1 The grinding and processing of terrazzo may be
stretch.
commenced not less than 2 days from the time of
3.6.2 The terrazzo mix shall be placed on the screed completion of laying for manual grinding and not less
bed and compacted thoroughly by tamping or rolling than 7 days for machine grinding. The period that
and trowelled smooth, The. time interval allowed be- should be allowed before the floor is fit for grinding
tween each successive trowelling is important as only depends upon the materials, their proportions and the
that much trowelling, which is sufficient to give a level weather. The sooner the grinding is done the easier it
surface, is needed immediately after layer. Further is; if it is done too soon the grinding may tear out the
compacting shall be carried out at intervals, the amount chips from the matrix.
depending upon the temperature and rate of set of the
cement. Excessive trowelling or rolling in early stages 3.8.2 The filling shall be done with a grout using the
shall be avoided as this tends to work up cement to the same coloured cement (without marblepowder) as the
surface~producing a finish liable to cracking and also original mix for terrazzo topping and a portion of the
necessitates more grinding of surface to expose the coloured cement shall be kept for this purpose when
I
marble chips. the floor is laid; this ensures that the parches do not
differ in appearance from the remainder of the floor.
3.6.3 The surface shall then be rammed in order to
consolidate the terrazzo; it is not sufficient just to 3.8.3 Grinding and polishing may be done either by
‘float’ lightly, as this would cause depressions which hand or by machine. The operations shall be as given
have to be filled with mortar. A piece of smooth marble below :
stone of size 150 mm x 150 mm x 25 mm may be
advantageously used for ramming. Following the ram- a) The first grinding shall be done with carborun-
mer, a trowel may be used. When using the trowel the dum stones of 60 grit size.
object should be to make surface level and smooth with b) The surface shall then be washed clean and
as little use of the float as possible relying on pressure grouted with neat cement mortar of the same
rather than upon a~trowelling action to achieve this end. colour as matrix grout of cream like consisten-
Rolling will be easier than tamping and patting but a cy. It shall then be allowed to dry for 24 h and
rolled terrazzo is more likely to crack since the roller wetcured for 4 days in the same manner as
would draw cement to the surface unless the mixture specified in 3.7.
is very dry. The best results are obtained by tamping c) The second grinding shall be done with car-
combined with minimum of trowelling. The compac- borundum stone of 80 grit size.
tion shall ensure that the air bubbles are cleared from d) The surface shall then be prepared once more
the mix. as in 3.8.3 (b).
e) The third grinding shall be done with carborun-
3.6.4 Work on Borders and Decorative Designs dum stone of 120 to 150 grit size.
Borders and decorative designs shall be laid before the f) The surface shall again be washed clean and
main body of the flooring. They shall Abe laid and allowed to dry for 12 h and wetcured for 4 days
finished in the same manner as flooring, preferably in the same manner as in 3.7.
using dividing strips. Where, however, stencils or g) The fourth grinding shall be done with car-
framework of wood or metal are used instead of divid- borundum stone of 320 to 400 grit size.
ing strips, they shall be removed before the topping h) The surface shall again be washed clean and
mix commences to harden. The removal shall be rubbed hard with felt and slightly moistened
effected with as little disturbance to the materials as oxalic acid powder; 5 g of oxalic acid powder
possible and any ragged edges left after removal of the is adequate for 1 m2 of floor surface.

195
SP 62 (S & T) : 1997

3.8.4 When all constructional and finishing works, 4 Tile flooring may be laid on most types of
namely, painting, distempering, electrical work, reasonably rigid base, provided that the sub-
plumbing, joinery work, etc, are completed and just floor is of sufficient strength for the type of
before the area is occupied the floor shall be wahsed flooring proposed and is not liable to settle-
clean with dilute oxalic acid solution and dried. Floor ment at any time. Cement concrete flooring
polishing machine fitted with felt or hessian bobs shall tiles are not recommended for use where they
then be run over it until the floor shines. will be exposed to the action of acids and
In case wax-polished surface is desired, the wax-polish alkalis. However, they give suitable service if
shall be sparingly applied with soft linen on the clean exposed to seawater, vegetable oil or fats.
dry surface. Then the polishing machine fitted with b) For the purpose of selecting tiles, floors are
bobs shall be run over it. Clean sawdust shall then be generally classified into the following types :
spread Dver the floor and polishing machine again be 1) General purpose or light duty floors, that
applied mopping up surplus wax leaving glossy sur- is, those subject to pedestrian traffic as in
face. Care shall be taken to see that the floor is not left offices, domestic buildings, hospitals,
slippery. colleges, banks etc;
3.9 Laying Terrazzo Skirtings and Dados 2) Medium duty floors, that is, those subject
to heavy pedestrian traffic from trolleys,
3.9.1 Underlayer casts, etc, as in factories, pavements, plat-
forms, railway stations, driveways etc;
For terrazzo finish on vertical surfaces like skirting and
dados, the underlayer shall consist of a layer of stiff and
cement mortar 1:3 (by volume) and finished rough so 3) Non-slip floors (where chequered tiles are
as to provide adequate key for topping. used), that is, footpaths and pavements,
special factory floors, platforms, ramps,
3.9.2 Thickness etc.

The combined thickness of underlayer and terrazzo 4.2 Materials

topping shall be not less than 20 mm. The minimum
thickness of terrazzo topping shall be not less than 4.2.1 Sand
6 mm. The sand to be used for mortar for laying of tiles shall
3.9.3 The other operations like laying, curing, grind- conform to IS 2116 : 1980 and the sand shall have a
ing, polishing and maintenance shall be similar to minimum fineness modulus of 1.5.
those described for in-situ terrazzo flooring except that
grinding will be done~manually. 4.2.2 Cement

3.10 Maintenance The cement used for laying the tiles and grouting shall
conform to IS 269 : 1989, or IS 455 : 1989, or IS 1489
Under normal conditions, the flooring may be kept (Parts I & 2) : 1991, or as specified.
clean by washing periodically with water and
occasionally with a dilute solution of oxalic acid after 4.2.3 Lime
which it shall be mopped down with cold water and Class B or Class C conforming to IS 712 : 1984.
dried. If desired, the floor may be polished using a hard
wax-polish or an emulsionpolish. 4.2.4 Tiles
Soap in any form shall not be used as it tends to make
The cement concrete flooring tiles to be used shall
the terrazzo dangerously slippery; excessive polishing
conform to IS 1237 : 1980.
has a similar effect. The surface may also be kept free
from oil and grease toavoid slipperiness. 4.2.5 Pigments
4 CEMENT CONCRETE FLOORING TILES .Pigments incorporated in mortar or used for grating
4.1 General shall conform to Table 9.5.

The usefulness of tiles as.a flooring material consists 4.2.6 Water

mainly in their plesant appearance as it eliminates the
Water used shall conform to requirements laid down
possibility of unsightly cracks and facility for quick
Chapter 5.
installation. The appearance and performance of tiled
floor will, however, depend not only on the quality of 4.2.7 Oxalic acid used in polishing of tiles shall be
materials used but also on the care taken in bedding, such as to give satisfactory performance without
laying and finishing of the tiles. detrimental effects.

196
 SP 62 (S & T) : 1997

4.3 Preparatory Work 4.5.2 Surplus cement slurry after the days work shall
be cleaned and joints washed fairly deep.
4.3.1 Completion of Work Before Laying of Tiles
4.5.3 The day after the tiles have been laid, joints shall
4 All the inside walls, ceiling and outside walls be filled with cement grout of the same shade as the
shall be plastered and door frames and win- colour of the matrix of the tile. The freshly laid portion
dows fixed in position. of-the tiles shall be prevented from damage by provid-
b) The sub-floor shall be finished to a reasonably ing suitable barricades.
true plane surface about 35 to 50 mm below the 4.5.4 Tiles which are fixed to the floor adjoining the
level of the finished floor, properly graded and wall shall go about 10 mm under the plaster, skirting
free from loose earth, dirt or dust and lumps. or dado as may be required by the designer. For this
cl Before tiling work is started, all points of level purpose the wall plaster may be left unfinished by
for the finished tile surface shall be marked out. about 50 mm above the level of the proposed finished
This is particularly necesary in the case of flooring and the unfinished strip may be plastered later
finished staircase landings. Wherever slopes in or after the tiles are fixed.
finished floors are desired points of level and
4.5.5 In odd situations where a full tile cannot be
outlets shall be correctly marked and outlet
provided, tile shall be cut to size and then fixed.
openings made before hand.
4 Where it is feared or suspected that dampness 4.5.6 After fixing the tiles, the floor shall be kept
may percolate either from the ground floor or moist and allowed to mature for 7 days so that the
walls, the same shall be damp-proofed or bedding and joints set properly. After this, it may be
waterproofed as described in Chapter 12. used for light traffic. Heavy traffic shall not be allowed
on the floor for at least 14 days after fixing the tiles.
4.4 Bedding
4.5.7 Wherever big areas of floor are to be tiled, the
a>Spreading ofCement Mortar- The base shall level of the central portion of the floor shall be kept
be well compacted and the surface shall be about 10 mm higher than the level marked at walls
rough to form a suitable key. The base shall be unless specified otherwise. This is normally done to
cleaned and wetted without allowing any pools avoid the optical illusion of a depression in the central
of water on the surface. Cement mortar 1:6 for portion of the tiled hall.
shall be evenly spread over the base for two
rows of tiles and about 3 to 5 m in length with 4.6 Grinding and Polishing
thread level fixed at both ends to act as a guide. 4.6.1 Grinding and polishing of tiles shall commence
The top of the mortar shall be kept rough so only after the floor as well as the joints have properly
that cement slurry can be absorbed. The thick- set and in no case earlier than 14 days of laying.
ness of bedding shall he not less than 10 mm
4.6.2 ~Grinding should preferably done by machine
and not more than 30 mm in any one place.
except for skirting.
Tiles shall then be laid as in 4.5.
4.6.3 For grinding terrazzo tile flooring, the first
b) Spreading of Lime Mortar - After preparing grinding-shall be with machine fitted with carborun-
the surface as in (a) above lime mortar 1:1:2
dum stones of 48 to 60 grit. When the floor is rubbed
(1 lime: 1 SURKHI: 2 coarse sand) or 1:3 (1
even and chips show uniformity it shall be cleaned
lime: 3 SURKHI) or 1:3 (1 lime: 3 coarse sand)
with water marking base all pinholes. Grouting in the
shall be spread evenly limiting the thickness as
same shade is then briskly applied so that all pinholes
in (a).
are properly filled in. The grout shall be kept moist for
4.5 Laying of Tiles a week for proper setting. Thereafter, the second grind-
ing operation with Carborundum of 120 grit is com-
4.51 Laying of tiles should commence next morning menced. The floor is grouted again to fill in fine pin-
by which time the bedding becomes sufficiently hard holes. After curing, the flooring is left with protective
to offer a rigid cushion for the tile and enable masons film till other works are completed and all workers
to place wooden planks and squat on them. Neat quit. Before the final grinding the floor is swept clean.
cement slurry of honey like consistency shall be spread Final grinding is done with carborundum of 220 to 350
over the mortar bed, over such an area at a time as grit using plenty of water and taking care that any
would accomodate 20 tiles. The tiles shall be fixed foreign matter, particles of sand, etc, are prevented.
with grout one after the~other, each tile being tapped When surface is rendered smooth, it is washed with
gently with a wooden mallet till it is properly bedded water. Afterwards oxalic acid powder is vigorously
and in level with the adjoining tiles. The joints shall be applied with machine fitted with hessian bobs to bring
kept as close as possible and in straight lines. The joints out sheen. Wash the floor clean and apply dry linen to
between the tiles shall normally be 1.5 mm wide. suck in moisture. If desired wax-polish may finally be

197
SP 62 (S & T) : 1997

applied mechanically with clean hessian bobs. Super- 4.9.2 Before fixing tiles on brick or concrete wall, the
fluous wax is mopped-up with saw dust till occupation. wall surface shall first be wetted with clean water.
This will protect the surface and help increase lustre. Thereafter, in case of dado the wall surface shall be
-When saw dust is spread, water should not be spilled uniformly and evenly covered with about 10 mm thick
as this is likely to give stains on the polished surface. backing of cement mortar 1:4 (1 cement: 4 coarse
sand). In the case of-skirting the tiles shall be directly
4.6.4 When hand grinding and polishing has to be
fixed with cement mortar 1:4 without initial backing.
adopted, the various processes in the same sequence
Before the cushioning mortar has hardened, the back
sha!l be carried out as in 4.6.3, except that stones with
of each tile to be fixed shall be covered with a thin layer
coarser grit may be used.
of neat cement paste and the tile shall then be gently
4.6.5 In the case of plain cement and coloured tiles, tapped against the wall with a wooden mallet. The
the process of polishing shall be the same as in 4.6.3 fixing shall be done from bottom of wall upwards.
except that initial grinding with Carborundum stone of Each tile shall be fixed as close as possible to the one
48 to 60 grit may not be necessary. adjoining and any difference in thickness of tile shall
be evened out in the cushioning mortar or cement paste
4.6.6 Chequered and Grooved Tiles
so that all the tile faces are set in conformity with one
These tiles normally do not require polishing. But another.
where polishing is required, the same shall be done as 4.9.3 Wherever possible, skirtings and dado shall be
in 4.6.5. ground and polished just as for floor work with
machine suitable for the purpose. Skirtings and dado
4.7 Laying of Rough Tiles
may also be polished by hand.
4.7.1 Where the tiles have been supplied and fixed in 4.9.4 Precast treads and risers for staircases shall be
rough condition (not ground and filled by the manufac- laid and polished as for flooring.
turer), the first grinding shallbe done not less than 14
4.9.5 The laying and polishing of tiles for external
days after fixing the tiles. The initial grinding shall be
paving shall be done similar to that of ordinary floor-
done with Carborundum stones of 36 to 48 grit. The
ing.
remaining process shall be as in 4.6.3.
4.10 Maintenance
4.8 Tolerance in Laying
a) After laying, the floor shall be allowed to
The permissible deviation from datum depends on the remain clean and free from cement, oil, paint,
area involved; for a large open area a deviation upto plaster droppings and all materials likely to
15 mm may be tolerated. Localized deviation of 3 mm stain or spoil the tiles. If appliances, such as,
in any 3 m may be accepted in nominally flat floor. trestles, ladders, steps etc, have to be used for
electrician’s plumber and other light work, it
4.9 Skirting, Dado Work and Staircase - Tread
shall be ensured that parts in contact with the
Work
flooring are padded and no sliding of the ap-
49.1 Tile skirtings, where required, shall be fixed pliances shall be permitted.
only after laying the tiles on the floors. If tiles are to
b) Subsequent maintenance shall be done by
be fixed on walls as dados, the portion of the wall to regularly swabbing with clean water followed
be tiled shall be left unplastered. Also, dado work shall by rubbing with dry linen.
be done only after laying tiles on the floor.

ANNEX A
(Clauses 1.8 and 2.2)
SURFACE TREATMENT TO CEMENT CONCRETE FLOOR TOPPING

A-l CLEANING THE SURFACE tions to penetrate. Thorough cleaning of the surface
shall be ensured particularly in old surfaces. The top
A-l.1 The top surface of concrete shall be clean and
surface shall be wetted with water and scrubbed with
free from grease or oil to enable the hardening solu-
coir or steel wire brush and cleaned with water. The

198 f
 SP 62 (S & T) : 1997

floor shall be allowed to dry before applying hardening A-2.2 Silica-Flouride

solution.
The crystals of magnesium silica-flouride or of zinc
A-2 TREATMENTS
silica-flouride should be dissolved in water at the rate
A-2.1 Sodium~Silicate of 0.1 g/cm3 for the first coat and 0.2 g/cm’ for sub-
sequent coats. Three coats are usually applied after
A solution containng one part by volume of sodium
24 h intervals. There is no need to wash the top surface
silicate andfour parts of water should be spread evenly
between coats, but it is advisable to wash with clean
over the concrete top surface with a mop or soft brush.
water after the final treatment.
Any excess material shall be wiped off and the floor
allowed to dry. After washing the floor with clean
A-2.3 Drying Oil and Surface Sealers
water, a second coat, containing one part of sodium
silicate to three or four parts of water should be applied
Drying oils, either neat or thinned with turpentine or
and this should be allowed to dry similarly. After
white spirit, or surface sealers, may be applied to the
drying, a third coat shall be applied after washing the
top surface by brushing. Any excess should be wiped
floor if it is still porous. After drying, the floor should
off about 2 h after application.
be washed with clean hot water. Effective results are
obtained if the treatment is applied 7 to 10 days after A-2.4 Calcium chloride shall not be used with high
the end of curing. alumina cement.

PART 3 INDUSTRIAL FLOOR FINISHES

1 GENERAL circumstances, such as, non-slippery, dustless, noise-

less, non-sparking, anti-static, etc.
Ll In industrial floors finishes the following are
covered: 2.1.1 A finish for the floor of an industrial building
may begenerally selected out of the following types
4 Industrial floors to IS 497 1 : 1968. to suit the requirements of particular case:
b) Dairy floors to IS 7956 : 1975.
cl Bitumen mastic flooring for industries han- 4 Plain concrete - as described in Part 2,
dling LPG and other light hydrocarbon b) Grarwlithic concrete - as described in Part 2,
products to IS 13074 : 1991.
c>Precast concrete tile - as described in Part 2,
1.2 In the selection of industrial floor finishes, 4 Paving brick - as described in Part 1,
special care is required in view of diversity of the
requirements to be met with and the different charac-
e>Magnesium oxychloride - as described in
Part 4,
teristics of individual floorfinishes. The strength and
stability of finishes will depend on the structural floor, f-l Bitumen mastic - as descrbied in Part 4,
the sub-floor or the foundation. Overloading, thermal g> Linoleum - as described in Part 4,
expansion and movements due to bad design may h) Rubber, PVC &eets - as described in Part 4,
cause failure of an otherwise satisfacfoty floor finish. j) Epoxy resin - as described in Part 4,
Spillage of chemical solutions, acids, alkalis, etc, on Fire clay brick - conforming to IS 6727 :
k)
the floor contribute towards the failure of a floor 1972,
finish.
m>Ceramic unglazed vitreous acid resistant tiles
- conforming to IS 4457 : 1982,
2 TYPES OF INDUSTRIAL FLOOR FINISHES
n>Stones,
2.1 Types P> Steel or cast iron units - conforming to IS
3502: 1981,
This will deal with the selection of industrial floor 9) Wooden block~with lead lining, and
finishes where the floor is subject to heavy abrasion, r) Acid resistant brick - conforming to IS 4860 :
impact, chemical action; floor finish under special 1968.
SP 62 (S & T) : 1997

2.2 Considerations for Selection of Floor Finish bitumen mastic or magnesium

2.2.1 The~important features that govern the selection oxychloride composition. A lead lining
of industrial floor finish are durability, incidence of may be provided over the base concrete or
loading, safety, resistance to chemical action, con- wooden flooring where explosives are
being stored.
venience of the user, appearance and overall economy.
It may be necessary to use a floor which
Table 9.6 gives in general a summary of requirements
conducts electricity and thus prevents the
of floor finishes for various industrial buildings.
accumulation of static electrical charges
a) Durability which may cause a spark.
1) Wear - The nature of mechanical wear c) Resistance to chemicals and water - The
that a floor has to resist varies consider- spillage or splashing of chemical solutions
ably. For general information the type of acids, etc, may cause corrosion, deterioration,
wear may be classified as below: induce slipperiness or give to other fire or
Type of Wear Examples health risks. The possibility of wetting or
Very severe abrasion Heavy engineering flooding the floor with water may be taken into
iogether with heavy workshops and places account.
impact where milk cans are being 2.3 Properties of Floor Finishes
handled in dairies
2.3.1 Properties of floor 5nishes are listed in
Very severe abrasion Places where steel-tyred Table 9.7.
trucks constantly move
Severe abrasion Floors having traffic of
a>Centent_concretefinishes - Plain cement con-
crete is used for a wide variety of industrial
more than 2 000 persons tloors i,z-situ form. Portland cement concrete
per day in definite traffic is resistant to a wide variety of chemicals,
lanes including mineral oils and greases but is slowly
attacked by acids, vegetable oils, fats and sugar
2) Impact - Consideration should be given solutions. Frequent cleaning reduces the at-
to impact, as many flooring materials that tack, but prolonged exposure will bring about
will stand abrasion may suffer rapid a gradual deterioration of the cement concrete
damage under impact. flooring.
~3) Load carrying capacity - Depending on
Granolithic flooring is hard wearing, resists
the nature of loading and type of traffic,
Y impact and is resistant to alkalis and mineral
such as foot, rubber, tyred, metal’wheeled,
oils. On the other hand, it is hard to the feet,
etc, the flooring should be selected to
cold, noisy and susceptible to chemical attack
withstand the severe condition.
including acids, sulphates and vegetable oils
b) Safety and fats.
1) Resistance to high temperature or fire - Concrete tiles have good resistance to wear and
In industrial structures high temperatures chemical attack but cannot withstand heavy
occur without spread of fire. Floor finishes impact; where good appearance and cleanli-
do not by themselves add to fire risks, ness are required for the floors, concrete~tiles
provided the floor superstructure has ade- may be selected.
quate resistance to fire. In certain special
circumstances, however there may be b) Brick and tile finishes - They have good
resistance to wear and impact.
risks arising from the usage of the floor.
For example, oil or other flammable Paving brieks to IS 3583 : 1988 may be used
liquids spilled on floor will lead to greater for heavy duty and industrial floors, loading
afire risks with floors which are absorbent and unloading platforms where the floor is
or themselves combustible, such as, tim- subjected to heavy wear and tear.
ber or bitumen, than with inert dense Fireclay brick to IS 6727 : 1972 may be used
materials, such as, concrete or tiles. in situation where high temperatures are to be
2) Sparking - In factories or stores where met with, such as those around metallurgical
explosives and substances liable to cause furnaces.
explosions are being handled, sparks Acid resistant bricks conforming to IS 4860 :
caused by friction on a floor surface may 1968 have good resistance to all acids except
cause fire or explosion. Therefore, it is hydrofluoric acid and perchloric acid and other
assential to use non-sparkling floor chemicals. They are suitable for floorings sub-
finishes, such as rubber or special grade of ject to acid attack and abrasion.

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Table 9.6 Requirements of Floor Finishes for Various Industrial Buildings

(Clnuse 2.2.1)
Resistance to Attack by
St Type of Building Resis- Resis- Resis- Even- War- App- ,H
No. tancc tance tance ness mth cara- Water Mine- Org- Al- Solu- Mine- Vege- Heat
to to to or to nce ml anic ka- ions ml table Resi-
Abra- Imp- Slip- Smoo- Touch Acids Acids lis of Oil Oil stance
sion act peii- tbness SUI- and and
‘ness phates, Gre- Fats
Phos- ases
phates
and Nit-
rates

(1) (2) (3) (4) (3 (6) (7) (8) (9) (10) (II) (12) (13) (14) (15) (16)

0 Factories and
workshops
a) Heavy industries VI VI I -- R - - - - I 0
b) Light industries I I I D R - - - I< 0

ii) Loading and un- VI VI I D 1 - - - R R

loading platforms

iii) Shops and offices I I I R R -

iv) Food factories, I I VI D I D VI R D R VI

factories processing
meat, vegetables,
animal or vegetable
oils. breweries, beer
cellars, etc

v) Factories using I R I D I R I D D D D
process involving
sugar solutions, etc

vi) Dairies VI I VI D VI D I - - R

vii) Factories handling I I I D I VI - I VI D D

or using salts, salt
solutions,
fertilizers, etc

viii) Chemical factories VI VI I R VI VI VI VI VI R R

(miscellaneous),
chemical laboratories
and explosives~manu-
facturing factories

VI = Very important, D = Desirable. 1=~Important. - = Not usually required, R = Required to some degree, 0 = Variable, very
important to not required sometimes.

Ceramic unglazed vitreous acid resistant tiles withstand impact and wear and where the floor
conforming to IS 4457 : 1982 have good resis- need not be too smooth and even.
tance to acids and are suitable for floorings Quartzite slabs are used mainly for entrance
subject to acid attack, impact and abrasion. halls or where a decorative appearance com-
cl Stoneflooring- The~types of stones useful for bined with good wearing properties under
flooring are granite, basalt, quartzite and heavy foot traffic is required. The stone is easy
sandstone. Granite is very hard and resistant to clean and does not become slippery.
to wear by abrasion or impact, and to attack by Sandstones (see IS 3622 : 1977) of suitable
chemicalagents. variety and thickness may be used for light
It is readily cleaned and if kept clean, it is non- duty flooring.
slippery till unworn; after considerable wear, it 4 Steel und cast iron floor firtish - Metal floor
may become smooth and slippery and finishes are used where severe wearing condi-
mechanical roughening may be necessary. It is tions are encountered. Several types of steel or
used in thick slabs of various sizes depending cast iron units are used for heavy duty flooring.
upon the conditions of use. Granite slabs are This type of finish includes:
suitable for the flooring of loading and unioad- 1) open metal grids embedded in gran-
ing platforms in workshops, godowns, etc. nolithic concrete or in bitumen mastic,
Basalt flooring will be suitable for heavy 2) soild tiles or solid plates, and ’
engineering factories and garages as it may 3) open metal grid suspended floors.

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SP 62 (S & T) : 1997

Open metal grids embedded in granolithic con- may cause indentation. In selecting bitumen
crete are suitable for loading platforms subject mastic flooring consideration may be given to
to impact and wear caused by movements of be anticipated service conditions, particularly
trollies with iron wheels, under wet or greasy the type of traffic and possible contact with
conditions as in the case where bottled milk are oils, acids and the like. Thesurface of bitumen
handled. Steel tiles with a smaller proportion mastic flooring is liable to become slowly
of open space than the grids embedded in softened by prolonged contact with greases,
granolithic concrete are suitable for situations fats and oils. Contamination with such
subject to heavy abrasion and impact. The open materials shall be avoided.
metal grids and steel tiles tend to become slip-
h) Linoleum flooring - Linoleum provides a
pery when oily and to corrode when wet. Solid clean, dust free and resilient flooring. In light
faced metal tiles (usually made of cast iron) are industry, such as, in electronic industry,
highly resitant to wear and impact and to action linoleum flooring may be used as the risk of
of oils, fats,salts and alkalis provided the joints damage by cutting to which linoleum is vul-
are filled with appropriate chemical resistant nerable is small. If linoleum gets wet, it ex-
material (see Part 4). The plain surface types pands, mildews and eventually rots.
are liable to become slippery if wet or even
when dry if polished by wear, and hence spe- j> Rubber flooring - The flooring is resilient
and noiseless. The flooring is suitable for
cial types with patterned surface shall be used
electronic industry, computer rooms, etc.
under these conditions The solid metal tiles
are particularly usetil, on loading bays where k) Flexible PVCflooring - The PVC flooring
there is heavy trucking and in dairies where a provides a clean, dust free and resilient floor-
high standard of cleanliness combined with ing. The flooring may be easily cleaned with
high resistance to-wear and~chemical attack is wet cloth, as dirt and grime do not penetrate the
required. surface.
Steel or cast iron grid suspended floors are used m>Epoxy resinfloor topping - The use of epoxy
for elevated platforms or walk ways around resin floor toppings is characterized by its ex-
large machinery. Floors on which liquids or ceptional physical and chemical properties,
solids are continuously being spilled may be such as, chemical resistance, hardness,
made of supported steel grids with suitable abrasion resistance; compressive, impact and
channels beneath, from which the spilled structural strengths; dimensional stability and
material may be drained or recovered. adhesion to concrete, metal and other surfaces.
This is suitable for use on industrial floors,
e>Wooden block with lead lining - This such as, chemical plants manufacturing
provides a non-sparking floor finish and is fertilizers, pharmaceuticals, acids, solvents,
suitable for floors where explosives are etc, in dairies, tanneries, breweries, garages,
stored. service stations, warehouses, metal plating and
pickling areas.
f) Magnesium oxychloride - The flooring mix
gives a fairly strong and durable floor with 2.4 Recommendations for Floor Finish for
good appearance. However, the flooring is Industrial-Buildings (see Table 9.8)
affected by continued exposure to water, acids,
and salt solution. Too wet a mix with excessive 2.4.1 Floors for Heavy Engineering Factories,
magnesium chloride results in sweating of the Workshops and Garages
floor surface. Mineral oils, greases, vegetable, Floors in heavy engineering factories, workshops and
oils, ~milk products and mild alkalis do not garages shall be resistant to impact, abrasion and attack
affect the floor. by lubricating oils. The epoxy resin floor topping is
S) Bitumen mastic jlooring - Bitumen mastic suitable for heavy industrial floors. The extent to
flooring is considered suitable for industrial which the floors will be subjected to heavy wear and
buildings, storage houses, etc, because of its impact will often vary widely in different parts and
resiliency, wearing quality and ease of main- since the more important type of finishes are more
tenance. Bitumen mastic flooring to expensive it is advisable to ascertain as far as possible,
IS 1196 : 1978 is dustless, odourless, jointless before laying the finishes, where trucking gangways
and impervious to the transmission of moisture or processes involving impact will be located and to
either in liquid or vapour form. The flooring is provide accordingly. Steel or cast iron tiles or plates,
easily cleaned, quiet under traffic and resilient. embedded in granolithic concrete may be used for
Bitumen mastic flooring is also durable. While areas of heavy abrasion by steel-tyred trucks or where
it may carry heavy loads, concentrated loads a high resistance to impact is required.

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Table 9.7 Properties of Floor Furnishes

(Clause 2.3.1)

SI Type of Finish Resi- Free- Even- War- Appe- Resi- Resistance to Attack~by Heat
dom ness mtb A \ Resis-
No. sta- ara- sta- /
nce from or to nce nce Water Mineral Org- Alka- Solu- Mine- Vege- tance
to Slip- Smoo- Tou- to Acids anic lis tions rat table
Abra- peri- th- cb Im- Weak St&g Acids of Oils Oils
sion ness ness pact Sulp- and and
hates, Gre- Fats
Phos- ases
pha-
tes
and
Nit-
rates

:I) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

i) Portland cement
concrete
a) In-situ V%-P VG VG-P P G G-P VG P VP F-P G P-VP G P G
b) Precast VG-G VG VG-P P G G-F VG P VP F-P G P-VP G P G
ii) Steel tiles or VG G P P F VG VG-F P VP F-P G P-VP G P G
grids embedded
in concrete
iii) Cast iron tiles VG F -F-P P F VG G-P P VP G F F-P VG G VG
iv) Natural stones VG-F G-F G-F P G-F VG-F G G-P F-VP G G-F F G G G
v) Heavy duty burnt G VG F P F G VG G G-P G F-VP G-P G G G
clay brick/paving
brick
vi) Fire brick G VG F P F G-F VG VG G G G-P G G VG
vii) Acid resistant VG VG F P G VG VG VG G G G G G VG
brick and tiles
viii) Magnesium VG G VG G VG VG P P VP G G VG VG G
oxychloride
cement
ix) Bituminous G-F G G F F G VG F-P VP P G F FP
mastics
x) Linoleum F VG VG VG VG G G G G-P G G G GF
xi) Rubbersheetsl F VG VG F VG G G G-P G-VP F G P GP
tiles
xii) PVC-asbestos F VG G G VG G VG F F VG VG VG VG VG
tiles
xiii) Epoxy resins VG G F G G G VG G G-F G VG VG VG G
xiv) Polyester resins G G F G G G VG G G-F G VG G G G

VG = Very good, G = Good, F = Fair, P = Poor, VP = Very poor.

G-P denotes variation with the quality of the material or with severity of conditions.

2.4.1.1 Granalithic concrete with suitable ,materials embedded in granolithic concrete are suitable
and good workmanship will provide in light industrial for loading and unloading platforms subjected
workshops and garages a floor finish of reasonable to heavy impact.
durability. Special aggregates and metallic floor har-
2.4.3 Food Factories, Factories Processing Meat,
deners may be added to the granolithic concrete where
Vegetables, Animal or Vegetable Oils, Breweries,
heavy impact and wear is expected.
Beer Cellars, etc
2.4.2 Loading and Unloading Platforms There are many factories making soap, candles and
lubricating oils, in which the floors are subject to the
4 The requirements of loading and unloading
platforms and industrial loading bays are action of animal or vegetable oils or fats due to spillage
primarily high resistance to impact and combined with abrasion. The epoxy resin floor topping,
abrasion and non-slipperiness. is suitable in such situations. Magnesium oxychloride
flooring or heavy duty brick flooring may also be
b) Steel tiles or ‘anchor-plates’ or metal grids adopted.

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Table 93 Recommended Floor Finishes forlndustrial Buildings

(Clause 2.4)
SI Type of Building Situation and Recommended Jointing and
No. Conditions met with Floor Finish Bedding Mortar
(1) (2) (3) (4) (5)
i) Floor for heavy engineering a) Normal conditions Granohthic concrete or -
factories, workshops and paving bricks
garages
b) Heavy impact or wear Epoxy resin floor topping
c) Spillage containing lubricating oils Epoxy resin floor topping -
d) Floors subjected to heavy Steel or cast iron tiles or plates -
abrasions by steel tyred trucks embedded in granolithic concrete

ii) Loading and unloading a) Platforms involving Granolithic concrete or granite slabs -
platforms normal loading conditions or paving bricks
b) Platforms involving heavy impact Steel tiles or anchor plates or metal -
grids embedded in granohthicconcrete
iii) Food factories, factories a) Floors subjected to the action Epoxy resin floor topping or paving -
processing meat, animal or of lubricating oils combined bricks or ceramic unglazed vitreous,
vegetable oils, breweries, with the action of hot water acid-resisting tiles
beer, cellars, etc
b) Abrasion resistance not severe Magnesium oxychloride flooring -
c) Severe abrasion Epoxy resin floor topping or paving bricks -
iv) Factories using processes a) Places where abrasion and Epoxy resin floor topping or unglazed
involving sugar solutions and impact are not excessive vitreous acid-resistant tiles or acid-resistant
weak acids bricks
b) Places where hot sugar solution Unglazed vitreous acid-resistant tiles or Tiles or bricks
or molasses are used acid-resistant bricks shall be bedded
and jointed in
acid-resistant
mortar
v) Factories handling or using a) Places where common salt Granolithic concrete or bitumen mastic -
salts or salt solutions and is the main constituent of
fertilizers spillage
b) Spillage containing any type Epoxy resin floor topping or ceramic -
of salts or fertilizers unglazed vitreous acid-resistant tiles or
acid-resisting bricks

2.4.4 Factories Using Processes Involving Sugar ful to the floor finishes. Bitumen mastic floor-
Solutions and Weak Acids ing is suitable for such situations because of its
impermeability and resistance to chemical
In factories processing fruits and vegetables or
action. Granolithic concrete may also be used.
using sugar syrups, as for example, preserve,
~b) Nitrates, sulphates and phosphates which are
canning, pickle, fruit drink, sweet or sugar
widely handled in the fertilizer industry, may
factories, the floors are subject to chemical
lead to rapid deterioration of the cement con-
action by fruit acids, vinegar and sugar syrup
crete floor. Epoxy resin floor topping or floor
and often to impact and abrasion by movement
paved with ceramic unglazed vitreous acid-
of casks and~by trucking.
resistant tiles or acid-resistant bricks will be
b) Unglazed vitreous acid-resistant tiles or acid- suitable in such situations.
resistant bricks properly bedded and jointed 2.5 Bedding and Jointing Materials
with chemical resistant mortar [IS 4832 (Parts
2.51 Appropriate choice of bedding and jointing
1 and 2) : 1969, IS 4832 (Part 3) : 1968 (see
materials is essential if the risk of defective floors or
also Part 4 of this Chapter)] provide a satisfac-
premature failure is to be avoided, even when the main
tory floor for such situations. Epoxy resin floor
flooring material, that is, block, slab or tile, is of a type
topping is also suitable for such situations.
which would otherwise be satisfactory.
2.4.5 Factories Handling or Using Salts or Salt
a) The various materials used for bedding and
Solutions and Fertilizers
jointing materials and their resistance to
a) The risk of deterioration of floors upon which deterioration is indicated in Table 9.9. The
salts or salt solutions may be spilled as in material shall adhere properly to the base on
tanning, bacon curing, or chemical factories which the finish is laid and to the finishing
depends on the nature of the salts, chlorides, as units. It shall be durable and resist chemical
in common salt when spills are not very harm- attack.

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b) Bedding materials and jointing materials could 3 DAIRY FLOOR FINISHES

be different in the same floor. If spillage of
3.1 General
harmful material is not likely to be appreciable
or where the floor may be cleaned frequently, Floors in dairies and other premises used for process-
it may be sufficient to point the joints with the ing milk and milk products are subject to heavy impact,
chemical resistant mortar and to use cement abrasion and chemical attack. Selection of suitable
mortar for bedding. It may also sometimes be floor finishing materials and design of drains are,
an advantage to bed the units in a bituminous therefore, important for low maintenance cost and long
waterproof compound and to point the joint life of the floor. For small dairies, processing up to
with a chemical resistant mortar. In general, 10 000 1of milk per day.
the use of one type of mortar with very thin
3.2 Floor Finishes for Different Sections of a Dairy
joints requiring no pointing should be
Floor
preferred even if a separate bitumen or other
waterproof layer is laid before bedding and 3.2.1 Structural Base
jointing the tiles.
The structural base should be so constructed that a
slope of not less than 1 in 80 is imparted to the floor

Table 9.9 Properties of Bedding and Jointing Materials

(Clauses 2.5.1 and 3.2.4.4)
Sl Type of Manner Hard- Adhe- Resis- Resistance to Attack by Resis-
No. Material of Use ness sion tance ) h 9 tance
to to Water Mineral Acids Orga- Alka- Solu- Mine- Vege- to
*
Smoo- Wear Weak Stro;lg nit lis tions ral Temp-
th Acids of Oils Oils era-
Sur- Sul- and and ture
phates Gre- Fats
Phos- ases
ohates
and
Nit-
rates

(1) (2) (3) (4) (3 (6) (7) (8) (9) (10) (11) (12) (13) (14) (13
0 Portland 1:3 Hard F F VG VP VP F-P VG P G P. G
cement mortar
ii) Bituminous Hot, as Plastic G G-F VG F P P G G P P P
mastics supplied
iii) Rubber latex Rubber, Resilient VG G G G-P P P G F F F P
cement mortar latex with
portland
cement
iv) Chemical Silicate Hard and G F P VG VG VG P G G G G
resistant solution rather
silicate type and brittle
mortars fillers
Vl Chemical Sulphur Hard G G VG G G-F G G G G F P
resistant and tillers,
sulphur type dry mortar
mottars to be melted
before use
vi) Chemical Resin syrup.
resistant tillers and
resin type hardners
mortars
-
a) EPOXY Hardand VG VG VG VG G-F G VG G VG
resin mortars/ tough
fumae~resin
mortars
b) Cashew do do VG VG VG VG G-F P G VG VG
nutshell
liquid resin
c) mother do do G G G G F G-P G-P G-F VG-P
resin mortars

NOTE - VG = Very good; G = Good; F = Fair; P = Poor; VP = Very poor.

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 SP 62 (S & T) : 1997

surface. This fall should be such that liquid spillage on 3.2.3.3 Metal grids are frequently used as a surface
the floor surface will be drained quickly by the shortest reinforcement to increase the impact resistance. The
route. It is essential to have a waterproof membrane grids may be of cast iron or steel and hexagonal or
(see 3.3) between the base and the floor finish. The square mesh. The usual matrix into which they are laid
joints in the structural base shall be provided in accord- may be either granolithic concrete (see Part 2) or
ance with the details given in IS 3414 : 1968 covered cement rubber latex. The grid may be supplied either
in Chapter 13. All laitance shall be removed and the as a roll of interlocking metal trips from which a grid
surface roughened before laying the floor finish. can be formed or as small units. Mats framed on two
sides only are best because this avoids the weak joints
3.2.2 Group I
between sections.
This group consists of the following sections:
The top edges of the grid form part of wearing surface
a) Loading dock or dispatch dock, and of the floor and distribute impact and wear. Because
of uneven wear between the grid and the material in
b) Cold storage room.
which it is embedded such floors may become noisy
3.2.2.1 These sections are subject to very heavy im- in use.
pact and abrasion. Spillage of milk and milk products
also takes place. Floor finishes recommended for these 3.2.4 Group III
sections are steel or cast iron tiles or solid steel plates.
The floor finish of steel or cast iron tiles may be This group consists of the following sections :
supported structurally by sub-floor. Solid steel plates
may be used as a structural finish supported on a under
a>Milk drum tank pit;

floor framework. b) Milk storage room;

cl Processing hall, milk pasteurization section;
3.2.3 Group II
4 Butter, ice-cream, cheese and ghee section;
This group consists of the following sections:
e>Milkfilling section;
a) Milk can reception room, 0 Roller drier room;
b) Empty can and bottle reception desk, and g) Toned milk room;
c) Empty can and bottle~washing room. h) Corridors; and
._3.2.3.1 These sections are subjected to very heavy j) Laboratory rooms.
impact and abrasion, but little spillage of milk and milk 3.2.4.1 Floor finishes in these sections should be resis-
f products. Floor finishes recommended for these sec- tant to normal impact and wear, to frequent spillage of
tions are steel or cast iron tiles or metal grids with milk and milk products, to mild acids, and alkalis and
filling ~materials, such as, cement concrete, cement- good resistance to hot and cold water as the floors are
rubber latex, etc. subject to frequent washing. The general choice may
3.2.3.2 There are two main types of metal tiles used be made from the floor finsihes given in 3.2.4.2
for industrial purposes which are suitable for dairy to 3.2.4.5.
floors. They withstand impact, abrasion and resist the
action of alkalis but are liable to attack by weak acids. 3.2.4.2 Portland cement concrete is slowly attacked
by milk and milk products particularly by lactic acids
a) One type, called an anchor plate, is in the form
and therefore is not suitable for these sections. How-
of a shallow tray, made of steel. The wearing
ever in such areas where ac.idic action is not
surface is punched to give twisted anchors or
predominent, cement concrete flooring tiles, as
grips which form the key for the bedding and
described in Part 2 or stones, such as, Kotah stones may
when bedded in the concrete give a floor which
be used.
is generally 40 mm thick. A typical illustration
is given in Fig. 9.9. It is essential for the success 3.2.4.3 Acid and alkali resistant stones laid with
of this type of floor finish that tiles are com- phenolic type resin mortar (as per Part 4) for bedding
pletely-filled~with concrete. Tiles which are not and jointing
solid by embedded give continuous trouble
because the steel is not strong enough to bridge Sandstones of highly siliceous and compact variety
hollow places and is bent under traffic. containing low quantity of aluminium oxide, calcium
b) Another type of tile is called honeycomb cast oxide and magnesium oxide, etc, have good acid and
iron tile. These types of tiles are manufactured alkali resisting quality. Such stones are found in places
with a taper in honeycomb for better grip with like Dholpur, Gwalior, Rewa, Cuddapah and
concrete. A typical illustration of such a tile is Mandana, etc. The stones may be tested for acid resis-
shown in Fig. 9.10. tance in accordance with methods of test described in

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 SP 62 (S & T) : 1997

IS 4457 : 1982. However a maximum of 4 percent such as, water-tightness and resistance to oil. The
weight loss during acid treatment may be accepted as techniques of mixing and laying is different than that
adequate acid resistance for the purpose ofdairy floors. of ordinary concrete and therefore advice of an expert,
These floors give long life but become slippery in due would be required when using these floor finishes.
course and hence would require periodical roughen-
NOTE - The latex normally takes the form of dispersion in
ing. water of natural rubber latex, but for a special circumstance, for
example, for oil resistance, synthetic rubber may be used,
3.2.4.4 Ceramic unglazed vitreous acid resistant tiles
or acid resistant bricks 4 The latex is stabilized against premature
Vitreous ceramic tiles (IS 4457 : 1982) or acid resistant coagulation. It should~not contain vulcanizing
bricks (IS 4860 : 1968) could be used for floor finish. ingredients. If these are required they should
These tiles and bricks could provide over a long period, be incorporated at the time of preparing the
a good resistance against acidic conditions provided mixture.
by milk and milk products. These materials would also b) The emulsion is diluted with water as required
offer adequate resistance against the mild alkaline and is then mixed with cement and aggregate
conditions provided by washing soaps, detergents, etc. to form a mix of the desired rubber latex con-
4 The life of a good quality brick or tile floor is tent. The proportion of the rubber latex used
largely determined by the material used for varies 8 to 25 percent by weight of the total
bedding and jointing and to some extent by~the mix.
width of the joints. Hence careful selection
3.2.5 Group IV
shall be made in the choice of bedding and
jointing mortar, and the thickness of the joints. This group consists of the following :
Whatever be the choice of mortars these should a) Boiler room,
necessarily show adequate strength when
b) Refrigeration room,
tested according to IS 4456 (Part 1 or 2) : 1967
as appropriate. c) Stores and godowns, and
d) Workshops.
b) For bedding and jointing mortars, selections
may be made from the following : 3.2.5.1 These sections require good wear resistance
1) Chemical resistant resin type of mortars and occassionally resistance to alkalis and very mild
[see IS 4832 (Part 2) : 1969 and also Part acidic conditions.
4 of this Chapter], 3.2.5.2 The choice of floor finishes for these sections
2) Rubber latex cement mortars, and may be made from:
3) Supersulphated cement (see IS 6909 :
1990) or Portland blast furnace slag ce- a) Granolithic cement concrete to IS 549 1 : 1969
ment (see IS 455 : 1989). (see Part 2)
c>Among the resin based chemical resistant mor- b) Power compacted concrete grade Ml50 with
tars, epoxy resins and phenol formaldehyde iron chippings mixed with the aggregates, or
type [see IS 4832 (Part 2) : 19691 are quite
suitable as joint mortar. c) Hydraulic pressed cement concerete tiles to
IS 1237 : 1980 (see Part 2).
d) Sodiumsilicate or potassium silicate and resis-
-7
tant mortars [see IS 4832 (Part 1) : 19691 3.2.5.3 Wherever slippery conditions prevail, cement
although have good properties under dry con- concrete tiles with chequered surface finish would be
ditions, are not suitable as jointing mortars in suitable. Where in-situ concrete is provided and non-
these sections of the dairies as these mortars slip surface finish is desired, a hard abrasive material,
are slowly attacked by cold water and rapidly such as, silicone carbide or aluminium oxide may be
by hot water. However, these may be used as sprinkled evenly on the concrete surface at the rate of
bedding mortars in conjunction with resin type 2 kg/m2 and worked into the surface by power floats
mortar. For ~properties of these mortars see and finallyby steel trowelling. Iron particles may also
Table 9.9. be used in the same way to increase the wear resistance
of the surface.
3.2.4.5 Jointless cement - latex rubber$nish
3.2.6 Group V
This is prepared from a mixture of rubber latex or
synthetic rubber and portland cement or portland slag This group consists of chemical stores for storage of
cement. The resistance of these mixes to milk and milk concentrated acid and other chemicals. Cermaic un-
p&duct is generally much higher than that of cor- glazed vitreous acid resistant tiles conforming to
tiponding mixes without latex. The choice of type of IS 4457 : 1982 or acid resistant bricks conforming to
latex will also determine the preporties of the floor, IS 4860 : 1968 may be used.

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SP 62 (S & T) : 1997

FIG. 9.9 -ILLUSTRATION

OFONE OF THE TYPICAL STEEL FLOORING
TILESFORDAIRYFLOORS

3.3 Waterproof Membrane for Dairy Floors 3.4.2 There are three methods of arranging the
3.3.1 The floor finish of any section ‘of the dairy drainage as below:
should necessarily prevent the leakage of effluents to a) The floor finish may slope from each of the
the base concrete. To install a permeable floor finish side walls into centre channel which runs along
is dangerous as the point of attack is not visible. Even the length of the building or from the centre of
more dangerous than the attack of concrete is the !-- -----L
the floor to the side of wall channels.
possibility of corrosion of reinforcement in a 1
suspended floor. A water tight membrane shall there- b) The floor finish may be laid in bays with chan-
nels across the width of the building. \ .
fore be provided. This membrane should be resistant
to all mild acids and alkalis. Bitumen mastic laid on I
c) The floor may be divided into a series of rec-
saturated bitumen felt to IS 1322 : 1993 or fibre glass tangular troughs each with a central drain. J,
based saturated bitumen felt (see IS 7193 : 1974) can /
be considered. Chapter 12 details the membrane treat- 3.4.3 The drains should be open channel covered by
ment based on IS 1196 : 1978. a grid, discharging into an ordinary closed drain. The
edges and corners of the floors and drains should be
3.4 Drainage in Dairies rounded off to prevent dirt from harbouring there.
3.4.1 A slope of 1 in 80 is adequate if the floor finish
is smooth and even and little spillage. A slope of 1 in 3.4.4 The most suitable material for the drains is
40 would be required if the floor finish is rough with chemically resistant salt glazed pipes to IS 651 : 1992
much spillage. and similar chemical resistant resin mortar.
 SP 62 (S & T) .: 1997

TERRAZZO FINISH

SCREED TOP LAYER

INSIDE HOLLOWS

UME CONCRETE

ENLARGEDSECTION YY

C-

.
III III , tlr
f?ARl PLAN OF GRID FLOOR

F1o.9.10 ILLUSTRATIONOFONEOFTHETYPICALHONEYCOMBCASTIRONTILES

3.5 Maintenance of Dairy Floors 4.2 Thickness

a>The floors should be scrubbed several times a The total thickness to which bitumen mastic should be
laid shall be between 20 mm to 25 mm as specified.
day to remove milk waste and grit which not
only causes insanitary conditions but also is 4.3 Preparatory Work
detrimental to the floor finish.
4.3.1 Preparation of Base
b) Use of straight soaps is not recommended since
they tend to precipitate insoluole salts if the The base on which the bitumen mastic is to be laid shall
water is hard or acidic or alkaline, resulting in be able to receive the mastic and to sustain the an-
slippery floors. Detergents may be used; they ticipated load on it.
need only to be sprinkled. Scrubbing with The base shall have an even and dry surface which has
machines shall be followed with rinsing. been roughened with stiff broom or wire or coir brush --
and should be free from ridges and hollows. The base
c) Use drip trays under machines to limit areas of
spillage of milk. may be provided with a suitable slope for drainage.

4 BITUMEN MASTIC FLOORING FOR LPG 4.4 Laying

4.1 General 4.4.1 The molten mastic shall be carried in flat mortar
pans. The pans are sprinkled -with lime stone dust, to
Bitumen mastic is jointless and impervious to the prevent sticking of mastic. Grease or oil shall not be
transmission of moisture. The anticipated service con- used.
ditions for bitumen mastic flooring for hydrocarbon 4.4.2 The mastic should be laid in bays in one or more
services shall be as given in IS 13026 : 1991, which is layers. The specified thickness shall be maintained.
a specification for bitumen mastic for flooring for The multi-layered work should be treated in the same
industries handling LPG and other hydrocarbon manner as a single layer mastic. Bubbles formed
products. The material shall be anti-static and electri- during laying should be punctured and the area rec-
cal conducting grade (see IS 8374 : 1977). tified while mastic is hot.

209
L- . ._

SP 62 (S & T) : 1997

4.4.3 The laid surface shall be protected from damage 4.4.4 Damaged areas shall be cut into rectangular
due to movement of heavy loads, spillages, etc during strips and replaced with a new mastic. Blow lamp
laying. The mastic shall not be opened to traffic techniques to remove damaged layersare preferred.
until the material has cooled down to ambient 4.4.5 Bitumen mastic flooring requires little main-
temperature. tenance. Dirt and dust shall be rehoved periodically.

PART 4 SPECIAL FLOORS AND FLOOR COVERINGS

1 GENERAL water or moisture by periodic applications of wax-

polish or oil at regular intervals.
1.1 The following Indian Standards cover the use of
various types of special floors and floor coverings: Magnesium oxychloride flooring should not be used
in any situation where it would be exposed to damp
a>Mangensium oxychloride composition floors - conditions for long periods, unless other suitable
IS 658 : 1982 protective measures are taken; it should not be used in
1196 : 1978 places where it will be exposed to acids or salts con-
b) Bitumen mastic flooring -IS
tinuously.
c>Rubber floors -IS 1197 : 1970
2.2 Types
4 Linoleum floors -IS 1198 : 1982
4 General Purpose Floor (Trowel Finish) -
e>Chemical resistant mortar, Silicate type - IS This type of floor shall contain an adequate
4441 : 1980 amount of calcined magnensite, fillers such as,
talc, saw dust and asbestos; and fine aggregates
Chemical resistant mortar, Sulphur type - IS
which with magnesium chloride of suitable
4442 : 1980
strength make a product which may be trow-
ia Chemical resistant mortar, Resin type - IS elled to a dense smooth glossy finish. The
4443 : 1980 composition may be applied monolithically. It
has wearing properties which make it adapt-
h) Epoxy resin floor toppings - IS 463 1 : 1986 able for service conditions in offices, ship
9 Flexible PVC sheet and tile flooring -IS 53 18 : decking, railway carriages, hospital rooms and
1969 wards, residential and industrial floors.

k) Parquet flooring -IS 5389 : 1969 and IS 9472 : b) Heavy Duty Floor(Trowe1 Finish) -This type
1980 is closely related to the general purpose floor.
The principal difference is that the quantity of
2 MAGNESIUM OXYCHLORIDE
fillers used is minimum and theproportion of
COMPOSITION FLOORS
aggregates is increased, the aggregates being
2.1 General of hardness similar to crushed granite. It is
adapted for special service conditions in
Magnesium oxycholoride composition consisting of industrial and restaurant kitchens, light
~mixture of calcined filler and pigments provides a industrial plants, corridors, lobbies and busi-
good floor if proper ingredients are mixed in correct ness establishment having large usage.
proportions and skilled labour is employed in laying Non-spark Static Discharging Floor (Trowel
c)
the floor. Too wet a mix with excess magnesium or Ground Finish) - This type of floor is
chloride results in sweating of the floor surface. similar to heavy duty floor except that the
Mineral oils, greases or vegetable oils do not affect the aggregates used are not siliceous and do not
floor. The flooring is not seriously affected by alkalis, contain materials which will produce a spark
but strong alkalis, such as, soda or harsh cleaning when struck with any object. This type of floor
agents tend to attack the protective dressing and thus is suitable for hospital operation theatre,
exposing the flooring to action of water. However, the ammunition and chemical plants or other areas
finished floor tends to be protected from excessive subject to explosion hazards.

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 SP 62 (S & T) : 1997

Non-slip Floor (General Purpose) - This from substances capable of producing a

type of floor is similar to heavy duty floor spark when struck or abraded with a steel
except that certain proportion ofthe aggregates tool.
is of abrasive type. This floor is specially 3) Dry mix for non-slip floor - About 35
adaptable to areas, such as, entrance lobbies, percent by weight of the aggregates used
ramps, stair treads, landings, etc. in the dry mix for non-slip floors shall
consist of abrasive aggregates which shall
Mosaic or Terrazzo Floor (Ground Finish) -
be of non-rusting natural (emery) or
The matrix in this case is the same as in general
manufactured (fused alumina) product,
purpose, non-sparking or non-slip floors but
the particles of which are of irregular
the aggregate used is marble chips with each
shape and of slightly open texture.
100 kg of the dry mix, 125 to 200 kg of coarse
aggregate is used. The-floor is adaptable for 2.4 Properties of MagnesiumOxychloride Floars
places where a highly decorative effect
coupled with wear resistance is required. a>Magnesium oxide floor should not be exposed
Industrial Granolithic Floor - This type of to action of sea water; and is not recom-
floor is essentially the same as mosaic or ter- meneded where it may be exposed to high
razzo floor in which the matrix is the same as humidity or damp conditions; damp proof
in the heavy duty floor and the coarse ag- course should be incorporated if the base is in
gregate consists of granite chips or similar hard direct contact with the ground.
stone chips. With each 100 kg of dry mix, 200 b) Floor finish should be sel&ted by sample size
to 225 kg of coarse aggregate is used. This type of 300 mm x 300 mm x 20 mm which finished
of floor is recommended for the most severe work should conform in hardness (as per
and abrasive service conditions. IS 658 : 1982) near to colour, texture, number
Base Coat - This type has the maximum and thickness of coats.
resilience and is employed as a light-weight cl Resistance to Checmical Attack
base for the types of oxychltde floors men- 1) The floor finish, if not adequately
tioned in 2.2 (a) to (f). Two sub-types are protected by oiling or waxing gradually
generally employed : disintegrates under continuous exposure
Sub-type 1 - General purpose base coat, and to water.
Sub-type 2 - Heavy duty base coat. 2) The floor finish is not affected by alkalis
but strong alkalis such as soda or harsh
2.3 Materials cleaning agents attack the protective
dressing and expose the floor finish to the
4 All the materials used in the manufacture of action of water.
magnesium oxychloride floor finish should 3) The floor finish is subject to attack by
comply with IS 657 : 1982. The test limits for acids. Adequate protection against
calcined magnesite in this standard are based occasional contact with dilute acids may
on a notional mix of calcined magnesite and be obtained by oiling or waxing.
saw dust gauged with magnesium chloride and 4) The floor finish is subject to attack by
do not obviate the need to test the floor finish- continuous exposure to salts; under nor-
ing mixes in order to check compliance with mal conditions of use, some protection
IS 658 : 1982. Materials for magnesium may be obtained by oiling or waxing.
oxyflouride composition floors shall be sup- 5) It should not be slippery when treated as
plied in two parts, namely, dry mix and mag- described in 2.5. Special non-slip sur-
nesium chloride. faces may be obtained by incorporating
abrasive grit in the floor finish.
b) Dry Mix
1) Dry mixfor all types offloors - The dry 6) Sweating of magnesium oxychloride
mix shall consist of an intimately mixed floor finish is characterised by beads of
magnesium chloride solution forming on
composition of dry ingredients. If talc is
the surface in humid atmospheres and is
used as a filler it shall not exceed 5 percent
not merely the result of the condensation
by weight of dry mix.
of moisture on a cold surface. The ten-
2) Dry mix for non-spark static discharge
dency to sweat is inherent in the material,
floors - The dry mix for non-spark static
discahrging floor shall contain only such since magnesium chloride takes up readily
moisture from damp air.
materials in its composition which are free

211
SP 62 (S & T) : 1997

7) If the ingredient of the floor finsih mixture floor finish, such as, dovetailed wooden bat-
comply with IS 657 : 1982, there should tens or galvanized wire netting firmly screwed
be little tendency towards efflorescence. to the base at approximately 200 mm centre.
8) The thickness of floor finish shall be not An equal number of galvanized clout nails
less than 10 mm. should be used at 200 mm centres and be left
9) Contamination of the floor finish mixes proud of the base.
with free lime tends to cause expansion.
2.5.2 Preparation of Floor Finish Mixture
The floor finish is likely to crack or lift~if
laid on light weight concrete base or on a Magnesium chloride both before and after it is dis-
dense screed which is not firmly bonded solved should not be allowed to came into contact with
to the base. any floors and walls. The solid chloride should be
10) Coves and skirtings can be formed with broken up and dissolved in water tight vessel by cover-
magnesium oxychloride finishing ing the same with clean water, that is, clean and free
material. Contact between the from deleterious acids, alkalis, salts or organic
oxychloride mix and the wall plaster material and stirring the same from time to time. The
should be avoided by the use of an inter- solution should be allowed to stand over night so that
vening fillet of wood or other suitable the residue, dust, impurities, etc, may settle to the
material. A sand cement rendering on the bottom. The clean concentrated solution shall be well
wall surface is desirable as a backing. stirred after each dilution. The solution shall be
11) Metalwork, such as, partitions, or gas, prepared sufficiently early so that it is cooled to room
water and electrical services in contact temperature before use. The specific gravity of the
witha magnesium~oxychloride floor finish solution should be maintained at the value selected
is liable to corrode and should be isolated from the table given below. This value will depend on
from the floor finish, by not less than the type given of work, the nature of the base and
25 mm of untracked dense concrete or ambient and temperature conditions.
protected by a coating of bitumen or coal-
Floor Finish Mix Baume’ (BE) Specific
tar composition or by a suitable material
Scale Gravity
(see 2.8).

2.5 Application Single coat and 20’ to 24’ 1.16 to 1.20

-top coat
2.5.1 Preparation of the Base
Bottom coat, 18’ to 20’ 1.14 to 1.16
The base shall be rigid, sound, free from rising damp
coves and skirtings
and not unduly porous. Highly absorbent materials,
such as, pumice concrete, breeze or clinker concrete 2.5.3 Proportions of Dry Materials
and aerated concrete shall not be used unless a layer of The proportions of dry materials may be varied within
damp-proof course is laid between the base and the certain limits in order that the properties of the finished
main floor. product may be suited to the conditions of use. Propor-
tions shall be by weight and the dry material should be
a>New cement concrete base - The base shall
be true and even and slightly coarsened by stiff thoroughly mixed by machine.
brush or broom. A steel trowel finish is not
desirable. The cover to steel of base concrete
a>Proportion of chloride solution- A strong
floor finishing material may be formed by ad-
shall be not less than 25 mm, since the reinfor- dition of only sufficient magnesium chloride
cement would be damaged by magnesium solution to make the dry mixed materials
oxychloride compound. New concrete should damp. For single coat and top coat some addi-
age for 28 days before receiving the flooring. tional solution is usually required to enable the
No lime admixture shall be allowed in con- mix to be placed and brought to a smooth
crete. finish. The extra chloride does not improve the
b) Existing concrete base - The existing con- strength of the mixture and the use of excessive
crete base should be roughened to a suitable amount will have harmful effects.
degree by tooth chisling, picking or by any
b). The amount of solution required for a given
other suitable process before oxychloride com- weight of dry mix cannot be stated accurately;
position is laid. Absorption may be checked however, the following guidelines may be
and if porous screed may be spread on the base. used:
C) Timber base - A suitable mechanical key 1) Bottom coatfloorfinish mixes - Bottom
should be provided between timber base and coat finish mixes should be gauged to a

212
 SP 62 (S & T) : 1997

damp but not plastic consistency; just suf- 3) Each coat should be throughly compacted
ficient solution should be used to enable ensuring no formation of iaitance.
the mix to bind together when thoroughly 4) When the top coat has hardened suffi-
compacted by tamping. As a guide, a mix ciently, its surface shall be felt finished
from which liquid can be squeezed by after trowelling. Scraping shall be under-
hand should be considered as suitable. taken on ornamental work such as mottled
2) Bottom coat mixes for coves and skirtin& finishes.
- The mixes should be gauged to a con-
2.5.6 Curing
sistency just sufficiently plastic to allow
the mix to be spread on the wall. Rapid drying of floor shall be avoided~at least for
3) Single coat and top coat mixes - These 24 h after laying the floor.
mixes should be gauged with no more It should be allowed to set and harden at least for
solution than is needed to produce a stiff 3 days before opening it to traffic. It should not be
mix which is just sufficiently plastic to be allowed for heavy traffic for some weeks till it is fully
spread with a trowel. dried and hardened. During hardening it should not be
2.54 Final Mixing exposed to sun or rain.

2.5.7 Sulfate Treatment

The mixing of the chloride solution with the dry mix
shall be done in a containerand not on the floor. The The floor finish should be washed with clean warm
quantity of mix should be sufficient to be laid in one water changed frequently and wiped dry at regular
batch before it sets; no solution should be added during intervals until the effloroscence has ceased. At this
laying. If the mix is too stiff it should be discarded. stage the finish may be treated with a mixture of
linseed oil (double boiled) (-see IS 77 : 1977) and
2.55 Laying the Floor Finish turpentine (see IS 533 : 1973) in equal volumes or with
a suitable wax or drying oil. For mottled floor finish,
a>Size of bay will depend on the temperature
the finish should be laid in two coat work.
conditions generally; the controlling factor
would be the time taken to obtain adequate 2.6 Testing
compaction of the floor finish.
Testing shall be carried out on samples mixes from
b) Joints shall be provided if the floor dimensions three different parts of the vessel. The tests should be
are more than 5 m in either direction. The joints done as per IS 658 : 1982.
may be mastic insertions or strips of hardwood,
vulcanite, non-ferrous metal or other suitable 2.7 Maintenance
material, 5 mm wide, bedded flush with the The floor surface shall be cleaned with warm water
surface of the flooring material. These joints only. A mild house soap free from alkali may be used
should coincide with the joints of the base, if occassionally; but strong household cleaning powders,
any. soda, etc, should not be used.
c>The concrete base should be dampened before 2.8 Protection of Metal -Work
laying; excessive flooding should be avoided.
The dampening should be done either with a Metal work may receive anti-corrosive treatment;
solution of magnesium chloride which should suitable materials are bituminous coaltar composition
not be weaker than 12’ BE nor stronger than with or without added fillers, intended for hot applica-
--
14’ BE; or a wash composed of a 14’ BE tion. For cold application a solution of bitumen or of
magnesium chloride solution and magnesia coaltar in a volatile solvent with or without added
mixed to the consistence of cream and brushed fillers but excluding bituminous paipts with drying oils
over the base. may be used.
1) If a thickness of 40 mm or more is re- 3 BITUMEN MASTIC FLOORING
quired,~additional coats may be laid, each
of which should not be more than 20 mm 3.1 General
thick. Bitumen mastic is a dustless, odourless, jointless floor-
2) For skirting on sand cement rendering, the ing and impervious to the transmission of moisture,
mix may be applied in a single-coat not either in liquid or vapour form. The surface is easily
less than 5 mm thick; then the backing is cleaned, noiseless under traffic conditions and
unrendered. The mix should be applied in resilient. While it may carry heavy loads, application
two coats to a total thickness of not less of concentrated point loads may cause indentation.
than 15 mm. Bitumen mastic is, therefore, suitable for a variety of

213
SP 62 (S & T) : 1997

uses under a wide range of climatic and service condi- load over it. The-base shall be true, even and
tions, except as detailed below: dry surface which has been slightly roughened
by means of a stiff broom or wire brush and
a) The surface of bitumen mastic is liable to be-
should be free from ridges and hollows. A steel
come gradually sofetened by prolonged con-
trowelled finish is not desirable. The levels of
tact with greases, fats and oils. Contamination
the base should be such that the specified thick-
with such materials shall~be avoided.
ness of bitumen mastic may be applied
b) Susceptibility of bitumen mastic floor finishes uniformly.
to chemical attackis given in Table 9.10.
b) The total thickness to which bitumen mastic
should be laid depends on the traffic conditions
Table 9.10 Susceptibility of Bitumen Mastic
to which the floor will be subjected.
Floor Finishes to Chemical Attack
(Clause 3.1) c) Usually bitumen mastic should be laid in one-
coat, but two-coat work may be used depend-
Sl Agency Susceptibility to Attack
No. ing on the thickness of floor finish. As a general
guide the thickness given below are recom-
i) Acids and vegetable Normal grades subject to attack
extracts by acids; special grades can
mended.
withstand attack by dilute solu- Light duty 15 mm to 20 mm thick
tions
Medium duty 20 mm to 25 mm-thick
ii) Alcoholic liquors Normal grades are subject to Heavy duty 25 mm to 30 mm thick
attack by certain alocholic li-
quors. Special grades may be 4 There may be a siope of not less than 1 in 75,
used in breweries and distill- in the base, if the finished floor is likely to have
eries
water or industrial liquors upon it. Channels
iii) Alkalis Not affected by low concentra-
should be provided to ensure adequate
tion alcoholic solutions
Alcoholic solutions above 38’C drainage.
will affect
iv) Brine (sodium and calcium Unaffected under normal d The base may be treated in any of the following
chroide) and sulphate salts circumstances ways:
v) Complex industrial liquors Conduct tests to choose the 1) A screed bed of cement concrete or lime
grade of bitumen mastic concrete not less than 25 mm thick;
vi) Radio active materials Special grades of bitumen be
used
2) An isolation membrane or underlay (see
3.3.2 and 3.3.3); or
vii) Dairy products and milk Normal grade where hygenic
conditions are maintained (see 3) On metal floors, a thin priming coat of
Part3) bitumen paint applied over a clean and dry
viii) Mineral, animal and Subject to attack surface. The paint should be dry before the
vegetable oils, fats and
mastic is laid.
greases
ix) Sugar syrup, sugar Unaffected by low concentra-
3.3.2 Isolqting Membrane
tion sugar solutions syrup,
molasses, etc, will affect at all
An isolating membrane conforming to IS 1322 : 1993
temperatures
x) Water Unaffected unless the water is is normally used where bitumen mastic up to 20 mm
hot, for which high temperature in thickness is laid where the base is in direct contact
mastic may be used with the ground; glass fibre feli (see IS 7193 : 1974)
3.2 Materials may be used as an alternative. Thickness of bitumen
mastic exceeding 20 mm on new concrete is usually
a) Bitumen mastic shall conform to the require- laid without fan isolating ~membrane. Isolating
ments given in IS 1195 : 1978. membranes should be laid loose.
b) Special types of metal armouring may be
incorporated in bitumen mastic flooring for 3.3.3 Underlay
industrial purposes to increase resistance to
The underlay, when required, should be laid loose.
abrasion (see Part 3).
3.3.4 Remelting of broken bitumen mastic blocks is
3.3 Preparatory Work
permitted.
3.3.1 Base
3.4 Laying
a) The base shall be adequately strong to receive 3.4.1 When the material is sufficiently molten to be
the bitumen mastic and to carry the anticipated workable, it should be carried in flat mortar pans, to

214
 SP62(S&T):l!N7

the-point of laying. To prevent sticking of mastic to the buses and ships. It provides a resilient and noise-free
pans, inorganic dust may be sprinkled on the pans. floor surface. The life of rubber floor is related to its
3.4.2 Bitumen mastic should be generally laid in bays thickness, since it~is not possible to be specific about
of one coat. It should be spread to the specified thick- wear resistance. Provision of mats will reduce the
ness by means of hand tools. Bitumen mastic should amount of abrasive grit carried to the floor. The
then be floated to a uniformly level surface by a heavy durability of rubber floor is increased if the material is
wooden float and should be free from roughness and laid correctly and maintained carefully. IS 809:1992
-imperfection. If ‘blowing’ occurs, the bubbles should lays down the requirements for rubber flooring
be punctured and the area affected shall be made good materials both in sheet and tile form.
while the mastic is still hot. Flooring made of natural rubber is not recommended
Two-coat of single-coat work, but care should be taken in situations where it may came into contact with fat,
to arrange that the joints in successive layers are stag- grease, oil or petrol, as these substances may cause
gered. swelling, softening or other deterioration. To meet
such situations, flooring made from various kinds of
~3.4.3 Sulfate Fmish synthetic rubber may be utilized.
Surface finish could be either matt finish or polished 4.2 Preparatory Work
finish, or as desired.
4.2.1 Sub-jloor and Base
Immediately after laying, the bitumen mastic shall be
protected from damage till it cools to the surrounding a) New concrete floors - In the case of newly-
temperature. Bitumen mastic should be allowed for laid concrete floors in contact with the ground,
traffic after the material has cooled. Frequent polish- a damp-proof membrane or a bitumen mastic
ing, should be avoided as it will become slippery. layer shall be incorporated ln the thickness of
the floor and it shall be properly joined with the
3.4.4 Bedding damp-proof course in the walls. Special
Special care shall be taken to effect proper bond precautions, such as, tanking may be necessary
between new and old sections of work. The contact against water pressure and to prevent the entry
edges of the previously laid work should be cleaned of moisture into floorsbelow ground level.
and warmed by additional applications of hot mastic.
b) Existing~concretefloors - If the floor surface
This procedure also should be adopted for joints be- is not smooth and true, it shall be well hacked
tween the floor finish and skirts and coves or fillets.
to provide key for the screeding. It shall then
3.4.5 Skirtings should be executed in not less than be brought to an even surface with a screeded
two-coats particular care being taken td ensure proper bed at least 25 mm thick. Concrete floors
adhesion of~the first coat to the base. Special care shall which are in contact with the ground but have
be taken at external angles to ensure the full thickness been damp-proofed shall be covered with a bed
of material. of at least 15 mm thick bitumen mastic con-
forming to IS 1195 : 1978. Over the-bitumen
3.4.6 Maintenance
mastic 40 mm thick cement concrete shall be
Bitumen mastic surface requires relatively little main- laid.
tanance. Superficial dirt may normally be removed by
washing with warm water and suitable detergents. cl New timber floor - Timber floors shall be
constructed with tongued and grooved board-
‘After the dirt is removed, the floor should be mopped
ing and shall be adequately ventilated to
with clean water.
prevent dry set. There should not be any gap
3.4.7 Repairs between the planks which may permit air to
penetrate from bottom and affect the bonding
The correct method, to remove damaged area, is to
of the rubber flooring material with the timber
place hot mastic around, and over the area concerned
base. Where plywood is used as a base, it shall
and after this has sofetened the area concerned, it
be of the moistureproof grade.
should be cut away and made good.

4 RUBBER FLOORS 4 Existing timberfloors - Damaged and worn !

floors should be repaired and brought to an
I
4.1 General even and smooth surface, an underlay also may /
be used. j/:
Rubber floor coverings are mainly suitable for use in P^
domestic buildings and those of a non-industrial char- e>Metal floors - The surface of metal floors
acter, such as, schools, hospitals, offices, where traffic shall be smooth. Screws, bolts, etc, used in the
is expected to be essentially pedestrian and also in flooring shall be of counter sunk type. When

215
SP 62 (S & T) : 1997

they project above the surface, the metal floor f) The tiles should be laid in exactly the same
shall be covered with a base bringing the floor manner as the sheet. Any adhesive contaminat-
on level before the rubber flooring is laid on. ing the face of the rubber shall be removed as
The metal floors should be rust free and a rust the work proceeds within 24 h. A minimum
proof coating should be ~applied before the period of 24 h shall be allowed for proper
rubber flooring is laid. development of bond and no traffic should be
allowed. Thereafter the flooring shall be
4.2.2 Underlay cleaned with a wet cloth, soaked in warm soap
solution (two spoons of soap in 5 1 of warm
An underlay shall be used where the base is of timber.
water) .
It may also be used when it is necessary to make the
flooring quieter, warmer and more resilient. Underlay s> In case of stairs, where rubber nosings are to
be laid as separate units and are of heavier
shall be either tibre-based saturated bitumen felt
gauge, the difference in thickness shall be
(Type I) conforming to IS 1322 : 1993 or other suitable
made up in design, or by screed or with
material.
plywood or ~bitumen mastic. Rubber in sheet
The underlay shall be butt jointed and so laid that the form is not used for coves and skirtings; suit-
joints are at 45’ to the principal joints in the rubber ably moulded units should be used.
flooring. The underlay shall be secured by a suitable
h) Rubber shall not be cleaned by softsoaps, soaps
adhesive except on a timber base in which case it may containing _essential oils, soaps with free
be nailed. alkalis, pastes or powders containing coarse
abrasives, scrubbing brushes or petrol benzine,
4.3 Laying and Fixing of Rubber Flooring
naptha and similar solvents.
4 The sub-floor shall be cleaned with dry cloth. j> A wax-polish shall be used for polishing rubber
. floors; polishes containing organic solvents
b) The lay out of the rubber flooring shall be first shall not be used.
laid on the sub-floor to be covered and should
be marked with guidelines. The rubber flooring 5 LINOLEUM FLOORS
shall be first laid for trial without using the 5.1 General
adhesive according to the layout.
Linoleum provides a satisfactory floor for residential
cl The adhesive shall then be applied by using a and public buildings, railway coaches, ships, etc. It is
notched trowel, to the sub-floor and to the also suitable for most type of non-industrial floors. In
backside of the rubber sheet or tile flooring. light industry, such as, electronic industry linoleum
When set sufficiently for laying, the adhesive may be used, as the risk of damage by cutting, to which
will be tacky to touch, but will not mark linoleum is vulnerable, is small. However, if it gets
fingers. In general, the adhesive will set in wet, it expands and eventually rots.
about half an hour; but it should not be left for 5.1.1 Linoleum is not suitable for locations subjected
too long a period as the adhesive properties will to rising damp, external exposure, exposure to traffic
be lost owing to dust film and other causes. It with indentations from heels or static loads, and where
is preferable to avoid laying the flooring under high polish is required because it becomes slippery.
high humidity conditions so as to prevent con-
5.2 Materials
densation. The area of adhesive to be spread
depends on the local circumstances; in a small a) Flooring material shall conform to IS 653 :
room the area can be covered at one stretch. 1992.
b) Underlay shall be as below:
4 When the adhesive is tack free, the rubber
flooring sheet shall be carefully taken and For timber - Plywood at least 4 mm thick
placed in position from one end onwards slow- sub-floors
ly so that air will be completely squeezed out - Hardboard at least 3 mm
between the sheet and the background surface. thick
Then the sheet shall be pressed with suitable - Fibrebased bitumen felt at
roller to develop proper contact with the sub- least 1 mm thick, to IS 1322 :
floor. The next sheet with it backside applied 1993
with adhesive shall be laid edge to edge with
For concrete - Bitumen mastic to IS 1195 :
the sheet already laid so that there is a mini-
sub-floors 1978
mum gap between joints.
- Bitumen to IS 1580 : 1991.
e) Alignment should be checked and if not per- c) Adhesives shall be as per recommendations of
fect, the sheets may be trimmed. the manufacturer.

216
 SP 62 (S & T) : 1997

5.3 Preparatory Work When laid on concrete floors it is desirable to

prime the back of linoleum with the adhesive.
53.1 Sub-floor
Cork tiles should be fixed with the adhesive.
Sub-floors should be thoroughly dry before laying of Linoleum coving and skirting shall be formed
linoleum since entrapped moisture cannot escape. It from the sheet material on the job in grades up
should also be even to ensure thorough bonding with to 3.2 mm thick.
the linoleum.
Normally 4.5 and 3.2 mm thick linoleum can
Timber sub-floors - A timber sub-floor be used for commercial and institutional build-
should be sound, rigid and dry. It should be ings respectively; for domestic buildings
well ventilated to discourage fungal attack. 1.6 mm thick linoleum may be used.
In case of new construction, tongued and
d) The surface, after cleaning of all debris, etc,
grooved boarding shall be used. All nails shall may be wax-polished or a coat of ~emulsion
be punched down and timber floor made even. polish may be applied. No traffic shall be per-
In existing floors, when it is not possible to mitted till the completion of all related works.
obtain an even surface, use of diagonal board-
ing is recommended, after removing and e) All surfaces shall be swept clean and washed
with a cloth dampened with an aqueous solu-
replacing badly affected boarding; alternative-
tion of neutral detergent.
ly plywood may be used to get an even surface.
6 EPOXY RESIN FLOOR TOPPINGS
b) Concrete sub-floor - Concrete sub-floor may
be finished as mentioned in Part 2, to give an 6.1 General
even and dry surface. Rising damp may be
Epoxy resins are suitable for use on industrial floors,
protected by using bitumen mastic, 15 mm
such as, in chemical plants manufacturing fertilizers,
thick, conforming to IS 1196 : 1978 as
pharmaceuticals, acids and solvents, in dairy industry,
described in 3.
tanneries, breweries, garages, service stations,
c>Other sub-floors - They should be dry and warehouses, metal plating and pickling areas. They
even. have good qualities of adhesion and chemical resis-
tance, hardness, abrasion resistance; physical proper-
5.4 Laying
ties, such as, compressive, impact and flexural
4 Linoleum should be stored at room tempera- strength; neglegible shrinkage, dimensional stability
ture of not less than 20°C for at least 48 h and adhesion to cured concrete, metals and other
before unrolling; after unrolling, it shrinks in surfaces.
length and expands in width. When two widths
6.2 Materials
of linoleum are to meet, they shall be left with
an overlap until the expansion has stopped and a>Epoxy resin shall conform to IS 9197 : 1979,
then cut to fit. b) Hardeness shall conform to IS 9197 : 1979,
b) The linoleum should be laid either loose or
c>Accelerator shall conform to IS 9197 : 1979,

fixed to the sub-floor by means of suitable

4 Plasticizers and non-reactive diluents shall
conform to IS 9197 : 1979,
adhesives. Any priming coat should be allowed
4 Liquid coal tar shall conform to IS 9197 : 1979,
to dry before the adhesive is spread. Adhesives
and
should be spread evenly as per manufacturers’
instructions. Naked lights should be avoided, f) Aggregates shall conform to IS 9 197 : 1979.
if the adhesives having low flash solvent (con- 6.3 Types of Epoxy Resin Toppings
taining petroleum and naphtha) are used. The There are two types of epoxy resin floor toppings:
area shall be well ventilated and smoking shall
be prohibited. a>Trowel Type - This is usually heavily filled
with sand or other suitable aggregates and the
cl The underlay shall be fixed to the sub-floor in compound is applied by trowel. Such com-
such a way~that a smooth surface is available.
pounds are often referred to as mortars or
The finished underlay shall be cleaned of all
screeds.
dirt and dust, chemicals, paints, etc. The
linoleum shall be firmly pressed into the ad- b) Flow Type - This is usually a solventless
hesive spread over the underlay. To ensure compound containing filler and pigment and
good bond, the surface can be rolled with a the mixture is poured directly on to the surface
roller of 70 kg weight, washing from centre to when the blend will flow and level itself with
the walls. If necessary, sand bags may be little assistance to form a smooth continuous
placed at some points. coating.

217
SP 62 (S & T) : 1997

6.3.1 Terrazzo Floors 6.5.2 Application

The Portland cement in conventional terrazzo floors is a>The blended epoxy resin mix shall be applied
replaced by epoxy resin binder. Such flooring formula- uniformly, over the area prepared, to a uniform
tions serve the dual purpose of providing a good thickness.
appearance and chemical resistance.
b) For some areas where heavily tilled trowelling
6.3.2 Non-skid Floors compound is to be applied, the prepared area
shall be first covered with a tack coat of un-
This type of floor may be prepared by sprinkling a
filled resin-hardner mix applied by brush
suitable grit on an epoxy resin floor topping when the
which shall be allowed to cure to a tacky stage.
latter is still in a tacky state.
6.3.3 The following minimum thicknesses are recom- cl Where heavily filled trowelling compound is
used, it is advisable to apply a seal coat of
mended :
unfinished resin to ensure that pores, if any, are
a) Trowel type - 4 mm for normal use and sealed adequately.
,
6.5 mm in areas of ther-
mal shock and heavy d) As mild steel tools are liable to cause stains on
light coloured surfaces, it is recommended that
traffic on horizontal
stainless steel, chromium on rigid PVC tools
surfaces
should be used after laying of epoxy resin floor
b) Flow type - 2mm toppings.
c) Terrauofloors - 10 mm. d After application of the epoxy resin topping,
the floor shall be allowed to set without distur-
6.4 Preparatory Work
bance for a minimum period of 24 h. The floor
6.4.1 Concrete surfaces shall be properly cured and can be brought to normal use after a period of
dried and kept rough. Laitance shall be removed. All 7 days at a temperature of 20’ C and above
cracks and broken areas of an existing base shall be though light traffic may be permitted after
sealed, fresh concrete applied and cured. Grease and 24 h of laying the floor topping. -Below 20°C
oil shall be removed with solvents, such as, acetone or special hardeners may be used as recom-
a suitable detergent. mended by the formulator in order to obtain
proper setting of the floor topping.
The concrete surface shall be even,
f) Expansion joints to coincide with those in the
6.4.2 Mild steel and cast iron surfaces shall be washed base concrete should be provided in epoxy
with a suitable solvent or detergent solution to remove resin toppings. The expansion joints in the
grease or oil. The surface shall then be sand blasted or epoxy topping shall be filled with a flexible
abraded with emery cloth, abrasive disc or with wire putty that shows appropriate waterand chemi-
brushes. cal resistance as recommended by the for-
mulator.
6.5 Laying
6.5.3 Safety Precautions
6.51 Mixing of Epoxy Resin Blend
Epoxy resins cause irritation to persons having sensi-
The mixing shall be carried out at the site as follows : tive skin. Good ventilation is necessary and the most
effective precaution is the use of rubber or
a>The constituents required shall be mixed in the
polyethelene gloves. It is preferable to wear thin
correct proportions as specified by the
cotton gloves underneath for comfort. Other methods
formulator.
recommended are regular washing hands, arms and
b) Unless otherwise specified, the order of addi- face with soap and luke warm water followed by
tion of the constituents shall be resin, hardener thorough drying with a clean towel and the use of a
and aggregate. barrier cream. Splashes on skin should be removed
immediately by washing with soap and luke warm
cl Aggregates, when required, shall be added to water. On no account should a solvent be used for this
the blend in a mixer in dry condition.
purpose.
d) The duration ~of mixing shall be adequate to 6.5.4 Chemical resistance of epoxy resin flooring
ensure thorough mixing; the quantity mixed at mixes to various substances is given in Table 9.11 for
one time shall be such that a uniform thickness general guidance. Table 9.11 shows that systems
of epoxy resin topping may be applied over the cured with amines exhibit higher chemical resistance.
whole floor. Polyamide hardeners should be used where floors are

218
 SP 62 (S & T) : 1997

exposed to frequent impact stress and fluctuations in the floor. Use of powerful oxidizing agents
temperature. The performance of floor will, however, should be avoided.
depend on whether the chemical and mechanical stress
occur simultaneously. Variations in temperature b) The resin flooring tend to develop cracks when
subjected to quick thermal cycles. Hence fre-
would also affect the performance of the floor topping.
quent use of alternate cold and hot water hosing
6.6 Maintenance should be avoided.

Very little maintenance is required for epoxy floor c) Dragging of heavy sharp edged loads shall be
toppings. However, the following precautions would avoided since the flooring is liable to scoring.
prolong the service life of the topping.
d) Spillages of powerful solvents like acetone and
a) Usual house hold detergents, soap and warm trichloroethylene should be drained away
water (up to 60°C) may be used for cleaning quickly.

Table 9.11 Chemical Resistance of Epoxy Resin Flooring Mixes

(Clause 6.5.4)
Substance Chemical Resistance at 2O*C
’ Compounds Cured with Compounds Cured with ’
Amine or Amine-Adduct Polyamide Hardeners
Hardeners
S
(1)
Acetic acid, 5 percent -
(:J
-- (4)
X
(1) R
-- (9’)
X
-
Acetic acid, 10 percent
Acetic acid, 50 percent
-
- -- -
-
X
X -
-
- X
X
Acetic acid, anhydride
Ammonium hydroxide,
-
X - -
-
X
- X -
X

10 percent
Ammonium hydroxide, - X - - - X
30 percent
Alcohols (ethyl alcohols) -
--X - -- - X
Aliphatic hydrocarbons (naphtha)
Aromatic hydrocarbons (toluene) -
X

--
-
X -- -
X

-
X
X
Beer
Blood X
-
-
- -- X
X
-
X
Boric acid
Calcium chloride, X
-
- - X
X -
50 percent solution
-
Caustic soda, 10 percent
Caustic soda, 50 percent
X

-
X -- -
-- -

-
X
X -
Chlorinated hydro carbons X X
(carbon tetrachloride)
- -
Citric acid, 10 percent
Cooking fats and oils
-
X
X -
- -- -
X -
X

Ester
Ether (ethyl ether) -
X
--
X
-
- -- - -
-
X
X
X - X
Fats and oils
Formaldehyde, 37 percent X
- - -- -
-
X
X
Glycerine
Hydrochloric, 10 percent -
- --X
-
- - -
-
X

- -
X
Hydrochloric, 37 percent X
- - - -
Javel water
Ketone (acetone)
-
-- X
X
- -
- -
X
Lactic acid, 10 percent
Liquid fuel (petrol or oil)
-
X - -
X

- -
X -
X

Milk, sour or fresh

Nitric acid, 10 percent - -X -
X -
-
X
-
Nitric acid, SO percent
Soaps and detergents
-
X -- -
- --X X -
Sugar (saturated solution)
Sulphuric acid, 10 percent -
-
X
-- -
X - -
X

Sulphuric acid, 50 percent

Tap water X -- -
--X X
-
Urine
Vegetable oils
X
X -- -
-- X
X
-
Water (distilled) X - X

NOTE - E = Excellent; G = Good; S = Satisfactory; P = Poor.

