RCC Slab(Grade,Roof) Construction Procedure

Standard operating procedure for constructing RCC slabs, ensuring structural integrity, quality control, and compliance with IS 456:2000 and safety guidelines for the 50MWP Ampyr Solar Project in Dhule, Maharashtra.

Duration: 7-14 days Team: 5-10 workers Risk Level: Medium

1. Purpose

To define a standard and safe method for constructing RCC slabs, ensuring structural integrity, quality control, and compliance with IS 456:2000 and safety guidelines for the 50MWP Ampyr Solar Project in Dhule, Maharashtra.

2. Scope

Applicable to all residential, commercial, and industrial construction projects involving one-way, two-way, and flat slabs.

3. Responsibilities

Site Engineer

Supervises work & ensures compliance with structural drawings

Surveyor

Marks the slab levels and layout

Safety Officer

Enforces PPE usage and safety protocols

Steel Fixers

Install and secure reinforcement as per design

Masons & Helpers

Perform formwork and concrete works

4. Tools & Equipment

Measuring Tools

Measuring Tape, Chalk Line, Spirit Level

Cutting Equipment

Steel Cutting & Bending Machines

Formwork

Shuttering Plates, Props, Clamps

Concrete Equipment

Concrete Mixer, Vibrator Machine

Safety Equipment

Helmets, Gloves, Safety Shoes, Reflective Vests

5. Procedure

1
Pre-Construction Preparations
  • Review structural drawings for slab thickness, reinforcement details, and load specifications
  • Ensure materials (cement, sand, aggregate, steel) are tested and available
  • Check column alignment and beam levels before proceeding
  • Conduct a safety briefing for all workers
2
Formwork / Shuttering
  • Install shuttering plates (plywood, MS plates) as per slab dimensions
  • Provide sufficient supports (props, jacks) to prevent deflection
  • Apply shuttering oil for easy removal after curing
  • Ensure proper leveling and alignment before reinforcement work
  • Side supports should be strong to prevent leakage during concreting
3
Reinforcement Work
  • Cut and bend steel bars as per BBS (Bar Bending Schedule)
  • Lay bottom and top reinforcement mesh as per design
  • Provide cover blocks (20-25mm) to maintain clear cover
  • Tie reinforcement bars securely with binding wire

Lapping Guidelines (IS 456:2000):

  • Bottom Bars (Tension Zone): Lapping should be at the middle of the span (L/2), where bending moment is minimal
  • Top Bars (Compression Zone): Lapping should be at the supports (L/4) where bending moment is lower
  • Lap Length: 40D to 50D (where D = diameter of the bar)
  • Staggered Laps: Laps should be staggered in adjacent bars to prevent weak points
4
Electrical & Plumbing Conduits
  • Fix electrical conduits and plumbing pipes before concreting
  • Ensure proper placement to avoid disturbing reinforcement
  • Secure conduits to reinforcement using binding wire
5
Concreting Process
  • Ensure proper concrete mix (M20, M25, or as per design)
  • Pour concrete in layers and use vibrators to remove air gaps
  • Use mechanical trowels for surface finishing
  • Avoid over-vibrating to prevent segregation
  • Maintain proper slope for drainage where required
6
Curing & Deshuttering
  • Keep slab wet for at least 7–14 days for proper strength
  • Follow deshuttering time guidelines as per IS 456:2000:

Deshuttering Time Guidelines:

  • Side Shutters: After 24–48 hours
  • Props Supporting Slab:
  • Up to 4.5m span: Minimum 7 days
  • More than 4.5m and up to 6m span: Minimum 14 days
  • More than 6m span: 21 days

Consider factors affecting deshuttering time:

  • Concrete mix strength (higher grades may need more curing)
  • Weather conditions (hot and dry climates require extended curing)
  • Structural load (longer spans require more support time)

Post Deshuttering Checks:

  • Inspect for honeycombs or cracks and repair if needed
  • Conduct surface finishing if required

6. Safety Measures

PPE Usage

Ensure all workers wear required PPE at all times

Work Area

Keep work area clean to avoid tripping hazards

Scaffolding

Use proper scaffolding for working at heights

Formwork Stability

Ensure formwork is stable before concreting

Emergency Plan

Have emergency response plan ready

7. Post-Construction Activities

Remove debris and clean the site
Conduct a final inspection of slab alignment and strength
Ensure the slab is ready for further construction stages (plastering, flooring, etc.)
Document any deviations from design specifications
Obtain approval from structural engineer if needed

8. Documentation & Compliance

Maintain daily progress records
Conduct quality and safety audits
Ensure compliance with IS 456:2000 standards
Document material test results
Take photographic evidence at key stages

9. Conclusion

Following this Standard Operating Procedure ensures safe, efficient, and structurally sound slab construction. Proper execution guarantees durability, strength, and long-lasting performance. All work must be inspected and approved before proceeding to the next construction phase.

10. Pro Tips

Alignment Check

Use strings to verify slab level at multiple points

Curing Technique

Create small containment walls around slab edges to hold water

Handling Reinforcement

Store bars on wooden blocks to prevent rusting

Vibration Technique

Insert vibrator horizontally for effective air removal

Weather Considerations

Avoid concreting during extreme weather conditions

Timing Strategy

Begin concreting early in the day for large slabs

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