219
SP 62 (S & T) : 1997

7 FLEXIBLE PVC SHEET AND TILE at the rate of 1.5 kg/mm2 after the concrete has
FLOORING set; or ~bitumen felt conforming to IS 1322 :
1993 may be sandwiched between the two
7.1 -General
concrete layers. If dampness is expected from
PVC flooring material manufactured in different pat- surrounding walls, the same treatment may be
terns to match and suit any decorating scheme is nor- extended, up to 150 mm above the floor level,
mally used for covering floors from decorative point over the walls. The basement floor shall be
of view in residential and office buildings and also in damp proofed as per IS 1609 : 199 1 (see Chap-
railway coaches. The material gives a resilient and ter 12). Before the PVC sheeting is laid ample
non-porous surface which can be easily cleaned with time shall be allowed for water to dry com-
a wet cloth as dust and grime do not penetrate the pletely from the concrete floor.
surface. Since burning cigarette will/damage the neat In new work the finish shall be produced with
surface of the PVC sheet, special care should be taken a trowel. With old concrete~the sub-floor shall
to prevent burning cigarette stumps to come in contact be scrapped free of all foreign material and
with the PVC flooring material swept clean. The surface shall be kept wet for
7.2 Materials 24 h by sprinkling water and then a screed
topping of 3 mm thickness, shall be provided.
a>Flooring shall comply with IS 3461 : 1980 and
IS 3462 : 1986. The thickness depends on 4 Metal floors shall be made free from rust and
service conditions. scale by chipping and or vigorous wire brush-
ing and cleaning. All joints shall be ground
b) Underlay for use on concrete sub-floor shall be smooth. Painting and grease shall be removed
the screed topping. Underlay for use on an by caustic soda. Suitable putty compatible with
uneven and rough wood sub-floor shall be 3 the adhesive shall be used to fill metal surfaces
mm thick BWR grade plywood conforming to obtain a smooth and even surface.
to IS 303 : 1989.
7.4 Laying
c>Rubber based adhesives are suitable for fixing
a>The material shall be brought to the tempera-
PVC sheet and tiles over concrete wood and
ture of the area on which it has to be laid by
metal sub-floors. PVA based adhesives may be
stacking it near the area for 24 h.
used for concrete and wood sub-floors. PVA
based adhesives are not suitable for metallic b) Where air-conditioning is installed, the floor-
surfaces and also for locations where there is a ing shall not be laid for 7 days from commen-
constant spillage of water. cement of operation of air-conditioning.
During this period the temperature shall
7.3 Preparatory Work neither fall below 20°C nor exceed 30°C.
These conditions shall be maintained during
a>It is important that the sub-floor and underlay
laying and 48 h thereafter.
should be thoroughly dry before the PVC floor-
ing is laid since moisture cannot evaporate cl The layout of PVC flooring shall be marked on
once the PVC flooring is laid. The sub-floor the sub-floor. The flooring shall be laid for trial
should be even since irregular surface creates without adhesive according to the layout.
improper adhesion.
4 The adhesive shall be applied by using a
notched trowel to the sub-floor and to the back-
b) In case of new timber construction~tongued and
grooved boarding constritction shall be used. side of the PVC sheet or tile flooring. In
All nail heads shall be punched down and all general, the adhesive will take about half an
irregularities planed off and holes frlled in. hour for setting; it should not be left too long a
Adequate ventilation should be ensured. period as the adhesive properties will be lost
owing to dust films and other causes.
c>In case of existing or damaged timber floor, if
Care should be taken while laying under high
it-is not possible to obtain an even surface, the
humidity conditions so that condensation does
use of diagonal boarding is recommended after
not take place on the surface of the adhesive.
removing the damaged boarding. Alternatively
The area of spreading the adhesive at any one
plywood boarding may be used.
time depends on local conditions; in case of a
4 Concrete sub-floors shall be finished with a smallroom the entire area may be spread at one
trowel and shall be left long enough to dry out. time.
Concrete sub-floor shall be in two layers. The
e) When the adhesive is tack free, the PVC floor-
top of the lower layer shall be painted with two
ing shall be placed in position from one end
coats of bitumen conforming to IS 1580 : 1991

220
 SP 62 (S & T) : 1997

onwards, so that air is squeezed from below the chemical resistance by physical bond formed
PVC material. Press with a roller to develop by the chemical action of the acid with the
proper contact with the adhesive. The sheets mortar, the acid should have apH value of 4 or
shall be laid edge to edge, with minimum gap less. Manufacturer should be consulted regard-
between joints. The alignment shall be ing usage of these mortars.
checked after laying each row of sheet is com-
pleted.
b) Sulphur mortars have good resistance against
most of the acids except for concentrated
fl The tiles shall be fixed in the same manner as oxidizing acids, but have very poor resistance
the sheets. It is preferably to start from the to alkalis. The sulphur mortar shall always be
centre of the area. used at less than 9O’C. Where conditions are
Any adhesive squeezed out between the tiles questionable, specific recommendations of the
shall be wiped off immediately with a wet cloth manufacturer shall be obtained.
before the adhesive hardens. Hardened ad- c) Resin mortars have fairly good resistance to
hesive shall be removed by a suitable solvent; non-oxidizing mineral acids but have a poor
a solution of commercial butylacetate and tur- resistance to oxidizing mineral acids. They are
pentile oil (1:3) is a suitable solvent for the fairly resistant to inorganic alkalis. Manufac-
purpose. turer should be consulted on the usage of these
mortars.
g) No traffic shall be -permitted for 24 h after
laying. 8.3 Clauses 9 to 11 would cover the use of these
mortars, namely, silicate type, resin type and sulphur
h) Where the edges of the PVC sheets are ex-
posed, it is important to protect it by metallic type.
or other edge strips. 9 SILICATE TYPE CHEMICAL RESISTANT
MORTARS
3 PVC flooring shall be kept clean by mopping
with a soap solution using clean damp cloth. 9.1 Material
Water shall not be poured on PVC flooring as
Silicate type mortar shall conform to IS 4832 (Part 1) :
it may seep through the joints. The flooring
1969.
may be periodically polished to keep a good
appearance and a good wearing surface. A 9.2 Mortar
regular brushing, at 4 to 6 weeks interval, shall
The chemically setting silicate type chemical resistant
be given.
mortar is an intimate mixture of a chemically inert
solid filler, asetting agent usually contained in the
8 CHEMICAL RESISTANT MORTARS
filler and a liquid silicate binder. When the filler and
binder are mixed at ordinary temperatures, a trowel-
8.1 There are three types of chemical resistant mortars
able mortar is formed, which subsequently hardens by
for different end uses, covered by the following Indian
the chemical reaction between setting agent and the
Standards:
liquid silicate binder.
a) Use of Silicate Type by IS 4441 : 1980,
9.3 Storage
b) Use of Sulphur Type by IS 4442 : 1980, and
The filler shall be protected from water during storage.
c) Use of Resin Type by IS 4443 : 1980. The filler shall be kept in the containers if it cannot be
8.2 A mo&r suitable for a particular environment is protected otherwise. The liquid binder shall be
unsuitable for another. protected from freezing during storage until used.
Under unavoidable circumstances Liquid binder that
a) Chemically setting silicate type of mortars are has frozen may be used, provided the liquid binder is
resistant to most acids and have been found to thawed and thorough!y remixed before use and it can
be satisfactory against nitric, chromic, sul- be restored to its original consistency.
phuric and hydrochloric acids. They are used
for acid proof bricks or tiles. These mortars are 9.4 Mixing
not suitable for hydrofluoric and concentrated Unless otherwise specified by the manufacturfer, two
orthophosphoric acids. They are also not resis- to three parts by weight of filler to one part by weight
tant to alkalis, boiling water or steam and are of binder may be used. The optimum proportions
likely to deteriorate by continuous exposure to might vary slightly due to climatic conditions, but it is
water or frequent washing with water. In view important to have a mortar that is fluid enough to be
of the fact that silicate type of mortars develop workable and sufficikntly stiff for the masonry unit to
SP 62 (S & T) : 1997

retain its position without slipping or sliding or without harden fully. Cure the joints as given in
the mortar being exuded from the joint after the mason- 9.6~(b).
ry unit has been placed in position. 2) For walls - Spread the silicate mortar 6
to 8 mm thick on the back of the unit.
a>Weigh the filler and binder in separate con-
Smear the two adjacent sides of the unit
tainers according to the recommended propor-
with 4 to 6 mm mortar. Press the unit
tion.
against the wall until joint in each case is
b) Add approximately three-fourths of the filler 2 to 3 mm thick. Trim off excess mortar.
to the liquid binder in a clean container and mix While carrying out the jointing allow suf-
with a trowel until all the filler has gone into ficient time to avoid the joints at bottom
paste. Add the remaining filler to the paste and getting disturbed and sliding of the unit.
continue mixing until the mortar is uniform. Only one course of unit shall be laid
In any batch only that quantity of mortar that during’the initial setting. Cure joints as
could be used before it starts setting shall be given in 9.6 (b).
mixed.
4 Mortar Application with Different Bedding
cl Mortar that has begun to set shall not be and Jointing Materials - When the job has to
tempered by adding liquid binder or water but ‘come into contact with water weaker acid solu-
shall be discarded before preparing fresh tions and alkalis, silicate type of mortar may be
batches. used for bedding and resin type of mortar for
4 Portland cement or water shall not be added to jointing. The job shall be carried out with only
the silicate type of mortar. Care shall be taken class I bricks, if used.
that the mortar does not come into contact with On floors - Spread on the two adjacent
cement concrete surface. sides of the tile or brick the silicate type of
mortar 6 to 8 mm thick. Press the unit on
e) Special precautions shall be taken ~when sili-
cate mortars are exposed to temperatures the bed until the joint in each case isnot
below 10°C or above 27’C during mixing, more than 6 mm. Before the silicate mortar
application or setting. sets completely, remove the mortar in the
joints to a depth of 20 mm. Cure the joints
9.5 Application
as in 9.6 (b) and fill the joints full with
4 Sueace Preparation - The surface on which jointing mortar taking care to fill up the
bricks to IS 4860 : 1968 or tiles to IS 4457 : entire length of the joint. Trim off the
1982 are to be laid shall be free from dirt and excess mortar and make the joints smooth
dampness and shall be properly cured and and plane.
dried. On walls - Spread on to the back and two
adjacent sides of the unit the silicate type
b) Application of Membrane-A coat of bitumen
of mortar 6 to 8 mm thick. Press the unit
primer conforming to IS 3384 : 1986 be ap-
against the wall until the joint in each case
plied, and then covered with a coat of bitumen
is not more than 6 mm. Only one~course
conforming to IS 1580 : 1991. If the bedding
of the unit shall be laid during the initial
material is epoxy or polyester resin, the tiles or
setting time to avoid the joints at the bot-
bricks may be laid directly on the, surface
tom getting disturbed and sliding of the
without application of bitumen primer. In case -?---+a
unit. Cure the joints as given in 9.6 (b) and ,
of furane, cashewnut shell liquid and phenolic
fill the joints full with the jointing mortar
types resins, a coat of bitumen primer conform-
to fill up the entire length of the joint. If .
ing to IS 3384 : 1986 shall-be subject to service I
sulphur mortar is used, seal the vertical
conditions. Other membranes such as lead,
and horizontal joint with a strip of
polyisobutane and fibre reinforced plastics
gummed paper 25 mm wide to prevent the
may also be used.
flow of sulphur -mortar from the joints.
c>Mortar Application with the Same Bedding Strip off the gummed paper after the mor-
and Jointing Materials tar has set. Trim off excess mortar to make
1) Forfloors - Spread the silicate type of the joints smoothand plane.
mortar 6 to 8 mm thick on the back of the
9.6 Acid-Curing
tile or brick. Smear two adjacent sides of
the unit with 4 to 6 mm thick mortar. Press a) Acid-curing shall be carried out as -per
the unit into the bed and push the unit until manufacturer’s instructions, using safety
the joint in each case is 2 to 3 mm thick. precautions normally used when handling such
Trim off excess mortar and allow it to acids. The operators shall be provided with

222
 SP 62 (S & T) : 1997

suitable aprons, gloves, boots, etc. The mortar Table 9.12 Chemical Resistance of Silicate Type
joints shall be cured with 20 to 25 percent Mortars
hydrochloric acid or with 30 to 40 percent (Clause 9.7)
sulphuric acid no sooner than 2 days and not SI Substance Chemical Resistance
later than 6 days after the masonry units have A
No. r \
been bonded with the mortar. The curing time Sodium Potassium
shall be at least 60 min. If the constructed unit Silicate Silicate
Type Type
is designed to contain a liquid, it may be filled
(1) (2) (3) (4)
with acid of the type and concentration stated
Acids
above, with in the time interval stated, in lieu
of washing the joints. In no case shall the acid i) Hydrochloric acid (concentrated) R R
ii) Sulphuric acid (10%) R R
solution be made by partially filling the tank
iii) Sulphuric acid (10.50%) L R
with water and then adding acid. When sul-
iv) Sulphuric acid (above 50%) N R
phuric acid is used for curing, the solution shall
v) Nitric acid (concentrated) R R
not be prepared inside the unit. R R
vi) Organic acids (concentrated)
NOTE -20 percent hydrochloric acid can be made by vii) Hydrofluoric acid (any strength) N N
mixing 3 parts by volume of commercial 20” Baum6
hydrochloric acid with 2 parts by volume of water. Alkalis
Forty percent sulphuric acid can be made by mixing 2 i) Sodium hydroxide (any strength) N N
parts by volume of commercial 66” Baum& sulphuric ii) Sodium carbonate (any strength) N N
acid with 5 parts by volume of water.
Salt Solution
b) When the bedding material is silicate type mor- i) Acidic (PH value less than 4) R R
tar and the jointing material is epoxy resin type ii) Alkaline N N
or polyester type or sulphur type mortar, no- Solvents
acid curing is required. When the bedding 0 Aliphatic hydrocarbons R R
material is silicate type and the jointing ii) Aromatic hydrocarbons R R
material is phenolic resin type or furane type iii) Alcohols R R
or cashewnut shell liquid type, the joints shall iv) Ketones R R
be cured as in 9.6 (a) before applying the v) Chlorinated hydrocarbons R R
jointing material. Fats and oils R R
R = Generally recommended; AL= Limited use;
9.7 Chemical Resistance of Silicate Type Mortars
N = Not recommended.
A general guide for chemical resistance of silicate type
of mortars to various subtances is given in Table 9.12. 10.3 Safety Precautions
The ratings are for immersion service at ambient 4 Both the liquid and powder ingredients may
temperatureand may be usually upgraded for spillage contain materials that may affect the skin.
only. The chemical resistance of silicate type of mor- Therefore either gloves or barrier cream shall
tars shall be determined by IS 4456 (Part 1) : 1967. be used while handling these materials.
10 RESIN TYPE CHEMICAL RESISTANT
MORTAR
b) Vapours are present in most of the resin mor-
tars and same -produce gases during curing.
10.1 Material Adequate ventilation shall be provided in the
The resin shall conform to the requirements laid down mixing and working areas. Under confined
in IS 4832 (Part_2) : 1969. areas like vessel lining, etc, forced air draught
10.2 Storage may be used.

The resin shall be stored in a clean dry place away from c>Resin. mortars, labelled as inflammable by
spen flame and under roof with containers tightly manufacturers shall be used with adequate
closed. The resins could be generally stored without safety precautions against fire.
deterioration at 27k 2’C for periods not exceeding the
i values given below. The filler or resin that has-become
4 Solvents used for cleaning tools are generally
inflammable. Fires shall be kept away from the
wet shall not be used.
area in which such solvents are used and ‘No _,
Type of Resin Storage Period in Months Smoking’ sign shall be posted in these areas.
i’
i) Cashewnut shell 9
10.4 Mixing
liquid
ii) Epoxy 12 a) For handmixing required quantity of liquid
iii) Furane 12 resin shall be poured into a basin. The powder
iv) Phenolic 3 shall then be added gradually and the mixture
v) Polyester 3 shall be well stirred, working out all lumps and

223
SP 62 (S & T) : 1997

air bubbles. The mortar shall be mixed to the 4 to 6 mm mortar. Press the unit against
proportion as specified by the manufacturer for the wall until the joint in each case is 2 to
a particular type ofjob. A stainless steel spatula 3 mm thick. Trim off excess mortar and
may be used for mixing purposes. allow it to harden fully. While carrying out
the jointing allow sufficient time~to avoid
b) Only such quantity of mortar that could be the joints at the bottom getting disturbed
consumed within 15 to 20 min shall be
and sliding of the unit. Only one course of
prepared unless otherwise recommended by
tile or brick shall be laid duting the initial
the manufacturer.
setting. Cure with acid as in 10.7 except
10.5 Handling for epoxy and polyesterresin.

4 Resin mortars cure slowly at low temperatures. d) Mortar Application with Different Bedding
If the work is to be carried out at temperature and Jointing Materials
below 15’C, to masonry units should be Onfloc%- Spread on to the back and two
warmed and the area of work shall be enclosed adjacent sides of the unit the silicate type
and heated to above 15’C by using infrared mortar 6 to 8 mm thick. Press the unit on
lamp, to obtain proper curing. the bed until the joint in each case is 3 to
6 mm thick. Before the silicate mortar sets
b) Mixed mortar, that has ~become unworkable completely, the jointing material is re-
shall not be re-tempered with liquid resin, but
moved to a depth of 20 mm.The materlal
shall be discarded.
thus removed may be used for bedding
10.6 Application providing it is trowelable and has not har-
dened. After the bedding mortar is proper-
4 Surface Preparation - The surface on which ly set cure the joints as given in 10.7 and
bricks conforming to IS 4860:1968 or tiles
fill the joints full with resin type mortar
conforming to IS 4457: 1982 are to be laid shall
taking special care to ~fill up the entire
be free from dirt and dampness and shall be
length of the joint. Trim off excess mortar
proper1 y cured and dried.
to make the joints smooth and plane.
b) Application ofMembrane- A coat of bitumen 2) On ~walls - Spread to the back and two
primer conforming to IS 3384 : 1986 shall be adjacent sides of the tile or brick the sili-
applied on the prepared surface. A uniform cate type mortar 6 to 8 mm thick. Press the
coat of bitumen conforming to IS 1580 : 1991 unit against the wall until the joint in each
shall then be applied. If the bedding material is case is 3 to 6 mm thick. Only one course
epoxy or polyester resin, the tiles or bricks can of the unit shall be~laid during the initial
be laid directly on to the surfaces ~without ap- setting time to avoid the joints at the bot-
plication of bitumen primer. In case of furane, tom getting disturbed and sliding of the
cashewnut shell liquid and phenolic resin, a unit. Before the silicate mortar sets com-
coat of bitumen primer shall be used subject to pletely, the jointing material shall be
service conditions. Other membranes, such as, removed to a depth of 20 mm which may
rubber, lead, polyisobutane and fibre-rein- be used for bedding provided it-is trowel-
forced plastics can be used in place of bitumen able and has not hardened. Cure the joints
primer. as given in 10.7 and fill the joints full with
resin type of mortar taking care to fill the c-“-----k
cl Mortar Application with the Same Bedding
entire length for the joint. Trim off excess
and Jointing Materials
mortar to make the joints smooth and
1) Onfloors - Spread the resin type of mor-
plane.
tar 6 to 8 mm thick on the back of the unit.
Smear two adjacent sides of the unit with 10.7 Acid-Curing
4 to 6 mm thick mortar. Press the unit into Except for epoxy and polyester resins, cure the joints :
the bed and push against the floor and the for a minimum period -for 72 h with 20 to 25
unit until the joint in each case is 2 to 3 percent hydrochloric acid or with 30 to 40 percent
mm thick. Trim off excess mortar and sulphuric acid before applying the resin type of mor-
allow it to harden fully. Cure with acid as tars. After acid-curing, wash the free acid in the joints
given in 10.7 axcept for epoxy and with clean water and allow sufficient time for thorough
polyester resins. drying. Resin mortars shall then be filled into the
2) On walls - Spread the resin type mortar joints.
6 to 8 mm thick on the back of the unit.
10.7.1 Resin mortars are normally self curing and do
Smear two adjacent sides of the unit with
not generally require an auxilliary curing. They should

224
 SP 62 (S & T) : 1997

not be put to use before 48 h in the case of furane, pouring is carried out shall be checked for
epoxy and polyester resin type mortars. They may be flammable or explosive gases and a flame per-
put~to use after 48 h provided the setting temperature mit shall be issued before the fir&s are lit or
is at least 20°C. In the case of phenolic and cashewnut molten sulphur mortar is carried into the area.
shell liquid resin and for lower temperatures the period Soda acid type fire extinguisher and wet cloth
of curing shall be extended as recommended by the shall be made available for extinguishing fire
manufacturer. Without any heat treatment phenolic or preventing its spread. Water shall be kept
resin and the cashewnut shell liquid resin shall not be away-from molten sulphur mortar in order to
put to use for 7 to 28 days respectively. With the avoid foaming. Adequate ventilation should be
treatmentphenolic resin and the cashewnut shell liquid provided wherever sulphur mortars are used.
resin shall not~be put to use for 7 to 28 days respective-
ly. With heat treatment the phenolic and cashewnut Table 9.13 Chemical Resistance of Resin Type
shell liquid resin may be put to use after 2 to 6 days ~Mortars
respectively. The construction shall be protected from (Clause 10.8)
weather and water and from accidental mechanical
SI Sobs~ance Epoxy Poly- Pheno- Fur- Cashewnut
damage until the mortar is cured. Heat treatment may -No. ester lit nae Nutshell
be given with infrared lamp. Liquid
(1) (2) (3) (4) (9 (6) (7)
10.8 Chemical Resistance of Resin Type Mortars Add.?

0 Acetic acid 10% R R R R R

As a general guide the chemical resistance of resin-type
ii) Chromic acid 10% N R L N L
mortars to various substances is as given in Table 9.13.
iii) Hydrochloricacid \ R R R R R
The rating are for immersion service at ambient (cone)
temperature and may be upgraded for spillage only.
iv) Hydrofluoric acid N N R R R
Manufacturer’s instructions shall generally be fol- (see Note)
lowed. IS 4456 (Part 1) : 1967 may be used for testing. Lactic acid 2% R R R R R
v)

11 SULPHUR TYPE CHEMICAL RESISTAdT vi) Nitric acid 10% L N L N L

MORTAR vii) Nitric acid (cone) N N N N N

viii) Phosphoric acid 10% R R R R R
11.1 Material
ix) Sulphuric acid 10% R R R R R
Sulphur type mortar shall conform to IS 4832 x) Sulphuric acid 40% R R R R R
(Part 3) : 1968. xi) Sulphuric acid N N L N N
(cotlc)
11.2 Storage
Alkalis
Sulphur mortar shall be kept in a dry place prior to use. i) Ammonia 0.880 R N L R R
The mortar shall not deteriorate during storage. ii) Sodium hydroxide 40%R N L R L
iii) Sodium carbonate R L R R R
11.3 Safety Precautions
iv) Calcium hydroxide R N R R R
a) Sulphur mortar is melted and poured between Sult Solutions
bricks or tiles. If overheated, it ignites and i) Salt solution R R R R R
burns with a low blue flame. When the blue (acidic)
flame is observed, heating shall be stopped and ii) Salt solution R L R R R
(alkaline) II-
the vessel shall be covered with a tight fitting
lid or wet gunny bags until the tire is extin- Solvents
guished. When applying sulphur mortar in a i) Aliphatic hydrocarbonsR R R R N
confined space, each pail or molten material ii) Aromatic hydrocarbonsL N R R N
shall be checked to ensure that the mortar is not iii) Alcohols R R R R R
burning. The blue flame shall be checked in a iv) Ketones L N L R R
dark place. v) Chlorinated hydrocarbon&. L R R N

b) All surfaces coming into contact with molten Wet guses (oxidizing) N N N N N
Wet gases (reducing) R R R R R
sulphur mortar shall be kept dry. Adequate
Mineral oils R R R R L
i>
safety precautions shall be taken during melt- Vegetable oils anclfuts R R R R L
ing and pouring of sulphur mortars. The R = Generally recommended; L = Limited use; N = Not
operators shall be provided with leather recommended
aprons, asbestos gloves, asbestos boots, gog-
NOTE - Carbon and graphite tillers should be used for
gles and masks. The areas where melting and hydrofluoric acid service.

225
SP 62 (S & T) : 1997

11.4 Melting and Pouring 2) On walls - The chemically resistant unit

shall be placed 6 mm away from the-wall
a) The mortar shall be melted in a clean vessel and the adjacent unit using spacer chips
made of cast iron, or steel, or aluminium. It with a surface area of 1 cm2 and 6 mm
shall be filled with dry sulphur mortar to not thick and made out of sulphur mortar. The
more than one half and heated slowly until the vertical and horizqntal joints are sealed
mortar has melted to a black, smooth liquid with gummed strip of paper 25 mm wide
with a mirror bright surface and the liquid is to prevent molten sulphur mortar flowing
almost as free flowing as water, while stirring from the joints. The mortar shall be filled
frequently with a steel laddle. The sulphur leaving a gap of 25 mm from the top and
mortar must be dry at the time of use to avoid avoid air entrapment. A further course of
foaming. The mortar shall be heated to a the unit shall be laid in the same way
temperature of about 135’C. Below 130°C immediately thereafter. The gummed
some of the liquid will congeal over the top or paper can be stripped off as soon as the
around the sides of the vessel. If the mortar is sulphur mortar has hardened.
heated much above 135’C, the viscosity in-
c) Mortar Application with Different Bedding
creases until the mortar thickens and loses its
and Jointing Materials
mirror like appearance.
1) Onfloc%s- Spread on to the back and two
b) If the mortar thickens on overheating, it should adjacent sides of the unit the silicate type
be allowed to cool and stirred until thin; then of mortar 6 to 8 mm thick. Press the unit
more cold mortar may be added, if necessary, on the bed and push against the floor and
overheating for long periods may permanently the unit until the joint is not more than 6
damage the mortar. Care shall be taken that mm thick. Before the silicate mortar sets
water or damp mortar do not get into the heat- completely, the jointing material is
ing vessel so as to avoid foaming. removed to a depth of 20 mm. The
material thus removed may be used for
c>The molten sulphur mortar shall be taken in
bedding provided it is trowelable and has
galvanized bucket. The nose of the bucket shall
not hardened. Cure the joints with acid for
be directed towards the joint and the hot and
a minimum period of 72 h and dry. If the
viscous mortar is poured slowly into the joint
bedding material silicate mortar, the
without air entrapment. Any entrapped air
laying and curing shall be done as per 9.6.
should be removed while the mortar is hot by
Fill up the joint completely to its entire
poking with a thin mild steel rod.
length with sulphur mortar as in .11.4.
Trim off excess mortar to make the joints
11.5 Application
smooth and plane with a hot trowel.
2) On walls - Spread on the back and two
4 Surface Preparation - The surface to rec-
adjacent sides of the unit, silicate mortar 6
veive the acid resistant bricks and tiles shall be
to 8 mm thick. Press the unit against the
free from dirt and dampness and shall be cured
wall and with the adjacent unit until the
and dried.
joint in each case is not more than 6 mm
b) Mortar Application with Same Bedding and thick. Only one course of the unit be laid
Jointing Materials during initial setting time to avoid the
1) OnfZoors - Spacer chips with a surface joints at the bottom getting disturbed and
area of about 1 cm2 and 6 mm thick and the unit getting slided. Before the mortar
made of sulphur mortar conforming to sets completely remove the jointing
IS 4832 (Part 3) : 1968 shall be made material to a depth of 20 mm. The material
available. The chemical resistant brick or thus removed may be used for bedding
tile shall be placed on spacer chips, 3 chips provided it is trowelable and has not har-
being used under each tile. Between the dened. After the bedding mortar has set,
floor and tile or brick 6 mm space shall be cure the joints with resin for a minimum
provided.~The molten sulphur mortar shall period of 72 h and dry. If the bedding
be poured in a maximum oftwo opera- material is silicate type the laying and
tions in spaces between floor and the units curing shall be as per 9.6. Seal the vertical
avoiding air pockets till it completely fills and horizontal joints with a strip of
the joints. Trim off excess mortar to make gummed paper 25 mm wide to prevent the
the joints smooth and plane using a hot flow of sulphur mortar from the joints. Fill
trowel. up the joints completely with molten

226
 SP 62 (S & T) : 1997

sulphur mortar avoiding air entrapment. 12 PARQUET FLOORING

Strip off the gummed paper after the mor- 12.1 General
tar has hardened. Trim off excess mortar
Parquet flooring is covered by the following Indian
with a hot trowel to make the joints
Standards :
smooth and plane.
IS 5389 : 1969 Hardwood parquet and wood
4 Protecting the Units from Mortar - Various block floors
methods are available for masking the masonry
IS 9472 : 1980 Mosaic parquet flooring
units to prevent sulphur mortar from adhering
to them. Paraffin wax, paper, etc, may be used a) Parquet flooring are used in auditoria, squash
to cover the masonry units. The paraffin wax courts, skating rinks, dancing halls, etc.
or paper shall be removed after use. b) Mosaic parquet floors consists of many small
pieces of (slats) which are liable to compensate
4 Floors laid with sulphur mortar shall not be put very successfully the inevitable warping of
into service before 8 h of hying.
wood due to variations in humidity without
11.6 Chemical Resistance of Sulphur Type resulting in gaps so objectionable in strip par-
Mortars quet; at the same time glueing also remains
perfect. New patterns may be provided with
11.6.1 A genera1 guide for chemical resistance of
mosaic parquet which are not possible with
sulphur type mortars is given in Table 9.14. The ratings
conventional strip parquet.
are for immersion service at ambient temperature and
may usually be upgraded for spillage. The chemical 12.2 Materials
resistance of sulphur type mortar shall be determined
a) The species of timber for hardwood parquet
in accordance with the method described-in IS 4456 and wood block floors are given in Annex B
(Part 2) : 1967. along with the indentation index, compared to
teak as 100. The sawn timber shall be non-
Table 9.14 Chemical Resistance of Sulphur Type refractory and the thickness of floor blocks and
Mortar parquets shall be 25 to 40 mm. Nails used shall
(Clause 11.6.1) be diamond pointed (see IS 723 : 1972).
SI Substance Chemical
b) The percentage indentation for hardness shall
No. Resistance
be not less than 55 so as to withstand constant
Acid.r wear and tear.
0 Hydrochloric acid (concentrated) R
cl Timber shall be seasoned as per IS 114 I : 1993
ii) Sulphuric acid (70%) R
and fhereafter treated with preservatives as per
iii) Sulphuric acid (above 70%) L IS 401 : 1982. In case water soluble preserv-
iv) Nitric acid (40%) R atives are used, timber shall be seasoned a
v) Nitric acid (above 40%) N second time after preservation. Termite control
vi) Organic acid L shall be as per Chapter 6. Damp-proofing shall
vii) Hydrofluoric acid (40%) (see Note) R be as per Chapter 12.
Alkulis 12.3 Classes of Mosaic Parquet Flooring
i) Sodium hydroxide (1 W) R
They shall be of two classes.
ii) Sodium hydroxide (above 1%) N
iii) Sodium carbonate (concentrated) R
4 Class I - Slats may be quarter, half quarter or
rectangular sawn provided that the number of
iv) Salt solutions (acidic) R
tangential sawn slats does not exceed 30 per-
v) Salt solutions (alkaline) L cent of the slats in~each panel.
Solvents
Face shall be free from sound knots exceeding
i) Aliphatic hydrocarbons L 2 mm in-diameter and loose knots exceeding
ii) Aromatic hydrocarbons L 1 mm in diameter. Knots up to 5 mm diameter
iii) Alcohols R may be~permitted in the back.
iv) Ketones L
b) Class II - Only one of the defects mentioned
v) Chlorinated hydrocarbons L
from i) to v) below, apart from sound knot is
Fats und Oils L permitted on the face of a slat; back may ex-
R = Generally recommended; L = Limited use; hibit knots and other defects of a larger size.
N = Not recommended.
i) Sound knots, of acolour very nearly approach-
NOTE - Graphite and carbon filler should be used for ing that of adjoining wood; i width of slat.
hydrofluoric acid service.

227
c
‘.
azl'6 321’6
1 I
9Z1’6 VZC’G .
311’6 all’6
.
311’6 all.6

I4 Vll’6
L66l:(JLD S)Z9dS
 SP 62 (S & T) : 1997

12.5 Woo&Block Flooring Patterns (Types of Blocks and Wood Block Floor)

They shall be as! given in Fig. 9.13, Fig 9.14 and Fig. 9.15.

9.13A Herring-Bone Pattern 9.138 Basket Pattern

FIG. 9.13 PATTERNS OF WOOD BLOCK FLOORING

9.14A With Dove-tailed 9.148 Tongued and

Grooves on the Bottom Grooved

9.14C With Tongues on 9.140 With a Dove-tail

the Ends Groove on the Bottom with a
Narrow Groove Alround

FIG. 9.14 DIFFERENT TYPES OF WOOD BLOCKS

All dimensions
in centimetres.
FIG. 9.15 WOOD BLOCK FLOOR

229
SP 62 (S & T) : 1997

12.6 Mosaic Parquet Panel 2) Tongued and grooved,

3) Tongues on the ends, and
It shall be as in Fig. 9.16. Dovetailed groove on the-bottom and with
4)
12.7 Dimensions a narrow groove.

Mosaic parquet floors shall be of 6, 8 and 10 mm d) Laying of woodblock floor shall be done as
thickness; 6 mm thickness is not suitable for softwood below:
and softer grades of hardwood; width shall be 18 to 1) Sub-floor shall consist of cement con-
25 mm. Length shall be 100 to 165 mm. crete flooring of 5 to 7.5 cm thick, finished
smooth.
12.8 Fabrication and Laying cm x 7.5 cm
2) The woodblockssizestiom25
a) Parquet floor shall be consist~of the following : to 30 cm x 7.5 cm, shall be dipped in
1) ‘Sub-jZoor - The sub-floor shall be planed liquid mastic composition adhering to
before laying of parquets. It shall be made cement.
of timber boarded floor 50 to 75 mm thick. 3) The centre of the floor shallbe laid first
(see IS 3670 : 1989 or Part 5). The sub- with the border cut and fitted to it.
floor may also be of cement concrete. Generally two rows of wood blocks shall
2) Panels - These shall be generally 30 to be laid longitudinally to serve as border.
35 cm2. The floor is scraped and planed to an even
3) Square edged hardwood battens-These surface and sand papered.
shall be generally 15 to 50 cm in length, 4) The pores in the floor shall be sealed by an
5 to 10 cm in width and 5 to 10 mm in appropriate floor seal.
thickness. e) Mosaic parquet floors shall be laid as
b) The laying of parquet floor shall be done as below:
below: 1) Adhesives for glueing mosaic parquet
1) Border shah be fitted first to a width shall be of solvent and dispersion type,
of 60 cm and the area is laid and fitted such as, epoxy resin or phenolic resin
dry. (resorcinol formaldehyde), or urea for-
2) Every individual piece of parquet is taken maldehyde synthetic adhesives. All par-
up in turn and placed in position with quet adhesives are diluted (mixed) with
mastic; various mineral components; they are ap-
3) Before the mastic hardens, nails are driven plied by means of a toothed steel trowel
in; as thin as possible. Only a limited area
4) The floor is scraped or planed to an even shall be primed in order to prevent setting.
surface and sand papered; and
5) The nail holes punched in area filled with 2) Mosaic parquet are laid over battened
putty and the floor is polsihed with the use floors which are even. The mosaic par-
of power-driven machines. quet shall be laid diagonally to the direc-
tion of battens. In old and uneven battened
c) The wood block floors shall be in herring-bone
floors, plywood or other boards may be
or basket patterns. The blocks shall of the types
inserted between the floor and mosaic par-
given below:
quet. The boards may be glued or nailed
1) Simple square end -block with dove-
to the floor and, the old batten floor be
detailed grooveson the bottom,
made even.

1 SLATS

FIG.9.16TYPICALILLUSTRATION
OFMOSAICPARQUET
PANEL

230
 SP 62 (S & T)-: 1997

3) Adhesive shall be applied on the prepared 4) Mosaic parquet floors shall be finished
and dry surface and the back of parquet. as in Chapter 15 on finishes of wood
Apply pressure on the parquet panel to get work.
a good bond. Joints shall be very thin and
fine.

ANNEX B
(Clause 12.2)
SPECIES OF TIMBER RECOMMENDED FOR SLATS, FLOOR BOARDS AND
PARQUET FLOORS

Name Hardness Name Hardness

1. Gurjan 135 14. Kindal 95
2. Rahini 130 15. Pali 90
3. Padauk 130 16. Kokko 90
4. Satinwood 130 17. Rosewood 90
5. Maniawga 125 18. Kassi $5
6. Axelwood 120 19. Sissoo 85
7. Kala Siris 120 20. Piney 85
8. Bijasal 100 21. Jarul 80
9. Laurel 100 22. Hollock 75
10. White Chuglam 100 23. Anjan 70
11. Teak 100 24. Fir 65
12. Lendi 95 25. Cypress 60
13. White Cedar 95 26. Machillus 55

-PART 5 TLMBER FLOORS

1 GENERAL a) Species of timber selected for girders, binders

and projecting joists shall be as given below:
1.1 Timber floors are provided in auditoria, gymnasia, 1) For spans of 12 m and greater, all the
dancing halls, squash courts, public balconies, gal- species of Group ‘Super’ specified in
leries, skating rinks, etc, for noise retardent floor finish IS 3629 : 1986.
and in hilly areas as thermal insulating floor finish. 2) For spans greater than 6 m but less than
These floors may also he used in timber framed con- 12 m, all the species of Group ‘Standard’
struction to serve as structural floors. specified in IS 3629 : 1986.
3) For spans up to and including 6 m, all the
2 MATERIALS species of Group ‘Ordinary’ specified in
IS 3629 : 1986.
2.1 The species of timber recommended for floor
board shall be as given in Annex B of Part 4 of this b) Timber selected for construction of floor
boards and supporting members shall conform
Chapter, with their percentage of indentation for hard-
to the following :
ness, taking teak as 100.

231
SP 62 (S & T) : 1997

I) The species should be non-refractory; h) Wall plates and ends of joists should not be
2) The thickness of boards shal! be from built into the side walls. Spacing of joists may
25 to 40 mm. be between 300 to 450 mm.
3) Forjoists, binders and girders the modulus
of elasticity should be not less than 3 On properly fixed joists, wooden boards
25-30 mm thick, IOO- 150 mm wide and 3 m
5 625 N/mm’ and the extreme fibre stress
longgenerally widend by tongued and grooved
should be not less 8.5 N/mm*.
joints shall be laid and fixed by screws/nails.
2.2 Nails shall conform to IS 723 : I972 and diamond
pointed. k) The surface of the boards are levelled and
rubbed smooth.
2.3 All timber shall be seasoned as per IS 114 I : 1993
and preserved as per IS 401 : 1982. If water preserv- 4.1.1 Timber Floors,for Upper Floors
atives are used, it shall be seasoned a second time. The details are as in Fig. 9.18.
Proper anti-termite measures as in Chapter 6 shall be
adopted for use in buildings. Damp-proofing, w-here 4.2 Double Joisted Timber Floor
necessary, shall be done as per Chapter 12. These are used for longer spans between 3.5 m and
3 TYPES OF TIMBER FLOORS 5 m. To make it more sound proof the construction
3.1 Timber floors are generally of the following types: procedure is as follows (see Fig. 9.19):

4 Single joisted floors having bridge joist only; 4 The bridging joists, instead of spanning from
wall to wall, are supported by larger horizontal
b) Double joisted floors having bridge joists sup- members (binders) at suitable intervals, be-
ported on binders; tween 2 m to 5 m in the shorter direction of the
room.
cl Triple joisted floors having bridging joists sup-
ported on binders and framed into girders; b) Floor boards are supported on bridging joists.
4 Solid timber floors/wood block floor; and c>The binders shall not be placed over door win-
dow openings unless designed as lintels. Ends
e) Purpose made floor/parquet floors, etc.
of binders should not touch masonry.
4 CONSTRUCTION
4.1 Single Joisted Timber Floor
4 Ceilings may be fixed to the bottom of the
binders.
This Lype of floor is constructed on ground floor,
generally in theatres where dance and drama perfor- 4.3 Triple Joisted Timber Floor
mances are regularly held. Also they are suited for The details are as in Fig. 9.20.
buildings in hilly regions and damp areas. The con-
struction sequence is as below: 4.4 Solid Timber Floors

The details are as in Fig. 9.21.

4 Clear the site of vegetation, etc.
4.5 Purpose-Made Floors
b) Honey-combed dwarf walls are built, preferab-
ly half brick thick at intervals of 2 m to a These are not generally made solid; they are primarily
suitable height (see Chapter 4). hollow floors. They are named according to purpose
cl In case of basement floors, particularly, for they serve, namely, Skating-rink floor, Badminton
theatres, the space between the dwarf walls floor, Squash floor, etc. Some details are as in
may be filled with dry sand up to DPC level as Fig. 9.22.
shown in Fig. 9.17.
5 TIMBER FLOOR BOARDS
4 Over the DPC on dwarf walls longitudinally 5.1 The timber floor boards, 25 to 30 mm thick,
wooden members, or wall plates, are solidly
100 to 150 mm wide and 2 to 3 m long are joined by
bedded level by means of suitable lime or
widening joints listed in order of efficiency as given
cement mortar.
below (see Fig. 9.23):
The timber floor joists (bridging joists) are
nailed to these wall plates. 4 Ploughed and tongued joints;
Proper ventilation should be ensured to prevent b) Splayed, rebated, tongued and grooved joints;
dry rot of timber.
c>Rebated, tongued and grooved joints;
There should be a gap between the underside
of every joist/girder of the ground floor and top 4 Tongued and grooved joints;
surface of sand filling or site concrete. e>Rebated joints;

232
 SP 62 ($ & T) : 1997

f) Rebated and fitted joints; For all these joints, screws shall be driven from top of
floor boards to the joists below and then concealed by
g) Splayed joints; and
putty.
h) Square butt joints. 5.2 The pores of timber floor shall be sealed with a
floor seal.
FLOOR BOARD

CONCRETE

r BRIDGING JOIST

~SOLID
TIMBER
STRUTTING

ilMBER FLOOR !ING

BOARD

LTRIMMING JOIST

18 SINGLEJOISTEDUPPERFLOOR
FIG.~.
SP 62 (S & T) : 1997

TRIMMING
JOIST T

TRIMMEO
JOIST-

TRIMMER
InlCT-

FLOOR BOARD

RIDGING JOISTS

---...- ------_, _
---..-_..__
_..__.__------
-__._-
-.__ .. . -h---------3
-----______------___
-7-----A_-__

ENLARGED SECTION XX

Fc9.19 DOUBLEJOISTEDFLOOR

234
 SP 62 (S & T) : 1997

7
c

.BRIDGING
JOIST

-BINDER

L. GIRDER I_SPAClMG OF+ f

-MASONRY WALL
GIRDER 95rn

FLOOR BOARD
/-
/ ,- BRIDGING JOIST

ENLARGED SECTION XX

FIG.9.20 FRAMEDOR TRIPLEJOISTEDFLOOR

235
SP 62 (S & T) : 1997

T L125 x ~O;~IE~OODEN kEMENT CONCRETi

50 TO 75 mm THICK
WITH ONE COAT OF
(MAIN FLOOR OF TIMBER WITHOUT PLANKS) B’TUMENBmm
25 mm -MIN
/-ONE COAT OF BITUMEN AIRGAP
f_ _ __- , .. _ -_ .
+$Lti. l . .,_; .I.!. 4 +I$&.- ‘:- 1, y,y;*:,&&; ‘-6..! .,a:, i 1.q 3

50 TO
SECTION XX 75 mm f
(MAIN FLOOR OF TIMBER WITH PLANK3

FIG. 9.2 1 ROOM SHOWING SUB-FLOOROF CEMENT CONCRETEAND WOODEN FILLETS

SCREW FOR FIXING

THE FLOOR PLANKS/

kONCRETE FLOORJ

BOLT FOR FIXING THE

FLOOR JOIST WITH
SECTION SIDE ELEVATION
CONCRETE FLOOR

JOIST

SCREW FOR FIXING

THE TIMBER FLOOR

TOP PLAN

FIG. 9.22 TYPICAL DETAIL OF FIXINGOF FLOOR JOISTAND TIMBERFLOUR

236
 SP 62 (S & T) z I997

9.23A Square 9.238 Splayed 9.23C Rebated and 9.23D

or Butt Filleted Rebated

9.23E Tongued and Grooved

9.23F Rebated, 9.23G Splayed, 9.23H Ploughed and

Tonguedand Rebated, Tongued and Tongued
Grooved Grooved

FIG. 9.23 DIFFERENTTYPES OF JOINTSIN TWBER FLOORINGBOARDS

As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER10

WALL AND CEILING FINISHES AND

COVERINGS AND WALLING
 CONTENTS

PART 1 WALL AND CEILING FINtSHES AND 6.2 Materials

COVERINGS 6.3 Types of Facings and Fixing by Cramps
6.4 Supports
1 GENERAL 6.5 Joints
2 LIMEPLASTERFINISH 6.6 Fixing Precast Concrete Slab Facings
2.1 General 6.7 Control of Alignment
2.2 Materials
2.3 Preparatory Work 7 EXTERNALFACINGSAND VENEERS- WALL
2.4 Preparation of Background TILINGAND MOSAICS
2.5 Preparation of Lime Mortars for Plastering 7.1 General
2.6 Application of Lime Plaster 7.2 Materials
2.7 Curing 7.3 Preparatory Work
2.8 Special Finishes 7.4 Application of Floated Coat for Tiles and
2.9 Miscellaneous Works Mosaics
3 CEMENTANDCEMENT-LIME PLASTERFINISH 7.5 Fixing of Tiles
3.1 General 7.6 Fixing of Ceramic Mosaics
3.2 Materials 7.7 Fixing of Marble Mosaics
3.3 Preparatory Work
8 WALLCOVERINGS
3.4 Sequence of Operations
3.5 Thickness of Plaster 8.1 General
3.6 Number of Coats 8.2 Materials
3.7 Application of Undercoats 8.3 Preparatory Work
3.8 Curing 8.4 Fixing of Boards
4 EXTERNAL RENDERED FINISHES
4.1 General 9 CEILINGCOVERINGS
4.2 Types of Rendered Finishes 9.1 General
4.3 Nature of Background in Relation to Choice of 9.2 Preparatory Work
Rendering 9.3 Fixing of Coverings
4.4 Recommended Mix Proportions
4.5 Preparatory Work 10 FIXINGDEVICIZS
4.6 Application of Rendering Coats
4.7 Curing 10.1 Types
10.2 Fixing
5 EXTERNAL FACINGANDVENEERS -STONEFACING
ANNEXA SPECIALMIXES FOR SULPHATEBACK-
5.1 General
GROUNDS
5.2 Materials
5.3 Types of Facings ANNEXB FABRICATION AND FIXING OF TIMBER
5.4 Fixing theFacings with Cramps CEILING
5.5 Joints
PART 2 WALLING
5.6 Fixing of Stone Facings
5.7 Finishing of Joints 1 GENERAL
5.8 Ashlar Facing
2 REEDWALLING
5.9 Control of Alignment
6 EXTERNALFACINGSAND VENEERS- CEMENT 2.1 General
CONCRETE 2.2 Materials
2.3 Preparatory Work
6.1 General
 2‘4 Fixing of Reed Board 4 NO-FINES
CONCRETE
25 Fixing of Reeds for h-situ wall Construction
2.6 Finishing 4.1 General
4.2 Materials
3 C&PSUM
BLWKPAKTITIONS
-NON-LOADBEARING 4.3 Mixes
4.4 Transporting, Placing, Compacting, Curing
3.1 &net+ and Workmanship
3.2 Material8
4.3 Laying of Blocks
As in the Original Standard, this Page is Intentionally Left Blank
 SP62(S&T):1997

CHAPTER 10

WALL AND CEILING FINISHES AND

COVERINGS AND WALLING

PART 1 WALL AND CEILING FINISHES AND COVERINGS

1 GENERAL If dubbing out is necessary, it should be done in ad-

Vance so that an adequate time interval may be avail-
1.1 Wall and ceiling finishes and coverings are
able before the application of the first undercoat.
covered by the following Indian Standards:
Plaster work shall not be started until necessary fix-
a) IS 1414 : 1989 Fixing of wall coverings tures, such as, door and window frames, etc. are com-
b) IS 1661 : 1972 Cement and cement-lime pleted and all pipes, etc, are embedded in the wall so
plaster finish that there is no need to cut the plaster.
c) IS 1946 : 1961 Use of fixing devices in walls,
ceilings and floors of solid construction 2.4 Preparation of Background
d) IS 2394 : 1984 Lime plaster finish
e) IS 2402 : 1963 External rendered finishes
a>Ensure proper bond between background and
the first coat of plaster. For this all joints in
f) IS 2441 : 1984 Fixing ceiling coverings back masonry shall be raked out to a depth of
g) IS 4101 (Part 1) : 1967 External facings and not less than 12 mm while the mortar in the
veneers, stone facing joint is still green. Roughening and cleaning
h) IS 4101 (Part 2) : 1967 External facings and of background shall be done; for roughening
veneers, cement concrete facing thin wire brush may be used and the roughened
j) IS 4101 (Part 3) : 1985 External facings and surface moistioned; for cleaning it should be
veneers, wall tiling and mosaics. brushed to remove dust, loose particles, etc.
2 LIME PLASTER FJNISH b) Where necessary, dubbing shall be carried out;
the need would arise where the background is
2.1 General uneven and it cannot be made up by regular
Lime plaster finish and allied finishes are commonly courses of plastering. The dubbing process
used in the country for internal finishes as well as for consists of filling the holes and depressions
external renderings. Application of lime plaster finish with mortar of the same mix as the first coat.
to walls, ceilings, columns and similar surfaces are The patches of plaster are left rough so that
covered here. subsequent coat of plaster would stick to it.
cl The masonry shall be allowed to dry out for
2.2 Materials sufficient period so that initial drying
shrinkage is fairly complete and suction adjust-
) Lime shall conform to IS 712 : 1984 ment is possible during plastering. Suction is
:, Pozzolana shall conform to IS 1344 : 1981 and
the force by which the plaster is held on the
IS 3812 : 1981
surface after it is laid by the trowel and it has
c) Sand shall conform to IS 1542 : 1992 hardened. However, very strong suction
4 Cement shall conform to IS 269 : 1989, IS 455 : would suck all moisture from the plaster
1989, IS 1489 (Parts 1 & 2) : 1991 and any
making it weak, porous and friable. Therefore,
other as specified
careful adjustment is necessary for good
e> Lime putty shall conform to IS 1635 : 1992.
plastering~by wetting the backing suitably if it
2.3 Preparatory Work is dry; the wall shall not be soaked but only
dampened evenly before applying the plaster
2.3.1 All surfaces to receive lime plaster shall be since too much water also makes it impossible
sufficiently cured and dry; all service pipes, etc, to be to keep the plaster in position. It is preferable
embedded in masonry shall be protected against cor- to do plastering under shady conditions.
rosion before plaster work is begun. Plastering work d) Differential movements between the back-
shall be protected from damage during and after the ground and plaster due to moisture change will
operation; the plaster hardens by drying and recar- cause cracking of plaster. Major part of such
bonation which is a slow process and hence susceptible movements shall be allowed to set before the
to damage. plaster is applied, for example, by giving

243
SP 62 ( S & T ) : 1997

sufficient drying time to the background. How- 4) Metals in contact with plaster are liable to
ever, concrete blocks and foam concrete blocks corrosion. However, when a rich mix of
shall be only lightly wetted before plastering. cement lime plaster (1: 1:6) is used, it
The reasons for cracking of plaster are as would have less corrosive effect on iron
under: and steel.
1) Quick drying of the mortar due to hot 5) Plastering shall be completed before the
weather and low humidity; setting process for mortar has started. If
2) Strong mix is used on a weak background; hydraulic lime is used the mortar shall be
3) Lack of bond with the background; used within 4 h after grinding. Lime
4) Masonry underneath has not undergone pozzolana mortar shall be used within 24 h
initial shrinkage; of grinding.
5) Lack of proper raking of joints; b) To ensure even thickness and a true surface,
6) Discontinuity in backgrounds, such as, plaster about 150 mm x 150 mm shall be first
change from wall to ceiling, from concrete laid, horizontally and vertically, at not more
to brickwork, from clay brickwork to con- than 2 m intervals over the entire surface to
crete block work, etc. This can be over- serve as gauges; they shall be uniformly thick
come by separating the two portions by a but slightly more than the specified thickness.
neat cut through the plaster at the junction; These shall be beaten by wooden straight edge
7) Due to roof movement by variation in and brought to true surface after thoroughly
temperature, cracks may occur in parti- filling the joints. Excessive trowelling or
tions; this can be prevented by isolating floating should be avoided. During the process
the top of partition from roof slab; and a solution of lime putty shall be applied on the
8) When bridging joints in slabs, the plaster surface to make the latter workable. All
will crack due to higher stresses; this can corners, arrises, angles and junctions shall be
be avoided by reinforcing the plaster at the truly vertical or horizontal as the case may be.
joint by wire or jute scrim. Rounding or chamfering shall be done with
2.5 Preparation of Lime Mortars for Plastering proper templates.

This is covered in Chapter 4. cl The plaster shall be left cut clean to line both
horizontally and vertically, while stopping
2.6 Application of Lime Plaster work at the end of the day. For recommencing
a) General - It is an advantage to plaster the the work, the sedge of the old work shall be
ceiling first and then to plaster the walls start- scrapped clean, wetted with lime putty.before
ing from top and working downwards. This plaster is applied to the adjacent areas. The
will permit the removal of scaffolding as easily plastering work shall be closed at the end of the
as possible. day on the body of the wall but not nearer than
150 mm to any corner or anises. There shall
1) The range of coats normally employed for
be no horizontal joints in plasterwork on
different backgrounds are as follows:
parapet tops and copings. No portion of work
Brickwork (internal and external) 1 or 2
initially be left out to be patched later on.
Stonework (internal and external) 2 or 3
Concrete blocks 1 or2 In case ballies pierce the wall, the holes shall
Wood laths 2 or 3 be made good with brick and plastered.
Soffits and ceilings 1 or2 d) One Coat Plaster work - The plaster of
2) Thickness for plaster work exclusive of specified thickness shall be applied to the full
key or dubbing out shall generally be-as length of the wall up to natural breaking points,
below: such as, doors and windows. The mix for ceil-
First Second Third ings shall be stiffer than that used for walls. On
Coat Coat Coat soffits the mortar shall be laid in long even
Brick masonry spreads outwards from the operator overlap-
a) Single coat work 15mm - - ping each trowel full and using sufficient pres-
b) Double coat work 10 mm 10 mm - sure to ensure intimate contact with the
Stone masonry 15mm 10mm - background. On walls, the mortar shall be laid
Stone masonry (very in long even spreads upwards and across, under
rough surface) 15mm 10mm 10mm pressure.
3) The plasters shall be finished to a smooth On smooth background, the mortar may have
surface. to be dashed on to ensure adequate bond.

244
 SP62(S&T):1997

The plaster shall be laid on little more than the required The sand shall be ground fine. The marble also
thickness and levelled with a wooden float. The shall be ground fine and filtered through mus-
plaster shall be water cured as described in 2.7. lin. The materials shall be mixed with water
e> Two Coat Plaster Work and~kept in a heap, well wetted ftr 2 days.
1) First coat-The first coat shall be applied c>On this coat of(b), the same mix as in (b) shall
as in (d) above. Before the first coat har- be ground on flat stone slabs with stone rollers
dens, itssurface shall be beaten up by the to the coinsistency of fine river mud and ap-
edges of wooden thapis and close dents plied to a thickness of 2 mm over the second
shall be made on the surface, which serve coat (b) which is wetted before hand.
as a key to the next coat. The next coat 4 The surface of the third coat (c) shall be
shall be applied, after the first coat has set polished first with trowels and then with very
for 3 to 5 days. The surface shall not be hard smooth stones. While polishing opera-
allowed to dry during this period. tion is in progress soap stone powder contained
2) First coat on wooden lath and metal lath- in muslin bags shall be dusted on the surface.
ing - The mortar shall be stiff enough to The operation shall be continued till a high
cling and hold when laid and shall be smooth polish is obtained.
applied spreading diagonally across the
d Curing shall be done as in 2.7.
lath work overlapping each trowel full
under pressure. The average thickness 2.9 Miscellaneous Works
shall not be exceeding 10 mm. 2.9.1 Repairs.
3) Second coat - The second coat shall be
completed in exactly the same manner as a>Cracked, crumbled or hollow sounding por-
tions of plaster shall be removed to a shape of a
the first coat. The finishing coat shall be
square or a rectangle. The edges shall be undercut
laid with a mason’s trowel to an average
slightly to provide a key to new plaster.
thickness of 5 mm.
4) Curing shall be done as in 2.7. b) The visible joints shall be raked out to a mini-
f) Three Coat Plaster Work- The first two coats mum depth of 12 mm in the case of brick work
shall be applied as in (e); the third coat shall be and 20 mm in the case of stone work. The
completed to the specified thickness in the surface of the masonry shall be scrubbed with
same manner as the second coat; curing shall wire brushes to remove all-mortar; it shall then
be done as in 2.7. be washed with water and kept wet before
2.7 Curing commencing plastering.

Curing shall be started 24 h after finishing the plaster. c>Plaster shall then be applied as in one ‘coat
The plaster shall be kept wet for 7 days; during this plaster work [see 2.6 (d)]. The surface shallbe
period it shall be protected. finished even and flush with the old smound-
ing plaster.
2.8 Special Finishes
2.8.1 Madras Plaster 2.9.2 Avoidance of Crazing
This~is a special plaster finish applied in three or more a) Surface crazing-is due to excessive shrinkage
coats to obtain a smooth polished surfaces in places caused by drying.
where shell lime and fine sand are easily available. b) In order to prevent this, it is necessary to limit
a> The first coat of lime plaster shall be applied the differences in shrinkage, as below:
as in 2.6 (d). This shall be allowed to set for 2
1) Use well graded materials;
or 4 days and then the surface scoured
2) Ensure thorough grinding of mortar and
thoroughly in diagonal lines crossing each thorough mixing of constituents;
other. The plaster shall be kept constantly Observe carefully the time intervals
3)
watered till it is~nearly set and then the second between successive coats so that each coat
and third coats be applied as in 2.6 (e) and (f). undergoes a portion of its shrinkage before
b) On this coat, a mix specified below about 5 mm the next coat is applied; and
thick shall be applied to an exact level surface Avoid quick drying at initial stages.
4)
with long wooden floats or where required by
3 CEMENT AND CEMENT-LIME PLASTER
curved moulds. The surace of the undercoat
FINISH
may be watered, if necessary, before applying
this coat. 3.1 General
Shell lime (slaked) 12 parts by volume Cement plaster and cement plaster gauged with lime
Fine white sand 9 parts by volume are widely used in the country for finishing of walls
Powdered marble 1 part by volume and ceilings.

245
SP62(S&T):1997

3.2 Materirils e>Plastering of cornices, decorative features, etc,

Cement~shall conform to IS 269 : 1989 or IS 455 : 1989 shall normally be completed before the finish-
ing coat is applied.
or IS 1489 (Parts 1 & 2) : 199 1 or any other as
specified. Cfass B and Class C lime shall conform to 0 Holes in walls left by scaffolding shall be made
IS 712 : 1984. Sand shall conform to IS 1542 : 1992. good and plastered true, even and smooth in
conformity with the rest of the wall.
3.3 Preparatory Work Where corners and edges have to be rounded off,
8)
3.3.1 Preparation of Background for Application of this should be done along with the finishing coat,
Plaster so that no sign of any joint shows out later.
a) For the durability of the plaster or rendering, it 3.5 Thickness of Plaster
is vital to obtain a satisfactory bond between 4 Finishing coats (and single coat work, when
the background and the first plaster coat and employed) shall be such minimum thickness
also to ensure that the bond is maintained sub- that provides sufficient body material to hard-
sequently. en -satisfactori!y under-site conditions in any
b) It is also important to clean the background; particular case. The total thickness of two c_oat
remove dust, laitance, etc. The background work, excluding keys and dubbing out shall be
should be made rough and then moistened, about 20 mm thick~and not more than 15 mm
joints shall be raked. Suction of the back- thick in case of in-situ concrete soffits. The
ground should be suitably adjusted. The back- thickness of three coat work shall be about
ground shall be even. The strength and 25 mm. The thickness of an individual coat shall
elasticity of plaster shall be compatible with be generally as recommended in Table 10.1.
the background. Precautions against discon-
tinuity of the background should be taken to Table 10.1 Recommended Plaster Mix and
prevent cracking; the best treatment appears to Thickness
be to separate the two backgrounds by a neat (Clause 3.5)
cut through the plaster at the junction. S1 No. of Coats Situation Mix Proportion Thickness
c) Brickwork or Hollow Block Background - No. of Plaster by Volume
The masonry shall be allowed to dry out for (cement:lime:sand)
i) Single coat Both internal I:03 10 to 15 mm
sufficient period so that the initial drying plaster and external I :0:4
shrinkage is fairly complete and suction adjust- 1:0:6
1:1:6
ment is possible during plastering. Joints shall 1:2:9
ii) Two coat
be raked out and projecting bricks trimmed off. plaster
Old brick work shall be thoroughly brushed a) Backing do I :0:3 IO to i2 mm
coat I :0:4
down and low spots dubbed out by a mix 1:0:6
similar to the first coat to be applied. l:1:6
b) Finishing d0 ; 9;; to 6 3 to 8 mm
d) Concrete Background - The surface shall be coat
I :2:9
clean and rough. The surface shall be evenly iii) Three coat Very rough
wetted (not saturated) to provide correct suc- plaster surface; both
internal and
tion. All projections shall be removed. external
a) Base coat 1:0:3 lOto I5 mm
3.4 Sequence of Operations 1:0:4
1:0:6
1:1:6
4 For external plaster, the plastering operations b) Second ; ;R; to 6 3to8mm
may be started from the top floor and carried coat
1:2:9
downwards. For internal plaster, the plastering c) Finishing Fat lime and fine 3 to 5 mm
operations may be started wherever the build- coat sand or marble dust
in equal proportions
ing frame and cladding work are ready and the NOTES
temporary supports of the ceiling resting on 1 Where two or more coats are adopted, as far as possible the
wall or the floor have been removed. mix for undercoats should contain cozuse sand conforming to
b) Constant supply of plaster shall be ensured. grading Zone II of IS 383 : 1970.

c> The first undercoat is then applied to ceilings 2 For single coat plaster the fineness modulus of sand should
and walls. It is an advantage to plaster the be, as far as possible I .5 and conforming to Zone IV of IS 383 :
1970. WhereDnly tine sand is available, the fineness modulus
ceiling first ~to remove the scaffolding before
may be improved by mixing the required percentage of coarse
the plastering work on the wall. sand. The strength of plaster mix reduces with the reduction in
4 After a suitable interval, not more than 5 days, the fineness modulus of sand.
the second coat may be applied. After a further 3 Other mixes of cement/lime and sand may also be adopted
suitable interval, the finishing coat may be depending on the quality of sand available and local conditions
provided the strength conforms to any of the above mixes.
applied first to the ceilings and then the walls.

246
 SP62(S&T):1997

3.6 Number of Coats Background Number of Coats

a) The ideal number of coats, where practical, is 9 Brickwork or hollow clay tiles 2 or 1
two, namely, the undercoat followed by finish- ii) Concrete, cast in-situ 2or 1
ing coat. This is possible on reasonably plane iii) Building blocks 2or 1
backgrounds of brick, concrete and similar iv) Wood or metal lath 3 or2
materials. However, for very rough surfaces, 201-I
v) Fibre building boards
such as, rough stone masonry, three coat
vi) Wood-wool slabs 2or i
plastering may be necessary. Metal lathing re-
quires three coat plaster finish. Renovation vii) Cork slabs 2or I
work on wooden laths should also be carried viii) Uneven rough stone masonry 3 or 2
out in three coats.
b) A summary of background data for internal
The range of coats for different backgrounds is plastering is given in Table 10.2.
as follows:

Table 10.2 Data for Internal Plastering

(Clause 3.6)
Sl Class Type Drying Characteri- Preparation Remarks
No. Shrinkage stics of Surface
Movement
(1) (2) (3) (4) (5) (6) (7)

i) Solid a) Dense clay Negligible Low May require Note I

bricks and suction - more than raking
blocks and poor joints bonding
key agents, spatter-
dash or wire. mesh
or special
plasters
b) Normal .Negligible Moderate to Rake joints Note 2
clay brick high suction unless key
and blocks and reason- provided
able key
c) Dense Low to high Suction gene- Unless keyed Note 3
concrete, differential rally low but use spatter-
either . thermal varies accord- dash,
precast or movement ing to aggre- bonding
in-situ varies with gate and water treatment
aggregate cement ratio or special
poor key plasters
d) No tines Varies from Low suction None -
concrete low to mode- andgoodkey
rate. Varies
with
aggregate
-e) Open tex- Moderate to Low suction None Note 4
tured con- high and good key
crete with
light weight
aggregate
f) Close tex- Moderate to Variable May need treat- Note 5
tured high suction ment with
concrete bonding agent
blocks to provide key
g) Aerated Moderate to Moderate to May be necessary Note 6
concrete high high suction, to reduce suction
reasonable unless special
key plasters are
used
ii) Slab a) Wood-wool High but Low suction None other Note 7
generally andgoodkey joints
fixed dry scrimmed
‘and may
also be
restrained

247
SP62(S&T):1997

Table 10.2 - Concluded

(1) (2) (3) (4) (5) (6) (7)

b) Strawboard - No key Key can be -

provided by use
of bonding
treatment or
wire netting or
metal iathing.
Joints should
be scrimmed
c) Cork - Low suction If the surface -
key variable provides in-
sufficient
mechanical key
a 1: 1 cement
fine sand
slutry should be
brushed on and
wire mesh fixed
iii) Boards a) Plasterboard Negligible Low suction, Joints scrimmed -
adequate key unless gypsum
with suitable lath is used
plasters
b) Insulating High, but Low suction, Joints Note 8
tibreboard fixed dry adequate key scrimmed
and easily with suitable
restrained plasters
c) Expanded - Low suction, None, other Note 9
plastics adequate key than joint
with suitable scrimming
plasters when recommended
by manufacturer
iv) Metal Metal and clay - Good key None -
lathing

NOTES

1 Spatterdash coat, 1:2 or 3 cement : coarse sand should be allowed to harden before applying under coat. Wire mesh should be fixed
at least 6 mm in clear of surface.

2 Should bc dry to minimize efflorescence.

3 Use bonding treatment or special plasters according to manufacturers’ recommendations.

4 Should be dry to minimize shrinkage movement.

5 Differential thermal movement may be high with some aggregates.

6 Should be dry to minimize shrinkage movement.

7 When used as permanent shuttering special precautions are necessary.

8 Boards must be conditioned at site.

9 Consideration should be given to the strength of the board and the possibility of impact damage.

3.7 Application of Undercoats b) Second Coat/Floating Coat - The surface of

the first coat shall be dampened evenly, the
a) First Coat/Rendering Coat - The rendering second coat shall be 3 mm to 8 mm thick.
coat shall be at least 10 mm thick and carried
to the full length of the wall. Before it hardens c) Finishing Coat
it shall be roughened to provide key to the next 1) The second coat shall -be dampened.
coat. The coat should be trowelled hard and
tight.
2) Coloured cement work - The pigment
may be intimately ground with cement
On smooth concrete walls, the surface shall be clinker, or pigments are added to the white
roughened and then the first coat shall be cement or ordinary grey cement to get the
dashed on it. required shade.

248
 SP 62 ( S & T ) : 1997

3) In case of coloured cement plastering, 4.2.4 Machine Applied Finishes

waterproofing compounds should be
added on the undercoats to minimize the There are various types, mainly proprietory materials
risk of efflorescence. and processes operated by specialists. The types are
as follows:
3.8 Curing
a) Finishes in which the material is thrown at
random - These have an open porous struc-
a) Each coat shall be cured for a maximum period
ture, behave similarly to hard-applied scraped
of 7 days and-shall be kept damp till the next
finishes and are equal to the latter and to hand-
coat is applied.
thrown finishes in water proofness, durability
b) After completion of the finishing coat, the and resistance to cracking and crazing.
plaster shall be kept wet at least for 7 days.
b) Finishes which are applied by gun spray -
These give low density porous finishes.
4 EXTERNAL RENDERED FINISHES
There are other finishes solely applied by means of
4.1 General cement gun under pressure which produce somewhat
similar appearance to roughcast but less attractive.
‘Rendering’ denotes generally external plaster and They are more dense and therefore give very effective
allied finishes, plain or textured, applied for the pur- protection.
pose of protection and decoration. Rendered finish
can withstand different exposure conditions, such as, 4.3 Nature of Background in Relation to Choice of
severe or moderate exposure to rain; dusty, clear or Rendering
corrosive atmosphere, or subject to large variations in
temperature or other climatic cycles. Rendering in- Broadly the background may be classified under the
creases, durability and ensures better performance. following types so far as application of rendering is
concerned:
Plain internal finishes are covered in 2 and 3 of Part 1
of this Chapter. a) Dense, strong and smooth materials;
b) Moderately strong and porous materials;
4.2 Types of Rendered Finishes
c) Moderately weak and porous materials;
4.2.1 Trowelled or Floated Plain Finishes 4 No-lines concrete; and
Steel trowelled finishes are not recommended for ex- d Lathing or other similar backing materials.
ternal renderings. Plain floated finishes require a high The characteristics of these backgrounds are given in
standard of workmanship to minimize the risk of Table 10.3.
cracking, crazing and irregular discolouration.
4.4 Recommended Mix Proportions
4.2.2 Scraped or Textured Finishes, Hand Applied

Scraped or textured finishes are generally less liable to Mixes suitable for different types of renderings are
crack or craze than plain finishes and are easier to bring given in Table 10.4. Where alternate mixes are given
to a uniform appearance; this is specially important selection shall be made on the following considera-
when coloured renderings are used. Although rough tions:
texture offers more lodgement for dirt, it tends to an a) The mix for each successive coat shall never
evenness of discolouration; rain water is distributed be of a type richer in cement than the mix used
reducing the risk of penetration through the rendering. for the coat to which it is applied; and
4.2.3 Hand-Thrown Finishes, Rough Cast and b) Richer type of mix shall be~preferred in winter
Dry-Dash, etc conditions.

These finishes have all the advantages of scraped or -4.5 Preparatory Work
textured finish. Under severe conditions of exposure
these are more satisfactory from weather proofing, 4.5.1 Independent scaffolding may be used wherever
t durability, reistance to cracking and crazing than the possible to avoid put log holes.
types as in 4.2.1 and 4.2.2.

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SP 62 ( S & T ) : 1997

Table 10.3 Backgrounds for Renderings

(Clause 4.3)
SI Backing Materials Strength Porosity Mechanical Resistance to
No. and Key and Penetration,
Suction Adhesion Protection
Required

i) Poured cement Roughening, Sufficient

conciete moistening resistance;no
and sometimes further treat-
ii) Cement concrete treatintingthe ment apart from
blocks Strong Low surface with rendering
cement and
iii) grout (1:l)
is necessary
iv) Bricks, ordinary Moderately High Satisfactory; Sufficient
porous type strong if suction is resistance, no
irregular use further treat-
cement and ment apart from
sand mix 1:1 rendering
over the
surface
v) No-fines concrete Sometimes Large voids, Very
weak a few small satisfactory
pores, capillarity
absent; suction
low
vi) Lathing Shall be - Purpose is to Two coats of
strength- provide key rendering are
ened necessary. First
coat shall be of
relatively
impervious mix

Table 10.4 Recommended Mixes for External Renderings

(Clause 4.4)
Background Type of Type of Mix Recommended for Given Exposure
Material Finish Conditions
A
f ,
Firstand Subsequent Final Coat
Undercoat
rs
/ . I ,
Severe Moderate Light Severe Moderate Light

(1) (2) (3) (4) (5) (6) (7) (8)

Wood-float 1 20r3 2, 3 itr 4
Dense and strong Scraped or 2 : 2or3 :. : 20r3
Textured

Moderatelystrong Roughem : 55 5 -6 -6 -6
and porous Dry-dash

Wood-float
Moderately weak Scraped or ’ 2 3 4 Same as for undercoats - *
and porous Textured 1
Wood-float 20r3 : 3or4
Scmped or 2or3 3or4
No-fines concrete Textured
Roughcast 5 5 : 6 6 6
Dry-dash 5 5 - - -
+
Wood-float
Metal lathing Scraped or I 1 1 2 2 2
or Textured
expanded metal Roughcast 6 6 6
Dry-d& : : 5 - - -
NOTES

1 Mixtypes.Type1-1:0:4,Type2-1:0:5to6,Type3-1:1:6to7,Type4-1:2:9to10,Type5-1:0.3,Type6-1:3
Types 1 to 5 shall-consist of cement:lime:sand by volume; Type 6 shall consist ofcement, coarse aggregate of size 6 to 12 mm by volume.
2 For special mixes for high sulphate backgrounds (see Annex A).
3 Where alternate sand contents are shown, the higher one may be used if the sand’is coarse or well graded and lower sand content may
be used of the sand is fine.
 SF’ 62 ( S & T ) : 1997

45.2 Preparation of Background 2) The aggregate used for dashing shall be

well washed and drained.
a) The background shall be brushed with a stiff
3) To ensure satisfactory bond between the
bristle or wire brush. Laitance if any on fresh
dashing and mortar, the aggregate may be
concrete shall be removed.
slightly tapped into the mortar with a
b) The baekground shall be roughened and mois- wood float or to a trowel.
tened. Joints in masonry shall be raked to a h) Machine-Applied Finishes - All damaged ad-
depth of 1 cm. jacent surfaces shall be masked. The finish
shall be applied at such a rate as to ensure the
c) Adequate time shall be allowed between erec- desired texture.
tion and application of rendering to make the
surface suitable for suction adjustment. The
4.7 Curing
backing shall be wetted, if it is dry, for this
purpose; it shall not be soaked but dampened The moistening shall commence as soon as the plaster
evenly. has hardened; the surface shall be kept wet for at least
4 Ensure evenness of background before apply- 7 days by using a fine fog spray. Soaking of wall shall
ing rendering. be avoided.

e) Differential movements of mixed backgrounds 5 EXTERNAL FACING AND VENEERS -

shall be provided for. STONE FACING

4.6 Application of Rendering Coats 5.1 General

4 General -When using high alumina cement, Facing with stones of various types like marble,
the work shall not be done in hot weather. granite, lime stone,~etc, is a popular external finish.
Between coats, give 24 h interval in hot and dry Therefore, these require careful fixing techniques
weather and more in cold weather. involving proper preparation, appropriate choice of
fixing devices and weather proof construction. Fixing
b) First Undercoat - This may be applied either
by laying or throwing from the trowel. It accessories, like cramps, dowels used in facing work
shall be as uniform as possible up to a thickness are commonly of copper alloys but also of aluminium
of 8 to 12 mm. It shall be rough and then alloy, plastics, etc.
combed and scratched to provide a key to the
5.2 Materials
next coat.

c) Subsequent undercoat, if necessary, may Abe a>Facing Stone - The stone shall be sound,
laid similarly to (b). dense and free from defects which impair
strength durability and appearance. The
d) Plain Finishing Coats - The finishing coat facings may be of marble, granite, syenite,
shall be not less than 3 mm or more than 8 mm
basalt, limestone, sand stone or slate. Lime-
thick; the coat shall be laid with a trowel and
stone slabs from Sahabad, Taiduran, Kotah and
finished with a wood, felt, cork or other suitab-
Yerraguntla of 20 mm thickness and above are
ly faced float.
used.
e) Scraped or Textured Coats - Various scraped In case of sandstone, patches or streaks shall
or textured finishes can be~obtained by hand or not be allowed; however scattered spots of
machine application. The thickness of the 10 mm diameter may be allowed.
final coat is governed by the texture required.
Marble facings (blocks, slab and tiles) shall
For scraped finishes the final coat is of a thick-
conform to IS 1130 : 1969.
ness of 6 to 12 mm of which about 3 mm is
removed in the scraping process. For textural The thickness of stone veneer shall not be less
finish the surface skin of the mortar shall be than 20 mm.
removed to expose the aggregate. b) Cramps - The material for cramps shall have
high resistance to corrosion under conditions
Roughcast Finish -The final coat, the mix of
of dampness and chemical action of mortar in
which shall be quite wet and plastic, is thrown
which it~is embedded. They may be of copper
on by means of a trowel or scoop.
alloyed with zinc, tin, nickel, lead and
Dry-Dash Finish aluminium or stainless steel. Aluminium H9
1) For this finish the undercoat shall be up to alloy in W condition (see IS 737 : 1986) may
a thickness of 8 mm and slightly pressed. be used for cramps.

251
SP 62 ( S & T ) : 1997

c) Metal Angle Supports - Mild steel angle sup- b) to hold the units in position and also to support
ports may be used; they should be protected the unit transferring the weight to the backing.
from corrosion. 5.4.1 Supporting arrangements shall be as shown~in
d) Cement shall conform to IS 269 : 1989, Fig. 10.1 A to 10.1 H; cramps may be attached to the
IS 1489 (Parts 1 & 2) : 1991 or any other as sides (Fig. 10.1 A and lO.lB), or top and bottom (Fig.
specified. Sand shall conform to IS 2116 : lO.lC, Fig. lO.lD, Fig. lO.lE andFig. lO.lF), or sides
1980 and lime to IS 712 : 1984 and SURKHZ and bottom (Fig. lO.lG and Fig. lO.lH).
to IS 1344 : 1981. 5.4.2 Facings Integrally Bonded to Backing
5.3 Types of Facings
The attachment for integral bond should be either:
a) Facings which are not integrally bonded with
a) the facing unit contains projections~which are
the backing do not generally appreciably con-
mechanically bonded with the backing and
tribute to the stability and load bearing
supporting unit; or
capacity of the wall.
b) by means of masonry bond or keying to the
b) Facings which are integrally bonded with the backing, or
backing so that both together contribute to the
c) a combination of both (a) and (b).
stability and load carrying capacity of the wall
in which at least 15 percent of the face consists 5.5 Joints
of bonding stones extending up to 10 cm into
The joints between units should be finished flush, tuck,
the backing.
ruled, square, weathered-struck or rebated as in
5.4 Fixing the Facings with Cramps Fig. 10.2
Cramps may be used either: Expansion joints in -the backing shall be carried
a) to hold the facing units in position only and through in the~facing. The joints may be sealed with
transfer the weight of the unit to the facing appropriate joint sealing compounds, to prevent
beneath; or ingress of moisture.

10.1A Side Attachment 10.1B Side Attachment 10.1C Top and Bottom 10.1 D’Top and Bottom
Attachment Attachment

10.1 E Top and Bottom 10.1 F Top and Bottom 10.1G Side, Top and 10.1H Side, Top and
Attachment Attachment Bottom Attachment Bottom Attachment

NOTE - Cramps shown in diagrams ‘A-H’ are arranged for facings with the longer sides vertical. For facings having the longer sides
horizontal, cramps wouldbe positionedto suitthe alteredproportions
of the facings.

FIG. 10.1 DIAGRAMATICARRANGEMENTS

OFCRAMPSFOR ATTACHINGFACINGSTO BACKINGWALL

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 SP62(S&T):1997

FIG. 10.2 TYPESOF FINISHESFORJOINTS

5.6 -Fixing of Stone Facings enlarged to improve the anchorage of the cramp.
During fixing, cramps shall not be bent, unless
The stone facings shall be wetted before laying. While provided for in the design.
applying mortar for fixing the facings in position, no
5.6.1 Use of stone dowels and metal pins for fixing
chips or fillings of any sort shall be used.
veneering to wall are shown in Fig. 10.4. Cramps
The facings may be fixed according to the different illustrated in Fig. 10SA shall not be used for load
types of arrangements (see 5.4.1) and shown in bearing purposes. Details of copper pin dowel is
Fig. 10.3. In case of load bearing cramps (designed to shown in Fig. 10.5, details of metal and stone cramps
carry the load), the holes in the backing shall be are as in Fig. 10.6.

FIG. 10.3 TYPIS OF CRAMPSFORSTONEFACINGS

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SP62(S&T):1997

/-BRICK BACKING GUN METAL CRAMP7 rBRlCX BACKING

FIG. 10.4 DETAILSOFFIXINGSTONEVENEERING

10.5A 10.56
All dimensions
incentimetres.
FIG. 10.5 COPPERPINDOWELS

HOLE FOR ATTACHING

HANNEL TO FORMWORX

METAL CRAMP

STONE VENEERING

6A MetalCramp 68 Stone Cramp

FIG. 10.6 CRAMPS

5.7 Finishing of Joints a

For a close but joint the thickness shall not exceed 4
Exposed joints shall be pointed with 1:2:9 mortar as 1.5 mm. Crushed stone sand from the same stone as the r .
specified, the thickness of joint shall not exceed 6 mm. facing unit is preferable as the aggregate in mortar. 3
s I

254
 SP62(S&T):1997

When distinct joints are necessary, a wiping of white 6.3 Types of Facings and Fixing by Cramps
cement~slurry or tinted white linseed oil-putty may be
applied to the tightly butting slabs; but this shall not be 6.3.1 Facings and veneerings may be of two types:
used under severely exposed positions.
Attached facings for use with backing as a safe
5.8 Ashlar Facing means of attachment without essentially con-
Facing with ashlar built integrally with backing shall tributing to the stability of the load bearing
be as in Chapter 4. properties of the wall, and

5.9 Control of Alignment Integrally reacting facings which are bonded

with the backing and contribute to the struc-
Alignment shall be accurate to present a good ap-
tural stability and strength of the wall.
pearance. Inaccuracies will easily show up. Masking
may be attempted by treatment of joints, such as, by
6.3.2 Cramps
use of chamfered, rounded or rebated edge in place of
a simple square edge.
4 Using cramps to hold the facing units in posi-
6 EXTERNAL FACINGS AND VENEERS - tion only, the weight of the unit being sup-
CEMENT CONCRETE ported by the unit beneath, or
6.1 General -b) Using cramps to hold the units in position and
Concrete slabs or precast blocks with different textures in addition to support the units thus transferring
and finishes provide possibilities for a wide range of the load to the backing; or
architectural treatment for external facing and are par- c) The facing unit may contain projections which
ticularly suited for a wide scale adoption. While mechanically bond into the backing and sup-
availability of natural stones is limited, concrete port the unit; or
finishes can be made in a wide range of textures and
colours. d) By means of masonry bond or keying to the
backing; or
6.2 Materials
e>By combinations of the above methods.
a) Precast concrete blocks shall conform general-
ly to IS 2185 (Part 1) : 1979; IS 2185 (Part 2) : 6.4 Supports
1983; IS 2185 (Part 3) : 1984 (see also Chapter Supporting arrangements by means of projections
4), and in addition shall have special treatment which bond mechanically into the facing is a common
.
in regard to durability, colourand surface tex- method. Supporting by cramps are as shown in
tures for the exposed facing. The size com- Fig. 10.7A to 10.75. Cramps may be attached to its
monly adopted for concrete facing slabs is sides (Fig. 10.7A andB), or top and bottom (Fig. 10.7C
600 mm x 400 mm x 30 mm. The face finish to E), to its side, top and bottom (Fig. 10.7F to H), or
of slabs shall also be adequately waterproofed. in its centre (Fig. 10.7J).
For obtaining various colours in the admix-
tures, reference may be made to IS 2114 : 1984 6.5 Joints
and also Chapter 9 regarding pigments to be The joints between facing unns may be finished flush,
used in concrete mixes. tuck, ruled, square, weathered-struck or rebated as in
Fig. 10.8. Where expansion joints are formed in the
b) The material for cramps shall have high resis-
tance to corrosion under conditions of damp- backing walls, they should be extended to the facing.
ness and chemical action of mortar or concrete The joints may be sealed with appropriate sealing
in which it is embedded. The cramps may be compounds, to~prevent ingress of moisture.
of copper, alloyed with zinc, tin, nickel and
aluminium or stainless steel. Aluminium alloy 6.6 Fixing Precast Concrete Slab Facings
I
,
H9 in W condition (see IS 733 : 1983) may also
be used for cramps. The facings can be fixed with butt joints, single or
double joggle joints or grouted joints as shown in
C>Metal angle supports used shall be protected Fig. 10.9 and Fig. 10.10. When the backing wall is of
from corrosion. in-situ concrete it will be an advantage to use dove-
d) Cement shall conform to IS 269 : 1989, IS 455 : tailed non-corrosive metal channels cast vertically in
1989, IS 1489 (Parts 18z 2) : 1991 or any other the backing wall in which one end of the cramps fit,
as specified. Sand shall conform to IS 2116 : the other end being cranked or drilled for dowels, the
1980 and lime to IS 712 : 1984, surklin to IS cramps being set into the channel as the fixing
1344 : 1981. proceeds.

255
SP62(S&T):1997

10.7A Side Attachment 10.78 Side Attachmeht 10.7C Top and Bottom 1O.fD Top and Bottom
Attaohmbnt Attachment

10.7E Top and Bottom 10.7F Top and Bottom 10.7G Side, Top clnd 10.7t-l Side, Top and 10.7J Centre
Attachment Attachment Bottom Attachment Bottam Attachment Attachment

NOTE- Cramps shownin diagrams‘A-H’nrearranged forfncingswiththe longer sides vertical. For facings having the longer sides
horizontal, cramps would be positioned to suit the altered proportions of the facings.

FIG. 10.7 DIAGRAMATICARRANGEMENTS

OF CRAMPSEORATTACHING WALLS
FACINGSfo h~CKlNt3

FIG. 10.8 TYPESOF FINISHESFORJOINTS I

256 3
;
P
1”3
 SP 62 ( S & T ) : 1997

10.9A

10.9c 10.9D

FIG. 10.9 DETAILS OF CRAMP FOR PRECASTCONCRETEFACINGS

a) Buttjoint is the simplest form of joint and may c) Double joggle joint is not suitable for vertical
be used when the facing unit has a projection joints as the sliding action necessary to engage
-ar’*
into a backing to provide mechanical bond. It the unit vertically will interfere with the proper
may also be used when it has no such projec- bedding of the horizontal joint and the bond to
tion with the arrangements, either for carrying the backing with mortar. This type of joint is
the weight of the units by cramps or by the suitable for horizontal joints; it locks the units
backing as shown in Fig. 10.7. to one another but cramps may be required to
hold the units to the wall.
b) In single joggle joint when side cramps are
used they need only be single cramp as one side d) The grouted joints shall stabilize the facing
of the cramp is already held in position. The system if applied to all horizontal and vertical
positioning of single cramp will be easier than joints. Crampsmay beusedforsupportingtheunit
that of a double cramp; when ledged facing with the wall and also bearing load partially.
is used in conjunction with an inverted joggle
6.7 Control of Alignment
joint, probably cramps may not be
i
necessary and the joint shall be as shown in The appearance of the finished wall will be easily
Fig. 10.11. marked by inaccuracies of alignment. Inaccuracies
will to some extent be marked by the treatment of
I
SP62(S&T):1997

E
A2

B2 83
RAG BOLT7

D2 D3

FIG. 10.10 PRECASTCONCRETEFACING CRAMP AND JOINTDETAILS

7 EXTERNAL FACING AND VENEERS -

WALL TILING AND MOSAICS

7.1 General

Wall tiles provide a wide range of architectural treat-

ment for external rendering. Generally the methods
covered here for wall tiles and mosaics are a plicable
-P
to the unit of an area not exceeding 900 cm . Larger
shapes and ,sizes of tiles and mosaics require special
methods not covered herein.

7.2 Materials

Tiles, mosaics and other materials shall conform to the

following:

4 Terrazzo tiles shall conform to IS 1237 : 1980.

NOTE - The invertedjogglejoint at the top of the ledgeis b) Ceramic glazed tiles shall conform to IS 777 :
suitableonlywhenthejoiningis appliedto a cavitywall. 1988.
FLG. 10.11CONCRETEFACINGS SUPPORTEDON c) Unglazed clay facing brick tile shall conform
LEDGES toIS 2691 : 1988.
joints, for example, by chamfered, slightly rounded or 4 Mosaics are of a variety of shapes and sizes.
rebated edge in place of simple square edge. Where
e) For mortar, cement shall be to IS 269 : 1989
practical the backing shall be built simultaneously with or IS 455 : 1989 or IS 1489 (Parts 1 & 2) :
the facings to maintain correct alignment of facings. 1991 or IS 3466 : 1988 or any other as
Treatment of joints will avoid chipping due to specified. Lime shall conform to IS 7 12 : 1984.
handling. Sand shall conform to IS 2116 : 1980 for

258
 SP62(S&T):1997

mortar bedding and to IS 1542 : 1992 for d) The mix for bedding can be sand cement mor-
floating coat and pointing. tar or sand cement mortar with additives; I:4
mix should be adequate; additives can be plas-
7.3 Preparatory Work ticizer, waterproofing agents, etc.

4 Sufficient time should elapse for complete in- 7.5 Fixing of Tiles
itial drying and shrinkage of the background
before application of floating coat. The sur- Tiles are fixed beginning at the uppermost
face shall be properly cleaned from dust and level working downwards to avoid disfiguring,
particles. staining damage and subsequent cleaning. The
tiles with non-porous bodies need not be
b) The surface should not be allowed to dry after
soaked; tiles with porous bodies should be
wetting before application of the floating coat.
completely immersed in clean water at least for
The floating should keep pace with wetting and
an hour before using. After soaking, the tiles
if necessary the surface shall be rewetted.
shall be stacked tightly on a clean surface to
Efflorescence or laitance shall be removed.
dry.
cl To provide an effective key for-surfaces con-
The tiles should be fixed on the wetted floated
taminated with oil or grease special treatment
coat, they should be tapped back firmly into
by fixing a metal lath or wire netting shall be
position so that the bed is covered entirely by
given. At least one-half of any smooth surface
the tile. The thickness of bed should be be-
shall be removed to a depth of 3 mm either by
tween 6 to 12 mm after fixing the tile. Uniform
hand or mechanically.
spacing between tiles should be obtained by
Weakbackgrounds, which are unlikely to sup- using spacer pegs as the work progresses. Any
port a floating coat should be covered with a adjustment of the tile shall be made within
firmly fixed metal lathing or wire netting. about 10 min. Ensure that the surface of tiling
4 Movement of joints due to shrinkage of back- shall be true and flat. Cleaning shall not be
ground and settlement of unit shall be provided started before 1; h after fixing.
for. Narmally these joints shall be at the level
Grouting or pointing of tiles should not be
of every storey height horizontally and every
3 m vertically. They shall coincide with struc- carried out, until the day after the tiles have
been fixed. A waterproofing agent may be
tural material changes, such as, top of slab for
added to the grouting mix.
horizontal joint. Movement joints shall extend
to depth of tile and bed and shall be minimum The grout should be applied with a squeeze working
6 mm wide. The joints shall be filled with back and forth over the area until all the joints are
cement mortar with about 15 percent gauging completely filled; all the surplus grout should be
with lime putty. removed from the tiles and polished.
7.4 Application of Floated Coat for Tiles and Pointing would be similar to grouting, except that a
Mosaics small portion of fine sand should be added to the mix.
The purpose of floated coat or rendering is to
7.6 Fixing of Ceramic Mosaics
form a surface suitable for application of tiling
when the background is unsuitable for direct a>Mosaics shall be assembled in the form of
fixing of tiles. sheets or varying mixes, the separate pieces of
b) Mix for the floated coat shall be 1:3 cement mosaic glued face down to any suitable
mortar (volume) for smooth and moderately material such as, paper, nylon, adhesive strips,
strong backgrounds, such as, high density etc. The paper strips. etc should be easily
bricks or blocks, precast or in-situ stone, etc. removable after fixing has taken place. All
To improve workability and thus to aid ap- dimensions be checked out so-that no difficulty
plication and finishing, a small portion of would arise in setting it out. Where mosaic has
hydrated lime may be added to the mix; for I:3 to be applied to a floated coat, the surface shall
cement mortar by volume, one-fourth lime by be slightly scratched and finished with a wood
volume may be added. float.

c) Thickness of each floated coat should not be b) The bedding mortar may be 10 mm thic-k.
more than 10 mm; the float shall be even and Before bedding the mosaic, the fixing side of
the mosaic sheet shall be grouted with a neat .
preferably scratched to provide a key for the
bedding mortar. cement slurry.
L
SP62(S&T):1997

c) After the sheets have been firmly beaten into 8.3 Preparatory Work
the facing, paper and glue sheets removed and,
a) The spacing of supports and fixing rigid wall
the final straightening done, a grout shall be
coverings shall be as given in Table 10.5.
rubbed over the surface to fill the voids in the
joints and then cleaned down. After the b) Joint thickness shall be of about 6 mm. All
cement in the joints has hardened, the whole vertical joints shall be staggered, particularly
surface may be washed down with a solution where both sides of the wall are covered.
of 10 percent hydrochloric acid and 90 percent
water and finally cleaned with water. Table 10.5 Spacings for Support and Fixing of
Rigid Wall Boards
7.7 Fixing of Marble Mosaics
(Clauses 8.3 and 8.4)
The fixing shall be the same as in 7.6 with the excep- SI Type of Board Thick- Spacing Nail Spacing Minimxm
tion that the back of the mosaics, after applying the No. ness of Centre to Centre Edge
cement grout into the joints, shall be covered with a (mm) S”(“m”ts ;tEdges Cl-y
at Supports
layer of two parts of fine sand and one part of cement Nails
to the level of the thickness. This is due to the variation (1) (2) (3) (4) (5) (6) (7)
9.5 400
in thickness of marble slabs.
i) Gypsum board 12.5 500 1 100 to 1.50 100 to 150 10
8 WALL COVERINGS 15 600

8.1 General board, particle 12 500 75 150 to 200 10

ii) board, etc
Fibre building 20
10 600 I
400
Wall coverings such as building boards, sheets, etc, are
extensively used in construction of light partitions. board, etc 12 500 150 300 10
iii) Plywood, block- 16
6.9 600 I
400
They are also used on solid wall buildings to obtain iv) Asbestos board 6 400 150 to 200 150 to 200 -
various decorative finishes which are easier to install
NOTE-Nails with shank diameter 2.00.2.24 or 2.50 mm are
and maintain than traditional plaster and allied
commonly used.
finishes. The selection of these boards depends on
appearance and performance requirements, methods .4 lhxmg ot Boards
of fixing and joining, different types of boards, etc.
Gypsum boards may be fixed as in Fig. 10.12.
The boards generally used are gypsum plasterboards
The joints may be filled with finishing
and wall boards; fibre building boards, plywood and
material, such as, gypsum plaster or any other
blockboard; chip boards particle boards; asbestos
material recommended by the manufacturer.
cement wall boards and multiple layer coverings.
After filling the joints, a thick skin of finishing
8.2 Materials materials shall be spread 50 mm on either side
of the joint and on to it shall be trowelled dry,
The materials shall conform to the following Indian
a reinforced scrim cloth about 100 mm wide;
Standards:
or the joints may be left open as desired.
a) Boards b) For fibre building boards (see Fig. 10.13). The
IS 303 : 1989 Common commercial plywood boards shall be stored for 24 h before fixing.
IS 710 : 1976 Marine plywood The studs and grounds for fixing shall be
IS 1328 : 1982 Veneered decorative plywood spaced as given in Table 10.5 The joints may
IS 7316 : 1974 Decorative plywood be open butt joint at least 3 mm wide. Various
types of joints shall be as in Fig. 10.14.
b) Fixing Accessories
c>Plywood, blockboard, etc, covering may be
IS451 : 1972 Wood screws fixed as in Fig. 10.15. The edges of plywood
IS 459 : 1992 Asbestos sheets (corrugated) shall be protected before fixing with a suitable
IS 723 : 1972 Nails sealer. The fixing may be done in panels;
IS 1658: 1977 Fibre building board horizontal panelling may be done in bays not
IS 1659: 1990 Block boards exceeding 2.7 m in length; vertical panelling may
IS 2095 : 1982 Gypsum~plaster board be done in bays not exceeding 0.9 to 1.2 m. Joint
IS 2098 : 1964 Plain asbestos sheets for plywood and blockboard boards shall be as
IS 3087 : 1985 Particle board medium density in Fig. Fig.lO.16 and Fig. 10.17 respectively.
IS 3097 : 1980 Particle board (veneered) 4 Particle boards may be fixed as in (c).
IS 3129 : 1985 Particle board (low density)
IS 3348 : 1965
d Fixing asbestos cement board shall Abe as
Fibre insulation boards
shown in Fii. 10.18 and Fig. 10.19 for flat and
IS 3478 : 1966 Particle boards (high density)
corrugated sheets respectively.
IS 5509 : 1980 Fire retardant plywood

260
 SP62(S&T):1997

When multiple layers of coverings have to be For better strength and stability, successive
done the first covering shall be fixed as in (a) boards may be fixed in perpendicular direction
to (e) above. Further covers shall be bonded to the one below it, or if all the layers are fixed
by suitable adhesive to the first cover or as vertically, the joints of each layer shall not
specified by the manufacturer. occur over the joints of the preceeding layer.

STUD
/
HEADER BEHIND

AElNFORClNf3
SCRM CLOTH

NAILS
1omm
FROM EDGE

FIG. 10.12 FIXING GYPSUM BOARDS

NAILS
IsoTo2oo
mm02

10.13A Boards with Longer Sides Vertical 10.138 Boards with Longer Sides Horizontal

FIG. 10.13 FIXING FIBREBOARDWALL SHEATHING

i
261
‘i - ,i:
SP 62 ( S & T ) : 1997

BEVELLEO EOGE BEVELLEO OPEN WOOD INLAV WOO0 INSERT

METAL SNAP ON WOOD COVER STRIP FIBREBOARD INSER 1 MOULO

COVER STRIP

-lr
REBATED OPEN BEVEL LAPPED IXVELLED EDGE METAL STRIP

4 J J

MOULDED TREATMENTS METAL COVER STRIPS

FIG. 10.14DETAILS01;FIBREBOARDJOINTS

FIG. 10.15FIXING PLYWOOD WALLSHEATHING

262
 SP62(S&T):1997

HEADLESS NAILING

HEADLESS NAILING

WOOD INSERT -INSERT MO!JLD

HEADLESS NAILING

WOOD COVER STRIP OPEN

;S NAILING

‘FRAMING

METAL STRIP OPEN

NOTES :
EDGE SEALING : Protect all the edges of the board using a suitable sealant or edge lipping to prevent moisture absorption.
SUGGESTED SEALANT : For 6 mm Ply : Epoxy resin, nitrocellulose lacquer.
SUGGESTED LIPPING : Veneers - 1.5 mm thick, solid wood strips, P.V.C. bands, elastic laminates, aluminium strips.

FIG. 10.16 DETAILS OF PLYWOOD JOINTS

 Lf3LOCKBOARD PANELLING 1 L BEADING
BUTT V-BUTT

BLOCKBOAR
OECORATIVE BATTENS PANEL“NG OPEN

HAROWO 00 BLOCKBOARD
FRAMfNG I- PANELL ING

BLOCK BOAR0 CORNERS

LIPPING
FIXED WI HARO WOOD
SYNTt-iETI FRAMING
GLUE

LIPPING OF EOGES

NOTES :
: Protect all the edges of the~board using a suitable sealant or edge Iipping to prevent moisture absorption. -V
EDGE SEALING
‘.
SUGGESTED LIPPING : Veneers - 1.5 mm thick,solid wood strips, P.V.C.bands, elastic laminates,aluminium strips.

FIG. 10.17 DETAILS OF BLOCKBOARD JOINTS $

L a
r
264 iv1 -.
 SP62(S&T):l997

rMETAL CHANNEL SHEET7,

AP

FIG. 10.18 FIXING FLAT ASBESTOS-CEMENT SHEETS

Asbestos cement IS 2098 : 1964 (Plain)

building board IS 459 : 1992
(Corrugated)

g) Wooden cover fillets for ceiling

W Cloth ceiling
3 Aluminium sheet ceiling
FIG. 10.19 FIXING CORRUGATEDASBESTOS-
CEMENT SHEETS k) Expanded polystyrene ceiling

9 CEILING COVERINGS
m>Mineral wood board
The f;abrication and fixing of timber ceiling is covered
by IS 5390 : 1984 (see Annex B).
9.1 General
9.2 Preparatory Work
Coverings are fixed on to the ceiling to give decorative
appearance, to conceal projections, such as beams a) Wooden or metal framework, consisting of
longitudinal,bearers and cross bearers by
occurring underneath floor slab, to provide a false
means of which the ceiling board are sup-
ceiling, to obtain special accoustic effects, insulation
ported, shall be designed for structural strength
against heat and cold, etc.
and stability as per IS 883 : 1970.
9.1.1 Fixing details using the following boards and b) The suspenders from RCC slabs for supporting
other are covered herein: the framework for false ceiling shall be of
sufficient length to reach the ceiling frame.
a) Insulating board IS 3348: 1965
b) Hardboard IS 1658: 1977 c) Ceiling boards, less than 5 kg/m2 in mass, can
be directly fixed to RCC by means of fixing
c) Plaster of Paris IS 2547 plugs, bolts, etc.
Ceiling & Plaster ot (Parts 1 & 2) : 1976
Paris tiles d) Where double ceiling boards are provided,
such as, in air conditioning installations, cold
d) Gypsum plaster board IS 2095 : 1982 storage rooms, the first layer of ceiling board
may be fixed to the ceiling with plugs or other
e) Plywood and IS 303 : 1989, IS 1328 :
fixing devices (see 10) in the concrete slabs at
blockboard 1982 (Plywood)
required spacings.
IS 7316 : 1974, IS 710:
1976,1S 1659 : 1990 e) Typical details of framework and methods of
(Blockboard) its suspension are shown in Fig. 10.20 and
Fig. 10.21.

265
 AL AND CROSS
60mm DEEP

MS FLAT--/ ~-CEILING LBOLT AND NUT

LANGLE IRON CLEATS

FIXED AT EVER’/
CROSS JUNCTION

FIG. 10.20 DETAILS OF CEILING FRAME SUSPENDED FROM RCC SLAB

ROD HANPJER

A SW HANGER WlTH
ANGLE RUNNER B ROD HANGERWlTH
PIPE RUNNER

C ‘STRAP HANGER WITH mn- E FIXING OF CEILING BOARD WITH

CAL - SumG Ai3qANGEMEp.g STUD CLAMP

/ : ,

VARlOU5 PIF
OF CLIPPINC
F ANGLE AND TEE CEILING RE”IP.LI
_ _ . _ __
MEMBER SUSPENDED ‘\@ ,
FROM ROD HANGER 5
i,._--_ --I
G HORlZONTAL~LlDlNQ HANGER WITH
DC4JBl.E ANGLE TRUSS MEMBER
7 H SUSPENSION OF CEILING 5OARD
WITH VARIQUS TYPES OF CLIP5

Different methods of attachmentof hangersto Top Members are illustrated in A, B, D and G, and to Ceiling Frames are illustrated in
A,C,D,FandG.

Use of clips, studsand hooks for fixing bolts are illustrated in H aad E.

FIG. 10.21 DETAILS SHOWING SOME TYPICAL METHODSOF SUSPENSIONOF CEILING FRAME FROM
STRUCTURAL MEMBERS

266
 SP62(S&T):1997

9.3 Fixing of Coverings b) Fixing

9.3.1 Insulating Building Board

1) The framework and board shall generally
be fixed as in 9.3.1 (b). Wood screws may
be used.
a>Materials - The timber for framework and
beading shall be treated and chosen from any 2) The joints may be normally filled with
of the species in IS 3629 : 1986. Insulating plaster. If the hardboard has to be cement
building boards may be particle boards (low plastered the joints shall have a gap of
density) to IS 3129 : 1985 or fibre insulating 6 mm covered with scrim and bedded in
boards to IS 3348 : 1965. Nails, conforming cement plaster before the finishing coat is
to IS 723 : 1972 shall be long enough to cover applied.
the thickness of board plus 25 mm. Gal- 3) The finishing shall be as in 9.3.1(b) (3).
vanized lost head nails to IS 6738 : 1972 of
2.80 mm dia may be used when joints are left 9.3.3 Plaster of Paris
exposed. Where joints are to be covered by
beading, galvanized felt nails of 2.50 mm dia 4 Materials- Timber for framing shall conform
conforming to IS 6730 : 1972 may be used. to IS 5390 : 1984. Plaster of Paris shall con-
Wood screws shall conform to IS 6760 : 1972. form to IS 2547 (Parts 1 and 2) : 1976. The
other materials shall be as in 9.3.1 (a).
b) Fixing - Cut the boards to the required size.
The edges shall be slightly sand papered to b) Fixing
make them smooth. The framework with bat- 1) In case of sloping roofs, wooden battens
tens, size ranging from 60 to 75 mm shall then of suitable section (50 mm x 60 mm) shall
be fixed. Aluminium frame may also be used be firmly fixed as main supports, to the
instead of timber frame. The building board underside of the beams at required centres
shall then be fixed with lengths parallel to all by means of bolts and nuts.
joints centered over the framing members. In case of flat roofs, treated battens shall
Where the joints are to be covered the boards be securely fixed to the walls and pillars
shall be spaced 3 to 6 mm apart. Where the by holding down bolts and shall be fas-
joints are to be exposed the sheets shall be butt tened to the slabs above with iron straps or
jointed with their edges abutting each other. mild steel bars anchored therein. Cross
The boards are first nailed to intermediate battens (treated) of 50 mm x 40 mm at
framing member proceeding from the centre of about 400 mm centres shall then be fixed
the board outwards, the edges being nailed last. at right angles to the main battens. The
1) Where joints are exposed, the outer row of underside of the framework shall be true
nails shall be at 100 mm centres and about to planes and slopes.
12 mm from edge of the sheet. The rows Aluminium frame may also be used if
in the middle of the sheet shall be at 20 mm specified.
centres. Nails in the outer rows on either 2) Wooden strips or laths 25 mm x 6 mm
side shall be paired and not staggered. shall be fixed to the cross battens in paral-
Nails shall be countersunk in the under- lel rows with felt nails. The strips shall be
side of the board. butt jointed and joints staggered.
2) Where joints are to be covered with bead- 3) Rabbit wire mesh shall be fixed with rails
ings, the procedure is the same as in (1) of a pitch of 150 mm to 200 mm to the
above, except that in the outer rows, the underside of wooden strips. The wire
nails spaced at 200 mm may be staggered. mesh shall be straight, tight and true to
The beadings shall then be fixed over the planes and slopes without any sagging and
sheets with screws at 200 mm centres. slightly below the underside of the laths.
3) The exposed side shall be truly level; 4) Plaster of Paris shall be mixed with water
joints truly parallel and perpendicular to to a workable consistency. The plaster
the walls. shall be applied to the underside of laths
over the rabbit wire mesh in suitable sized
9.3.2 Hardboard panels and finished to a smooth surface by
steel trowels. The thickness over the laths
a) Materials - Timber shall conform to IS 5390 :
shall be as specified but not less than
1984. The hardboard shall conform to IS 1658:
12 mm. Joints shall be finished flush; the
1977. The other materials shall be as per
surface shall be smooth and true to plane,
9.3.1 (a).
slope or curve as required.

267
SP62(S&T):1997

9.3.4 Plaster of Paris Tiles 50 mm on either side and trowelled dry. When
4 Materials - .Timber for making framework metal scrim is used, a stiffer plaster may be
shall be from any species in IS 5390 : 1984. necessary. The joints may also be left open if
Plaster of Paris shall conform to IS 2547 (Parts desired.
1 and 2) : 1976; thickness of tiles shall be not 9.3.6 Plywood and Blockboard
less than 12 mm. Hessian cloth shall conform
to IS 2818 (Part 1) : 1990; hessian cloth shall a) Materials - Timber for framework shall con-
be of an open webbed texture. form to IS 5390 : 1984. Plywood shall con-
form to IS 303 : 1989 or IS 710 : 1976 or
b) Preparation of Tiles-Tiles of plaster of Paris IS7316 : 1974 or IS 1328 : 1982~or IS 5509 :
reinforced with hessiancloth shall be prepared 1980. Blockboard shall conform to IS 1659 :
to the required size. The maximum size shall 1990; screws shall conform to IS 6760 : 1972.
be limited to 750 mm in each direction. The
tiles may be made on a glass sheet with wooden b! Fixing - The fixing shall be as in 9.3.1(b);
surrounds; a thin coating of non-staining oil except that for boards in thickness 4 to 10 mm
may be given to the glass sheet for easy the spacings may vary from 450 to 600 mm for
removal of tiles. Plaster of Paris shall be even- longitudinal battens and 600 to 1 200 mm for
ly spread to about half the thickness and then cross battens; for boards above 10 mm thick,
hessian cloth spread over it; on this, plaster of the spacings may be 600 to 900 mm for lon-
Paris is spread again to the full thickness. Tiles gitudinal battens and 900 to 1300 mm for cross
shall be allowed to set for an hour and then battens. The spacing of fixing countersunk
removed to dry and harden for about a week. screws may be adjusted according to thickness
A good tile will give a ringing sound when of board. Joints if left open shall be filled with
struck. painters putty and brought to level; joints may
also be left open. Thejoints may be rebated or
cl Fixing - The timber frame shall be so made tounge and grooved.
that each tile has supporting scantlings to fix
The ceiling shall be finished by hand-sanding
them. Aluminium frame may also be used.
and waxed or polished or clear varnished or
Tiles may be fixed to the cross battens with
painted as required (see Chapter 15).
40 mm long brass screws to IS 6760 : 1972 at
200 mm centres. Ties may be laid adjacent to 9.3.7 hbestos Cement Building Board
each other without leaving any gap. The
screws shall be at least 15 mm away from the a) Materials-Timber for framework catibe any
of the species in IS 5390 : 1984; asbestos board
edge. Holes for screws shall be drilled. The
shall conform to IS 2098 : 1964; screws shall
countersunk heads of screws shall be covered
conform to IS 6730 : 1972.
with plaster of Paris and smoothly finished.
When unbroken surface is desired, joints shall b) Fixing - Framework shall be fixed as in
be filled with plaster of Paris and trowelled 9.3.1 (b). The asbestos board shall be laid truly
smooth. parallel or perpendicular to the walls and shall
9.3.5 Gypsum Plaster Board be fixed to the battens with countersunk screws
by using metal channels and clips. Holes shall
4 Materials - The boards shall conform to IS
be drilled at least 12 mm from edge. They
2095 : 1982. Nails shall conform to IS 723 : should be butt jointed. If a gap of 3 to 6 mm
1972. The length of the nail shall be 30 mm between sheets is given the gap should be
for boards 10 mm thick and- 40 mm for covered with wooden beading or similar
12.5 mm or 16 mm thick boards. Screws shall material.
conform to IS 6730 : 1972. Steel screws
No finishing treatment’is necessary.
without brass or nickel coating shall not be
used. Screw sizes shall be 3.10 or.3.45 mm; 9.3.8 Wooden Cover Fillets Beading
length shall be 30 mm for 10 mm thick board
and 35 or 40 mm for 12.5 mm and l-6 mm a) Materials - Timber for framework may be
board. any of the species of IS 5390 : 1984. Screws
shall conform toIS 6730 : 1972. Beading shall
b) Fixing - The frame work shall be fixed as in
be planed, smooth and true on the rear surface.
9.3.1 (b). Joints may be 6 mm wide. Jointing
It may be 12 mm x 40 mm or as specified. I’
may be in a decorative pattern. The joints may
be finished with a filling of gypsum plaster or b) Fixing - The beading shall be fixed centrally
other materials; after filling the joint, a thick over the butt joints between two timber planks
skin of the finishing material shall be spread with screws in two rows on either side of joint.

268
 SP 62 ( S & T ) : 1997

The junction of beading shall be fully mitred b) Fixing - Adhesive shall be applied to the tiles
or as specified. The beadings shall be finished and fixed to the framework. The white
smooth. polysterene ceiling may Abe painted as
specified.
9.3.9 Cloth
9.3.12 Mineral Wood Board
a>Material - Timber for framework shall be as
per IS 5390 : 1984. Bamboo of good quality a> Materials - Timber for ceiling’shall be from
may be used for framework. In general thick IS 5390 : 1984; nails to IS 723 : 1972, screws
cloth can be used or as specified. Screws shall to IS 6730 : 1972 and mineral wool to IS 3677 :
conform to IS 6730 : 1972 and nails to IS 723 : 1985.
1972.
b) Fixing - A metal ‘T’ grid shall be suspended
b) Fixing - The framework shall be securely first and mineral wool board may be cut to size
spiked to the wall plaster/ceiling joints or and stuck with suitable adhesive. For timber
beams. The cloth shall be wetted, stretched framework, the mineral wool board shall be
and nailed to the upperside of the framework. stuck with an adhesive. Similar procedure
In case of bamboo framework, the cloth shall may be followed with local modifications, as
be tied to it without tearing. To prevent the necessary, for different ceilings.
cloth from blowing and flapping, wooden
10 FIXING DEVICES
beadings shall be fixed. The cloth ~may be
white washed and distempered. 10.1 Types
9.3.10 Aluminium Sheet The fixing devices covered are as below:

a> Materials - The framework may be made of -4 Expansion wall plugs,

aluminium ‘T’ grid and trays of aluminium
alloy sheets 19000 or 31000 of IS 737 : 1986. b) Expansion shells,
The grid shall be made of extruded aluminium c>Caulked-in anchor devices, and
‘T’ section of 63404lWa of IS 733 : 1983. The
fillings shall be made out of aluminium or rust d) Butt-in devices.
proofed steel. 10.2 Fiiing
b) Fixing - The ceiling may be formed as an Proper devices and tools ensure a neat fixing work with
exposed grid or a concealed grid using the minimum effort and little damage, and the fixtures will
above sections. The aluminium false ceiling have adequate strength and durability. Special devices
may be left asit is if anodized or painted with are also available for resisting dampness, chemical
an acrylic resin paint. attack, thermal effects, etc. Details of fixing devices
are given in IS 1946 : 1961.
9.3.11 Expanded Polystyrene
Fixing devices, mentioned above are for solid walls.
a> Material - Expanded polystyrene shall con- Devices for hollow walls are also coming into vogue.
form to IS 4671 : 1984. Screws shall conform
to IS 6730 : 1972. The framework may be of NOTE - Since the date of publication of this standard several
new innovations have been introduced; the trade may be con-
wood or metal.
sulted for more information.

ANNEX A
(Table 10.4)
SPECIAL MIXES FOR SULPHATE BACKGROUNDS

A-l GENERAL cement resistant to sulphate action may be used, name-

ly sulphate resisting cement; or in very severe condi-
i
A-l.1 A separate support may be provided for the tions, high alumina cement or blast furnace slag i: 9.
$
rendering on backgrounds with soluble sulphates. A cement may be used. it,
SP 62 ( S & T ) : 1997

A-2 MIXES In place of Use 1 part high alumina cement:

Type 1 mix 3 parts sand, by volume.
A-2.1 For sulphate resisting cement the mixes indi- In place of Use 1 part high alumina cement:
cated in Table 10.4 may be used. Where alternatives Type 2 mix l/2 to 314 part zinc sulphate pow-
are given, the richer ones shall be used. der : 4 parts sand, by volume.
Use 1 part high alumina cement:
A-2.2 For high alumina cement, lime shall not be In place Of
1 part zinc sulphate: 5 to 6 parts
mixed. The mixes should be as below (see Table 10.4): Type 3 m1x
sand, by volume.

ANNEX B
(CZuuse9.1)
FABRICATION AND FIXING OF TIMBERCEILING

B-l CONSTRUCTION OF TIMBER CEILINGS B-l.3 Types

B-l.1 General a) Fixirzg Ceilings - Planks shall be butt and

beading jointed or overlap or half lap or ton-
Timber ceilings are provided to give decorative ap- gued and grooved.
pearance, to conceal air-conditioning or other service
ducts and also to obtain accoustic effects and thermal b) Sloping Ceilings - The ceiling shall be fixed
to the underside of rafters.
insulation.

B-l.2 Material c) Closed Ceiling - The ceiling shall be fixed to

the underside of the ceiling joists.
Timber for making planks shall be from any of the d) The planks shall be fixed to the timber frame
species given in Table 10.6 and the ceiling framework suspended from the slab. The surface of
and beading shall conform to IS 3629 : 1966 ap- finished ceiling shall be truC and plane.
propriately seasoned and treated. Nails shall conform
to IS 723 : 1972 and the wood screws to IS 45 1 : 1972. Table 10.6 Species for Timber Ceilings
Suspenders may be mild steel flats or other material (Clause B-1.2)
sections.
Anjan Jarul Machilus Teak
The dimensions of timber units for ceiling may be as Axlewood Maniagwa White Cedar
Karl
below:
Bijasal Katasih’s Pali White Chuglam
1) Timber scantling for 60-75 mm thick x Chir Kasi Piney
ceiling and framework 50 mm wide Cypress Kindal Rohini
2) Timber planks 15-20 mm thick x Deodur K&co Rosewood
100-150 mm wide Fir Laurel Satinwood
3) Beading 12 mm thick x 30 mm Gurjan Lendi Sisoo
wide

PART 2 WALLING

1 GENERAL 2 REED WALLING

1.1 Walls and partitions of the foIlowing types are 2.1 General
covered herein:
Reed walling is a traditional construction in certain
a) Reed walling to IS 4407 : 1967, parts of India; in Assam EKRA and NAL are used; in
Punjab SARKANDA reed is used. In addition machine
b) No fines in-situ to IS 12727 : 1989, and
made reed boards are~also used. In these boards, reeds
c) Gypsum block partitions to IS 3630 : 1992. are considerably strengthened by binding together

270
 SP62(S&T):1997

with galvanized wire. Reed walling~and roofing have d) For cutting diagonally or in shapes combine
advantages like thermal insulation and light weight the two methods in (a) and (c).
and are found specially suited for earthquake resistant
2.3.2 Joining the Reed Boards
consEruction, where flexible light weight material is
needed for walling (see Chapter 17). Use of reed With the reeds vertical, the joining shall be done as in
walling will facilitate additional advantages of Fig. 10.23.
prefabricated construction particularly suited for panel 2.4 Fixing of Reed Board
filling, partitions and roof construction.
a ) Fixing of Partitions - Reed boards shall be
2.2 Materials fixed with reeds vertical to horizontal runner
spaced at 1 m centres. The adjacent boards
a) Reed boards, made by binding reeds with gal- shall be butt jointed and the joint shall be
vanized wire, are available in three different located at the centre. Fixing shall be done with
thicknesses of 2.5 cm,~4 cm and 5 cm. Preferred wood screws with a spacing of 30 cm. While
widths are 1 m and 2 m. The boards are general- fixing to frames, boards shall not be fixed into
ly used as below: a groove. While locating the door and window
openings, work should be carefully planned so
Component Thickness as to keep cutting and wastage to a minimum.
For door and window panelling, 2.5 cm thick The board of window sill shall be so cut that it
for wall facing, for partitions and covers half the frame runners on all sides (see
for ceiling Fig. 10.24).

For sloping and gabled roof’), 4 cm thick b) For roof construction, reed board shall be used
for weather board partition walls, for pitched roof as in Fig. 10.25 and not flat
for fencing, for wall insulation, etc roof.

For panel walls of exterior use, 5 cm thick 2.5 Fixing of Reeds for In-situ Wall Construction
for sloping and gabled roofs,
for weather boards, etc
4 Grooves, 15 mm wide shall be made in the
timber frame and the reeds slipped into the
b) The reeds may be EKRA, KHASRA, NAL, grooves one by one. The reed walling may be
SARKANDA. These reeds shall be cut from stiffened by means of double bamboo slips
mature plant, which have their sheaths firmly 25 mm wide and not less than 6 mm thick
attached; they shall be dried in the sun. spaced at around 40 cm apart. One slip shall be
attached to each side of the reed and tied
2.3 Preparatory Work together. Reeds may be fixed with just suffi-
cient space of 1cm between each other so that
2.3.1 Cutting of Reed Boards the mortar may be applied on one side for
finishing so that it penetrates to the other side
Cutting of reed board shall be done as follows:
to form a key for plaster. All vertical timbers
4 Cut each running wire half way between the in walling shall have grooves (4 cm x 1.5 cm
required hook wire and the next one as in Fig. deep) to force plaster into it.
10.22. After each running wire is cut, bend the
ends tightly over the respective hooks. Remove b) The reeds shall not be used for roofing, without
making them into boards. Reed may, however,
the reeds which are left between two hook
be used for thatching.
wires exposing the running wire on the under-
side of the board. 2.6 Finishing

b) Place the boards erect and cut the running wire Reed boards may be pebble-dash plastered or rough
on the other side and bend the cut ends over the cast finished after fixing. Reed boards should be dry
hook wire. before applying plaster. The mix shall generally be
cement mortar 1:6 applied in two coats not more than
c>Cutting across the reed may be done with the
15 mm, lime plaster mix may be 1:3 using class C lime
use of a saw or a sharp broad chisel. Cutting
of IS 712 : 1984; mud plaster may be as in Chapter 4.
shall not be done near the wire and at least
Waterproofing may be done using bitumen felts (see
25 mm of the board~shall be left to cover as
Chapter 12). The reed walling may also be painted it
edge beyond the running wire.
required.

‘) The spacing of purlins for roof shall not be more than 0.5 m centres.

271
SP62(S&T):1997

-POSITION OF CUT Et& BACK

l-

LHOOK WIRE
‘%UNNlNG WIRE

KY
REEDS
BEING REMOVED

FIG. 10.22 OPERATIONSFORCUTTING OF REEDBOARD

WIRE

1 0.6 mm ‘$
LACING WIRE

FIG.IO.23 DETAILSOF JOININGOF REED BOARD

 SP62(S&T):1997

HORIZONTAL
YEMSPR
OF WINDOW FRAME
I
-TOP MEMBER OF WINOOW scnew OR NAIL
FRAME

PtAIN GALVANIZED SHEET

PAlNTEO FOR PROTECTION

ROUGH CAST PLASTER

b -5Om THICIIREEDWARD
\ VERXAL TIMSLR
POST

0UlYOE

HoRlZOtJTAL NEMBER
OF WINDOW FRAME
/tumuONT*~ NEM~ER
OF WINDOW FRAME

/ PLASTER FINISHED SMOOTH

PLAJN GAMNUED SHEET

rROUGN CAST PLA3TER
FAINTED FOR PR0TECTION

ROUGH CAST PLASTER

LVEI)TICAL
TlYllER
P0ST 5Dmm THICK REED BOARD

LVERTICAL IIMBER POST

FIG. 10.24 DETAILSOFCONSTRUCTIONFORTHEREEDWALLINGATTHESILLOFWINDOWS

FIG. 10.25 REEDBOARDRIDGINGFOR ROOF

3 GYPSUM BLOCK PARTITIONS - NON- 3.2 Materials

LOAD BEARING
a) Gypsum block shall conform to IS 2849 : 1983
3.1 General for both soild and hollow blocks. The surfaces
of the block shall be smooth or -scored; the
Gypsum block partitions are light in weight, fireproof scoring shall not be more than 5 mm deep.
and free from pest infestation. There is a scope for
b) Mortar shall consist of one part gypsum and
large scale use in multistoreyed construction. They are
three parts fine aggregate conforming to IS 383 :
not suitable for external use.
1970 or sand by ~weight; sodium citrate in

213
 -- I”

SP 62 ( S & T ) : 1997

proportionof0.25percentoftheweightofgypsum wise it may be left as it is but cleaned down and

may be added as amtarder. For fine work, that is, any defects made good with neat gypsum
work with fine mortar joints, the mortar may also plaster with mortar as in 3.2 (b).
consist ofgypsum and lime in the ratio of 1:3 by
weight’with 0.25 percent of sodium citrate. 4 NO-FINES CONCRETE

c) Reinforcing material may be mesh, expanded 4.1 General

metal ties, light gauge expanded metal, steel
strips, etc. No-fines cement concrete has highly permeable mass
with large air spaces. It is an aggolmeration of coarse
3.3 Laying of Block
aggregate ~particles each surrounded by a coating of
4 Gypsum block partitions shall not be wetted cement paste, up to about 1.25 mm thick. As the
before~laying, however the surfaces in contact aggregates to be used is almost single sized, resulting
with mortar may be wetted, to reduce suction, in formation of enough voids and therefore light in
with minimum quantity of water. weight and eliminates the rise of dampness. No-fines
b) Gypsum block partitions shall be built in half can be used in walls, foundations where eliminaton
bond in true level and regular courses (see Fig. dampness is desirable.
10.26).
No-fines cement concrete can substitute brickmasonry
ci The joints shall be as thin as possible. Where
where good bricks are not available. Further the ther-
the partition is to be plastered, the joints shall
mal conductivity of wall made from no-fines concrete
be left roughly flush or may be raked out.
with conventional aggregate and a solid brickwall of
d) Where possible, frames for openings shall ex-
the same thickness is about the same.
tend from floor to ceiling to secure a positive
fixing at both ends; they shall have a groove to 4.2 Materials
receive the ends of blocks.
e> Gypsum block lintel 0.5 m wide, may span the a>Cement shall conform to IS 269 : 1989 or
openings. The lintel blocks may span in an arch IS 1489 (Parts 1 & 2) : 1991 or IS 455 : 1989
form also (see Fig. 10.27). and IS 8041 : 1990 or any other as specified.
At the ceiling the partition shall be secured and
b) Aggregate should conform to IS 383 : 1970;
isolated with wedges as in Fig. 10.28. the aggregate would be nominally graded from
Cracking in partitions takes place due tomvaria- 40 mm to 20 mm. Whichever size is used, the
tions in volume of blocks; this can be taken proportions of oversized and undersized
care of as in Fig. 10.29. material shall be kept as low as possible;
h) Vertical joints may be reinforced as in generally oversize and undersize material
Fig. 10.26. should not be used more than 5 percent and
j> For strength and stability purposes the height of 10 percent respectively.
partition shall be limited to 36 times the thickness
c) Brick ballast may be used preferably broken at
of block; except when lateral support is provided
site; no unburnt bricks shall be used. Stone
it shall not exceed 72 times the thickness.
ballast may be used with a flakiness index of
W The block may be finished with a rendering of less than 15 percent.
gypsum plaster not less than 6 mm thick; other-
12 n-m Q STEEL BARS
40 cm LONG IN EACH
/- CORE HOLE OF BLOCKS

NOTE - Number of reinforcement bars will depend on number of holes in the block.

FIG. IO.26 REINFORCINGOF VERTICAL JOINTSOF GYPSUM BLOCKS AS A SAFE GUARD AGAINST CRACKING

274
 SP62(S&T):1997

\600 x 300 METAL LATH BOTH SIDES7

L 631 ANCHOR 125 mm

INTO JOINTS
All dimensions in millimetres.
FIG. 10.27 ~EIwPcJIZ~E~~ENT
AROUND OPENINGIN GYPSUM BLOCK PARTITIONS

. ..; .,*..:- (.. ..,. “: .,.._ ‘...,

”

/-n-- 200 mm 4

FIG. 10.28 POSITIONOF WEDGE AND GYPSUM BLOCK PARTITIONWALL AROVE SKIRTING

275
SP62(S&T):1997

-ALTERNATIVE
METHODS

FIBRE 80 PLASTER
OTHER RE
?ACK
10.29A Edge Isolation at
Partition Wall 10.298 Edge Isolation at Walls only

GVPSUM’EILDCK OR SLAU GVPSUi.4 BLOCK OR SL

PARTITION
7

PACKING
LWOODEN FILLET
WOODEN POST OR
FIXEO TO POST PLATE FIXED TO
WOODEN POST OR PLATE WALLS. FLOORS OR
FIXED TO WALL C&LlNGS

10.29C Edge Isolation at Wall, Floor or Ceiling 10.290 Alternative Edge Isolation at Wall, Floor or Ceiling

FIG. 10.29 METHODS OF EDGE ISOLATION FOR PARTITIONS

4.3 Mixes 4.4.3 Concrete shall not be vibrated for compaction;
The no-fines concrete mixed shall be as Table 10.7 compaction may be done by rod or gentle ramming.
below for guidance. No water should be added during ramming.
4.4.4 Curing shall be done by spraying water at least
Table 10.7 Strength of Various No-fines for 7 days.
Concrete Mixes
4.4.5 Workmanship
(Clause 4.3)
Construction Joints in Walls - Vertical or
SI Maximum Mix by Water Cement Expected
No. Size of Volumes Ratio Compressive
raking construction joints shall not be per-
Ballast (Cement: (Optimum) Strength in mitted except where expansion joints are to be
Aggregate) 28 Days, N/mm’ formed. Horizontal joints should be as few as
i) 20 1:8 0.40 5.5 possible. Cracks due to shrinkage and setting
ii) 20 1:9 0.42 4.9
iii) 20 I:10 0.45 3.5 can be avoided by locating expansion joints at
iv) 20 1:12 0.48 3.5 30 m interval.
v) 40 1:lO 0.48 3.5 Wall ties may be used between floors and walls
vi) 40 I:12 0.50 2.6
b)
throughout the building. Cracks may be
4.4 Transporting, Placing, Compacting, Curing, avoided at openings by placing two 10 mm dia
and Workmanship mild steel bars under the window sill. Concrete
4.4.1 Concrete shall be transported by methods which cover should be 50 mm minimum.
will prevent segregation or loss of any of the c>
It is impractical to nail into no-fines concrete.
ingredients. In hot or cold weather it shall be Therefore for fixing, fixing devices should be
transported in deep containers, adopting suitable incorporated before pouring concrete; or holes,
methods to prevent loss of moisture. etc, should be formed by finishing suitable
4.4.2 The concrete should be poured in horizontal coves in the shuttering for services.
layers. Care shall be taken to ensure that the ballast is
4 Plastering may be done on both internal and t
uniformly coated with cement layer. Thickness of external surfaces; the thickness may be 10 mm
concrete placed in a wall should not exceed 500 mm; to 12 mm in two layers.
minimum thickness may be 230 mm.
c

276
 CHAPTER 11

ROOFSANDROOFING
 CONTENTS

1 GENERAL 6 ROOFS AND FLOORS WITH JOIST AND FILLER

BLOCKS- HOLLOWCLAY FILLERBLOCKS
PART 1 FLAT ROOFS
6. I General
1 GENERAL
6.2 Materials
2 JACK-ARCHTYPEROOF
6.3 Components of the Roof
2.1 General
6.4 Preparatory Work
2.2 Materials 6.5 Laying of the Roof
2.3 Typical Details 6.6 Finishing
2.4 Preparatory Work
7 ROOFS AND FLOORS WITH JOISTS AND FILLER
2.5 Construction of Jack-Arches BLOCKS- PRECASTHOLLOWCLAY BLOCK JOISTS
2.6 Finish AND HOLLOWCLAY FILLERBLOCKS

3 BRICK-CUM-CONCRETE COMPOSITE ROOF 7.1 General

(MADRASTERRACE) 7.2 Materials
3.1 General 7.3 Preparatory Work
3.2 Materials 7.4 Structural Clay Block Joists
3.3 Preparatory Work 7.5 Structural Clay Block Slab
3.4 Laying of Terrace Bricks 7.6 Construction of Roof
3.5 Laying ofLime Brick Aggregate Concrete 7.7 Finishing
3.6 Finishing 8 ROOFS AND FLOORSWITH JOISTS AND ‘FILLER
4 STONE SLABOVERJOISTFLOOR BLOCKS-PRECAST HOLLOWCLAY BLOCK SLAB
PANELS
4.1 General
8.1 General
4.2 Materials
8.2 Materials
4.3 Preparatory Work
8.3 Preparatory Work
4.4 Laying of Stone Slabs
8.4 Slab Panel
4.5 Laying of Concrete Layer over the Stone Slabs
8.5 Construction of Roof
4.6 Finishing
8.6 Finishing
5 ROOFS AND FLOORS WITH JOIST AND FILLER
BLOCKS- HOLLOWCONCRETEFILLER BLOCKS ANNEX A SPECIFIC-ATION
FORCRUDE-OIL FORUSE IN
MORTARSFORMADRAS TERRACEWORK
5.1 General
PART 2 SLOPING RBOFS
5.2 Materials
I WOODEN SHINGLEROOF
5.3 Components of the Roof
5.4 Preparatory Work 1.1 General
5.5 Laying of the Roof 1.2 Materials
5.6 FiniShing 1.3 Preparatory Work

oii
 1.4 Laying of Shingles 6 ASBESTOSCEMENT SHEETS- SEMI-C• KNJGATED
1.5 Maintenance 6. I General
2 ROOFINGWITHMANGALORETILES ANNEX B TIMBERFORWOODEN SHINGLES

2.1 General PART3 SHELL ROOFS

2.2 Materials 1 GENERAL
2.3 Preparatory Work
2 REINFORCEDCONCRETESHELLROOF CAST /N-s1711
2.4 Fixing of Reepers
2.1 Shell Dimensions
2.5 Laying of Mangalore Tiles
2.2 Type of Shells
3 SLOPEDROOFCOVERING- SLATING
2.3 Design
3.1 General 2.4 Sequence of Construction
3.2 Materials
3 PRECASTDOUBLYCURVEDSHELLUNITS
3.3 Preparatory Work
PART 4 FLAT ROOF FINISH - MUD
3.4 Laying of Slates PHUSKA
3.5 Finishing Around Projections/Junctions
1 GENERAL
4 SLOPED ROOF USING PLAIN AND CORRUGATED 2 MATERrALs
GALVANIZEDSTEELSHEETS
3 PREPARATORY
WORK
4. I General
4 LAYINGOFMUD PHUSKA
4.2 Materials
4.3 Preparatory Work 4.1 Preparation
4.4 Laying and Fixing of Sheets 4.2 Laying
4.5 Ridges and Hips 4.3 Applying Mud Plaster
4.6 Valleys and Flashings 4.4 Paving with Brick Tiles
5 ASBESTOSCEMENTSHEETS- CORRUGATED 4.5 Maintenance

PART 5 THATCHED ROOFS

5.1 General
5.2 Materials 1 THATCHINGOF ROOF

5.3 Preparatory Work 1.1 General

5.4 Laying and Fixing of Sheets I .2 Materials
5.5 Safety Precautions 1.3 Fire Retardant Treatment
As in the Original Standard, this Page is Intentionally Left Blank
 SP62(S&T):1997

CHAPTER 11

ROOFS AND ROOFIN-G

1 GENERAL Part 2 Sloping Roofs

1.1 A number of roofing materials are used and dif- Part 3 Shell Roofs
ferent types of roofs are constructed in the country. Part 4 Flat Roof Finish -Mud Phuska
They can be broadly grouped as under: Part 5 Thatched Roof
Part 1 Flat Roofs

PART 1 FLAT ROOFS

1 GENERAL shall be encased in cement concrete with a

minimum cover of 40 mm. Joists shall not be
Flat roofs are covered by the Indian Standards given at spaced at more than 2 m.
the end of the Handbook.
b) Centering shall be erected to support the jack-
2 JACK-ARCH TYPE ROOF arch. Temporary supports may be given to the
joiststo prevent sagging of joists during laying
2.1 General of jack-arch work.

The jack-arch type of roof is a composite construction c>The bricks shall be laid on edge in cement
consisting of a row of brick arches with a small rise mortar 1:4 or equivalent lime mortar, to form
and having a lime concrete layer over it. The strength an arch, with a rise between l/6 to l/8, spring-
of the roof is due both to the arch action as well as the ing from the bottom flange of the joists. The
bond between the lime concrete layer with brick. joints at bottom shall not exceed 10 mm in
thickness. The brickwork shall then be cured
2.2 Materials by keeping moist and allowed to set for 10
days, before laying the lime broken brick
Bricks should conform to IS 1077 : 1992; sand for aggregate over it. The centering of the jack-
lime concrete shall conform to IS 383 : 1970 and fine arches shall be eased at the end of 7 days for
brick aggregate shall conform to IS 3 182 : 1986. arches constructed with lime mortar.
Cementmay be to IS 269 : 1989 or to IS 455 : 1989 or
to IS 1489 (Parts 1 & 2) : 1991 or any other as specified. 4 Laying of Lime Concrete
Lime shall conform to IS 712 : 1984; lime concrete 1) On the hardened brick arch, a layer of lime
shall be as given in Chapter 5. Steel joists shall conform broken brick aggregate concrete mix 1:2.5
to IS 805 : 1968; steel tie rods shall conform to IS 432 (1ime:broken brick aggregate by volume)
(Part 1) : 1982. or layer of lime pozzolanic material and
2.3 Typical Details fine aggregate mix 1: 1: 1 (lime:poz-
zolana:fine aggregate by volume) shall be
Typical details of jack-arch type of roof is as shown in
spread to an initial thickness of 75 mm
Fig. 11.1.
over the crown of the arch.
2.4 Preparatory Work
2) The lime broken brick aggregate concrete
The bricks shall be immersed in water for 24 h before mix shall then be consolidated with
use. The skin shall then beallowed to dry so as to give wooden hammers~to a thickness of 60 mm
the necessary adhesion with mortar required for laying over the crown of the arch. The concrete
the brickwork. The tie rods shall be given a protective shall be further beaten with wooden hand
coating of bituminous paint and the paint may extend beater. During compaction the surface
10 to 20 mm beyond the required length in the portion shall be wetted with lime water and a
to be exposed. solution; which may be 3 kg of jaggery in
100 1 of water alongwith 1.5 kg of BAEL
2.5 Construction of Jack-Arches
fruit or similar solution of KADUKAI or
a) The steel joists shall be fixed in position at the HARARH or jaggery and GUGAL. The
designed spacing over supporting elements concrete shall be cured for at least
such as walls, on appropriate bed blocks. Joists 6 days.

281
SP62(S&T):1997

PLAN

k:BRICK TlLES IN LIME

‘OR CEMNT MORTAR

CEILING flNISH
AS SPECIFIED STEEL JOISTS Of3 WILT-UP SECTION
ENCASED IN CONCRETE CAST IN- SITU;
ALTERNATIVELY, SUJTABLE SHAPED
PRECAST CONCRETE SECTIONS

SECTION AA

X = spacing ofjoists
Y = spacing of tie rods
Z = riseofarch
FIG. 11.1 TYPICALDETAILSOFJACK-ARCHFLOOROR ROOFCONSTRUCTION

2.6 Finish mortar (1:3) mixed-with crude oil (10 percent of mass
The completed terrace shall then be finished with of cement), laid in such a way as to break joints. Instead
specified finish. The finishmay be tiled roof with flat of two course of flat tile, one course of pressed clay
clay tiles (2 courses) (see Fig.ll.2) laid in cement tile may be used (see Fig.1 1.3)

lwocouRsESoF
FLAT TILES

P--. 11.2 TYPICALDETAILSSHOWINGTHEMETHODOFLAYINGTwo COURSESOF RAT TILESFORROOF

282
 SP62(S&T):1997

ONECOUF OF
PRESSED Tl E ESi
END TILE
LEVELLING COURSE 0~

AGGJWiATE CONCRETE

FIG. 11.3 TYPICAL DETAILSSHOWINGTHE METHOD OF LAYING

ONE COURSEOF PRESSEDTILES FOR ROOF

The ceiling shall be finished with lime plaster of I:2 3.4 Laying of Terrace Bricks
mix or cement plaster mix 1:3. Plaster shall be 12 mm
a) The terracing bricks shall be laid on edge in
thick and done as mentioned in Chapter 10. It shall be diagonal rows spanning over the joists. The
cured for 3 weeks. The exposed length of tie rod shall laying shall start from one corner and proceed
be painted (see Chapter 15). towards the opposite corner. Each row shall be
complete before the next one, adjacent to it, is
3 BRICK-CUM-CONCRETE COMPOSITE
started. The terrace work shall have a bearing
ROOF (MADRAS TERRACE)
of at least 150 mm on the walls or support all
round. The bricks shall be laid in lime mortar
3.1 General
1: 1.5 (lime putty: sand by volume); the thick-
A composite floor/roof construction consisting of ter- ness of mortar joints shall be not less than
race bricks and lime concrete is widely adopted par- 10 mm (see Fig. 11.4).
ticularly in the southern parts of India; this is b) During _laying the bricks shall be pressed
commonly known as Madras Terrace construction. against the adjacent row already laid so that it
This construction has been found to be quite strong, bonds well with the mortar and also partially
durable and waterproof. Supporting action of the develops lateral adhesion preventing it from
bricks results from the arch action in the bricks which slipping. To enhance the setf supporting action
are packed in rows to form a flat layer over closely of the brickwork, the bricks may be so laid as
spaced joists; and the support is enhanced by the to obtain for the brickwork, a slight rise be-
super-incumbent lime concrete layer by virtue of bond tween the joists, generally not exceeding 5 mm.
between it and the bricks. The joists may be supported from below by
wedged uprights while the roof is being laid. The
3.2 Materials brickwork shall be cured for at least 10 days.
3.5 Laying of Lime Brick Aggregate Concrete
Broken brick coarse aggregate shall conform to
IS 3068 : 1986. Cement shall conform to IS 269 : I989 4 After the terracing has set, a layer of lime
or IS 455 ; 1989 or IS 1489 (Parts 1 & 2) : 1991 or as broken brick aggregate concrete of mix 1:2.5
specified. Lime shall conform to IS 7 12 : 1984. Terrac- (slaked lime: aggregate by volume) shall be
ing bricks shall conform to IS 2690 (Part 2) : 1992 hand spread to a thickness of 100 mm.
made bricks. Timber joists shall conform to IS 3629 :
b) After laying the lime concrete, it shall be
1986. Steel joists shall conform to IS 883 : 1970. rammed so that the layer consolidates to
Crude oil shall conform to the requirements given in 75 mm. After this further consolidation be
Annex A. done with a hand beater for at least 7 days so
that concrete hardens and the beater makes no
3.3 Preparatory Work
impression on the concrete. During hand beat-
ing the surface-shall be wetted by sprinkling
Terracing bricks shall be immersed in water for at least
lime water and sugar solution may be of 3 kg
4 h before use in the work; the skin shall be allowed to
ofjaggery in 100 I of water and I .5 kgof BAEL
dry. Steel joists shall be protected with one coat of
fruit; or solution of KADUKAI or HA~RARH or
primer before fixing. Timber joists shall be protected
with two coats of tar and then a primer to the exposed ~GUR and GUGAL.
portions. The surface shall be cured for 6 days.

283
SP62(S&T):1997

ROOF OR FLOOR FINISH

lSOmm mar
TERRACE BRICKS

SECTION XX

FIG. 11.4 TYPICALDETAILSOFMADRAS TERRACEFLOORORROOFCONSTRUCTION

3.6 Finishing 4.2 Materials

The roof may be finished with two courses of flat clay
tiles in cement mortar 1:3 mixed with crude oil about Cement shall conform to IS 269 : 1989 or IS 455 : 1989
10 percent the mass of cement, ensuring breaking of orIS 1489 (Parts I & 2) : 1991 or any other cement as
joints. Instead of two courses of flat tiles one course of specified. Lime shall conform to IS 712 : 1984. Ag-
pressed clay tiles may be used (see Fig. 11.5 and Fig. gregate shall conform to IS 383 : 1970 and SURKHI
11.6). The ceiling shall be finished with cement mortar to IS 1344 : 1981. Stone slabs may be granite,
I:3 and the finished terrace shall be cured for a period sandstone including quartzite, limestone or slate. The
of not less than 3 weeks. slabs may be chisel dressed to a smooth or rough
surface as required for the finishes at top and bottom
4 STONE SLAB OVER JOIST FLOOR of roof. The slab shall not absorb more than 5 percent
4.1 General of moisture.

Slabs of natural stone, such as, granite limestone,

4.3 Preparatory Work
sandstone, etc, are availbale in parts of Andhra
Pradesh, Mysore, Maharashtra, Rajasthan, Uttar
All steelwork shall be painted with one coat of primer.
Pradesh, for use in floor and roof construction. These .
In case of timber joists they shall have two coats of tar
stone slabs are supported over closely spaced joists and
and one coat of primer before fixing. All edges of stone
covered with a layer of lime concrete or cement con-
slabs shall be chiseled square so that mortar joints will
crete and the required floor or roof finish.
be of even thickness.

284
 SP 62 ( S & T ) : 1997

EXTERNAL
RENDERING

END TILE
LAID AT C!i”

LIME BROKEN BR:,n

/I- AGGREGATE CONCRETE /-TWO COURSES
OF FLAT TILES

12mm THICK

&????BR,cK
wALL ‘JOIST

FIG. 11.5 TYPICAL DETAILS SHOWINGTHE METHOD OF LAYING Two COURSESOF FLAT TILES FORROOF

RENDERING

LIME BROKEN BRICK

AGGREGATE CONCRETE
OURSE
ESSED

12 mm THICK
PLASTER

WALL

FIG. 11.6 TVPICAL DETAILS SHOWINGTHE METHOD OF LAYING ONE COURSEOF PRESSEDTILES FOR ROOF

4.4 Laying of Stone Slabs 4.5 Laying of Concrete Layer over the Stone Slab
a) The joists’shall be fixed in position. a) Lime concrete mix of 1: I :2 shall be laid over
b) The stone slabs shall be placed over the joists. the stone slabs already laid and grouted, to
The slabs set in rows close to each other and provide adequate waterproofing. A ihix of
the joints grouted with cement mortar 1:3. The 1: 1.53 may be used in situations where exposure
mortar shall be of stiff consistency and pressed to weather is not much or where separate
into the joints. If may be desirable to treat the waterproofing is provided. The lime concrete
mortar with crude oil, about 5 percent the mass shall be consolidated with wooden hand
of cement. beaters to a thickness of not less than 7.5 cm.
The consolidation shall be done for at least for
The underside of the joints shall be pointed or other
6 days till the concrete hardens and the beater
finish as desired (see Fig. 11.7).
does not make an impression on the concrete.
c

285
SP62(S&T):1997

FLOOR OR ROOF FINISH

shuttering. But the roof should not be used where

h- LIME OR CEMENT
CONCRETE BASE

+25 mm MIN
impact loads or vibrations are likely to occur.
5.2 Materials

Cement shall coliform to IS 269 : 1989 or IS 455 : 1989

or IS 1489 (Parts I & 2) : 1991 or any other as
specified. Aggregate shall conform to IS 383 : 1970.
OINTS POINTED
Precast hollow cement filler blocks should be as in
Fig. 11.8. Precast joists should be designed to IS 456 :
1978 or IS 1343 : 1980.

5.3 Components of the Roaf

The floor and roof shall consist of the following com-

TYPICAL SECTION OF TYPICAL SECTION OF ponents:
RCC JOIST STEEL JOIST
4 Precast reinforced/prestressed concrete joists
NOTE - Precast RCC o: steel joists may be used. at suitable centres;
FIG. 1 I .7 STONE SLAB OVERJOIST FLOOR
b) Precast cement concrete hollow blocks laid
b) Cement concrete base shall be laid as in over in the space between precast reinforced
terrazzo flooring described in Chapter 9. concrete joists;
4.6 Finishing cl Structural topping concrete nominally rein-
The stone roof may be finished with either cement forced laid in-situ;
plaster mix 1:3, 20 mm thick; or any other finish such 4 The required floor or roof finish at top; and
as with tiles, mud phuska (see Part 4) etc.
e>A suitable ceiling finish applied to the bottom
5 ROOFS AND FLOORS WITH JOIST AND of the joists and hollow blocks, if desired.
FILLER BLOCKS-HOLLOW CONCRETE
FILLER BLOCKS 5.4 Preparatory Work
5.1 General
All supporting elements like walls, pillars, etc, shall be
Floor and roofconstruction using precast reinforced or completed and a 75 mm plain concrete (1:2:4) bed
prestressed concrete joists and hollow cement concrete block may be provided over the walls, if necessary.
filler blocks is advantageous because of durability, fire Arrangements for all service pipes, etc, passing
resistance, thermal insulation, lower dead load and through the roof should be taken care of.
high speed of construction; it eliminates the use of

4 3o.k

All dimensions
in millimetres.
FIG. 11.8 TYPICAL HOLLOW CONCRETE FILLER BLOCK

286
 SP 62 (S & T) : 1997

5.5 Laying of the Roof 6 ROOFS AND FLOORS WITH JOIST AND
FILLER BLOCKS - HOLLOW CLAY
a) The precast joists shall be placed in position at
FILLER BLOCKS
the spacings designed. The joists may be tem-
porarily supported before laying the topping, 6.1 General
at predesignated points; and left in place for
7 days after laying the topping. F~OOFand roof construction with hollow clay fillet
blocks has been found to be advantageous over the
b) The hollow block shall be placed between
conventional type of beam and slab construction. This
joists with their ends resting on the projecting
type of construction consists of placing reinforced
lips of the joists~as in Fig. 1 I .9.
cement concrete precast beams or prestressed concrete
c) Reinforcement shall be provided for structural beams at suitable spacing and the gap between them is
topping slab; at least 0.15 percent steel shall be filled with hollow clay blocks. This type of con-
provided along the joists and 0.20 percent steel struciton is lighter in weight and provides~better sound
across the joists for the structural topping slab; and thermal insulation to the buildings. It also ensures
the spacing of bars shall not exceed 300 mm. rapid construction and eliminates the use of shuttering
The top reinforcement in the slab over the joists required in conventional construction. This type of
shall be tied to the stirrups projecting from the floor or roof is not recommended where impact loads
joists. Weld mesh may be used as an alterna- occur or vibration is expected.
tive. Concrete should be M 15 grade; it shall be
laid over the hollow blocks to a designed thick- 6.2 Materials
ness or minimum of 50 mm. The top surface
shall be finished smooth. In-situ concrete shall Cement shall conform to IS 269 : 1989 or IS 455 : 1989
or IS 1489 (Parts 1 & 2) : 1991 or any other as
be cured for a week.
specified. Aggregates shall conform to IS 383 : 1970.
5.6 Finishing Hollow clay blocks or tiles shall conform to IS 3951
Theconcrete topping may be finished as specified. The (Part 1) : 1975. Precast joists shall be designed to
ceiling may be rendered or plastered as desired. IS 456 : 1978 or IS 1343 : 1980; Ml 5 grade concrete
may be used.

HOLLOW BLOCK

BITUMEN
STRUCTURAL CONCRETE
4iuD PHUSKA/FOAM

INTER-FLOOR
PRECAST REINFORCED/
PRESTRESSED CON -
CRETE JOIST

SECTION XX

FIG. 11.9 PRECASTCONCRETE

JOISTSAND HOLLOWFILLERBLOCKFLOORINGAND ROOFING

287
SP 62 ( S & T ) : 1997

6.3 Components af the Roof nate. Concrete should be Ml5 grade; it shall be
laid over the skin-dry blocks to the designed
The construction shall consist of the-following: thickness or a minimum of 50 mm. In-situ
a>Precast reinforced concrete joists spaced at concrete should be cured for a week.
suitable centres;
6.6 Finishing
b) Hollow clay filler blocks laid in the space
between the joists; The concrete surface shall be finished as specified. The
ceiling~may be rendered or plastered as necessary.
c>Topping concrete laid in-situ over the hollow
clay blocks with reinforcement; 7 ROOFS AND FLOORS WITH JOISTS AND
FILLER BLOCKS - PRECAST HOLLOW
d) The required floor finish at the top; and CLAY BLOCK JOISTS AND HOLLOW CLAY
e) Suitable ceiling finish applied to the bottom, if FILLER BLOCKS
desired.
--. . 7.1 General
6.4 Preparatory worK
This construction also-has the advantage mentioned
All supporting elements like walls, PillW main beams fin6.1. 1naddition a number of plants for manufacture
and frames, shall be completed and a 75 mm plain of clay blocks have come up in different parts of the
concrete bed block may be provided over the walls if country, this kind of prefabricated floor or roof con-
necessary. Arragements for all service pipes, etc, pass- struction where structural clay blocks are used both as
ing through roof shall be taken care of. an element of joist and filler will find greater applica-
6.5 Laying of the Roof tion. In joist and filler scheme, clay blocks are used in
conjunction with concrete to serve as structural com-
The precast joists shall be placed in position at ponent in carrying flexural compression. The shape of
the designed spacing so as to span between the structural clay blocks are so designed that the same
supporting beams or walls; generally not more clay blocks can be used as an element of joist and infill
than 600 mm. The joists may be temporarily element-
supported, before the topping is laid, at
predesignated points, and left in position for 7-2 Materials
7 days after laying the topping.
a) Hollow Clay Block (Structural Type) - This
b) The hollow blocks shall be placed in between shall conform to IS 3951(Part 2) : 1975 with
the joists with their ends resting on the project- dimensions preferably as in Fig. 11.11. The
ing lips of the joists as shown in Fig.1 1.10. average crushing strength of the blocks shall
not beenless than 20N/mm2 with an individual
c) Reinforcement shall be provided for the top-
value of minimum 15 N/mm2.
ping concrete slab in accordance with the
relevant provisions of IS 456 : 1978. At-least b) Cement concrete shall be of Ml5 grade con-
0.15 percent reinforcement along the joists and forming to IS 456 : 1978.
0.2 percent across the joists shall be provided c) Mortar shall be either cement mortar or cement
for the structural topping concrete finish. The lime mortar with a minimum compressive
spacing of reinforcement shall not exceed strength of 10 N/mm2 (see Chapter 4)
300 mm. The reinforcement over the supports
d) Reinforcement shall be as given in IS 456 :
should be tied to the stirrups projecting from
1978. 1
the joists. Weld mesh may be used as an alter- I

HOllOW CLN BLOCN

PRECAST CONCRE’TE JOIST
f /
y TOPPIND &ASl-IN -Sl’l U)
SOmm MINl \

SUITABLE CEILING FINISHI be---.-m 600 mm ~~~--------_rrl

FIG. 11.10PLACING HOLLOW BLOCKS IN BETWEENJOISTS

288
 SP62(S&T):1997

1:2:4 CONCRETE

All dimensions
in mihimetres.
FIG. 11.11 TYPICAL CLAY BLOCK

7.3 Preparatory Work removed after 45 to 90 min, depending on the

weather conditions (see Fig. 11.12).
All supporting elements like walls, pillars, etc, shall be
completed and cured well before placing cement con-
b) One day after precasting the joists, they shall
be cured with water on the precasting platform
crete or mortar bed blocks over load bearing walls, if
itself. After about 4 days when the concrete has
necessary. Arrangements for all service pipes, etc,
developed sufficient strength to withstand
passing through the roof shall be taken care of.
handling stresses, the joists shall be inverted
7.4 Structural Clay Block Joists upside down and removed to a curing yard and
kept continuously moist for 14 days from the
a) The joists shall be precast by placing hollow day of casting.
clay blocks end to end, on a level platform c>After water curing, the joists shall be further
protected from wind and sun, and jointing them cured for another 14 days in the shade.
with 1:3 cement mortar or equivalent cement-
lime-mortar. The clay blocks shall be
d) Lifting and stacking ofjoists shall be done with
care.
thoroughly wetted and they shall be skin-dry at
the time of use. Two wooden planks, cleaned 7.5 Structural Clay block Slab
and oiled shall be then placed on the sides of
the joist held with clamps. The reinforcement 4 The slab shall be designed for two stage load-
shall be placed in the two hollow spaces be- ing. In the first stage of loading shall carry its
tween the two planks and clay blocks, ensuring own weight, dead load of blocks and cement
proper cover from the top and ends. The hollow concrete. In the second stage when cement
spaces shall then be filled with Ml5 concrete concrete has attained full strength, it shall carry
to the top level of the clay blocks. Side planks dead and live loads.
may be removed after 45 to 90 min, depending
on the weather conditions. Side planks may be
b) The design shall be as per IS 456 : 1978.

RUNFORCEMENI

MS CLAMP FOR COMPLETED JOIST

CLAY BLOCKS MOLDINO SIDE PLANK
ASSEMBLE0 AS JOIST JOIST READY FOR
GROUTING

FIG. 11.12 DIFFERENT STAGES OF PREFABRICATIONOF JOIST

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SP62(S&T):1997

7.6 Construction of Roof 8 ROOFS AND FLOORS WITH JOIST AND

FILLER BLOCKS - PRECAST HOLLOW
The joists shall be placed at designed intervals,
CLAY BLOCK SLAB PANELS
generally, around 300 mm. In the intervening
space structural clay blocks shall be placed 8.X General
with mortar joint with the wider base towards
the ceiling of the slab (see Fig. I I. 13). While The construction of floor or roof using structural clay
placing infill blocks, the joints in the joist blocks is a suitable substitute for in-situ RCC slab
members and infill blocks shall be broken with construction. This type of slab is comparatively
half length units. cheaper, saves cement and steel and provides better
b) The space between joists and blocks shall be thermal insulation. In this type of floor or roof, the clay
filled with Ml5 concrete. For continuity over blocks are used to prefabricate a slab panel like a wall.
support. negative reinforcement shall be It is the clay blocks that take part in the structural action
provided in the space with proper cover. In by carrying the flexural compression. The shape of the
case the joist are used as cantilevers. they shall blocks are so designed that the panel can be used to
be supported from the bottom all along the build a wall.
length. Negative reinforcement for cantilever
movement shall be provided in the space 8.2 Materials
before filling with concrete. The bottom sup-
4 Hollow clay blocks (structural type) shall
port shall be removed only when the infill
conform to requirements of IS 395 I (Part 2) :
concrete has attained adequate strength.
1975 with dimensions as shown in Fig. I 1.14.
c> Bearing of the slab shall be 75 mm minimum The average crushing strength shall not be less
in the direction of spanning and 20 mm than 20 N/mm2; the individual value shall not
minimum at end. be less than I4 N/mm’.
4 Structural clay blocks shall be immersed in water
b) Cement concrete to be used over the support to
for about 20 to 30 min before use. Thickness of fill the joint between slab panels shall conform
mortar joint shall not be more than I2 mm. toMl5ofIS456: 1978.
e> Fixtures like fan hooks, wooden plugs, junc-
cl Mortar shall be either cement mortar or
tion boxes, floor traps, etc. shall be located in cement-lime mortar conforming to Chapter 4,
the infills rows of clay block by omitting one with a minimum compressive strength of
of them at the desired location. The fixture IO N/mm2.
shall be placed in position and the remaining
space filled with concrete. Concealed electri- 8.3 Preparatory Work
cal conduits shall be placed inside the hollow
bottom/portion of filler blocks. All supporting elements like walls, pillars, etc, shall be
completed and cured well before placing cement con-
7.7 Finishing
crete or mortar bed blocks over load bearing walls.
The roof may further be finished with the specified Arrangements for all service pipes etc, passing through
roof finish. The ceiling may be rendered or plastered the roof shall be taken care of.
as may be necessary.

FIG. 11.13 J~ISTANDINFILLCLAYBLOCKSLABASSEMBLY

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 SP62(S&T):1997

All dimensions in millimetres.

FIG. 11.14 TYPICAL STRUCTURALCLAY BLOCK FOR PANEL SCHEME

8.4 Slab Panel vertical or horizontal position with plumbed

face towards the bottom.
a> The slab panel shall be cast with hollow struc-
tural blocks on a level platform protected_from d) The slab shall be designed as in 7.5.
wind and sun; and jointing ~them with 1:3 ce-
8.5 Construction of Roof
ment mortar or equivalent cement-lime-mor-
tar. The blocks shall be placed with a short face a>The slab panels shall be placed side by side
on the platform. A layer of mortar shall then be abutting each other over the supports~and the
applied over the top surface ahd the reinforcing joints shall be finished with 1:2 cement mor-
bar shall be placed in one df Ihe logitudinal tar. Bearing for the slab shall be 75 mm mini-
oval shaped grooves. Next a layer of mortar mum in the direction of span and 20 mm at the
shall again be applied to that the total thickness end.
of the mortar joint is about 10 mm. Another Negative reinforcement, where needed for
course of clay blocks shall then be laid as continuity shall be provided; it shall be in the
before and this operation shall be repeated to a longitudinal groove which comes on top face
maximum height of 600 mm, as in Fig. 11.15. of the slab; the reinforcement may be projected
Vertical joints shall be broken in each course at ends by 60 mm for lap welding at site.
by using half units of clay blocks. The face
towards which the main reinforcement is
b) The clay blocks shall be immersed in water for
20 to 30 min and &in-dry at the time of use.
placed shall be made plumb and this face shall
The thickness of joints shall be 12 mm mini-
form the ceiling face.
mum. Fixtures, service conduits, etc shall be
b) After casting, the slab panel shall be cured with water
placed inside the hollow block.
for 14 days and furtheraircuredfor 14days.
8.6 Finishing
cl The slab panels shall be lifted after 28 days
from the casting yard; they shall be carefully The roof shall be finished as specified. The ceiling may
transported to the site. They shall be stacked in be rendered or plastered as may be necessary.

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SP 62 ( S & T ) : 1997

FIG. 11.15 SLAB PANELSBUILTLIKEA WALLUSINGCLAY BLOCK

ANNEX A
(Clause 3.2)
SPECIFICATION FOR CRUDE OIL FOR USE IN MORTARS FOR
MADRAS TERRACE WORK

A-l GENERAL A-6 VISCOSITY

A-l.1 The crude oil shall be a petroleum oil conform-
A-6.1 When tested by the procedure given in A-6.2
ing to the requirements of A-2 to A-7.
the viscosity number of the crude oil shall be between
A-2 SPECIFIC GRAVITY 40 and 45.
A-2.1 The specific gravity shall be between 0.930 and A-6.2 The viscosity shall be tested in Englor’s vis-
0.940 at a temperature of 25°C. cometer at 5O’C. 240 ml of the oil shall be takenin
the container maintained at 50°C for at least 3 min, and
A-3 SOLUBILITY then allowed flow out through the nozzle. The period
A-3.1 The solubility of the crude oil in carbon disul- of flow for the first 100 ml shall be noted as the
phide shall be not less than 99.9 percent. viscosity number.
A-7 LOSS ON IGNITION
A-4 BITUMEN CONTENT
A-7.1 When tested in accordance with the procedure
A-4.1 The content of bitumen, insoluble in 36’ BE paraf- given in A-7.2, the loss in mass in the crude oil shall
tin naphtha shall be between 1.5 and 2.5 percent by mass. not exceed 2 percent by mass.
A-5 RESIDUAL COKE CONTENT A-7.2 Twenty grams of the material shall be heated
for 5 h in cylindrical tin dish, 80 mm in diameter and
A-5.1 The content of residual coke in the crude oil 25 mm deep, and the temperature of ignition shall be
shall be between 2.5 and 4 percent by mass. 163’C.

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 SP62(S&T):1997

PART 2 SLOPING ROOFS

1 WOODEN SHINGLE ROOF e>The shingle covering shall be at least three

courses deep at every section; the minimum
-1.1 General
overlap shall be one-third of the length of the
Wooden shingles are used for pitched roofs in some of shingle.
the Himalayan Regions of India where suitable species The spacing of rafters shall not normally
of timber are available, such as, in Jammu & Kashmir, exceed 600 mm or as determined by IS 883 :
North Punjab, Himachal Pradesh, Assam; as also in 1970. The size of battens shall not be less than
Andaman and Nicobar Islands. 50 mm x 25 mm.
Wooden shingles are short, thin, rectangular pieces of
s) When ceiling board is adopted, the planking
timber usually tapering in thickness along the grain, shall not be less than 12 mm and shall preferab-
used in the same way as tiles for covering roofs of ly be tongued and grooved. The ceiling boards
buildings. Thickness of shingles ordinarly reduces may either be nailed to the rafters or may
from tail (butt) to head. Shingles are nailed to the direcly be fixed to the purlins.
battens and arranged generally in a number of courses
overlapping each other so as to ensure leak proof h) Wooden shingles shall be given fire retardant
drainage. treatment by pressure impregnation with
chemicals, such as, ammonium mono-phos-
1.2 Materials phate, ammonium di-phosphate, sodium
a) Wooden shingles shall conform to the species arsenate, or sodium tetraborate.
specified in Annex B.
1.4 Laying of Shingles
b) Nails shall conform to IS 723 : 1972; preferab-
ly rust resistant or hot dip galvanized nails shall 4 Each wooden shingle shall be fixed to the
be used. Nails shall be of 2.00 or 2.24 mm battens by two nails (see Fig. 11.16 and Fig.
shank diameter and 40 mm in length depending 11.18). The distance of nails from the~butt end
upon the species. Subsidiary battens shall be of shingle, shall be equal to the shingle ex-
fixed to main battens by 2.80 mm or 3.15 mm posure plus 10 to 15 mm, the edge distance of
diameter, 60 mm long nails. nails from the sides of the shingle shall not be
c) Timber for battens and rafters shall conform to more than 20 mm; the nails may be driven
structural timber specified in IS 3629 : 1986 flush.
properly seasoned and treated (see Fig. b) Each course of wooden shingle shall be over-
11.16). lapped by another course such ~that only one-
1.3 Preparatory Work third of the length of the shingle in the lower
course is left uncovered; the remaining two-
4 In case of low pitched roofs, p&ticularly in third length shall be overlapped. Except for the
areas of high winds, it is necessary to have an bottom two courses, wooden shingle shall be
underlay of roofing sheets or timber roofing three course deep throughout the roof area.
boards. In areas of heavy rainfall and in very
damp climates, spaced -roofing boards may c>In each horizontal course, the shingles shall be
preferably be used to permit quick drying of laid 3 to 6 mm apart to allow for swelling when
the underside of shingles. The provision of an wet. Each horizontal course of wooden
undercover for the roof will not only add in- shingles shall break joints with two courses
sulation and waterproofing but also prevent above and two courses below it.
debris from falling in. 4 The gaps between the wooden shingles in each
b) No gutter or rain water pipe shall discharge course shall be off set at least 40 mm centre to
from~one roof to another. centre from corresponding gaps between the
shingles in the course above. The two courses
c>The size and shape of the shingles shall be as
of shingles at eaves shall also be break-jointed.
in Fig. 11.17
4 Spacing of battens shall be equal to about one-
e>The first shingle course laid in double should
extend 50 mm to 60 mm beyond facia member,
third of the length of shingles, that is, 100 to
if adopted, to prevent the water from backing
130mmasinFig. 11.18.
up underneath the shingles.

293
SP 62 ( S 8: T ) : 1997

WOODEN RIDGE

-
DETAIL OF RIDGE

WOODEN RAFTER

SLOPE OF
ROOF

L12O TO 150 . PLAN

WIRE NAILS 1
LOmm LONG-I 7

III.“LL~

(THICKE R END) ENLARGED SECTION Xx

All dimensions
in millimetres.

FIG. 11.16 TYPICAL DETAIL SHOWINGROOFING WITH WOODEN SHINGLES

f-3 mm

112-5mm
7
30 TO 40cm--j

FIG. Il. 17 TYPICALWOODENSHINGLE

294
 SP62(S&T):1997

STEEL CORRUGATED
SHEETS
2 WIRE NAILS
FOR ONE SHINGLE-, _&I MAIN BAT TEN

SUBSIDIARY
BATTENS

pi Ah)
SHINGLE CUT TO THE
I b-8.
REQUIRED SIZE7
ANGULAR WOODEN-j
RIDGE (ONE PIEC

STEEL CORRUGA
EAVES BOARD-I SHEETS1 d

SUBS;IDENBATIE;LO~5-j _

LMAIN BATTEN 50 x10

WOODEN RAFTER (TRUSS)

SECTIONAL ELEVATION

/I -Overlapped length 2 L I3
B - Exposed length L / 3
NOTE-One piece ridge arrangement of shingles shall be followed for hip ridges also.

All dimensions in millimetres.

FIG 11.18 TYPICAL DETAIL SHOWINGROOFINGWITHWOODENSHINGLES
OVERGI CORRUGATED
SHEETS

295
-SP62(S&T):1997

1.5 Maintenance b) Spacing of reepers shall not normally exceed

600 mm; the size unless otherwise designed,
Wooden shingle roofing shall be periodically painted
shall be normally 50 mm x 25 mm for Man-
(say after every 3 years) by a suitable preservative (see
galore tiles laid over flat tiles over reepers; and
Chapter 7). Any decayed shingle and batten shall be
50 mm x 15 mm for Mangalore tiles laid over
replaced in time.
reepers or over ceiling tiles laid on reepers.
2 ROOFING WITH MANGALORE TILES c>Where ceiling. board is adopted, it shall not be
2.1 General less than 12 mm thick and shall be tongued and
grooved. The boarding shall be nailed to the
Mangalore tiles are machine made burnt-clay tiles rafters first so as to form a continuous surface
widely used for roofing work in the coutnry. Its design from ridge to the eaves, and the reepers nailed
incorporates corrugation for drainage and also an effi- over them. Alternatively the ceiling boarding
cient interlocking system between the tiles, enabling may be fixed direct to the purlins. The size of
them when laid to form a leakproof layer. Depending reepers shall not be less than 25 mm x 25 mm
on the degree of protection needed from the roof, fixed at suitable distances apart to suit the tile
Mangalore tiles may be laid as such or with an under- spacing. The maximum spacing of sleepers
layer of flat tiles or ceiling tiles, etc. A specific shall not exceed 750 mm.
advantage of a tiled roof is the ease of maintenance
d) Dimensional coordination be done between the
since any broken tile can be easily replaced. The design various elements of Mangalore tiled roof to
of Mangalore tile takes into account this aspect and the avoid cutting of tiles.
tile aslaid on the roof will be able to carry the~weight
of a man it is called on to support during such repair.
e) No gutter on roof drainage shall discharge
water from one roof to another, except from the
Though originally produced in areas near Mangalore,
dormer.
this tile is now manufactured and used in many parts
of the country. f> Glass tiles, of the same shape and size as the
Mangalore tiles may be fixed in the same
2.2 Materials manner as other tiles.

4 Mangalore tiles shall conform to IS 654 : 1992. g) While considering the strength of framework
the following dead loads shall be taken into
b) Ridge tiles shall conform to IS 1464 : 1992.
account:
c>Mortar shall be composite mortar (cement :
Description Rise/Span Dead Load,
hme : sand) 1 : 2 : 9.
kg/m*
4 Flat tiles shall have one of the dimensions
equal to the gauge of the Mangalore tile. Mangalore tiles embedded l/4 to 112 110
in mortar over tiles
e>Glass tiles shall preferably be of the same
shape as the Mangalore tile. Mangalore tiles with flat l/4 to l/3 80
tiles without mortar for
f) Ventilating tiles shall be equal in size to one
plain Mangalore tile or two tiles laid side by embedment
side after allowing for overlapping. They shall Mangalore tiles alone l/4 to l/3 90
be provided at the rate of two per every 10 m* h) Flat tiles shall be immersed in water for 2 h and
area of finished roof surface. air dried before laying. The underside of the
s>Ceiling tile shall conform to IS 1464 : 1992. flat tiles, if so specified, shall be dipped in
h) Nails shall conform to IS 723 : 1972; they shall whitewash mixed to a creamy consistency and
be plain head nails of size 2.50 mm or 2.24 mm then the tiles dried. .
and shall be galvanized. j) Mangalore tiles shall be first soaked in water
j) Sheet metal for valley gutters shall be gal- for at least 2 h before laying.
vanized and at least 1.25 mm thick.
2.4 Fixing of Reepers
k) Reepers shall be of any of the species given in
IS 883: 1970. 4 The reepers shall be fixed over the rafters at the
specified spacing and nailed. The nails shall
m) Wire for tying down the tiles shall be gal- penetrate at least 2 cm into the rafters. They
vanized and conform to IS 280 : 1978.
shall extend at least three span lengths between
-2.3 Preparatory Work rafters; their length may be extended by a butt
joint occurring on the rafters. The joints of two
4 The roof framework shall be completed and the
adjacent rows of reepers shall not occur on the
reepers nailed into position. The pitch of the
same rafter. At the eaves a tilting fillet shall be
roof shall neither be less than 24’ nor more
fixed, if necessary (see Fig. 11.19)
than 45’.

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 sp 62 ( S & T ) : 1997

MANGALORE TILE
GALVANIZED WIRE FOR TYING
DOWN TILES TO THE REEPER

BATTEN OR REEPER EDGE BEDDING IN MORTAR

WOODEN RAFTER MANGALORE TILE

ENLARGED DETAIL AT A

GAUGE OF TILE

GALVANIZED /-TYING LUG

MANGALORE TILE --,
MS FIAT-
h!S GALVANIZED
SCREW
7

BATTENS OR REEPERS

WOODEN RAFTER

TILTING FILLET

\ REEPER
LEAVES BOARD
EAVES GUTTER ENLARGED SECTION THROUGH TYING LUG
(OF MANGALORE TILE)

FIG. 11.19 DETAILOFMANGALORETILESLAIDONREEPERS

b) Where cejling boards are used instead of fixed to the roof. Mortar bands 200 mm to
reepers they shall be fixed as in 2.3 (c). 250 mm wide and 60 mm to 65 mm deep may
also be spread over the tiled roof at a spacing
-2.5 Laying of Mangalore Tiles of 2.5 m to 3 m for additional protection against
wind (see Fig. 11.20).
a) The tiles shall be laid from eaves towards the
c>Mangalore Tiles over a Flat Tile Undercover
ridge properly interlocked according to the -The flat tiles shall be laid over the reeper; a
design of the tile. The tiles shall be laid break- mortar layer 25 mm thick shall be spread over
ing joints, that is, the left channel of the upper the tlat tile. Mangalore tiles shall then be laid
tile shall lie in the right channel of tile below. over the mortar and fully embeded. Where the
The hips and ridges of roof shall be covered pitch of the roof is more than 30°, additional
with ridge tiles which shall be edge-bedded in fillets shall be fixed at a spacing of about 1 m
mortar as shown in Fig. 11.19. The mortar in centres, so that the-flat tiles laid between them
edge bedding may be further finished with are retained in position (see Fig. 11.21).-The
plaster or paint to match the colour of the tiles. Mangalore tiles may also be fixed over flat tiles
If the courses of roof tiles adjacent to the hip without mortar bedding, if so specified.
or ridge do not fit exactly underneath the ridge
tiles, either purpose made tiles or tiles cut to 4 Mangalore Tiles over Ceiling Tiles - The
suitable shape may be use. At eaves the lower ceiling tiles shall be laid over the reepers and
most course of tiles shall overhang the tiling the Mangalore tiles shall be laid over them with
fillet by a distance sufficient to ensure that the appropriate interlocking between tiles in two
mater drained off from the roof, discharges layers (see Fig. 11.22).
clear off the eaves into the gutter. 4 The eaves line and ridge-line shall be perfect-
b) A suitable arrangement shall be made so that ly straight horizontal and parallel to each other.
the lower most course of tiles are not blown f) The joints between hip and ridges shall be
away by wind. The bottom most layer, or even grouted so as to be leak proof. A metal saddle
more layers of tiles above it shall be tied to the not less than 45 cm*~in area may preferably be
reepers or other roof elements by means of used underneath such junctions as additional
galvanized wire; or by a galvanized steel flat protection against leakage.

297
SP62(S&T):1997

GABLE PARAPE NIZED MS FLAT

TYING DOWN TILES

FIG. 11.20 NOMENCLATURE OF A PITCHEDROOF

A-MANGALORE TILES

MORTAR LAYER RETAINING FILLETS TO

BE USED WHEN PITCH
IS MORE THAN 3d-, ,
A
MANGALORE TILES

LREEPER OR BATTEN

WOODEN RAFTER OODEN RAFTER

ENLARGED DETAIL AT A
REEPERS OR BATTENS

FIG. 11.2 1 DETAIL OF MANGALORE TILES EMBEDDED IN MORTAR OVER FLAT TILES

g) A clear and unobstructed channel shall be Where necessary, tiles shall be let into the wall
formed in the valley. Undercover shall be to a depth of 50 mm at least and a drip mould-
provided for the courses of tiles adjacent to the ing shall be provided at about 100 mm above
valley (see Fig. 11.23). the roof surface and the joints between the wall
h) In case of chimney stacks and other similar and roof be grouted with waterproofing mortar
features projecting through the roof, full tiles (see 3.5).
shall be used around them and taken into
3 SLOPED ROOF COVERING - SLATING
masonry.% addition metal or bitumen flashing
shall be used to cover the intersection between
3.1 General
the top edge of tiling and any projection
through the roof. The flashing shall be well R ec tangular slates of uniform thickness are widely
tucked into either joints in masonry or grooves used for roofing work in the country. The advantage
in concrete as the case may be and shall be of this roofing is the ease with which any broken slate
wedged and pointed. can be replaced. Depending on the protection needed
j) At junctions of roof and wall, waterproofing from roof, generally two ways of slating are adopted,
treatment (see Chapter 12) may be given. they are single slating and double slating.

298
 SP62(S&T):1997

MANGALORE TILES

OF
TILE

WOODEN RAFTER

ENLARGED DETAIL AT A

FIG. 11.22 MANGALORE TILE LAID OVERCEILING TILES

VALLEY BOARD

VALLEY RAFTER
STEEL SHEET

FIG. 11.23 FIXING OF VALLEY GUTTER

3.2 Materials 2) The slates shall be impervious to moisture;

the percentage absorption by weight of
4 Slates shall be of uniform thickness and rectan- the slate after immersing it in water for
gular in shape. Generally, slate sizes 60 cm x 24 h shall not be more than two. When the
30 cm, 50 cm x 25 cm and 40 cm x 20 cm and slate is kept immersed on its edge in water
of thickness varying from 5 mm to 10 mm may for 6 h, the water level shall not rise to
be used for rooting. Slates shall be so selected more than 12 mm and the immersed edge
that the thickness of any one lot of 20 slates, shall not show signs of swelling, splitting
selected from an individual consignment and and flaking.
closely packed one above the other shall not b) The timber for plankings, reepers and rafters
exceed that of any other lot of 20 of the same shall conform to structural timber specified in
size taken from the same consignment, by IS 3629 : 1986.
more than 25 percent. c> Nails shall conform to IS 723 : 1972 of size
1) The slates shall be of uniform size, colour 2.50 mm or 2.25 mm and shall be galvanized.
and texture, free from white patches and The length of nails shall be such that they
be hard and brittle but not tough; when penetrate at least 2 cm into the rafters. Copper
struck it shall give a ringing sound and nails, if used, shall conform to IS 725 : 1961.
shall not break when it is let fall flat on Screws conforming to IS 451 : 1972 may be
hard ground from a height of 1.25 m. The used instead of nails.
slates shall be of reasonably straight
3.3 Preparatory Work
cleawage. The grains shall be longitudinal
and not transverse. The surface shall be a) As far as possible, hipped roof shall be
such as to permit proper laying of slates. adopted. The slope of the roof may vary from
SP62(S&T):1997

22’ to 30’. It is also advisable to adopt slates 2) Timber planking of thickness 15 mm to

of’size 60 cm x 30 cm, when the slope-of roof 20 mm shall be laid on the wooden rafters,
is 22’, size of 50 cm x 25 cm when the slope is spaced at between 30 cm to 150 cm apart.
27’; and size of 40 cm X 20 cm when the slope On~the planking bitumen felt conforming
is 30’. to IS 1322 : 1993 shall be laid according
to the procedure laid down in Chapter 12.
b) Galvanized steel sheet ridge and hip pieces
(see IS 277 : 1992) shall be used and these shall Bitumen felt shall overlap at horizontal
be fixed with roofing screws, limpet and joints by not less than 7.5 cm and at other
washers which are preferably dipped in anti- joints by not less than 15 cm. At hips a
corrosive bituminous paint conforming to strip not less than 60 cm wide shall be laid
IS 158 : 1981. Corresponding holes in slates from top to bottom overlapping the felt-
below the hip or ridge pieces shall be made to ing of roof. At valleys a similar strip shall
receive the stews. The ridge and hip pieces be lapped under the felting. Polyethylene
shall have an overlap of 7.5~cm over the slates. may also be used instead of bitumen felt.
The thickness of galvanized steel sheets shall 3) On bitumen felt, wooden sleepers shall be
preferably be 0.63 mm or 0.80 mm. fixed, one under the head of each; a reeper
shall be fixed in the middle of each slate
c) Valleys shall be formed by laying lead or gal- (see Fig. 11.24). The spacing of sleepers
vanized steel sheet gutter on boarding fixed thus depends on the length of the slate. The
into the valley bottom. The gutter shall extend top surface of the reepers shall conform to
20 cm on each side of the valley line, the edges the underside of the slate resting over
being turned over to form beaded edges and them. The reepers shall be nailed to the
shall be fixed down by nails with correspond- planking and the bitumen layer.
ing suitable holes in the slates. The slates shall The bottom course of the slates near the
4)
be cut to shape and fixed with a lap of 7.5 cm eaves shall project 7.5 cm outside the
over the gutter. The edges of slates shall be planking and shall be half the length plus
made true and the face of the edges shall be 7.5 cm. This course shall be laid of double
chisel dressed. slates, the joint of the top layer shall be in
the centre of the bottom layer.
3.4 Laying of Slates
5) Over the bottom course, other courses
Slates may be laid in one of the following two ways: shall be laid. Each slate shall be laid with
an overlap of minimum 7.5 cm over the
a) Single Slating
bottom and of 5 cm on the sides.
1) Slates shall be laid on wooden reepers as
6) Slates shall be fixed to the reepers with flat
shown in Fig. 11.24.
headed glavanized wire nails of 2.5 mm

1I.24B ENLARGED SECTION XX

FIG.11 .~~DETAILSOFSINGLE SLATING
 SP62(S&T):1997

shank diameter and length of 3 or 4 cm. It sheds, godowns and factory buildings, besides their
is preferable to dip the nails in anti- extensive use in remote areas. These are easy and quick
corrosive paint and dry them before use. It to erect and economical. This type of construction is
shall be ensured that the nails are driven into also popular in hilly areas and for temporary construc-
the reeper by at least 2 cm or two-thirds of tion.
the depth of reeper whichever is less. NOTE - If corrugated nluminium sheets to IS 1254: 1991 are
7) Nails shall be fixed on two holes, 3.75 cm used similar procedures may be followed.
from top edge and 5 cm from side edges,
made from front to back side in each side, 4.2 Materials
thus leaving a centre sunk on the top sur-
face of slates. All slates shall be head- a>Steel sheet shall conform to IS 277 : 1992 with
nailed with two nails each. a grade of coating 600 or 450.

8) Ridge pieces shall be laid as shown in b) Hook bolts shall conform to IS 730 : 1978.
Fig. 11.25. Steel bolts, nuts and washers shall be
galvanized. Neoprene washers, if used, shall
b) Double Slating
conform to IS 8869 : 1978.
1) Slates shall be laid on reepers as shown in
Fig. I 1.26. 4.3 Preparatory Work
2) Timber planking shall be laid on rafters as
described in 3.4 (a)(2). Bitumen may not a) In addition to end purlins for each layer of
be provided except in case,of important sheets, at least one purlin should be placed (on
building where procedures as detailed in simple rafter) to support sheets at midway to
3.4 (a)(3) may~be followed. avoid sagging. In case of fabricated roof
3) All other details shall be as in 3.4 (a). trusses, the spacing of purlins is guided by the
maximum distances as given below:
3.5 Finishing Around Projections/Junctions
Thickness of Steel Maximum Spacing
a>Proper precaution shall be taken to prevent
Sheet, mm of Purlifls, c/c, m
leakage of water by providing galvanized sheet
and double layer of felt at junctions of roof and 1.oo 2.0
roof projections, such as, chimneys.
0.80 1.8
b) At junctions of wall and roof the treatment
shall be as given in Fig. 11.27. 0.63 1.6
4 SLOPED ROOF USING PLAIN AND Ridge purlins shall be fixed 75 mm to 115 mm
CORRUGATED GALVANIZED STEEL from apex of the roof, that is, from the bolt
SHEETS point.

4.1 General b) Sheets shall be laid with a minimum end lap of

I50 mm and side lap of two corrugations; these
Sloped roof coverings using plain and corrugated gal- may be increased to avoid cutting.
vanized steel sheets are generally used for storage

/-GALVANIZED STEEL RIDGE

BITUMEN FELT

SCREWS AND

Y-
L WOODEN PLANK

FIG. I 1.25 DETAILSA’rTHEEDGEOF SLATEDROOF

SP62(S&T):1997

WOODEN PLANU

Il.26 A~PICfGR[AkVIEW
BITUMEN FEL?

WOODEN PLANK

11.26EtENLARGED SECTION XX
FIG. 11.26 DETAILSOFDOUBLESLATING
DRIPWOULblNG
RAIN~WATER GUTTER
CEMENT MORTAR
SLATES
A

TILTING FILLET

BITUMEN FELT

FIG. 11.27 DETAILSATTHEJUNCTION

OFTHEROOFWITHWALL
(WHERE-SLATES THEMSELVESAREUSEDFORROOFDRAINAGE)

4.4 Laying and Fixing of Sheets beyond the edges of purlins. For alignment of
sheets, one piece of timber batten shall be
a>The sheets shall be laid on the purlins or other fixed, projecting up to the depth of purlin, on
structural members as indicated, to a true
the first and last structural member (truss or
plane, with the lines of corrugation truly paral-
rafter); and with both these batten pieces a
lel or normal to the sides of the areas to be
thread shall be tied to check straightness, etc,
covered, unless otherwise required as in spe-
and then the sheets shall be fixed. First the
cial shaped roofs.
bottom layer of sheets shall be laid temporarily
b) Laying of the sheets shall commencefrom the by 50_mm long nails. After laying all the sheets
lower end (bottom) of roof. Longer length up to the ridge, permanent fixing shall be done
sheets shall be fixed first and then shorter by means of J or L hook bolts (see Fig. 11.28
length sheets fixed towards the ridge. Mini- and Fig. 11.29.
mum 300 mm length of sheet should project

302
 SP-62(S&T):1997

r--STEEL
END LAP
150 min. _

RAFTER OR TOP CHORD

OF ROOF TRUSS

l
NUT
J OR L BOLT> r
\ / t--LIMPET WASHER

E.$z.$,
BITUMEN WASHER

WITH 150mm
OVERLAP

ENLARGED DETAIL AT ‘A’

All dimensions in millimetres.

..FIG. 11.28 FIXING DETAILS OF STEEL SHEETS

STEEL SHEE 1 drilled but not punched. The holes in the

7 washers shall be the diameter of the bolt. The
nuts shall be tightened from above to give leak
proof roof. Sheets shall not generally be built
into gables and parapets. Junction with a wall
shall be treated to make it leak proof.
L SIDE LAP
(2 CORRUGAflONS) 4.5 Ridges and Hips

FIG. 11.29 DETAILS OF LAPPING a>Ridges and hips shall becovered with ridge and
hip sections with a minimum lap of 150 mm on
either side over the roofing sheets; they shall
c>For fixing of sheets the cover shall not be less
be properly bent to shape and fixed.
than 85 mm. The sheets shall be placed
‘alternate’, that is, one sheet (the lower) being b) Ridges and hips shall be fixed to roof members
fixed with edges turning away from the bearer with J or L hook bolts M 6 or M 8; at least one
or purlin to which the sheeting is fixed and the of them should pass through the end laps of
cover sheet on side being fixed with edges ridges and hips. End laps shall be joined togeth-
turning in towards the bearer or purlin. er by M 6 hook bolts. The hips and ridges shall
fit in squarely on the sheets.
4 Sheets shall be fixed to the purlins by J or L
(M 6 or M 8) hook bolts; these shall be a
4.6 Valleys and Flashings
minimum of three hook bolts placed at ridges
of corrugation in each sheet on every purlin
with a spacing not exceeding 300 mm. Sheet- a) Valleys and flashings shall lap with corrugated
sheets not less than 150 mm width on ei&er
ing on steel purlins, shall be riveted together
side; the end laps shall also be not less than
with 6 mm dia galvanized wrought iron rivets
150 mm and painted with red lead.
and galvanized washers, two to each~rivet, at
c spacing of 200 mm maximum for the side laps; b) Valley sheets should be fixed to the roof mem-
and on every corrugation for end laps. bers with J or L hook bolts; at least one bolt
e) All holes for bolts, rivets, etc, shall be made in should pass through the end laps on either side.
the crown of the corrugation and shall be Junctions with wall shall be properly treated to
make it leak proof.

303
SP62(S&T):1997

5 ASBESTOS CEMENT SHEETS - lengths between adjacent sheets [see 5.3 (Q]
CORRUGATED shall be increased.
b) Purlins shall be so spaced to see that the sheets
5.1 General do not deflect; generally for 6 mm thick sheet,
Unreinforced corrugated absestos cement sheets are the purlins should be spaced at I.4 m for roof
commonly used in this country for providing structural covering and 1.7 m for side cladding.
surfaces exposed to weather, such as, roofs for c>Ridge purlins shall be fixed 75 mm to 1 I5 mm
industrial, institutional, commercial and residential from the apex of roof, that is, from bolt point.
buildings. These sheets have several advantages, such
as, lightness, ease and quickness of construction and
4 Additional trimmers shall be used between
purlins at points where considerable traffic is
durability.
likely to occur, such as, adjoining valleys or
5.2 Materials gutters, etc. For smaller sheets,-it is desirable
to arrange for closer purlin spacing at eaves
a>Asbestos cement sheets shall conform to
rather than at edges.
IS 459 : 1992. Asbestos building boards shall
conform to IS 2098 : -1964. d Hip and valley runners should be fixed flush
with top face of the purlin and span bet-ween
b) Fixing accessories, such as, J or L bolts,
them. The runners should be parallel to the
washers, etc, shall conform to IS 730 : 1978.
edge of the sheeting to permit fixing of
Coach-screws shall conform to IS I 120 : 1975.
accessories.
c>All bolts, washers, etc. shall be galvanized.
The side lap should be half corrugation (see
5.3 Preparatory Work Fig. 11.30).

a) The pitch of roof be preferably not less than For normal pitches, equal to and more than 18’, the
18’; if steeper pitches are used, the end lap end lap shall not be less than 150 mm (see Fig. 11.3 1).

J-TYPE HOOK BOLT

f-

GI FLAT WASHER
BITUMINOUSFELT WASHER

_ WIND DIRECTION

FIG. 1 I .30 DETAIL OF SIDE LAP

MS ANGLE PURLIN

FIG. I 1.3 I DETAILOFEND LAP

 SP62(S&T):1997

For low roof pitches, less than 18’, manufacturers shall j> Fixing bolts and screws shall be 8 mm or more
be consulted for side laps; also for normal pitches in in diameter and the nuts of the-hook bolts shall
exposed conditions side laps should be as per manufac- bear on galvanized iron washers which in turn
turers instructions. shall be embedded on bituminous felt washers.
The side lap shall be away from the prevailing wind The screws and nuts shall be sufficiently
direction. The free over-hang at eaves, measured from tightened only to seat the bitumen washer over
lower edge to centre of bolt holes, shall be not more the corrugations, so that natural movement in
than 300 mm. the sub-structure of the roof may not damage
the sheeting.
Wherever four corners of sheets overlap, two of them
shall be mined to secure a perfect tit. To avoid undue k) The length of J-bolt or crank bolt shall be
width of flashing, the sheets should finish at abutments 75 mm longer than the depth of the purlin for
with an upturned edge. single sheet and 90 mm longer for double sheet
or where ridges or other accessories have to be
5.4 Laying and Fixing of Sheets fixed.

5.4.1 Holes and Accessories

m>The minimum length of square head coach
screws for timber purlins shall be 110 mm. The
number and length of bolts and washers shall
a>Holes in sheets shall be drihed and not punched
be as given below:
and should be 2 mm larger than the diameter
of the hook bolt; they shall be at the crown of Situation No. of Bolts, Length of
corrugation and not at the valleys. Washers Bolt
1. At horizontal Twice the num- Depth of
b) Holes for fixing sheeting shall be drilled in the
centre of the end lap of sheets to suit, that is, (end) laps of ber of sheets in purlin plus
the centre line of the purlins if these are of sheets; at eaves one horizontal 90 mm
timber when square head coach screws are when filler pieces course
used; or as close to the back of purlins, if J or are used; at ridge
L bolts are used with steel angles, precast when sheet and
concrete or timber purlins. No hole shall be ridge pieces are
drilled nearer than 40 mm to any edge of sheet secured by the
or an accessory. same bolt

c>Galvanized iron J-hook bolts or cranked hook 2. At eaves when Twice the num- Depth of
bolts and nuts bearing on galvanized iron filler pieces are ber of sheets in purlin plus
washers and bitumen washers shall be used for not used; at ridge one horizontal 75 mm
fixing sheets on angle iron purlins. when sheet and course
ridge pieces are
4 Galvanized iron L-ho&bolts and nuts bearing
not secured by
on galvanized iron washers and bitumen
the same bolt
washers shall be used for fixing sheets on RS
joist, precast concrete or timber purlins. 3. At intermediate Twice the num- Depth of
purlins where ber of sheets in purlin plus
4 Galvanized iron coach screws bearing on gal- horizontal laps one horizontal 75 mm
vanized iron washers and bitumen washers
do not occur course
shall be used for fixing sheets on timber
purlins. n>The washers shall be 25 mm in diameter and
1.6 mm thick for flat iron washers; 35 ~rnrn in
f) Galvanized iron roof bolts and nuts bearing on
diameter and 1.5 mm thick for bitumen
galvanized iron flat washers and bitumen
washers.
wahsers shall be used for stitching on sheets,
fixtures like ridge cappings, corner pieces, P) Ridge cappings shall be secured to the ridge
ventilators, north light curves, etc. purlins by the same bolts which secure sheet-
ing.
S) Where sheets are laid on tubular purlins the
fixing bolt should be designed to encompass at 5.4.2 Laying of Sheets
least half the tube periphery and precautions
should be taken to prevent its rotation. a>Check purlin spacing and length of sheets for
securing the appropriate laps,~overhang, etc.
h) Direct fixing of sheets to drilled metal
framework or by stud welding is undesirable b) Sheets shall be laid with smooth side upwards
as it tends to restrain movement of sheets. and with side and end laps as given in
Fig. 11.30 and Fig. 1 I .3 1. The courses of

305
SP62(S&T):1997

sheets shall be so laid that the corrugations run 3) The sheets in the second and other intermediate
in continuous straight lines. If the building is -rows shall have bottom right hand corner and
in exposed position and is subject to driving top left hand corner cut;-the last sheet shall
rain and wind, it is advisable to commence have only the top left hand corner cut.
laying of sheets from the end opposite to the 4) The last or top row ofsheets shall have bottom
direction of wind. right hand corner cut with the exception of the
c>The sheets shall be laid starting either from last sheet which shall be laid uncut.
eaves from left to right or right to left depend- The whole sequence is reversed if laid from
ing on direction of prevailing wind, to avoid it. right to left.
See Fig. 11.32 for laying sheets from left to c
The mitre is cut from a point 15 cm up the
right, for details.
vertical side of the sheet to 4.5 cm along the
The sequence for left to right starting from eaves could horizontal edge; this is necessary when four
be as follows: sheets meet at a lap.
1) The first sheet is laid uncut. d) Nuts and screws shall be tightened lightly at
2) The remaining sheets in the bottom row shall first and then fully tightened when a dozen or
have top left hand corners cut or mitred. more sheets are laid. One bolt or screw shall be
used on each side of the lap.

--SIDE LAP

PURLIN POSITION T
SUIT OVERHAN

A = Uncut sheet
B = Top left hand corner cut
C = Bottom right hand corner cut
I) = Top left hand corner and bottom right hand corner cut

FIG.Il.32 LAYINGOFSHEETS(SHEETS
LAIDFROMLEFTTORIGHT)

306
 SP62(S&T):1997

5.43 Asbestos Accessories tion and shall be fixed as in Fig. 11.33 and
a> Moulded asbestos accessories should be Fig. 11.34.
selected as far as possible from the range of Correct fitting of ridge capping will be
standard patterns. Special fittings, if required automatic, if a template is used when
shall be designed to conform closely to the fixing roof sheets.
sheet profile. Roofing accessories should 2) The work shall be started from left hand
generally be secured to the roof or wall clad- verge, placing frost small roll wing (inner)
ding by the same bolts which secure the sheets. and positioning it in such a way that the
first valley on the right hand side of the
b) Ridge capping should be secured to the purlins,
as far as possible, by the same bolts which ridge fits into the valley at side lap of roof
secure the sheets, where this is not possible sheeting. In case of large roll wing, it shall
each wing of the ridge capping should be ade- be so positioned that the first valley of left
quately secured to the sheets by roofing bolts. hand side of the ridge wing fits into valley
of side lap of roof sheeting.
I) Close fitting adjustable ridge capping
shall be designed to fit~the corrugations of 3) Serrated adjustable ridge cappings, sup-
sheets laid with side lap of half corruga- plied in pairs, are as shown in Fig. I 1.35.

J-TYPE HOCU BOLT

FIG. 11.33 TYPICAL CLOSE FITTINGADJUSTABLERIDGE

OF SHEETS

POSITION OF SMALL INNER POSITION OF MALL INNER POSITION OF LARGE OUTER POSITION OF LARGE OUTER
WING ON SHEETS LAID WING ON SHEETS LAID WING ON SHEETS LAID WING ON SHEETS LAID
RIGHT TO LEFT LEFT TO RIGHT RIGHT TO LEFT LEFT TO RIGHT

RIDGE (LARGE
OUTER WING)

LARGE OUTER WMG

TEMPLATE FOR CORRECT GAUGING

OF CORRUGATED SHEET SIDE LAP

LPD9rn-I

SMALL INNER WING

FIXING OF ADJUSTABLE
RIDGE PIECES

FIG. 11.34DETAILS SHOWING METHOD OF FIXING CLOSE FITTINGADJUSTABLERIDGE PIECES

SP62(S&T):1997

The method if laying and fixing of ridges 4) Fixing with a typical north light two piece
shall be as shown in Fig. 11.36. adjustable ridge shall be as shown in Fig.
11.37.

TIP PAINTED BLACK

TO FACILITATE FwNG

r
FIG. Il.35 TYPICAL SERRATED ADJUSTABLE RIDGE

THIS PORTION OF SERRATION SUITABLY

INNER WING OF PAINTED ON RIDGES
BRIDGE TO BE TO FIT IN CORRUGATIONS
TRIMMED OFF WHERE SHEETS OVERLAP
A

THIS PORTION OF OUTER WING

OF RIOGE TO EE TRIMMED OFF

INNER WING

FIG. 11.36 DETAILS SHOWING FIXING OF SERRATED ADJUSTABLE RIDGES

(SHEETS LAU) FROM LEFT TO RIGHT)

308
 SP62(S&T):1997

M?rSHROOMHEAD ROOFING
BlTlJMlNOUS
AND
INNERWING

J-TYPE HOOK BOLT

GLASS
MSANGLE GLAZING
GLAZINGGEE

F1c.Il.37 TYPICALNORTHLIGHTTWO-PIECEADJUSTABLERIDGE

c) in one piece should be secured to

Ridge finial the rafter by means of coach screws.
the ridge bolt through the crown. Two piece e) Eaves, may be closed by piece as in Fig. 1-I.40,
ridge finial should be secured to the ridge cap- above glazing and at the bottom of vertical
ping and roof sheeting by one bolt through each sheeting. Alternatively, the sheeting at eaves
wing of the fitting, in addition they should be may be bedded in mortar if the walls of the
secured to the ridge capping by one roofing building are of brick, block, or similar con-
bolt at the crown (see Fig. 11.38). struction.
4 Hip capping or hip tiles - The roofing sheet t1 For top edges and abutments, apron flashings
at hips should be cut to the required mitre and should generally be used (see Fig. 11.4 1) and
be close butted. The hip joint may be covered suitably fixed.
with two piece plain wind hip tiles (see Fig.
g) Special moulded pieces may be used for yen-
11.39), one piece socketted plain wing angular
tilators and lights and suitably fixed (see Fig.
hip tiles or heavy half round hip tiles. Alterna-
11.42, Fig. 11.43 and Fig. 11.44). If rooflights
tively, an apron type capping may be used over
are required, purpose made rootlights may be
the plain wing ridge should be secured through
used either as fixed skylights or as adjustable
the roof sheets to the hip runners, by one bolt
skylights (see Fig. 11.45 and Fig. 11.46).
on each side immediately above the socket. On
Alternatively, corrugated glass may be used.
timber roof, the hip tile should be secured to

, /-MUSHROOM HEAD
ROOFING BOLT

J-TYPE

ELEVATION
(BARGE BOARD REMOVED)

FIG. 11.38 TYPICALRIDGEFINIAL

309
SP 62 ( S & T ) : 1997

NOTE - Serrations,
asdesired,
should
becutatsitetofitcorrugations
athipslopes.
FIG. 11.39 TYPICALUNSERRATED ADJUSTABLE RIDGEFORHIPS

b.iS AkGLE PURLIN

FIG. 11.40 TYPICALEAVESFILLERPIECE

h) Other asbestos cement fittings may be used as b) Expansion joints shall be provided as in
corner rolls, barge-boards, etc (see Fig. 11.47) Fig. 11.48, for large roofs where there is likely
and secured to the structure or sheeting. to be some movements of the structure due to
variations in climate conditions.
5.4.4 Guttersand rain water pipes shall be fixed as per
IS 2527 : 1984.
c) The number and length of bolts, bituminous
5.5 Safety Precautions felt washers and galvanized iron washers shall - ‘,

a) No person other than workmen employed shall be as below:

be permitted access to any area over which
Situation No. of Bolts Length of
sheeting is being laid.
and Washers Bolts
b) Cat ladders of roof boards shall be used by men
working on roofs. 1. At horizontal SHORTBOLTS Depth of
laps of sheets; at The number of p u r 1i n + 7 5
6 ASBESTOS CEMENT SHEETS - SEMI-
CORRUGATED eaves with filler sheets in one mm
pieces; at ridges horizonta1
6.1 General
when sheets and course + two
All the provisions of 5 for corrugated sheets and its ridge pieces are
subclauses shall apply for fixing semi-corrugated screwed by the LONG BOLTS Depth of 3
sheets except as modified below: same bolt The number of purlin + 90
f
a) Fig. 11.28 is modified to suit semi-corrugated sheets in one mm
[:
sheet. course less one
k .
1 *
3‘10
& _,
t
 SP62(S&T):1997

Situation No. of Bolts Length of 4 The length of the mitre, when done, shall be
and Washers Bolts 15 mm and the width shall be equal to the width
-2. At eaves when Twice the num- Depth of of side lap.
pieces are not ber of sheets in purlin+75mm e) Typical semi-corrugated adjustable ridge and
used; at ridge one horizontal its fixings are as shown in Fig. 11.49 and
when sheets and course one Fig. 11.50 and typical plain adjustable ridge as
the ridge pieces in Fig. 11.51 and Fig. 11.52.
are not screwed Other modifications as needed by semi-
by the same bolt corrugation in Fig. 11.30 to Fig. 11.47 shall
3. At intermediate The number of Depth of be done.
purlins where sheets in one purlin+75mm
horizontal laps horizontal
do not occur course plus one

J-TYPE

SIDE CL
‘Tf
50 mm
APRON I
4

LEAN-TO ROOF1 j

STANCHION -

FIG. 11.4 1 TYPICALAPRONPIECE

SP62(S&T):1997

HOOK BOLT

MUSHROOM HEAD
ROOFING BOLT

REBUIRED ONLY IN
STORMY WIND REGION

ANGLE WELDED AT THE

BACK OF PRINCIPAL RAFT

VENTILATOR CURVE

k-TYPE .LOU’fRE

FIG. 11.42TYPICAL NORTHLIGHTCURVES

LOUVRE SUPPORT
MS ANGLE OR FLAT

r-w
/-
rm

I :

1 4410 Gl

WAc;UFPe
..__. .-...J
SECTION XX

LAPPING OF LOUVRES

FIG. 11.43TYPICAL ‘S’ TYPE LOUVRE

312
 SP62(S&T):1997

J-TYPE HOOK BO

ANGLE PURLIN

MAKE AN OPENI
IN THE SHEET

FMU!iiHFtOOM HEAD
ROOFMG BOLT

PLAN

FIG. 11.44TYPICAL~COWLTYPE VENTILATOR

l-1 m (NOM)
t-

FIG. 1I .45 TYPICAL ROOFLIGHT

313
SP62(S&T):1997

r MUSHROOM HEAD
ROOFING BOLT

/ROOFLIGHT

k WIRED GLASS

NORTHLIGHT AC SHEET
ROOF TRUSS
\
7
J rAC GUTTER I

FIG. 11.46TYPICALROOFLIGHT
USEDAS NORTHLZIGHT
GLAZING

IOOmm LAP
/-

BARGE
IF-
BOARD AT VERGE
OF THE ROOF

FIG. 11.47TYPICALDETAILSOFBARGEBOARDORCORNERPIECE(VIEW FROMEAVES)

 SP62(S&T):1997

J-TYPE HOOK
GI FLAT WASHER
BITUMINOUS FELT WA

SEMI-CORRUGATED SHEET

MS ANGLE PURLIN

NOTE -The end lap of expansion joints is thesame,asthatof theroofingsheets,thatis, usually150mm.If expansion
jointslap
betweenpurlinstheyshouldbe stitchedbyroofingbolts.

FIG. 11.48 TYPICALEXPANSION

JOINTFORSEMI-CORRUGATED
SHEETS

FIG. 11.49 TYPICALSEMI-CORRUGATED

ADJUSTABLE
RIDGE
SP62(S&T):1997

B
3
I EOGE OF RIDGE WING
TO BE TRlUMF.0 OFF-

ix YI i- SEMI-CORRUGATED SHEETS

OUTER WING OF RIDGE

J-TYPE SEMI-CORRUGATED

ENLARGED SECTION XX

FIG. 11.50DETAILSSHOWINGFIXINGOFSEMI-CORRUGATED
ADJUSTABLE
RIDGES

I-TYPE

FIG. 11S 1 TYPICALPLAINWING ADJUSTABLE

RIDGE

316
 SP62(S&T):1997

SECTION SHOWING ALTERNATIVE

FIXING ACCESSORIES

FIG. 11.52 TYPICAL ONE-PIECE PLAIN ANGULAR RIDGE

ANNEX PI
(Clause 1.2)
TIMBER FOR WOODEN SHINGLES

B-l QUALITY 7. Deodar (Cedrus deodura)

B-l.1 The wood should be durable, dimensionally 8. Star Apple (Chtysophyllum roxburghii)
stable, light in weight, with good insulating properties, 9. Cypress (Cupressus torulosu)
adequate strength, even grain and ability to take stains, 10. Thingan (Hopeu odorata)
paint or preservative. 11. Pyinma (Lagerstraemiu hypdecuu)
B-2 SPECIES 12. Pali (Paluquim elliptiem)
B-2.1 The following species of timber may be used 13. Chir (Pinus roxburghii)
for wooden shingles: 14. Kail (Pinus wullichiunu)
1. Fir (Abies pindrow)
15. Padauk (Pterocarpus dalbergiodes)
2. Mundani (Acrocarpusfraxinitolius)
16. Oak (Quercus lamellosa)
3. Haldu (Adina cordifoliu)
4. Semul (Bombay_ceiba) 17. Yew (Tuxus baccatu)

5. Didu (B. Znsignea) 18. Teak (Tectona grundis)

6. Indian Chestnut (Custunopsis spp) 19. Irul (Xyliu dolubriformis)

PART 3 SHELL ROOFS (CURVED ROOFS)

1 GENERAL 1962 are chosen commonly for covering large clear

t column free areas, such as, factory buildings,
1.1 Shell roofs are cast in-situ or precast; they can be godowns, power stations, garages, island platforms of
of single curvature or double curvature. Reinforced railway stations, stadia, etc. Precast concrete doubly
concrete in-situ concrete shells covered by IS 2204 : curved shells, covered by IS 6332 : 1984 also serves
SP62(S&T):1997

similar end uses. Shell units are effectively used for cal shells, Shells of evolution, Translation shells, etc.
replacing solid slabs; they may be used in conjunction Figures illustrating those are given in IS 2204 : 1962.
with precast joists or battens or planks; or as waffle
shells by providing in-situ ribs in two directions. The 2.3 Design
shells are lighter in weight and save reinforcing steel
Design shall be according to relevant IS Codes. The
and concrete. It eliminates the use of shuttering fully
thickness of singly-curved shells shall not however be
and scaffolding partially. The sizes of shells are chosen
less than 5 cm; it is the usual practice to thicken the
depending or handling facility. But shell construction
shell near the edges and the traverses. The thickness of
is a specialized job and the designers specifications
doubly-curved shells shall be not less than 4 cm; this
should be adhered to.
thickness is adequate, as shells of double curvature are
2 REINFORCED CONCRETE SHELL not developable and hence are more resistant to buck-
ROOF CAST IN-SITU ling; more over flexural stresses are small. End frames
or traverses are provided to preserve the shape of the
2.1 Shell Dimensions
shell; it may a solid diaphragm, an arch rib, a portal
a>Chord width (see B of Fig. 1,153) is the frame or a bowstering girder.
horizontal projection of the arc of the shell.
a) Reinforcement shall not be less than 5 mm in
b) Radius R, at any point of the skin in one of two diameter in the unthickened portion of the shell
principal directions in the case of cylindrical and shall not be greater than the following:
shells. For shells from 4 cm up to 10 mmdia
c>Rise (seefof Fig. 11.53) is the rise of the shell less than 5 cm thick
at any section in vertical direction between the For shells from 5 cm up to 12 mm dia
lower springing level and the highest level or less than 6-5 cm thick
apex of shell.
For shells from 6.5 cm and over 16 mm dia
4 Span (see L in Fig. 11.53) is the distance be- b) Concrete mix shall be as per IS 456 : 1978.
tween the centre lines of two adjacent end
frames or traverses. 2.4 Sequence of Construction
2.2 Type of Shells
Since the construction of shell is of utmost importance
There are many types of shells due to combination of for its stability, the sequence, framework, placing of
geometric shapes, such as, Barrel shells, Continuous reinforcement, etc, shall be carried out by an expert
cylindrical shells, Corrugated shells, Cylindrical contractor. For guidance IS 2204 : 1962 may be
shells, Multiple cylindrical shells, Northlight cylindri- referred to.

FIG. 11.53 S~NGLEBARRELSHELL

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 SP62(S&T):1997

3 PRECAST DOUBLY CURVED SHELL UNITS 3.2 Construction

3.1 Funicular shell units shall be cast as described in Reference may be made to IS 6332 : 1984.
IS 6332 : 1984.
NOTE - Since design and construction of shell structures is a
specialized job. reference may be made to specialised literature.

PART 4 FLAT ROOF FINISH - MUD PHUSKA

1 GENERAL shall be allowed to rot for a period of not

less than 7 days. During this period it shall be
1.1 Mud Phusku is a common type of insulating
pugged manually to get a homogeneous mass
course in the roof used in shot dry regions of the
free of lumps and clods. The wheat straw may
country, such as in Punjab, UP, Haryana, etc. where
be of any size since it would be broken to small
rainfall is not heavy. It is cheap, reasonably durable
size during the period.
and adds enough thermal insulation for maintaining
relatively comfortable temperature in the interior. Of The slump, when tested as per IS 1199 : 1959
course the reduction in temperature would be less than shall be about 70 mm. Alternatively, consisten-
what can be obtained from using polystyrene and other cy of mortar may be adjusted by taking it in a
factory made products. trowel and observing as to how it slides off the
face of the trowel. The mortar shall readily
2 MATERIALS slide off, but at the same time shall not be so
wet as to part into large drops before falling.
Mud Phuska layer by itself is not sufficiently
waterproof for the roof and it may be necessary 4 Cutback bitumen shall be prepared by adding
to provide beneath it a waterproofing layer or 20 parts of kerosene oil and one part of paraffin
membrane to be effective in this respect. Care wax to80partsof8OO/lOObitumen (see IS 217 :
shall also be taken while doing roof finish work 1988) melted on gentle fire. The mixture shall
to compact mud Plzuska layer to maximum be worked to a homogeneous mass.
density. e) Mud mortar used as bedding under brick tile
1) Soil mud Phuska shall be free from gravel layer shall be prepared in the same-manner as
and coarse sand of particle size greater mud plaster but without any addition.of fibrous
than 2 mm, vegetable matter and reinforcing material and binding material. The
KANKAR particles. The coarse material mud mortar may be used immediately without
shall not exceed 25 percent by mass. The any rotting period. The mortar shall be mixed
soil shall also be free from harmful and with 2 percent bitumen cut back by mass of dry
efflorescent salts. The plasticity index of soil and worked to a homogeneous mass.
the soil shall be between 10 to 15 percent.
9 LEEPINGplaster (GOBRI LEEPING) shall be
2) Generally soil suitable for brick making is prepared by mixing soil with equal parts of
suitable for mud Phuska also. The plas- cowdung and adding the required quantity of
ticity index will indicate a reasonable water to make a thin paste; soil used shall be
cohesive soil. Soil infested with white ants free from coarse sand and gravel. The mixture
shall not be used. shall then be worked into a homogeneous
mass. Five percent of cutback bitumen by mass
b) Soil for mud plaster and mud mortar shall be
free from vegetable roots, gravel and coarse of dry soil may be added to improve the water
sand of particle size greater than 2 mm. The proofing characteristics.
coarse material shall not exceed 10 percent by g) Brick tiles shall conform to IS 2690 (Part 1) :
mass and the soil shall be free from harmful 1993 and IS 2690 (Part 2) : 1992.
and efflorescent salts. The plasticity index
shall be between 10 to IS percent.
h) Cement shall conform to IS 269 : 1989 or
IS 455 : 1989 or IS 1489 (Parts 1 & 2) : 1991
C ) Mud plaster shall be prepared from soil or any other as specified.
prescribed in 2 (b). The dry soil shall be
reduced to fine powder and mixed with water
3 Sand and fine aggregate shall conform to
IS 383 : 1970. -- -
in a pit, adding wheatstraw 6 percent by mass
and cowdung 12 percent by mass. The mixture ok) Burnt clay pozzolana shall conform to IS 1344
1981.

319
L . .

SP 62 (US& T ) : 1997

m) Cement mortar for grouting shall be a 1:3 mix 4.3 Applying Mud Plaster
or any richer mortar as may be specified. i
3 PREPERATORY WORK
a>On the mud Phuska, a layer of minimum
25 mm thick mud plaster shall be laid; the
3.1 The slope of terrace shall be such that all rainwater plaster may be applied in single coat or two
can be drained off; preferably the slope shall be not coats of 15 mm and 10 mm; two coats are
less than 1 to 40. If the slope cannot be given in the preferable. Hair cracks if any shall be grouted
mud Phuska layer, part of the slope can be given in the with the binder material of LEEPING. The
sub-floor itself. surface level shall be checked.
3.2 The durability of the mud Phuska layer depends
b) When the mud plaster coating has dried, a thin
on how the protective layer, namely, the mud plaster coat, not less than 3 mm, of LEEPlNG shall be
or bricktiles are maintained free of cracks. applied. The surface shall be allowed to dry
3.3 Where there is no rainfall and there is very little and any hair carcks shall be grouted as before.
variation in temperature, paving with tiles may not be The LEEPING shall be finished with a trowel
necessary over mud Phuska layer. or float.
3.4 Waterproofing treatment (see Chapter 12) as
deemed necessary shall be done on the sub-floor. 4.4 Paving with Brick Tiles

4 LAYING OF MUD PHUSKA a>The brick tiles, where necessary, shall be laid
4.1 Preparation flat on a thin layer of mud mortar. The mud
mortar shall be used to the minimum extent to
The soil as described in 2 (a) shall be stacked in
give a level surface. Tiles shall be laid close
requisite quantities in about 300 mm high stacks over
together with a thickness of joint between
a level ground and the tqp surface divided into suitable
6 mm and 15 mm; it shall be ensured that the
compartments by bunding. The estimated quantity of
mud mortar rises in the joints. The brickwork
water corresponding to the optimum moisture content
shall be allowed to dry for 24 h before grouting
shall be added about 12 h before the use and allowed
the joints. Care shall be. taken at the time of
to soak. The stacks of soil shall then be worked up with
grouting that the tiles are not displaced.
spades and hands to ensure proper distribution of mois-
ture at the time of use of soil. b) While grouting with the 1:3 mix, ensure that all
joints are filled. Allow the mortar to set for
NOTE - Generally soil of this type will require an optimum
moisture of about 145 l/m”. Soil suitable for good compaction 12 h before pointing, if it is to be done.
should contain that much quantity of moisture, which when
moulded with hand to the shape of form, just retains its form.
c>Check evenness and desired slope.

4 Cure the surface for not less than 7 days.

4.2 Laying
e) The junction between the roof finish and
a) The mud Phuska shall be laid loose to a thick- parapets shall be treated as described in
ness of not more than 150 mm. It shall be Chapter 12 on waterproofing of flat roofs in
brought to proper slope and then rammed buildings.
manually with wooden THAPPIES so as to
4.5 Maintenance
obtain maximum density. The final thickness
should not be less than 100 mm. Annual maintenance is required when the roof is
finished~only with LEEPING; in such case theLEEP-
b) The surface shall be allowed to dry for a period
ING shall be applied as necessary before monsoon.
of not less than 24 h. If any cracks appears, they
After monsoon, grass if any shall be removed.
should be filled with a grout of the binder
material that is used in the LEEPZNG (usually
GOBRI)

PART 5 THATCHED ROOFS

1 THATCHING OF ROOF in huts and fire occurs very often in huts. It spreads
very fast and conflagration results in great loss to life .
1.1 General and property. The main thatch materials are reeds,
Phoons, palmyrah, coconut, rice paddy. Treatment for
Thatch roof is made of highly combustible and easily rendering thatch fire retartdant is a measure of tire
ignitable materials. In rural and slum areas pedple live protection.

320
 SP62(S&T):1997

1.2 Materials 3) SUTLI, 1.5 kg;

4) Stabilized mud, 0.35 cubic metre; and
1.2.1 For Fire Retardant Treatment
5) Wheat straw 25 kg.
4 Cutback bitumen of 80/100 to IS 217 : 1988. Average thickness is 110 mm, as in Reed thatch.
b) Cutback made by mixing 80/100 bitumen with c) Coconut leaves thatch - This type of thatch
kerosene oil in the ratio of 5:l requires the following for an area of roof of
(Bitumen:Kerosene). The mixture should be 9m2:
stirred to ensure thorough mixing.
1) Coconut (Cadjan) leaves, 65;
cl Soil shall~have a clay content of 25-35 percent 2) Bamboos, 20 (3.3 m long and 25 mm
1) Mud shall be made with soil and wheat- diameter;
straw or rice paddy, cut to 50 mm length SUTLI, 1 kg;
3)
roughly; keep it wet for a week and knead
4) Stabilized mud, 0.35 cubic metre;
daily.. The general proportion of mix is to
add about 16 kg of straw to 0.25 cubic 5) Wheat straw, 25 kg; and
metre of soil. 6) One wooden pole 100 mm dia and 3.3 m
long.
2) To stabilize the mud, add cutback bitumen
(about 2 to 4 percent) and mix thoroughly. Average thickness 60 mm, made up of 25 mm each
thatch and top mud plaster and 10 mm mud plaster on
4 One part of molten bitumen may be added to 2
parts of kerosene oil and stir it till a bottom.
homogenous water proof solution,is formed. d) Rice paddy thatch - This type of thatch
requires the following for a roof area of
e>GOBRI shall be made with cowdung and soil
about 9 m2 :
mixed in equal proportion and then add cut-
back bitumen at the rate of 16 kg for 0.25 cubic 1) Rice paddy, 136 bundles (each bundle of
metre. 1 kg);
Lime wash be prepared mixed with animal 2) Bamboo, 23 (3.3 m long and 25 mm
glue and ultramarine blue for whitening. diametre);
3) SUTLI 1 kg;
1.2.2 For all Types of Thatches Stabilized mud, 0.35 cubic metre;
4)
a) ReedJPhoons) thatch - For an area roughly 5) Wheat straw, 25 kg; and
9 m2 of roof the following are required: 6) A wooden pole, 100 mm in dia and 3.3 m
1) Reeds (Phoons), 130 bundles of 500 g and long.
1 m long; Average thickness would be 150 mm of thatch plus
2) Bamboo, 20 numbers, 50 mm dia and 25 mm mud plaster on top and 10 mm on bottom
3.3 m long; surface.
3) SUTLI, 1 kg; 1.3 Fire Retardant Treatment
4) Bitumen stabilized mud, 0.35 cubic metre;
Fire retardant and water repellant treatment is done as
5) Wheat straw, 25 kg; and
below:
6) Bhind (SARKANDA), 3 bundles, each
300 mm long and 400 mm thick. a>The stabilized mud is applied on top of the
thatch as plaster, in two stages, each 10 mm
The average thickness would be 75 mm thatch
thick and allowed to dry. For the bottom one
plus 25 mm mud plaster on top and 10 mm on
coat is enough. Then GOBRI is applied and
bottom surface.
allowed to dry. Finally two coats of either a
b) Palmyrah leaves thatch - ‘This type of thatch lime wash or simple GOBRI is applied. Thus
requires the following for an area of roof of the thatch becomes fire retardant and water
9 m2: repellant.
1) Palmyrah leaves 90; b) Addition of bitumen makes the thatch rot resis-
2) Bamboos, 20 (3.3 m long and 50 mm in tant and durable even up to 10 years.
diameter);

321
As in the Original Standard, this Page is Intentionally Left Blank
 CiiIAPTER1.2

DAMP-PROOFINGANDWATERPROOFING
 CONTENTS

1 GENERAL 2.2 Materials

2.3 Lime Concrete
2 ~GENERAL WORKFOR
PREPARATORY DAMP-PKOOF-
2.4 Laying
INGAND WATERPROOFING
2.5 Finish
2.1 General
3 BITUMEN
FELT
2.2 Preparatory Work
2.3 Planning in Relation to Sub-Soil Drainage 3.1 General
2.4 Preparation of Surface 3.2 Materials
3.3 Waterproofing Treatment
PART 1 DAMP-PROOFING 3.4 Concrete and Masonry Roofs, Flat or Sloping
1 GENERAL 3.5 Timber Roofs, Sloping
3.6 Laying of Felt
1.1 Preparatory Work
4 BITUMENMASTIC
2 BITUMENFELTTREATMENT
4.1 Materials
2. I Materials
4.2 Preparatory Work
2.2 Damp-Proofing Treatment above Ground 4.3 Number of Coats and Thickness
Level
4.4 Movement of Joints
2.3 Damp-Proofing Treatment below Ground 4.5 Laying of Bitumen Mastic
Level
2.4 Laying of Damp-Proofing Treatment 5 POLYETHYLENE
FILM
3 BITUMENMASTICTREATMENT 5.1 General
5.2 Material
3.1 Materials 5.3 Types of Waterproofing Treatment
3.2 Damp-Proofing Treatment above Ground
5.4 Laying
Level
3.3 External Tanking 6 GLASSFIBRETISSUEREINFORCED
BITUMEN
3.4 Internal Tanking 6.1 General
3.5 Remelting of Mastic 6.2 Materials
3.6 Thickness and Method of Laying 6.3 h-situ Waterproofing Treatment of Roofs
4 GLASS FIBRE TISSUE REINFORCEDBITUMEN 6.4 Laying
TREATMENT 7 WATWPROOFING OF UNDERGROUND
RESERVOIRS
4.1 General AND SWIMMING POOLS
4.2 Materials 7.1 General
4.3 In-situ Damp -Proofing Treatment 7.2 Design Features
4.4 Laying In-situ Treatment 7.3 Materials
5 WATERPROOEING AND DAMP-PROOFING
OF WET 7.4 Waterproofing Treatment
AREASIN BUILDING 7.5 Construction Details
5.1 General 8 SILICONE
BASEDWATERREPELLENT
5.2 Recommendations 8.1 General
PART 2 WATERPROOFING 8.2 Materials
8.3 Preparation of the Surface
1 GENERAL 8.4 Application of Repellent
2 LIMECONCRETE
WATERPROOFED
FINISH ANNEXA TEST FORMEASURINGOF WATER VAPOUR
2.1 General TRANSMISSION
OF POLYETHYLENE
FILM
 SP62(S&T):1997

CHAPTER 12

DAMP-PROOFING AND WATERPROOFING

1 GENERAL 2 GENERAL PREPARATORY WORK FOR
DAMP-PROOFING AND WATERPROOFING
1.1 Damp-proofing of basements and floors and
waterproofing of roofs is necessary for protection 2.1 General
against entry of moisture either from ground capillary
Different types of damp-proofing and waterproofing
action or from rain water. These aspects are covered
materials are used in the building industry. In order to
by Indian Standards which can be grouped as below:
obtain satisfactory performance, it is essential that
a) General Prepamtoty Work -1s 3067 : 1988 prior to the application ofthese materials for the damp-
covering general details and preparatory work proofing and waterproofing treatment. special care has
for damp-proofing and waterproofing of build- to be taken regarding the design details and carefully
ings. preparing the building surface (sub-floor) for receiv-
b) Damp-Proqfing Treatment ing the treatment. Thus this is an essential adjunct to
IS 13182: 1991 Covering waterproofing and construction details of damp-proofing and waterproof-
damp-proofing of wet areas in ing treatment dealt with subsequently in this chapter
building both for Part 1 and Part 2, unless otherwise modified.

Is’ 1609 : 1991 Covering laying of damp-proof- 2.2 Preparatory Work

ing treatment using bitumen felts
a) Damp-proofing and waterproofing shall be
IS 7198 : 1974 Covering damp-proofing using taken up only when the sub-soil water level~is
bitumen mastic at its lowest, that is, in the dry season.
IS 9918 : 1981 Covering in-situ waterproofing b) For efficient design and construction of the
and damp-proofing treatments treatment the following particulars among
with glass fibre tissue reinforced others would be of use:
bitumen
1) Anticipated highest water level;
c) Wuterproofing Treatment
2) Anticipated water level in rainy season;
IS 3036 : 1992 Covering laying of lime concrete Shape of roof, that is. flat, sloping or
3)
for a waterproofed roof finish curved;
IS 1346 : 1991 Covering waterproofing of roofs 4) Type of roof;
with bitumen felts
5) Type of thermaLinsulation treatment, that
IS 4365 : 1967 Covering application of bitumen is, mud Phuska or polystyrene slab, etc;
mastic for waterproofing of roofs Projections through roofs;
6)
IS 7290 : 1979 Covering recommendations for Drainage arrangement;
7)
use of polyethylene film for
8) Intensity of rainfall; and
waterproofing of roofs
9) Drawings as needed.
IS 9918 : 1981 In-situ waterproofing and damp-
c) For effective damp-proofing of basements the
proofing using glass fibre tissue
following be considered:
reinforced bitumen
1s 6494 : 1988 Covering waterproofing of 1) Construction joints, as far as possible,
shall be avoided;
underground water reservoirs and
swimming pools 2) In case expansion joints are necessary,
adequate supports shall be provided at the
IS 12054: 1987 Covering application of silicone
vertical and horizontal joints to support
based water repellent
the damp-proofing treatment from burst-
1.2 The materials generally used for damp-proofing ing under water pressure;
and waterproofing are lime concrete, bitumen felts, The wall faces, as far as possible, shall be
3)
bitumen mastic, glass fibre reinforced bitumen and free from obstruction toenablecontinuous
polyethylene film; silicone based water repellents are laying of damp-proofing treatment;
also coming into vogue. However, whatever be the
4) Damp-proofing shall be external for ali
new materials, the construction practices would large-
new buildings. Sufficient working space
ly be as reflected in the standards for damp-proofing
shall always be provided which shall in no
and waterproofing.

325
SP62(S&T):1997

case be less than 600 mm suitably there is any standing water it shall be drained,
protected all-round the basement; and out. If percolation persists, dewatering by
5) In the ca& of reinforced concrete work, well-point system may be done. Where it is not
dowels shall be used on underground possible to employ well-point system for
structures subject to sub-soil water pres- dewatering and the pressure of water during
sure, otherwise the damp-proofing gunite the dry season is negligible, it is possible to
may be blown on the surface on which it carry out the work by pumping the water out,
is applied. with a pump located on the floor. In this case
the damp-proofing treatment shall be carried
d) For waterproofing of roofs, its effectiveness
out both on the floor and walls. When the
will depend on the following:
treatment is completed, the pump shall be
1) The expansion joint in the roof shall be so removed, and damp-proofing done over the
designed as not to impair the effectiveness
area occupied by the pump, after suitably
of the treatment; the joint may be treated plugging the area with cement concrete.
with non-absorbant, compressible, non-
brittle and watertight sealants; and NOTE - For dewatering and lowering of water table by
well point method reference
maybe madeto IS 9759 :
2) Adequate openings shall be provided to 1981.
drain water from the roof; the design shall
be such that waterproofing treatment may 2.3.2 Time Schedule
be easily applied to the openings.
In damp-proofing operations of basement due con-
2.3 Planning in Relation to Sub-Soil Drainage sideration shall be given to economical utilization of
pumps and other equipment by co-ordinating the
2.3.1 Site and Underground Drainage
activities of the general contractor and the damp-
4 The site shall be drained during the entire proofing contractor.
period of laying the damp-proofing treatment.
2.4 Preparation of Surface
Typical arrangement of dewatering in some
casesisshowninFigs.12.1,12.2,12.3and12.4. 2.41 Damp-Proofing of Basement
b) For existing structures, internal tanking for
damp-proofing has per force to be adopted. a) For treatment above ground level-The rise of
Damp-proofing treatment has to be taken up moisture due to capillary action has to be dealt
when the water is not there in the basement; if with suitably.

STRUCTURAL DETAILS
SAME AS IN FIG.12.6

ElUND TO PREVENT
BACK FLOW

FOOT VALVE

L SUMP

PLAN

FIG. 12.1 ARRANGEMENT

SHOWINGDEWATERING
OFSMALLBASEMENTBY DRAINSAND PUMPS

326
 SP62(S&T):1997

BUN0 TO PREVENT
BACK FLOW

STRUCTURAL DETAILS
SAME AS IN FIG.12.6

SUCTION PIPE

LAND DRAIN2 \FOOT VALVE

SECTION XX

LAND DRAIN

TAR FELT OR
SIMILAR COVER
FOR LAND DRAIN

-I- --tr,,,,
kOLLECTING
DRAIN
X
PLAN

FIG. 12.2 ARRANGEMENTSHOWINGDEWATERINGOFLARGE AREAS WHEREIT IS NECESSARYTO

DEWATERUNDER THEFLOOR

CEMENT CONCRETE
OR BRICK FLAT

R f’ FLOOR7
7
\ /
r DAMRPROOF TREATMENT

ILAR
LAND DRAIN
FILLED WITH AIN
LOOSE BALLAST

FIG. 12.3 CROSS SECTION OF LAND DRAIN WITH DETAILS

1) In places where rise in sub-soil water is tion of lime concrete treatment which shall 1

severe, typical details of treatment are as act as a plastering.

given in Fig. 12.5. The mortar bed on 2) When a horizontal damp-proofing treat-
which the damp-proofing treatment is to ment has to be carried over to a vertical
be laid shall be levelled and made free face, a cement mortar (1 : 4) fillet 75 mm
from projections liable to cause damage to in radius shall be provided at the junction.
the damp-proofing treatment. The damp- Both the horizontal and vertical surfaces
proofing treatment shall cover the full shall be finished smooth.
thickness of wall and shall not be set back
3) For residential buildings, a cement mortar
from wall face for pointing. In the case of
(1 : 4) or 1 : 2 : 4 concrete 12 mm thick with
lime terracing, at the junction of roof and
waterproofing compound (see IS 2645 : 1975)
the parapet, a cavity shall be left for inser-
added may be laid below the course of brick.

327
SP 62 ( S & T ) : 1997

SECTION XX

FIG. 12.4ALTERNATEARRANGEMENTSOFDEWATERINGFOR LAYINGDAMP-PROOFTREATMENTIN

BASEMENTWHERESPACE IS RESTRICTED

FLOOR FINISH
LIME OR CEMENT CONCRETE
BRICK SOLING
rDAMP PROOF TREATMENT

ED EARTH

L 75 mm LEAN CEMENT CONCRETE

SMOOTH FINISHEO
CEMENT CONCRETE FILLET

12.5A
- 1

FLOOR FINISH

LIME OR CEMENT CONCRETE

FILLING UNDER FLOOR

P PROOF COURSE IN CEMENT

TAR l:L, 12mm THICK WITH
ER PROOFING COMPOUND OR
ENT CONCRETE 1:Z:L

12.5B
FIG.12.5DAMP-PROOF TREATMENTABOVE GROUND LEVEL FORNEW BUILDING

328
 SP62(S&T):1997

b) For treatment below ground level roughened as required. For vertical damp-
1) For internal tanking of existing buildings proofing to be laid continuous with
the vertical walls shall be roughened for horizontal one, a fillet 75 mm radius of 1:4
proper grip; the floor shall be cleaned and cement mortar shall be provided.
levelled; and a fillet of cement mortar c>Gunite work -- Guniting may be done (see
(1 : 4) 75 mm in radius may be provided Chapter 5) for damp-proofing of both masonry
at the junction between vertical land and concrete surfaces both below and above
horizontal faces. ground level. The surfaces shall be prepared
2) For external tanking of new buildings, by removing all loose and disintegrated
where space is available for excavation, material cleaned by compressed air and water;
details are as given in Fig. 12.6, where the concrete surfaces may also be roughened
space for excavation is limited, the exter- and the joints in masonry walls be raked to a
nal protective wall shall be constructed depth of 12 mm.
first and internal face plasteredevenly but
rough; details are as in Fig. 12.7. The 2.4.2 Waterproojhg of Roofs
damp-proofing treatment shall be con-
The perparations, where necessary, apply to the use of
tinuous over the wall and the floor; a space
bitumen felts, bitumen mastic, lime concrete, guniting,
of around 100 mm should be left between
use of films, etc.
the vertical external protective wall and
internal protective wall, which shall be 2.4.2.1 Preparation of concrete and masonry roofs
grouted after laying of damp-proofing
treatment. a) Well defined cracks, other than hair line cracks
3) For external tanking of new building a in the roof, shall be cut to a ‘V’ shape, cleaned
base slab of lean cement concrete rendered and filled flush with cement sand slurry or with
to a smooth surface finish shall be con- cold applied bituminous caulking compound
structed on the floor of the excavation. conforming to IS 1580 : 1991. The roof sur-
The slab shall project 250 mm beyond the face shall be regraded and cured prior to
outer faces of the structural walls when application of waterproofing treatment.
completed. The exterior of the structural b) The surface of roof and related parts to receive
w-all shall be true and free from the treatment shall be cleaned of all foreign
protrusions, but shall be smooth or matter by wire brushing and dusting.

r.
SPACE TO BE CEMENT DAMP PROOF
GROUTED TREAT MEN17

OUTER
~PROTECTIVE
WALL

LBASE SLAB OF
LEAN CEMENT CONCRETE
$N$ET E

NOTE -Sequence of work.

A - Base slab B - Horizontal damp-proofing treatment
C~- Brick flat or cement concrete (1:3) D - Structural walls and floor
E - Vertical damp-proofing treatment on outside F - Outer protective walls
faces of structural walls .
.
FIG.12.6 TYPICALDAMP-PROOFTREATMENTFORBASEMENTINNEWBUILDINGSUNDERCONSTRUCTION

329
SP62(S &T):1997

TO ~400mm THICK
OUTER PROTECTIVE WALL DAMP PROOF
ON DEPTH TREATMENT-I

SPACE TO BE
CEMENT GROUTED

L R75mm BASE SLAB OF

CEMENT
LEAN CEMENT CONCRETE
CONCRETE
f ILLET

NOTE - Sequence of work.

A - Base slab B - Outer protective wall

C - Horizontal damp-proofing treatment D -Vertical damp-proofing treatment on the inside of
outer protective walls
E - Brick flat or cement concrete I:3 F - Inner protective walls
G - RCC structural wall or floor thickness and reinfor-
cementwill be designed according to the depth
and maximum water pressure

FIG. 12.7ALTERNATEDAMP-PROOFTREATMENT
FORBASEMENTINNEW BUILDINGS UNDER CONSTRUCTION

c) In case of lime concrete treatment, the struc- f) In case of parapet walls over 450 mm in height,
tural roof surface shall be finished rough to typical details are as given in Fig. 12.9 A; in
provide adequate bond. case of low parapet wall typical details are as
4 Drain outlets shall be suitably placed with in Fig. 12.9 B. In case of existing RCC and
respect to roof drainage to prevent accumula- stone paparpet walls, typical details are as in
tion of water. Masonry drain mouths shall be Fig. 12.10.
widened 2.5 times the dia of the drain, and NOTE- Regarding thejunction of parapet wall and roof,
rounded with cement mortar (I:4). For cast improved treatment is as shown in Fig. 12.I 1.
iron drain outlets, a groove shall be cut all g) At the drain mouths fillet (see Fig. 12.9A and
round to tuck the treatment. 12.9 B) shall be suitably cutback and rounded
4 -For projections or pipes passing through a roof, off for easy application of the treatment and
treatment should be typically as shown in’ig. 12.8. easy flow of water.

BITUMEN GROUT
BITUMEN GROUT METAL COLLAR
CEMENT CONCRE MElAl_ COLLAR
ANGLE FILLET
CEMENT CONCRETE
ANGLE FILt_ET

110

TUMEN FELT

12.8A Projecting Pipe on Flat Roof 12.88 Projecting Pipe on Sloping Roof

FIG. 12.8 TYPICAL WATERPROOFING TREATMENT WHEN A PIPE PASSES THROUGH A CONCRETE ROOF

330
 SP62(S&T):1997

PARAPET WALL

CHASE FILLED WIT” ANGLE FILLET WITH

CEMENT MORTAR (I :4) CEMENT CONCRETE

RCC ROOF

12.9A Parapet Wall over 450 mm in 12.98 Parapet Wall 450 mm or Less in
Height Height

FIG. 12.9 WATERPROOFINGTREATMENTOF JUNCTIONON ROOF AND PARAPETWA1 .L

/-COPING

rRCC OR STONE
/ PARAPET WALL

r L
BITUMEN

CONCRETE
FILLING

FILLET

BITUMEN

BITUMEN FELT

All dimensions
in millimetres.
FIG. 12.10DETAILS OF WATERPROOFINGTREATMENTIN PARAPETWALL WHERE
CUTTING OF GROOVE IS NOT POSSIBLE

7cl.z

FIG. 12.11DETAILS AT THEJUNCTIONOFTHE ROOF WITH WALL

(WHERE.SLATESTHEMSELVESARE USED FORROOF DRAINAGE)
SP 62 ( S & T ) : 1997

2.4.2.2 Preparation of timber roofs rounded or chamfered.

a>Qn boarded roofs where timber boards are not cl When a timber roof meets a vertical wall, a
tongued and grooved, the gap at joints‘ shall be timber fillet 75 mm x 75 mm shall be provided
caulked with hemp, hessian or other suitable at the junction. For timber walls, wooden
fibre impregnated with bitumen or some other moulding shall be used to secure and seal the
suitable filler. In case of boards joined by top edge of the bitumen felt at a height of
tongue and groove joints, it is necessary to 150 mm from the junction.
caulk the gaps, if any (see Fig. 12.12 for typical d) Where a projection or pipe passes through
details). timber roof typical treatment should be as
b) All the boards shall be nailed to minimize shown in Fig. 12.13.
curling. All-sharp edges and corners shall be

AULKED WITH HEMP

OR HESSIAN

CHASE FILL-ED WITH

EMENT MORTAR (1:4)

WOODEN FILLET TIMBER BOAR

BITUMEN FELT
DETAILS OF JOINTS
IN TIMBER BOARDING
TWO LAYERS OF
BITUMEN FELT WITH
ITUMEN IN BETWEEN

TIMBER BOARDING

CORNER

STONE CORBEL

FIG. 12.12 WATERPROOFINGTREATMENTOF TIMBER-ROOF

I
METAL COLLAR

FLAN
I

BITUMEN FELT COLLAR

COMMON AAFTER

L WOOOEN BOARDNG

FIG. 12.13 WATERPROOFINGTREATMENTOF SLOPINGTIMBERROOF WITH PIPE PROJECTING .

332
 SP62(S&T):1997

PART 1 DAMP-PROOFING

1 GENERAL b) For preparing the surface, cement mortar (1:4)

be laid with cement conforming to IS 269 :
t 1.1 Preparatory Work
1989 and sand to IS 2116 : 1980.
The provisions of preparatory work and other details
2.2 Damp-Proofing Treatment above Ground
given in 2 at the beginning of the Chapter shall apply.
Level
In order to provide continuity in tanking, provision of
openings for service, such as, pipes, cables. etc, in 2.2.1 The damp-proofing treatment for floors and for
walls or floors should be avoided. Where un- walls above ground level shall be in layers as described
avoidable, special treatment as given in Fig. 12.14 below. The bitumen primer, if prescribed, shall be first
shall be given. brushed qver the roof surface and allowed to dry;
generally 0.2 to 0.4 l/m2 is recommended.
Dewatering shall be continued during the laying of the
layers of damp-proofing materials until they have a) Forfloors (one layer offelt)
hardened and the surface has developed enough 1) Hot applied blown bitumen at the rate of
strength to resist full hydrostatic pressure. 1.5 kg/m*;
The surface on which the material has to be laid may 2) Hessian base self-finished felt Type 3,
be first sprayed with bitumen primer conforming to Grade 2 or glass fibre base Type 2, Grade
IS 3384 : 1986. II; and
3) Hot~applied blown bitumen at the rate of
1.5 kg/m2.
b) For walls (one or two layers offelt)
1) One or two layers of hessian base self
finished felt Type 3, Grade 2, or glass fibre
base felt Type 2, Grade II shall be laid
according to the life of the building using
the blown bitumen between the wall and
felt.
NOTE- Adopt one layer of felt for an expected life
of building up to 10 years and two layers for more
than 10 years.
.+.--_ -t
2.3 Damp-Proofing Treatment below Ground
Level

2.3.1 A multiple layer, that is, more than two layer

damp-proofing treatment shall be laid according to
either of the three methods described below. It may be
noted that fibre based self-finished felt in IS 1322 :
1993 is not recommended for use in basements.
a) Normal treatment (two layers of felt) “I

1) Primer (for vertical faces only j at the rate

of 0.27 l/m2;
2) Hot applied blown bitumen at the rate of
FIG. 12.14 TYPICAL ARRANGEMENTOF DAMP- 1.5 kg/m*;
PROOFINGAROUND A PIPETHROUGHAN OPENING 3) Hessian base self-finished felt, Type 3
Grade 2 or glass fibre base felt Type 2
2 BITUMEN FELT TREATMENT Grade II;
4) Hot applied blown bitumen at the rate of
2.1 Materials 1.5 kg/m2;
a) The bitumen felt shall conform to the require- 5) Hessian base self-finished felt, Type 3,
ments of IS l322 : 1993 and IS 7193 : 1974; Grade 2 or glass fibre base felt, Type 2
bitumen primer shall conform to IS 3384 : Grade II; and
1986; blown bitumen shall conform to 6) Hot applied blown bitumen at the rate of
IS 702 : 1988~of Grades 85125 or 90/l 5. I .5 kg/m2.

333
!SP62(S&T):1997

b) Heavy treatment (three layers offelt) and brushed clean of dusting materials and laid
Primer (for vertical faces only) at the rate flat on a level dry and clean surface; then it may
1)
of 0.27 l/m2; be rolled up.

2) Hot applied blown bitumen at the rate of b) The laying of felt shall commence on the floor
1.5 kg/m’; first and shall be completed before it is applied
to the wall. Hot bitumen is poured in front of
3) Hessian base self-finished felt, Type 3
Grade 2 or glass fibre felt, Type 2, Grade II; the rolled up felt on the floor to the full width
of felt. The rolled felt is now gradually unrolled
4) Hot applied blown bitumen at the rate of
with aslight pressure to squeeze out the excess
1.5 kg/m*;
bitumen.
5) Hessian base self-finished felt Type 3,
Grade 2, or glass fibre base felt, Type 2 cl After the whole floor is thus covered and over-
lapping joints properly sealed, the felt is laid
Grade II;
on the vertical face in a similar manner. In this
6) Hot applied blown bitumen at the rate of
case the roll of felt is held at the floor level and
1.5 kg/m*;
then gradually unrolled up the wall face as hot
7) Hessian base self-finished felt, Type 3 blown bitumen is poured between the roll and
Grade 2, or glass fibre base felt, Type 2 the wall face. The minimum overlap shall be
Grade II; and 100 mm both at sides and ends.
8) Hot applied blown bitumen at the rate of
4 The subsequent layers of felts shall break joint
1.5 kg/m*. midway between the joints of the layer beneath
c) Extra heavy treatment flour layers offelt) it.
1) Primer (for vertical faces only) at the rate 3 BITUMEN MASTIC TRE;ATMENT
of 0.27 l/m’;
3.1 Materials
2) Hot applied blown bitumen at the rate of
1.5 kg/m*; The bitumen mastic shall conform to the requirements
3) Hessian base self-finished felt, Type 3 of IS 5871 : 1987; bitumen primer shall conform to
Grade 2, or glass fibre felt Type 2 Grade IS 3384 : 1986.
II; 3.2 Damp-Proofing Treatment above Ground
4) Hot applied blown bitumen at the rate of Level
1.5 kg/m*;
The damp-proofing treatment shall be laid across the
5) Hessian base self-finished felt, Type 3
full thickness of walls excluding plaster or each of the
Grade 2 or glass fibre felt, Type 2 Grade
base of cavity walls shall not be set back for pointing.
II;
The damp-proofing in the wall shall be continuous
6) Hot applied blown bitumen at the rate of with the layer of bitumen mastic in adjacent floors; and
1.5 kg/v’; where necessary, a vertical damp-proofing course
7) Hessian base self-finished felt, Type 3, shall be provided on the inner surface of the wall as
Grade 2 or glass fibre base felt, Type 2 shown in Fig. 12.15.
Grade II;
8) Hot applied blown bitumen at the rate of
1.5 kg/m’;
9) Hessian base self-finished felt, Type 3
Grade 2 or glass fibre base felt, Type 2
Grade II; and
10) Hot applied blown bitumen at the rate of
1.5 kg/m*.
2.4 Laying of Damp-Proofing Treatment
2.4.1 General
The damp-proofing treatment shall be continuous
throughout and the overlap of joints in felts, wherever
they exist, shall be correctly made.
2.4.2 L,aying of Felt
FIG.12.15 TYPICALARRANGEMENTOF
The felt shall be laid as mentioned below:
CONTINUOUSDAMP-PROOFINGIN~ALLAND
a) The felt shall be first cut to the required lengths ADJACENTFLOOR

334
-_.. .__.- . .._ -

SP62(S&T):1997

3.3 External Tanking and the loading coats have been hardened as
shown in Fig. 12.17.
The following points shall be kept in view for exter-
nally applied tanking: 4 As in external tanking, a protective layers of
screed should be laid and then the structural
4 The working space outside the walls may be floors and walls laid.
not less than 0.6 m.
b) The base concrete of 100 mm in thickness shall
be structurally sound; it shall be extended at OUTER WALL

least 150 mm beyond the edges of wall to

STRUCTURAL FORM
permit angle fillet to form at the junction of
horizontal and vertical damp-proofing (see
OTECTIVE SCREEO7
Fig. 12.16).
_..- -
RllUMEN MASl
I /- ANGLE FILLET, /

LEAN EASE
CONCRETE

STRUCTURAL

L HARD .
WORKING PLATFORM SUCH

FIG.12.17 INTERNALLYAPPLIEDTANKING

3.5 Remelting of Mastic

Remelting shall be done at site in a mechanical mixer;

the temperature of mastic shall not exceed 2OO’C
ANGLE
FILLET
/“AR0 WoRilNG PLATFORM S”i” AS during remelting. Blocks of bitumen mastic shall be
RUBBLE SOLING, RAMMED EARTH,ETC
broken into pieces and then stocked in layers first
round the sides and then inwards towards the centre of
FIG. 12.16 EXTERNALLYAPPLIEDTANKING the mixer. The charge shall be gradually heated to
about 200°C and when the mastic has attained a molten
c) As soon as the horizontal layer of mastic condition, it shall be agitated continuously to ensure a
asphalt has been laid, it shall be covered with uniform consistency. The duration of heating shall be
a screed of cement and sand 50 mm thick, to such that the properties of bitumen are not impaired.
prevent damage. The horizontal coat of struc-
tural slab shall be laid as quickly as possible. 3.6 Thickness and Method of Laying
The I50 mm offset structurally protected by
the screed. 3.6.1 Thickness

4 Immediately after the vertical damp-proofing Bitumen mastic shall be applied in one or three coats
bitumen mastic is laid, the outside of the wall as stated below to all surfaces, whether sloping,
shall be protected against damage by erection horizontal or vertical. The thickness shall be as
of a brick wall. follows:
3.4 Internal Tanking a>For walls and floors above ground level the
The following precautions shall be taken before apply- bitumen mastic shall be laid in one coat
ing bitumen mastic: minimum of 10 mm thickness.

a>A space of 300 mm outside the wall shall be b) For vertical surfaces and surfaces steeper than
provided as far as possible during excavation 30’ to the horizontal below the ground level,
to keep the wall dry at the time of laying the bitumen mastic shall be applied in three
bitumen mastic. coats to a total thickness of not less than
20 mm.
b) The base slab shall be provided with an even
surface and the walls shall be built to the full c) For horizontal surfaces and sloping surfaces
height before mastic asphalt laying is com- not steeper than 30’ to be horizontal below the
menced. ground level, the bitumen mastic shall be
applied in three coats to a total thickness of not
Earth shall not be filled outside the wall until
less than 30 mm.
three coats of vertical mastic have been applied
SP62(S&T):1997

3.6.2 Method of Laying be used as bonding material. The penetration of

bitumen shall be not more than 40 when tested in
Bitumen mastic, shall be applied thinly on any
accordance with IS 1203 : 1978. Bitumen primer shall
surface and a first coat in three coat treatment,
conform to IS 3384 : 1986.
so that it acts as an adhesive layer and also
prevents blowing. 4.3 In-situ Damp-Proofing Treatment
b) While laying a horizontal surface each coat
should be spread with a float evenly and 4.3.1 The following in-situ treatments above ground
uniformly over the previously prepared surface level is recommended:
to the recommended thickness. For laying on a) Normal duty treatment
a vertical surface, the first coat may be
1) Clean and prime the surface with bitumen
plastered with a metal trowel as evenly and
primer at the rate of 0.4 kg/m*;
uniformly as possible. The second and sub-
sequent coats may be applied with a wooden 2) First coat of hot applied bitumen at the rate
float to a uniform thickness; these coats should of 2.4 kg/m*, Min;
be applied as quickly as possible to prevent 3) First layer of glass fibre tissue; and
accumulation of dust or dirt between layers. 4) Second coat of hot applied bitumen at the
cl Blows entrapped in each coat formed by rate of 2.4 kg/m*, Min.
entrapped air or moisture during the laying b) Heavy duty treatment
shall be punctured and repaired while the
I to 4) As for items (1) to (4) of normal duty
asphalt is warm and before the next coat is
treatment of 4.3.1 (a);
applied.
5) Second layer of glass fibre tissue. This
3.6.3 Chases layer of glass fibre tissue shall be perpen-
The top of the vertical bitumen mastic shall be turned dicular to the first one; and
into a chase in the wall not less than 25 mm x 25 mm Third coat of hot applied bitumen at the
6)
unless it is being continued horizontally. rate of 2.4 kg/m*, Min.
3.6.4 Fillet 4.3.2 The following in-situ treatment below ground
Angle fillet not less than 50 mm wide shall be applied level is recommended:
in two coats at the junction of two planes forming an
a) Normal duty treatment
internal angle.
1) Bitumen primer at the rate of 0.4 kg/m*;
3.6.5 Construction Joints
2) First coat of hot ~bitumen at the rate of
Edges of the mastic already laid should be warmed 2.4 kg/m*, Min;
with hot asphalt and then cut out with a metal trowel First layer of glass fibre tissue;
3)
to remove any dust or dirt that may have collected.
4) Second coat of hot applied bitumen at the
The fresh mastic should be poured before the warmed
rate of 2.4 kg/m*. Min;
up surface of the joint cools off.
5) Second layer of glass fibre tissue; this
4 GLASS FIBRE TISSUE REINFORCED
layer shall be at right angles to the first
BITUMEN TREATMENT
layer; and
4.1 General Third coat of hot applied bitumen at the
6)
Glass fibre is more resistant to weathering and has rate of 2.4 kg/m*, Min.
come into use for waterproofing and damp-proofing of b) Heavy duty treatment
buildings.
I to 6) As for items (I) to (6) of normal duty
4.2 Materials treatment of 4.3.2 (a);
4.2.1 Glass Fibre Tissue 7) Third layer of glass fibre tissue. This layer
The glass fibre tissue shall conform to the require- shall be at right angles to the previous
ments given in Appendix A of IS 7193 : 1994. It shall layer; and
be a thin, flexible, uniformly bonded mat composed of 8) Fourth coat of hot applied bitumen at the
chemically reistant borosilicate staple glass fibres dis- rate of 2.4 kg/m*, Min.
tributed in a random open porous structure, bonded c) Extru heavy duty treatment
together with a thermosetting resin (phenolic type).
I to 8) As for items (1) to (8) of heavy duty treat-
The minimum weight of the tissue shall be 40 g/m2 and ment of 4.3.2 (b);
the nominal thickness shall be 0.5 + 0.1 mm. Fourth layer of glass fibre tissue. This
9)
4.2.2 Blown bitumen shall conform to IS 702 : 1988 layer shall be at right angles to the
or residual bitumen conforming to IS 73 : 1992 may previous layer; and

336
 SP62(S&T):1997

10) Fifth coat of hot bitumen at the rate of e) The minimum overlap of joints shall be
2.4 kg/m2, Min. 100 mm at both sides and ends. All overlaps
NOTES
shall be firmly bonded with bitumen.

1 The treatments (a), (b) and (c) are recommended for 5 WATERPROOFING AND DAMP-
normal, severe and very severe conditions respectively. PROOFING OF WET AREAS IN BUlLDING
2 A IO/15 mm thick coat of mastic asphalt conforming to
IS I 19.5 : I978 may bc included as an added protection over
5.1 General
the basement floor treatment, as deemed necessary.
Bathroom, kitchen, water closet and to lesser extent
3 The basement wall treatment should be protected with verandah, balconies and sunshades may be termed as
asuitable lining, as may be decided, against any possible
wet areas of buildings which are more vulnerable to
damage while backfilling.
water due to their functional requirements. These wet
4.4 Laying In-situ Treatment areas are one of the main source of leakage and damp-
ness in a building which leads to unhygienic conditions
4 Cut the required length at glass fibre tissue and affecting badly the health and comfort of the in-
roll it. habitants and seriously deteriorating the stability of the
b) Pour hot bitumen on the surface to the full building. The causes of leakage and dampness may be
width of roll and simultaneously embed the due to defective design, sub-standard material, im-
glass tibre into it. Proceed in this manner proper execution and incorrect usage by the occupant.
throughout the length of the floor. 5.2 Recommendations
C) After the whole floor has been covered, the IS 13 182 : 1991 gives detailed recommendations for
overlapping joints shall be sealed; the glass
identifying sources of leakage and dampness and their
fibre is laid on the walls in the same way. The
prevention in a systematic fashion for water closets,
roll of glass fibre is held at floor level, and then bathrooms, kitchen, open verandah, balconies and sun-
gradually unrolled as the hot bitumen is poured
shades, floor traps, pipe work, water tank, sanitary
between the roll and the wall face.
shaft and external wall. These recommendations are
4 The joints between successive layers of glass copiously illustrated w&h sketches.
fibre tissue shall be staggered. Reference may be made to IS 13 182 : 199 1 for details.

PART 2 WATERPROOFING

1 GENERAL is also used for waterproofed roof finish. The intro-

duction of pozzolanic materials, such as burnt brick
1.~1 The preparatory work and general details given in 2
pozzolana in lime concrete and compaction to-maxi-
at the beginning of the Chapter shall apply. Waterproof-
mum density enhances the waterproofing effect.
ing treatment to be efficient and lasting has to be carefully
carriedout from the time the surface is prepared to receive 2.2 Materials
the treatment, such as, membrane, film, lime concrete,
a) Lime-As far as possible Class C (fat lime) in
etc, to the finishing of the treated surface. Special atten- the form of hydrated lime conforming to
tion and strict supervision has to be paid to proper over- IS 712 : 1984 shall be used. Quick lime shall
lapping of joints, particularly in felts and film, treatment be slaked in accordance with IS 1635 : 1992.
around drainage openings in the roof and treatment of
b) Pozzolanic Material - Calcined clay poz-
parapets. The sticking of membrane to the roof by means
zolana shall conform to LP 40 of IS 4098 :
of hot bitumen also requires skill, if the job is to be done
19K3.
economically and to give good results. For roof fnish
reference~may be made to Chapter 11, after laying the c) Coarse aggregate shall be of broken brick
waterproofing treatment. (burnt clay) and conform to IS 3068 : 1986 01
natural stone aggregates conforming to
2 LIME CONCR-ETE WATERPROOFED
IS 383 : 1970.
FINISH
2.1 General
d) Water shall be clean and free from injurious
amounts of deleterious materials. Sea water
Lime concrete, apart from its use as a structural shall not be used. Potable water is generally
material in several situations in building construction, considered satisfactory for use.

337
2.3 Lime Concrete 2.4.3 If the surface becomes uneven during compac-
tion, the surface shall be pricked up and fresh lime
Limeconcrete shall be prepared as mentioned in Chap-
concrete spread and consolidated, adequate bonding
~ter 4 and IS 2.541 : 1991. Lime concrete shall be used
between old and new concrete should be ensured by
in the work within 36 h of its preparation if burnt clay
sprinkling requisite quantities of lime water (1 part
pozzolana is incorporated.
putty to 3 or 4 parts of water) with any of the solutions
NOTE- Addition of 12 kg of washing soap and 4 kg of alum in 2.4.4.
dissolved in water in each cubic metre of lime concrete will
improve the waterproofing quality of lime concrete. 2.4.4 During compaction by hand beating, the sur-
faces shall be sprinkled with lime water with a small
2.4 Laying portion of sugar solution or a solution of dry nuts of
2.4.1 Laying of lime concrete shall be started from a Termirlalia Chebula soaked in water for improving the
corner of the roof and proceed diagonally towards the waterproofing of concrete (see Notes). On completion
centre and other sides considering the slopes required of compaction, the mortar that comes up on top shall
for draining rain water smoothly. The average thick- be smoothened and if necessary sugar solution and
ness of lime concrete shall be not less than 100 mm; in lime putty may be added.
case the thickness is more than 100 mm, each layer NOTES
shall be not more than 100 to 125 mm. If the roof is
1 The sugarsolutionis preparedby mixing about3 kg ofjaggery
flat a slope of not less than 1 in 60 shall be given; in and 112kg of BAEL fruit to 100 litres of water by boiling.
areas of heavy rainfall a slope of 1 in 40 is recom-
2 The solution of Termiwliu Chebulrc (KADUKAf) my be
mended. The compacted of concrete layer shall not be
prepared as follows:
less than 50 mm. Dry nuts shall be broken to small pieces and allowed to soak in
water; about600 g of nuts,200 g ofjaggery and 40 I ofwater for
2.4.2 The lime concrete shall then be rammed with a
10 m* of work can be used. The solution is brewed for 12 to
rammer not more than 2 kg by mass and the surface 24 h; the resulting liqueur, after decantation, is used for work.
brought to the required evenness and slope; further Sometimes M&i, jaggery and hemp are also added while
consolidation shall be done by Thapis with rounded preparing and laying lime concrete.

edges; the beating shall be done at least for 7 days until 2.4.5 The lime concrete shall be cured for a minimum
the Thapis does not make an impression and rebound of 10 days or until it hardens.
readily when struck. The ramming and compacting
can also be done by a machine. Compaction shall be 2.4.6 Treatment of junction between roof finish and
done carefully at junctions with parapet wall. parapets is as shown in Fig. 12.18 and Fig. 12.19.

BRICK MASONRY

12 mm GAP PARTIALLY
FILLED WITH BITUMEN

STRIP (CONCAVE RIP (CONCAVE OR CONVEX)

LSTRUCTURAL ROOF
LSTRUCTURAL ROOF SLAB
SLAB
-LIME CONCRETE
,LiME CONCRETE

12.18A Structural Roof Slab and Lime 12.18B Structural Roof Slab and Lime Concrete Finish not
Concrete Finish Extending to the Full Width of Wall Extending to the Full Width of Wall
AT JUNCT~ONBETWEENLIMECONCRETEWATERPROOFEDROOFFINISH
FIG.12.18 TYPICALDETAILS AND
PARAPET WALL - Continued
338
 SP62(S&T):_l997

/.-COPING

BRICK MASONRY

STRIP (CONCAVE OR CONVEX)

LIME CONCRETE

12.18C Detail Showing Arrangement of Downpipe for

12.18A

SLOPE IN PLASTER

BRICK MASONRY

LIME CONCRETE LAID TO

Amin.SLOPE OF 1 IN 50 7

20 mm DEEP PLASTER
DRIP COURSE
I
12 mm WIDE GAP PARTIALLY
FILLED WITH BITUMEN FILLER

I
. .: a... ..’ -. . . ..a... ._.-..

STRUCTURAL ROOF SLAB -I\

CHAMFER PROVIDED IN PLASTER

\-CEMENT PLASTER WITH LIME

WASH OR KRAFT PAPER

PAINTED WITH HOT BITUMEN OF

APPROVE0 QUALITY SO/100 OR
EQUIVALENT @ l-7 kg/m2 BLENOED
WITH 0*008m3 OF COARSE SAND
PER SQUARE METRE OF AREA _--I

12.18D Junction of Roof with Parapet Wall (Alternate Arrangement)

FIG.12.18 TYPICALDETA~LSATJUNCTIONBETWEENLIMECONCRETEWATERPROOFED
ROOFFINISH AND
PARAPETWALL- Continued

339
SP62(S&T):1997

SLOPE IN PLASTER
/
PAINTED WITH HOT BITUMEN OF _.
APPROVED QUALITY Rn/lnn __ 0_R
EQUIVALENT @ 11.7 kg/m2 BLENDED
WITH @006 m3 OF COARSE SAND
PER SQUARE METRE OF AREA,
CEMENT

DOOR

12 mnl : GAP
PARTI FILLE
WITH 4EN F STRUCTURAL ROOF SLAB

KHURRA LO cm SOULIRE LAID

4ED
:3)

I-230-4 LCEMENT PLASTER WITH LIMk

WASH OR KRAFT PAPER
i RAIN WATER PIPE
12.18E Detail of Khurra for 12.18D
All dimensionsin millimetres.
FK_l2.18 TYPICAL DETAILS AT JUNCTION BETWEEN LIME CONCRETE WATERPROOFED ROOF FINISH AND
PARAPET WALL - Concluded

2.5 Finish
m /-RCC PARAPET
Roof finish should be as described in Chapter 11 using
-pi/; LIME CONCRETE FILLET burnt clay flat terracing tiles to IS 2690 (Part 1) : 1993
and IS 2690 (Part 2) : 1992. However in extreme
LIME CONCRETE TERRACING
conditions where there is considerable expansion and
contraction, two layers of tiles may be laid on the lime
concrete; the tiles should be joined by non-shrinking
impervious mortar by adding an integral waterproof-
ing admixtures or 5 percent engine oil and finished
neat.
To drain rainwater every 40 m* area of roof shall have
a 100 mm dia rainwater pipe or as in Table 3 of
12.19A JunctionBetween Roof Slab and RCC Parapet IS 2527 : 1984 depending on the rainfall intensities of
the locality.
3 BITUMEN FELT
RCC PARAPET
3.1 General
,-LIME CONCRETE FILLET
LIME CONCRE’IE TERRACING Bitumen felt is one of the materials used for
waterproofing of roofs. Waterproofing treatment with
bitumen felt is adopted not only in the case of buildings
and structures, but also in railway coaches, bus bodies,
etc.
CE 3.2 Materials
Cl RAIN WATER SPOUT
4 Regarding of the roof surface shall be carried
out with suitable cement mortar incorporating
clean, medium coarse sand or with a lime-
12.19B Details of Roof Slab and Rain Water Pipe SURKHI mortar or any other suitable material.
b) Bitumen primer shall conform to IS 3384 :
FIG. 12.19 TYPICAL DETAILS AT THE JUNCTION 1986.
BETWEEN LIME CONCRETE WATERPROOFED ROOF
FINISH AND RCC PARAPET WALL
c>Bitumen felt shall conform to IS 1322 : 1993
and IS 7193 : 1974.

340
 SP62(S&T):1997

d) Bonding material for use between successive 5) Hessian base self-finished felt, Type 3
felts and between roof surface and felt shall Grade 1 or glass fibre base felt, Type 2
conform to industrial blown type bitumen of Grade 1;
Grade 85125 or 90115 conforming to IS 702 : 6) Hot applied bitumen at the rate of
1988. For top dressing bitumen shall be 1.2 kg/m2, Min; and
industrial blown type to IS 702 : 1988 of Pea-sized gravel or grit devoid of fine sand
7)
penetration not more than 40 when tested in at the rate of 0.006 m3/m2.
accordance with IS 1203 : 1978.
OR
For vertical surfaces up to 1 m in height blown type
bitumen to IS 702 : 1988 of Grade 85/25 or 90/15 and 1) Primer at the rate of 0.27 1/m2, Min;
above 1 m Grade 115/15 may be used. 2) Hot applied bitumen at the rate of
1.2 kg/m2, Min;
3.3 Waterproofing Treatment
3) Fibre base self-finished felt, Type 2 Grade
In selecting a combination of layers and grades of felt 1 or Grade 2;
to be used, consideration shall be given to the type and
4) Hot applied bitumen at the rate of
construction of buildings, climatic and atmospheric
1.2 kg/m2, Min;
conditions and the degree of permanance required.
5) Fibre base self-finished felt, Type 2 Grade
3.4 Concrete and Masonry Roofs, Flat or Sloping 1 or Grade 2;
The following treatments are recommended: 6) Hot applied bitumen at the rate of
a) Normal Treatment - Five courses for 2.5 kg/m2, Min; and
moderate conditions: 7) Pea-sized gravel or grit devoid of fine sand
1) Primer at the rate of 0.27 l/m2,’ Min; at the rate of 0.008 m3/m2.
2) Hot applied bitumen at the rate of OR
1.2 kg/m2, Min;
Floating Treatment
3) Hessian based self-finished felt, Type 3,
Grade 1, or glass fibre base, Type 2, Grade
1) Fibre base bitumen saturated underlay,
Type 1;
1;
2) Hot applied bitumen at the rate of
4) Hot applied bitumen at the rate of
1.2 kg/m2, Min;
1.2 kg/m2, Min; and
3) Fibre base self-finished felt, Type 2 Grade
5) Pea-sized gravel or grit devoid of fine sand
1 or Grade 2;
at the rate of 0.006 m3/m2.
4) Hot applied bitumen at the rate of
OR 1.2 kg/m2, Min;
Floating Treatment 5) Fibre base self-finished felt, Type 2 Grade
1) Fibre base felt bitumen saturated under- 1 or Grade 2;
lay, Type 1; 6) Hot applied bitumen at the rate of
2) Hot applied bitumen at the rate of 2.5 kg/m2, Min; and
1.2 kg/m2, Min; 7) Pea-sized gravel~or grit devoid of fine sand
3) Fibre base self-finished felt, Type 2 Grade at the rate of 0.008 m3/m2.
1 or Grade 2;
c) Extra Heavy Treatment - Nine courses for
4) Hot applied bitumen at the rate of very severe conditions:
1.2 kg/m2; and
1) Primer at the rate of 0.27 l/m2, Min;
5) Pea-sized gravel or grit devoid of fine sand
at the rate of 0.008 m3/m2, Min.
2) Hot applied bitumen at the rate of
1.2 kg/m2, Min;
b) Heavy Treatment - Seven courses for severe Hessian base self-finished felt, Type 3
3)
conditions: Grade 1 or glass fibre base felt, Type 2
1) Primer at the rate of 0.27 1/m2, Min; Grade 1;
2) Hot applied bitumen at the rate of 4) Hot applied bitumen at the rate of
1.2 kg/m2, Min; 1.2 kg/m2, Min;
3) Hessian base self-finished felt, Type 3 5) Hessian base self-finished felt, Type 3
Grade 1 or glass fibre base felt, Type 2 Grade 1 or glass fibre base felt, Type 2
Grade 1; Grade 1;
4) Hot applied bitumen at the rate of 6) Hot applied bitumen at the rate of
1.2 kg/m2, Min; 1.2 kg/m2, Min;

341
SP62(S&T):1997

,?I Hessian base self-finished felt, Type 3 b) Heavy Treatment

Grade I or glass fibre base felt, Type 2
1) Fibre base self-finished felt, Type 2 Grade
Grade 1; 1, or hessian base felt, Type 3 Grade 2, or
8) Hot applied bitumen at the rate of glass fibre base felt, Type 2 Grade 2;
I .2 kg/m*, Min; and
2) Hot applied bitumen at the rate of
9) Pea-sized gravel or grit devoid of tine sand 1.2 kg/m2, Min;
at the rate of 0.006~m3/m2. Fibre base self-finished felt, Type 2 Grade
3)
OR I or Grade 2, or hessian base felt, Type 3
1) Primer at the rate of 0.27 l/m*, Min; Grade 2, or glass fibre base felt, Type 2
2) Hot applied bitumen at the rate of Grade 2.
1.2 kg/m’, Min; 3.5.1 Timber roofs shall be finished with hot applied
3) Fibre base self-finished felt, Type 2 Grade bitumen at the rate of 1.2 kg/m*, Min; or with two coats
I or Grade 2; of bituminous paint at the rate of 0.1 l/m2 per coat or
a single coat of bituminous emulsion at the rate of
4) Hot applied bitumen at the rate of
0.5 l/m* over it.
1.2 kg/m*, Min;
3.6 Laying of Felt
5) Fibre base self-finished felt, Type 2 Grade
1 or Grade 2; 3.6.1 Sequence of Operations for all Types of Roofs
6) Hot applied bitumen at the rate of
Preparatory work (see 2 given in the beginning
1.2 kg/m*, Min;
of the Chapter);
7) Fibre base self-finished felt, Type 2 Grade
1 or Grade 2; b) Cleaning roof surface of foreign matter;
8) Hot applied bitumen at the rate of c>Treatment of main roof;
2.5 kg/m*, Min; and d) Treatment of flashings and projecting pipes;
9) Peasized gravel or grit devoid of fine sand e) Treatment of gutters and drain mouths;
at the rate of O.Ob8 m3/m2.
0 Top dressing, that is gravel or grit, fixing and
NOTE -Where pea-sized gravel or grit is not available, coarse laying tile or concrete protection or applying
sand may be used. paint or emulsion; and
3.4.1 Surface finish of pea-sized gravel or grit affords
g) Cleaning and removal of surplus materials.
a protection to the treatment and its durability. On the
3.6.2 Concrete and Masonry Roofs
flashings and at the drain mouths, the gravel or grit
may be omitted and instead two coats of bituminous a) The felt is normally laid in lengths at right
paint at the minimum rate of 0.1 l/m2 per coat or a angles to the direction of the run-off gradient,
single coat of bituminous emulsion at the rate of commencing at the lowest level and working
0.5 l/m2 may be applied. up to the crest. In this way, the overlaps of the
adjacent layers of felt offers minimum obstruc-
a) Surface finish, when subjected to foot traffic, shall
tion to the flow-off of water.
be cement concrete flooring tiles or burnt clay flat
terracing tiles as described in Chapter 9. 1) Bitumen primer shall be brushed over the
roof-surface and left to dry afterthe sur-
b) Alternatively, a screeding of I:4 cement sand
face is thoroughly cleaned.
mix layer 45 mm thick may be laid over the
roofing treatment and marked off into squares of 2) The felt shall be cut to the required
600 mm made with expansion joints at adistance lengths, brushed clean of dusting
of 3 m caulked with bituminous sealing com- materials and laid out flat on the roof and
pound (see Grade A of IS I834 : 1984). allowed to soften. Each length of feh shall
then be laid in position and roiled up for a
3.5 Timber Roofs, Sloping
distance of half its length. The hot bond-
a) Nov-ma1 Treatment ing material shall be poured on to the roof
1) Fibre base bitumen saturated underlay across the full length of the-rolled felt as
Type 1. or hessian base felt, Type 3 Grade the latter is roiled out steadily and pressed
1 or glass fibre base felt, Type 2 Grade 1; down. The excess bonding material is
2) Hot applied bitumen at the rate of squeezed out at the ends and is removed
1.2 kg/m’, Min; and as the laying~proceeds.
3) Fibre base self-finished felt, Type 2 Grade 3) When the first half of the strip of fehhas
I, or hessian base felt Type 3 Grade I, or been bonded to the roof, the other half
glass tibre base felt, Type 2 Grade I. shall be rolled up and then unrolled on the
hot bending material in the same way.

342
 SP62(S&T):1997

4) Minimum overlaps of 100 and 75 mm 3) Two coats of bituminous paint at the rate
shall be allowed at the end and sides of of 0.1 l/m* per coat or a single coat of
strips of felt respectively. All overlaps bituminous emulsion at the rate of 0.5 l/m*
shall be firmly bonded with hot bitumen. shall be applied.
5) The laying of the second layer shall be so 3.6.3 Timber Roqfs Sloping (see Fig. 12.12)
arranged that the ioints are stacreered with
.a vu

those of the layer beneath it. The underlay or first layer of feltshall be secured by
nails spaced at 100 to 150 mm centres along overlaps
6) In the case of pent roofs where the type of
treatment consists of one layer of felt only and at 20 mm from the exposed edges. In case of
as in normal treatment 3.4 (a), an addition- struck on treatment, the felt shall be bonded on timber
al layer of felt shall be provided at the roof in the same manner as in the case of masonry roof
ridge which shall cover a minimum length but with nailing strips and back nailing.
of the slope of 250 mm on both sides-of 1) Where required, additional nailing may be
the ridge. provided between overlapsat 150 mm centres.
b) Junctions ofparapet wall and roof- Felt shall 2) The second and subsequent layers of felt shall
be laid as a flashing with minimum overlaps of then be applied with bonding materials as in
100 mm. The lower edge of the flashing shall concrete and masonry roofs.
overlap the felt laid on the flat portion of the
3) In the case of gabled roof, one single strip of
roof and the upper edge of the flashing shall be
felt shall cover from gutter to gutter over the
tucked into the groove made in the parapet on
ridge. If the treatment consists of one layer of
the vertical face of the wall. Each layer shall
felt, additional layer of felt shall be provided at
be so arranged that the joints are staggered with
the ridge which shall cover a length of slope of
those of the layer beneath it.
250 mm on both sides of the ridge.
After the layers of felt are laid and bonded, the
4) Flashings - If the parapet is of masonry con-
grooves shall be filled with cement mortar
struction, the flashings shall be treated in the
( 1:4) or lime mortar ( 1:3) or cement concrete
same way as in 3.6.2 (b). In case the roof butts
(1:3:6) which when set will satisfactorily
against a timber wall, the flashings shall be
secure the treatment to the wall. A fillet of
continuously bonded down over the felt turn up
cement mortar (1:4) shall be done at the junc-
and angle fillet. Joints in the felt tlashings shall
tion of wall and roof.
be lapped 100 mm and sealed. The upper end
c>Drain mouths - Drain mouths with a bell of the flashing shall be firmly secured to the
shaped entry shall be fixed and properly set to timber wall by screwing down with a timber
allow the waterto flow into it. Felt shall general- batten.
ly be laid as on the other portion of the roof and
the treatment shall be carried inside the drain 3.6.4 Shell Roqfs
pipes overlapping at least 100 mm. If possible a
grating cap should be provided over the drain a) In the case of shell roofs additional layer of felt
mouth to protect choking caused by leaves, shall be provided for the valley gutter for nor-
stones, etc. mal treatment and for other type of treatment;
the number of felts in valley gutters shall be
4 Gutter - The treatment to be laid in gutters
Dne layer extra. The treatment on the valley
shall provide for one layer of roofing felt more
should be laid first and the height to which the L 4
than is provided on the roof proper. A priming
felt is to be taken shall be at least 150 mm above
coat shall first be applied. Over this, the first
the anticipated standing water in the gutter.
layer of felt shall be bonded with hot bitumen
For normal treatment on pent roofs, the felt
followed by successive layers of felt bonded
should be laid parallel to the direction of run-
securely together and finally painted with a
off gradient. The felt in the case of shell roofs
coat of hot bitumen at not less than 1.5 kg/m*.
shall be laid from one edge of the valley gutter
1) The first layer laid separately in the gutters to the other, that is, around the curvature. In
shall be overlapped with the correspond- case of northtight cylindrical shells, it can
ing layer on the roof proper. The felt either start from the valley gutter or from the
layers in the gutter shall be carried down upper edge. ,The upper edge shall be securely
to the outlet pipes to a minimum depth of anchored at the edge of the shell.
100 mm.
NOTE - Where insulation is specified, the insulating
2) For gutters in pent roofs the flashings shall material shnll be applied on top of the shell surface and
be laid separately at the sides and carried plastered, if necessary, with cement mortar to provide
well under the caves of the pent roofs. adequate base for application of waterproofing treatment.

343
SP62(S&T):1997

1) When the felt is laid parallel to the direc- emulsion at the rate of 0.5 l/m2 per coat, or one
tion of run-off gradient, that is, around the coat of acrylic based coating at the rate of
curvature in the case of shell roof, the side 0.3 l/m2 shall be applied.
overlap should be 100 mm minimum and
end overlap should be 75 mm minimum; 3.6.5 Expansion Joints
this means that the overlap lengths are
interchanged with those when felts are Expansion joint coverings may be zinc or a lead sheet
laid across the gradient [see 3.6.2 (a)]. or of bitumen felt. In the case of the latter, a minimum
b) For surface finish instead of the normal of two layers of bitumen felt, Type 2, Grade 2 as
bituminous gravel finish, either two coats of specified in IS 1322 : 1993 or Type 2 Grade 1 of
bituminous aluminium paint at the rate of IS 7193 : 1974 shall be used with top dressing of gravel
0.1 l/m2 per coat or one coat colour bituminous or other suitable finish (see Fig. 12.20).

GRAVEL
FIRST LAYER BITUMEN
FELT FREE FR?M BASE
BITUMEN FELT, GRAVEL
\ CEMENT PLASTER
BITUMEN-, \ \ f r f n-BITUMEN

BITUMEN FE :LT

12.20A Expansion Joint with Tee Iron Tile and Terrace Construction in Level with Roof Surface

FIRST LAYER BITUMEN

FELT FREE FROM BASE

FLAT AND FIRST

BITUMEN FELT OF
PIECE SEALED AT

12.208 Expansion Joint with WC Slab onmRoof Surface

FIRST LAYER BITUMEN

FELT FREE FROM BASE

BITUMEN FELT CEMENT PLASTER

RCC SLAB

BITUMEN PAINT

BITUMEN FELT
BITUMEN FELT

FIRST LAYER BITUMEN

FELT FREE

---BITUMEN FEL3 LAP JOINTS SEALED

12.2OC Raised Type Expansion Joint

FIG. 12.20 EXPANSIONJOINTS

 SP62(S&T):1997

3.6.6 Treatment of Bubble Formation lathing with coating of bitumen may be used for rein-
forcement for laying bitumen to vertical sloping sur-
If balooning occurs, remove the gravel on the balooned
faces. The underlay may be bitumen felt to IS 1322 :
surface. Then cut open and squeeze out the trapped
1993. Vapour barrier should be hessian based Type 3
vapour by firm pressure applied by hand. Seal the
felt to IS 1322 : 1993.
bitumen felt so lifted, back on to the surface by apply-
ing additional bitumen. Finally seal the cut with a
4.2 Preparatory Work
piece of bitumen felt with bitumen application and
re-apply the gravel finish over it to make the surface
In addition to requirements of 1.1 of this Part, the
look uniform with the rest.
following points may be considered.
3.6.7 Roof Gardens a) Keying - Bitumen mastic will not adhere to
Where it is required to create a roof garden the vertical and sloping surfaces unless such sur-
waterproofing shall be carried out as per the treatment faces afford an adequate key.
of damp-proofing covered in 2, Part 1 of this Chapter. When bitumen mastic is applied to vertical
As far as possible, plants should be planted in con- surfaces including skirting the top of the
tainers to avoid roof penetration-into the roof below. mastic shall be tucked into a continuous
groove of not less than 25 mm x 25 mm in
4 BITUMEN MASTIC
the structure and its exposed part shall be
4.1 Materials formed with a splay to shed rain water.
2) Horizontal joints in brickwork should not
Bitumen mastic shall conform to IS 3037 : 1986.
be less than 10 mm wide and the mortar
Bonding bitumen shall conform to IS 702 : 1988 or
joint shall be raked out and brushed clean
residual bitumen to IS 73 : 1992. The penetration of
blown bitumen shall be limited to 45 when tested in to form a key to the bitumen mastic (see
accordance with IS 1203 : 1978. Expanded metal Fig. 12.2 1).

DAMP-PROOFING TREATMENT

POINTED IN MORTAR

METAL FLASHING

25 x 25mm CHASE CUT IN WALL

13 mm BITUMEN MASTIC SKIRTING

IN TWO COATS

50 mm METAL TACK AT
750 mm INTERVALS

JOINTS RAKED OUT TO FORM

KEY FOR BITUMEN MASTIC
20 mm BITUMEN MASTIC
IN TWO COATS

FIG. 12.21 BITUMENMASTICLAID ON SCREEDED

ROOFAND BITUMENMASTICSKIRTINGTO BRICKWALL
SP62(S&T):1997

For vertical surfaces on concrete, the total thickness of not less than 20 mm (see
details arenas in Fig. 12.22. Fig. 12.23).
3) For vertical timber surfaces, a layer of At the intersection of two planes forming an
metal reinforcement shall be securely internal angle and after the bitumen mastic has
fixed by nails. All vertical metal surfaces been laid on the horizontal, sloping and vertical
shall be primed with a rubber bitumen surfaces, a solid angle fillet of bitumen mastic,
emulsion before the bitumen mastic is not less than 50_mm wide, shall be formed in
applied. two coat work (see Fig. 12.22 and Fig. 12.23).
4) Other surfaces, wherever possible, shall
4.4 Movement of Joints
be hacked to give key to bitumen mastic.
Where it is considered necessary to provide movement
4.3 Number of Coats and Thickness
of joints in the roof structure, details could be as in
Fig. 12.24.
The number of coats depends on the particular position
of the surface and the maximum thickness of mastic 4.5 Laying of Bitumen Mastic
that is possible to apply while it is a warm state.
4.5.1 Spreading
a>On a horizontal surface and on slopes up 30°,
two coats of equal thickness to a total thickness a>Each coat of bitumen mastic of each bay
of 20 mm shall be applied, excluding horizon- marked out, shall be spread evenly and
tal treatment in walls. uniformly by means of float to the recom-
b) On a horizontal roof subject to foot traffic, two mended thickness, on to the previously
coats of mastic shall be applied; the first coat prepared surface, the isolating membrane or
shahbe not less than 10 mm and the second the preceeding coat.
coat not less than 15 mm. b) Each coat of bitumen mastic shall be followed,
c) On vertical surfaces other than timber, includ- without delay by the succeeding coat, since
ing skirtings, upstands and drips and slopes exposure to contamination might impair
over 30°, two equal coats of total thickness of adhesion and cause blistering.
not less than 12 mm or three coats of total cl The junction between two contiguous bays of
thickness not less than 20 mm shah be applied. a coat of bitumen mastic shall be not less than
d) On vertical or sloping timber surfaces, three 150 mm from a corresponding junction in a
coats of bitumen mastic shall be applied to a preceding coat.

GROOVE FORMED WITH 50 X 25 mm TIMBER

BATTEN LOWER EDGE SPLAYED

POINTED IN MORTAR

13mm BITUMEN MASTIC

SKIRTING IN TWO COATS
FACE OF CONCRETE LEFT ROUGH TO
FORM A KEY FOR BITUMEN MASTIC

( :: C.‘.:.;,BL1, ,-20 mm BITUMEN MASTIC

FIG.12.22 BITUMEN MASTIC LAID ON SCREEDED ROOFAND BITUMENMASTIC

TO
SKIKTING CONCRETE WALL

346
tL_._._._. .. .__. . ,. ,.

SP62(S&T):1997

POINT WITH MORTAR

DAMP-PROOFING
TREATMENT----. /-METAL FLASHING
-

13mm-4 I_ TIMBER ROOF

TIMBER BOARDING JL

FIG.12.23BITUMENMASTICLAIDONTIMBERROOFANDBITUMENMASTIC
SKIRTINGONFREE-STANDING
KERB

PLUG
METAL PLATE

-25 mm w-125 mm

20mm BITUMEN MASTIC

IN TWO COATS
GRAVELFINISH

L SCREEDING E XJPOAYON
hOOF SLAB
f BITUMEN FELT UNDERLAY

FIG. 12.24EXPANSIONJOINTINFLATROOF
TWINKERB TYPE

d) When bitumen mastic is laid horizontally, tim- f) Any blows shall be pierced and the affected
ber gauges of specified thickness shall be used area made good while the bitumen mastic is
during the laying of each coat. still warm.
4 When bitumen mastic is laid over vertical or 4.5.2 Surface /7irl,ish
steeply sloping surfaces, the first coat is essen-
Immediately after completion of the laying of mastic,
tially-an~adhesive layer which acts as a base to
ensure complete bonding of subsequent coats. the surfaces shall be rubbed with a wood float using
cleah sharp sand passing 8.50 micron IS Sieve and

347
SP62(S&T):1997

retained on 300 micron IS Sieve, while the mastic is shall be laid between the~base and the insula-
still warm. tion layer.
b) Skirtings and upstands - The exposed upper-
4.53 Final Finish most part of bitumen mastic skirting shall be
formed with a splay to shed rain water, even
a>To avoid absorption of solar heat, light though a metal flashing is laid to cover the
coloured mineral aggregates or-pea-size gravel exposed part.
may be evenly spread shoulder to shoulder
A similar splay is formed when bitumen mastic
over the entire surface. The aggregates shall
is continued through the wall to form a
be stuck to the top of the surface with
horizontal damp-proofing treatment (see
bituminous bonding material.
Fig. 12.26).
b) The bitumen mastic may also be finished with c) All internal angles shall be laid in two coats, as
roofing materials as described in Chapter 11
a separate operation. It is essential that the last
using light coloured tiles, etc.
coat of bitumen mastic of contiguous surfaces
cl Where decorative finish is necessary, shall be warmed and cleaned, before the solid
aluminium paint free from material deleterious fillets are formed, by hot bitumen.
to bitumen mastic or any other coloured emul-
sion paint may be used.
4 Projecting pipes should be surrounded by
mastic as shown in Fig. 12.27. The treatment
4.5.4 Other Details is continued over the metal surface coated with
bituminous paint up to a stipulated height. The
a> Insulating materials - Where it is necessary
metallic reinforcements shall be placed verti-
to prevent fluctuation of temperature inside a
cally against the first layer of bitumen mastic.
building, additional thermal insulation is
The top layer shall be built over the reinforce-
obtainable by placing a layer of insulating
ment. Neat bitumen or plastic bitumen shall be
material immediately below the mastic roof-
used as a grout at thejoint. A metal collar shall
ing. A vapour barrier as shown in Fig. 12.25
be fixed over it.

13 mm BITUMEN MASTIC DAMP- PROOFING TREATMENT

IN ONE COAT, SCORED AND GRITTED WHEN LAID

13mm BITUMEN MASTIC

SKIRTING IN TWO COATS

JOINTS RAKED OUT TO FORM

KEY FOR BITUMEN MASTIC

r
20mm BITUMEN MASTIC
IN TWO COATS
y;.. :,.::.. ‘.:.‘~.~:;‘~.~.:‘,:.:,~::‘~‘;I. :.:: ‘,
‘. ‘r $

_~._, l.._.j

/ 1 / BONDINGCOMPOUND

VAPOUR BARRIER LSCREEDING

FOLDED OVER INSULATION

FIG.12.25 BITUMENMASTICLAIDONTHERMALINSULATINGMATERIAL

348
 SP 62 ( S & T ) : 1997

L
13mm BITUMEN MASTIC DAMP-PROOFING TREATMENT
a: IN ONE COAT,SCORED AND GRITTED WHEN LAID

13mm BITUMEN MASTIC

SKIRTING IN TWO COATS

JOINTS -RAKED OUT TO FORM

KEY FOR BITUMEN MASTIC

,-20 mm BITUMEN MASTIC

FIG.12.26-BITUMENMASTICLAIDON SCIIEEDEDROOFWITHBITUMENMASTIC SKIRTINGANDDAMP-

PROOFINGTREATMENT TO WALL

r+----ft /-CAST IRON PIPE

I rMETALLlC REINFORCEMENT

BITUMEN

& 1-20 mm BITUMEN MASTIC

IN TWO COATS

iA /-GRAVEL FINISH

L BITUMEN FELT UNDERLAY

FIG.12.27TREATMENT WHEN A PIPE PASSES THROUGH A ROOF SLAB

349
SP62(S&T):1997

5 POLYETHYLENE FILM Over the film a cold cutback bitumen conform-

ing to IS 73 : 1992 may be used; the tempera-
5.1 General
ture of the cutback shall not be more than 50°C
Polyethylene film-is one of the materials which are at the time of application.
being used for waterproofing of roofs in buildings.
5.3 Types of Waterproofing Treatment
Experience gained so far indicates that when
polyethylene film is laid on the roof as recommended, 5.3.1 Pre-sloped Roofs
the treatment provides satisfactory performance
against water penetration. Special care shall be taken a) Single layer treatment (see Fig. 12.28)finished
for effective bonding of the polyethylene film to the with plaster or gravel
background surface as well as in the overlaps. Proper 1) Primer at the rate of 0.3 to 0.5 kg/m’,
precautions shall be taken against puncturing of the where necessary, till the surface is impreg-
film and entrapping air while laying the treatment. nated and the solvent oil in the primer is
allowed to evaporate completely;
5.2 Material
2) Hot applied bitumen (straight-run
Polyethylene film shall conform to 1s 2508 : bitumen) at the rate of 0.70 kg/m2 Min;
1984. In addition it shall satisfy the following
3) Polyethylene film with cold cutback
conditions:
adhesive in overlaps;
1) The film may be natural or black in colour. Cold cutback bitumen at the rate of
The black film shall contain not less than 4)
1.9 kglm2;
2.0 percent of carbon black of an average
5) Binding materials, such as fine sand in dry
particle size not exceeding 0.06 micron,
condition at the rate of 0.5 to 1.0 kg/m
well dispersed in mass. The natural film
dusted over bitumen in (4) above; and
shall be ultraviolet stablized quality only.
6) Finishing layer, such as gravel on the flat
2) Water vapour transmission through the
surface and cement plaster 116 or lime
film determined by the procedure
mortar 1:3 on all vertical surfaces; or
described in Annex A shall not be more
cement plaster 1:6 or lim% mortar 1:3 on
than 5.53 g/24 hlm2.
the entire treated area.
b) Bitumen primer shall conform to IS 3384 :
1986. NOTE -Where pea-size gravel or grit finish is required, the
size of the gravel should be 3 to 6 mm properly impregnated at
c) Bonding materials shall be straight run 0.006 r&m*.
bitumen grades conforming to IS 73 : 1992.

TILES OR CEMENT CONCRETE

OR PATENT STONE

KRAFT PAPER LAMINATED WITH

AND COATED WITH BITUMEN

r POLYETHY~LENE FILM

/-BITUMEN

L PRIMER
L ROOF SLAB
THERMAL INSULATION

R~.12.28 SINGLE LAYERFILMTREATMENTOVERTHETHERMALINS~JLATIONONTHEROOF

350
 ,.
,___ - -. _ .._

i-
SP62(S&T):1997

b) Single layer treatment finished with tiles or 5.3.1 (b) items (1) to (5) and protective treat-
patent stone or cement concrete ment, such as, mud Phuska and one or two
1) Primer at 0.3 to 0.5 kg/m2, till the surface layers of tiles.
is properly impregnated, where necessary; b) Treatment laid below lime terracing - As in
2) Hot applied bitumen $straight-run grade) 5.3.1 (b) items (1) to (5) and protective treat-
at the rate of 0.7 kg/m , Min; ment, such~as, lime terracing.
3) Polyethylene film with cold cutbackad-
5.4 Laying
hesive in overlaps;
4) 100 g brown kraft paper laminated in-situ 5.4.1 Sequence of operations shall be as in 3.6.1.
over the film with semi-hot layer of
straight-run bitumen. The technique of 5.42 Laying
fixing kraft paper to polyethylene film is
to paint semi-hot bitumen on the paper, 4 The number of laps shall be minimized by
reverse it and laminate over the film;. selecting film of suitable width; the minimum
5) Semi-hot applied bitumen (straight-run width of laps shall be 100 mm both at ends and
grade) at the rate of 0.7 kg/m2 dusted with sides.
fine sand; and b) The primer shall be applied on the prepared
6) Finishing layer of tiles or patent stones roof surface by brushing and allowing it to dry
(see Chapter 10). for 6 to 12 h.

c>Multi-layer treatment - In severe conditions cl Hot bitumen shall be spread over the roof sur-
of exposure, such as, heavy rainfall or impor- face and allowed to cool to a temperature so
tant structures it is advisable to provide multi- that the film may be laid without any damage
layer treatment. Normally, a two layer to it.
treatment is sufficient to obtain adequate resis- 4 The polyethylene film shall be carefully laid on
tance to rain penetration. the bituminous layer and firmly but carefully
1) Lower layer - Items (1) to (4) as in pressed down with the help ofa gunny cloth so
5.3.1 (b). as to prevent any damage to the film.
2) Upper layer - Items (2) to (5) as in 1) The next length of the film shall be
5.3.1 (a) or items (2) to (5) as in 5.3.1 (b). similarly laid down on the roof with
3) Finish - Item (6) of 5.3.1 (b) or Item (6) proper longitudinal and end overlaps and
as in 5.3.1 (a). firmly pressed down on the biutminous
layer. The joints and overlaps shall be
5.3.2 Flat Roofs with Mud ‘Phuska’ Finish or Lime
carefully sealed with the help of cutback
Terracing
bitumen applied over the upper surface of
a) Treatment laid below mud Phuska (see Fig. the lower layer of the film.
12.29) - as in 5.3.1 (a) items (1) to (4) or
‘:CUTBACK BITUMEN WITH FILLER

THERMAL INSULATION LIKE MUD-

PHUSKA OR LIME SURKHI MORTAR

ii- r FINISHING LAYER LIKE

TILES OR BRICKS ETC.

1 L PRIMER
HOT BITUMEN L LROOF SLAB
_ POLYETHYLENE FILM
SP62(S&T):1997

2) As far as possible, the polyethylene film The laying of film should be immediately
shall be laid as in Fig. 12.3OA for flat followed by subsequent operations of covering
roofs; as in Fig. 12.30B for sloping roofs with bituminous compositions. If the film is
and as in Fig. 12.3OC for curved shell left exposed, it can lead to softening of bitumen
roofs. layer underneath causing wrinkles leading to
e) As far as possible, laps shall be avoided in the damage. The work therefore should not be
troughs or valleys; where unavoidable, they carried out when the temperature is high.
shall be covered with an additional film strip It is necessary to hold the film high and finally
of adequate width. pressed in position by cloth pad, so that the film
5.4.3 Precautions to be taken into account in laying sets securely on bituminous underlay. Other-
film treatment are as follows: wise this will result in the formation of air
bubbles below the film, which will lead to poor
4 Excessive bitumen should not be used for
bonding.
bonding the film to the prepared surface, which
may result in the film sliding and wrinkling. The workmen should preferably walk
barefooted or with canvas shoes in order to
b) The film should not be overstretched, which prevent damage to the film.
otherwise leads to wrinkles when the film
If the polyethylene film is to be carried over
retracts. These wrinkles may get reproduced
in the final treatment and are liable to get from horizontal to vertical surface, it should be
over a fillet and protected with cement plaster
eroded and cause failure of treatment.
or any other treatment.

FILM LAID ACROSS

THE SLOPE

LROOF SLAB

GRADING MATERIAL LAID TO SLOPE

12.30A FlatRoof

ALONG SLOPE

12.308SlopingRoof

FIG. 12.30 TYPICALARRANGEMENT FORLAYINGPOLYETHYLENEFILM- Contirlued

352
 SP62(S&T):1997

POLYETHYLENEFILM

12.3OCShell
Roof

FIG. 12.30 TYPICALARKANGEMENTFORLAYINGPOLYETHYLENEFILM- Lncluded

5.4.4 Projections 54.5 For roof drainage, extra piece of polyethylene

film shall be provided in the opening covering the edge
Typical details for treatment of roof projections, of the down pipe and covered with cement plaster 1:6.
projection through roofs, etc are as given in Fig. 12.3 I,
12.32 and 12.33.

CUTBACK BITUMEN

Alldinlensions
in millimetrcs.

FIG. 12.31 TYPICALBETAILOFWATERPROOFINGTREATMENTINCASEOF

ROOFPROJECTING~BEYOND~THEWALL

353
SP62(S&T):1997

OVER FILLET C-EMENT MORTAR

t1:11

r
COLD CUT RACK WITH ~FltLER
OPC

CHASE FILLED WITH

POLYETHYLENE FILM
CE MEN1
HOT BIlUMEN

FINISHING LAYER

TION
I LSEPARATING LAYER

FIG. 12.32 TYPICALDETAILOFWATERPROOFINGTREATMENTINCASEOFROOFSABUTTINGAGAINSTTHE

PARAPETWALL

COLD CUTBACK
BITUMEN WITH FILLER

CtlASE FILLED WITH POLYETHYLENE FILM

CEMENT MORTAR II:‘.) HOT BITUMEN

COVER FILLET
FINISHING LAYER

THERMAL INSULATION

SEPARATING SLAYER

6 GLASS FIBRE TISSUE REINFORCED c) Bonding material shall be blown bitumen to

BITUMEN IS 702 : 1988 or residual bitumen to IS 73 : .
.,
6.1 General 1992, or a mixture thereof selected to suit local
conditions. The penetration of bitumen shall
Information on use of glass fibre tissue reinforced
not~be more than 40 when tested in accordance
bitumen as damp-proofing material is covered in
with IS 1203 : 1978.
Part 1 of this Chapter. This mateiia! is also used for
waterproofing of roofs.
6.3 In-situ Waterproofing Treatment of Roofs
6.2 Materials
4 Bitumen primer shall conform to IS 3384 : 6.3.1 In selecting the combination of layers of glass
1986. fibre tissue membrane consideration shall be given to %
,
b) Glass fibre tissue shall conform to IS 7 193 : the type and construction of buildings, climatic and !
1974. Other details of glass fibre shall be as in atmospheric conditions and the degree of permanence
4.2.1 of Part 1 of this Chapter. required.

354
 SP62(S&T):1997

6.3.2 For concrete, masonry and metallic roofs, flat or 2 Where pea-size gravel is not available. coarse sand may be
used. Also tiles, finish, etc. shall be done as in Chapter 10.
sloping, the following treatments are recommended:
3 In the case of flat roofs with precast slabs, where the roof is
a) Normal treatment graded with lime concrete and surfaces plastered, normal treat-
ment as in 6.3.2 (a) can be adopted. In case of sloping roofs,
I) Bitumen primer at the rate of 0.4 kg/m2; heavy treatment as in 6.3.2 (b) can be adopted. In case of too
2) Hot bitumen at the rate of 1.6 kg/m2, Min; much of structural movements, an additional layer of glass fibre
tissue embedded in hot bitumen may be provided.
3) Glass fibre tissue;
4) Hot bitumen at the rate of 1.6 kg/m”, Min; 6.3.3 Junction of parapet wall and roof shall be treated
and as shown in Fig. 12.34 and 12.35.
5) Pea-sized gravel or grit devoid of fine sand 6.3.4 For expansion joints two layers of glass fibre
at the rate of 0.006 m”/m2. base felt, Type 2 Grade 1 shall be laid loose
overlapping one and other with one end of the felt stuck
b) Heavy treatment with bitumen alternately and finally covered with a
I to 4) Same as in 6.3.2 (a) items (1) to (4); layer of glass tibre tissue impregnated with hot
5) Second layer of glass fibre tissue laid per- bitumen. Typical arrangement is shown in Fig. 12.36.
pendicular to previous layer;
Hot applied bitumen at the rate of 6.3.5 Sloping Roofs
6)
1.6 kg/m2, Min; and
Typical details of special treatment of AC and GI
7) Finish as in 6.3.2 (a), item 5.
corrugated roofing at joints is given in Fig. 12.37.
c) Extra heavy treatment
6.4 Laying
1 to 6) Same as in 6.3.2 (b) item 1 to 6;
7) Third layer of glass fibre tissue laid per-
6.4.1 Sequence of operations shall be as in 3.6.1.
pendicular to previous layer;
8) Hot applied bitumen at the rate of 1.6 6.4.2 Procedure
kg/m2, Min; and
9) Finish as in 6.3.2 (a), item (5). a) Clean the surface to be treated with wire
NOTES brushes;
1 Five course treatment is recommended for moderate condi- b) Prime the entire surface;
tions (about 50 cm) of rainfall. Seven course treatment is c) Cut the required length of glass fibre tissue and
suggested for severe conditions (between SO to 150 cm) of
roll it;
rainfall. Nine course treatment is recommended for very severe
condition ( 150 cm and above) of rainfall.

BRlcK PARAPE I

,-CHASE IFOR TUC~KlNG GLASS FIBRE TISSUE/

GLASS FIBRE FAClORY MADE FELr WITH
/ CEMENT MORTAR)II:L)

t+OT APPLIED BITUMEN

/ /-

lOOmm OVERLAP
BITUMINOUS PRIMER

PEA- SIZED GRAVEL/ GRIT

C-EVENT MORTAR (1:4) PLASTER

FILLET IGOLA) 75mm CE
IN RADIUS

FIG. 12.34 WATERPROOFING ON A FLAT ROOFWITHBRICKPARAPET

OVER450 mm IN HEIGHT-TYPICAL DETAILS
SP62 ( S & T ) : 1997

_/-HOT APPLIED BITUMEN

GLASS Fb3RE TISSUE/ GLASS FIBRE

FACTORY- MADE F E Ll

// / rEiITUMINOUS PRIMER

R.Cc
PARAPET

-SAND .CEMENT ~-FLAT fim~

PL ASZER SURFACE
L CEMENT MORTAR ( 1 :L 1
FILLET IGOL A) 75 mm RADIUS

FIG. 12.35 WATERPROOFING ON A FLATROOF WITH RCC PARAPET

450 mm OR LE& INHEIGHT-TYPICAL DETAILS

r
GfUVEL

,- HOTAFPUED BITUMEN

Ouss FIERE TlSSUE

Rml UYER CiLAss FIBUE eAsE0

FELT FREE FROM BASE
CEMENT PLASTER

GLASS FIBRE IN SITU

WAlERPRWFlNO

0 .
.;’
-‘. _. 1
. .- J J.

All dimensions
in millimetres.

FIG. 12.36 WATERPROOFING

OF EXPANSIONJOINTWITH GLASSFIBREIN-SITUTREATMENT
ON RCC ROOF
SLAB-TYPICAL DETAILS
w

4 Pour hot bitumen on the surface to the extent h) The finishing materials like pea-sized gravel or
of roll width and simultaneously embed the grit surface dry shall be embedded into hot
glass ftbre tissue into it. Proceed in this manner bitumen while it is being poured, by applying
throughout the length of the roll. Precaution minimum pressure.
should be taken to ensure adequate sealing of 7 ~WATERPROOFING OF UNDERGROUND
overlaps; RESERVOIRS AND SWIMMING POOLS
e>Apply second coat of hot bitumen; 7.1 General : ‘,
0 In case of multilayer treatments, the joints in During construction of underground water resources :;
the glass fibre tissue between successive layers ;,
and concrete swimming pools and reservoirs, it is
should be staggered midway; essential to ensure watertightness of the resulting
8) The minimum overlap at ends and sides shall structures so that the flow of water from inside the
be 100 mm. All overlaps shall be firmly structure to outside and the infiltration of the water
bonded with hot bitumen; and from the surrounding soil into the structure are . .’
effectively prevented.
* ‘.
356
 SP62(S&T):1997

HOT APPLIED BITUMEN

GLASS FIB% TISSUE.
GIASS FlfflE FACTORY
MADE FELT ,- BITUMEN PRIMER
\

DETAIL AT A-A

L GLASSFlBRETlSWO
GLASS FIBRE FACTMY
MADE FELT

FIG. 12.37 SPECIALTREATMENT FORAC/G1 CO~JCATED SURFACEJOINTS-TYPICAL DETAILS

7.2 Design Features d) Lapping of reinforcement in circular tanks

shoildbe so arranged that not more than 25
7.2.1 Suitable precautions should be taken to avoid
percent of the bars are jointed at any one
cracks and resulting leakages from the following:
vertical section.
a>Movements due to shrinkage and creep;
b) Movements due to variation of temperature 7’3 Materials
and humidity;
a) Bitumen mastic shall conform to IS 5871 :
c>Movements due to dissipation of heat 1987. Bitumen felt shall conform to IS 1322 :
generated by the concrete in the process of 1993 Type 3 -Grade 2; or IS 7193 : 1974,
hydration; Type 2 Grade 1. Bitumen for bonding shall
d) Damage to concrete by the percolation of conform to IS 702 : 1988.
chemically aggressive liquids from outside; b) Cement, steel, water shall conform to IS 3370
e>Damage due to uneven settlement of founda- (Part 1) : 1965.
tions;
7.4 Waterproofing Treatment
fl Cracking of concrete caused by rusting of bars;
and 7.4.1 Preventive Measures
g) Hydrostatic uplift force. \
w The ground should slope away from~the struc-
7.2.2 -The design shall Abe according to IS 3370 ture for a distance of about 3 m to divert the
(Part 1) : 1965. run-off. The surfaces near the side walls
4 The concrete mix proportions should be so should be paved; drainage to divert the water
designed to give an impermeable structure; this awayfrom the structure shall be provided.
depends on the choice of water cement ratio,
b) Waterproofing shall be done as in 3 using
concrete mix, curing, etc. bitumen felt or 6 using glass fibre tissue; and
b) To reduce shrinkage stresses as far as possible, damp-proofing treatment shall as in 3 Part 1 of
there should not be less than 0.3 percent of steel this Chapter using bitumen mastic.
in any direction.
c) The treatment mentioned in 7.4.1 (b) shall be
c) To avoid temperature changes, reservoirs, covered with a cement screed of I:3 adding
shall be partly built into the ground, so that soil integral waterproofing compound. The
is available to cover the roof and to enclose the surface of the screed should be levelled t
reservoir completely in a covering of earth, if
d) The inside of walls and floors should be
necessary; and
plastered, with cement plaster 1:3 with
+

’ ^
357
SP62(S&T):1997

waterproofing compound added in two coats; repellents as below:

the first coat being 12 mm thick and the second Class A - Silicone solvent solution for clay
coat 10 mm thick. The outside surface of walls brickwork, hydraulic cement-based materials,
should be rendered with waterproofing natural and cast stone masonr-y for a
compound added in a similar manner. predominantly siliceous nature.
e>A coat of hot bitumen shall be applied to the Class B - Silicone solvent solution for natural
outside wall after the rendening has dried. and cast stone masonry work of predominantly
calcareous nature and calcium silicate brick-
7.5 Construction Details work.
Class C-Aqueous solution of sodium methyl
a>In long walls, they may be divided into 15 m
siliconate for clay brickwork, natural and cast
sections with a gap of about 30 cm left between
sections so that shrinkage in the long sections stone masonry of a predominantly calcareous
may occur, as far as possible, before the gap is nature.
concreted and the longer this can be deferred NOTE-Where the type of masonry cannot be classified,
the better. Class B repellentmay be used.

b) Vibrators shall be used wherever possible, for 8.2.1 Preparation of Water Repellent
compaction.
a) From Class A and Class B materials - The
c>Construction joints should be perpendicular to Class A and Class B material may be diluted
the general direction of the member. As far as with mineral spirit nor xylene. The mineral
possible vertical joints should be avoided. spirit should have minimum flash point of
4 It is not practicable to provide expansion joints 27’C, boiling range of 135 to 185’C and mini-
in small and medium reservoirs and swimming mum Kauri-Butanol value of 34. For best
pools. In large reservoirs expansion joints results these classes of materials should con-
shall be provided at not more than 35 m for tain 5 percent solids.
underground structures and not more than b) From Class C, the material may be diluted with
28 m for exposed structures. water to a concentration of 3 percent solids just
prior to the application.
e) Pipes and special fixtures should be fixed in
position before concreting is done. 8.3 Preparation of the Surface,
f) For testing and remedial treatment reference a>Cracks wider than 0.1 mm and defective mor-
may be made to IS 6494 : 1988. tar joints shall be repaired. Surfaces Should be
clean and dry. Detergents and wetting agents
8 SILICONE BASED WATER REPELLENT
should not be used.
8.1 General b) When drying of surface is difficult, Class C
material shall be used either Asia full treatment
Application of the appropriate class of water repellent or prior to application of Class A or Class B
to all exterior surfaces free from cracks wider than treatment.
0.1 mm above ground level provides protection against Efflorescence, if visible, shall be washed with
cl
absorption of water, salt and dirt. Applied over cement 5 to 10 percent muriatic acid (HCI) solution
based paints, the repellent preserves the colour, bright- and then rinse it with clear water. If it re- 4

ness and appearance. Used as primers for oil based appears in some places after drying, the repel-
paints, the repellents minimize peeling and blistering lent shall be applied and allowed to cure
caused by damp and salt from the masonry walls. The for 24 h and the surface be again washed with
repellents should be applied to complete masonry muriatic acid (HCl) and rinsed. Then the sur-
rather than to individual units, in order to avoid inad- face may be treated with the repellent.
vertent treatment of bedding faces which would be The masonry, concrete, cement plaster and
detrimental to bonding of mortar. Normally the repel- cement based painted surfaces shall be allowed
lent does not alter the dry appearance of the surface. to cure for 21 days before applying the repel-
Application of water repellent on exposed brickwork lent. If cement paint surfaces are treated with
surfaces reduce the appearance of efflorescence of the repellent on a small area and if water repel-
solublesulphates. lency has not developed, such surface shall be
cured for a longer period.
S.2 Materials
8.4 Application of Repellent
a) The silicone water repellent shall conform to a) Normally a single generous or flood coat by
IS 12027 : 1987. They are three classes of the brush or spray would be sufficient. The

358
 SP62(S&T):1997

material should be applied liberally so that it atomized or misted, but in a solid stream by
runs down the surface freely to about 15 cm maintaining a low nozzle pressure.
below the point of application. c) Safety instructions of manufacturer should be
b) When spraying, the solution should not be followed.

ANNEX A
[Clause 5.2 (a)]
TEST FOR MEASURING OF WATER VAPOUR TRANSMISSION OF POLYETHYLENE FILM

A-l GENERAL shall be so located that the conditioned air circulates

over the exposed surface of the specimen with the
A-l.1 This test lays the procedure for measuring water
specified velocity.
vapour transmission of polyethylene film.
A-3.3 Make successive weighings of the assembly at
A-2 TEST SPECIMENS regular intervals until a constant weight is reached. If
A-2.1 Four test specimens shall be tested, two being the assembly is removed from the chamber, it should
attached to an open mouth (30 cm2) dish with a desig- be returned to the chamber immediately after weigh-
nated side out and the other two with the opposite side ing.
out, unless otherwise specified. Great care shall be A-3.4 Calculation
taken not to contaminate the test area of the specimen. .
Calculate the water vapour transmission of the
A-3 -PROCEDURE specimen from the rate of gain or loss found in the
A-3.1 Place a desiccant, such as, anhydrous calcium straight line portion of the plot of weighings versus
chloride to a depth of at least 15 mm in the dish. Seal time, as follows:
the specimen to the opening of the dish (about 30 cm*), G x 24
Water vapour transmission, in g/24h/m* = tea
in such a manner that the leakage of water vapour at
and through the edges is prevented. where
A-3.2 Weigh the assembly and place it in a rack inside G = weight gain or loss, in g;
a test chamber (or cabinet) with circulating air main- t = time, in hours, during which gain or loss G
tained at 38 + OS°C and 90 + 2 percent relative was observed; and
humidity, in an inverted position so that the desiccant a = exposed area of specimen, in m2.
is in direct contact with the test specimen; the assembly
As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER13

JOINTS IN BUILDINGS
(CONTROL OF CRACKS IN BUILDINGS)
 CONTENTS

1 GENERAL 3.5 Additional Measures

2 TYPESOFJOINTS 3.6 Other Defects
2.1 Expansion Joints MATERIAU
2.2 Construction Joints
4.1 Joint Filler and Sealing Compound
2.3 Contraction Joints
4.2 Waterbar
2.4 Sliding Joints
2.5 Joint Filler INSTALLATION
OFJOINTS
2.6 Sealing Compound 5.1 Expansion Joints in Walls
2.7 Waterbar 5.2 Expansion Joints in Roofs and Floors
3 DESIGNFEATURES 5.3 Roof or Floor to Wall Joints
5.4 Expansion Joints in Framed Buildings
3.1 General
5.5 Contraction Joints in Roofs
3.2 Evaluation ofDimensional Changes
3.3 Deformation MAINTENANCE
3.4 Spacing of Expansion Joints REFERENCES

--
 SP62(S&T):1997

CHAPTER 13

JOINTS IN BUILDINGS
(CONTROL OF CRACKS IN BUILDINGS)
1 GENERAL structure or the number of storeys it has, the greater the
extent to which such movements take place.
1.1 When a material is stressed beyond its tensile or
shear strength it cracks. The stresses may be due to 1.4 There are two ways of dealing with expansion and
external loads or restraint imposed against dimen- contraction of structures. The structures may be
,
sional changes. Moisture movement and temperature monolithic and heavy reinforcement may link each
variations cause such stresses which are resisted by the section so that all the stresses formed may be accom-
building elements. modated without fracture. Alternatively, the structure
may be provided with a number of joints which relieve
All building materials expand or contract with change
the stresses by allowing pre-determined sections of the
in temperature and variation of moisture content. The
structure to move. In the first method accurate assess-
magnitude of these changes vary with the type ot
ment shall be made of all the conditions which are
materials used. Most building materials expand while
likely to induce stresses in the structure. This is not
wetted and shrink while drying. Some materials con-
always possible but nevertheless the method is
tain moisture at the time of construction and dry out
followed in cases like rigid frame structures and shell
subsequently. Such materials are stone, brick and
structures; in rigid frames provision of joints will
concrete and major dimensional changes are caused by
interfere with the rigidity of the structure. In the
their contraction.
second method where joints are provided reasonable
,1.2 If the resulting contraction or expansion are care has to be exercised for design, location, detailing
restricted partly or wholly by any means, for example, ofjoints and selecting materials such as joint fillers and
restraining effect of cross and end walls in large build- waterbars so that large movements may be accom-
ings, internal stresses, like tension during contraction modated without structural failure, disfiguring cracks
and compression during expansion, occur in the struc- or penetration of moisture.
ture and their magnitude depends upon:
2 TYPES OF JOINTS
the extent to which such free movement has
been prevented due to connection of element 2.1 Expansion Joints
to other structural members;
Joints are provided to accommodate the expansion of
the extent to which the movement would have adjacent building parts and relieve compressive stresses
taken place if there were no restraint; that may otherwise develop. Expansion joints essen-
the extent to which the material creeps and tially provide a space between the parts and may
flows under stress; and sometimes be provided with load transmitting devices
the extent to which elastic deformation takes between parts and generally tilled with expansion joint
place. filler which is compressible enough to accommodate
expansion of adjacent parts, and having ability to
These four factors are interdependent and the move-
regain 75 percent of the original thickness, when
ment which actually occurs depends on the restraint to
pressure is reduced.
these movements as well as creep.
2.2 Construction Joints
Hence to minimize cracking in buildings, it would be
necessary to avoid materials which expand or contract Joints installed in location whereconstruction stops for
considerably due to thermal and moisture movements any reason and when the location of stoppage does not
and design the structure so as to minimize restraint to coincide with the planned location of an expansion or
expansion or contraction of the material. Use of contraction joint.
materials having maximum extensibility, that is, total
creep and elastic deformation before cracking and 2.3 Contraction Joints
reducing the range of variation in temperature and These are essentially separations or planes of weak-
moisture movement also helps in minimizing the ness introduced in concrete structures to localize
cracking in buildings. shrinkage movements which would otherwise lead to
1.3 In tropical country like India, occurrence of large unsightly cracks. They may be of any of the following
variations in the atmospheric temperature and types:
humidity are to be expected and problems of crack a) Complete Contraction Joint - In this type of
prevention assumes greater importance. The larger the joint the bond between adjacent sections of a

363
SP 62 ( S & T ) : 1997

structure may be broken completely by paint- changes. In estimating these movements the tempera-
ing one face with a bituminous material or by ture at the time of construction may be considered. If
setting a layer of waterproof paper or roofing concrete is laid in summer the main movement will be
felt against the face of the section before cast- contraction and in such cases the expansion joints may
ing the next section up to it. be further placed apart provided the design takes care
b) Partial Contracting Joint - When structural of the tensile stresses caused by contraction. If con-
stability is required between sections of a rein- struction is in winter, the expansion joints may be
forced concrete structure separated by a con- nearer to avoid excessive compressive stresses.
traction joint, it is sometimes convenient to The coefficient of thermal expansion of some of the
continue the reinforcement across the joint. common building materials is given below:
Due to the presence of reinforcement, the Material Coegicient
movement at these partial contaction joints is
Brick and brick work 5 to 7 x 10V6per “C
usually small.
Cement mortars and concrete 10 to 14 x lOA per ‘C
c>Dummy Joints-Dummy joints are used more
Stones:
particularly in thin sections of concrete. In
these joints a plane of weakness is creaied by Igneous rocks (granite, etc) 8 to 10 x 10” per ‘C
forming a groove in either or each of surfaces Limestones 2.4 to 9 x 10” per ‘C
of concrete, the total depth of the groove being Marbles 1.4tollxlO+j per°C
one-third to one-fifth of the thickness of the Sandstones 7 to 16 x 10m6 per°C
section.
Slates 6 to 10x 10-6peroC
2.4 Sliding Joints Metals:
When variations in temperature, moisture content or Aluminium 25 x lO& per OC
loading result in tendency for one part of a structure to Bronze 17.6 x low6 per ‘C
move at right angles to the plane of another part, it is
Copper 17.3 x lOA per OC
necessary to provide a slip plane between the two parts
Lead 29x IO4 per°C
thus enabling freedom of movement in both the planes.
Sliding joints are usually formed by applying a layer Steel and iron 7t013x10-6 per°C
of plaster to one of the surfaces and finishing it smooth NOTE-For natural materials like stones, because of moisture
before the other is cast on it or by any other approved movements and the range of temperatures experienced,
suitable method. co effcents of thermal expansion cannot be specified accurately.
This is only rough data arrd can be used by the des@
2.5 Joint Filer construction agency.

A strip af compressible material used to form and fill 3.2.2 Variation in Moisture Content
the expansion joints in structure.
Brickwork and concrete contract on drying out and
2.6 Sealing Compound expand when wetted again; and the process of contrac-
A material of plastic consistency applied to the joint in tion may continue even for a long time after construc-
the form of liquid or paste. The function of the sealing tion depending on the external humidity conditions.
compound is to prevent the ingress of moisture or The degree of moisture immediately after setting or
foreign matter. hardening of the mortar or concrete may also vary from
part to part during construction.
2.7 Waterbar
A strip which is placed across the joint during con- For dense concretes, the contraction due to drying
struction so as to form an impervious diaphragm. shrinkage may vary from 0.2 to 0.5 mm/m; for light
weight blocks the shrinkage may be larger varying
3 DESIGN FEATURES
from 0.5 to 0.8 mm/m; for autoclaved aerated concrete
3.1 General still greater shrinkage of the order of 3 mm/m may be
The design of a joint will depend on the type of allowed for. However if care is taken to allow non-
structure, the method of construction and the jointing aerated concrete, specially precast blocks to dry and
materials available. The dimensional changes due to thus contract before use, the shrinkage may be consi-
moisture and temperature variations have to be derably reduced and a value of 0.6 mm/m may be
accounted for in the design of.a joint. allowed.

3.2 Evaluation of Dimensional Changes 3.3 Deformation

3.2.1 Temperature Variations
Deformation may also be caused as a result of loading.
Spacing of expansion joints is determined in relation Allowance for movement in the joint shall be provided
to the movement which will occur due to temperature for to accommodate deformation due to loading

364
 SP62(S&T):lY97

parricularly to allow for the following factors: taken through the foundation concrete. Rein-
Difference in compressibility of the various forcements shall not pass through the joint.
materials used in the individual sections of the b) In the case of masonry walls resting on pile
building; foundation, the vertical control joint shall be
Unequal loading of the individual parts of a taken up to the top of the grade beam over the
building; for example as a result of differences piles. Reinforcement shall not pass through
in height when constructing sections in parts or the joint.
in the final stage; and cl In the case of reinforced concrete structures,
Differential settlement due to unequal loading, the vertical control joints between two
variable load bearing capacity of the soil on columns shall extend from top of the column
account of constructing a building partly on old to the top ~of the pedestal provided over the
foundations; due to overlapping of the load RCC footing.
distribution with that of the adjacent founda-
3.5 Additional Measures
tions or due to the variation in moisture condi-
tions in the sub-soil. In addition to provision of joints, the following
3.4 Spacing of Expansion Joints measures may also be taken to reduce or prevent
damage due to thermal effects.
Generally the spacing of expansion joints shall be
according to Table 13. I. a ) Choosing texture and colour for the exposed
surface such that most of the solar radiation is
Table 13.1 Recommended Spacing of reflected and the minimum is absorbed; white
Expansion Joints washing of roofing would be advantageous;
(Clause 3.4) and

Sl Items and Description Spacing of Joints

b) Providing insulating surfaces on top of the slab
No. to reduce and delay penetration of heat into the
structure; such insulated slabs shall be
i) Wulls
I) Load bearing walls with 3Omintervals
provided with expansion joints, at suitable
cross walls at intervals. intervals.
Traditional type of one-
brick thick or more 3.6 Other Defects
2) Walls of warehouse type Expansion joints at 30 m
construction maximum intervals. If they Many defects other than expansion may also lend to
are panel walls between development.of cracks, and such cracks. may not be
columns is 9 m or less no
related to the defective provision of expansion joints,
joints are necessary.Control
joints over cenlre of open- for example, surface shrinkage cracks, stress
ings may be given at half the concentration in reinforcement due to corrosion and
spacing of expansion joinls effects of frost action. \
ii) Sunshades, balconies and 6 to 12 m intervals
parapets 4 MATERIALS
iii) Roofi
I) Ordinary roof slabs of RCC 20 to 30 m intervals. and at
4.1 Joint Filler and Sealing Compound
protected by layers of mud changes in directions as in L,
Phusko or other insulating T, H and V shaped structures Joint filler shall conform to IS 1838 (Part 1) : 1983 or
media in unframed con- IS 1838 (Part 2) : 1984; sealing compound shall con-
struction
form to IS 1834 : 1984. Ofher organic solvents may
2) Thin unprotected slabs IS m intervals also be considered, such as, polysulphate based joint
iv) Frcmtes sealants to IS 11433 (Part 1) : 1985 nor IS 12118
Joint in structure through slabs. Corners of L, H. T and C
(Part 1) : 1987.
beams, columns. etc dividing shaped structures and at
building into independent 30 m intervals in long
structural units uniform structures 4.2 Waterbar
v) Coping Corresponding to the joints
in the roof slabs Waterbars may be necessary while the joint is subject
to groundwater pressure or where the method of con-
3.4.1 Vertical Control Joints
struction makes it difficult to accurately seal the sur-
a) In the case of masonry walls the vertical con- face cavity. Waterbars may be of natural and synthetic
trol (expansion) joints shall be provide’d from rubber, PVC or metal. Some common shapes of water-
top of the wall to the top of the concrete foun- bars are given in Fig. 13. I, 13.2 and 13.3. For metallic
dations. The vertical control joint shall not be waterbars copper is most suitable.
SP62(S&T):1997

13.18

13.1A

13.1E
13.1D

All dimensions in millimetxes.

FIG. 13.1 TYPICALDESIGNSOFVALVE TYPEPVC WATERBARS

13.2A

Alldimensions in millimetres.

FIG. 13.2 TYPICALDESIGNSOFNATURALRUBBERWATERBARS- Continued

 SP62(S&T):1997

T L
5

13.2C 13.2D

All dimensionsin millimetres.

FIG. 13.2 TYPICALDESIGNSOF NATURALRUBBERWATERBARS- C~nchded

13.38

13.3c 13.3D

13.3E

13.3G
13.3H

;
13.3K
13.3L

FIG. 13.3 TYPICALDESIGNSOF METALLICWATERBARS

SP62(S&T):1997

5 INSTALLATION OF JOINTS of joint is less than 15 mm, use of sealing

compound will suffice, but for wider joints, a
5.1 Expansion Joints in Walls joint filler shall be used. The installation of
a) In brick or stone masonry joints normally need joint with joint filler and sealing compound
not be provided except in case of long walls shall be as shown in Fig. 13.4 A and with angle
exceeding 30 m in length; in such long walls, irons shall be as shown in Fig. 13.4 B.
the expansion joints shall be not less than c) For walls below ground level or for walls sub-
15 mm wide and shall be placed at not more ject to water pressure, use of an efficient water-
than 30 m apart. bar is essential in expansion joints. The water-
bar shall be installed as in Fig. 13.4 C for walls
b) For walls above ground level where the width
subject to water pressure.

SEALING COMPOUND7 -;&r JOINT FILLER

METAL SHEET

SCREWS FIXED BY RAWL

PLUG ON ONE SIDE ONLY FLAT ASBESTOS CEMENT SHEET
OR PLYWOOD OR ANY OTHER
EQUALLY SUITABLE MATERIAL
150mm WIDE

13.4A Expansion Joint Using Joint Filler and Sealing Compound

METAL SHEET

SCREWS FIXED BY RAWL FLAT ASBESTOS CEMENT SHEET

PLUG ON ONE SIDE ONLY OR PLYWOOD OR ANY OTHER
EQUALLY SUITABLE MATERIAL
150mm WIDE

13.4B Expansion Joint Using Steel or Aluminium Angles

INITIAL GAP
WATER BAR- -v-

CONCRETE AN0 STEEL

13.4C Expansion Joint Subject to Water Pressure

FIG. 13.4 TYPICAL DETAILS OF EXPANSIONJOINTSIN WALLS

368
 SP62(S&T):1997

5.2 Expansion Joints in Roofs and Floors be installed in the expansion joint. The joint
shall suitably ~treated for waterproofing.
a) The expansion joints used in roof shall be
Typical sketches of expansion joints in roofs
finished such as to obtain an effective seal
are shown in Fig. 13.5 and 13.6.
against penetration of water. A waterbar shall
BITUMEN FELT

r
BITUMEN LAID IN CEMENT PLASTER
TWO LAYERS
n / @CC PRECAST TILE 1Zmm THICK

BI-IUMEN FILLER

/-LIME TERRACING

FILLED UP WITH BITUMEN

\-METAL CRADLE

\-DRAWL PLUGS AND SCREWS WITH

OVALSHAPED SLOT AND WASHER
AC SHEET
RAWL PLUG AND SCREWS

Alldimensions
in millimetres.
13.5A Expansion Joint Using RCC Precast Tiles over Joint

BITUMEN FILLER
RAWL PLUG AND 5Omm SCREWS
RAWL PLUG AND SCREW WITH
rip ABOUT 300mm C/C
OVAL SHAPED SLOT AND WASHER
GS SHEET TO BE CARRIED
OVER FLAT TILES BY 50mm
PLASTIC BITUMEN-,

13.58 Expansion Joint where Flat Tiles Laid over Roof

PHUSRA OR LIGHT WEIGHT

‘ONCRETE LA’D lo SLoPE ~RlCrCS LAID WITH VERTICAL
JOINT IN MORTARtr
TILES LAID TO SLOI
*I MUG, PHUSKA

\RCC SLAB
ToC, SURFACE
\ CONCRETE BED
RENDERED SMOOTH
WITH THICll WHITE WASH
L-WALL

13.5C Expansion Joint where Flat Tiles Laid over Roof and Brick Layer over Joint

FIG. 13.5 TYPICALDETAILSOF TREATMENT

FOREXPANSION
JOINTSAT ROOFS- Corltinued

369
L.

SP62(S&T): 1997

BITUMEN FELT
STONE CHIPS

CEMENT
PRECASl
co
BITUMEN FILLER
STONE CHIPS /- PLASTER

/- BITUMEN FELT
/-

b#ETAL CRAOLE ’
II mm GAP

13.5D Raised Type Expansion Joint with Coping

FIRSTLAVER JITUMEN
8ITUMEN FEL FREE FROM BAST
MEhiT PLASTER

FLAT AND FIRST LIVE@

13.5E Expansion Joint with RCC Slab Covered over Joint

FII(S.1 LAVEI BITUMEN

FELT FREE FROM BASE
BITUMEN FELT CEMENT PLASTLR

FELT
N

\ BITUMEN FELT LAP JOINTS SEALED

13SF Raised Type Expansion Joint Without Coping

FIG. 13.5 TYPICALDETAILSOF TREATMENT JOINTSAT ROOFS-

FOREXPANSION Concluded
\

FIRST LWER BITUMEN

FELT FREE FROM BASE
BITUMEN FELT
CEMENT PLASTER
BITUMEN BITUMEN

FLAT AND FIRST LAYER /-- ,-BITUMEN FELT

BITUMEN FELT OF CROWN
PIECE SEALED AT LAP JOINT TUMEN

FIG. 13.6 TYPICALDETAILSOF EXPANSION

JOINTINLEVELWITHROOF SURFACE

370
 SP 62 ( S & T ) : 1997

b) For floors, waterbar is not necessary. When 2) Topreventcracks in the masonry below or
the floor part of the joint is left open chamfer- above the expansion joint in cases where
ing shall be provided on either side of the joint it is not possible to provide a vertical joint
to improve appearance. If open joint is not in the masonry, RCC or plain cement con-
acceptable, a cover plate fixed to one side and crete bed plates shall be provided on the
free to slide over the concrete on the other side bearing.
may be provided as in Fig. 13.7.
5.3 Roof or Floor to Wall Joints
C) In case of long sunshades, balconies and
The roof slab shall be free to move at the bearings on
parapets, the joints shall be at intervals of 6 to
the walls and sliding joints shall be provided at the
12 m. The expansion joint shall not extend to
bearings. This may be achieved by resting the slab on
the portion where the sunshade is embedded
a smooth surface obtained by a plaster finish over the
into the masonry but shall stop short of face by
bed blocks or bearing surface of wall; then giving a
5 cm; and the distribution reinforcement, in the
white wash finish would give a smoother surface. A
embedded portion and in the 5 cm portion of
similar treatment may also be given in the case of floor
the sunshade where there is not expansion
slabs bearing on walls (see Fig. 13.8, 13.9 and 13. IO).
joint. shall be increased to 0.3 percent of the
gross cross sectional area to take up tempera- 5.4 Expansion Joints in %ramed Buildings
ture stresses. In case of covered verandah
The details of joints between panel wall and the frame
slabs, the expansion joints spacing may be
shall be as shown in Fig. 13.11. In case of continuous
increased to I2 to 14 m and the expansion joint
expansion joints between two parts of buildings twin
shall not be extended beyond the wall. The
columns shall be provided and the details of expansion
gap may be sealed by copper cradle.
joints between them shall be as shown in Fig. 13.12.
Aluminium cradles insulated with a thick coat
In addition to the expansion joints necessary in rein-
of bitumen may also be used in place of copper
forced concrete frame, contraction joints shall be
cradles.
provided in the masonry in the facade. These joints
I) Where the verandah slab is the extension may be either straight or staggered joints in the mason-
of floor slab, the distribution reinforce- ry and the joints finished with suitable sealing com-
ment in the portion of the slab resting on pound to match the appearance of the cladding. Resin
the masonry shall be increased to twice its based building mastics may be found suitable for seal-
normal amount. Reinforcement not re- ing joints in the facade as they will be available in
quired from structural considerations may various colours. PVC cover strips may also be used.
be considered effective as distribution In the case of glass block partition felted mineral fibre
reinforcement for the purpose. will be particularly suitable as a joint filler.

RCC PRECAST TILE 25 mm THICK

TO MATCH THE FLOOR FINISH AND
LAID OVER A COAT OF HOT BITUMEN

.METAL CRADLE
FILLED UP WITH
BITUMEN FILLER

RAWL PLUGS AND SCREWS WITH

OVAL SHAPED SLOT AND WASHER

RAWL PLUG AND SCREWS

FIG. 13.7 TYPICALDETA~LSOFEXPANSIONJOINTATFLOOR

371
SP63(S&T):1997

WCC COPING 75mm 1lllCK

,-PAINT

FIG. 13.8TYPICALDETAILS OF EXPANSIONJOINTAT WALL AND ROOF JUNCTION

TWO LAYERS OF REINFORCED

PRECAST TILES1

CEMENT PLASl ‘ER

LIME TERRACING7 ’
-rFtOOR FINISH

&CC SLAB

METAL CRADLE

b?CC BEAM

L25 mm GAP
All dimensions in millimetres.
FIG. 139 TYPICAL DETAILS OF EXPANSIONJOINTAT ROOF BY THE SIDE OF WALL

COPING

rHlGHER ROOF

sl /-BlfUMEN FELT

,12mm GAP LIGHTLY FILLED

WITH WEAK MORTAR

BEARING J
/

FIG. 13.10TYPICAL DETAILSOF EXPANSIONJOINTAT DIFFERENTFLOORLEVELS

372
 SP62(S&T):1997

METAL PLUG

JOINT FILLER7 rOUTSlOE I \ 7 JOINT FILLE A

STRIP LSEALING CGMPOUNG ‘PLASTER r,ETAL PLUGS

METAL SHEET

13.llA Unplastered Interior 13.11 B Plastered Interior

FIG. 13. I 1 TYPICALDETAILSOFEXPANSIONJOINTAT PANELWALLS OFRCC FRAMEDSTRUCTURE

15Omm WIDE ASBESlOS CEHENl

RAWL FLU0 AND SHEET, ALUMINIUY PLAIE,
STEEL PLATE OR SIMILAR MATERIAL

RAWI. PulG AND SOmm

13.12A Typical D&ails of Expansion Joint on Outer Face of Columns

RAWL PLUG AN0

5Omm SCREWS
WALL
STEEL

‘ER

13.128 Typical Details of Expansion Joint at Comer Columns

f-JOINT FILLER I 1

COMPOUND

13.12C Typical Details of Expansion Joint at Isolated Twin Columns

FIG. 13.12 TYPICALDETAILSOF EXPANSIONJOINTSAT TWIN COLUMNSOF RCC FRAMEDSTRUCTURELS

5.5 Contraction Joints in Roofs and lip type. Typical sketches of these types of joints
iuoofs are as shown in Fig.13.13 and 13.14.
Joints are generally oftwo types, namely, parapet type
SP 62(S & T): 1997

/-SEALING COMPOUND
y-ROOF TERRACING

L INSULATION LAYER \ROOF SLAB

13.13A Typical Details of Lip Type Joint in Roof Terracing where there
is no Joint in Roof Slab
/SEALING COMPOUND
BITUMEN FELT FIXED
rBlTlJMEN FILLER
WITH BITUMEN MASTIC- /

TOP OF WALL
RENDERED SMOOTH
AND WHITE WASHED WITH WEAK MORTAR

13.13B Typical Details of Lip Type Joint where there

is Joint in Roof Slab over a Wall

FIG. 13.13
TYPICALDETAILSOF LIPTYPEJOINTSINROOF

BRICK TILES 7

-PIPE IN SLOPE WHERE

INSULATION LAYER7

BITUMEN FELT
PASTED WITH GAP FILLED LIGHTLY
WITH WEAK MORTAR
BITUMEN MASTIC
PL4STER FINISHED SMOOTH AND
WHITE WASHED OVERALL

FIG. 13.14
TYPICALDETAILSOF PARAPETJOINTINROOFTERRACING
WITHOR WITHOUTWALL

6 MAINTENANCE 20mm and this shall be filled with cold-applied

bitumen or hot-applied mastic.
a) It may be advantageous to carry out main-
tenance work during dry spells of weather in 7 REFERENCES
the spring, at which time of the year, the width
of the joints and cracks will be intermediate 7.1 SP 25 (S&T) : 1984covers the causes and preven-
between summer and winter conditions, and tion of cracks in buildings. This Handbook gives
subsequent strains for sealing compound and detailed information on treatment of cracks also.
joint filler will be equally divided between 7.2 Chapter 4 on Masonry and Chapter 5 on Concrete
expansion and compression. of this Handbook essentially cover procedures for
b) Isolated and well defined cracks in vertical construction of masonry and concrete; if followed
surfaces shall be cut out to provide a substantial carefully and meticulously the formation of cracks
cavity to a width of 15 mm, and depth of 15 to could be reduced to a large extent.

374
 SP62(S&T):1997

7.3 Similarly good construction practices covered in durability, maintenance and ambient conditions. The
Chapter 3 on foundations, Chapters 9, 10 and 11 deal- standard only elaborates a little of these functions and
ing with good construction practices for floors, wall no constructional details are given.
finishes and roofs respectively would help in contain-
ing initiation of cracks in buildings. IS 11817 : 1986 covers classification of joints for
accommodation of dimensional deviations during con-
7.4 Apart from IS 3414 : 1968 on joints in buildings,
struction. Three types of joints are classified to deal
three more Indian Standards are available based on
with accommodation of dimensional deviations.
IS0 standards. IS 10958 : 1984 gives a general check
These standards may be considered for appropriate
list of functions of joints in buildings. The functions
situations, such as, in prefab or use of precast elements.
include environmental factors, capacity to withstand
stress, safety, accommodation of dimensional devia- Further IS 11818 : 1986 covers the test for laboratory
tions, fixing of components, appearance, economics, determination of air permeability ofjoints in buildings.
As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER14

WHITEWASHING,COLOURWASHINGAND
PAINTINGOFMASONRY,CONCRETEAND
PLASTER~SURFACES
(CALCAREOUSSURFACES)
 CONTENTS

GENERAL OF THE BACKGROUNDAND

3 CHARACTERISTICS
TREATMENT
PART 1 WHITEWASHING AND
COLOUR WASHING 3.1 General
GENERAL 3.2 Planning of all Painting Operations in Relation
to Dampness in the Background
MATERIALS
3.3 Painting and Other Finishes on Both Sides of
PREPARATORY
WORK the Wall
3.1 New Surface 3.4 Variation in Suction
3.2 Old Surface 3.5 Surface Imperfections
PREPARATION
OFWHITEWASH
ANDCOLOURWASH 3.6 Growth of Moulds, Fungi, Algae and Lichens

4.1 Preparation of Whitewash 4 PREPARATION

OFBACKGROUND
4.2 Preparation of Colour Wash 4.1 For Lime Plaster Surfaces
APPLICATION
OF WHITEWASH
ANDCOLOURWASH 4.2 For Cement and Cement Concrete Surfaces
5.1 Application of Whitewash 4.3 For Gypsum Plaster Surfaces
-5.2 Application of Colour Wash 4.4 For Masonry Surfaces
5.3 Painting Schedule of Whitewashing and 4.5 For Absestos Cement Surfaces
Colour Washing
5 APPLICATION
OFPAINTS
6 PROTECTIVE
MEASURES
ANNEX A CHARACTERISTICS OF CALCAREOUS
PART 2 PAINTING OF MASONRY, SURFACESWITHREGARDTO PAINT FINISH
CONCRETE AND PLASTER SURFACES
ANNEX B APPLICATION OF ALUMINIUM FOIL TO
1 GENERAL CALCAREOUSSURFACES

2 MATERIALS ANNEX C TEST RELATINGTO FITNESS OF PLASTER

FORPAINTING
-. ..-

SP 62 ( S & T ) : 1997

CHAPTER 14

WHITEWASHING, COLOUR WASHING AND PAINTING

OF MASONRY, CONCRETE AND PLASTER SURFACES
(CALCAREOUS SURFACES)
1 GENERAL tion and it takes a long time for greater part of the water
to evaporate even when the atmospheric conditions are
1.1 Whitewashing and_colour washing of surfaces of
favourable. Therefore cognizance of stored up mois-
buildings is necessary for both hygienic and aesthetic
ture has to be taken while applying a paint system on
reasons. In order to obtain a neat, clean and uniform
these surfaces; the alaklinity of the surface is another
finish it is necessary to prepare the surfaces, such as, aspect to be
1 : taken note of. These surfaces are porous
concrete, masonry or plaster.
and present problems, such as, variable suction, sur-
1.2 Painting of ~masonry, concrete and plaster and face imperfections, growth of moulds, mosses, lichens
similar calcareous surfaces is carried out not only for and algae. Each of these have adverse effect on most
hygienic or aesthetic reasons but also for waterproof- of the surface coating materials and therefore finishing
ing and chemical attack from industrial atmospheres of these surfaces, need special care.
ccmtaminated with corrosive fumes. 1.3 This Chapter is divided into two Parts, Part 1
Calcareous surfaces like lime and cement plastered dealing with Whitewashing and colour washing and
surfaces are highly alkaline in the initial stages, and Part 2 dealing with Painting of masonry, concrete and
they retain large quantities of water during construc- plaster surfaces.

PART 1 WHITEWASHING AND COLOWR WASHING

1 ~GENERAL 3.2 Old Surface

1.1 This Part deals with the preparation of surfaces a) Surfaces, where the same colour wash is to be
and application of whitewash and colour wash over repeated, shall be broomed to remove all dust
masonry, concrete and plaster surfaces. and dirt. All loose scales of lime wash and
other foreign matter shall also be removed.
2 MATERIALS
Where heavy scaling has taken place the entire
2.1 Lime used shall conform to Class ‘C’ (fat lime) to surface shall be scraped clean. This will also
IS 712 : 1984 and white in colour. Water shall be apply, where a colour wash has to be given on
clear, free from all organic and suspended impurities; an already whitewashed surface.
potable water is suitable for this purpose. Sodium b) For surfaces where different colour wash is to
chloride shall conform to IS 253 : 1985 or Grade II be applied, the old colour wash on surfaces
of IS 797 : 1982. Ultra marine blue or indigo shall shall be entirely removed before whitewash or
conform to IS 55 : 1970. Pigments of yellow and red different colour wash is applied. The surface
ochre shall conform to IS 44 : 199 1; and pigments of shall be prepared by brushing or by scraping or
blue vitriol shall be fresh crystals of anhydrous copper by other suitable means to produce a clean
sulphate (blue vitriol) and conform to l[S 261 : 1982 surface and shall be broomed to remove dust,
ground to fine powder. dirt, etc.

3 PREPARATORY WORK cl Old surface spoiled by smoke soot shall be

scraped with steel wire brushes or steel
3.1 New Surface scrapers. -The surface shall be broomed to
remove all dust and dirt and shall be washed
The surface shall be thoroughly cleaned of all dirt, with clean water.
dust, mortar drops and other foreign matter before
whitewash is to be applied.
4 Oil and grease spots shall be removed by a
suitable chemical and surfaces rubbed with
wire brushes.
SP62(S&T):1997

A!! unsound portions of surface plaster shall be screened through a clean coarse cloth. Add I kg of
removed to full depth of plaster in rectangular gum dissolved in hot water to each cu.m of lime cream.
patches and plastered again after raking the About 1.3 kg of sodium chloride dissolved in hot water
masonry joints properly. Such portions shall may be added to every 10 kg of lime. Small quantity
be wetted and allowed to dry. They shall be ofultramarine blue (up to 3 g/kg of lime) shall also be
given one coat of whitewash. Al! unnecessary added to the last two coats of whitewash solution and
nails shall be removed; and the holes and the whole solution be stirred thoroughly (see Notes 1
cracks shall be filled with lime putty or plaster and 2).
of Paris to make the surface smooth. NOTES
When whitewashing old surfaces, if surfaces
1 The addition of sodium chloride (common salt) to lime wash
are found to be infected with mould growth, it helps in quick carbonation of calcium hydroxide making the
shall be treated as below. coating hard and rub-resistant.

Any growth of moulds, moss shall be removed 2 For exterior work the whitewash or colour wash that will
by scraping with steel scraper and ammoniacal adhere well to stone and masonry surfaces may also be prepared
by scattering one part by weight of tallow in small lumps over
copper solution consisting of 15 g of copper
I2 parts of quick lime, slaking it with onlyjust sufficient water
carbonate dissolved in 60 ml of liquor to form a thick paste, stirring occasionally to assist dispersing
ammonia in500 ml water, shall be applied to the tallow and allowing it to stand until cool. The resultant paste
the surface and allowed to dry thoroughly shall then be let down to thin wash, which is strained through a
coarse cloth. If tallow is not obtainable, then linseed oil or castor
before applying colour wash or whitewash.
oil about 10 percent by weight of dry lime may be used. If the
An alternative to ammoniacal copper solution oil does not saponify and incorporate with lime, it should be
treatment may consist of 2 percent sodium heated up until the oil disappears. The oil forms with lime an
pentachlorophenate solution in water. insoluble soap, which when once dry, will not wash off with
heavy rain. In case of colour wash, mineral colours such as oxide
Local areas affected by eftlorescence shall be of iron, red and yellow colours, based on chromium oxide and
initially treated as described below and then carbon black not affected by lime may be added. Use of linseed
applied whitewash or colour wash. oil is likely to give slight yellow tinge to whitewash.

Efflorescence will continue as long as there is 4.2 Preparation of Colour Wash

sufficient water in the structure backings to
Sufficient quantity of colour wash enough for the
carry the soluble salts forward and it is use-
complete job shall be prepared in one operation to
less to sea! the moisture by paint film in the
avoid any difference in shade. To the basic whitewash
surface.
solution prepared in accordance with 4.1, mineral
For removing eftlorescence dry brushing colours not affected by lime shall be added.
appears to be the only remedy. Efflorescence
shall not be removed by washing with water as 5 APPLlCATION OF WHITEWASH AND
it may carry some salts back into the pores; on COLOUR WASH
redrying efflorescence may be even worse than
5.1 Application of Whitewash
before if the salts were still present in the
structure. The treatment of an old wall with Whitewash shall be applied with Moorzj brush or other
hydrofuge silicone will frequently stop the brush to the specified number of coats. The operation
efflorescence as the liquids block the passage of each coat shall consist of astroke of the brush given
of moisture. In the case of efflorescence due from the top downwards, another from the bottom
to rising of salt solutions through capillary upwards over the first stroke, and similarly one stroke
action from sub-soil the only remedy is to horizontaly from the right and another from the left
provide bitumen or metallic seals in the walls before it dries. Each coat shall be allowed to dry before
above ground level so that an effective barrier the next coat is applied. No portion of the surface shall
to capillary action is treated. be left out initially to be patched up later on. The~brush
shall be dipped in whitewash pressed lightly against
4 PREPARATION OF WHITEWAS3-I AND the wall of the container, and then applied lightly
COLOUR WASH pressing against the surface with full swing of hand.
a) The ceiling should be whitewashed prior to the
4.1 Preparation of Whitewash
walls.

Whitewash shall be prepared from fat lime conforming b) For new work, a minimum of two coats shall
to IS 712 : 1984. The lime shall be slaked at site and be applied so that the surface presents a smooth
shall be mixed and stirred with about 5 I of water for and uniform finish through which the plaster
I kg of unslaked lime to make a thin cream. This shall does not show. The finished dry surface shall
be allowed to stand for a period of 24 h and shall be not show any signs of cracking and peeling and

380
 ., - i-__ _^.I.
I+---

SP62(S&T):1997

the whitewash shall not come offreadily on the a) For colour washing of old surfaces prepared as
hand when rubbed. in 3.2, a coat of colour wash shall be applied
cl For old work, after the surface has been for the patches and repairs. Then the specified
prepared as in 3.2, a coat of whitewash shall be number of coats of colour wash shall be applied
applied over patches and repairs. Then one or over the entire surface. The colour wash shall
two or more coats of whitewash shall be present a uniform colour shade. No primary
appliedovertheentiresurface. The whitewashed coat is needed for old surface bearing colour of
surface shall present a uniform finish through the same shade.
which the plaster patches do not show. b) On surfaces requiring a changeof colour, after
the surface has been prepared as in 3.2 (b), two
5.2 Application of Colour Wash
coats of whitewash shall be applied before
The colour wash shall be applied in accordance with application of specified number (minimum
the procedure laid down in 5.1. For colour washing or two) of coats of colour wash of the new shade.
new work, after the surface has been prepared as in 3.1,
the first orimary coat shall be of whitewash and the 5.3 Painting Schedule of Whitewashing and
subsequent coats (minimum two) shall be colour wash; Colour Washing
the entire surface shall present a smooth and uniform
The schedules are given in Part 2.
finish. To start with 0.1 m2 of the prepared surface
shall be colour washed with the first coat of whitewash 6 PROTECTIVE MEASURES
and subsequent coats of colour wash solution in full
number of coats and the shade so obtained shall be 6.1 Surfaces of doors, windows, floors, articles of
examined before the entire work of colour washing is furniture, etc, and such other parts of building not to
taken up in hand. It shall then be noted that small areas be whitewashed or colour washed, shall be protected
of colour wash will appear lighter in shade than when from being splashed upon. Such surfaces shall be
the same shades are applied to larger surfaces. cleaned of whitewash or colour wash splashes, if any.

PART 2 PAINTING OF MASONRY, CONCRETE AND PLASTER SURFACES

1 GENERAL plasters. The characteristics of different calcareous

surfaces are described in Annex A.
1.1 This Part will deal with painting, namely, dis-
tempering, oil paint, emulsion paint, cement paint,
3.2 Planning of all Painting Operafions in Relation
synthetic gloss paints, bituminous paints, etc, on
to Dampness in the Background
masonry, concrete and plaster surfaces (calcareous
surfaces).
3 ) When painting new walls, any type of paint
2 MATERIALS system which will seal in the moisture shall be
avoided.
2.1 Dry distemper shall conform to IS 427 : 1965; oil
bound distemper to IS 428 : 1969; enamel interior and b) The material for initial decoration shall there-
exterior paint to IS 133 : 1993 and IS 2933 : 1975 and fore be chosen in due relation to the ultimate
cement paint to IS 5410 : 1992. scheme for re-decoration. If, for example, it is
intended eventually to paint the surface with an
3 CHARACTERISTICS OF THE oil paint, the initial decoration shall be done
BACKGROUND AND TREATMENT either with a material which can be removed
3.1 General easily and completely, or with one which is
suitable to receive oil paint.
In painting calcareous surfaces, careful consideration
shall be given to physical and chemical properties of c) When the surface has properly set and cured
and when all excess moisture has dried out
the background and the backing materials which are
from it and from the backing and further move-
strongly alkaline. Concrete, lime and cement plasters
ments of moisture will be negligible, painting
are likely tocausealkali attack on paint. This will have
may be done as specified, it being merely
to be clearly distinguished from materials which are
necessary to select an alkali resistant priming
neutral or nearly so, as in the case of calcium sulphate
SP62(S&T):1997

paint when oil based paints are used to suit the type of paint to be used:
porosity of the surface.
Type of Paint Pretreatment
d) However, where it will not be possible to allow
i) Size bound distemper
the required time for the surface to dry out
1) One coat A coat of clearcole
fully, the decoration in such cases shall be with
application
a porous finish, such as, lime wash, colour
2) Two coat A coat of size alone will be
wash, cement paint, oil-free distemper or
application sufficient
suitable emulsion paint which will allow
drying to continue at a reasonable rate through ii) Dry distemper A coat of the same dis-
their films. Gloss paint shall not be used until temper thinned with water or
drying is complete. petrifying liquid supplied by
the manufacturer; Or A coat
e) If a surface remains persistently damp, the
of sharp colour or primer-
cause shall be examined and the surface suitab-
sealer with the addition of
ly treated before attempting to decorate. If
finely ground pumice
remedy is impractical, isolation of affected
surfaces by battening out and plastering or iii) foil paint A coat of thin primer or
boarding may be necessary. Local areas af- primer-sealer, preferably in
fected by efflorescence shall be cut out and consultation with the manu-
replastered or treated with efflorescence foil of facturer of the paint
aluminium to prevent the absorption of water iv) Emulsion paint A coat of the same paint
from the exterior or penetration of water into thinned with water or sealers
the interior (see Annex B). recommended by the
manufacturer
3.3 Painting and Other Finishes on Both Sides
of the Wall v) Cement paint and Wet the surface before
lime wash applying paints
Painting new walls or partitions on both sides may
result in an increased risk of the paint failure, because 3.5 Surface Imperfections
the means of escape of water introduced during con-
Imperfections on surface either plastered or otherwise
struction operations are restricted. A difference in mar the appearance of the paint finish and are especial-
porosity of the paint films applied to either side of a ly conspicuous if the finish is glossy. Where smooth
wall may result in one side being more affected than
finishes are required, particular attention shall be paid
the other. The risk is similar and greater when only
to the preparation of surface, including any necessary
one side is painted and the other side is sealed by some rubbing down, sealing stopping or filling.
impermeable treatment, for example, wall tiling. Par-
ticularly severe conditions may be met when walls, Plaster, if improperly gauged and worked, is liable to
partitions and ceilings are built of materials that need develop surface crazing (map crazing). This defect, if
large quantities of water for curing and setting. For present, shall be treated according to the method given
solid walls, partitions and ceilings, the precautions in 4.1.1 or 4.1.2 beforepainting to prevent the cracks
outlined in 3.2 shall be carefully observed.. or their positions from showing in the finished work.

3.6 Growth of Moulds,-Fungi, Algae and Lichens

3.4 Variation in Suction
a) Characteristics of Mould Growth - The
The variation in suction characteristics of the surface
growth of mould is generally associated with
to be painted require corresponding variation of the
continued dampness, either of the material
priming coat, or in some cases, the use of glue size,
painted or of the surrounding atmosphere. It
petrifying liquid or sealers according to the type of
shows itself in the form of black or vari-
paint to be used. Surfaces which show local variations coloured spots or colonies which may be on, in
in suction, as for example, between individual bricks
or beneath the paint film, and are easily recog-
or on patches produced on plastered surfaces by local nizable under microscope. Mould growth may
over-troweliing or by efflorescence, shall be treated by occur on almost any type of building material,
the application of suitable primer. Lime plaster including plastered surfaces. Some growths
finishes have a moderate suction, which can easily be may penetrate the underlying plaster or brick-
counteracted by use of sealers. work and become difficult to eradicate. On
3.4.1 If the suction is so high or variable that a normal new work mould growth is unlikely to be
painting procedure is unlikely to give a good finish, encountered. The surface of old work
one of the following pretreatments shall be applied (covered as it may be with wall paper, dis-
over the whole surface as a primer, according to the temper, or oil paint) may already be infected

3.82
 SP62(S&T):1997

with mould, particularly in premises which manent decoration. Other types of paint
have been left unoccupied for sometime or suitable for early application are cement paints,
where there has been a persistent damp silicate paints and washable distemper depend-
penetration, and especially where walls have ing on the final decoration in view.
been saturated with water in the course of fire
cl If the background of the plaster is one likely to
fighting. contain large amounts of water, for example,
Precautions - Exterior surface of porous new brickwork, concrete or building blocks, no
building materials like brick, stone and cement attempts shall be made to apply oil paint (espe-
rendering, especially if unpainted, may cially gloss finish) until there is every reason
develop growths of vegetation ranging from to believe that the walls are thoroughly dry.
thick beds ~of moss to slimy steaks or patches Some indication of the progress of drying can
of algae. Any such growth shall be removed be obtained by means of tests described in
and ammoniacal copper solution (see Note) Annex C.
shall be applied to the surface and allowed to
4 If the background is of a dry type, for example,
dry thoroughly before painting. wood or metal lath, oil paints may be applied
NOTE- A recommended composition and concentrntion with safety after a few weeks of drying, and oil
of the ammoniacal wash shnll consist of 71: of copper bound distempers even earlier.
cnrbonatedissolvedin 80ml ofliquorammoniaunddiluted
to 1 1 with water. Alternatively, 2.5 percent magnesium 4.1.1 In case of old unpainted plaster surfaces any
silicofluoride solution may be used. source of dampness in walls and ceilings shall be
c>For prevention of recurrence of mould growth removed and painting shal be deferred until the plaster
the following procedure shall be followed: has dried.
1) Remove the source of dampness and dry Any major cracks or defects in the plaster shall be cut
out the walls; out and made good. Cracks may be wetted thoroughly
2) Improve ventilation, if necessary; prior to filling or priming paint may be applied to the
sides of cracks to avoid undue absorption of water and
3) Remove the infected paint~or paper; and
subsequent shrinkage of the filling. For filling, a
4) Sterilize the surface by applying an
retarded hemi-hydrate calcium sulphate plaster
antiseptic wash, such as, 2 percent sodium
gauged with about one-third of its volume of hydrated
pentachlorophenate or any other
lime may be used.
proprietary material and allowed to dry.
Prior to painting, fine cracks may be filleb with a
4 PREPARATION OF JMCKGROUND
mixture of oil, putty and white lead or a distemper type
4.1 For Lime Plaster Surfaces of filling composition depending on the finish which
In the case of new lime plaster, precautions with regard is to follow.
to the drying of background shall be observed carefully 4.1.2 In the case previously painted lime plaster
as these will considerably effect the performance of the surfaces the following precautions shall be observed:
finish. In case of new lime plaster, the essential prin-
4 Any existing fungus or mould growth shall be
ciples with respect to drying of background will be the completely .removed. The surface shall be
following:
thoroughly scraped and rubbed down with
4 If possible lime plaster shall be left unpainted bristle brush and sand paper and then washed
for the first few months so as to allow the down with clean water and allowed to dry. A
plaster to carbonate, harden and dry thorough- coat of fungicidal wash shall then be applied
ly. If the plaster has any tendency to craze or and allowed to dry after which a further coat
crack owing to shrinkage on drying, the move- shall be applied and left for sometime to dry
ments shall be allowed to occur before the thoroughly. The surface shall be kept under
surface is painted so as to enable provision of observation for sometime during drying out
suitable proprietary treatment. Heating the period and if the mould recurs, the treatment
rooms, if accompanied by good ventilation, and drying shall be repeated before painting.
will assist drying, but shall be cautiously The surface shall be brushed with soft bristle
adopted. Too rapid a drying may damage the brush to remove any dust particles 24 h after
plaster by causing undue shrinkage and separa- the wash. Painting shall becarried out over the
tion of the plaster coats. fungicidal wash without removing it with
b) If there is any objection to leaving the plaster water.
bare, a temporary decoration of soft distemper b) Any existing paint showing extensive tlaking,
may be applied. This may be removed easily bleaching or saponification (as shown by stick-
at a later date and replaced by a more per- ness or the presence of yellow soapy runs) shall

383
 ^. ^ . ___.^ . _.,,..-II. ll--.-.-_._L

SP62(S&T):1997

be removed by scraping and washing and the the alkalinity may be tested in accordance with
surface allowed to dry completely. It may Ihen Annex C.
be repainted as prescribed for new surfaces.
If the surface of the plaster has a patchy appearance
c) Local defective patches shall be treated in- and shows wide variations in suction due to efflore-
dividually by removing all loose or softened scence or other causes, a paint primer shall be applied
paint and bringing forward the treated patches before application of a regular paint.
with primer and undercoating before applying
For old surfaces, unpainted or previously painted, the
a fresh coating over the white areas.
preparation of background will be the same as in the
4 Dry distempers and lime wash shall be totally case of lime plasters. If it is a neutral surface, the
removed prior to repainting. It may sometimes application priming paint may not be necessary.
be necessary to wet the surface before scrap-
4.4 For Masonry Surfaces
ing. This shall not be overdone and all surfaces
shall be perfectly dry prior to the application of All mortarjoints shall be brought to a sound condition
any priming coats. before painting operations are started. In the case of
new brickwork, painting shall be deferred for at least
e>Certain wall and ceiling surfaces may ‘reveal
three months after completion of the masonry work
hairline cracks. After complete removal of the
existing paint systems and if the lime plaster and longer if the weather during this period has be-
come unfavourable for drying. Dirt may be removed
has cured and dried completely, use at least two
coats of any of the primers for the paint system by washing with water. In case of old masonry,
wherever there is extensive growth of vegetable
to be adopted. When oil paint is to be used, the
primer at least shall be of alkali resistant type. matter, it shall be treated suitably according to 3.6.
Previously painted surfaces of brickwork shall be
Lime fast pigments shall be used.
prepared in the manner given in 4.1.2.
Water based paint or washable distemper, if in
a clean, sound condition, need not be removed 4.5 For Asbestos Cement Surfaces
if similar coatings are to be applied in the new Asbestos cement being based on portland cement will
paint system. By using a mild detergent, the be, specially when new and damp, sufficiently alkaline
surface may be washed and then after a light to attack oil paint. -The asbestos cement sheets are
sanding it will be ready to receive a fresh coat porous, permit suction and also fungus ~growth on
(with spot priming, if required). them. The necessary precautions in the painting work
4.2 For Cement and Cement Concrete Surfaces to overcome there difficulties are as below:

For new surface it is preferable that the surface is left a>The best way, probably, to reduce the risk of
alkali attack is to allow the sheets to weather
unpainted for as long as possible to allow drying.
for some months. The alkali become car-
Before painting, the surface shall be thoroughly
bonated on exposure to air, and rain will often
brushed to remove all dirt and remains of loose or
wash them off the surface to some extent. With
powdered materials.
long exposure, however, surfaces become
Treatment of the surface with solution of acids or salts,
powdery and dirty, and offer poor key for paint
such as, zinc sulphate is not advisable as the risk of not
unless properly cleaned. Although weathering
reducing the alkali attack appreciably and efflore-
reduces the risk, it may not entirely overcome
scence may be increased. -But on old unpainted sur-
the danger of alkali attack.
faces, if there is an extensive growth of vegetable
material which cannot be removed by brushing, the b) Asbestos cement sheets shall not be treated
growth shall be destroyed by applying a wash of with chemicals like hydrochloric acid or zinc
ammoniacal copper solution in accordance with sulphate to neutralize the alkalis. Also the use
3.6(b). The dead and dry remains of the growth shall of chemicals will often leave powdery deposit
be brushed off prior to painting. Any loose or uneven on the surface which may interfere with
areas or any major cracks in cement concrete or plaster adhesion of paint. The use of hydrochloric
background shall be cut out and made good and the acid for cleaning will also make the asbes-
repairs allowed to dry thoroughly before painting is tos cement sheet brittle.
commenced. Minor repairs may be made with cement cl Asbestos cement sheets are porous in varying
mortar. Cement plaster or concrete which is degrees and moisture absorbed will often cause
previously painted shall be prepared in the same man- failure of the paint system. It is therefore
ner as in 4.1.2. essential that absestos cement sheets are dry
4.3 For Gypsum Plaster Surfaces when they are painted. To ensure this each
sheet shall be left with both sides exposed to
Before application of the paint it shall be
good drying conditions for 7 to IO days before
ensured whether the surface is alkaline or neutral and
painting.

384
 SP62(S&T):1997

4 When there is a danger of moisture entering the If the suction is very high and variable that
sheets from the back owing to dampness or normal painting procedure is unlikely to give a
condensation, ‘back painting’ shall be done satisfactory finish, suitable pretreatment to the
with an alkali-resistant primer conforming to surface shall be given as described in 3.4.1.
IS 109 : 1968 or bitumen paint conforming to
f) It is important to remove and kill any existing
IS 158 : 1981 or a colourless waterproofer. fungus growth. For this the surface shall be
Usually ‘back painting’ will have to be done scraped and rubbed down with glasswool and
before the sheets are fixed and will be par- sandpaper and then washed down with clean
ticularly necessary where impervious painting water and allowed to dry. A coat of fungicidal
system is adopted for painting of the surface. wash shall then be applied and left for some-
Back painting means coating the back and time to dry thoroughly (see 3.6 and 4.1.2).
edges of the sheets with a specified paint to
4.5.1 Preparation ofhjface
prevent entry of moisture from the back.
Whenever impervious paint or paint system is The surface shall be cleaned by rubbing with
used on the face, ‘back painting’ shall be done. sandpaper. Any glazed area shall be roughened.
When the backs of sheets are inaccessible for Loose powdery material after rubbing shall be brushed
back painting, a porous paint shall be chosen. off. Wire brushes shall be avoided in cleaning opera-
Porous paints will allow the sheets to breathe tions as they will lead to difficulties from deposited
so that there is less risk of trouble caused by particles of iron causing iron stains.
moisture. In the case of previously painted surface the prepara-
e>Glazed patches are often visible on asbestos tion of surface shall be as in 4.1.2, as applicable. Before
cement sheets and they have to be roughened applying the paint finish, sheets shall be given a final
to provide a key to the paint. More absorbent sand papering and then washed down with clean water
patches, which are whiter than the rest on the and allowed to dry thoroughly. If the old paint film is
surface, tend to suck medium out of the paint sound, one or two coats only of any of the finishing
and this is likely to affect the durability of the paints may be applied.
paint on these patches. The suction is also high 5 APPLLCATION OF PAINTS
and also variable. To overcome this effect
5.1 The application of paints shall generally be as
pretreatment with primer as mentioned in the
given in Table 14.1 and Table 14.2 along with pretreat-
paint schedules (see 5) shall be applied over the ments where necessary for corresponding types of
whole surface. Application of the primer shall
paints. The painting operations shall be as given in
be minimtim two coats.
Chapter 15.

Table 14.1 Schedules for Painting New Calcareous Surfaces - Interior

(Clause 5.1)
-
Sl Final Finish Required Primer Coat Under Coat Finishing Coats
No.
(1) (2) (3) (4) (5)
i) Whitewash One coat of whitewash - Whitewash (two coats)
ii) Colour wash One coat of colour wash - Colour wash (two coats)
iii) Distemper
a) Dry distemper (non-washable) Clearcole or size, etc Filler to be used, Dry distemper (two coats)
if required (IS 427 : 1965)
b) Oil bound distemper One coat of alkali do Oil bound distemper
resistant primer (two coats) (IS 428 : 1969)
iv) Emulsion paint’) One coat of emulsion do Emulsion paint (two coats)
paint [IS 5411 (Part 1) : 19741
v) Flat/Semigloss paint’) One coat of alkali Underdoat as requi- Flat/Semigloss paint
resistant primer red, filler, if required (two coats)
vi) Gloss paint’) do do Gloss paint (two coats)
(IS 133 : 1993)
vii) Chemical resistant paint’) One coat of the paint Filler, if required Chemical, resistant paint
(two coats)
viii) Cement paint’) One coat of cement paint Nil Cement paint (two coats)
(IS 5410 : 1992)
ix) Bituminous paint’) One coat of the paint Nil Bituminous paint (two coats)
(IS 9862 : 1981)
I) May be thinned according to manufacturer’s recommendation.

385

.
SP62(S&T):1997

Table 14.2 Schedules for Painting New Calcareous Surfaces - Exterior

(Clause 5.1)

SI Final Finish Required Primer Coat Under Coat Finishing Coats

No.
(1) (2) (3) (4)
i) Whitewash One coat of whitewash Nil Whitewash (two coats)
ii) Colour wash One coat of whitewash Nil Colour wash (two coats)

iii) Emulsion paint’) One coat of emulsion paint Filler, if required Emulsion paint (two coats)
[IS 5411 (Part 2) : 19721
iv) Flat/Semigloss paint’) One coat of alkali Undercoat as required Flat/Semigloss paint (two coats)
resistant primer (IS 168 : 1973 and
IS 1232 : 1964)

v) Gloss paint’) do do Gloss paint (two coats)

(IS 2932 : 1993 and
IS 2933 : 1975)
vi) Chemical resistant paint One coat of the paint Filler, if required Chemical resistant paint
(two coats)
vii) Cement paint’) One coat of cement paint Nil Cement paint (two coats)
(IS 5410 : 1992)

viii) Bituminous paint’) One coat of the paint Nil Bituminous paint (m,o coats)
(IS 9862 : 1981 and
IS 158 : 1981)
‘) May be thinned according to manufacturer’s recommendation.

5.1.1 Normally stopping or filling as required be Where it is desired to tone down the natural
carried out before any painting is done and care should colour of the sheets, a wash of green copper (as
be taken to see that any cracks between plaster and ferrous sulphate about 0.1 g/ml of water) shall
wood work (for example, skirtings) are securely filled. be used. This will give a durable brownish
If such cracks are wide, caulking with hemp or similar stain, although the finish is unlikely to be
material may be necessary to support the filling and uniform.
prevent it falling away through the gaps. Minor Gutters, downpipes, etc, should receive water-
defects are frequently more apparent once the priming proofing coating of bitumen on the inside. For
or first coat has been applied, and if any further stop- outer surfaces alkali-resistant _porous paint
ping or filling is done over this first coat the area must shall be used.
be brought forward with appropriate paint to restore
For painting asbestos cement sheets, in choos-
even porosity over the surface.
ing a paint system for a particular job, the risk
of attack by alkali shall be taken into account.
5.1.2 In regard to painting of asbestos cement sheets,
Paints which are by themselves highly resistant
the following points may be noted:
to alkali attack may be used. But where paints
used are not alkali-resistant, at least two coats
a) Asbestos cement sheets shall be thoroughly
dry at the time of painting; of alkali-resistant primer shall be applied. The
primer shall not only be resistant but also form
b) Back painting shall be done when an imper- an impervious barrier so that alkali cannot get
vious paint system is adopted for the finish, if
through to attack the paint system above.
practicable it shall be done after the face of the
sheet has been painted, though, normally back
5.2 Maintenance
painting will have to be done before the sheets
are fixed.
In case of painting relating to maintenance work, the
cl For external sheeting an alkali-resistant paint principles given in Table 14.3 should generally be
either porous or impervious (with back paint- applied.
ing) may be chosen.

386
 ‘SP62(S&T):1997

Table 14.3 Recommended Practice for Maintenance Painting

(Clause 5.2)
SI Condition of Surface Cleaning and Painting
No. , Practice
Blister- Effl- Chal- Crack- Flak- ’ (see Notes 1 and 2)
ing and ores- king ing ing
Soften-
ing

(1) (2) (3) (4) (5) (6) (7)

9 Nil Nil Yes Nil Nil Clean, rub down with abrasive paper, apply
one finishing coat.

ii) Nil Yes Yes Nil Nil Rub down the affected surface to bare
plaster, allow to dry, touch up with primer
coat and then apply required number of
coats; and follow by a reviver coat on the
entire surface, if required.

iii) Yes Nil Nil Nil Nil Scrap off the soft film, allow the surface to
dry completely, touch up with primer coat
and then apply required number of coats;
apd follow by reviver coat on the entire
surface, if necesary.

iv) Nil Nil Nil Yes Nil Rub down and even up the surface with
sand paper to remove cracked film. Touch
up with primer and apply the required
number of coats and follow by reviver
coat on the entire surface, if necessary.

v) Nil Nil Nil Nil Yes Remove the paint from the affected portion
completely and _follow part of or full
schedule of painting as the case may be.

NOTES

1 In case of anyserious characteristics failure mentioned above (except chalking), the paint shall be completely removed and the full
schedule of painting be followed.

2 There is no effective remedy for efflorescence.

ANNEX A
(Clause 3.1)
CHARACTERISTICS OF CALCAREOUS SURFACES WITH REGARD TO PAINT FINISH

A-l CHARACTERISTICS OF LIME PLASTER c) Lime plaster develops efflorescence less

quickly than other plaster finishes.
a) Lime plasters are highly alkaline and hence,
until they are thoroughly dry and matured, they d) Lime plaster, if improperly gauged and
are likely to cause alkali attack on oil contain- worked, is likely to develop surface crazing.
ing paints and distempers and fading of dis- This defect If present, may be reduced by
tempers. The severity of the attack varies with special treatment as described in 4.1.1 or 4.1.2
the proportion of soluble alkalis (soda and to prevent cracks or their positions showing-in
potash) in lime used, but it is always wise to the finished painted surface.
take full precautions against alkali attack
irrespective of the type of lime used. e) Lime plaster, being softer than other plasters,
b) Lime plaster finishes have a moderately high is liable to mechanical damage in certain solu-
suction. This may be encountered by suitable tions. The plaster shall, however, be made to
adjustment of the priming coat. harden more quickly by suitable gauging.

387
SP62(S&T):1997

A-2 CHARACTERISTICS OF GYPSUM application of artificial heat. An impervious

PLASTER backing to a thin plaster finishing coat may be
as dangerous as one which is too absorbant,
4 When the plaster is properly set and hardened since it holds little or no reserve of water and
and the plaster backing and background are
the finish dries quickly.
dry, gypsum plasters may be painted success-
fully with almost any type of paint except The condition of ‘dry out’ is not, usually,
cement paint. apparent at the time the surface is decorated
but, if an impervious coat of paint is applied,
b) The finishing coat of gypsum plaster can be water from the backing may cause expansion
applied over any type of undercoat; the under-
of the partially hydrated plaster producing
coat does notaffect the painting procedure and
ridges, blistering and disintegration in the
it is the composition of the plaster finishing
plaster and often causing the paint to loose
coat that is chiefly to be considered.
adhesion.
c>Plaster finishes gauged with lime involve a
s>While, it is possible to obtain a satisfactory
greater painting risk than other plasters, owing
paint on any type of gypsum plaster, provided
to the possibility of alkali attack. The risk is
the appropriate precautions are observed, it is
least with retarded hemi-hydrate gypsum
preferable, from the painters point of view that
plasters but for practical purposes, it is ad-
the plaster surface shall not be too highly
visable to take precautions against alkali from
trowelled and made non-absorbant. A plaster
any plaster to which lime has been added.
surface which shows a moderate and uniform
4 Neat calcium sulphate plasters have no ap- degree of suction provides a margin of safety
preciable chemical action on paint, and the inthe matter of paint adhesion. It is particular-
paint defects which occur on them are general- ly desirable to have a surface of this type when
ly associated with the action of moisture and of emulsion paints, water paints and distempers
efflorescent salts. are to be used, since these adhere less strongly,
On anhydrite plaster, patches of efflorescence to impervious surfaces than do oil paints.
sometimes develop on areas differing in suc- A gloss paint finish shows up any irregularities
tion from remainder of the surface and there is in the plaster surface, and hence, in places
a tendency for paint to fail in adhesion at these where such a finish is required, the plaster used
places. Extra care in priming is needed to shall be one which can readily be brought to a
secure adequate adhesion and even finish. The smooth level finish. To some extent, this con-
technique of ‘priming following the trowel’ flicts with the requirements that the plaster
helps to overcome the difficulty. shall be trowelled only to the minimum needed
e) Retarded hemi-hydrate plasters, when exposed to produce a smooth finish and no attempt shall
continuously to damp conditions, are liable to be made to produce a high polish.
‘sweet out’, a defect characterized by failure to
h) Gypsum plasters may conform to IS 2547
harden or by disintegration. This may occur in (Parts 1 & 2) : 1976.
various circumstances, for example, when the
background of the plaster is permanently damp A-3 CHARACTERISTICS OF CEMENT AND
or when moisture is sealed into the plaster by RENDERINGS
premature application of an impervious paint film.
Care shall be taken to avoid these conditions. a>New portland cement concrete and renderings
are strongly alkaline, and for this reason oil
fi Gypsum plasters are liable to a defect known paints when applied to them are subject for
as ‘dry out’ characterized by friable condition
sponification and bleaching. In addition there
of the plaster surfacing and sometimes affect-
is a risk of damage by efflorescence.
ing the whole thickness of the finishing coat.
It occurs when plaster is allowed to dry out too b) The drying and surface combination cannot be
quickly before it had time to combine with all hastened by treatment. Oil paint, therefore,
the water needed for setting and hardening shall not be used on such surfaces until several
processes. A ‘dry out’ can be caused by months shave passed; but earlier decoration
application of the plaster finish to a highly may be carried out with cement paints or
absorbant undercoat, by conditions favouring silicate paints.
by rapid evaporation or by the premature

388
 SP62(S&T):1997

ANNEX B
(Clause 3.2)
APPLICATION OF ALUMINIUM FOIL TO CALCAREOUS SURFACES

B-l PROCEDURE (0.025 mm thick) shall immediately be unrolled on the

surface applied with hot bitumen. All joints shall have
B-l.1 The area to-be treated shall be cleared of dust
at least 50 mm overlap and shall be hot sealed. If
and allowed to dry prior to the application by means
of a brush of a thin coat of bitumen primer conforming required the blown type bitumen at 175’C at the rate
of 1.5 kg/m2 may be applied over the aluminium foil
to IS 3384 : 1986. Blown bitumen (penetration 10 to
as a sealer coat. Thereafter, the aluminium foil or the
20) conforming to IS 702: 1988 shall be hot applied by
bitumen sealer coat shall be painted with a plastic
brush at a temperature of 175’C to the surface at the
emulsion paint or water based paint as required.
rate of approximately 1.5 kg/m2. The aluminium foil

ANNEX C
(Clauses 4.1 and 4.3)
TESTS RELATING TO FITNESS OF PLASTER FOR PAINTING

C-l TEST FOR ALKALINITY process shall be repeated, if necessary, until no more
C-l.1 Representative areas of plaster shall be treated salts appear. Conditions shall then be reasonably safe
with an oil-gloss paint or other alkali-sensitive paint for permanent painting. The test shall be carried
(tinted with prussian blue) and left for at least a week. out under conditions of warmth and ventilation
If at the end the lime there is no sign of sponification appro-ximating those of occupational conditions.
or bleaching, conditions shall be reasonably safe for
permanent decoration. If on the other hand, bleaching C-3 TEST FOR DRYNESS
and sponification has occurred, further small areas
C-3.1 It shall be noted that those tests covered in C-l
shall be treated. This shall be repeated until sample
and C-2 are not sufficient since a plastered wall may
areas remain undamaged.
be neutral and show no signs efflorescence and yet be
C-l.2 Alternative Procedure damp which is liable to cause paint to fail in adhesion.
Alkalinity may also be detected by the use of mois- Moisture metre for testing the dryness of walls may be
tened red litmus paper on the surface. If it turns blue used in deciding when a surface has reached a condi-
the presence of alkaline background may be inferred. tion to receive paint. However, no form of test may
indicate the condition of more than a small area and
C-2 TEST FOR EFFLORESCENCE
since plastered wall seldom dries uniformly, the test
C-2.1 Small areas of plaster where the efflorescence shall be repeated at a number of places. Again it shall
is most conspicious shall be rubbed down with a be noted that deep seated moisture which is not always
suitable abrasive followed by the application of damp detected by superficial tests may make its presence felt
(not wet) cloth and left for at least one week. This after the surface is painted.

389
As in the Original Standard, this Page is Intentionally Left Blank
 CHAPTER15

PAINTINGJARNISHINGANDALLIED
FINISHES(WOODANDMETALS)
 CONTENTS

1 GENERAL 11 BURNISHING
PART 1 FINISHING OF WOOD AND WOOD ANNEX A PAINTING
CHARACTERISTICS
OF TIMBERS
BASED MATERIALS ANNEXB MERGINGTYPEGLAZEANDSTAINS
1 GENERAL PART 2 PAINTING OF FERROUS
OFWOOD ANDWOOD
2 GENERALCHARACTERISTICS METALS IN BUILMNGS
BASEDMATERIALS 1 GENERAL
2.1 General
2 FACTORY
PRETREATMENT
3 DESIGNCONSIDERATIONS
2.1 General
3.1 Detailing of Timber Joinery 2.2 Removal of Oil, Grease, Dirt and Swarf
3.2 Selection of Coating Materials 2.3 Removal of Rust and Scale
4 PAINTINGOFNEWWOODWORK 2.4 Phosphate Treatment
4.1 Surface Preparation 2.5 Intermediate Protective Pretreatments
4.2 Priming 3 ON-SITEPRETREATMENT
4.3 Stopping and Filling
3.1 Untreated Surface
4.4 Application of Undercoat
3.2 Surface with Temporary Protective Treatment
4.5 Finishing
3.3 Surfaces Already Pretreated and/or Primed in
5 APPLICATIONS
OFCLEARFINISHES Factory
5.1 General 3.4 Brush Derusting with Phosphoric Acid
5.2 Procedure 3.5 Solvent Cleaning, etc
5.3 Filling 4 APPLICATION
OFPAINTS
5.4 Staining
4.1 General
5.5 Sealing
4.2 Painting
5.6 Varnishing
4.3 Schedule
6 FRENCHPOLISH 4.4 Maintenance
6.1 Preparation of Polish
PART 3 PAINTING OF NON-FERROUS
6.2 Preparation of Surface
METALS IN BUILDINGS
6.3 Application of Polish
7 FINISHING
OF WOODBASEDMATERIALS 1 GENERAL
7.1 Plywood 2 SURFACE
PREPARATION
ANDPRETREATMENT
7.2 Hardboard 2.1 General
7.3 Particle Board 2.2 Aluminium and Aluminium Alloys
7.4 Insulation Board 2.3 Zinc
7.5 Wood Treated with Preservative 2.4 Magnesium
8 PAINTINGSCHEDULE 2.5 Cadmium
2.6 Copper and Copper Alloys
9 MAINTENANCE
2.7 Lead
10 FINISHING OF WOOD PRODUCTS WITH 2.8 Lead-Tin
NITROCELLULOSE AND COLD CATALYSED 2.9 Tin
MATERIALS
3 PAINTING
10. I General
3.1 General
10.2 Finishing
10.3 Pulling Cover 3.2 Painting Schedule
 SP-62 ( S & T ) : 1997

CHAPTER 15

PAINTING, VARNISHING AND ALLIED FINISHES

(WOOD AND METALS)
1 GENERAL Part 1 Covering finishing of wood and wood
based materials
1.1 This Chapter deals with painting, varnishing and
allied finishes of wood and wood based materials, Part 2 Covering painting of ferrous metals in
ferrous metals and non-ferrous metals. For con- buildings
venience, this Chapter is arranged in three Parts as Part 3 Covering painting of non-ferrous metals in
below: buildings

PART 1 FINISHING OF WOOD AND WOOD BASED MATERIALS

1 GENERAL 2 GENERAL CHARACTERISTICS OF WOOD

AND WOOD BASED MATERIALS
1.1 Wood and wood based materials are finished for
decoration and for protection. The finishes are of two 2 I Genera,
.
types, namely, opaque and transparent. Opaque (pig-
mented) coatings or paints conceal the grain and colour 4 There are several species of wood and an
of the substrate and substitute in their place a surface increasingly large number of wood based panel
of an entirely different colour and texture. Transparent products often differing from each other in
finishes on the other hand bring out the grain and surface characteristics. They may be hard,
colour of the substrate, thereby enhancing its inherent soft, resinous or porous in varying degrees.
beauty.
b) Wood is a hygroscopic material and tries to
1.2 Protection furnished by wood finishes is mainly a
reach a state of equilibrium with the atmos-
matter of retarding the absorption and subsequent phere in so far as its moisture content is con-
drying out of moisture from the finished surfaces. By
cerned. Changes in moisture content are
retarding the passage of moisture into the wood, the accompanied by swelling and shrinkage,
finish minimizes the changes in dimensions and often
pronounced across the grain of the wood.
inshape. The durable film on a surface finish may also
provide protection against spotting and discolouration Due to moisture movement, the summerwoods
swell to a greater extent than springwoods and
caused by dust, gases, grease or handling. To a limited
extent it takes up abrasion resulting from hard usage. this sets up stress concentration at the sharply
Finishes as a rule do not protect wood from biological defined iunctions between one -year’s summer
growth at the next year’s spring growth and the
decay.
failure commences about this region. The
1.3 The following Indian Standards are available on resulting stresses on the film of finishing
wood finishes: material are such as to cause fissures to develop
along the grain under adverse circumstances.
IS No. Title
c) Before painting the wood shall be properly
2338 (Part 1) : Code of practice for finishing of seasoned as per IS 1141 : 1~93 and treated as
1967 wood and wood based materials: per IS 401 : 1982 and the moisture content
Part 1 Operations and workmanship shall be brought to the level as given in Chapter
2338 (Part 2) : Code of practice for finishing of 7 (or IS 287 : 1993) so as to prevent uneven
1967 wood and wood based materials: shrinkage during drying which may result in
Part 2 Schedules distortion or even in cracks in the paint finish.
4597 : 1968 Code of practice for finishing of It is also advisable not to finish excessively
wood and wood based products with drywood. The painting characteristics ofsome
,nitrocellulose and cold catalysed of the softwoods and hardwoods are given in
materials Annex A.

393
SP62(S&.T):1997

4 The cellular structure of wood has a strong unduly restrained in tixing. End grain shall
influence on the absorption of liquid com- receive special care in painting.
ponents of finishes. Non-uniform absorption
of vehicle by the wood upsetspigment-binder 3.2 Selection of CoatingMaterials
*-atio; impairing the appearance and life of the
coating. 3.2.1 Prime Coat

e) plywood, blockboard, hardboard and particle

4 A suitable wood primer shall adhere firm!y to
board have greater dimensional stability than the surface, form a sound foundation for
solid wood and provide more uniform surface further coating and fulfill special functions.
for finishing. such as, acting as a sealer on porous wood and
hardboard.
3 DESIGN CONSIDERATIONS
b) Wherever the timber has large pores, a priming
3.1 Detailing of Timber Joinery with a quick drying varnish of the gold size
type conforming to IS 198 : 1978 is desirable.
Water can find access through unpainted surface or
The varnish shall be forced with a brush well
joints and may encourage decay, in all cases where
into the pores so that the pores are completely
wood surface is in contact with surfaces which are
filled. The filling of pores shall not be
likely to get wet, such as brickwork or concrete; one
regarded as a substitute for normal priming and
or two priming coats shall be applied to wood surfaces
shall be followed by a coat of the primer.
before fixing to minimize absorption of water (seen/so
Chapter 7). Special attention is drawn to the follow- c>Pink wood primer (see IS 3536 : 1966) or the
ing: mixture of white and red lead primer may be
used in painting structures containing a slight
a) Window and door frames, flush with the wall excess of moisture as they allow minute quan-
face may allow ingress of moisture between
tities of moisture to pass through without
the structural walling and the woodwork, and
disrupting it.
the paint is then likely to fail unless two prime
coats are applied to the surface and allowed to 4 Aluminium primer may be used for wood
dry before fixing. having knots and resinous matter. The primer
prevents the resin of the wood from bleeding.
b) The rails of gates shall be bevelled to shed
water and help to prevent it from entering the 3.2.2 Stoppers and Fillers
joints between vertical and horizontal
members. For deep holes, plastic wood conforming to IS 423 :
c) Door posts and sash frames resting on steps or 1961 may be used. Far high class work filling opera-
sills are liable to absorb water unless the steps tions shall be done over the whole surface using fillers
or sills are designed and built as to drain away conforming to IS 110 : 1983. For clear finishes,
water. Door posts, sash frames and similar appropriate filler shah be used.
joinery shall be adequately primed all over,
taking special care to prime any cut surfaces 3.2.3 Undercoat and Fitlishing Coat Materials
before fixing.
Before considering application of undercoat and
d) Wherever required, in joinery exposed to finishing coat it shall be made sure that those selected
weather, tenons and other concealed surfaces are compatible with each other. If a non-elastic finish-
shall be primed before assembly. Members ing coat is applied over elastic primer coat it may lead
shall be assembled when the paint is wet. to cracking or alligatering of the finishing coat and the
When surfaces are to be glued, priming may primer coat may become visible through cracks. If the
not be possible and hence the use of waterproof finishing coat contains a strong solvent, it may attack
glue is recommended. Any painted beads or the primer coat and lead to shrivelling (wrinkling) of
steps shall be primed on the underside and the entire paint structure. It is therefore essential to
fixed in position while paint is wet. specify and ensure that the various types of paints to
e) In design, consideration shall always be given be used are compatible with each other and as Indian
to the grain direction and effects of shrinkage, Standards on paints allow enough latitude for the
swelling and warping which may tend to open manufacturer to adjust his materials, it is advisable to
joints and break paint tlim. Wide boards shall consult the paint manufacturer and obtain his guar-
be fixed centrally or at one edge only, bearing antee that the paints purchased not only satisfy the
in mind that movement may be sufficient to specified requirements but are also compatible with
rupture the paint film or may cause the board each other. As a general rule, it is safer to use primer
and with it the paint to split’ if the movement is and finishing paints made by the same manufacturer.

394
 SP62(S&T):1997

4 PAINTING NEW WOODWORK c) Unless specified otherwise, all joinery work

which is intended to be painted shall receive at
4.1 Surface Preparation least two priming coats. It is particularly impor-
a) Wood that is to be painted should be well tant that end grains be so treated and, if it is
seasoned and free from discoloured sapwood necessary to cut the joinery before fitting, all cut
and from large resinous or loose knots. If the ends shall be painted with two priming coats.
wood is not properly seasoned, the surface may 4.3 Stopping and Filling
become uneven on drying and cracks may also
Stopping and filling shall be done after priming. If the
develop. Paint applied over discoloured sap-
surface is not first primed, the filler or stopping may
wood is liable to become discoloured; resin
shrink and fall away owing to absorption of some of
from knots tends to exude through the paint.
the binder.
Any such unsound portions should, therefore,
be cut out and replaced with sound wood. 4 Stopping is made to the consistency of stiff
paste and is used to fill holes and cracks while
b) Nails should be punched well below the sur- the function of the filler is to level up slight
face to provide a firm key for stopping.
irregularities of the surface. Filler is usually
cl Mouldings should be carefully smoothed with applied with a putty knife and is subsequently
abrasive paper and projecting fibres left after rubbed down to a level surface with abrasive
machining should be removed. Quirks need paper, pumice stone or other suitable abrasive.
particular attention since paint collects on any For certain work, fillers are mixed to the con-
rough projections and the finished appearance sistency of thick paint and applied with a brush.
is then marred.
b) The filler coat should be of optimum thickness
4 Flat portions should be smoothed off with and should be allowed to fully harden and
abrasive paper used across the grain prior to flatten before subsequent coat is applied.
painting and with the grain prior to staining or Apply as many layers as necessary allowing
if the wood is left in its natural colour. Wood- the coats to harden and flatten between coats.
work which is to be stained is sometimes
The primary function of fillers is to -fill the
smoothed by scraping instead of by glass
opened cells of the wood in the surface layer.
papering.
This is necessary to prevent excessive penetra-
e) Any knots, resinous streaks or bluish sapwood tion of the finish that is subsequently applied,
that are not large enough to justify cutting out and to level off the surface of a porous wood
should be treated with two coats of pure shellac to make a smooth top finish possible.
knotting, applied thinly and extended about
2.5 mm beyond the actual area requiring treat- 4.4 Application of Undercoat
ment. Aluminium primer may be used in place Undercoat shall be applied after the surface has been
of shellac knotting. If the area is small and the primed, stopped, filled and rubbed down to a smooth
wood is not highly resinous, it is permissible, surface. Undercoat may be-brushed or sprayed. After
instead of applying two coats of knotting, to drying the coat shall be carefully rubbed down and
apply one coat slightly pigmented with wiped clean before the next coat is applied.
aluminium powder.
4.5 Finishing
4.2 Priming
The application of finishing paint varies according to
4 If there is a dirt or any other extraneous the type of paint employed (see 8). Cleanliness is
material this shall be removed. If the wood- essential and as far as possible the application should
work is not already primed, a pi-iming coat be carried out in normal dry conditions. The finishing
shall be applied. In case there is a primer coat coat may be applied either with the brush or sprayed.
but an unsatisfactory one, it shall be rubbed 5 APPLICATIONS OF CLEAR FINISHES
down to barewood and the surface reprimed.
Primer shall be applied by brushing. 5.1 General
Clear finishes for wood are generally used for interior
b) Care shall be taken to primer not only the
surface of the wood that will be visible after surfaces as their durability when used on external
fixing but also any surface which will be in surfaces is less than that of pigmented coating. This is
contact with materials, such as, brickwork or mainly because of the destructive action on the clear
concrete from which the wood may absorb finishes by the ultraviolet rays present in the sunlight.
moisture. It would be an advantage to give The ultraviolet radiation is to a great extent absorbed
such surfaces a further coat of primer before by pigments present in the coating while it may cause
fixing. considerable damage to clear finishes.
L
SP62(S&T):1997

5.2 Procedure different penetrating properties and therefore, shall be

selected to suit the performance required.
For the application of clear finishes, the following
procedure shall generally be adopted: a>Water stains - Water stains are made with
water soluble dyes. They emphasize the
a) Filling,
grain, especially of softwoods, since they are
b) Staining, readily absorbed by the porous portions but
c) Sealing, and less readily by the dense, more resinous por-
d) Finishing. tions. They will raise the grain of wood thus
spoiling the smoothness of the finish if a high-
5.3 Filling ly polished effect is required; this difficulty can
4 On hardwood with large open vessels, a be overcome by first wetting the surface with
suitable filler may be used. water to raise the grain and then, after drying,
smoothing it with abrasive paper before stain-
b) For special stain effects coloured fillers shall ing. Where it is necessary to provide a tem-
be used.
porary staining treatment on wood, that is,
cl A combination of filler and stain may be used damp or unseasoned, water stain is preferable
for reasons of cost, that is, to eliminate a to other types of stain.
separate staining operation. However, the
result lacks the grain and colour contrast
b) Spirit stains - Spirit stains are solutions of
spirit soluble dyes in industrial methylated
characteristic of wood stains.
spirit. Like water stains, spirit stains penetrate
4 On fine textured woods having minute pores more into the softer portions of the wood and
that do not require filling, unfilled drying oils, so accentuate the grain but they do not cause
thin varnishes, lacquer or shellac may be used. fibres to swell nor raise the grain. They will
e>Filler or stain filler shall be heavily applied to dry very quickly and shall be applied quickly
the wood surface by hand, using hessian orjute and skillfully to avoid patchy effects. If ap-
rag across the grain. It may be rubbed down plied to damp wood the dyes in the stains are
when still wet to get better penetration. After liable to be thrown out of solution. The surface
5 to 10 min it shall be wiped off by hand across after staining with spirit stains may be finished
the grain followed by light wipe with the grain. in the same way as after treating with water
Picking out corners and carvings may be done stains.
with a rag wrapped around the end of a shar-
pened wood dowel. The filled surface shall be
c>Oil stains - Oil stains may~be solutions of oil
soluble dyes in linseed oil but usually, to give
dried preferably overnight and smoothened wider range of colours, they consist of in-
with abrasive paper. Wipe withaclean softrag soluble, semi-transparent pigments ground in
to remove dust, etc. linseed oil and thinned with turpentine or other
5.4 Staining solvent. Sometimes wax is added to make the
stain less penetrating. Oil stains will give a
5.4.1 General softer effect than water stains or spirit stains.
Staining of wood may be resorted to for indoor fittings Generally, they may be finished with glass or
and even then only for subsequent clear finishes. The fat oil varnish. If wax-polished, the stain shall
object of staining wood is to darken it as a part of a be first given time to dry hard. If applied to
decorative scheme. If skillfully carried out, staining damp wood they are likely to develop a milky
may be used with good effect to enhance the natural effect or bloom. The application of oil stains
grain or figuring of the wood. and varnish will retard the drying of wood. Oil
stains do not take on certain resinous or oily
The depth and colour produced by staining will depend
woods, such as teak. Sometimes, these woods
not only on the concentration of the stain but also on
are penetrated with solvents to remove the
the extent to which it is absorbed by the surface. Stain
greasy matter from the surface prior to oil
is readily absorbed by soft porous springwood but
staining and varnishing.
comparatively little by the harder and denser summer-
wood. Hardwoods, being less absorbant, will present 5.4.2 Wash Coating
less difficulty, the stain may be applied liberally and If grain raising stains have been employed or if it is
allowed to remain until sufficient quantity is absorbed, desired to reduce to a minimum the risk of stain bleed-
the excess being wiped off, if necessary. The effects ing into top coats and to prevent discolouration of
produced by knots, resinous portions and other mark- wood by absorption of oil and stains from the filler, a
ings may be similarly accentuated. The different types thin coat of shellac or lacquer shall be applied on the
of stains, such as, water, spirit and oil stains have stained surfaces before sanding.

396
 SP 62 ( S & T ) : 1997

The stain may also be mixed with varnish to produce b) The stained surface shall be varnished, wax-
the combined effect in one operation; the result will, polished or French polished as required after it
however, be not as satisfactory as when the ‘finishing’ has dried. -For reasons of economy, the surface
follows as a separate operation after staining. Alter- shall be sized before varnishing, in which case
natively, the stain may also be mixed with wax so that it is important to allow the size to dry thorough-
after the application in one operation the wax may ly. Where a more durable finish is required
be polished. Here again the results will not be as two or three coats of finishing clear varnish is
satisfactory as in two stage system. recommended.
54.3 Prepuration of Wood,for Staining 5.5 Sealing

4 Surface intended for staining shall be kept A suitable sealer shall be applied on the filled and
scrupulously clean and free from greasy finger sanded surface to prevent absorption by the wood of
marks. It shall be prepared by careful smooth- the succeeding coats of finish and to seal the stain and
ing with fine abrasive paper, used in the direc- filler and thus preclude their bleeding into the finish
tion of grain; scratches across the grain are coat.
likely to become stained darker than the rest a) Sealer may be sprayed on taking care not to
and so spoil the finished appearance. If water flood the surface. It shall be allowed to dry
stain is to be used, the surface of the wood shall hard.
be wetted with water to raise the grain and then
b) A stain (toner) may be incorporated with the
be allowed to dry before finally smoothing. sealer for special colour.
b) Small cracks or nail holes may be stopped with c) When fully dry the surface shall be sanded
plastic wood, fine plaster of Paris or other taking care not to cut through at corners and
suitable stopping, if water stain or spirit stain
edges. Dust shall be blown off and surface
is to be used. The stopping shall be rubbed wiped with a clean rag.
down with fine abrasive paper when hard and
touched with a little thinned knotting before 5.6 Varnishing
staining. Where oil stain is to beused, stopping 5.6.1 Preparation of Wood for Varnishing
shall preferably be done after staining using
tinted putty or wood filler. Surfaces to be varnished shall be prepared to produce
a smooth, dry matt surface. Previous coats of paint or
C) If necessary, softwood may be treated with hot
stain, if any, should be allowed to dry and be rubbed
weak size before staining to prevent undue
down lightly, wiped off and allowed to dry..
absorption of stain, but an excess of size should
be avoided. To a certain extent the degree of 4 The operation of varnishing calls for careful
penetration of a stain may be controlled by attention to cleanliness. All dust and dirt
pretreatment of the absorbant surface with a should be removed from the surface to be
hot weak size of thinned shellac varnish. Size varnished and also from the neighbourhood. If
shall preferably be not used where the stained the surfaces are dampened to avoid raising of
surfaces are likely to come into contact with dust, they should be allowed to dry thoroughly
water, which may smear it. To control depth before varnishing is commenced. Damp
of colour, however, diluted stain may be made atmosphere and draughts should be avoided.
to soak well into the wood. Where size is used For exterior work. a normal dry day should be
the surface shall be allowed to dry thoroughly chosen. Exposure to extremes of heat or cold
before staining. In general, flat surfaces shall or to damp atmosphere will spoil the work.
be treated first and mouldings and edges last, b) In handling and applying varnish care shall be
that is, reversing the order recommended when taken to avoid forming froth or air bubbles.
applying paint, the object being to avoid Brushes and containers should be kept
double staining along the edges. scrupulously clean.

5.4.4 4pplication of Stains 56.2 Application

a) Stains may be applied by brushing, and wiping The varnish should be applied thoroughly with a brush
or by spraying. The stain shall be so thinned and spread evenly over a portion of the surface with
that it can be applied liberally without over- short light strokes to avoid frothing. It should be
staining. Care shall be taken, especially an allowed to flow out while the next section is being
absorbant softwoods, to apply stain evenly laid-in. Excess varnish should then be scraped out of
and without overlapping. Spirit stains, in the brush and the first section be crossed, recrossed and
particular require careful and quick application laid-off lightly. Too much or too little varnish left on
as they dry quickly. the surface will mar the appearance of the finish. The

397
 SP62’j&T):1997

varnish, once it has begun to set, should not be 7 FINISHING OF WOOD BASED MATERIALS
I retouched. If a mistake is made, the varnish should be 7.1 Plywood
removed and the work started afresh.
Plywood is similar to solid wood in the finishing
4 Where two coats of varnish are specified, the characteristics.
first should be a hard-drying undercoating or
flatting varnish; this should be allowed to dry 7.2 Hardboard
hard and then flattened down before applying
Hardboard is made up of fibres which are capable of
the finishing coat. If two coats are applied,
swelling under the influence of oil paints. Tempered
sufficient time should be allowed between
hardboard may be varnished or painted, if required.
coats.
A suitable treatment to prevent swelling under the
b) When flat varnish is used for finishing, a
influence of oil paints is necessary; one such treatment
preparatory coat of hard drying undercoating
is to use plastic emulsion paint thinned with water,
or flatting varnish should be first applied and
another is shellac varnish as the first coat and when
should be allowed to harden thoroughly. It
dry, rub down with fine grade gloss paper and follow
should then be lightly rpbbed down before the
with required undercoating and finishing coats as for
flat varnish is applied. Sections of the work,
solid wood.
such as panels, should be cut in clearly, so as
to avoid overlapping during application, as this 7.3 Particle Board
is likely to impart some measure of gloss to
The surface shall be filled with a thin brushable filler
partially dried areas, worked up in lapping. On
and finished as for solid wood.
larger areas, the flat varnish should be applied
rapidly, and the edges of each patch applied 7.4 Insulation Board
should not be allowed to set, but should be Two thin coats of water based paints shall be applied
followed up whilst-in free working condition. by spraying.
6 FRENCH POLISH 7.5 Wood Treated with Preservative
6.1 Preparation of Polish 7.5.1 Painting Characteristics
Pure shellac varying from pale orange to lemon yellow Wood treated with commonly used water soluble pre-
colour, free from resin or~dirt should be dissolved in servatives may be painted satisfactorily afterit is dried.
methylated spirit at the rate of 0.15 kg of shellac per The life of the coating may, in some instances, be
litre of spirit (see IS 348 : 1968). Suitable pigment slightly less than it would have been on untreated
should be applied to get the required colour. wood, but the loss in durability isnot such as to~offer
any practical objection to the use of treated wood for
6.2 Preparation of Surface
purposes where preservation against decay is neces-
All unevenness should be rubbed down to smoothness sary and the appearance of painted wood and protec-
with a sandpaper and the surface should be well dusted. tion against weathering are desired. Coal tar creosote
Fill up pores in the wood with a filler made of paste of or other dark oil preservatives tend to bleed through
whiting in water or methylated spirit (with a suitable paint unless the treated wood has been exposed to the
pigment like burnt sienna or umber, if required) other- weather for many months before it is painted.
~wise the French polish will get absorbed and a good
7.5.2 Treatment
gloss will be difficult to obtain.
Fairly satisfactory results may be obtained on
6.3 Application of Polish creosoted wood with rough surfaces (sawed or
A pad of woolen cloth covered by fine cloth should be weather-beaten surfaces) by applying exterior water
used to apply the polish. The pad should be moistened thinned paints, such as casein paints or resin emulsion
with polish and rubbed hard on the surface in a series paints.
of overlapping circles applying the polish sparingly a) Creosote treated wood shall not be painted
but uniformly over the entire area to give an even with ordinary paint as discolouration of the
surface. A trace of linseed oil on the face of the pad latter may result. One or two sealing coats of
facilitates this application. The surface should be aluminium paint or shellac knotting clear or
allowed to dry and the remaining coats applied in the pigmented with aluminium powder shall be
same w~ay. To finish off, the pad should be covered applied before it is finished with other paints.
with a fresh piece of clean line cloth, slightly damped
b) In the case of wood treated with other preserv-
with methylated spirit and rubbed lightly and quickly atives, such as, copper napthanate,
with circular motions. The finished surface should
chlorophenol and zinc silica-fluoride, a high
have a uniform texture and high gloss.
quality aluminium primer is desirable.
 SP62(S&T):1997

c) Alternatively, advice may also be sought from clauses above, as applicable, painting may be
the manufacturers of these preservatives for withdrawn. The painting schedule covers the finishing
information as to the suitable primer that may of wood and wood-based materials with paints, var-
be applied over there. nishes, polishes and other organic coatings. The dif-
ferent coats as specified in Table 15.1 and Table 15.2
8 PAINTING SCHEDULE
shall be applied along with stopping and filling where
8.1 After the woodwork is prepared according to the necessary for the corresponding type of finish.

Table 15.1 Schedules for Finishing New Woodwork-Interior

(CZuuse 8.1)
Sl Final Primer (One Undercoat First Finishing Secon~~~ishlng
No. Finish or Two Coats Coat
Required as Required)
(1) (2) (3) (4) (5) (6)
i) Enamel IS 102 : 1962 IS 133 : 1993 IS 133 : 1993 IS 133 : 1993
IS 3% : 1966
OR
IS 3585 : 1966
ii) Oil Gloss IS 102 : 1962 IS 3536 : 1966 IS 3537 : 1966 IS 3537 : 1966
IS 3% : 1966
OR

iii) Hat 102 : :1962

IS 3585 1966 IS 133 : 1993 IS 137 : 1965 IS 137 : 1965
OR
IS 3536 : 1966 IS 3% : 1966 IS 3% : 1966 IS 3% : 1966
OR OR
IS 3585 : 1966
iv) Varnish - IS 524 : 1983 IS 331: 1975 -1s 337 : 1975
OR
IS 5::: 1968 IS 524 : 1983 IS 5% 1983

IS 5% 1968 IS 5% 1968
v) Grained - Merging type _ Merging type IS 331: 1975
Work glaze~or stains glaze or-stains
(see Annex B) IS 5271983

IS 52:: 1968
NOTES
1 For finishes (i) and (ii) tillers conforming to IS 110 : 1983 may be applied after the prime coat as required.
2 French polish, when used, shall conform to IS 348 : 1968.

Table 15.2 Schedules for Finishing New Woodwork-Exterior

(Clause 8.1)
SI Final Primer (One Undercoat First Finishing Secon%fzishing
No. Finish or Two Coats Coat
Required as Required)
(1) (2) (3) (4) (5) (6)
i) Enamel IS 102 : 1962 IS 2932 : 1993 IS 2932 : 1993 IS 2932 : 1993
OR OR 7
IS 3536 : 1966 IS 2% : 1975 IS 2933 : 1975 IS 2% : 1975
IS 3:;. 1966
ii) Oil Gloss IS 102 : i962 IS 3536 : 1966 IS 3531 : 1983 IS 3531 : 1983
IS 3% : 1966 (AFRd) (AI&d)

OR IS 117 : 1964 IS 117 : 1964

IS 3585 : 1966 OR
IS 124 (Part 3) : 1979 IS 12Y(PaIt 3) :
1979
I
OR 1962
IS 12?z IS 1:: 1962
IS 128 : 1962
IS 12? 1962 u
iii) Flat <--------------Proprietary
m&e&& to b used----_________________>
iv) Varnish - IS 524 : 1983 IS 524 : 1983 IS 524 : 1983
OR
IS 525 : 1968
v) Grained - Merging type IS 524 : 1983 IS 524 : 1983
Work glaze or stains
(see Annex B)
NOTE - For finishes (i), (ii) and (iii) fillers conforming to IS 110 : 1983 may be applied after prime coat as required.

399

_:
SP62(S&T):1997

9 MAINTENANCE quired depends on the non-volatile content of

the material used.
9.1 The principles given in Table 15.3 shall generally c) For wood finish with cold catalysed material,
be adopted for maintenance work. All unsound work the sealer used may be single pack like shellac
should be burnt off or otherwise removed and brought sealer or two pack like cold catalysed sealer.
forward as new work. In both cases the application is by spray. The
9.2 The surface should be cleaned and rubbed down sealer is allowed to dry hard normally over-
with pumice stone or abrasive paper. All holes and night, and sanded with ‘0’ grade flint paper
cracks should be prepared for stopping by touching taking care not to cut through the edges and
them up with primer paint, with undercoat paint; when corners. The dust is blown off and surface
dry the stopping should be completed with a suitable wiped with a rag.
filler and the appropriate paint schedule as given in 8 4 If the sealer shows uneven surface necessitat-
should then be applied. ing levelling off at this stage a transparent,
nitrocellulose based wood filler is used. It is
10 FINISHING OF WOOD PRODUCTS WITH applied with a putty knife in straight strokes,
NITROCELLULOSE AND. COLD air dried for 1 h and dry sanded with ‘0’ grade
CATALYSED MATERIALS flint paper.

10.1 General 10.2 Finishing

4 Nitrocellulose based two-pack material (a
The sequence mentioned in 5.2, namely filling, stain- lacquer and an activator) has limited pot life
ing and sealing shall be followed except as modified after mixing. Therefore, only a limited amount
below: required for use shall be mixed and used within
a) The filler is air dried overnight and levelled off the recommended time.
by dry sanding with ‘0’ grade flint paper. b) It may be applied over the sealer, or in many
b) The sealer should be nitrocellulose based if the cases, directly over the filler. The application
final finish is of the same material and is is by spray and the number of coats depends on
applied by spray. The number of coats re- the non-volatile content of the material used.

Table 15.3 Recommended Practice for Maintenance Painting

(Clause 9.1)
Sl Condition of Surface Cleaning and Painting Practice
No. f
A
7

Blistering Cracking Checking Chalking

(1) (2) (3) (4) (5) (6)

0 Nil Nil Nil Nil Clean, rub with sand paper, apply one reviver coat

ii) Nil Nil Yes Nil Blat down to remove checked film, clean, apply one or two
reviver coats
iii) Nil Yes Nil Nil Rub down with steel wool/sand paper to remove cracked/crazed
Localized film, touch up with primer where damaged, apply two coats of
finishing
iv) Yes Nil Nil Nil Scrap and rub down (with sand paper) the spot to bare wood,
Localized feather out the edge of paint, allow the surface to breathe out;
touch up with primer; apply two coats of undercoat; if necessary

v) Yes Nil Nil Yes Treatments (i) and (iv) combined

Localized

vi) Yes Nil Yes Nil Treatments (ii) and (iv) combined
Localized

vii) Yes Yes Nil Nil Completely remove paint to localized deep base wood and
follow full schedule
viii) Nil Yes Nil Nil do
Deep

ix) Yes Nil Nil Nil do

Heavy
NOTE-Quality of paints for interior and exterior as in Table 15.1 and Table 15.2.

400
 SP62(S&T):1997

c) In case of nitrocellulose finish, it is recom- and a circular motion is used. This works out
mended that at a time two coats are sprayed wet all the marks in the film and-the final straighten-
on wet, with 15 to 30 min air drying between ing up motion~leaves a bright and full finish.
coats; air dried over-night and wet flatted with cl The pull over solution leaves some solvent in
‘400’ grade abrasive paper and soap water the finish and hence at least I2 h air drying is
before spraying the next two coats. In place of required before handling and packing. How-
sealer the finish coats may be applied after ever, the fittings may be fixed during the
checking that it has no effect like grain raising period.
or bleeding of woodfiller. In addition to the
sealer coat, one coat of finish is considered
4 For best results pulling over is followed up
with a polish.
adequate for furniture whereas two or three
coats of finish are required for radio cabinets. 11 BURNISHING
d) In the case of cold catalysed type of finish, in The best appearance may be obtained from
place of the sealer, a coat of finish may be nitrocellulose and cold catalysed type of
applied after checking that it has no effect like finishes by means of burnishing.
grain raising or bleeding of woodfiller. Each
coat of finish is air dried for at least 4 h so as b) Levelling before burnishing is advisable. The
film is wet sanded with a fine abrasive paper
to be dry enough for subsequent operations.
(400 grade) and soap water. The sanding is
Before re-coating it shall be ensured that the
done along the grain taking care not to cut
surface is clean and dry. In addition to the
through edges and corners.
sealer coat, one coat of finish is considered
adequate for furniture whereas two or three c>A suitable burnishing compound is used for
coats of finish are required for radio cabinets. further levelling. The application is by pad.

e) After the application of the final coat the film 4 A final light rub with a flexible shaft polishing
is allowed to age at least for 24 h. machine using a soft lambs wool mop gives the
best results. Small items which can be easily
10.3 Pulling Cover manipulated may be mopped on a stationery
polishing machine. Care shall be taken to
4 Pull off solution may be used to level off only
the nitrocelluiose finish. However, if burnish- avoid burning the finish by local overheating.
ing and polishing is going to be done this e>In case of semiglossy or matt finishes with
operation may be eliminated. nitrocellulose based materials burnishing is
not required. However, wet sanding with 400
b) The application is by pad. The pad should be
moderately damp when theoperation is started. grade paper and soap water may be done to
The initial application is along the grain and obtain a smooth even surface.
then as the pad dries, the pressure is increased

ANNEX A
(Clause 2.1)
PAINTING CHARACTERISTICS OF TIMBERS

A-l Some of the soft and hard woods given in A-l.1 Trade Name Botanical Name
and A-l.2 are resinous or show oil exudation
Chir Pinus roxburghii Sargent
occasionally and hence they require special treatment.
In general hardwoods given in A-l.3 do not require Cypress Cupressus~torulosa Don
filling as their pores are less than about 100 microns in
Deodar Cedrus deodara Loudon
diameter or are filled with gum.
Kail Pinus wallichiana A.B. Jacks
A-l.1 The following softwoods are resinous and may
Spruce Picea smilthana Boiss
exude resin through paint films:
SP62(S&T):1997

A-l.2 The following hardwoods may show oil exuda- Trade Name Botanical Name
tion occasionally: Axelwood Anogeissus latifolia wall
Trade Name Botanical Name Birch Betula spp
Gurjan Dipterocarpus spp Boxwood Buzus spp
Hollong Dipterocarpus macrocarpus Gardenia Gardenia spp
vesque Haldu Adina cardifolia Hook F
Piney Kingiodendron pinnatum Kaim Mitragyna parvifolia (Roxb.)
(Roxb.) Harms Korth
White cedar Dysoxylum malabaricum - Bedd Red sanders Pterocarpus Santalinus Linn. F
A-l.3 The following hardwoods do not require filling Satinwood Chloroxylon Swietenia DC
because their pores are less than about 100 microns in
diameter or are filled with gum:

ANNEX B
(Tables 15.1 and 15.2)
MERGING TYPE GLAZE AND STAINS

B-l MERGING TYPE GLAZE although not normally classed as water stains, are often
used to darken wood, such as floor boards. Potassium
B-l.1 Merging type glaze. which faciltates the blend-
permanganate is a well known example.
ing of various colours after application is a transparent
pigment bound with a medium having good tlowing B-2.4 Spirit stains are solutions of spirit soluble dyes
properties, thinned with volatile solvent. in industrial methylated spirit.
B-2 STAINS B-2.5 Oil stains may be solutions of oil-soluble dyes
B-2.1 Stains are soluble fast dyes or transparent pig- in linseed oil but usually to give a wider range of
ments, dissolved or suspended in an oil, water or spirit colours, they consist of insoluble, transparent semi-
medium. The consistency shall be such as to ensure pigments ground in linseed oil and thinned with
complete penetration. turpentine or other solvents. Sometimes, wax is added
to make stain less penetrating.
B-2.2 Stains are supplied either in liquid or as
powders to be dissolved in the suitable medium as B-2.6 Oil stains are sometimes supplied mixed with
mentioned in B-2.1. If the medium is in oil, driers and varnish and sold as varnish stains, ,but where it is
thinners may be needed. desired to enhance and not conceal the appearance of
B-2.3 Water stains are solutions of vegetable dyes wood, better results can be obtained by staining and
in water. Solution of certain chemicals in water, varnishing separately.

PART 2 PAINTING OF FERROUS METALS IN BUILDINGS

1 GENERAL applying the so called ‘shop coat’ of paint after fabrica-

tion which consists of wiping the surface with oily rag
1.1 Painting of ferrous surfaces is preceded by or cotton waste left over from other operations, defeats
pretreatment at the factory or at site. Steel is normally the purpose of painting at the start. Any paint coat
supplied covered with oil and grease either as a protec- applied on greasy or oily steel surfaces will lack proper
tive layer to prevent corrosion or as a left over from adhesion and will lead to the failure of paint film. It is
machining and handling. The customary procedure of therefore necessary to have pretreatment which

402
 SP62(S&T):1997

eludes removal of oil, grease, dirt, rust, scale, swat-f, b) Chemical Cleaning - Where descaling is
etc, from the steel surfaces before painting is com- required to be done chemically, pickling with
menced. sulphuric or hydrochloric or phosphdric acids
is necessary. Pickling shall be carried out as
2 FACTORY PRETREATMENT
per IS 6005 : 1970.
2.1 General 2.4 Phosphate Treatment
Pretreatment and priming of ferrous metals under con- The most widely used pretreatments, for preparing
trolled conditions at the factory gives the best results metal surfaces for painting, are the numerous hot-tank
and it is therefore advisable to adopt this method phosphating processes. Details of phosphating are
wherever possible. The object of such a treatment is covered in IS 6005 : 1970.
to preserve and maintain metal surface during 2.5 Intermediate Protective Pretreatments
transport, storage and erection and to minimize the
After the preparation of surfaces and prior to applica-
‘on-site’ preparation for final painting.
tion of paint finishes, a number of intermediate treat-
Application of a priming coat should follow pretreat- ments such as red oxide or zinc rich primer may be
ment without delay. Subsequent coats of paint may be applied to give additional protection against corrosion.
applied on the site after cleaning down any damaged Etching or wash primers may be used; this is based on
parts and touching up with the primer paint. a deposition of acid-bound resinous film on ferrous
surface which would enhance the adhesion of
2.2 Removal of Oil, Grease, Dirt and Swarf
subsequent paint coatings.
Generally, the application of any coating, lining 3 ON-SITE PRETREATMENT
material, adhesive or paint, requires as its first essential
3.1 Untreated Surface
a clean surface, while dealing with painting of ferrous
metals. Grease removal shall be carried out either with a> Temporary protective materials applied to
solvent type or alkali type degreasing agents. steel sheets to protect during storage, transport
and erection should be removed with suitable
2.2.1 Solvent Cleaning solvent as a preliminary to other preparatory
A number of proprietary brands of solvent, alkaline treatments.
and emulsion cleaners are availAble; whenever these b) Lubricants used during the rolling of steel
are used, manufacturers instructions shall be followed. sheets may be particularly tenacious and may
Some of the processes are petroleum-solvent cleaning, have undesirable effects on paint adhesion.
trichloroethylene cleaning, alkaline cleaning, etc. For The use of abrasive paper with suitable solvent,
details of procedure for carrying out these processes, is effective in removing the worst effects of
IS 6005 : 1970 may be referred to. these materials. Where joints are welded,
soldered or brazed, care should be taken to
2.3 Removal of Rust and Scale
remove fluxing material before painting. This
When steel leaves a rolling mill it has a firmly-adher- may be effected with a 10 percent solution of
ing skin known as ‘mill-scale’. On exposure to the formic acid followed by thorough washing or
atmosphere, the mill-scale absorbs moisture, works with suitable solvents.
itself loose allowing moisture to penetrate between
scale and steel resulting in rusting. Therefore, derust-
c>In case of heat hardened alloys, the surface
shall be treated by mechanical roughening
ing and descaling are essential prior to application of combined by degreasing. Such work should be
paint. The problem is much worse for old steel com- carried out as thoroughly as possible to ensure
pared to new steel surfaces. Generally, derusting and that the paint will adhere well and give protec-
descaling may be carried out mechanically or chemi- tion and durability. The surface should be well
cally. scraped or swabbed with a suitable solvent and
a) Mechanical Cleaning - This may be done by then abrased with an abrasive paper and finally
scraping, chipping, wire brushing, rubbing rinsed with successive portions of clean
with abrasive paper or steel wool, by flame solvent on clean swabs.
cleaning and sand or shot-blasting. For com-
4 Proprietary compositions may be used as
plete removal of all types of mill-scale, the recommended by the manufacturer to degrease
only really efficient mechanical method is and passivate or degrease and etch the surface;
sand- blasting or shot-blasting. but care should be taken unless specified other-
Flame cleaning is carried out with the help of wise, to remove all residues by wiping or wash-
a special oxy-acetylene torch; but it is not ing where possible and to ensure that the
suitable for use in confined spaces due to fire compositions do not contaminate other parts of
risk. the structure.

403
SP 62 ( S & T ) : 1997

3.2 Surfaces Containing Temporary Protective 4.3 Schedules

Treatment The selection ofpaints and painting system shall be in
Temporary rust protective treatment shall be removed. accordance with Table 15.4.
Descaling may be done by mechanical means such as 4_4 Maintenance
hand-scraping or shot-blasting or flame cleaning.
Where only derusting is to be done, the mechanical or Maintenance schedule shall be as in Table 15.5.
chemical method may be followed. 4.4.1 Renovation
3.3 Surfaces Already Pretreated and/or Primed in a) Where specification of painting is known
Factory
1) If the paint film is only chalking and other-
They should be inspected and damaged areas should wise the filmis in good condition wipe off
be thoroughly degreased by clean solvent swabbing; chalked film with wet rag or wash with
corrosion products should be removed and touched up water, remove gloss, allow the water to
with a coat of wash or etching primer on suitable dry off and apply one coat of finishing all
chemical pretreatment solutions. The rectified areas over the surface. If the chalking is in
should be brought forward with appropriate primer, patches, apply one coat at the chalked
putty, finish coats, etc. areas and after it is dry, apply another coat
3.4 Brush Derusting with Phosphoric Acid all over the surface.

Apply phosphoric acid with a brush or swab, rubbing 2) If fine chalking and/or hair line cracking
where needed with a steel wool pad, to assist have appeared and the film underneath is
rust removal. Keep the surface well wetted with firm, without symptoms of rust, cut the
phosphoric acid. paint film by wet rubbing, remove all the
cracked film, wash, allow water to
3.5 Solvent Cleaning, etc evaporate and apply one or two coats of
Solvent cleaning, mechanical cleaning, etching with finishing paint or enamel. If the defects
primers shall be done as in 2.2.1. are noticed as patches, after cutting down
the film in these patches, apply one coat
4 APPLICATION OF PAINTS
of the finishing paint/enamel on this area
4.1 General and then follow with a coat all over the
Immediately after the pretreatment process, the first surface.
primer coat shall be applied within the shortest 3) If the cracking is deeper, with or without
possible interval, unless rust proofing or other interior flaking, reaching up to the primer, without
process is employed. This is particularly important in symptoms of rust and the primer coat is in
areas with high humidity. good condition then proceed as follows:
4.2 Painting If the defect is all over the surface, cut
down the top two coats to the primer by
4 Primer coats may be applied by spray or brush,
preferably the latter working in the paint into wet rubbing, allow water to dry off, touch
the fine dents and ensuring a continuous film up the primer coat and build up the entire
without ‘holidays’. After the first coat is dry film by applying fillers, undercoating and
apply the second coat. finishing coat as required.
If the defect is only in patches, cut down
b) Filler Coats - After the second primer coat is
hard and dry, sand the surface without scratch- the top coat only in these areas feathering
ing or in anyway damaging the primer coats. the top coat, build up film in these patches
Fill the deep dents with paste filler using good ending with one finishing coat and apply
putty knife pressing firmly into the dents. a coat of finish all over the surface.
Allow to hard dry and cut down by wet rubbing 4) If blistering with or without flaking is
to a smooth finish. Apply as many coats of noticed and the primer coat is sound,
filler as required. follow the procedure in 4.4.1 (a)(3).

cl Undercoats may be applied by brush or spray 5) If rust spots are noticed in certain areas
after rubbing down the entire surface. Allow only with or without any other symptoms
it to hard dry and rub dow,n cutting to a smooth of breakdown, cut down the film in those
finish. spots to metal, feathering off the top coats,
apply two coats of primer and build up the
4 Finishing coat may be applied by brush or
film following the schedules. Rough sand
spray. Gently remove the gloss of the entire
the entire surface, wash off if necessary
surface.
and apply a finishing coat.

404
 SP62 ( S& T ) : 1997

Table 15.4 Painting Schedules for Ferrous Surface

(Clause 4.3)
St Final Finish Primer Undercoat Finishing Coat Number and Thickness of Coating
No. Required
(1) (2) (3) (4) (5) (6)
A FORINTERIORS

i) Full gloss IS 102 : 1962 IS 133 : 1993 (B)‘) IS 133 : 1993 (B)‘) For optimum results, two coats of primer,
(enamel (see Note) IS 2933 : 1975 (B, S)‘) IS 2933 : 1975 (B, S)‘) one undercoat, and two finishing coats are
gloss) IS 207 : 1964 recommended. The total film thickness shall
be not less than 100 microns.
ii) Oilgloss Same as IS 133 : 1993 (B) Same as for (i)
for (i) OR
IS 144: 1950 (S)
iii) Eggshell IS 102 : 1962 IS 137 : 1965 - Same as for (i)
gloss (see Note)
iv) Flat IS 102 : 1962 IS 137 : 1965 IS 137 : 1965 Same as for (i)
(see Note)
v) Metallic Same as - IS 2339 : 1963 (B) One coat of primer and two finishing coats;
finishes for(i) IS 2339 : 1963 (S) if bituminous aluminium paint is used, three
OR coats will be necessary.
Bituminous
aluminium paints
vi) Bitumen Same as - IS 158 : 1981 Three coats of bitumen shall be used.
for(i)

B FOR EXTERIORS

vii) Full IS 102 : 1962 IS 2933 : 1975’) IS 2933 : 1975’) For optimum results, two coats of primer,
gloss (see Note) one~undercoat and two finishing coats am
recommended. The total film thickness shall
not be less than 1BO micron.
viii) Oil Same as - IS 117 : 1964 Same as for (vii)
gloss for (vii) OR
IS 128 : 1962
ix) Eggshell - - -
gloss
x) Flat IS 102 : 1962 - - -
(see Note)
xi) Metallic Same as for - IS 2339 : 1963 One coat of primer and two finishing coats;
finishes (vii) OR if bituminous aluminium paint is used, three
Bituminous coats will be necessary.
aluminium
paint
NOTE -Paint primer conforming to IS 102:1962 may be used only where special precautions for drying of the primer coat are taken
and where satisfactory drying conditions is ensured before applicationof further coats.
‘) Each of these Indian Standards cover both undercoating and finishing paints, and paints appropriate for the function shall be used.
(B) is brushing.
(S) is spraying.

6) Fresh painting should be done after scrap- 44.2 Removal of Old Paint for Repainting
ing off the entire old paint film if
- the rusting is noticed all over the sur- a) Caution should be exercised while removing
face, or old paint. Paint removers of the alkali based or
solvent type are available and if proper care is
- the rusting is severe; or
not taken, they may do more harm than good.
- cracking and blistering has damaged While washing down after using alkali type,
the primer coat exposing the metal other structures, such as wood, may be adver-
and is noticed all over the surface; or sely affected. For the solvent type, the fume
- the paint film has eroded badly. and fire hazard is to be counted. They contain
waxes and removal of last traces of wax is
b) Where the specification of painting is not
known - follow the procedure given in 4.4.1 essential as otherwise adhesion of paint coats
(a), Renovate with best quality materials to may be adversely affected.
perform under the conditions of exposure.

405
SP 62 ( S & T ) : 1997

Table 15.5 Recommended Painting Practice for Maintenance Work

(Clause 4.4)
SI Conditions of Service Cleaning and Painting Procedure
No. h
\
f
Rusting Cracking Checking Chalking

(1) (2) (3) (4) (5) (6)

0 Nil Nil Nil Yes Clean; rub down with sand paper; apply one reviver coat

ii) Nil Nil Yes, fine Nil Flat down to remove checked film; clean; apply one or two
checking reviver coats

iii) Nil Yes, not Nil Treat as in 4.4.1 (a)(2)

reached the
surface

iv) Yes Nil Nil Yes Treat as in 4.4.1 (a)(5)

v) a) Localized Nil Nil Yes Treat as in 4.4.1 (a)(5)

b) Localized Nil Yes Nil Treat as in 4.4.1 (a)(5)

c) Localized Yes - - Completely remove paint to bare metal and paint to full
schedule

vi) Heavy do
rusting

b) Burning off old paint carried out with caution (see Note) shall be applied to the surface and allowed
is better than using paint removers. to dry thoroughly before repainting.
c) Removal of old paint by mechanical method of NOTE - A recommended composition and concentration of
chipping and scraping is the best. ammoniacal wash shall consist of 7 g of copper carbonate
dissolved in 80 ml of liquor ammonia and diluted to I 1with
4.4.3 ~Removal oj’ Fungi water. Alternatively, 2.5 percent of magnesium silicofluoride
Exterior paint surfaces may develop fungi which solution nay be used.

shall be removed and ammoniacal copper solution

PART 3 PAIWTING OF NON-FERROUS METALS IN BUILDINGS

1 GENERAL There-has also been an increase in the use of non-

ferrous metals, particularly zinc and ,aluminium in
1.1 The increasing importance and use of non-ferrous various ways as protective coating on steel. If un-
metals as structural materials in variety of conditions painted, such metallic coatings afford protection of the
and environments had led to an increase in the forms steel under most conditions for periods related to the
which require painting. Zinc, copper and lead when thickness applied. If properly painted and adequately
used in sheet form for roof coverings are rarely painted maintained even greater protection is conferred.
and in other forms, such as pipes and fittings the areas Zinc in sheet form or galvanized steel, when new,
to be painted are small. The development and exten- always requires degreasing before painting, and to
sion of the use of non-ferrous metals fin the form of ensure adequate adhesion of the paint film, the surface
claddings and linings for frame buildings and in light should be modified by pretreatment, or by about three
gauge sections as structural members call for an months weathering in a clean atmosphere or as alter-
appreciation of their painting requirements. Zinc, native, a special primer may be used.
copper, lead, pure aluminium and some aluminium
alloys require painting only when in contact with 2 SURFACE PREPARATION AND
corrosive materials or atmospheres or for decoration. PRETREATMENT

The original bright metallic appearance of the non- 2.1 General

ferrous metals, may be preserved by the use of clear
Pretreatment and priming of non-ferrous metals under
finishes, but frequent renewal and maintenance of the
controlled conditions at the factory gives the best
coating is necessary.

406
~~~~_~ _.. ^_._...- --

SP62(S&T):1997

results and it is, therefore, advisable to adopt this 4 Casting in aluminium alloys may often be
method wherever possible. Application of suitable painted without any pretreatment other than
priming coat should follow the pretreatment without degreasing.
delay. Subsequent coats of paint may be applied on- e>For unpainted aluminium surfaces, when they
site after-cleaning down the primer and touching up acquire a surface layer of corrosion products,
with the primer paint any damaged parts. Pretreatment it shall be removed.
processes are dealt with under two heads for each
substrates, namely factory treatment and on-site 2.3 Zinc
treatment. 2.3.1 Factory Treatment
For surfaces already factory pretreated, primed, ap- The surface should be freed of oil, grease or any
plication of further coats of paint should be followed foreign contaminant by means of solvent-cleaning
in the usual manner after suitable rectification of method before applying any of the treatments
damaged areas, if any, arising out of during storage recommended below:
and/or handling.
a) Crystalline zinc phosphating treatment,
2.2 Aluminium and Aluminium Alloys b) Chromate treatment,

2.2.1 Factory Pretreatment c) Aqueous chromic organic treatment, and

d) Etching or wash primers.
This covers the following:
2.3.2 On-Site Pretreatment - Surfaces Untreated
4 Mechanical treatment - Mechanical treat-
ment can be done by hand or~power wire brush- a>The surface should be thorough!y degreased.
ing or other abrasive treatment or sand The use of mordants containing copper is not
blasting. recommended.

b) Solvent cleaning - Solvent cleaning, where b) If the zinc sheet or galvanized steel is allowed
possible, should be followed by chemical treat- to weather up tii, Lhebright spangles disappear
ment or anodic treatment. before painting, it attains a condition suitable
to receive paint without the necessity of
cl Chemical treatment- The chemical treatment
degreasing or etching. Galvanizing alone, of
could include alkaline etching, sulphuric acid
reasonable thickness, is sufficient to protect the
etching, phosphoric acid cleaners, acid
steel from corrosion for some years under
flouride deoxidizer, crystalline phosphate
normal exposures.
treatment, amorphous phosphate treatment,
carbonate chromate treatment, amorphous 2.4 Magnesium
chromate treatment, etching or wash primers.
Chemical treatment at site is not easy and, therefore,
4 Anodic treatment-This includes treatment& factory treatment is preferred.
either chromic or sulphuric acid electrolyte.
2.4.1 Factory Pretreatment
Anodic treatment should not be used on
assemblies of dissimilar metals. a) For metal exposed to indoor (mildly corrosive)
conditions, mechanical (abrasive) treatment,
2.2.2 On-Site Pretreatment solvent cleaning, alkaline solution treatment
This is applicable to surfaces untreated or protected and acid pickling are suitable.
with a temporary protection and details are as below: b) For exposure to higher degree of corrosion
Temporary protective materials applied to (outdoor), surface preparation by a suitable
aluminium should be removed with a suitable conversion coating treatment such as
solvent. dichromate method shall be adopted. Certain
anoidic treatments may also be considered.
Lubricants used in rolling of aluminium sheet
should also be removed. The use of abrasive c>Wash or etching primers may also be ~applied
paper wetted with a suitable solvent is effective on previously cleaned surfaces.
in removing the effects of these materials. 2.4.2 On-Site Pretreatment
Flux of welded joints should be removed with
The most satisfactory method is to apply an etching
IO percent solution of formic acid followed by
primer after degreasing by solvent cleaner or prefer-
thorough washing or with-suitable solvents.
ably an etch cleaner based on phosphoric acid. The
c) In the case of heat hardened alloys, the surface combination of etching primer and etching pretreat-
shall be treated by mechanical roughening ment gives better results than if either of them were
combined with degreasing. used alone.

407
SP62(S&T):1997

2.5 Cadmium weight of barium chromate or kaolin in an oil

varnish medium, the content being between 50
Similar to zinc except that weathering is not required.
to 60 percent by weight and free from water-
2.6 Copper and Copper Alloys soluble sulphates and chlorides.

The surface should be thoroughly cleaned with an Bitumen or bituminous pastes and rubber
organic solvent and then roughened with fine abrasive based jointing compounds are used for other
paper and applied with one coat of etching primer. metals.
Where factory preparation is possible, an electro- In all cases the joint should be made while the
deposited coating of tin is useful in preparation for jointing compound is still wet, the metal
painting. having been previously prepared and primed.

2.7 Lead 3.2 Painting Schedule

New lead surface should be weathered or pretreated a>Where metals are to come into contact with
alkaline materials like concrete, etc, they
before painting, the latter being preferable because of
should be given one or two coats of bituminous
interaction between lead and many conventional
paint, and where the conditions are persistently
paints. The application of etching primer is satisfac-
damp, even thicker coatings are desirable.
tory as a pretreatment of bright lead. An alternative is
Similar treatment is necessary if the metals are
to treat the surface with dilute solution of otthophos-
to come into contact with hardwoods. Only
phoric acid (about 20 percent by volume) followed by
copper appears not to require this protection.
thorough washing and drying.
2.8 Lead Tin~(Including Terne Plate)
b) For aluminium, zinc chrome or a modified zinc
chrome paint even with an etch primer, should
The main preparation required for these surfaces is be used. For subsequent coats, normal types of
through degreasing with white spirit or other suitable oil, oleoresinous or synthetic resinous paints
solvent, followed by a washing with hot water. An may be used provided that they are compatible
etching process recommended for maximumadhesion ~with the priming paint. Bituminous paints may
is to swab with a solution of 5 parts of concentrated also be used.
hydrochloric acid with 95 parts methylated spirit until
a~crystalline pattern is seen (about 10 s) and washed in
c>Copper, Lead - The first coating or primer
may be unpigmented resin varnish or an etch-
hot water. ing primer. If alight coloured finish is required
2.9 Tin a coat of aluminium paint over the resin varnish
may be applied. The finishing coats are as
The painting of tin applied by methods other than hot given for aluminium.
dipping present no difficulties, but adhesion may be d) Zinc and Zinc Coated Metals - After pretreat-
defective on hot dip coating which should be ment, the subsequent coatings are as given for
roughened or treated with etch primer prior to painting. aluminium.

3 PAINTING d Magnesium - The medium for painting mag-

nesium should be highly resistant to water and
3.1 General alkali; for example, a stoving or air-drying
medium, such as that based on oil/phenolic
4 Certain non-ferrous metals, for example, resin varnish. The primer should not contain
aluminium, zinc, cadmium, copper, lead and graphite, lead pigments or metallic lead,
tin are capable of resisting corrosion without bronze or aluminium; it should however con-
painting under natural exposures. Anodized tain zinc chromate in appropriate percentages
aluminium is quite resistant to corrosion. suitable to the exposure conditions; for normal
b) Jointing compound is needed to insulate metal exposure 20 percent by weight of the dry paint
to metal contact, specially if they are exposed film.
to damp conditions and the metals are dis- 3.2.1 Painting systems could be by ordinary or sophis-
similar. ticated methods; like roller coat, electrostatic spraying,
Jointing materials are usually paste-like air drying, force drying~or stoving.
materials. 3.23 Maintenance painting should be done after
When dissimilar metals are used in conjunc- removing the old paint; for this organic solvent type
tion, a jointing compound containing paint remover is preferred. If paint has flaked only in
chromates are preferred where aluminium or certain patches, only such patches may be removed.
magnesium is one of the metals. A typical After removal of old paint, priming and finishing
jointing compound consists of equal parts by should be done as in 3.2.
 CHAPTER 16

WATERSUPPLYANDDRAINAGE
 CONTENTS

1 GENERAL 2.3 Gradients and Pipe Sizes

PART 1 WATER SUPPLY
2.4 Choice of Materials for Pipes
2.5 Drainage Pipes
1 GENERAL
2.6 Manholes
2 MATERIALs
2.1 Pipes 3 STORMWATERDRAINAGE
2.2 Choice of Pipes 3.1 General
3 CONVEYANCEAND DISTRIBUTIONOF WATER 3.2 Rainwater Pipes for Roof Drainage
WITHINTHEPREMISES 3.3 Disposal
3.1 Basic Principles
4 SUBSOILWATERDRAINAGE
4 GENERALREQUIREMENTS
OFPIPEWORK
4. I -General
5 LAYINGOFPIPES
4.2 Systems of Subsoil Drainage
5.1 Service Pipes
5.2 Securing and Supporting of Pipes 5 CONVEYANCE
OFSANITARY
WASTES
5.3 Pipes Laid Through Ducts, Chases, Notches or 5.1 Laying of Pipes
Holes
5.2 Protection of Pipes
5.4 Lagging of Pipes
5.3 Jointing of Pipes
6 JOINTINGOFPIPES
5.4 Connection to an Existing-Sewer
6.1 Wrought Iron and Steel Screwed Pipes
5.5 Backfilling
6.2 Polyethylene and Unplasticized PVC Pipes
PART 3 WATER SUPPLY AND DRAINAGE
6.3 Asbestos Cement Pipes
IN HIGH ALTITUDES/SUB-ZERO REGIONS
6.4 Lead Pipes
1 GENERAL
6.5 Copper Pipes
7 STORAGEOFWATER 2 WATERSUPPLY
8 CLEANINGAND DISINFECI-IONOF THE SUPPLY 2.1 Selection and Sources
SYSTEM
2.2 Pumping Installations
9 INSPECTION.
TESTINGAND MAINTENANCE
2.3 Protection and Storage of Water and Treatment
10 REQUIREMENTS
OFOTHERWORK 2.4 Transmission and Distribution
PART 2 BUILDING DRAlNAGE
3 WASTEDISPOSAL
1 GENERAL
3.1 General
2 DESIGNCONSIDERATIONS
3.2 Waterborne System
2. I Disposal of Sewage
2.2 Layout
 SP 62 ( S & T ) : 1997

CHAPTER 16

WATER SUPPLY AND DRAINAGE

1 GENERAL maintenance of drains inside buildings and from the
buildings up to the connection to public sewer,
1.1 Plumbing system shall include water supply and
cesspool or other water course.
distribution pipes; plumbing fittings and traps; soil,
waste, vent pipes, antisphonage pipes; building drains
1.4 For convenience, the Chapter is divided into three
and building sewers including their respective connec-
Parts, Part 1 Water supply, Part 2 Drainage and Part 3
tions, devices, appurtenances within the property lines
Water supply and drainage at high altitudes and/or
of the premises.
sub-zero temperature regions.
1.2 This Chapter deals with water supply, plumbing
connected to public water supply systems, principles 1.5 SP 35 (S & T) : 1987 which has been already
of conveyance and distribution of water within the prepared is taken note of in preparing this Chapter.
premises; it also covers water supply systems in high
altitudes and/or sub-zero temperatures. 1.6 Local municipal byelaws should also be consulted
1.3 This Chapter also covers the drainage and sanita- and work carried out after their approval.
tion requirements of buildings. Construction and

PART 1 WATER SUPPLY

1 GENERAL h) Lead to IS 404 (Part 1) : 1993.

1.1 This Part deals with general requirements of 2.2 Choice of Pipes
plumbing connected to public water supply and instal- The materials for piping and fittings, shall be resistant
lation of water supply system consisting of water to corrosion both inside and outside or shall be suitably
service pipe, water distribution pipe, connecting pipes, protected. Lead piping shall not be used for conveying
fittings, valves and all related appurtenances in or domestic water supply; they may however be used for
adjacentto buildings. flushing and overflow pipes. Copper piping may be
1.2 The water supply requirements of buildings and used for hot water supply systems, provided water is
design of distribution systems shall be as per IS 1172 : not capable of dissolving an undue amount of copper.
1993 and IS 2065 : 1983 respectively. In using asbestos cement pipes adequate precaution
shall be taken while laying backfilling. Mild steel tubes
1.3 Figure 16.1 is a typical sketch of the different
used in plumbing shall be of medium class to IS 1239
types of water supply pipes in buildings.
(Part 1) : 1990. Polyethylene and PVC pipes should
1.4 Excavation, if required, shall be as per Chapter 2. not be laid on hot surfaces or in too close a proximity
2 MATERIALS to the hot -water pipes. Care should also be taken to
2.1 Pipes avoid locations where they are likely to be exposed to
atmosphere charged with coal gas.
Pipes may be of any of the following materials:
3 CONVEYANCE AND DISTRIBUTION OF
a ) Cast iron, vertically cast or centrifugally (spun)
WATER WITHIN THE PREMISES
cast to IS 1536 : 1989 or IS 1537 : 1976.
3.1 Basic Principles
b) Mild steel tubes and tubulars to IS 1239
(Part I) : 1990. Some of the details of plumbing which are considered
c) Asbestos cement to IS 1626 (Part 1) : 1991 and necessary for properly designed, acceptably installed
IS 1592 : 1989. and adequately maintained plumbing systems are
given below from (a) to (k). Though the details of a
d) Polyethylene to IS 3076 : 1985 and IS 4984 :
1987. construction may vary, the basic sanitary and safety
principles are the same, and they merit serious study.
e) Unplasticized PVC to IS 4985 : 1988.
Furthermore in the event of any unforseen situation not
9 Copper to IS 1545 : 1982.
covered here, the principles enumerated may serve as
g) Brass to IS 407 : 1981.
useful guides.

411
SP62(S&T):1997

r
AB AN0 FO rCDMMUNlCAltON PtPES
BCDE = SUPPLY PIPE
PQ *OISTRIBUftNG PIPE
/ OH, Hl.HJ, JM.
Jfi,W BCDE,
PO .=CONSUMER’S PIPES

NOTE-The illustrationis not intendedto indicaterecommendedpositions of undergroundstoragetank (where provided), pipes, etc,
and this will~dependon local situations.

FIG. 16.1 TYPICAL SKETCH FOR IDENTIFICATIONOF DIFFERENTTYPES OF WATER SUPPLY PIPES

a) Wholesome water supply provided for drink- b) The design of the pipe shall be such that there
ing and culinary purposes shall not be liable to is no possibility of backflow towards the
contamination from any less satisfactory source of supply from any cistern or appliance
water. There shall therefore be no cross con- whether by siphonage or otherwise. Reflux or
nection whatsoever between a pipe or fitting non-return valves shall not be relied upon to
conveying or containing whole some water and prevent such backflow.
pipe or fitting containing impure water or c) Where a supply of less satisfactory water be-
water liable for contamination or of uncertain comes inevitable as an alternative or is re-
quality of water which has been used for any quired to be mixed with wholesome water, it
purpose. shall be delivered only into a cistern, and by a
The provision of reflux or non-return valves or pipe fitting discharging into the air gap at a
Y

closed and sealed stop valves shall not be con- height above the top edge of the cistern equal
strued as a permissible substitute for complete to twice its nominal bore, and in no case less
absence of cross connection. than 150 mm. It is necessary to maintain

412
 SP62(S&T):1997

definite air~gap in all appliances or taps used in 4.1.1 Communication Pipes

water closets.
a) Every premises shall have its own separate
d) All pipe work shall be so designed, laid or communication pipe for supply of water to-the
fixed, and maintained as to be and to remain Authority. In the case of a group or blocks of
completely watertight, thereby avoiding waste premises, the same communication pipe may
of water, damage to property and risk of supply water to more than one premises.
contamination of the water conveyed.
b) The communication pipe between the water
4 No piping shall be laid or fixed so as to pass main and the stopcock at the boundary of the
into, through or adjoining any sewer, scour premises shall be laid by the Authority.
outlet or drain or any manhole connected there-
c) Connection up to 50 mm dia may be made on
with nor through any ash pit or manure pit or
the water main by means of screwed ferrules,
any material of such nature that would be likely
provided the size of the connection does not
to cause undue deterioration of the pipe, except
exceed one-third the size of-the water main. In
as permitted in 3.1(f).
all other cases, the connection shall be made by
Where lines have to be laid in close proximity a-Tibranch off the water main (see 5.1).
to electric cables or in corrosive soils, adequate
d) As far as possible, the communication pipe
precautions should be taken to avoid electrical
and the underground service pipe shall be
accidents and corrosion.
laid at right angles to the main and in ap-
f) Where the laying of any pipe through corrosive proximately straight~lines to facilitate location
soil or previous material is unavoidable, the for repairs.
piping shall be properly protected from contact
e) Every communication pipe shall have a stop-
with such soil or material. Any existing pipe
cock and meter inserted in it. The waterway of
or fitting laid or fixed, which does not comply
such fitting shall not be less than the internal
with the above requirements, shall be removed
sectional area of the communicating pipe and
immediately and relaid in conformity with the
the fittings shall be located within the premises
above requirements.
at a conspicuous place accessible to the
s) To reduce friction losses, piping shall be as Authority which shall have exclusive control
smooth as possible inside. Methods of jointing over it.
shall be such as to avoid internal roughness and __ _
projection at the joints, whether of the joining 4.12 Consumer Pipes
materials or otherwise.
4 No consumer pipe shall be laid in the premises
h) Change in diameter and in direction shall be to connect the communication pipe without the
gradual rather than abrupt to avoid undue loss permission of the Authority.
of head. No bend or curve in piping shall be
b) The consumer pipe within the premises shall
made which is~likely to materially diminish, or be laid underground with a suitable cover to
alter the cross-section. safeguard against damage from traffic and
_i>Underground piping shall be laid at such a extremes of weather.
depth that it is unlikely to be damaged by frost
ortraffic loads and vibrations. It shall not be
c>To control the branch pipe to each separately
occupied part of a building a stop valve shall
laid in ground liable to subsidence; but where be fixed to minimize the interruption of supply
such ground cannot be avoided, special precau- during repairs. All, such stop valves shall be
tions shall be taken to avoid damage to the fixed in accessible positions and properly
piping. Where piping has to be laid across protected. To provide for drinking or culinary
recently disturbed ground, the ground shall be purposes, direct taps shall be provided on the
thoroughly consolidated so as to provide a branch pipes connected directly to the con-
continuous and~even support. sumer pipe. In case of multistoreyed build-
k) No boiler for generating steam or closed ings, down take pipes shall be supplied from
boilers of any description or any machinery ’ overhead tanks.
shall be supplied direct from a service or
4 Pumps shall not be allowed on the service pipe,
supply pipe. Every such boiler or equipment as they cause~a drop in pressure on the suction
shall be supplied from a feed cistern. side, thereby affecting the supply to the ad-
4 GENERAL REQUIREMENTS OF PIPE joining properties. In cases where pumping is
WORK required, a properly protected storage tank of
4.1 The following general principles shall comply in adequate capacity shall be provided to feed the
the layout and planning of the pipe work. pump.

413
SP62(S&T):1997

e) No direct boosting (by booster pumps) shall be screwed down ferrule of non-ferrous metal
allowed from the service pipes (communica- conforming to IS 2692 : 1989, but the ferrule
tion and consumer pipes). itself shall not be more than 25 mm bore.
Consumer pipes shall be so designed and con- Ferrules of 20 mm and above shall not be used
structed as to avoid air locks. Draining taps on mains of less than 100 mm bore. The main
shall be provided at the lowest points from is drilled and tapped and the ferrule screwed in.
which the piping shall rise continuously to the In case of large-sized trunk mains, this may be
drain off taps. done by a tapping under pressure machine,
which will obviate any interference with the
Consumer pipes shall be so designed as to
use of the main.
reduce the production and transmission of
noise as much as possible. b) Service pipes of 50 mm and above shall be
connected to special T-branches which have to
h) Consumer pipes in roof spaces, unventilated be inserted into the line of the main. Special
air spaces, underfloors or in basements shall be
branch pipes shall also be used for service
protected against corrosion.
pipes of less thati 50 mm bore where the bore
j> Consumer pipes shall be so located that they of the main is not greater than thrice that of the
are not unduly exposed to accidental damage service pipe.
and shall be fixed in such positions as to
facilitate cleaning and avoid accumulations of
cl Precautions against contamination of the
mains shall be taken when making a connec-
dirt.
tion, and where risk exists, the main shall be
k) All consumer pipes shall be so laid as to permit subsequently disinfected. The underground
expansion and contraction or other move- water service pipe and the building sewer or
ments. drain shall be kept at a sufficient distance apart
4.1.3 Prohibited Connections to the satisfaction of the Authority so as to
prevent contamination of water. Water service
4 A service pipe shall not be connected to a pipes or any underground water pipes shall not
distribution pipe, since such connection may be run or laid in the same trench as the building
permit backflow of water from a cistern into sewer or drainage pipe. Where this is un-
the service pipe, in certain circumstances, with avoidable, the following conditions shall be
subsequent damages of contamination and fulfilled:
depletion of storage capacity. It might result
1) The bottom of the service pipe, at all
in pipes and fittings being subjected to a pres- points, shall be at least 30 cm above the
sure higher than that for which they are top of the sewer line at its highest point.
designed and in tlooding from overflowing
cisterns. 2) The water service pipe shall be placed on
a solid shelf excavated at one side of the
b) No pipe for conveyance or in connection with common trench.
water supplied by the Authority shall com-
3) The number of joints in the service pipe
municate with any other receptacle used or
shall be kept to a minimum.
capable of being used for conveyance other
than water supplied by the Authority. 4) The materials and joints of sewer and
water service pipe shall be installed in
c>Where storage tanks are provided, no person
such a manner and shall possess the neces-
shall connect or be permitted to connect any
sary strength and durability so as to
service pipe with any distribution pipe.
prevent the escape of solids, liquids and
4 No service pipe shall be connected directly to gases there from due to temperature
any water closet or a urinal. All such pipes changes, settlement, vibrations and super-
shall be from flushing cisterns which shall be imposed loads.
supplied from storage tank.
4 The service pipe shall pass into or beneath the
e) No service or supply pipe shall be connected building at a depth below the external ground
directly to any hot water system or to any other level of not less than 0.75 m (provided the
appartus used for heating water other than foundation is deeper than 0.75 m) and at its
through a feed Fistern thereof. point of entry through the structure should be
5 LAYING OF PIPES accomodated in a sleeve which should have
been solidly built in. The space between the
5.1 Service Pi-Des pipe and sleeve shall be filled with bituminous
a) Service pipes less than 50 mm bore [nay be or other suitable material for a minimum length
connected to~mains by means of a right angled of 15 cm at both ends.

414
 SP62(S&T):1997

e) Care shall be taken to ensure that before the alround with waterproof insulating material
pipeline is charged all piping and fittings are and shall not be in direct contact with the wall.
clean internally and free from particles of sand Where it passes through a wall, whether into a
or soil, metal fittings, etc, which besides building or not, the lagging shall be continued
causing obstruction may lead to failure by along the pipe throughout the thickness of the
corrosion. wall, and where it emerges from the ground,
the lagging shall be continued into the ground
5.2 Securing and Supporting of Pipes
until the depth of 0.75 m is reached.
a>Lead piping of not more than 25 mm bore, in b) Lagged piping connected to cisterns, enclosed
vertical runs, may be secured directly to brick by insulating casing shall pass at right angles
walls (othei than external walls) by iron pipe through the casing and be lagged inde-
clamps driven into the wall joints, or may be pendently of the casing; if the piping is
secured to wooden battens or other woodwork sandwiched between the cistern and the casing,
by iron orbrass clips with ears for screw fixing, it will probably, not be sufficiently insulated.
the clamps or clips or holder bats being at not
more than 90 cm intervals. Damage to the
c>The minimum thickness of-insulating material
for lagging hot water piping inside buildings
piping by the clamps shall be prevented by
shall be 12 mm in the case of glass in fibre
insertion of small lead pads.
form, compressed felt, and felted slag or
b) Copper piping shall be secured by copper or mineral wool and 20 mm in the case of asbes-
copper alloy clips direct to woodwork, or-by tos, 85 percent magnesia, compressed backed
similar bracket clips built in to walls or cork and granulated cork (raw or baked).
screwed to plugs.
4 Ail lagging exposed to moist conditions shall
c>Wrought iron and steel piping shall be secured be waterproof or covered with waterproofing.
in a manner similar to that used for copper
piping, except that the clips shall be of iron and Table 16.1 Spacing of Fixing for Internal Piping
steel. (Clause 5.2. I)
4 Plastic pipes should be secured and supported Kind of Piping Size of Pipe Interval for Interval for
in accordance with IS 7634 (Part 2) : 1975 and Horizontal Runs Vertical Runs
IS 7634 (Part 3) : 1975. mm 111 m
Lead All sizes 2 3
5.2.1 Spacing of Fixing for Internal Pipes Copper, light gauge 1s I 2
20 2 2.5
Fixing on internal pipes shall be spaced at regular
25 2 2.5
intervals as given in Table 16.1. 32 2.5 3
40 2.5 3
5.3 Pipes Laid Through Ducts, Chases, Notches or 50 2.5 3
Holes 65 3 3.5
80 3 3.5
Ducts or chases in walls for piping shall be provided 100 3 3.5
during the building of the walls. If they are cut in the Copper, heavy IS 2 2.5
existing walls, they shall be finished sufficiently gauge, wrought 20 2.5 3
smooth and large enough for fixing the piping. In case iron and mild steel 25 2.5 3
of lead pipes, the joints may be wiped outside the duct, 32 2.5 3
40 3 3.5
and the pipes eased back into the duct after jointing. SO 3 3.5
a) Wherever possible back-boards shall be 65 3.5 s
provided in chases for fixing the piping, other- 80 3.5 5
100 4 5
wise lead piping shall be protected from con-
Cast iron 50 2 2
tact with lime or cement by building paper or
80 2.5 2.5
felt. Where covers are-provided to chases, they 100 2.5 2.5
shall be fixed to the screws for easy removal.
Plastic 20 0.70 I 1.Stimes
b) Piping laid in notches or holes shall not be 25 0.75 the hori-
subjected external pressure and shall be free to 32 0.825 zontal
40 0.975 spacing
expand and contract without noise due to SO 0.975
friction on the wood.
6 JOINTING OF PIPES
5.4 Lagging of Pipes
6.1 Wrought Iron and Steel Screwed Pipes
a) Where lagged ~piping outside buildings is Screwed wrought iron or steel piping may be jointed
attached to walls, it shall be entirely covered with screwed and socketed joints. Care shall be taken
L

415 i
SP62(S&T):1997

to remove any burrs from the end of the pipes after is of fully annealed copper, its ends shall be
screwing. Any jointing compound, approved by the made truly round before jointing.
Authority may be used together with a grummet of a c>-Copper piping may be autogenous welded or
few strands of fine yarn; but the compound shall con- bronze welded, the latter giving the stronger
tain no red lead. joint. Copper to be welded shall be
Any threads exposed after jointing shall be painted, or ‘deoxidized copper’ and not ‘tough pitch
in ease of underground piping thickly coated with copper’.
bituminous or other suitable composition to prevent d) Copper piping of small diameter shall be
corrosion. Screwed wrought iron or steel piping may jointed to cast iron, wrought iron or steel piping
also be jointed with screwed flanges. by the use of copper-alloy screwed unions or
ferrules. For screwed copper piping of
6.2 Polyethylene and Unplasticized PVC Pipes
diameter, larger than 40 mm, a flange joint
These pipes shall be joined in accordance with the shall be used. The copper pipe shall have a
recommendations of IS 7634 (Part 2) : 1975 and copper-alloy flange screwed, brazed or welded
IS 7634 (Part 3) : 1975 respectively. on, and this shall be jointed to the iron or steel
flange by alloy bolts or nuts.
6.3 Asbestos Cement Pipes
7 STORAGE OF WATER
Asbestos cement pipes are jointed with flexible joints
supplied by the manufacturer. 7.1 Details of materials for use of storage tanks,
grouping~of storage tanks, fitments, etc, shall be as
6.4 Lead Pipes
described in IS 2065: 1983.
Lead and lead alloy pipes shall be jointed with wiped 8 CLEANING AND DISINFECTION OF THE
solder joints or by other suitable methods. Lead and SUPPLY SYSTEM
lead alloy piping shall be jointed to cast iron, wrought
iron, steel or copper piping by the use of copper alloy 8.1 All water mains, communication pipes, service
screwed unions or ferrules. atid distribution pipes used for water for domestic
purposes shall be thoroughly and efficiently disin-
6.5 Copper Pipes fected before being taken into use and also after every
major repair. The method of disinfection shall be
Screwed copper piping shall be jointed with screwed subject to the approval of the Authority.
copper-alloy fittings after treating the clean screw
threads with raw linseed oil or other suitable jointing Similarly storage tanks and down take distribution
compound. Alternatively, the screw threads of the pipes shall also be disinfected.
pipe and fittings may be tinned, and the joint heated to 9 INSPECTION, TESTING AND
the melting point of the solder when being screwed. MAINTENANCE
a>Plain copper piping shall be jointed with com-
9.1 Irispection, testing and maintenance shall be
pression (manipulative or anon-manipulative)
according to IS 2065 : 1983.
or with capillary joints in each case using
copper-alloy fittings, or by welding. Only 10 REQUIREMENTS OF OTHER WORK
manipulative compression joints, that is, joints
10.1 Sanitary Installations
in which the pipe ends are flanged, belled or
swaged, are suitable for use with fully annealed The selection, installation and maintenance of sanitary
copper piping. appliances shall be according to IS 2064 : 1993.
b) In~fhe case of the capillary joint, the pipe and 10.2 Plumbing Installations in Multistoreyed
the interior of the socket of the fitting shall be Buildings
cleaned with steel wool, fluxed and fitted
together and the joint heated to just above Plumbing in multistoreyed buildings shall conform to
melting point of the solder, which is either IS 12183 (Part I) : 1987.
provided in the fitting or is touched into the 10.3 Domestic Hot Water Installations
joint with a solder stick, and which then tlows
by capillary to fill the joint space. If the pipe This shall conform to IS 7558 : 1974.

* ,

416
 SP 62 ( S & T ) : 1997

PART 2 BUILDING DRAINAGE

1 GENERAL not introduce crevices which are not possible

to inspect and clean readily. Pipes if not em-
1.1 This Part covers with construction of drains for
bedded shall be run well clear off the wall.
waste water, surface water and subsoil water and
Holes through walls to take~pipes shall be made
sewage together with all ancillary works used within
good on both sides to prevent entry of insects.
the building and from the building to the connection to
Materials used for embedding pipes shall be
a public sewer or to treatment works, a cesspool or a
rodent proof. Passage of rodents from room to
water course.
room orfrom floor to floor shall be prevented
1.2 Excavation shall be as per Chapter 2. by suitable sealing. The intermediate length of
ducts and chases shall be capable of easy in-
2 DESIGN CONSIDERATIONS
spection. Any unused drains, sewers, etc, shall
2.1 Disposal of Sewage be demolished or filled in to keep them free
from rodents.
4 Drainage may be connected to a public sewer. c>Alignment of Pipes - The pipes shall be laid
b) Where discharge into a public sewer is not in straight lines as far as possible and with
possible, the drainage of the building shall be uniform gradients. Anything that is likely to
on a separate system. Foul water shall be dis- cause irregularity of flow, such as, abrupt chan-
posed of by adequate treatment approved by ges of directions shall be avoided. No bends
the Authority at the site. The effluent from the or junctions whatsoever shall be permitted in
plant shall be discharged into a natural water sewers except at manholes and inspection
course or on the surface of the ground or dis- chambers.
posed of by subsoil dispersion, preferably
1) Where it is not possible to avoid a change
draining to a suitable outlet channel. of direction in case of drains, access shall
cl In the case of dilution into a natural stream be provided through manholes and inspec-
course, the quality of effluent shall conform to tion chambers. Necessary terminal bends
the requirements of Authority controlling the at junctions shall be 1/8or preferably l/l 6
prevention of pollution of stream. For bends.
guidance IS 4733 : 1972 may be followed. 2) All junctions shall be oblique and the con-
4 In the case of subsoil dispersion, the require- tained angle shall be not more than 60”.
ments of the Authority of water supply shall be 3) Drains may be laid under buildings only
observed to avoid any possible pollution of when unavoidable and whenit is not pos-
local water supplies or wells. sible to obtain otherwise a sufficient fall
e>Where no other method of disposal is possible, in the drain.
foul water may be collected and stored in im- 4) Where it is necessary to lay a drain under
pervious covered cesspool and arrangements a building or exposed locations within the
made with the Authority for satisfactory building, the following conditions shall be
periodical removal and conveyance to disposal observed:
works. - Pipes shall be of cast iron to IS 1536 :
9 Under the separate system, the drainage of the 1989 and IS 1537 : 1976.
building shall be done through septic tank or - The drains shall be laid in straight line
by destabilization ponds or by any method and at a uniform gradient.
approved by the Authority. - Means of access like manholes/in-
spection chambers shall be-provided
2.2 Layout
at each end, immediately outside the
a>General-Generally, rain water shall be dealt building.
with separately from sewage and sullage. - In case the pipe orany part of it is laid
Sewage and sullage shall be connected to above the natural surface of the
sewers. Storm water from the courtyard may ground, it shall be laid on concrete sup-
be connected to the sewer where it is not ports the bottom of which goes, at least
possible to drain otherwise after obtaining 150 mm, below the ground surface.
permission from the Authority. - Drains should be preferably taken
b) Protection Against Vermin and Dirt - Instal- under a staircase or passage and not
lation of sanitary appliances and fittings shall under a living room or kitchen.

417
SP62(S&T):l997

d) Surcharge of Sewers (Precautions) - Where pipes shall be used. The approximate

there is a risk of the sewer becoming sur- gradients which give a velocity of flow of
charged under storm conditions, all gullies and 2.4 m/s for the various sizes of pipes and the
sanitary fittings shall be located above the level corresponding discharge when flowing half-
of maximum surcharge of the sewer. Where it full are as-follows:
is not practicable, an anti-flood valve shall be
Diameter Gradient Discharge
provided in the manhole nearest to the junction
mm m3/min
of drain and sewer. Parts exposed to wear in
anti-flood valves shall be of non-corrodable 100 1 in 5.6 0.59
metal and easily accessible. The cross section- 150 1 in 9.7 1.32
al area of flow through the valve shall not be 200 1 in 14 2.40
less than that of the pipe concerned. In extreme 230 1 in 17 2.98
cases, pumping may have to be considered. 250 1 in 19 3.60
The distance between inspection chamber and 300 I in 24.5 5.30
gully chamber shall not exceed 6 m. NOTE-The discharge values given in 2.3.1 (b) and (d)
are based on Mannings formula with IZ = 0.0 15.
2.3 Gradients and Pipe Sizes

2.3.1 Gradients 2.3.2 Pipe Sizes

4 The discharge of water through a domestic Subject to a minimum of 100 mm, the sizes of pipes
drain is intermittent and limited in quantity shall be decided in relation to the estimated quantity
and, therefore, small accumulations of solid of flow and the available gradient.
matter are liable to form in the drains between
2.4 Choice of Materials of Pipes
the building and the public sewer. There is
usually a gradual shifting of these deposits as 4 Salt Glazed Stoneware Pipes - For all sewers
discharges take place. Gradients shall be and drains in all soils, except where supports
sufficient to prevent these temporary building are required as in made up ground, glazed
up and blocking the drains. stoneware pipe shall be used as far as possible
b) Normally, the sewer shall be designed to dis- in preference to other type of pipes; they are
charge three times the dry-weather flow flow- particularly suitable where acid effluents or
ing half-full with a minimum self-cleansing acid subsoil conditions are likely to be en-
velocity 0.75 m/s. The approximate gradients countered. Salt glazed stoneware pipes shall
which give this velocity for the sizes of pipes conform to IS 651 : 1992 or IS 3006 : 1979.
likely to be used in building drainage and the b) Cement Concrete Pipes - When properly
corresponding discharges when flowing half- ventilated, cement concrete pipes with spigot
full are as follows: and socket collar joints present as an alterna-
Diameter Gradient tive to glazed stoneware pipes over 150 mm
Discharge
mm diameter. These shall not be used to early acid
m3/min
effluents or sewage under condition favourable
100 1 in 57 0.18 for the production of hydrogen sulphide and
150 1 in 100 0.42 shall not be laid in subsoils which are likely to
200 I in 145 0.73 affect adversely the quality or strength of con-
230 1 in 175 0.93 crete. Cement concrete pipes may be used for
250 1 in 195 1.10 surface water drains in all diameters. These
300 1 in 250 1.70 pipes shall conform to IS 458 : 1988. Where
so desired, the life of cement concrete pipe may
c) In cases where such ruling gradients cannot be
followed, a flatter gradient may be used but the be increased \>y lining inside of the pipe by
minimum velocity in such cases shall on no suitable coatings like epoxy polyester resin,
account be less than 0.61 m/s. etc.

NOTE - The practiceof using pipes of larger diameter c>Cast Iron Pipes - Cast iron pipes to IS 1536 :
than is required by the normal flow, where gradients are 1989-and IS 1537 : 1976 shall be used in the
restricted, does not result in increasing the velocity of flow following situations:
but reduces the depth of flow and for this reason, this
practice is to be deprecated. 1) In bad or unstable ground where soil
movement is expected;
4 On the other hand, it is undesirable to employ
gradients giving a velocity of flow greater than 2) In made-up or tipped ground;
2.4 m/s. Where it is unavoidable, cast iron 3) To provide for an increased strength
where a sewer is laid at insufficient depth,

418
 SP 62 ( S 8z T ) : 1997

where it is exposed or where it has to be be watertight, overlap shall be in the direction

carried on pipes above ground; of fall. The minimum fall shall be 1 in 120.
4) Under buildings and where pipes are 2.5 Drainage Pipes
suspended in basements and like situa-
tions;
a>Drainage pipes shall be kept clear of all other
services. Provision shall be made during the
5) In reaches where the velocity is more than construction of the building for the entry of the
2.4 m/s; and drainage pipes. In most cases, this may be
6) For crossings of water courses. done conveniently by building sleeves on
It may be noted that cast iron pipes, even conduit pipes into or under the structure in
when given a protective coating are liable appropriate positions. This will facilitate the
to severe corrosion in certain soils; among installation and maintenance of the services.
such soils are soils permeated by peaty b) Where soil and ventilating pipes are ac-
waters, and soils which contain appreci- comodated in ducts, access to cleaning eyes
able concentration of sulphates. Local shall be provided. Any connection to drain
data may be obtained for this purpose. shall be through gully with sealed cover to
Asbestos Cement Piyes - Asbestos cement guard against ingress of sewer gas, vermin or
pipes are commonly used for house drainage backflow. Trenches and subway shall be
system and they shall conform to IS 1626 ventilated preferably to the open air.
(Part 1) : 1991. They are not recommended for c>All vertical, waste ventilating and anti-
underground situations. However, asbestos siphonage pipes shall be covered on top with a
cement pressure pipes conforming to IS 1592 : copper or heavily galvanized iron wire dome
1989 may be used in underground situations or cast iron terminal guards.
also, provided they are not subjected to heavy All cast iron pipes which are to be painted
superimposed loads. These shall not be used periodically shall be fixed to the wall to give a
to carry acid effluents or sewage under condi- minimum clearance of 50 mm.
tions favourable for the production of
NOTE - Asbestos cement cowls may be used in case
hydrogen sulphide and shall not be laid in those
asbestos cement soil pipes are used.
subsoils which are likely to affect adversely the
quality or strength of asbestos cement pipes. 4 Drainage pipes shall be carried to a height
Where so desired, life of asbestos cement pipes above the buildings as specified for ventilating
may be increased by lining inside of the pipe pipe (see IS 5329 : 1983).
by suitable coatings like epoxy, polyester 2.6 Manholes
resins, etc. 4 At every change of alignment, gradient or
Lead Pipes - Branch soil pipes from fittings diameter Df drain, there shall be a manhole or
to main soil pipes and branch waste pipes from inspection chamber. Bends and junctions in
fittings to branch anti-siphonage pipes may be drains shall be grouped together in manholes,
of lead and shall conform to IS 404 (Part I) : as far as possible. The spacing of manhole pipe
1993. may be in accordance with IS 4111 (Part I) :
PVC Pipes - Unplasticized PVC pipes may 1986.
be used for drainage purposes; however where b) Where the diameter of the drain is increased,
hot water discharge is anticipated, the wall the crown of the pipe shall be fixed at the same
thickness should at least be 3 mm irrespective level and necessary slope given in the invert of
of the size and flow load. UPVC pipe shall the manhole chamber. In exceptional cases
conform to IS 4985: 1988. and where unavoidable the crown of the branch
sewer may be fixed at a lower level but in such
NOTE- Where possible high density polyethylene pipes
cases the peak flow level of the two sewers
(HDPE) and UPVC pipes may be used for drainage and
sanitation purposes, depending on suitability. HDPE pipes should be kept the same.
shall conform to IS 4984 : 1987. cl Chambers shall be of such size as will allow
Roof gutters shall be of galvanized iron sheets necessary examination or clearance of drains.
1.25 mm thick conforming to IS 277 : 1992. The size of manholes shall be adjusted to take
The gutter shall be semicircular in section with into account any increase in the number of
a width at top equal to abouttwice the diameter entries to the manhole. The minimum internal
of the down pipe. The gutters shall be fixed sizes of chambers (between masonry faces)
25 mm below the edge of roof. The gutter shall shall be as follows:
be supported by mild steel brackets at about 1) Fordepthoflmor0.8mx0.8m
l-2 m intervals. All junctions of gutters shall less

419
SP62(S&T):1997

2) For depth between 1.2 m x 0.9 m Typical sections of the manholes are illustrated
1 m and 1.5 m inFig. 16.2, 16.3, and 16.4.
3) For depths more Circular chambers
Drop Manholes - Where it is uneconomic or
than 1.5 m with a minimum dia of
impracticable to arrange the connection with
1.4 m or rectangular
600 mm height above the invert of the man-
chambers with mini-
hole, the connection shall be made by con-
mum internal dimen-
structing a vertical shaft outside the manhole
sion of 1.2 m x 0.9 m.
chamber as shown in Fig. 16.5.
NOTES
If the difference in level between the incoming
1 In adopting these sizes of chambers, it would be ensured that
these sizes accord full with or half-bricks with standard thickness drain and the sewer does not exceed 600 mm
of mortar joints so as to avoid wasteful cutting of the brick. and there is sufficient room in the manhole, the
2 The sizes of the chambers may be adjusted to suit the connecting pipe may be directly brought
availability of local building materials and economics of con- through the manhole wall and the fall accom-
struction. modated by constructing a ramp in the bench-
d) The access shaft shall be corbelled inwards on ing of the manhole.
three sides at the top to reduce its size to that g) Channels-These shall be semicircular in the
of the cover frame to be fitted or alternatively bottom half and of diameter~equal to that of the
the access shaft shall be covered over by a sewer. Above the horizontal diameter, the
reinforced concrete slab of suitable dimensions sides shall be extended vertically to the same
with an opening for manhole cover and frame. level as the crown of the outgoing pipe and the
e) The manhole shall be built on a base of con- top edge shall be suitably rounded off. ~The
crete of a thickness of at least 150 mm for branch channel shall also be similarly con-
manholes up to 1 m depth, at least 200 mm for structed with respect to the benching but at
manholes from 1 to 2 m in depth and 300 mm (or their junction with the main channel an ap-
one and half brick) for depths greater than 1.5 m. propriate fall suitably rounded off in the direc-
The actual thickness-in any case shall be calcu- tion of flow in the main channel shall be given.
lated on the basis of engineering design.

RENDERING WITH
CEMENT MORTAR I:2
/SLOPE 1 IN 6
/

i:
SECTIONAL PLAN Al ZZ

SECTION XX SECTION YY

NOTE-Wall thicknesses have been indicated in brick lengths to provide for use of~modular bricks (see IS 1077 : 1992) or traditional
bricks. In the figure, B = one brick length. I.5 B = one and a half brick length, etc.

FIG. 16.2 DETAILS OF MANHOLE (DEPTHS 1 m AND BELOW)

420
 !SP62(S&T): 1997

RENDERING WITH
CEMENT MORTAR I:2

DETAIL OF BENCHING

SECTIONAL PLAN AT ZZ.

I
w
z;
P

SECTION XX SECTION YY

NOTE - Wall thicknesses havebeenindicatedin brick lengths to provide for use of modular bricks (we IS 1077 : 1992) or traditional
bricks. In the figure, B = one brick length, 1.5 B = one and a half brick length, etc.

FIG. 16.3 DETAU OF MANHOLE (DEPTHS BETWEEN 1 AND 1.5 m)

DERINC WITH
MEN1 MORTAR ):2

DETAIL OF BENCHING

SECTIONAL PLAN AT 22

SECTION XX SECTION YY
NOTE-Wall thicknesses have been indicated in brick lengths to provide for use of modular bricks (see IS 1077 : 1992) or traditional
bricks. In the figure, B = one brick length, I .5 B = one and a half brick length, etc.

FIG. 16.4 DETAILS OF MANHOLE (DEPTHS 1.5 m AND ABOVE)

421
SP62(S&T):1997

r------

______ _______ J

SECTIONAL PLAN AT ZZ

m &LOQE I IN 6 I”;;//

SECTION XX SECTION YY ’
NOTE- Wall thicknesseshave been indicatedin brick lengths to provide for use of modular bricks (see IS 1077 : 1992)or traditional
bricks. In the figure, B = one brick length, I .5E = one and a half brick length,etc.
FIG. 16.5 DROP MANHOLE

h) Rungs shall be provided in all manholes over ing or in any passage therein. Ventilating
0.8 m in depth and shall be of cast iron con- covers shall not be used for domestic drains.
forming to IS 5455 : 1969. These rungs may
be set staggered in two vertical runs which may j> All brickwork in manhole chamber and shaft
be 380 mm apart horizontally. The top rung shall be carefully built in English bond. The
shall be 450 mm below the manhole cover and jointing face of each brick being well
the lowest not more than 300 mm above the ‘buttered’ with cement mortar before laying, so
benching. The size of the manhole cover shall as to ensure a full joint. The construction of
be such that there shall be a clear opening of at masonry shall be as per Chapter 4. The cement
least 500 mm in diameter for manholes exceed- mortar shall not be weaker than 1:3. The walls
ing 0.9 m in depth. Circular cover are con- shall be plastered with cement mortar 1:3 to a
sidered desirable. Manholes covers and minimum thickness of 15 mm both inside and
frames shall conform to the requirements given outside; where subsoil water exists richer mor-
in IS 1726 : 1991. tars may be used. All angles may be rounded
to 7.5 cm radius and all rendered internal
All manholes shall be constructed so as to be
surfaces shall have hard impervious finish
watertight under test. No manhole or inspec-
obtained by using a steel trowel.
tion chamber shall be permitted inside a build-

422

.
 k) The channel or drain at the bottom of the cham- b) Rainwater pipes shall be normally sized on the
ber shall be plastered with 1:2 cement mortar basis of roof areas according to Table 16.2.
and finished smooth to the grade where re- The roof area shall be taken as the horizontal
quired. The benching of the side shall be car- projection of the area. A bell mouth at the roof
ried out in such a manner as to provide no surface is found to give better drainage effect
lodgement for any splashings in case of ac- provided proper slopes are given to the roof
cidental flooding of the chamber. surface. The spacing of pipes depends on the
3 STORM WATER DRAINAGE position of the windows and each openings but
6 m apart is convenient distance. The strainer
3.1 General
area shall be 1; to 2 times the area of the pipe
The object of storm water drainage is to collect and to which it connects.
carry, for suitable disposal, the-rain water collected
cl A rainwater pipe conveying rainwater shall
within the premises of the building. The sources of discharge directly by means of a channel into
such water are precipitation and run off, depending on or over an inlet to a surface drain; or shall
the permeability of the surface and drainage from discharge freely into a compound, drained to
roofs. The disposal may be through a separate system surface drain or a sheet drain w~ithin 30 m from
to a water course or to storage tanks. the boundary of the premises but in no case
3.2 Rainwater Pipes for Roof Drainage shall it discharge directly into any closed drain.
a) Rainwater pipes shall be of cast iron, gal- 4 Where it is not possible to discharge as in (c),
vanized iron, asbestos cement, galvanized the rainwater shall be discharged into a gully
sheet or other equally suitable material. trap which shall be connected with the street
drain; such a gully trap shall have a screen and
1) Cast iron pipes shall be with socketed
joints having lugs cast on for fixing and silt catcher incorporated in its design.
shall conform to IS 1230 : 1979. The shoe e>If no street drain as in (c) is available, a rain-
may be fixed 150 mm above ground level. water pipe may directly discharge into a kerb
Bends and offsets are to be avoided as far drain and shall be taken through a pipe outlet
as possible. across the foot path, if any, without obstructing
the foot path.
2) Galvanized iron pipes shall be ‘fixed by A rainwater pipe shall not discharge into or
straps or dogs one for each 2 m length of
connect with any soil pipe or its ventilating
pipe. Joints between successive lengths
pipe or any waste pipe nor shall it discharge
of~pipes will be by collars at least 10 cm
into a sewer unless specially permitted to do so
deep riveted tightly and securely to the
by the Authority in which case such discharge
pipes and the straps or dogs riveted or
into a sewer shall be intercepted by means of a
bolted through this collar by 9.5 mm gal-
gully trap.
vanized iron bolts.
3) Asbestos cement pipes shall be fixed with
iz) The storm water shall be lead off in a suitable
drain to a water course. The open drain, if not
straps or clips.
pucca masonry throughout shall be made so at
4) All rainwater pipes or leaders from roofs least in sections where there is either a change
or terraces shall be screened off by grading
in direction or gradient.
at the top to prevent leaves, rodents, etc,
entering the pipes.
i-0 The rainwater pipes shall be fixed to the out-
side of the external walls of the building or in
5) The laying of pipes underground, man- recesses or chases cut or frame in such external
holes and chambers carried out as in the wall or in such other manners may be approved
case of sewers for foul water. by the Authority.

Table 16.2 Sizing of Rainwater Pipes for Roof Drainage

(Clause 3.2)
SI Dia of Average Rate of Rainfall in mm/h
No. A
Pipe f \
50 15 100 125 150 200
mm Roof Area in m*
(1) (2) (3) (4) (5) (6) (7) (8)
i) 50 13.4 8.9 6.6 5.3 4.4 3.3
ii) 65 24.1 16.0 12.0 9.6 8.0 6.0
iii) 75 40.8 27.0 20.4 16.3 13.6 10.2
iv) 100 85.4 57.0 42.7. 34.2 28.5 21.3
v) 125 - - 80.5 64.3 53.5 40.0
vi) 150 - - - - 83.6 62.1

423
SP62(S&T):1997

3.2.1 Size and Gradient of Pipes would contain much undesirable material. The
mouth of all pipes and openings shall be
The pipes shall be so designed as to give a velocity of covered with mosquito-insect proof wire net.
flow not less than 1 m/s when running half-full; the
maximum velocity shall not exceed 2.4 m/s. g) French drains or shallow rubble drains, filled
with coarse rubble, clinker or similar material,
3.3 Disposal with or without field drain pipes may be
employed as surface water drains and are use-
a>General - Surface water may be disposed off
ful in the drainage of unpaved surface, such as
in one or more ways as described below but
preferably by the method given in (b). playfields and certain types of roads. When
used for this purpose in addition to drain being
b) Separate System - All courtyards shall be
filled with rubble, it is often advisable to in-
provided with one or more outlets through
clude a field pipe drain in the trench bottom.
which rainwater shall be diverted into the
storm water drains and away from any opening 4 SUBSOIL WATER DRAINAGE
connecting with any sewer.
4.1 General
Usually each separate plot shall have a separate
drain connection made to a covered or open 4 Subsoil water is that portion of the rain-fall
public drain. Such connection to a covered which is absorbed into the ground and drainage
drain shall be made through a pipe at least of subsoil water may be necessary for the
3.5 m in length, laid at a gradient of not less following reasons:
than that of the connecting drain. The storm 1) to increase the stability of the surface;
water from the plot should discharge into the 2) to avoid surface flooding;
storm water drain directly and not through a 3) to alleviate or to avoid causing dampness
trap. in the building, especially in the cellars;
cl Combined or Partially Separate System - 4) to reduce the humidity in the immediate
Where levels do not permit connection to a vicinity of the building; and
public storm water drain, storm water from 5) to increase the workability of soil.
courtyard may be connected to a public sewer
b) The general direction of subsoil water may
provided it is designed to convey combined
usualy be judged by the general inclination of
discharge. In such cases, the surface water
the land surface and the main lines of the
shall be admitted to the soil sewer through
subsoil drains shall follow the natural falls
trapped gullies in order to prevent the escape
wherever possible.
of sewer air.
d) To a Water Course - It may be often con- c) Subsoil drains shall be sited so as not to
endanger the stability of the buildings or
venient to discharge surface water to a nearby
earthwork. In some portions of the drain, it
stream or water course. The invert level of the
may be necessary to use non- porous jointed
out-fall shall be about the same as the normal
pipes. No field pipe shall be laid in such a
water level in the water course. The out-fall
manner or in such a position as to communicate
shall be protected against floating debris by a
directly with any drain constructed or adapted
screen.
to be used for conveying sewage except where
e>To Storage Tanks - Water from the roof of a absolutely unavoidable and in that case a
building may be led straight from the pipes to suitable efficient trap shall be provided be-
one or more watertight storage tanks. Such tween subsoil drain and such sewer.
storage tanks shall be raised to a convenient
height above ground and shall always be 4.2 Systems of Subsoil Drainage
provided with ventilating covers, and have
4.2.1 Field Drain Pipes
draw off taps suitably placed so that the rain-
water may be drawn off for domestic washing Clay or concrete porous pipes may be used and shall
purposes or for garden water. A large imper- be laid in one of the following ways, depending on site
vious storage tank is sometimes constructed conditions.
underground, from which rain water is pumped 4 Natural - The pipes are laid to follow the
as required to the house. All storage tanks shall natural depressions, or valleys of the site,
be provided with an overflow. branches discharging into the main.
An arrangement shall be provided in a rain- b) Herringbone-A system consisting of a num-
water pipe or leader to divert the first washings ber of main drains into which discharge from
from the roof or terrace catchment as they both sides, smaller subsidiary branches parallel

424
 SP62(S&T):1997

to each other but at an angle to the mains cavated to a smooth surfaces, the pipes shall be
forming a series of herringbone patterns. laid in a cradle of fine concrete floor or a floor
c) Grid - A mainor mains near the boundaries of gravel and crushed stone overlaid with con-
of a site into which branches discharge from crete or on a well consolidated’gravel and
one side only. crushed stone bed only so as to ensure even
bearing.
d) Fan shaped - The drains are laid converging
to a single outlet at one point on the boundary c>Each separate pipe shall be individually set for
of a site, without the use of main or collecting line and for level using one of the following
drains. methods:

e) Moatorcutoffsystem-Sometimesdrains are 1) Where long lengths of sewer or drain are

to be constructed in trench with glazed
laid on one or more sides of a building to
earthenware or concrete pipes, properly
intercept the flow of subsoil water and thereby
painted sight rails shall be fixed across the
protect the foundations.
trench at a height, equal to the length of
42.2 Laying of Pipes boning rod to be used, above the required
invert level of the drain or sewer at the
a>For building sites the mains shall not be less
point where the sight rail is fixed. There
than 75 mm in diameter and the branches not
shall be a minimum of three sight rails in
less than 63 mm in diameter. The normal
position on each length of sewer or drain
practice is to use 100 mm dia for mains and
under construction at a particular gradient.
7.5 mm dia forbranches.
Properly cut wooden or iron pegs shall be
b) The pipes shall generally laid at depth of 600 driven into the floor of the trenches at
to 900 mm or to such a depth to which it is
intervals of at least 1 m less than the length
desirable to lower water table and the gradients
of the straight-edge, which is to be used.
are determined rather by the fall of land than
With the aid of boning rod, equal in length
by considerations of self-cleansing velocity.
to the height of the sight rail above the
c) The connecting of the branch drain to the main required invert level, each peg shall be
drain is best made by means of a clayware or driven until its top is at the exact level
concrete junction pipe. required for the invert of the pipeline at
4 The outlet of a subsoil system may discharge that point; this will occur when a true bone
into a soakway or through a catchpit into the is obtained over boning rod and sight rails.
nearest ditch or watercourse. Where these are The underside of a straight edge resting on
not available, the subsoil drains may be con- taps of those pegs will give level and
nected, with the approval of the Authority, gradient of the invert. The pegs shall be
through an intercepting trap to the surface withdrawn as pipe laying proceeds.
water drainage system. To obtain a true line along the grade, a side
NOTE - Cue shall be taken that there is no backflow line shall be used strung tautly at half-
from sub-surface drains during heavy rains. pipe level between ironpins firmly driven
5 CONVEYANCE OF SANITARY WASTES in the floor of the excavation for the man-
hole at each end of the proposed pipeline,
5.1 Laying of Pipes
and the pipes shall be laid in such a way
The pipes shall be laid with sockets leading uphill and that the sockets are fixed just free of this
shall rest on solid and even foundations for the full side line. For long lengths of drain, the
length of the barrel. Socket holes shall be formed in side line may require intermediate sup-
the foundation sufficiently deep, to allow sufficient port. The practice of laying to a top line
space for the pipe jointer to work right round the pipes is not recommended.
and as short as possible to accommodate the socket in
2) In case of short lengths of branch dr-ain,
proper position and allow the joint to be made.
where it is inconvenient to fix sight rails,
a>Where the pipes are not bedded in concrete, the pegs shall be driven into the floor of the
trench floor shall be left slightly high and care- trench and their tops boned in with the aid
fully bottomed up as pipe laying proceeds that of three equal boning rods, one of which
pipe barrels rest on ‘firm and undisturbed is used on the pegs to be driven and the
ground. If the excavation is carried too low, other two held at the invert level of the
any packing done shall be in concrete. pipes for fittings to be connected. A side
b) If the floor of the trench consists of hard rock line shall be used to obtain a true line in
or very hard ground that cannot be easily ex- the horizontal plane.

425
SP62(S&T):1997

3) In case of cast iron pipes, it is imprac- +-lScm-4

ticable to use a straight-edge~and the invert
of each pipe shall be fixed to a true bone
over sight-rails by~means of a boning rod,
which in such cases shall be provided
with a bottom shoe to rest on the invert of
the pipe being laid.
4) Where it is necessary to cut pipes, this
shall be done with a suitable wheel type
pipe cutter so as to leave a clean and
square section to the axis of the pipe.
5.2 Protection of Pipes
5.2.1 Gem&d l I

It may be necessary to support or surround pipe sewers I------- 4

or drains by ~means of concrete in certain circumstan-
W = D + 30cm, where D is the external diameter of the pipe.
ces. It may be done by bedding on concrete as in
Fig. 16.6. A concrete haunching may be done as in FIG. 16.8 SURROUNDOR ENCASING
Fig. 16.7. Encasing may be done as in Fig. 16.8.
1) When cover is less than 1 m below ground
level and where pipes are unavoidably
exposed above ground level, the pipes
shall be completely encased or surrounded
with concrete;
2) Where the pipes are laid on a soft soil with
the maximum water table laying at the
invert level of the pipe, the pipe shall be
bedded on concrete;
W= D + 30 cm, whereD is external diameterof the pipe. 3) Where the pipes are laid on soft soil with
T= 10 cm for pipes under I50 mm nominal dia.
the maximum water table rising above the
15 cm for pipes IS0 mm nominal dia andover.
invert but below the top of the barrel, the
FIG. 16.6 BEDDING pipe should be haunched;
4) Where the pipe is laid on soft soil and
where the maximum water table is likely
to rise above the top of the barrel, the pipe
shall be completely encased or surrounded
with concrete; and
5) Where the pipes are to laid adjacent to
growing trees, the pipes shall be sur-
rounded by concrete.
l------W--------I c) Pipes on Unstable Ground - In certain sub-
IV= D + 30 cm, where D is externnl diameter of the pipe.
T= 110 cm for-pipes under I50 mm nominal dia.
soils, rise and fall of subsoil water level -may
115 cm for pipes 150 mm nominal din and over. be the cause of considerable earth movement.
This and other conditions of unstable ground
-FIG. 16.7 HAUNCHING
call for additional support to the pipes in the
4 For cast iron pipes supporting pier may be form of piles or trestles or other suitable means.
provided where necessary. They shall be at
5.3 Jointing of Pipes
least 30 cm in length parallel to the axis of the
pipe and equal in section to haunching of 5.3.1 General
Fig. T6.7. Piers shall be built just behind the
pipe sockets, intermediate piers being All soil pipes, waste pipes, ventilating pipes and all
provided where necessary. However, in nor- otherpipes when above ground, shall be gas-tight. All
mal ground no support or protection is neces- sewers and drains below ground shall be watertight.
sary. a) Jointing lead and iron pipes-Where any lead
b) ~Glazed stoneware pipes - Glazed stoneware pipe, ventilating pipe or trap is conne’cted with
pipes shall be protected as follows: an iron pipe or drain communicating with a

426
 SP62(S&T):1997

sewer, there shall be inserted, between such WC TRAP

pipes, an ordinary thimble of copper or brass, /--
CEMENT MORTAR
which shall be connected to the lead pipe by
/- JOINT(l:l)
means of a wiped joint. The thimble shall be
connected with cast iron pipe by means of a
joint made with molten lead, properly caulked;
a sufficient quantity of lead shall be melted at
a time to finish the joint at one paring (see Fig.
L YARN

16.9). BRASS THIMBLE

WIT H SOCKET
LEAD PIPE

WIPED WIPED SOLDER

SOLDER JOINT
/ JOINT

\ LEAD PIPE
BRASS OR
COPPER
THIMBLE

k MOLTEN LEAD
JOINT WELL
CAULKED
FIG. 16.10 JOINTING
SEMI-VITRIFIED
STONEWARE OR
WARE PIPEOR TRAPTO LEAD PIPE

Cl PIPE
f- PIPE

CEMENT
FIG. 16.9 JOINTINGLEAD PIPETO CAST~RONPIPE MORTAR
JOINT(l:l-)
b) Jointing stoneware with lead pipes - Where
any stoneware or semi-vitrilied trap or pipe is
connected with a lead soil pipe, waste pipe or
trap communicating with a sewer, there shall
YARN
be inserted between the pipes, a socket of
copper, copper brass or other suitable alloy;
this shall be connected by means of a cement
wiped metallic joint as in Fig. 16.10.
SW PtPE
c) Jointing cast iron pipes with stoneware pipes
- For such connection, the beaded spigoted
end shall Abe inserted into a socket of such
stoneware~pipe as shown in Fig. 16.11.
When any water closet pan or earthenware trap
is to be jointed with a cast iron pipe, such joint FIG. 16.11 JOINTING
CI PIPETO STONEWAREPIPE
shall be flexible in nature; a mixture of bitumen
and asbestos fibre (not dust) may be used. e) Jointing stoneware pipes - These shall be
d) Jointing lead pipes - These joints shall be jointed as shown in Fig. 16.13.
made as shown in Fig. 16.12. The solder shall f) Jointing concrete pipes - These shall be
consist of two parts of lead and one part of jointed as per IS 783 : 1985.
tin.

427
SP62(S&T):1997

2) Lead-wool or lead-fbre joints - These

joints are suitable for wet conditions.
Special attention is necessary in caulking.
The socket shall be caulked with tarred
gasket or hemp yarn and then lead fibre
inserted into socket and tightly caulked
home skein by skein until the joint is filled.
Lead wool for caulking shall conform to
IS 782 : 1978.
3) Cement joints - Hemp yarn, dipped in
cement slurry, is first inserted to a slight
depth and well pressed in the same manner
as for lead jointing. Cement mortar (1 : 1)
should be rammed into the joint by caulk-
ing tools and completely filled. The joints
should be -kept wet for 24 h. Lead joints
may bemused at intervals.
h) Flanged joints - If a drain is constructed of
flanged pipes, the joints shall be securely
FIG. 16.12 JOINTING
LEADPIPETO LEADPIPE
bolted together with a rubber or other suitable
insertion.
g) Jointing cast iron pipes. 5.4 Connection to an Existing Sewer
1) Lead run joinfs (cast-lead joints) - The
spigot shall he centred in the adjoining As far as possible connection to existing sewer shall
socket by tarred gasket or hemp yarn leav- be done at the manholes. Where it is unavoidable to
ing half the depth of socket for lead; then make connection in between, it shall be done with the
a jointing shall he placed around the barrel permission and supervision of the Authority.
and against the faces of the socket. Mol-
5.5 Backfilling
ten lead, conforming to IS 782 : 1978,
shall then be poured to fill remainder of Backfilling shall not be done until the length of pipes
the socket; the lead shall be caulked, have been tested and passed. Backfilling shall be done
preferably finished 3 mm behind the carefully so as not to damage the pipes.
socket face. The pipes should be dry; if
wet, special care shall be taken.

CEMENT MORTAR TARRED GASKET OR

SPUN YARN SOAKED
IN NEAT CEMENT

X = Socket length
FIG. 16.13 TYPICALDETAILSOFCEMENTJOINTSFORGLAZEDSTONEWAREPIPES

428
 SP62(S&T):1997

PART 3 WATER SUPPLY AND DRAINAGE-IN HIGH ALTITUDE/

SUB-ZERO TEMPERATURE REGIONS

1 GENERAL depth of the soil, where necessary. Protection be given

to these casing pipes in case they are likely to be
1.1 The broad principles of water supply and drainage disjointed, crushed or damaged due to freezing of
covered in Parts 1 and 2 are generally applicable at surrounding soils; the protection may be an additional
high altitudes/sub-zero temperature regions with some casing~or other suitable means.
modifications. These are elaborated here.
Surface water from tanks are likely to freeze in winter,
1.2 High altitude/sub-zero conditions may be sum- forming an ice cover. The freezing action tends to
marized as low temperature, that is, below 4’C and/or concentrate mineral and organic content in the un-
low barometric pressures, that is, below 0.86 N/mm2. frozen water and for this reason, the unfrozen water
shall be analysed periodically for potability.
1.3 Effects of low temperature are described below:
a>Physical- Water is at its maximum density at Springs and rivers, which do not freeze completely
4’C, At O°C it solidifies and turns into ice after a continuous supply of water, should be perferred.
having expanded approximately one-twelth of Intake for river sourcesshall be placed well below the
its volume. The velocity of water and liquids depth of ice cover, if any, formed during the worst
increases with falling of temperatures thus periods. A deep pool of water should be created over
affecting the settling velocities of particles the intake. High intake velocities without surface
carried in suspension. turbulence shall be used for drawing out water when
Information on Kinematic viscosities and den- the atmospheric temperature is below 0°C.
sity of water at low temperature is given in 2.2 Pumping Installations
IS 6295 : 1986.
Pumps and pumping machinery shall be housed in
b) Chemical - In general most chemicals react well-insulated chambers. Where necessary, inside of
much slower at temperatures near freezing
pump houses shall be heated. Pump house shall, as far
than they do at normal temperatures. Conse-
as possible, be built directly above intake structures.
quently, longer reaction times are required for
satisfactory performance of chemical used in a) Pump;Selection -The use of centrifugal pump
treatment units. shall be preferred to reciprocating pumps be-
cause of the fact that gland~packings soaked in
Biological - Low temperatures retard
water are likely to freeze when the pumps are
biological activity. Thus sewage treatment
idle and the reciprocating pump cannot work
process depending on biological activities are
unless warmed up. Self priming pumps shall
affected.
be used to avoid provision of foot valves,
1.4 Effect of Low Barometric Pressures which help formation of ice which, in turn, clog
the impeller and damages it. For high altitude
Low barometric pressures limit pump suction head. regions it is always advisable to use submer-
Normal barometric pressures met at high altitudes are siblepumps in view of low suction heads avail-
given in IS 6295 : 1986. able in such places.

2 -WATER SUPPLY b) Suction Heads - Pump suction heads are

affected on account of reduced atmospheric
2.1 Selection and Sources pressures in high altitudes. Aerate of decrease
of 1.15 m, in the allowable suction head shall
The source selected shall be such as to minimize the
be made for every 1 000 m in elevation above
length of~transmission line so as to reduce the inspec- MSL.
tion and maintenance. Attempts shall also be made to
locate the source near the discharge of waste heat, such cl Eficiency of Pumping Set - A rate of fall of
as power plants provided that it does not affect the over all efficiency of 2 percent shall be allowed
potability of water. in case of electric prime movers and up to 4
percent in case of other types of prime movers
2.1.1 The sources may be melted ice or snow, ground for every 300 m elevation in altitude. Electric
water or surface water. Ground water is warmer than prime movers shall be preferred.
surface water in winter. Well casings for ground water Pump Drainage - Where
4 the ambient
shall be properly insulated along the front penetration temperature conditions warrant, provision

429
-_

SP62(S&T):1997

shall be made to ensure that the pumps are ground level in northern regions of India where
drained immediately after shutting down to freezing occurs. ’
prevent damage to plant due to freezing. b) To maintain temperature level of water, warm
e) Engine Driven Pumps - Where blow lamps water from hot springs shall be mixed with the
are used’ for heating the pump, compression source of water, where feasible. Insulation of
ignition engines shall be used instead of pipes may be done.
gasoline engines. c>Adequate number of break pressure tanks and
f) Engines shall be air cooled type rather than air release valves shall be provided in the
water cooled ones so as to avoid using anti- distribution system.
freeze coolants against the danger of freezing 4 Arrangements may be made to let out some
of cooling waters in them. Engines shall be water continuously, at suitable points, special-
provided with special heat and cold starting ly during no demand, so that ice formation in
devices for guard against starting troubles in pipes can be prevented.
winter. Draining taps of engines and pumps
shall be easily accessible and convenient to
e>HDPE pipes with proper break pressure cham-
bers are suitable for transmission and distribu-
operate with gloves on.
tion systems.
g) Fuels-Diesel and gasoline are not suitable at
low temperatures. Special fuels like water 2.4.1 Pipe Materials
grade and sub-zero grade depending on the Distribution pipes shall be made of any of the follow-
temperature shall be used as specified by the ing materials:
manufacturer.
a>High density polyethylene pipes to IS 4984 :
2.3 Protection and Storage of Water and 1987.
Treatment
b) Asbestos cement pipes to IS 1592 : 1989.
a) Settling Tanks - Settling process is generally c>Galvanized iron pipes to IS 1239 (Part 1) :
slowed down by increase of the viscosity of 1990.
water at low temperatures. Settling tanks
4 Cast iron pipes to IS 1536 : 1989.
operated at r&ear freezing temperature shall
provide surface loading rates nearly half that e>UPVC pipes to IS 4985 : 1988 when laid below
frost line.
for operation at 20°C. Settling tanks may be
covered for increasing efficiency. 2.4.2 hwulating Materials for Pipes
b) Chemical Reaction - For proper reaction Apart from straw, grass, hessian, etc, 85 percent
mixing times shall be tripled when water at 0’ magnesia, glasswool or asbestos coated logging ropes
to 4’C is being treated. Structures storing may be used.
chemicals should be as close as possible to the
treatment facilities because unnecessary 2.4.3 Distribution Methods
transplantation of chemicals can be avoided. In conventional system, the pipes should be buried
c) Filtration - Rapid sand filters and pressure below frost line; adequate draining points shall be
filters shall Abe preferred. Filter areas up to provided to prevent freezing of water. House service
twice that required for warmer water shall be connections shall be kept operative by the use of
provided. Provision for backwashing shall be adequate heat insulation as shown in Fig. 16.14.
made by the use of pump rather than ele.vated
3 WASTE DISPOSAL
water storage. Lower back washing rates will
be required than normal. 3.1 General
d) Chlorination - The pressure of chlorine gas The care exerc’ised for water supply systems should be
at 2 1.1 “C is more than five times as great as at
applicable to disposal systems also.
17.8’C and special considerations should be
.given to control chlorine dosing. Where 3.2 Waterborne System
bleaching powder is used adequate reaction
a) Sewers shall be laid below the frost line. Man-
time should be allowed for proper mixing.
holes shall be made airtight. Trenches shall be
2.4 Transmission and Distribution closely filled with earth, where possible sewers
shall be so located that the trench line is not in
a>Lay the pipe below frost line to avoid freezing shadow when the sun is shining. Concrete, cast
of buried pipe; the level of frost line is general- iron and stoneware pipes should be insulated.
ly found to be between 0.9 and 1.2 m below
 SP62(S&T):1997

b) Septic tanks shall be located well below the c) Seepage Pits - The discharge of effluent shall
frost line. Its capacity shall be increased by be made below the frost line.
100 percent for operation at 10°C over that for
operation at 20°C.

WATERPROOF
WRAPPING OVER

--a-d--m--- ------A- FROST LINE

---_

FIG. 16.14 INSULATION

DETAILSAT SERVICE-CONNECTION

431

c 1.1 .
As in the Original Standard, this Page is Intentionally Left Blank
-..

CHAPTER 17

SPECIALCONSTRUCTIONPROCEDURES-
EARTHQUAKEEFFECTS,ETC

.
 CONTENTS

1 GENERAL 4.4 Seismic StrengtheningArrangements

4.5 Framing of Thin Load Bearing Walls
PART 1 EARTHQUAKE RESISTANCE OF
NORMAL BUILDINGS 4.6 Hollow Block Masonry

1 GENERAL 5 SPECIALCONSTRUCTIONFEATURES- FLOORS

AND ROOFSWITH SMALLPRECASTCOMPONENTS
2 EARTHQUAKERESISTANTCONSTRUCTION
OF
NORMALBUILDINGS 6 TIMBERSTRUCTURES
- SPECIALARRANGEMENTS

2.1 Types of Construction 6.1 Foundation

6.2 Studwall or Brick Nogging Construction
3 GENERAL PRINCIPLESOF SEISMIC RESISTANCE
CONSTRUCTION ANNEX A BUILDING CATEGORIES BASED ON
EARTHQUAKE RESISTING FEATURES
3.1 Lightness
3.2 Continuity of Construction ANNEX B OPENINGSINLOAD BEARINGWALLS

3.3 Projecting or SuspendedParts PART 2 EARTHQUAKE RESISTANCE OF

3.4 Building Configuration WEAKER BUILDINGS

3.5 Strength in Various Directions 1 Low STRENGTH

MASONRYBUILDINGS
3.6 Foundation 1.1 General
3.7 Ductility 2. BRICKWORK
INWEAK MORTAR
’ ‘
3.8 Non-Structural Parts 3 STONE MASONRY (RANDOM RUBBLEOR
SEMI-DRESSED)
4 MASONRY STRUCTURES- SPECIALCONSTRUC-
TiONFEATURES 4 IMPROVINGEARTHQUAKERESISTANCEOF
EARTHENBUILDINGS
4.1 General ’
4.2 Mortars 5 REPAIRAND SEISMICSTRENGTHENING
OF
4.3 Cover BUILDINGS
 SP 62 ( S-L%T ) : 1997

CHAPTER 17

SPECIAL CONSTRUCTION PROCEDURES -

EARTHQUAKE EFFECTS, ETC
1 GENERAL earthquake, blast or other effects which would ensure
safety of the structure. As a first step, earthquake
1.1 This Chapter deals with construction procedures
resistant structures are covered in Parts 1 and 2.
required to take care of effects of forces like

PART 1 EARTHQUAKE RESISTANCE OF NORMAL BUILDINGS

1 GENERAL slabs shall be continuous throughout as far as

possible. Concrete slabs shall be rigidly
1.1 This Part deals with seismic resistant construction
connected or integrally cast with support
of normal buildings, using masonry, timber and
beams.
precast building components.
1.2 In addition, requirements of buildings against 3.3 -Projecting or Suspended Parts
earthquake forces using weaker materials, such as, low
a) Projections shall be avoided as far as possible.
strength masonry are covered in Part 2. Some If unavoidable, the parts projecting shall be
guidelines for improving earthquake resistance of ear- properly reinforced and firmly tied to the main
then buildings and repair and seismic strengthening of structure and their design shall be according to
buildings are also included in Part 2. IS 1893 : 1984.
1.3 The basic requirements of seismic design shall b) Ceiling plaster shall preferably be avoided, if
conform to IS 1893 : 1984. unavoidable it shall be as thin as possible.
2 EARTHQUAKE RESISTANT c> Suspended ceiling shall be preferably avoided;
CONSTRUCTION OF NORMAL BUILDINGS if unavoidable it shall be as light as possible.
2.1 Types of Construction 3.4 Building Configuration
The buildings covered include masonry construction In order to minimize torsion and stress consideration
using rectangular masonry units, timber construction in buildings the following shall be adhered to:
and buildings with prefabricated flooring/roofing
The building should be a simple rectangle in
units.
plan and symmetrical both with respect to mass
3 GENERAL PRINCIPLES OF SEISMIC and rigidity so that the centres of mass and
RESISTANT CONSTRUCTION rigidity coincide in which case no separation
sections other than expansion joints are neces-
3.1 Lightness sary. For provision of expansion joints (see
Since earthquake force is a function of the weight of Chapter 13).
the building, it shall be as light as possible. Roofs and
b) If symmetry is not possible in plan, elevation
upper storeys of buildings should be as light as or mass provision shaI1 be made for torsional
possible. and other effects due to earthquake forces in
3.2 Continuity of Construction structural design or through crumple sections.
The length of such building between separa-
a>As far as possible, the parts of the building tion sections shall not preferably exceed three
should be tied together in such a manner that
times the width.
the building acts as one unit.
NOTE-As an nlternntive to separation section to reduce
b) Additions and alterations to the structures shall the torsionnlmxnent, the centrc of rigidity of the building
be accompanied by provision of separation or may be brought close or coincident with centre of m~s by
crumple sections between new and old struc- adjusting the locations and/or sizes of columns and walls.
tures as far as possible, unless positive c>Buildings having plans with shapes like L, T,
measures are taken to establish continuity E and Y shall preferably be separated into
between them. rectangular parts by providing separation
c>For parts of building, between separation or sections at appropriate places. Typical ex-
crumple sections or expansion joints, floor amples are shown in Fig. 17.1.

435
SP62(S&T):1997

I I I I

0
L - SHAPE
0
T-SHAPE

Y-SHAPE Y -SHAPE

E-SHAPE

FIG. 17.1 TYPICAL SHAPESOF BUILDING WITH SEPARATIONSECTIONS

NOTES 3.6 Foundation

1 ~For buildings with small lengths of projections forming, L, T,
The structure shall not be founded on such loose soils
E or Y shapes need not be provided with separation section. In
such cases, the length of projection may not exceed I.5 to 20 which will subside or liquify during an earthquake,
percent of the total dimension of the building in the direction of resulting in large differential settlements.
projection (see Fig. 17.2).

2 For buildings with minor asymmetry in plan and elevation, 3.7 Ductility
separation sections may be omitted.
The main structural elements and their connections
3.5 Strength in Various Directions
shall be designed to have a ductile failure. This will
The building shall be designed to have adequate enable the structure to absorb energy during an
strength against earthquake effects along both the e‘arthquake to avoid sudden collapse of the structure.
horizontal axes. The design shall also be safe con- Details of ductile joints for reinforced concrete struc-
sidering the reversible nature of earehquake forces. tures are given in IS 13920 : 1993.

436
LL.

SP62(S&T):1997

I
A/L > O-15 TO O-2
41

A
C

3.8 Non-Structural
LJklLlAIL -> 0.25

Parts
L
A
AtLw0.15

FIG. 17.2 PLAN AND VERTICALIRREGULARITIES

1
A

4.3 Cover
,

Suitable details should be worked out to connect the Where steel reinforcing bars are provided in
non-structural parts with the structural frame so that masonry, the bars shall be embedded with adequate
the deformation of the structural frame leads to mini- cover; in cement sand mortar not leaner than 1:3 a
mum damage of the non-structural elements. minimum cover of 10 mm shall be provided or in
cement concrete grade Ml5 a minimum cover of
4 MASONRY STRUCTURES - SPECIAL 15 mm or the bar diameter whichever is more shall be
CONSTRUCTION FEATURES provided.

4.1 General 4.4 Seismic Strengthening Arrangements

Normal construction work in masonry shall be as per a) All masonry buildings shall be strengthened
Chapter 4. The special features for earthquake resis- by the methods as specified in Table 17.2.
tant construction are as detailed below. Figure 17.3 and 17.4 show the overall
strengthening arrangements to be adopted for
4.2 Mortars category D and E buildings, which consist of
horizontal bands of reinforcement at critical
Tne recommended mortar mixes are as in Table 17.1. levels, vertical reinforcing bars at corners,
junctions of walls and jambs of openings. For
Table 17.1 Recommended Mortar Mixes location of openings, which have a reducing
(Clause 4.2) effect on lateral load resistance (see
Building Category Proportions of Cement-Lime-Sand Annex B).

A M2 (cement-sand 1:6) or M3 (lime-cinder b) Lintel Band - Lintel band is a band provided

1 : 3) or richer at lintel level on all load bearing internal, ex-
BandC M2 (cement-lime-sand I : 2 : 9) or (cement- ternal longitudinal and cross walls. Lintel
sand 1 : 6) or richer band if provided in panel or partition wall also,
DandE H2 (cement-sand 1:4) or Ml (cement-lime- will improve their stability during severe
sand1:1:6)orricher earthquake.
NOTES Details of the specification of the band are
given in 4.4.1.
1 Mortar grades are given in Chapter 4.

2 Building category based on (xh values is given in IS 4326 : c> Roof Band - Roof band is a band provided
1993 (see ulso Annex A). immediately below the roof or floors. Such a
band need not be provided underneath slabs

437

.
SP 62 ( S & T ) : 1997

resting on bearing walls, provided that the roof band at eaves level. Details of the
slabs are continuous over the intermediate wall specification of the band are given in 4.4.1.
up to crumple sections, if any and cover the e) Plinth Band - Plinth band is a band
width of end walls, fully or at least 3/4 of the provided at plinth level of walls on top of the
wall thickness. Details of the specification of foundation wall. This is to be provided where
the band are given in 4.4.1. strip footings of masonry (other than rein-
4 Gable Band - Gable band is a band provided forced masonry or reinforced concrete) are
at the top of gable masonry below the purlins. used and the soil is either soft or uneven in its
This band shall be made continuous with the properties.

1. Lintel Band 4. Door

2. Roof/Floor Band 5. Window
3. Vertical Band

FIG. 17.3 OVERALL ARRANGEMENTOF REINFORCINGMASONRY BUILDINGS

1. Lintel Band 8. Holding DowmBolt

2. Eave Level (Roof) Band 9. Brick/Stone Wall
3. Gable Band 10. Door Lintel Integrated with Roof Band
4. Door a - Perspective View
5. Window b- Details of Truss Connection with Wall
6. Vertical Steel Bar c- Detail of Integrating Door Lintel with Roof Band
7. Rafter

FIG. 17.4 OVERALL ARRANGEMENTOF REINFORCINGMASONRY BUILDING HAVING PITCHEDROOF

438
 SP62(S&T):1997

Table 17.2 Strengthening Arrangements for b) In case of reinforced brickwork, the thickness
Masonry Buildings of joints for steel bars shall be increased to
(Clause 4.4) provide a cover of 10 mm. The area of steel
Building Category Number of Strengthening to be
shall be the same as for reinforced concrete
Storeys Provided in All Storeys work.
(I) (2) (3)
c) For full integrity of walls at corners and junc-
A i) 1 to 3 Mortar (see 4.2) tions of walls and effective horizontal building
ii) 4 Mortar (see 4.2), Lintel resistance of bands, continuity of reinforce-
and roof band and where
ment is essential (see Fig. 17.6).
neces sary gable band
(see 4.4)
B i) 1 to3 Same as A (ii) plus brac-
Table 17.3 Vertical Reinforcement in
ing in plan at tie level of Masonry Walls
roofs (see 4.4). where (Clauses 4.4 and 4.6)
necessary plinth band
(see 4.4) Building Category Storeys Diameter of Bar
/ > (Deformed)
ii) 4 Sameas B (i) plus vertical
No. Location
steel at comers (see 4.4)
(1) (2) (3) (4)
C i) I and 2 Same as B (i)
ii) 3 and 4 Same as B (ii) plus verti- B 1to3 - -
cal steel at jambs of open- 4 Top i0
ings (see 4.4) Third 10
Second 10
D i) 1 and2 Same as C (ii)
Bottom 12
ii) 3 and 4 Same as C (ii) plus dowel
bars (see 4.4) C I,2 - -
E 1to 3 Same as D (ii) 3 Top 10
Middle 10
NOTE - Fourth storey not allowed in Category E buildings. Bottom 12
4 Top 10
Dowel Bars -In category D and E buildings, Third 10
Second 12
to further integrate the box action of walls steel
Bottom 12
dowel bars may be used at corners and T junc-
tions of walls, at sill level of windows, to a D 1 10
2 Top 10
length of 900 mm from the inside corner in
Bottom ‘2
each wall. Such dowel may be in the form of 3 10
Top
U stirrups 8 mm dia; the dowels shall be laid in Middle 12
1:3 cement-sand mortar with a minimum cover Bottom 12
4 Top 10
of 10 mm.
Third 12
Vertical Reinforcement - Vertical steel at Second 16
corners and junctions of walls which are up to Bottom 20
340 mm (lf brick) thick, shall be provided as E I - 12
in Table 17.3. For walls thicker than 340 mm, 2 Top 12
the area of the bars shall be proportionately be Bottom 16
increased. 3 Top 12
Middle 16
Bracing in Plan - At tie level all trusses and Bottom 16
the gable end shall be provided with diagonal
NOTES
braces in plan so as to transmit the lateral shear
1 Four storeys not permitted in Category E buildings.
due to earthquake force to the gable walls
acting as shear walls at the ends. 2 For precast components (see 5).

3 No strengthening arrangement for Category A buildings up

4.4.1 Section and Reinforcement of Band
to three storeys.

a) The band shall be made of M 15 grade concrete 4 Vertical reinforcement shall pass through the plinth masonry
or reinforced brickwork in cement mortar 1 : 3. of foundations, roof slab, roof band, lintel bands in all storeys
(see Fig. 17.5).
The band shall be full width of the wall and not
less than 75 mm in depth and reinforced as 5 The vertical bars will be covered with concrete M IS or with
cement mortar (1:3) in suitably created pockets, around the bars
given in Table 17.4. In coastal areas the grade
(see Fig. 17.5).
of concrete shall be M 20.

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SP62(S&T):1997

4iizhll
3.

:
V

l/2
l-F--
--
b-
:
B-4

l -One brick length ;f - Half brick length, V-Vertical steel bar with mortnr/concrete filling in pocket

(a) and (btAlternate courses in one brick wall: (c) andCd)-Altemntecourses at comerjunctionof Ii brickwall; (e) and (D-Alternate

courses at T-junction of If brick wall

FIG. 17.5 TYPICALDETAILSOF PROVIDING VERTICAL STEEL BARS IN BRICK MASONRY

I
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 SP 62 ( S & T ) : 1997

(d 1
I b,

1. Longitudinal Bars 2. Lateral Ties

bl, b2- Wall Thickness
a) Section of Band with Two Bars b) Section of Band with Four Bars
c) Structural Plan at Comer Junction d) Sectional Plan at T-junction of Walls
All dimensions in millimetrcs.
FIG. 17.6 REINFORCEMENT AND BENDING DETAIL IN RC BAND

Table 17.4 Recommended Longitudinal Steel in 4.5 Framing of Thin Load Bearing Walls (see Fig.
Reinforced Bands (Deformed Bars) 17.7)
(Clauses 4.4,4.4.1,4.6 and 5.1)
a) For thin load bearing walls, 150 mm thick
Building Span, m Number of Diameter of Bar including plaster reinforced concrete columns
Category Bars (Deformed)
shall be provided at all corners and junctions
(1) (2) (3) (4) of walls, spaced at not more than I .5 m apart.
B i) 5. 6.7 2 8
b) Horizontal bands should be located at all floor,
ii) 8 2 IO
roof and levels of the openings.
C i) 5.6 2 8
ii) 7 2 10 ~C) The sequence of construction between walls
iii) 8 2 12
and the columns shall be first to build the wall
D i) 5 2 8
up to 4 to 6 courses height leaving toothed gaps
ii) 6 2 10 (tooth projection being about 40 mm only) for
iii) 7 2 12 the columns and then to pour Ml 5 grade con-
iv) 8 4 IO crete to fill the columns against the walls using
E i) 5 2 IO forms only on two sides. The band concrete
ii) 6 2 12 should be cast on the wall masonry directly so
iii) 7 4 IO as to develop full bond with it.
iv) 8 4 12 d) Such construction should be limited only to
NOTES two storeys. The horizontal length of wall
1 No strengtheningarrangementfor Category A buildingsup to should not exceed 7 m and the storey height to
3 storeys. 3 m.
2 For spans greater than 8 m. plasters or buttressesmay be
introducedto reduce the spnn. or special calculations have to be
4.6 Hollow Block Masonry
made.
The horizontal and vertical steel for earthquake resis-
3 For plain bars, the diameters should be IO, 12, 16, 20 and 25
tance shall be placed as described below.
respectively for deformed bars of 8. IO, 12. 16.20 given above.
4 For RC band a clear cover of 20 mm shall be provided for
a) Horizontal Band - U-shaped blocks may be
steel. used for construction of horizontal bands at
5 For RC band the vertical depth shall be 75 mm for 2 bars and various levels of the storeys as shown in Fig.
I50 mm for 4 bars. 17.8. The reinforcement shall be 2.5 percent
6 Stirrups shall be 6 mm dia spaced at 150 mm. more than that recommended fin Table 17.4.
Continuity of reinforcement shall be ensured.

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SP62(S&T):1997

1. Window 2. Door
3. Brick Panel 4. LintelBand
All dimensionsin millimetres.
FIG. 17.7 FRAMINGOF THIN LOAD-BEARING BRICK WALLS

FIG. 17.8 U-BLOCKS FORHORIZONTAL BANDS

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 SP62(S&T):1997

b) Vertical Reinforcement - Bars, as given in 1) Ml5 grade should be used for the beam
Table 17.3 shall be located inside the cavities and the reinforcement shall be as in
of hollow blocks, one bar in each cavity (see Table 17.4.
Fig. 17.9). When more than one bar have to be 2) If depth of the beam is more than 75 mm,
located, this can be done in two or more the reinforcement shall be provided at
adjacent cavities; these cavities should be each corner with 8 mm bar.
filled with cement-coarse sand mortar I:3 and A typical detail is shown in Fig. 17.10.
3)
compacted with rod.
b) Top Reinforcement - The reinforcement of
c) Splicing of reinforcement by welding or by 6 mm dia bars of 150 mm centres on top of the
overlap is permitted. To reduce the number of channel core units, shall project out at both
overlaps the block ends may be U-shaped as ends and tied to the tie beam reinforcement.
shown in Fig. 17.9 which will help in tieing the
bars together by binding wire. c) Deck Concrete - Deck concrete over the
precast units shall be of Ml5 grade to act
monolithically with the units; it shall be at least
5 SPECIAL CONSTRUCTION FEATURES -
35 mm thick,
FLOORS AND ROOFS WITH SMALL
PRECAST COMPONENTS d) In ~general for precast components, the prin-
ciple is to make them act as a diaphragm to
5.1 Special construction features for floor and roofs withstand seismic forces.
with small precast components, are given below : 6 TIMBER STRUCTURES - SPECIAL
ARRANGEMENTS
4 Tie Beam - Tie beam is a beam provided all
round the floor or roof to bind together all the 6.1 Foundation
precast components to make it into a
Timber structures shall preferably start on masonry or
diaphragm. The beam shall be full width of the
concrete foundations except small buildings (50 m2
wall allowing for bearing of precast units; the
or less) may rest on ground. The structure may be
depth shall be the depth of precast component.
fixed to~the foundation as shown in Fig. 17.11.

BINDING WIR

--i
304

17.9 VERTICALREINFORCEMENTIN
FIG, CAVITIES

443

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SP62(S&T):1997

REINFORCEMENT
OF TIE BEAM
d 6 MS BARS @ 150 c/c
BOTHWAYS TIE0 TO TIE
BEAM REINFORCEMENT

DECK CONCRETE

PRECAST UNIT

BEAM/WALL

17.1 OA Channel Unit Floor/Roof 17.1OB Cored Unit Floor/Roof

Alldimensions in millimetres.

FIG. 17.10 CONNECTIONOFCHANNEL/COREDUNIT FLOOR/ROOF

(WITHDECKCONCRETE)
WITHTIE BEAM

OR CONCRETE

17.11A Suitable for Strip Foundations 17.llB Suitable for Isolated Column Footings

All dimensions in millimetres.

FIG. 17.11 DETAILSOFCONNECTION
OFCOLUMN
WITHFOUNDATION

For small buildings of area less than 50 m2 resting on a) There shall be at least one diagonal brace of
ground, they may be fixed to vertical poles embedded minimum size 20 mm x 40 mm for every
in the ground. The superstructure has to be 1~5m2 area of the wall. Diagonal braces shall
strengthened for earthquake resistance. be connected to the stud wall members with at
least 4 nails.
6.2 Stud Wall or Brick Nogging Construction
b) Horizontal bracing, 20 mm x 90 mm shall be
It consists of timber studs and corner posts framed into provided at not more than 1 m apart. It shall
sills, top plates and wall plates. Horizontal struts and be provided at T- junctions and corners of wall
braces are used to stiffen the frame against horizontal at sills, first floor and eaves level. They shall
forces. Typical details are as in Fig. 17.12. be connected to the wall plates by at least 9
nails.

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 SP62( S &T)~: 1997

HORIZONTAL BRACE
20 x 90

DOUBLE STUD AT
WINDOW OPENING

‘AL

POST

All dimensions
in millimetlxx
FIG. 17.12 TIMBERFRAMINGINSTUDWALL CONSTRUCTION WITH OPENINGIN WALL

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SP62(S&T):1997

ANNEX A
(Table 17.1)
BUILDING CATEGORIES BASED ON EARTHQUAKE RESISTING FEATURES

A-l ~For the purpose of specifying the earthquake A-2 The building categories, A to E are listed below:
resisting features in masonry and wooden buildings,
the buildings may be categorised on the basis of value Building Categories Range Ofah

ofcch given by~cxt,= cc@I. p A 0.04 to 0.05

where
Cch = design seismic coefficient for the build- B 0.05 to 0.06
ing, C 0.06 to 0.08
cl0 = basic seismic coefficient for the zone in
which it is located as per IS 1893 : 1984, D 0.08 to 0.12
I = importance factor applicable to the build-
ing as per IS 1893 : 1984, and E 0.12 and above
P = soil foundation factor as per IS 1893 :
1984.

ANNEX B
(Clause 4.4)
OPENINGS IN LOAD BEARING WALLS

B-l Door and window openings in walls reduce their the size and position of openings are given in
lateral load resistance and hence, should preferably be Fig. 17.13 and Table 17.5.
small and more centrally located. The guidelines on

II
q&.,1/ me,,,
1. Door 3. Ventilator 2. Window

FIG. 17.~13DIMENSIONSOF OPENINGSAND PIERSFORRECOMMENDATIONSGIVEN IN TABLE 17.5

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 SP62(S&T):1997

Table 17.5 Size and Position of Openings in

Load Bearing Walls
(Clauses B- 1 arid B-3)

SI Position of Opening Details of Opening for Building

No. Category
f I
SECTION Al XX
AnndB C Dond E
(1) (2) (3) (4) (5)

i) Distance of bs from the Zero 230 mm 450 mm

inside comer of out-
side wall, Min
ii) For total length of
openmgs; the ratio
(171+ bz + h)lli, or
(bh + b7)/ 12shall not
exceed
a) for one-storeyed 0.60 0.55 0.50
X7 fx
building
b) for two-storeyed 0.50 0.46 0.42
building
c) 3-or 4-storeyed 0.42 0.37 0.33
W = Window ft = Thickness~of concrete
building
t = Wall thickness V = Vertical bar
iii) Pier width between 340 mm 450 mm 560 mm b = Lintel thickness
consecutive openings
bd, Min
iv) Vertical distance be- 600 mm 6OOmm 600mm
FIG. 17.14 STRENGTHENING MASONRY AROUND
tween two openings OPEINING
one above the other /13,
Min
B-4 Projecting windows/ventilators shall be suitably
B-2 Openings in any storey shall preferably have their anchored.
top at the same level so that a continuous band could
be provided over them, including lintels throughout B-5 If a tall opening from top to bottom were to split
the building. wall into two portions, these portions shall be rein-
forced with horizontal reinforcement of 6 mm diabars
B-3 Where openings do not comply with the
at not-more than 450 mm spacing, one on each face,
guidelines of Table 17.5, they should be strengthened
properly tied to the vertical steel at jambs, corners or
by providing reinforced concrete or reinforced brick-
junction of walls.
work as shown in Fig. 17.14 with high strength
deformed (H.S.D.) bars of 8 mm diametre. Quantity of B-6 The use of arches over openings is a source
steel shall be measured at the jambs. Vertical reinfor- of weakness. When used, steel ties should be
cement shall be as given in Table 17.3. provided.

PART 2 EARTHQUAKE RESISTANCE OF WEAKER BUILDINGS

1 LOW STRENGTH MASONRY BUILDINGS a ) This type of construction should not be per-
mitted for important buildings with I> 1.5 and
1.1 General should preferably be avoided for building
The use and strengthening of low strength masonry categories D and E.
buildings shall be restricted to Zones III and IV of b) To protect the weak mortar a damp-proof
IS 1893 : 1984. No special provisions are necessary course may be laid as prevent rain water from
for such buildings in Zones I and II. Low strength soaking the wall and softening the mortar. A
masonry includes brickwork laid in mud mortar, ran- water proof plaster may bemused.
dom rubble, uncoursed undressed or semi-dressed C) Resistance to overturning under the action of
stone masonry with weak mortars. Other requirements horizontal force shall be designed for.
of 4 and 6 of Part 1 shall apply.

447
SP62(S&T):1997

2 BRICKWORK IN WEAK MORTAR should be embedded in cement mortar 1:3 with

a) For this type of construction, the height of the a suitable cover of 6 mm.
building shall be restricted to the following: 3 STONE MASONRY (RANDOM RUBBLE 0~
Category - Three storeys with flat roof; SEMI-DRESSED)
A, B-ani C two storeys plus attic for a) Height of stone masonry wall should be
pitched roof. restricted to 2 storeys for category A and B if
Category D - Two storeys with flat roof one built with lime mortar or mud mortar; another
stoxy plus attic for pitched roof. storey may be permitted if built with cement
brick bonds should be followed. mortar. For category C and D two storeys may
b) Bond-Usual
For perpendicular walls, a sloping (stepped) be permitted with cement mortar; only one
joint is necessary by making the corners to a storey with lime or mud mortar. Attic may be
height of-600 mm and then building the wall in permitted for two storey buildings.
between them. Otherwise toothed joint should b) Masonry should preferably be brought to
be provided in both the walls; alternatively, it courses at not more than 600 mm lift. The wall
should be btiilt in lifts of about 450 mm (see thickness should be not largerthan 450 mm.
Fig. 17.15). c) Stones of the inner and outer wythes should be
interlocked. ‘Throu’gh’ stones of full length
c) The minimum wall thickness should be one
equal to the thickness of wall should be used in
brick for one storey construction; and one brick
every lift of 600 mm and not more than 1.2 m
for top storey and 1; brick for storeys below for
apart, horizontally. If full length stones ate not
3 storey construction.
available, stones in pairs each of about 3/4 of the
4 The mortar should be lime mortar 1:3 or mud wall thickness may be used (see Fig. 17.16).
mortar. When steel is provided horizontally it

(1.6. c = Toothed
jointsinwallA. B nnd C
All dimensions
inmillimetrw
FIG. 17.15 ALTERNATINGTOOTHEDJOINTSIN WALLS AT CORNERAND T-JUNCTION
t P&50

l-Through stone, P-Pair of overlapping stone, 3-S-shape tie, 4-Hooked tie, 5-Wood plank, 6Floor level.

17.16A Sectional Plan of Wall 17.168 Cross-Section of Wall

FIG. 17.16 THROUGHSTONEANDBOND ELEMENTS

448

.
 SP62(S&T):1997

4 In place of through stones, ‘bonding elements, c) Rammed earth in which moist soil is filled
of steel bars.8 to 10 mm dia bent to S shape or between forms and compacted manually or
as hooked links may be used with a cover of mechanically. The soil for rammed earth con-
25 mm from each face of the wall (see Fig. struction will generally have less clay than that
17.16). used for blocks or adobes. Small amounts of
e>Also in place of through stones wooden cut size straw, not more than one-fourths the volume of
pieces 40 mm x 40 mm cross section or con- soil water mix, shall be added for fissure
crete piece of section 50 mm x 50 mm with control.
8 mm bars may be inserted. d) Wood, bamboo or cane structures plastered
f-l Bonding elements should also be used at with mud (Ikra walling in N.E. Region) (see
corners and junctions of walls. Chapter 4).

g) Mortar should be either lime mortar 1 : 3, mud 4.1.1 The improvements are applicable to buildings in
mortar or cement mortar 1:6. Zones III, IV and V of IS 1893 : 1984, and without the
use of stabilizers for earthen elements.
h) Buttresses may be provided for walls longer.
than 5 m. 4.2 General arrangements for seismic resistance are as
4 IMPROVING EARTHQUAKE RESISTANCE beloa;:
OF EARTHEN BUILDINGS The height of adobe building should be
restricted to one storey plus attic only in Zones
4.1 General
IV and V and to two storeys in Zone III. Im-
Earthen walls may be constructed in the following portant building, with I > 1.5, shall not be
fourways: constructed with earthen walls in Zones IV and
Hand formed layers using mud lumps to form V; in Zone III they may be constructed but
walls is the weakest of all earthen walls. Use restricted only to single storey.
of straw will impart strength and reduce b) Sites with sand, loose soils, poorly compacted
fissures. clays and fill materials should generally be
avoided; also sites with high water table should
b) Block or adobe construction, cut from
hardened soil or formed in moulds and com- be avoided.
pacted, are laid in courses using mud mortar c) Foundation depth shah vary between one to two
from the same soil. Addition of straw in mud times the thickness of wall depending on number
mortar in equal volume would make it non- of storeys; depth shall be at least 0.4 m.
shrinking; the mortar mix should be allowed to d) Wall dimensions, openings, shall be as in
remain for 7 days before use. Normal breaking Fig. 17.17 and 17.18.
of joints and related masonry practices
e) The general configuration shall be as in
should be followed.
Fig. 17.19.

15 6LtTh AND
1’““l+-
f-77

-1- Cross wall, 2 - Pillaster, 3 - Buttress, t - Wall thickness

17.17A Walls and Buttressing 17.178 Tapered Wall

All dimensionsin millimetres.
FIG. 17.17 WALLDIMENSIONS

449
SP62(S&T):1997

l-l 1

W ORV W OR V
‘I D57200
WS1200
LS101
x 5 1200
v -c f?OO

.?I - Door, W - Window, Y - Ventilators

Alldimensions
inmillimetres.
FIG. 17.18WALL DIMENSIONS, PILLASTERS AT CORNERS

17.19A Building Configuration

17.198 Footing on Firm Soil 17.19C Footing on Soft Soil

1- Light roof; 2 - Light gable wall (matting or boarding); 3 - Rain protection overhang (about 500 mm);
4- Stable plaster; 5 - Plinth height for flood protection; 6 - Stable foundation; 7 - Good mortar; 8 - Floor
level; 9 - Ground level; 10 -Waterproof layer

All dimensions inmillimetres.

FIG. 17.19ADEQUATECONFIGURATION OFEARTHENBUILDING

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 SP62(S&T): 1997

4.3 Strengthening Arrangements e) For construction with wood/cane, strengthen-

ing arrangements are bracings as shown in
4 In load bearing walls, two horizontal continous Fig. 17.22.
reinforcing and bonding beams or bands
should be placed one coinciding with lintels f) For higher seismic intensities as in Zones VIII
over doors and windows, the other just below and IX, internal bracing as shown in Fig.
the rooflevel. If the wall height is less than 17.23 may be done.
2.5 m, the band at lintel level may be avoided.
5 REPAIR AND SEISiVfIC STRENGTHENING
b) ThebandsmaybeoftimberasshowninFig. 17.20.
OF BUILDINGS
cl The horizontal band should cover the but-
tresses and plasters. 5.1 Reference may be~made to I-S 13935 : 1993.
d) Vertical reinforcement in mesh form, may be
used in Zone V (see Fig. 17.21).

17.20A Band with Single Timber and Diagonal Brace at Corner

17.208 Band with Two Timbers in Parallel

1- Adobe; 2 - Mud mortar; 3 - Wooden band; 4 - Diagonal brace.

FIG. 17.20 WOODENBAND IN WALLS AT LINTELAND ROOFLEVELS

451

c
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SP62(S&T):1997

17.21A Pattern of Canes in Clay Mud Walls 17.21B Pattern in Adobe Walls

ir
d

17.21C Pattern in Adobe Walls

l- Clay mud Wall; 2 - Adobe; 3 -Vertical cane/bamboo; 4 - Horizontal crushed canes/split bamboo every
4th layer of abode b, S = Spacing about 400 mm; d = Diameter of cane/bamboo about 20 mm

FIG. 17.21 REINFORCEMENT IN EARTHEN WALLS

452
 SP62(S&T):1997

I-

1
E
E
8
ri 8
, m
s
rL
c:
\f
64

~
-

1 - Clay mud covering over framing 2 - Mud plaster on matting

3 - CanelBamboohVood framing 4 - Cane/Bamboo/lkra knitting
17.22A Elementary On-Site Construction 17.228 Prefabricated Panels

1 - Diagonal brace 2 - Mud plaster on matting

3 - CanelBambooMlood framing 4 - CanelBamboollkra knitting

17.22C Diagonal Bracing

FIG. 17.22BRACING OF EARTHENCONSTRUCTIONWITHCANES, BAMBOO OR WOODEN STRUCTURE

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SP62(S&T):1997

SYSTEM A SYSTEM B

PLAN

SHOWING SYSTEM ‘A’ SHOWING SYSTEM ‘f3’

. . SECTION- 1,l

HOLD FAST
(STEEL 1

CORNER
CORNER
BRACING BRACING
Minimum Dimensions
1 - Column lOOx75*OR loo@
2 - Sill 100x75
3 - Beam 100x100OR75~
4 - Diagonal 100x50
5 - Strut 100x50
6 - Ceiling beam 75xl25ORlOO~
l -Corner 100 x 100
7 - Holdfast
Joints - Use 6 gauge nails 75 mm long minimum 2 from each face through iron sheet gussets minimum 1 mm
thickness or straps of 2 mm thickness.

All dimensionsin millimetres.

FIG. 17.23 BRACED WOODFRAMEFORADOBEANDOTHERWALLSINMUDMORTAR

454

.
 CHAPTER18

DEMOLITION OF BUILDINGS
 CONTENTS

1 GENERAL 8.2 Masonry Structures

2 PLANNING 8.3 Reinforced Concrete
3 PRECAUTIONS AND PROTECTIVE MEASURES 8.4 PrecastReinforced Concrete
BEFORESTARTINGDEMOLITION
WORK 8.5 PrestressedConcrete
4 PROTECTION
OFTHEPUBLIC 8.6 Steel
5 SEQUENCEOF DEMOLITION
OPERATIONS 8.7 Other Elements
6 DEMOLITIONOFFLOORS 9 REMOVALOFMATERIALS
7 DEMOLITIONOF WALLS 9.1 General
7.1 Procedure 9.2 Through Chutes
7.2 Catch Platforms 9.3 Through Openings

8 DEMOLITION TYPESOFSTRUCTURES 10 REFERENCES

OFDIFFERENT
AND ELEMENTS
8.1 General
 SP62(S&T):1997

CHAPTER 18

DEMQLITION OF BUILDINGS
1 GENERAL Ensure that the demolition conditions do not,
at any stage, enhance the nuisance value
1.1 Demolition of any structure is, inherently, more of demolition work on ‘the use of adjacent
hazardous than the construction or erection of the buildings;
same. From the point of view of safety, the conditions No structure or part of the structure or any floor
usually encountered awhile dismantling a structure, or temporary support or scaffold, side wall or
whatever its magnitude, do not lend themselves to the any device for equipment shall be loaded in
degree of control possible in the construction opera-
excess of the safe load bearing capacity, in its
tions, where more stable conditions are generally
then existing condition; and
obtainable. It is all the more imperative, therefore, that
adequate attention is paid to planning and execution of Stairs and stair railings, passage ways and
ladders shall be left in place as long as possible.
demolition work, in its various stages, so as to mini-
mize the risk of accidents and injuries to the personnel These should be maintained in a safe
engaged in demolition operations. condition.

It has therefore become necessary to laydown certain 3 PRECAUTIONS AND PROTECTIVE

safety procedures which along with a planned MEASURES BEFORE STARTING
programme could ensure adequate safety, particularly DEMOLITION WORK
with the involvement of management, supervisors and
workers. 3.1 The following precautions land protective
1.2 The demolition work shall be proceeded in such a measures shall be taken before commencement of
way that: demolition work:
a) it causes least damage and nuisance to the 4 On every demolition job, danger signals shall
adjoining building and the members of the be conspicuously posted all around the struc-
public; and ture and all doors, openings giving access to
b) it satisf=s all safety requirements to avoid structures shall be kept barricaded or manned
accidents. except during the actual passage of workmen
or equipment. However provision shall be
1.3 A separate handbook on all aspects construction
made for at least two independent exits for
safety is under preparation by the Bureau of Indian
escape of workmen during any emergency.
Standards. This Chapter will therefore confine itself
to procedures and safety precautions for demolition b) Walkways and passageways shall be provided
and dismantling of buildings. for the use of the workmen who shall be
instructed to use them and all such walkways
2 PLANNING and passageways shall be kept adequately
lighted, free from all debris and other materials.
2.1 Before beginning the actual work of demolition, a
cl Where in any work of demolition it is impera-
careful study shall be made of the structure which is to tive, because of existing danger, to ensure that
be pulled down and also of its surroundings. This shall no unauthorized person shall enter the site of
include the following: demolition outside working hours, a watchman
a>The manner in which the various parts of build- shall be employed. In addition to watching the
ings are supported and how far the stage by site he~shall also be responsible for maintaining
stage demolition would affect the safety of the all signs, notices, lights, barricades, etc.
adjoining structure; During nights, red lights shall be placed on or
b) A definite plan and procedure of demolition about the barricades.
work shall be prepared, taking into account the d) The power on all electrical service lines shall
loads on various structural parts and their be shutoff and all such lines cut nor discon-
supports; nected at or outside the property line. The only
cl Before commencement of each stage of exception would be any powerlines required
demolition, the supervisor shall brief the for the demolition work itself. Prior to cutting
workmen in detail regarding the safety aspects of such lines, the necessary approval of the
to be kept in view; Authority shall be obtained.

457

4’
SP62(S&T):1997

e) All mains and meters of the building shall be anticipated to the adjoining structure, the
removed or protected from damage. same shall be got vacated to avoid any danger
to human life.
0 All gas, water, steam and other service lines
shall be shutoff and capped or otherwise con- 0 Ladders, when used, shall conform to IS 3696
trolled at or outside the property line. (Part 2) : 1991. Ladders or their side railsshall
If a structure to be demolished has been extend not less than 1.O m above the floor or
s)
partially wrecked by fire, explosion or other platform to which the ladder gives access. All
catastrophe, the walls and damaged roofs shall ladders shall be secured against slipping out at
be shored and braced suitably. the bottom and against movement in any
direction at the top.
h) Construction sheds and tool boxes should be so
located as to protect workers from injuries of u>All exterior wall openings which extend down
fatling objects, wall, etc. to the floor level shall be barricaded to a height
not less than 1 m above the floor level. All
9 A warning device should be installed in the floor openings and shafts not meant as material
area to be used to warn the workers, in case of
chutes shall be floored over and endorsed with
danger.
ground rails and toe boards.
k) Screens shall be placed, where necessary, to
prevent tlying pieces from injuring the fellow
v>All existing fixtures/services required during
demolition operations shall be well protected
workmen.
with~substantial covering to the satisfaction of
ml No demolition work shall be carried out during the Authority.
storm or heavy rain.
w) When demolition is to be done by mechanical
4 No demolition work shall be carried out at means such as weight ball and power showels,
night specially when the building or structure the following additional precautions are
to be demolished in an inhabited area. necessary :
P) All necessary safety appliances shall be issued 1) The area shall be barricaded for a mini-
to the workmen and their use explained. It mum distance of 1; times the height of the
shall be ensured that the workers are using all
wall;
the safety appliances while at work. The safety
appliances should be as follows: 2) While the mechanical device is in opera-
tion no workmen shall be allowed to enter
1) Safety helmets as per IS 2925 : 1984; the building being demolished;
2) Goggles made of celluloid lens to be worn 3) The device shall be so located as to.avoid
at the time of demolition of floors, walls,
falling debris; and
tearing of plaster, etc, specially when
4) The device when being used shall not
equipment like jack hammers are used for
cause any damage to adjacent structure,
demolition work, to protect the eyes from
powerline, other services, etc.
flying~pieces, dust, dirt, etc, that may be
blown up by wind. 4 PROTECTION OF THE PUBLIC
3) Leather or rubber gloves worn during 4.1 Protection of the public before and during demoli-
demolition of RCC work or removing tion is important and the following points should be
steel work, where the hands of workers are kept in mind:
likely to be injured.
a) Every sidewalk or road adjacent to the work
4) Safety belts while working at higher level shall be closed or protected. All main roads,
to-prevent falling from the structure. which are open to the public shall be~kept open
q) First-aid equipment shall be available at all to the public clear and unobstructed at all
demolition works of any magnitude. Also, by times.
prior arrangement, a qualified doctor be avail- b) dhildren and public shall be kept out of the
able at call. building and the adjoining yards.
r) When there is a possibility of fire breaking out, c) If the structure to be demolished is more than
appropriate portable first-aid fire appliances two- storeyed or 7.5-m high, measured from the
(see IS 2 190 : 1992) shall be kept at hand. sidewalk or street which cannot be closed or
s) The removal of a member may weaken the side safely diverted, and the horizontal distance
wall of an adjoining structure and to prevent from the inside edge of the side walk to the
possible damage, these walls shall be sup- structure is 4.5 m or less, a substantial side
ported until such time as permanent protection walk shed (see Fig. 18.1) [see nlso (k)] shall be
is provided. In case of any danger is constructed over the entire length of the

458
 PLANKING-I I n BUILDING UNDER DEMOLITION

POST RIGIDLY FIXEO

VARIES (FULL
WIDTH OF SIDEWALK)

FIG. 18.1 TYPICALSKETCHOFASIDEWALKSHED

sidewalk adjacent to the structure of sufficient the roof of the shed is not more than 600 kg/m*.
width with a view to accomodating the The height of the sidewalk shed shah be such
pedestrian traffic without causing congestion. as to give minimum clearance of 2.4 m.
The sidewalk shall be lighted sufficiently to
ensure safety at all times.
s>Sidewalk shed openings, for loading purposes,
shall be kept closed at all times except during
4 A toe board at least 1 m high above the roof actual loading operations.
the shed shall be provided on the outside edge
h) The deck flooring of the sidewalk shed shall
and ends of the sidewalk shed. Such boards consist of plank of not less than 50 mm thick-
may be vertical or inclined outward at not more ness closely laid and deck made watertight.
than 45”.
_i>All members of the shed shall be adequately
e) Except where the roofof a sidewalk shed solid- braced and connected to resist displacement of
ly abuts the structure, the face of the sidewalk members or distortion of framework.
shed towards the building shall be completely
closed by providing sheeting/planking to k) When the horizontal distance from the inside
edge of the sidewalk to the structure is more
prevent the falling material penetrating into the
than 4.5 m and less than 7.5 m, a sidewalk shed
shed.
or fence may be built or in their place a sub-
f) The roof of the sidewalk shed shall be capable stantial railing shall be constructed on the in-
of sustaining a load of 730 kg/m2. Only in side of the sidewalk or roadway along the
exceptional cases, say due to lack of other entire length of demolition side of the property
space, the storing of the material on a sidewalk with movable bars as may be necessary for the
shed may be permitted in which case the shed proper prosecution of the work.
shall be designed for a load of 1 460 kg/m*.
Where workers entrances to the building being
Roof of sidewalk shed shall be designed taking
demolished are not completely protected by
into account the impact of the falling debris.
sidewalk sheds, all such entrances shall be
By frequent removal of loads it shall be en-
protected by canopies extending from the face
sured that the maximum load, at any time, on
of the building to a point not less than 2.5 m

459
SP62(S&T):1997

from it. In such a case, overhead projection 6 DEMOLITION OF FLOORS

shall be at least 0.6 m wider than the building
6.1 For demolition of floors the following procedure
entrance or opening and every canopy shall be
may be followed:
as strong as the sidewalk shed.
a) A slit in width not exceeding 300 mm shall be
5 SEQUENCE OF DEMOLITION cut at the first stage for the entire length of the
OPERATIONS slab along which it spans (see Fig. 18.2). The
opening shall thereafter be increased to the
5.1 The sequence of demolition shall generally be as desired width by suitable instalments.
given below: b) Planks of sufficient strength not less than
50 mm thick and 250 mm wide shall be
a> The demolition shall always proceed sys-
provided at a spacing not greater than 0.4 m.
tematically storey by storey in descending
order and the demolition of upper floors shall These planks shall be so placed as to give
be completely over before any of the support- workmen firm support to guard against any
ing members or other important portion on the unexpected collapse.
lower floor is disturbed. No unnecessary c) Stringers of ample strength shall be installed to
work shall go on below when the demolition is support the planks where necessary and the
in progress above. When some work is to be ends of stringers shall be supported by floor
done at the lower level, adequate protection beams, girders and not by floor slab alone.
shall be provided for all the workmen so 4 When floors are being removed, no workmen
engaged. shall be allowed to work in the area, directly
underneath and such area shall be barricaded
b) The requirements of (a) shall not prohibit the
demolition of structures by sections, if means to prevent access to it [see 5.1(a)].
are taken to prevent injuries to persons nor d The demolition of the floor in question shall be
damage to property. started only after the surrounding area for a
distance of 6 m have been entirely cleared of
c) Roofs (or floors), generally, be demolished persons, and the debris and other unnecessary
first before demolishing the supporting walls
material removed.
structural elements.
f) Planks used for temporary protection shall be
4 All glazed sash, glazed doors and windows sound and at least 50 mm thick. They shall be
etc, shall be removed before the demolition of laid close together with ends overlapping at
roofs and walls starts. All fragile and loose least 100 mm over solid bearing to prevent
fixtures shall be removed. Lath and loose tipping underload.
plaster be stripped off throughout the entire
structure. 7 DEMOLITION OF WALLS
This is advantageous because it
reduces glass breakage and also eliminates a 7.1 Procedure
large amount of dust producing material before The following procedure should be followed when
more substantial parts of the building are demolishing walls:
removed.
a) While walls or sections of masonry are being
demolished it shall be ensured that they are not

STRIPS NOT TO
EXCEED 300 mm

INDEPENDENT WORKING
PLATFORM TO BE USED
WHEREVER POSSIBLE

LINES OF SUPPORT
DIRECTION OF SPAN UNDER FLOOR
MAIN RElNFORCEME

FIG. 18.2 DEMOLITION

OFREINFORCED
CONCRETEFLOORS

460

I.,
 SP62(S&T):1997

illowed to fall as a single mass on the floors of braced and the earth removed by sheet piling
:he building so as not to qxceed the safe carry- or sheathing.
lng capacity of the floors; wherever prac-
ticable, they-may fall away from the floors 7.2 Catch Platforms
[see 7.2) on to c~atch platforms. Overloading
3f floors shall be prevented by removing the Catch platforms shall be provided in case of demoli-
accumulating debris through chutes or by other tion of exterior walls in multistorey buildings. The
means immediately (see 9). The floor shall be following details may be considered:
inspected by the Authority before undertaking a>Catch platforms shall generaHy be provided for
demolition work and if the same is found in- multistoreyed buildings more than 20 m high
capable of carrying the load of debris, neces- to prevent injuries to the worker and to the
sary precautions shall be taken to prevent any public when exterior walls are being
unexpected collapse of the floor. demolished.
b) Walls shall be removed part by part. Stages b) Such platforms shall be constructed and main-
shall be provided for the men to work on, if the tained not more than three storeys below the
walls are very thin and dangerous to work by storey from which the exterior wall is being
standing over them. demolished. When demolition~has progressed
to within three storeys of ground level, catch
cl No section of the wall whose height,is more
than 15 times the thickness, shall be permitted platforms will not be considered necessary.
to stand without lateral bracing unless such a c>Catch platforms shall not be less than 1.5 m in
wall is in good condition and was originally width measured in a horizontal direction from
designed to stand without such lateral bracing the face of the structure and shall consist of
or support. outriggers supported not more than 3 m apart.
Planks shall be laid tight together, without
4 Structural or load supporting members on any
floor’ shall not be removed or cut until all the openings between them and the walls. Catch
storeys above that floor have been demolished platforms shall be provided with a continuous
and removed. solid parapet along its outer edge of at least
1 m height. The parapet may be constructed
4 Before demolishing any interior or exterior
with the same material as the platform.
wall within 3 m of the opening in the floor
immediately below, such opening shall be sub- 4 Catch platform shall be capable. of sustaining a
stantially planked over, unless access is denied live load of not less than 610 kg/m2.
to workmen to that portion of the floor imme- 4 Catch platforms shall neither be used’for stor-
diately below the opening, in the floor of the ing of materials nor dumping of materials.
storey being demolished, where any debris
passing through the opening may fall. 8 DEMOLITION OF DIFFERENT TYPES OF
In framed structures, the frame may be left in STRUCTURES AND ELEMENTS
position during demolition of masonry work.
Where this is done all beams, girders, etc, shall 8.1 General
be cleared of all loose materials as the demoli-
tion of masonry work progresses downward Structures may be dealt with as masonry, concrete,
provided it is still strong enough to stand as an steel and timber. The structures or their elements shall
independent structure. be dealt with as below, in addition to other require-
ments as applicabk.
8) Walkways shall be provided to enable
workmen to reach or leave their work on any
scaffold or wall. Such walkways shall neither 8.2 Masonry Structures
be less than 3 planks wide, nor less than 0.8 m
in width. a>Jack Arches - Where tie -rods are present
between main supporting beams, these should
h) After completion of each days work, all walls not be cut until after the arch or series of arches
shall be left stable to avoid any danger of
in the floor have been removed. Particular care
getting overturned.
should be exercised and full examination of
3 Foundation walls which serve as retaining structure be made before the demolition is
walls to support the earth or adjoining struc- commenced (see Fig. 18.3). The floor should
ture, shall not be demolished until such an be demolished in strips parallel to the span of
adjoining structure has been underpinned or arch rings (at right angles to the main floor
beam).
SP62(S&T):1997

REMOVE ALL ARCHES

BEFORE CUTTING TIE

FIG. 18.3 DEMOLITIONOF JACK ARCHES

b) Brick Arches Demolition may be proceeded as for a

1) As much dead load as possible may be single span care being taken to demolish
removed provided it does not interfere the spandrels down to the springing line as
with stability of main arch rings; it should the work proceeds (see Fig. 18.4 D).
be noted that the load carrying capacity of Where explosives are used it is preferable
many old arches relies on the filling be- to ensure the collapse of the whole struc-
tween the spandrels. On no account ture in one operation to obviate the chance
should the restraining influence of the of leaving unstable portions standing.
abutments be removed before the dead
load~of the spandrel fill and the arch rings 8.3 Reinforced Concrete
are removed. The normal sequence of
demolition shown in Fig. 18.4 A includes a) Before commencing demolition, the condition
the following: and position of reinforcement and possibility
- of lack of its continuity should be ascertained.
remove the spandrel filling down to
Demolition should be commenced by remov-
the springing line,
ing partitions, non-load bearing cladding, etc.
- remove the arch rings, and similarnon-structural elements.
- remove the abutments.
b) Where hand demolition methods are used, the
- special temporary support shall be following procedures should be used:
provided in the case of skew bridges.
1) Beams - For beams supporting rope
2) A single span arch can be demolished, by should be attached to the beam. Then the
hand, by cutting narrow segments concrete should be removed from both
progressively from each springing parallel ends by pneumatic drill and the reinforce-
to the span of the arch, until the width of ment exposed. The reinforcement should
the arch has been reduced to a minimum then be cut in such a way as to allow the
which can then collapse (see Fig. 18.4 B). beam to be lowered under control to the
Where it is impossible to allow debris to floor (see Fig. 185 A).
fall to the ground below, centering
2) Columns - For columns reinforcement
designed to carry the load should be should be exposed at the base after
erected and the arch demolished progres- restraining wire guy ropes have been
sively. The design of the centering should placed around the member at the top. The
make appropriate allowance for impact. reinforcement should then be cut in such
3) Where deliberate collapse is feasible the a way as to allow the column be pulled
crown may be broken by the demolition down to the floor under control (see Fig.
ball method working progressively from 18.5 B).
the edges to the centre (see Fig. 18.4 C). Walls - Reinforced concrete walls
3)
4) Collapse of structure can be effected in should be cut into strips and demolished
one action by the use of explosives. as for columns (see Fig. 18.5 C).
Charges should be inserted into boreholes Suspended Floors and proofs - Solid
4)
drilled in both arch and abutments. This slabs should be demolished as described
method is the most effective for demoli- in 6 and Fig. 18.2. Where ribbed construc-
tion of tall viaducts. tion is used, the principle of design and
5) In multi-span arches, before individual method of construction should be ascer-
spans are removed, lateral restraint should tained before demolition. Care should be
be provided at the springing level. taken not to cut the ribs inadvertently.
 SP62(S&T):1997

L ABUTMENTS -/
18.4A
E-DGE

:DGE
AR CH

6MPORARY CENTERING LDELIBERATE COLLAPSE

AS NECESSARY FOR CENTRE l*Om STRIP
/ ABUTMENT
ELEVATION PLAN
18.4B

EMOLISHING ARCH AT CROWN

OR’KING FROM EDGE EDGE OF
F ARCH To CENTR ARCH

EDGE OF ARCH
18.4C

~REsTR AINT
BEFORE INTERMEDIATE SPAN
IS DEMOLISHED
18.4D

NOTE-Order of demolition.
FIG. 18.4 DEMOLITION OF MASONRY AND BRICKWORK ARCHES

8.4 Precast Reinforced Concrete other part of the structure and wherever neces-
sary temporary suppports shall be provided.
a) Precast reinforced concrete units in a structure
are normally held~in position by the strength of 8.5 Prestressed Concrete
the joints in-situ or on supporting walls, etc.
Before commencing of the demolition~work involving
As such before starting on demolition the joint
such structures advise of an expert engineer should be
structures or the supporting mechanisms shall obtained
be studied and understood.
b) In devising and following demolition sequen- 8.6 Steel
ces, due precaution shall be taken to avoid a) No beams shall be cut until precautions have
toppling over of the prefabricated units or any been taken to prevent it from swinging freely

463
SP62(S&T):1997

ROPE SECURELY RESTRAINING ROPE l Y’

CUT2-, , / TIE0 AROUNO (IN OPPOSITE DIRECTION
TO PULLING ROPE)
\
ROPE SECURELY
TIED TO TOP Of

CUT 1’ L REQUlRED
BEAM IN LOWERE DIRECTI ON OF
POSITION FALL
18.5A RC Beams 18.58 RC Columns

SLOTS
THIS L

APPROX

-REMOVE CONC (31

ELEVATION SECTION
18.5C RC Walls

FIG. 18.5 HAND DEMOLITIONOF IN-SITUCONCRETESTRUCTURE

and possibly striking any worker or equipment frame should be independently and securely
or any part of the structure being demolished. guyed in both directions before work starts.
On no account should the bottom tie of a truss
b) All structural steel members shall be lowered
from the building and shall not be allowed to be cut until the principal rafters are prevented
drop. from making outward movement.

c>Tag lines shall be used on all materials being b) Cantilevers - A cantilever type of construc-
lowered or hoisted up and a standard signal tion depends on the balancing superimposed
system shall be used and workmen instructed structure for its stability. Canopies, cornices,
on the signals. No person shall be permitted to staircases and balconies should be demolished
ride the load line. or supported before the balancing load is
removed.
4 When a derrick or hoisting equipment is used
care shall be taken to see that the floor on which c) Heavy FloorBeams - Heavy baulks of timber
it is supported shall be strong enough for the should be supported before cutting at the ex-
loading. If necessary heavy planking shall be tremites and should then be lowered to a safe
used to distribute the load to floor beams and working place.
girders. Overloading/overturning of the 9 REMOVAL OF MATERIALS
equipment shall be avoided.
9.1 General
8.7 Other Elements
Removal of dismantled materials should be done care-
a>Roof Trusses-Roof trusses shall be removed fully; they may be thrown/lowered to the ground. The
to wall plate level by hand methods. Sufficient materials shall preferably be dumped inside the build-
purlins and bracing should be retained to ing. Normally such materials shall be lowered to the
ensure stability of the remaining roof trusses ground or to the top of the sidewalk shed where
while each individual truss is removed. provided by means of ropes or suitable tackles.
Temporary bracing should be added, where
9.2 Through Chutes
necessary, to minimize instability. The end
frame opposite to the end where dismantling is a) Wooden or metal chutes shall be~provided for
commenced, or a convenient intermediate removal of materials. The chutes shall

464
 SP62(S&T):1997

preferably be provided at the centre of the protected by standard railings and toe boards
building for efficient disposal of debris. (see IS 4912 : 1978) nor preferably planked
over if the holes are not being used for dumping
b) Chutes if provided at an angle of more than 45’
from the horizontal shall be entirely enclosed materials [see 3.1(s)].
on all sides, except for opening at or about the c) All intermediate floor openings for passage of
floor level for receiving materials. materials shall be completely closed with bar-
ricades or guard rails not less than 1 m high and
cl Opening for chutes shall not exceed I .20 m in
height measured along the wall of the chute and at a distance of not less than 1 m from the edge
in all storeys below the top floor such opening of the general opening. No barricades or guard
shall be kept closed when not in use. rails shall be removed until the storey immedi-
ately above has been demolished down to the
4 To prevent the descending material attaining a floor line and all debris cleared from the floor.
dangerous speed, the chute shall not extend in
an unbroken line for more than two storeys. A d) When cutting a hole in an intermediate floor,
gate or step shall be provided with suitable between the storage floor and the floor which
means of closing at the bottom of each chute to is being demolished, makes the intermediate
stop the flow of materials. floor or any portion of it unsafe, then such
intermediate tloor shall be properly shored. It
e) Chutes at an angle less than 45’ to the horizon- shall also be ensured that the supporting walls
tal may be left open on the upperside provided
are not kept without adequate lateral restraints.
that at the point where such chute discharges
into the chute steeper than 45” to the horizon- 10 REFERENCES
tal, the top of the steeper chute shall be boarded
Other Indian Standards on the subject of safety of
over to prevent the escape of materials.
workers, in addition to the handbook under preparation
Any opening into which workmen dump debris are as follows:
at the top of the chute shall be guarded by a
substantial guard rail extending at least 1 m IS No. Title
above the~level of the floor or other surface on 3696 (Part I) : Safety code of scaffolds and
which men stand to dump the materials into the 1987 ladders: Part 1 Scaffolds
chute. 40 14 (Part 2) : Code of practice for steel tubular
A toe board or bumper not less than 50 mm 1967 scaffolding: Part 2 Safety~regula-
thick and 150 mm high shall be provided at tions for scaffolding
each chute opening, if the~required material is 3764: 1992 Code of safety for excavation
dumped from the wheel barrows. Any space work first revision)
between the chute and the edge of the opening 7969 : 1975 Safety code for handling and
in the floor through which it passes shall be storage of building materials
solidly planked over. 13415 : 1992 Code of safety for protective bar-
riers in and around buildings
9.3 Through Openings 13416 (Part I) : Recommendations for preven-
1992 tive measures against hazards at
4 Debris may also be dropped through holes i? workplaces: Part 1 Falling
the floor without the use of chutes. In such a material hazards prevention
case the total area of the hole cut in the inter- 13416 (Part 2) : Recommendations for preven-
mediate floor, one which lies between tloor 1982 tive measures against hazards at
that is being demolished and the storage floor workplaces : Part 2 Fall preven-
shall not exceed 25 percent of such floor area. tion
It shall be ensured that the storage tloor is of 13430 : 1992 Code of practice for safety
adequate strength to withstand the impact of during additional construction
the falling material. and alteration to existing
buildings
b) Openings in all floors below the floor from
which materials are being removed, shall be

465
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W_l ‘ONSI
 SP 62 (S & T) : 1997

IS No. Title
*1904: 1986 Code of practice for design and construction of foundations in soils :
General requirements (third revision)
2062 : 1992 Steel for general structural purposes (fourth revision) (supersedes IS 226 :
1975) (Amendment 1)
2911 (Part l/Set I) : 1979 Code of practice for design and construction of pile foundations : Part 1
Concrete piles, Section 1 Driven case in-situ concrete piles @first revision)
(Amendments 2) (Reaffirmed 1987)
2911 (Part l/Set 2) : 1979 Code of practice for design and construction of pile foundations : Part 1
Concrete piles, Section 2 Bored cast in-situ piles (first revision) (Amend-
ments 3) (Reaffirmed 1987)
2911 (Part l/Set 3) : 1979 Code of practice for design and construction of pile foundations : Part 1
Concrete piles, Section 3 Driven precast concrete piles (first revision)
(Amendments 3) (Reaffirmed 1987)
2911 (Part l/Set 4) : 1984 Code of practice for design and construction of pile foundations : Part 1
Concrete piles, Section 4 Bored precast concrete piles (Amendment 1)
2911 (Part 2) : 1980 Code of practice for design and construction of pile foundations : Part 2
Timber piles (first revision) (Amendment 1) (Reaffirmed 1987)
29 11 (Part 3) : 1980 Code of practice for design and construction of pile foundations : Part 3
Under reamed piles @rst revision) (Amendments 3)
2911 (Part 4) : 1985 Code of practice for design and construction of pile foundations : Part 4
Load test on piles (first revision) (Amendment 1)
2950 (Part 1) : 1981 Code of practice for design and construction of raft foundations : Part 1
Design (second revision) (Amendment 1) (Reaffirmed 1993)
2974 (Part 1) : 1982 Code of practice for design and construction of machine foundations :
Part 1 Foundations for reciprocating type machines (second revision)
(Amendment 1) (Reaffirmed 1993)
2974 (Part 2) : 1980 Code of practice for design and construction of machine foundations :
Part 2 Foundations for impact type machine (hammer foundations) (first
revision) (Amendment 1) (Reaffirmed 1993)
2974 (Part 3) : 1992 Design and construction of machine foundations - Code of practice :
Part 3 Foundations for rotary type machines (medium and high frequency)
(secondrevision)
2974 (Part 4) : 1979 Code of practice for design and construcrtion of machine foundations :
Part 4 Foundations for rotary type machines of low frequency (first
revision) (Amendment 1) (Reaffirmed 1987)
2974 (Part 5) : 1987 Code of practice for design and constrution of machine foundations :
Part 5 Foundations for impact machines other than hammers (forging and
stamping press, pig breakers, drop crusher and jolter) (first revision)
(Reaffirmed 1993)
3629 : 1986 Specification for structural timber in building @rst revision) (Reaffirmed
1991)
4094 : 1979 Code of practice for design and construction of foundations for transmis-
sion line towers and poles (first revision) (Reaffirmed 1987)
6403 : 1981 Code of practice for determination of bearing capacity of shallow founda-
tions (first revision) (Amendment 1) (Reaffirmed 1990)
6909 : 1990 Specification for supersulphated cement (Amendments 2)
8009 (Part 1) : 1976 Code of practice for calculation of settlement of foundations: Part I Shallow
foundations subject to symmetrical static vertical loads (Amendments 2)
(Reaffirmed 1993)
8009 (Part 2) : I980 Code of practice for calculation of settlement of foundations : Part 2 Deep
foundations subjected to symmetrical static vertical loading (Amendment
1) (Reaffirmed 1987)

467
SP 62 (S & T) : 1997

IS No. Title
8041 : 1990 Rapid hardening Portland cement (second revision) (Amendments 2)
9456 : 1980 Code of practice for design and construction of conical and hyperbolic
paraboloidal types of shell foundations (Amendment 1) (Reaffirmed 1993)
“9556 : 1980 Code of practice for design and construction of diaphragm walls (Amend-
ment 1) (Reaffirmed 1993)
11089 : 1984 Code of practice for design and construction of ring foundation (Amend-
ment 1) (Reaffirmed 1990)
11233 : 1985 Code of practice for design and construction of radar antenna, microwave
and TV tower foundations (Reaffirmed 1990)
12269: 1987 53 grade ordinary Portland cement (Amendments 3) (Reaffirmed 1992)
13094 : 1992 Guidelines for selection of ground improvement techniques for foundation
in weak soils
SP 36 (Part 2) : 1988 Compendium of Indian Standards on soil engineering : Part 2 Field testing

CHAPTER 4
MASONRY

Part 1 Mortars

269 : 1989 33 grade ordinary Portland cement (fourth revision) (Amendments 3)

383 : 1970 Coarse and fine aggregates from natural sources for concrete (second
revision)-(Reaffirmed 1990)
455 : 1989 Portland slag cement (fourth revision) (Amendments 3)
456: 1978 Code of practice for plain and reinforced concrete (third revision) (Amend-
ments 2) (Reaffirmed 1991)
712 : 1984 Building limes (third revision) (Reaffirmed 1991)
1344: 1981 Calcined clay pozzolana (second revision) (Amendment 1) (Reaffirmed
1990)
1489 (Part 1) : 1991 Portland pozzolana cement: Part 1 Fly ash based (third revision)
1489 (Part 2) : 1991 Portland pozzolana cement: Part 2 Calcined clay based (third revisilwz)
(Amendment 1)
1635 : 1992 Code of practice for field slaking of building lime and preparation of putty
(second revision)
2116: 1980 Sand for masonry mortars (first revision) (Reaffirmed 1992)
2250: 1981 Code of practice for preparation and use of masonry mortars Cfirst revision)
(Reaffirmed 1990)
2686 : 1977 Cinder as fine aggregates for use in lime concrete (first revision) (Amend-
ment 1) (Reaffirmed 1992)
3182 : 1986 Broken brick (burnt clay) fine aggregates for use in lime mortar (second
revision) (Reaffirmed 1991)
3812: 1981 Fly ash for use as pozolana and admixture (first revision) (Reaffirmed 1992)
4098 : 1983 Lime-pozzolana mixture (first revision) (Amendments 2) (Reaffirmed
1989)
6452 : 1989 Specification for high alumina cement for structural use (Amendment 1)
6909 : 1990 Specification for supersulphated cement (Amendments 2)
8041 : 1990 Rapid hardening Portland cement (second revision) (Amendments 2)
8043 : 1991 Hydrophobic Portland cement (second revision) (Amendments 2)
81.12 : 1989 43 grade ordinary Portland cement yirst revision) (Amendments 3)
12269 : 1987 53 grade ordinary Portland cement (Amendments 3) (Reaffirmed 1992)
12600: 1989 Low heat Portland cement (Amendments 3)
13077 : 1991 Guide for preparation and use of mud mortar in masonry

468
 SP 62 (S & T) : 1997

IS No.
“SP 20 (S & Tj: 1991 Handbook on masonry design and construction (first revision)
SP 21 (S &T) : 1983 Summaries of Indian Standards for building materials

Part 2 Brickwork and Blockwork

Section 1 Brick~and Block Units

269 : 1989 33 grade ordinary Portland cement (fourth revision) (Amendments 3)

383 : 1970 Coarse and fine aggregates from natural sources for concrete (second
revision) (Reaffirmed 1990)
455 : 1989 Portland slag cement vourth revision) (Amendments 3)
456 : 1978 Code of practice for plain and reinforced concrete (third revision) (Amend-
ments 2) (Reaffirmed 1991)
712: 1984 Building limes (third revision) (Reaffirmed 199 1)
1077 : 1992 Common burnt clay building bricks (@t/z revision)
1344 : 1981 Calcined clay pozzolana (second revision) (Amendment 1) (Reaffirmed
1990)
1489 (Part 1) : 1991 Portland pozzolana cement: Part 1 Fly ash based (third revision)
1489 (Part 2) : 1991 Portland pozzolana cement: Part 2 Calcined clay based (third revision)
(Amendment 1)
1725 : 1982 Soil based blocks used in general building construction @-St revision)
(Reaffirmed 1992)
2117 : 1991 Guide for manufacture of hand-made common burnt clays building bricks
(third revision) .
2180: 1988 Heavy duty burnt clays building bricks (third revision) (Reaffirmed 1991)
2185 (Part 1) : 1979 Concrete masonry units : Part 1 Hollow and solid concrete blocks (second
revision) (Amendment 1) (Reaffirmed 1992)
2185 (Part 2) : 1983 Concrete masonry units : Part 2 Hollow and solid light weight concrete
blocks yirst revision) (superseding IS 3590) (Reaffirmed 1989)
2185 (Part 3) : 1984 Concrete masonry units : Part 3 Autoclaved cellular aerated concrete blocks
(first revision) (superseding IS 5482) (Reaffirmed 1990)
2222: 1991 Burnt clay perforated building bricks cfburth revision)
2645 : 1975 Integral cement waterproofing compounds (first revision) (Amendment I)
(Reaffirmed 1992)
2686 : 1977 ^ Cinder as fine aggregates for use in lime concrete (first revision) (Amend-
ment 1) (Reaffirmed 1992)
2691 : 1988 Burnt clay facing bricks (second revision)
3068 : 1986 Broken brick (burnt clay) coarse aggregates for use in lime concrete (second
revision) (Reaffirmed 1991)
3115 : 1992 Lime based blocks (second revision)
3495 : 1992 Methods of test for burnt clay building bricks (Parts 1 to 4 in one volume)
(third revision)
3812: 1981 Fly ash for use as pozzolana and admixture @rst revision) (Reaffirmed
1992)
3952 : 1988 Burnt clay hollow bricks for walls and partitions (second revision)
4098 : 1983 Lime-pozzolana mixture (first revision) (Amendments 2) (Reaffirmed
1989)
4139 : 1989 Calcium silicate bricks (second revision)
5454 : 1978 Methods of sampling of clay building bricks
6165 : 1992 Dimensions for special shapes of clay bricks (first revision)
6452 : 1989 Specification for high alumina cement for structural use (Amendment 1)

469
SP 62 (S & T) : 1997

IS No. Title

6909 : 1990 Specification for supersulphated cement (Amendments 2)

8041 : 1990 Rapid hardening Portland cement (second/ revision) (Amendments 2)
8042 : 1989 White Portland cement (second revision) (Amendments 4)
8043: 1991 Hydrophobic Portland cement (second revision) (Amendments 2)
8112: 1989 43 grade ordinary Portland cement @sf revision) (Amendments 3)
9103 : 1979 Admixture for concrete (Reaffirmed 1990)
11650 : 1991 Guide for manufacture of common burnt clay building bricks by semi-
mechanized process (first revision)
12269 : 1987 53 grade ordinary ~Portland cement (Amendments 3) (Reaffirmed 1992)
12440 : 1988 Precast concrete stone masonry blocks (Reaffirmed 1995)
12600 : 1989 Low heat Portland cement (Amendments 3)
12894: 1990 Fly ash lime bricks
SP20(S&T): 1991 Handbook on masonry design and construction (first revision)
SP21 (S&T): 1983 Summaries of Indian Standards for building materials
Section 2 Brickwork

1077 : 1992 Common burnt clay building bricks Vifth revision)

2212: 1991 Code of practice for brick work (first revision)
3696 (Part 1) : 1987 Safety code of scaffolds and ladders : Part 1 Scaffolds
4014 (Part 2) : 1967 Code of practice for steel tabular scaffolding : Part 2 Safety regulationsfor
scaffolding (Reaffirmed 1990)
SP 25 (S &T) : 1984 Handbook on caused and prevention of crakcs in building
Section 3 Blockwork

280 : 1978 Mild steel wire for general engineering purposes (third revision) (Amend-
ment I ) (Reaffirmed 1992)
456 : 1978 Code of practice for plain and reinforced concrete (third revision) (Amend-
ments 2) (Reaffirmed 199 1)
1905: 1987 Code of practice for structural use of un-reinforced masonry (third revision)
(Reaffirmed 1992)
2185 (Part 1) : 1979 Concrete masonry units : Part I Hollow and solid concrete blocks (second
revision) (Amendment 1) (Reaffirmed 1992)
2185 (Part 2) : 1983 Concrete masonry units : Part 2 Hollow and solid weight concrete blocks
(first revisiort) (superseding IS 3590) (Reaffirmed 1989)
2185 (Part 3) : 1984 Concrete masonry units : Part 3 Autoclaved cellular aerated concrete blocks
@rst revision) (superseding IS 5482) (Reaffirmed 1990)
*2572 : 1963 Code of practice for construction of hollow concrete block masonry
(Reaffirmed 1992)
*6041 : 1985 Code of practice for construction of autoclaved cellular concrete block
masonry Cfirstrevision) (Reaffirmed 1990)
*6042 : 1969 Code of practice for construction~of lightweight concrete block masonry
(Reaffirmed 1990)
Section 4 In-situ Construction with Soil Cement
217 : 1988 Cutback bitumen (second revision)
2110 : 1980 Code of practice for in-situ construction of walls, in building with
soil-cement (first revision) (Reaffirmed 1992)
Part 3 Stonework
CPWD 199 I -92 Specifications
1123 : 1975 Method of identification of natural building stones (first revision) (Reaf- i
firmed 1990)

470
-._. _,

SP 62 (S & T) : 1997

IS No. Titie
1127 : 1970 Recommendations for dimensions and workmanship of natural building
stones for masonry work (first revision) (Reaffirmed 1993)
1128 : 1974 Limestone (slab and tiles) (first revision) (Reaffirmed 1993)
1129: 1972 Recommendation for dressing of natural building stones (first revision)
(Reaffirmed 1993)
1130: 1969 Marble (blocks, slabs and tiles) (Reaffirmed 1993)
“1597 (Part 1) : 1992 Code of practice for construction of stone masonry : Part 1 Rubble stone
masonry yirst revision)
;k1597 (Part 2) : 1992 Code of practice for construction of stone masonry : Part 2 Ashlar masonry
(first revision)
1630 : 1984 Mason’s tools for plaster work and pointing work (first revision)
(Reaffirmed 1990)
1905 : 1987 Code of practice for structural use of un-reinforced masonry (third revision)
(Reaffirmed 1992)
2250 : 1981 Code of practice for preparation and use of masonry mortars first revision)
(Reaffirmed 1990)
3316 : 1974 Specification for structural granite (first revision) (Reaffirmed 1993)
3620 : 1979 Specification for laterite stone block for masonry (first revision)
(Reaffirmed 1993)
3622 : 1977 Specification for sandstone (slab and tiles) (first revision) (Reaffirmed 1993)
3696 (Part 1) : 1987 Safety code of scaffolds and ladders : Part 1 Scaffolds (Reaffirmed 199 1)
4101 (Part 1) : 1967 Code of practice for external facing and veneers : Part 1 Stone facing
(Reaffirmed 1990)
12440~: 1988 Precast concrete stone masonry blocks
“SP 20 (S &T) : 1991 Handbook on masonry design and construction Cfirst revision)
SP 21 (S & T) : 1983 Summarise of Indian Standards for building materials

CHAPTER 5
PLAINAND REINFORCED CONCRETE

269 : 1989 33 grade ordinary Portland cement (fourth revision) (Amendments 3)

383 : 1970 Coarse and fine aggregates from natural resources for concrete (second
revision) (Reaffirmed 1990)
432 (Part 1) : 1982 Mild steel and medium tensile steel bars and hard-drawn steel wire for
concrete reinforcement : Part 1 Mild steel and medium tensile steel bars
(third revision)
455 : 1989 Portland slag cement (fiourth revision) (Amendments 3)
456 : 1978 Code of practice for plain and reinforced concrete (third revision) (Amend-
ments 2) (Reaffirmed 1991)
516 : 1959 Method of test for strength of concrete (Amendments 2) (Reaffirmed 199 1)
712 : 1984 Building limes (third revision) (Reaffirmed 199 1)
875 (Part 1) : 1987 Code of practice for design loads (other than earthquake) for buildings and
structures : Part 1 Dead loads-Unit weights of building material and stored
materials (second revision) (incorporating IS 1911 : 1967) (Reaffumed 1992)
875 (Part 2) : 1987 Code of practice for design loads (other than earthquake) for buildings and
structures : Part 2 Imposed loads (second revision) (Reaffirmed 1992)
875 (Part 3) :.1987 Code of practice for design loads (other than earthquake) for buildings and
structures : Part 3 Wind loads (second revqion) (Reaffirmed 1992)
875 (Part 4) : 1987 Code of practice for design loads (other than earthquake) for buildings and
structures : Part 4 Snow loads (second revision) (Reaffirmed 1992)
875 (Part 5) : 1987 Code ofpractice for design loads (other than earthquake) for buildings and
structures : Part 5 Special loads and lopd combinations (second revision)
(Reaffirmed 1992)

471
SP 62 (S & T) : 1997

IS No. Title
883: 1970 Design of structural timber in building - Code of practice (third revision)
1199 : 1959 Methods of sampling and analysis of concrete (Reaffirmed 199 1)
1344 : 1981 Calcined clay pozzolana (second revision) (Amendment 1) (Reaffirmed
1990)
1489 (Part 1) : 1991 Portland pozzolana cement : Part 1 Ply ash based (third revision)
!489 (Part 2) : 1991 Portland pozzolana cement : Part 2 Calcined clay based (third revision)
(Amendment 1)
1566 : 1982 Hard-drawn steel wire fabric for concrete reinforcement (second revision)
(Amendments 2)
1786 : 1985 High strength deformed steel bars and wires for concrete reinforcement
(third revision) (superseding IS 1139 : 1966) (Amendment 1) (Reaffirmed
1990)
1791 : 1985 Batch type concrete mixers (second revision) (Reaffirmed 1990)
1946: 1961 Code of practice-for use of fixing devices in walls, ceilings and floors of
solid construction (Reaffirmed 1992)
2062 : 1992 Steel and general structural purposes (fourth revision) (supersedes
IS 226 : 1975) (Amendment 1)
2386 (Part 1) : 1963 Methods of test for aggregates for concrete : Part 1 Particle size and shape
(Amendments 2) (Reaffirmed 1990)
2386 (Part 2) : 1963 Methods of test for aggregates for concrete : Part 2 Estimation of deleterious
materials and organic impurities (Amendment 1) (Reaffirmed 1990)
2386 (Part 3) : 1963 Methods of test for aggregates for concrete : Part3 Specific gravity, density,
voids, absorption and bulking (Reaffirmed 1990)
2386 (Part 4) : 1963 Methods of test for aggregates for concrete : Part 4 Mechanical properties
(Amendments 3) (Reaffirmed 1990)
2386 (Part5) : 1963 Methods of test for aggregates for concrete : Part 5 Soundness (Reaffirmed
1990)
2386 (Part 6) : 1963 Methods of test for aggregates for concrete : Part 6 Measuring mortar
making properties of fine aggregates (Amendments 2) (Reaffirmed 1990)
2386 (Part 7) : 1963 Methods of test for aggregates for concrete : Part 7 Alkali aggregate
reactivity (Reaffirmed 1990)
2386 (Part 8) : 1963 Methods of test for aggregates for concrete : Part 8 Petrographic exami-
nation (Reaffirmed 1990)
2502 : 1963 Code of practice for bending and fixing of bars for concrete reinforcement
(Reaffirmed 1990)
2505 : 1980 Concrete vibrators-Immersion type-General requirements (Reaffirmed
1993)
2506 : 1985 General requirements for screed board concrete vibrators lfirst revision)
(Reaffirmed 1990)
2514 : 1963 Concrete vibrating tables (Reaffirmed 1991)
2541 : 1991 Code of practice for preparation and use of lime concrete (second revision)
2686 : 1977 Cinder as fine aggregates for use in lime concrete (first revision) (Amend-
ment 1) (Reaffirmed 1992)
2751 : 1979 Recommended practice for welding of mild steel plain and deformed bars
for reinforced construction (first revision) (Reaffirmed 1992)
3025 : 1964 Methods of sampling and test (physical and chemical) for water used in
industry
3036 : 1992 Laying lime concrete for a waterproofed roof finish - Code of practice
(second revision)
3068 : 1986 Broken brick (burnt clay) coarse aggregtates for use in lime concrete
(second revision) (Reaffirmed 1991)

472
-.-

SP 62 (S & T) : 1997

IS No. Title
3182: 1986 Broken brick (burnt clay) fine aggregates for use in lime mortar (second
revision) (Reaffirmed 199 1)
3812: 1981 Fly ash for use as pozzolana and admixture (first revision) (Reaffirmed 1992)
4031 (Part 1) : 1988 Methods of physical tests for hydraulic cement : Part 1 Determination of
fineness by dry sieving (first revision)
4098 : 1983 Lime-pozzolana mixture (first revision) (Amendments 2) (Reaffirmed
1989)
4656 : 1968 Form vibrators for concrete (Reaffirmed 199 I)
4925 : 1968 Concrete batching and mixing plant (Reaffirmed 1991)
4926 : 1976 Ready mixed concrete (first revision) (Reaffirmed 1990)
4990 : 1993 Plywood for concreteshuttering work (second revision)
5817: 1992 Preparation and use of lime-pozzolana mixture concrete in buildings and
roads - Code of practice (first revision)
6452: 1989 Specification for high alumina cement for structural use (Amendment 1)
6909 : 1990 Specification for supersulphated cement (Amendments 2)
7861 (Part 1) : 1975 Code of practice for extreme weather concreting : Part 1 Recommended
practice for hot weather concreting (Amendment 1) (Reaffirmed 1990)
7861 (Part2) : 1981 Code of practice for extreme weather concreting : Part 2 Recommended
practice for cold weather concreting (Amendment 1) (Reaffirmed 1992)
8041 : 1990 Rapid hardening Portland cement (second revision) (Amendments 2)
8043 : 1991 Hydrophobic Portland cement (second revision) (Amendments 2)
8112: 1989 43 grade ordinary Portland cement yirst revision) (Amendments 3)
9012: 1978 Recommended practice for shotcreting (Reaffirmed 1992)
9013 : 1978 Method of making, curing and determining compressive strength of
accelerated cured concrete test specimens (Amendment 1) (Reaffirmed 1992)
9103 : 1979 Admixtures for concrete (Reaffirmed 1990)
10262: 1982 Recommended guidelines for concrete mix design (Reaffirmed 1989)
12600: 1989 Low heat Portland cement (Amendments 3)
133 11 (Part 1) : 1992 Non-destructive testing of concrete - Methods of test : Part 1 Ultrasonic
pulse velocity
13311 (Part 2) : 1992 Non-destructive testing of concrete - Methods of test : Part 2Rebound
hammer
SP 23 (S & T) : 1982 Handbook on concrete mixes (based on Indian Standards ) (with Amend-
ment 1)
SP 24 (S & T) : 1983 Explanatory handbook on Indian Standard Code for plain and reinforced
concrete (IS 456 : 1978)
SP 33 (S &T) : 1986 Handbook on timber engineering
SP 34 (S &T) : 1987 Handbook on concrete reinforcement and detailing (Amendment 1)

CHAPTER 6
ANTI-TERMITE MEASURES

216 : 1961 Coaltar pitch (first revision) (Reaffirmed 1991)

401 : 1982 Code of practice for preservation of timber (third revision) (Amendments
2) (Reaffirmed 1990)
1141 : 1993 Seasoning of timber --Code of practice (second revision)
“6313 (Part 1) : 1981 Code of practice for anti-termite measures in buildings : Part 1 Con-
structional measures (first revision) (Reaffirmed 1991)
*6313 (Part 2) : 1981 Code of practice for anti-termite measures in buildings : Part 2 Pre-
constructional chemical treatment measures (first revision) (Amendments
3) (Reaffirmed 1991)

473

c
SP 62 (S & T) : 1997

IS No. Title
“6313 (Part 3) : 1981 Code of practice for anti-termite measures in buildings : Part 3 Treatment
for existing buildings (first revision) (Amendments 3) (Reaffirmed 199 I)
CHAPTER 7
DOORS AND WINDOWS (WOOD AND METAL)

208 : 1987 Door handles (fourth revision) (Reaffirmed 1992)

287 : 1993 Permissible moisture content for timber used for different purposes -
Recommendations (third revision)
303 : 1989 Plywood for general purposes (third revision) (Amendment 1) (Reaffirmed
1993)
399 : 1963 Classification of commercial timbers and their zonal distribution (revised)
(Amendment l)(Reaffirmed 1990)
401 : 1982 Code~of practice for preservation of timber (third revision) (Amendments
2) (Reaffirmed 1990)
419 : 1967 Putty, for use on window frames (first revisiun) (Amendments 3)
(Reaffirmed 1992)
1003 (Part 1) : 1991 Timber panelled and glazed shutters : Part I Door shutters (third revision)
(Amendment 1)
1003 (Part 2) : 1983 Timber panelled and glazed shutters : Part2 Window and ventilator shutters
(secand revision)
1038: 1983 Steel doors, windows and ventilators (third revision) (Amendment 1)
(Reaffirmed 1991)
“1081 : 1960 Code of practice for fixing and glazing of metal (steel and aluminium)
doors, windows and ventilators (Amendment 1) (Reaffirmed 1991)
1141 : 1993 Seasoning of timber - Code of practice (second revision)
1328 : 1982 Veneered decorative plywood (second revision) (Amendments 3) (Re-
affirmed 1990)
1658 : 1977 Fibre hardboards (second revision) (Amendment 1) (Reaffirmed 1990)
1659: 1990 Block boards (third revision) (Amendment 1)
2191 (Part 1) : 1983. Wooden flush door shutters (cellular and hollow core type) : Part 1 Plywood
face panels (t&u-th revision) (Reaffirmed 199 1)
219 1 (Part 2) : 1983 Wooden flush door shutters (cellular and hollow core type) : Part 2 Particle
board and hard board face panels (third revision) (Reaffirmed 1991) .
2202 (Part 1) : 1991 Wooden flush door shutters (solid core type) : Part 1 Plywood face panels
vifth revision) (Amendments 2)
2202 (Part 2) : 1983 Wooden flush door shutters (solid core type) : Part 2 Particle board and hard
board face panels (third revision) (Reaffirmed 1991)
2553 (Part 1) : 1990 Safety glass : Part 1 General purpose (third revision) (Amendment 1)
2835 : 1987 Flat transparent sheet glass (third revision) (Reaffirmed 1992)
3087 : 1985 Wood particle boards (medium density) for general purposes (firstrevision)
(Amendments 4) (Reaffirmed 1990)
3097 : 1980 Veneered particle boards (firstrevision) (Amendment 1) (Reaffirmed 1990)
3129 : 1985 Low density particle boards (first revision) (Reaffirmed 1990)
3348 : 1965 Specification for tibre insulation boards (Amendment 1) (Reaffirmed 1990)
3478 : 1966 Specification for high density wood particle boards (Amendment 1) (Re-
affirmed 1992)
3548 : 1988 Code of practice for glazaing in buildings (first revision)
3614 (Part 1) : 1966 Specification for fire check doors : Part I Plate metal covered and rolling
type (Reaffirmed 1990)
3614 (Part 2) : 1992 Specification for fire check doors : Part 2 Resistance test and performance
criteria

474
 SP 62 (S & T) : 1997

IS No. Title
4021 : 1983 Timber door, window and ventilator frames (seconrl revision) (Amendment
1) (Reaffirmed 1991)
4351 : 1976 Specification for steel door frames @rst revision) (Amendment 1) (Re-
affirmed 199 1)
*4913 : 1968 Code ofpractice for selection, installation and maintenance of timber doors
and windows (Reaffirmed 1991)
4962 : 1968 Specification for wooden side sliding doors (Reaffirmed 199 1)
4970 : 1973 Key for identification of commercial timbers (first revision) (Reaffirmed
1990)
5187 : 1972 Flush bolts (first revision) (Reaffirmed 1990)
5437 : 1970 Figured, rolled and wired glass (Reaffirmed 1984)
5509 : 1980 Fire retardant plywood @rst revision) (Amendments 3) (Reaffirmed 1990)
5539 : 1969 Specification for preservative treated plywood (Amendment 1) (Re-
affirmed 1990)
6198 : 1992 Ledged, braced and battened timber door shutters (second revision)
6248 : 1979 Specification for metal rolling shutters and rolling grills (first revision)
(Reaffirmed 1991)
6534 : 1971 Guiding principles of grading and inspection of timber (Reaffirmed 1990)
6701 : 1985 Tungsten filament miscellaneous electric lamps (first revision) (Re-
affirmed 1990)
7316 : 1974 Decorative plywood using plurality of veneers for decorative faces
(Amendments 2) (Reaffirmed 1992)
7452 : 1990 Hot-rolled steel sections for doors, windows and ventilators (second
revision)
10439 : 1983 Code of practice for patent glazing (Reaffirmed 1990)
10451 : 1983 Steel sliding shutters (top hung type) (Reaffirmed 1990)
10521 : 1983 Collapsible gates (Reaffirmed 1991)
10701: 1983 Structural plywood (Amendment 1) (Reaffirmed 1993)
11433 (Part 1) : 1985 One part grade polysulphide base joints sealant : Part 1 General require-
ments (Reaffirmed 1990)
11433 (Part 2) : 1986 One part grade polysulphide base joints sealant : Part 2 Methods of test
(Reaffirmed 199 1)
I2896 : 1990 Classification of Indian timbers for door and window shutters and frames
13622 : 1993 Indian timbers for furnitures and cabinets - Classificaiion
SP21 (S&T): 1983 Summarise of Indian Standards for building materials
SP 33 (S &T) : 1986 Handbook on timber engineering

CHAPTER 8
STEEL CONSTRUCTION

104: 1979 Ready mixed paint, brushing, zinc chrome, priming (second revision)
(Amendment 1) (Reaffirmed 1993)
123 : 1962 Ready mixed paint, brushing, finishing, semi-gloss, for general purposes
to Indian Standard Colours No. 445,446,448,449,451,473 and red oxide
(colour unspecified) (revised) (Amendment 1) (Reaffirmed 1991)
456 : 1978 Code of practice for plain and reinforced concrete (third revision) (Amend-
ment 2) (Reaffirmed 1991)
“800 : 1984 Code of practice for general construction in steel (second revision)
(Amendments 2) (Reaffirmed 1991)
801 : 1975 Code of practice for use of cold formed light gauge steel structural members
in general building construction Cfirsr revision) (Amendment 1) (Re-
affirmed 199 1)

475
SP 62 (S & T) : 1997

IS No. Title
*806 : 1968 Code of practice use of steel tubes in general building construction Cfirst
revision) (Amendment 1) (Reaffirmed 1991)
811 : 1988 Cold formed light gauge structural steel sections (revised)
814 : 1991 Covered electrodes for manual metal arc welding of carbon and carbon
manganese steel (fifth revision)
816 : 1969 Code of practice for use of metal arc welding for general construction in
mild steel (first revision) (Amendments 2) (Reaffirmed 1992)
817 (Part 1) : 1992 Code of practice for training and testing of metal arc welders: Part 1 Manual
metal arc welding (slcond revision)
819: 1957 Code of practice for resistance spot welding for light assemblies in mild
steel (Reaffirmed 1992)
919 (Part 1) : 1993 IS0 system of limits and fits : -Part 1 Bases of tolerances, deviations and
fits (second revision)
1024: 1979 Code of practice for use of welding in bridges and structures subject to
dynamic loading @rst revision) (Reaffirmed 1992)
1030: 1989 Carbon steel castings for general engineering purposes (fourth revision)
(Amendments 2)
1148: 1982 Hot-rolled rivet bars (up to 40 mm dia) for structural purposes (third
revision) (Reaffirmed 1992)
1149: 1982 High tensile steel rivet bars for structural purposes (third revision) (Re-
affirmed 1992)
1161 : 1979 Steel tubes for structural purposes (third revision) (Amendments 2) (Re-
affirmed 1990)
1261 : 1959 Code of practice for seam welding in mildsteel (Reaffirmed 1992)
1278 : 1972 Filler rods and wires for gas welding (second revision) (Amendments 2)
(Reaffirmed 1991)
1323 : 1982 Code of practice for oxy-acetylene welding for structural work in mild
steels (second revision) (Reaffirmed 1987)
1363 (Part 1) : 1992 Hexagon head bolts, screws and nuts of product grade C : Part 1 Hexagon
head bolts (size range M 5 to M 64) (third revision)
1363 (Part 2) : l992 Hexagon head bolts, screws and nuts of product grade C : Part 2 Hexagon
head screws (size range M 5 to M 64) (third revision)
1363 (Part 3) : 1992 Hexagon head bolts, screws and nuts of product grade C : Part 3 Hexagon
nuts (size range M 5 to M 64) (third revision)
1364 (Part 1) : 1992 Hexagon head bolts, screws and nuts of product grades A and B : Part 1
Hexagon head bolts (size range M 1.6 to M 64) (third revision)
1364 (Part 2) : 1992 Hexagon head bolts, screws and nuts of product grades A and B : Part 2
Hexagon head screws (size range M 1.6 to M 64) (third revision)
1364 (Part 3) : 1992 Hexagon head bolts, screws and nuts of product grades A and B : Part 3
Hexagon nuts (size range M 1.6 to M 64) (third revision)
1367 (Part 3) : 1991 Fasteners - Threaded steel - Technical supply conditions : Part 3
Mechanical~properties and test methods for bolts, screws and studs with full
loadability (third revision)
1393: 1961 Code of practice for training and testing of oxy-acetylene welders (Re-
affirmed 199 1)
1477 (Part 1) : 1971 Code of practice for painting of ferrous metals in buildings : Part 1
Pretreatment (first revision) (Reaffirmed 1990)
1477 (Part 2) : 1971 Code of practice for painting of ferrous metals in buildings : Part 2 Painting
(fwst revision) (Reaffirmed 1990)
1929: 1982 Hot forged steel rivets for hot closing (12’to 36 mm diameter) (first revision)
(Amendments 2) (Reaffirmed 1990)

476
 SP 62 (S 8z T) : 1997

IS No. Title
1977 : 1975 Structural steel (ordinary quality) (second revision) (Amendments 4)
(Reaffirmed 1992)
2062 : 1992 Steel for general structural purposes (fourth revision) (supersedes IS 226 :
1975) (Amendment 1)
2074 : 1992 Ready mixed paint, air drying, red oxide-zinc chrome, priming (second
revision)
2155 : 1982 Cold forged solid steel rivets for hot closing (6 to 16 mm diameter) (first
revision) (Amendment 1) (Reaffirmed 1990)
3502: 1981 Steel chequered plates (first revision)
3613 : 1974 Acceptance tests for wire flux combination for submerged arc welding (first
revision) (Amendment 1) (Reaffirmed 1987)
3640: 1982 Hexagon fit bolts @rst revision) (Reaffirmed 1991)
3757 : 1985 High strength structural bolts (second revision) (Amendment 1) (Re-
affirmed 1992)
5369: 1975 General requirements for plain washers and lock washers (first revision)
(Reaffirmed 199 1)
5370 : 1969 Plain washers with outside diameter cc3 x inside diameter (Reaffirmed 199 1)
5374: 1975 Taper washers for I-beams (ISMB) (first revision) (Reaffirmed 1991)
6419 : 1971 Welding rods and bare electrodes for gas shielded arc welding of structural
steel (Reaffirmed 199~1)
6560 : 1972 Molybdenum and chromium-molybdenum low alloy steel welding rods and
bare electrodes for gas shielded arc welding (Reaffirmed 1991)
6610 : 1972 Heavy washers for steel structures (Reaffirmed 1991)
6623 : 1985 High strength structural nuts (first revision) (Amendment 1) (Reaffirmed
1992)
6649 : 1985 Hardened and tempered washers for high strength structural bolts and nuts
(first revision) (Amendment 1) (Reaffirmed 1988)
7205 : 1974 Safety code-for erection of structural steel work (Reaffirmed 1991)
7215 : I974 Tolerances for fabrication of steel structures (Amendment I) (Reaffirmed
1991)
7280 : 1974 Bare wire electrodes for submerged arc welding of structural steels (Re-
affirmed 1991)
7307 (Part 1) : 1974 Approval tests for welding procedures : Part 1 Fusion welding of steel
(Reaffirmed 1991)
7310 (Part I) : 1974 Approval tests for welders working to approved welding procedures : Part 1
Fusion welding of steel (Reaffirmed 1987)
7318 (Part 1) : 1974 Approval tests for welders when welding procedure approval is not
required : Part 1 Fusion welding of steel (Reaffirmed 1991)
8500 : 1992 Structural steel -Microalloyed (medium and high strength qualities) (first
revision) (Amendment 1)
9595 : 1980 Recommendations for metal arc welding of carbon and carbon manganese
steel (Amendment 1) (Reaffirmed 1992)
12843 : 1989 Tolerances for erection of steel structures
SP 6(5) : 1980 Cold-formed, light-gauge steel structures @-St revision)

CHAPTER 9
FLOORS AND FLOOR COVERINGS

77 : 1976 Linseed oil, boiled for paints (second revision) (Reaffirmed 1993)
269 : 1989 33 grade ordinaryportland cement (fourth revision) (Amendments 3)
303 : 1989 Plywood for general purposes (third revision) (Amendment 1) (Reaffirmed ’
1993)

477
SP 62 (S & T) : 1997

IS No. Title
383: 1970 Coarse and fine aggregates from natura! sources for concrete (second
revision) (Reaffirmed 1990)
401 : 1982 Code of practice for preservation of timber (third revision) (Amendments
2) (Reaffirmed 1990)
455 : 1989 Portland slag cement (fiourth revision) (Amendments 3)
456 : 1978 Code of practice for plain and reinforced concrete (third revisian) (Amend-
ment 2) (Reaffirmed 199 1)
533 : 1973 Gum spirit of turpentine (oil of turpentine) (first revision) (Reaffirmed
1990)
651 : 1992 Salt glazed stoneware pipes and fittings (fifth revision)
653 : 1992 Linoleum sheets and tiles (third revision)
657 : 1982 Materials for use in the manufacture of magnesium oxychloride flooring
compositions (second revision) (Reaffirmed 1990)
658: 1982 Code of practice for magnesium oxychloride composition floors (second
revision) (Reaffirmed 1990)
712 : 1984 Building limes (third revision) (Reaffirmed 1991)
723 : 1972 Steel countersunk head wire nails (first revision) (Amendments 3) (Re-
affirmed 1990)
809 : 1992 Rubber flooring materials for general purposes (second revision)
1077: 1992 Common burnt clay building bricks (j@th rwision)
1141 : 1993 Seasoning of timber - Code of practice (second revision)
1195 : 1978 Bitumen mastic for flooring (second revision) (Reaffirmed 1990)
1196: 1978 Code of practice for laying bitumen mastic flooring (second revision)
(Reaffirmed 1990)
1197 : 1970 Code of practice for laying of rubber floors Cfirst revision) (Reaffirmed
1~990)
1198: 1982 Code of practice for laying, fixing and maintenance of linoleum floor (first
revision) (Reaffirmed 1990)
1237 : 1980 Cement concrete flooring tiles (first revision) (Reaffirmed 1990)
1322 : 1993 Bitumen felts for waterproofing and damp-proofing (fourtir revision)
“1443 : 1972 Code of practice for laying and finishing of cement concrete tlooring tiles
(first revision) (Reaffirmed 1991)
1489 (Part 1) : 1991 Portland pozzolana cement : Part 1 Fly ash based (third revision)
1489 (Part 2) : 1991 Portland pozzolana cement : Part 2 Calcined clay based (third revision)
(Amendment 1)
1580 : 1991 Bituminous compounds for waterproofing and caulking purposes (second
revision)
1609 : 1991 Code of practice for laying damp-proofing treatment using bitumen felts
(second revision)
1661 : 1972 Code of practice for application of cement and cement-lime plaster finishes
Cfirst revision) (Reaffirmed 1991)
“2114 : 1984 Code of practice for laying in-situ terrazo floor finish (first revision)
(Amendment 1) (Reaffirmed 1990)
2116: 1980 Sand for masonry mortars (first revision) (Reaffirmed 1992)
2180: 1988 Heavy duty burnt clay building bricks (third revision) (Reaffirmed 1991)
2386 (Part 4) : 1963 Methods of test for aggregates for concrete : Part 4 Mechanical properties
(Amendments 3) (Reaffirmed 1990)
‘“2571 : 1970 Code of practice for laying in-situ cement concrete flooring (first revision)
(Reaffirmed 1991)
3384 : 1986 Specification for bitumen primer for use in waterproofing and damp-
proofing (first revision) (Reaffirmed 199 1)

478
 SP 62 (S & T) : 1997

IS No. Title
3414 : 1968 Code of practice for design and installation of joints in buildings (Re-
affirmed 1990)
3461 : 1980 Specification for PVC-asbestos floor tiles (first revision) (Amendments 2)
(Reaffirmed 1990)
3462 : 1986 Specification for unbacked flexible PVC flooring (second revision)
(Amendment 1) (Reaffirmed 1991)
3502 : 1981 Steel chequered plates (first revision)
3583 : 1988 Specification of burnt clay paving bricks (second revision)
3622 : 1977 Specification for sandstone (slabs and tiles) (first revision) (Reaffirmed
1993)
3629 : 1986 Specification for structural timber in building (first revision) (Reaffirmed
1991)
3670: 1989 Code of practice for construction of timber floors (first revisiorz)
444 1 : 1980 Code of practice for use of silicate type chemical resistant mortars (first
revision) (Amendment 1) (Reaffirmed 1990)
4442 : 1980 Code of practice for use of sulphur type chemical resistant mortars (first
revision) (Reaffirmed 1990)
4443 : 1980 Code of practice for use of resin type chemical resistant mortars (first
revision) (Amendment 1) (Reaffirmed 1990)
4456 (Part I) : 1967 Methods of test for chemical resistant mortars : Part 1 Silicate typeand resin
type (Amendment 1) (Reaffirmed 1990)
4456 (Part 2) : 1967 Methods of test for chemical resistant mortars : Part 2 Sulphur type
(Reaffirmed 1990)
4457 : 1982 Ceramic unglazed vitreous acid resisting tile (first revision) (Reaffirmed
1990)
4631 : 1986 Code of practice for laying of epoxy resin floor toppings (first revision)
(Reaffirmed I99 1)
4832 (Part 1) : 1969 Specification for chemical resistant mortars : Part 1 Silicate type (Re-
affirmed 1990)
4832 (Part 2) : 1969 Specification for chemical resistant mortars : Part 2 Resin type (Amend-
ment I) (Reaffirmed 1990)
4832 (Part 3) : 1968 Specification for chemical resistant mortars : Part 3 Sulphur type (Re-
affirmed 1990)
4860 : 1968 Acid-resistant bricks (Reaffirmed 199 I)
4971 : 1968 Recommendations for selection of industrial floor finishes (Reaffirmed
1990)
5318 : 1969 Code of practice for laying of flexible PVC sheet and tile flooring (Re-
affirmed 1990)
5389: 1969 Code of practice for laying of hardwood parquet and wood block floors
(Reaffirmed 1992)
5491 : 1969 Code of practice for laying of in-situ granolithic concrete flooring~topping
(Reaffirmed 1990)
“5760 : 1983 Compressed argon (first revision) (Reaffirmed 1991)
5766 : 1970 Code of practice for laying of burnt clays brick flooring (Reaffirmed 199 1)
6727 : 1972 Fireclay checker bricks for open hearth furnace (Reaffirmed 1992)
6909 : 1990 Specification for supersulphated cement (Amendments 2)
7193 : 1974 Glassfibre base coaltar pitch and bitumen felts
7956 : 1975 Recommendations for selection of dairy floor finishes (Reaffirmed 1990)
8042 : 1989 White Portland cement (second revision) (Amendments 4)
8374 : 1977 Bitumen mastic, anti-static and electrically conducting grade (Reaffirmed
1990)

479
SP 62 (S & T) : 1997

IS No. Title
9077 : 1979 Code of practice for corrosion protection of steel reinforcement in RB and
RCC constiuction (Reaffirmed 1991)
9197: 1979 Epoxy resin, hardness and epoxy resin compositions for floor topping
(Reaffirmed 1990)
9472: 1980 Code of practice for laying mosaic parquet flooring (Reaffirmed 1992)
10440: 1983 Code of practice for construction of RB and RBC floors and roofs (Reaf-
firmed 1990)
13026: 1991 Bitumen mastic for flooring for industries handling LPG and~other light
hydrocarbon products (Amendment 1)
13074 : 1991 Laying of bitumen mastic flooring for industries handling LPG and other
light hydrocarbon products - Code of practice

CHAPTER 10
WALL AND CEILING FINISHES AND COVERINGS AND WALLING

269 : 1989 33 grade ordinary Portland cement fourth revision) (Amendments 3)

303 : 1989 Plywood for general purposes (third revision) (Amendment 1) (Reaffirmed
1993)
383 : 1970 Coarse and fine aggregates from natural sources for concrete (second
revision) (Reaffirmed 1990)
451 : 1972 Technical supply conditions for wood screws (second revision) (Amend-
ment 1) (Reaffirmed 1991)
455 : 1989 Portland slag cement (fourth revision) (Amendments 3)
459 : 1992 Corrugated and semi-corrugated asbestos cement sheets (third revision)
710 : 1976 Marine plywood (first revision) (Amendments 3) (Reaffirmed 1989)
712 : 1984 Building limes (third revision) (Reaffirmed 1991)
723 : 1972 Steel countersunk head wire nails (first revision) (Amendments 3) (Re-
affirmed 1990)
733 : 1983 Wrought aluminium and aluminium alloy bars, rods and sections for
general engineering purposes (third revision) (Reaffirmed 1991)
737 : 1986 Wrought aluminium and aluminium alloy sheet and strip for general
engineering purposes (third revision) (Reaffirmed 199 1)
777 : 1988 Glazed earthenware wall tiles (second revision) (Superseded by IS 13753,
13754,13755,13756)
883 : 1970 Design of structural timber in building - Code of practice (third revision)
1130: 1969 Marble (blocks, slabs and tiles) (Reaffirmed 1993)
1237 : 1980 Cement concrete flooring tiles (first revision) (Reaffirmed 1990)
1328: 1982 Veneered decorative plywood (second revision) (Amendments 3) (Re-
affirmed 1990)
1344 : 1981 Calcined clay pozzolana (second revision) (Amendment 1) (Reaffirmed
1990)
1414 : 1989 Code of practice for fixing wall covering
1489 (Part 1) : 1991 Portland pozzolana cement: Part 1 Fly ash based (third revision)
1489 (Part 2) : 1991 Portland pozzolana cement: Part 2 Calcined clay based (third revision)
(Amendment 1)
1542: 1992 Sand of plaster (second revision)
1635 : 1992 Code of practice for field slaking of building lime and preparation of putty
(second revision)
1658: 1977 Fibre hardboards (second revision) (Amendment 1) (Reaffirmed 1990)
1659: 1990 Block boards (third revision) (Amendment 1)
1661 : 1972 Code of practice for application of cement and cement-lime plaster finishes
(first revision) (Reaffirmed 1991)

480
 SP 62 (S & T) : 1997

IS No. Title

1946 : 1961 Code of practice for use of fixing devices in walls, ceilings and floors of
solid construction (Reaffirmed 1992)
2095 : 1982 Gypsum plaster boards (first revi.vion) (Amendment 1) (Reaffirmed 199 1)
2098 : 1964 Asbestos cement building boards (Amendments 2) (Reaffirmed 1992)
2114: 1984 Code of practice for laying in-situ terrazzo floor finish (first revision)
(Amendment 1) (Reaffirmed 1990)
2116: 1980 Sand for masonry mortar yirst revision) (Reaffirmed 1992)
2185 (Part 1) : 1979 Concrete masonry units : Part 1 Hollow and solid concrete blocks (second
revision) (superseding IS 3590) (Reaffirmed 1992)
2185 (Part 2) : 1983 Concrete masonry units : Part 2 Hollow and solid light weight concrete
blocks (first revision) (superseding IS 3590) (Reaffirmed 1989)
2185 (Part 3) : 1984 Concrete masonry units : Part 3 Autoclaved cellular aeratedconcrete blocks
(first revision) (superseding IS 5482) (Reaffirmed 1990)
2394 : 1984 Code of practice for application of lime plaster finish (fkst revision)
(Reaffirmed 1990)
2402 : 1963 Code of practice for external rendered finishes (Reaffirmed 1990)
2441 : 1984 Code of practice for fixing ceiling covering (j?rst revision) (Reaffirmed
1990)
2547 (Part 1) : 1976 Gypsum building plaster : Part 1 Excluding premixed lightweight plaster
(first revision) (Amendment 1) (Reaffirmed 1990)
2547 (Part 2) : I976 Gypsum building plaster: Part 2 Premixed lightweight plaster (first
revision) (Reaffirmed 1992)
2691 : 1988 Burnt clay facing bricks (second revision)
2818 (Part 1) : 1990 Indian hessian : Part 1 General (second revision)
2849 : 1983 Specification for non-load bearing gypsum partition blocks (solid and
hollow types) (Amendment 1) (Reaffirmed 1990)
3087 : 1985 Wood particle boards (medium density) for general purposes (first revision)
(Amendments 4) (Reaffirmed 1990)
3097 : 1980 Veneered particle boards (first revision) (Amendment 1) (Reaffirmed
1990)
3129: 1985 Low density particle boards (first revision) (Reaffirmed 1990)
3348 : 1965 Specification for fibre insulation boards (Amendment 1) (Reaffirmed 1990)
3466 : 1988 Specification for masonry cement (second revision) (Amendment 1)
3478 : 1966 Specification for high density wood particle boards (Amendment 1) (Re-
affirmed 1992)
3629 : 1986 Specification for structural timber in building (fi’rst revision) (Reaffirmed
1991)
3630 : 1992 Code of practice for construction of non-load bearing gypsum block
partitions (first revision)
3677 : 1985 Unbonded rock and slag wool for thermal insulation (second revision)
(superseding IS 5696) (Reaffirmed 1990)
3812: 1981 Fly ash for use as pozzolana and admixture (first revision) (Reaffirmed
1992)
4101 (Part 1) : 1967 Code of practice for external facing and veneers : Part 1 Stone facing
(Reaffirmed 1990)
4101 (Part 2) : 1967 Code of practice for external facing and veneers : Part 2 Cement concrete
facing (Reaffirmed 1990)
4101 (Part 3) : 1985 Code of practice for external facing and veneers : Part 3 Wall tiling and
mosaics (first revision) (Reaffirmed 1990)
4407 : 1967 Code of practice for reed walling (Reaffirmed 1992)

481
SP 62 (S Sr T) : 1997

IS No. Title
4671 : 1984 Expanded polystyrene for thermal insulation purposes (first revision)
(Reaffirmed 1990)
5390 : 1984 Code of practice for construction of timber ceiling (first revision) (Re-
affirmed 199 1)
i 5.509 : 1980 Fire retardant plywood (first revision) (Amendments 3) (Reaffirmed 1990)
6730 : 1972 Felt nails (Reaffirmed 1990)
6738 : 1972 Panel pins and lost head nails (Amendment 1) (Reaffirmed 1990)
6760 : 1972 Slotted countersunk head wood screws (Amendments 2) (Reaffirmed 1988)
7316 : 1974 Decorative plywood using plurality of veneers for decorative faces
(Amendments 2) (Reaffirmed 1992)
8041 : 1990 Rapid hardening Portland cement (second revision) (Amendments 2)
12727: 1989 Code of practice for no fines cast in-situ cement concrete

CHAPTER 11
ROOFS AND ROOFING

158 : 1981 Ready mixed paint, brushing, bituminous, black lead-free, acid alkali and
heat resisting (third revision) (Amendment 1) (Reaffirmed 1988)
217 : 1988 Cutback bitumen (second reb?sion)
269 : 1989 33 grade ordinary Portland cement yburth revision) (Amendments 3)
277 : 1992 Galvanized steel sheet (plain and corrugated) (fifth revision) (Amend-
ments 2)
280 : 1978 Mild steel wire for general engineering purposes (third revision) (Amend-
ment 1) (Reaffirmed 1992)
383 : 1970 Coarse and fine aggregates from natural sources for concrete (second
revision) (Reaffirmed 1990)
432 (Part 1) : 1982 Mild steel and medium tensile steel bars and hard-drawn steel wire for
concrete reinforcement : Part 1 Mild steel and medium tensile steel bars
(third revision)
451 : 1972 Technical supply conditions for wood screws (second revision) (Amend-
ment 1) (Reaffirmed 1991)
455 : 1989 Portland slag cement fourth revision) (Amendments 3)
456 : 1978 Code of practice for plain and reinforced concrete (third revision) (Amend-
ments 2) (Reaffirmed 1991)
459 : 1992 Corrugated and semi-corrugated asbestos cement sheets (third revision)
654 : 1992 Clay roofing tiles, Mangalore pattern (third revision)
712 : 1984 Building limes (third revision) (Reaffirmed 1991)
723 : 1972 Steel countersunk head wire nails (first revision) (Amendments 3) (Re-
affirmed 1990)
725 : 1961 Copper wire nails (revised) (Reaffirmed 1990)
730 : 1978 Hook bolts for corrugated sheet roofing (second revision) (Amendments 2)
(Reaffirmed 1988)
805 : 1968 Code of practice for use of steel in gravity water tanks (Reaffirmed 1991)
808 : 1989 Dimensions for hot-rolled steel beam, column channel and angle sections
(third revision) (Amendment 1)
883: 1970 Design of structural timber in building - Code of practice (third revision)
1077 : 1992 Common burnt clay building bricks @fh revision)
1120: 1975 Coach screws yirst revision) (Reaffirmed 1990)
1190 : 1990 Textile machinery - Healds twin wire for weaving - Specification (third
revision)
1199 : 1959 Methods of sampling and analysis of concrete (Reaffirmed 199 1)

482
 SP 62 (S & T) : 1997

IS No. Title

1254 : 1991 Corrugated aluminium sheet (third revision)

1322 : 1993 Bitumen felts for waterproofing and damp-proofing (fourth revision)
1343: 1980 Code of practice for prestressed concrete (first revision) (Amendment 1)
(Reaffirmed 1990)
1344 : 1981 Calcined clay pozzolana (second revision) (Amendment 1) (Reaffirmed
1990)
1464: 1992 Clay ridge and ceiling tiles (second revision)
1489 (Part 1) : 1991 Portland pozzolana cement: Part 1 Fly ash based (third revision)
1489 (Part 2) : 1991 Portland pozzolana cement: Part 2 Calcined clay based (third revision)
(Amendment I)
2098 : 1964 Asbestos cement building boards (Amendments 2) (Reaffirmed 1992)
*2115 : 1980 Code of practice for flat-roof finish, mud phuskn (seconrl revision) (Re-
affirmed 1992)
“2118 : 1980 Code of practice for construction ofjack-arch type of building floor or roof
Cfirst revision) (Reaffirmed 1992)
“2119 : 1980 Code of practice for construction of brick-cum-concrete composite (Madras
terrace) floor or roof (first revision) (Reaffirmed 1992)
2204 : 1962 Code of practice for construction of reinforced concrete shell roof (Re- 4
affirmed 1990)
2527 : 1984 Code of practice for fixing rainwater gutters and downpipes for roof
drainage (first revision) (Reaffirmed 1990)
2690 (Part 1) : 1993 Burnt clay flat terracing tiles : Part 1 Machine made (second revision)
2690 (Part 2) : 1992 Burnt clay flat terracing tiles : Part 2 Hand-made (second revision)
“2700 : 1987 Code of practice for roofing with wooden shingles yirst revision) (Re-
affirmed 1991)
*2792 : 1964 Code of practice for design and construction of stone slab over joist floor
(Reaffirmed 1990)
“2858 : 1984 Code of practice for roofing with Mangalore tiles (first revision) (Re-
affirmed 1990)
3007 (Part 1) : 1964 Code of practice for laying of asbestos cement sheets : Part 1 Corrugated
sheets (Reaffirmed 1991)
3007 (Part 2) : 1965 Code of practice for laying of asbestos cement sheets : Part 2 Semi-
corrugated sheets (Reaffirmed 199 1)
3068 : 1986 Broken brick (burnt clay) coarse aggregates for use in lime concrete (second
revision) (Reaffirmed 1991)
3182 : 1986 Broken brick (burnt clay) fine aggregates for use in lime mortar (second
revisiotz) (Reaffirmed 1991)
3629 : 1986 Specification for structural timber in building (first revision) (Reaffirmed
1991)
3951 (Part 1) : 1975 Specification for hollow clay tiles for floors and roofs : Part I Filler type
(fkst revision) (Reaffirmed 1991)
3951 (Part 2) : 1975 Specification for hollow clay tiles for floors and roofs : Part 2 Structural
type (first revision) (Reaffirmed 199 1)
“‘5119 (Part 1) : 1968 Code of practice for laying and fixing of sloped roof coverings : Part 1
Slating (Reaffirmed 1990)
“6061 (Part i) : 1971 Code of practice for construction of floor and roof with joists and filler
blocks : Part 1 With hollow concrete filler blocks (Reaffirmed 1992)
‘“6061 (Part 2) : 1981 Code of practice for construction of floor and roof with joists and filler
blocks : Part 2 With hollow clay filler blocks (first revision) (Reaffirmed
1990)

483
 SP 62 (S & T) : 1997

~1sNo. Title
*606 1 (Part 3) : 198 1 Code of practice for construction of floor and roof with joists and filler
blocks : Part 3 Precast hollow clay blocks joints and hollow clay filler
blocks (Reaffirmed 1992)
*6061 (Part 4) : 1981 Code of practice for construction of floor and roof with joists and filler
blocks : Part 4 With precast hollow clay blocks slab panels (Reaffirmed
1992)
6332 : 1984 Code of practice for construction of floor and roofs using precast doubly-
curved shell units (first revision) (Reaffirmed 1990)
8869 : 1978 Washers for corrugated sheet roofing (Reaffirmed 1990)
“12093 : 1987 Code of practice for laying and-fixing of sloped roof coverings using plain
and corrugated galvanized steel sheet (IS0 6589-1983):Reaffirmed 1993)
*12SO6 : 1988 Code of practice for improved thatching of roof with rot and fire retardant
treatment

CHAPTER 12
DAMP-PROOFING AND WATERPROOFING

73 : 1992 Paving bitumen (second revision)

269 : 1989 33 grade ordinary Portland cement (fourth revision) (Amendments 3)
383 : 1970 Coarse and fine aggregates from natural sources for concrete (second
revision) (Reaffirmed 1990)
702 : 1988 Industrial bitumen (second revision) (Amendment 1)
712 : 1984 Building limes (third revision) (Reaffirmed 199 1)
1195 : 1978 Bitumen mastic for flooring (second revision) (Reaffirmed 1990)
1203: 1978 Determination of penetration (Amendments 3) (Reaffirmed 1990)
1322: 1993 Bitumen felts for waterproofing and damp-proofing (fourth revision)
1346: 1991 Code of practice for waterproofing of roofs with bitumen felts (third
revision)
1580: 1991 Bituminous compounds for waterproofing and caulking purposes (Second
revision)
1609 : 1991 Code of practice for laying damp-proofing treatment using bitumen felts
(second revision)
1635 : 1992 Code of practice for field slaking of building lime and preparation of putty
(second revision)
1834: 1984 Hot applied sealing compund for joint in concrete (@st revision) (Re-
affirmed 1990)
2116: 1980 Sand for masonry mortars (first revision) (Reaffirmed.1 992)
2508 : 1984 Low density polyethylene films (second revision) (Amendment 1) (Re-
affirmed 199 I )
2527 : 1984 Code of practice for fixing rainwater gutters and downpipes for roof
drainage (first revision) (Reaffirmed 1990)
2541 : 1991 Code of practice for preparation and use of lime concrete (second revision)
2645 : 1975 Integral cement waterproofing compounds (first revision) (Amendment 1)
(Reaffirmed 1992)
2690 (Part 1) : 1993 Burnt clay flat terracing tiles : Part 1 Machine made (second revision)
2690 (Part 2) : 1992 Burnt clay flat terracing tiles : Part 2 Hand-made (second revision)
3036 :. 1992 Laying lime concrete for a waterproofed roof finish - Code of practice
(second revision)
3037 : 1986 Bitumen mastic for use in waterproofing of roofs (first revision) (Re-
affirmed 199 1)
’ 3067 : 1988 Code of practice for general design details and preparatory work for
damp-proofing and waterproofing of buildings (first revision)

484

^”
 SP 62 (S & T) : 1997

IS No. Title
3068 : 1986 Broken brick (burnt clay) coarse aggregates for use in lime concrete (second
revision) (Reaffirmed 1991)
3370 (Part I) : 1965 Code of practice for concrete structures for the storage of liquids : Part I
General requirements (Amendment 1) (Reaffirmed 1991)
3384: 1986 Specification for bitumen primer for use in waterproofing and damp-
proofing (first revision) (Reaffirmed 1991)
4098 : 1983 Lime-pozzolana mixture (first revision) (Amendments 2) (Reaffirmed
1989)
4365 : 1967 Code of practice for application of bitumen mastic for waterproofing of
roofs (Reaffirmed 1990)
5871 : 1987 Bitumen mastic for tanking and damp-proofing (first revision) (Reaffirmed
1991)
6494 : 1988 Code of practice for waterproofing of underground water reservoirs and
swimming pools (first revision) (Reaffirmed 1994)
7193 : 1974 Glass fibre base coaltar pitch and bitumen felts
7198 : 1974 Code of practice for damp-proofing using bitumen mastic (Reaffirmed
1990)
7290 : 1979 Recommendations for use of polyethylene film for waterproofing of roofs
first,revisinn) (Reaffirmed 1990)
9759 : 1981 Guidelines for de-watering during construction (Amendment 1) (Re-
affirmed 1987)
9918 : 1981 Code of practice for in-situ waterproofing and damp-proofing treatments
with glass fibre tissue reinforced bitumen (Reaffirmed 1990)
12027 : 1987 Silicone-based water repellents (Reaffirmed 1992)
12054 : 1987 Code of practice for application of silicone based water repellent (Re-
a affirmed 1992)
13182 : 1991 Waterproofing and damp-proofing of wet areas in building -
Recommendations

CHAPTER 13
JOlNTS IN BUILDINGS (CONTROL OF CRACKS IN BUILDINGS)

1834 : 1984 Hot applied sealing compound for joint in concrete @rst revision) (Re-
affirmed 1990)
1838 (Part I) : 1983 Preformed fillers for expansion joint in concrete pavements and structures
(non extruding and resilient type) : Part I Bitumen impregnated fibre Virst
revision) (Reaffirmed 1990)
1838 (Part 2) : 1984 Preformed fillers for expansion joint in concrete pavements and structures
(non extruding and resilient type) : Part 2 CNSL Aldehyde resin and
coconut pith
3414: 1968 Code of practice for design and installation of joints in buildings (Re-
affirmed 1990)
10958 : 1984 General check list of functions of joints in buildings (Reaffirmed 1992)
11433 (Part 1) : 1985 One part grade polysulphide based joint sealant : Part 1 General requirements
11817: 1986 Classification of joints in buildings for accomodation of dimensional
deviations during construction (Reaffirmed 1992)
11-818 : 1986 Method oftest for laboratory determination of air permeability of joints in
buildings (Reaffirmed 1992)
12118 (Part 1) : 1987 Two parts polysulphide based sealant : Part 1 General requirements (Re-
affirmed 1992)

485
SP 62 (S & T) : 1997

CHAPTER 14
WHITEWASHING, COLOUR WASHING AND PAINTING OF MASONRY, CONCRETE
AND PLASTER SURFACES (CALCAREOUS SURFACES)

IS No. Title

44: 1991 Iron oxide pigments for paints (second revision)

55 : 1970 Ultramarine blue for paints (first revision) (Amendments 2) (Reaffirmed
1991)
109 : 1968 Ready mixed paint, brushing, priming, plaster, to Indian Standard Colour
No. 361 and 631 White and off white (first revision) (Amendments 3)(Re-
affirmed 1993)
133 : 1993 Enamel, interior : (a) undercoating, (b) finishing (third revision)
158 : 1981 Ready mixed paint, brushing, bituminous, black, lead-free, acid, alkali and
heat resisting (third revision) (Amendment 1) (Reaffirmed 1988)
168 : 1993 Ready mixed paint, air drying, for general purpose (third revision)
253 : 1985 Edible common salt (third revision) (Reaffirmed 1990)
261 : 1982 Copper sulphate (second revision) (Amendment 1) (Reaffirmed 1988)
427 : 1965 Distemper, dry, colour as required (revised) (Amendments 4) (Reaffirmed
1993)
428 : 1969 Distemper, oil emulsion, colour as required (first revision) (Amendments
3) (Reaffirmed 1993)
702 : 1988 Industrial bitumen (skcond revision) (Amendment ‘1)
712 : 1984 Building limes (third revision) (Reaffirmed 1991)
797 : 1982 Common salt for chemical industries (third revision) (Amendment 1)
(Reaffirmed 1992)
“2395 (Part 1) : 1966 Code of practice for painting concrete masonry and plaster surfaces :
Part 1 Operation and workmanship (Reaffirmed 1990)
“2395 (Part 2) : 1967 Code of practice for painting concrete masonry and plaster surfaces :
Part 2 Schedule (Reaffirmed 1990)
2547 (Part 1) : 1976 Gypsum building plaster : Part 1 Excluding premixed lightweight plaster
@rst revision) (Amendment 1) (Reaffirmed 1990)
2547 (Part 2) : 1976 Gypsum building plaster : Part 2 Premixed lightweight plaster (first
revision) (Reaffirmed 1992)
2932 : 1993 Enamel, synthetic, exterior (a) undercoating, (b) finishing (second revision)
2933 : 1975 Enamel exterior (a) undercoating, (b) finishing (first revision) (Amend-
ments 2) (Reaffirmed 1991)
:“3140 : 1965 Code of practice for painting asbestos cement building products (Re-
affirmed 1990)
3384: 1986 Specification for bitumen primer for use in waterproofing and damp-
proofing Cjirst revision) (Reaffirmed 1991)
5410: 1992 Cement paint (first revision) (Amendment 1)
5411 (Part 1) ; 1974 Plastic emulsion paint : Part 1 For interior use (first revision) (Amendments
4) (Reaffirmed 1991)
54 11 (Part 2) : 1972 Plastic emulsion paint : Part 2 For exterior use (Amendments 5) (Re-
affirmed 1991)
‘I6278 : 1971 Code of practice for whitewashing and colour washing (Reaffirmed 199 1)
9862: 1981 Ready mixed paint, brushing, bituminous, black, lead-free, acid, alkali,
water and chlorine resisting (Amendment 1) (Reaffirmed 1988)

486
SP 62 (S & T) : 1997

IS No. Title
*2.524 (Part 1) : 1968 Code of practice for painting of non-ferrous metals in buildings : Part 1
Pretreatment (Reaffirmed 1990)
*2524 (Part 2) : 1968 Code of practice for painting of non-ferrous metals in buildings : Part 2
Painting (Reaffirmed 1990)
2932 : 1993 Enamel, synthetic, exterior (a) undercoating, (b) finishing (secondrevision)
2933 : 1975 Enamel exterior (a) undercoating, (b) finishing (first revision) (Amend-
ments 2) (Reaffirmed 1991)
3531 : 1983 Glossary of terms relating to corrosion of metals first revision) (Reaffirmed
1991)
3536 : 1966 Ready mixed paint, brushing, wood primer, pink (Amendments 4) (Re-
affirmed 1988) ,
3537 : 1966 Ready mixed paint, finishing, interior, for general purposes, to Indian
Standard Colours No. 101,216,217,219,275,281,352, 353, 358 to 361,
363,364,388,410,442,444,628,631,632,634,693,697, white and black
(Amendment 1) (Reaffirmed 1991)
3539 : 1966 Ready mixed paint, undercoating, for use under oil finishes to Indian
Standard Colours, as required (Amendments 3) (Reaffirmed 1988)
3585 : 1966 Ready mixed paint, aluminium, brushing priming, water resistant, for
woodwork (Amendments 2) (Reaffirmed 1988)
4597 : 1968 Code of practice for finishing of wood and wood based products with
nitrocellulose and cold catalysed materials (Reaffirmed 1990)
6005 : 1970 Code of practice for phosphating of.iron and steel (Reaffirmed 199 1)

CHAPTER 16
WATER SUPPLY AND DRAINAGE

Part 1 Water Supply

404 (Part 1) : 1993 Lead pipes : Part 1 For other than chemical purposes (third revision)
407: 1981 Brass tubes for general purposes (third revision) (Reaffirmed 199 1)
1172: 1993 Code of basic requirements for water supply, drainage and sanitation
vourth revision)
1239 (Part 1) : 1990 Mild steel tubes, tubulars and other wrought steel fittings : Part 1 Mild steel
tubes (fifth revision) (Amendments 3)
1536: 1989 Centrifugally cast (spun) iron pressure pipes for water, gas and sewage
(third revision) (Amendments 2) (Reaffirmed 1993)
1537: 1976 Vertically cast iron pressure pipes for water, gas and sewage cfirst revision)
(Amendments 5) (Reaffirmed 1991)
1545: 1982 Solid drawn copper and copper alloy tubes for condenser and heat
exchangers (second revision) (Reaffirmed 1991)
1592 : 1989 Asbestos cement pressure pipes (third revision)
1626 (Part 1) : 1991 Asbestos cement building pipes and pipe fittings, gutters and gutter fittings
and roofing fittings : Part 1 Pipe and pipe fittings (second revision)
2064 : 1993 Selection, installation and~maintenance of sanitary appliances - Code of
practice (second revision)
2065 : 1983 Code of practice for water supply in buildings (second revision) (Re-
affirmed 1990)
“2692 : 1989 Ferrules for water services (second revision) (Amendment 1)
3076 : 1985 Low density polyethylene pipes for potable water supplies (second
revision) (Amendment 1) (Reaffirmed 1991)
4984: 1987 Specification for high density polyethylene pipes for potable water
supplies; sewage and industrial effluents (third revision)

488
 SP62(S&T):1997

IS No. Title
4985 : 1988 Specification for unplasticised PVC pipes for potable water supplies
(second revision) (Amendment 1)
7558 : 1974 Code of practice for domestic hot water installations (Reaffirmed 1990)
7634 (Part 2) : 1975 Code of practice for plastics pipe work for potable water supplies : Part 2
Laying and jointing polyethylene (PE) pipes (Amendment 1) (Reaffirmed
1992)
7634 (Part 3) : 1975 Code of practice for plastics pipe work for potable water supplies : Part 3
Laying and jointing of UPVC pipes (Amendments 2) (Reaffirmed 1992)
12183 (Part 1) : 1987 Code of practice for plumbing in multi-storeyed buildings : Part 1 Water
supply (Reaffirmed 1992)
NBC, 1983 National -Building Code of India, 1983
SP 35 (S &T) : 1987 Handbook on water supply and drainage with special emphasis on plumb-
ing

Part 2 Building Drainage

277 : 1992 Galvanized steel sheet (plain and.corrugated) vifrh revision) (Amendments 2)
404 (Part 1) : 1993 Lead pipes : Part 1 For other than chemical purposes (third revision)
458 : 1988 Precast concrete pipes (with and without reinforcement) (third revision)
(Amendments 2)
651 : 1992 Salt glazed stoneware pipes and fittings (fifrh revision)
782 : 1978 Caulking lead (third revision) (Reaffirmed 1992)
783 : 19g5 Code of practice for laying of concrete pipes (first revision) (Amendment 1)
(ReaffirmedX990)
1230: 1979 Cast iron rainwater pipes and fittings (second revision) (Amendment 1)
(Reaffirmed 199 1)
1536 : 1989 Centrifugally cast (spun) iron pressure pipes for water, gas and sewage
(third revision) (Amendments 2) (Reaffirmed 1993)
1537 1976 Vertically cast iron pressure pipes for water, gas and sewage (first revision)
(Amendments 5) (Reaffirmed 1991)
1592 1989 Asbestos cement pressure pipes (third revision)
1626 (.Part 1) : 1991 Asbestos cement building pipes and pipe fittings, gutters and gutter fittings
and roofing fittings : Part 1 Pipe and pipe fittings (first revision)
1726: 1991 Cast iron manhole covers and frames (third revision)
*1742: 1983 Code of practice for building drainage (second revision) (Reaffirmed 1990)
3006 : 1979 Specification for chemically resistant glazed stoneware pipes and fittings
(first revision) (Reaffirmed 1992)
4111 (Part 1) : 1986 Code of practice for ancillary structures in sewerage system : Part 1
Manholes (fkst revision) (Reaffirmed 199 1)
4733 : 1972 Methods of sampling and test for sewage effluents (first revision) (Re-
affirmed 1992)
4984 : 1987 Specification for high density polyethylene pipes for potable water sup-
plies; sewage and industrial effluents (third revision)
4985 : 1988 Specification for unplasticised PVC pipes for potable water supplies
(second revision) (Amendment 1)
5329 : 1983 Code of practice for sanitary pipe work above ground for buildings (first
revision) (Reaffirmed 1990)
5455 : 1969 Cast-iron steps for manholes (Reaffirmed 1992)

Part 3 Water Supply and Drainage in High Altitudes/Sub-Zero Regions

6295 : 1986 Code of practice for water supply and drainage in high *altitudes and/or
sub-zero temperature regions (first revision) (Reaffirmed 1991)

489
SP 62 (S & T) : 1997

CHAPTER 17
SPECIAL CONSTRUCTION PROCEDURES EARTHQUAKE EFFECTS, Etc

IS No. Title

1893 : 1984 Criteria for earthquake resistant design of structures (fourth revision)
(Amendment 1) (Reaffirmed 1991)
4326 : 1993 Earthquake resistant design and construction of buildings - Code of
practice (second revision)
“13827 : 1993 Improving earthquake resitance of earthen buildings - Guidelines
“13828 : lb93 Improving earthquake resistance of low strength masonry buildings -
Guidelines
13920 : 1993 Ductile detailing of reinforced concrete structures subjected to seismic
forces - Code of practice
13935 : 1993 Repair and seismic strengthening of buildings - Guidelines

CHAPTER 18
DEMOLITION OF BUILDINGS

2190: 1992 Selection, installation and maintenance of first-aid fire extinguishers -

Code of practice (second revision) (Amendment 1) (Reaffirmed 1990)
2925 : 1984 Specification for industrial safety helmets (second revision) (Amendment
1) (Reaffirmed 1990)
3696 (Part 2) : 199 I Safety code of scaffolds and ladders : Part 2 Ladders
*413Q : 1991’ Demolition of buildings - Code of safety (second revision)
4912: 1978 Safety requirements for floor and wall openings, railings and toe boards
(first revision) (Reaffirmed 199 1)

490