production of building materials under mgnregs · 2015. 5. 17. · mord, goi pankaj s. duberkar...

PRODUCTION OF BUILDING MATERIALS UNDER MGNREGS

G. N. SHARMA

IRRIGATION & SOIL ENGINEERING EXPERT, UNDP CONSULTANT, MGNREGA DN.

MORD, GOI

PANKAJ S. DUBERKAR

PROJECT EXECUTIVE. ALTERNATIVE TECHNOLOGY,

UNDP CONSULTANT, MGNREGA DN.

MORD, GOI

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CONTEXT

• For number of building construction works that are allowed to be taken up under MGNREGA, clay bricks, hollow bricks, tiles, metal (grit) etc. are used. Production of such building material provides employment to unskilled labour. The entire cost of such building material including the cost of unskilled labour, is counted towards material cost for the purpose of computing the labour-material ratio. This creates an anomaly in terms of the labour-material ratio.

• Thus, the production of building material required in execution of MGNREGA works, as one of the activities under MGNREGA has been included in schedule-1,MGNREGA at Para 4.(1) (vii) . Pursuant to this, the guidelines for production of building material has been issued vide Ministry letter No. J-11017/26/2008-MGNREGA (UN) dated 13th January, 2014 and are as follows

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CONTEXT

Unskilled labour in the production of building material

Works permitted under MGNREGA

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1. From the Annual District Plan (ADP) of the GP, total requirement of building materials for MGNREGA works should be ascertained. The production of building materials should be spread in such a manner that building materials are not allowed to be stored for long period as this would affect the quality and lead to breakage/ wastage.

2. The location where building material will be produced shall be selected based on the availability of water and the required quality of raw material/ soil etc.

3. For unskilled labour, workers that hold job cards only will be engaged. The un-skilled task to be carried out by an un-skilled labour should be worked out by the State.

GUIDELINES ISSUED DATED 13TH JANUARY, 2014

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6. Self Help Groups of MGNREGA workers, interested in building material production will be formed in the Block. The DPC will arrange required training, through the concerned agencies, before the production is taken up and such SHGs will be employed, whenever production is taken up in the Block.

7. Some existing willing building material producer may be identified as

non commercial ‘resource persons’ who can work as ‘mates’ for the programme. These identified mates may select the places and train the wage seekers in basic processes, before starting the production.

8. All processes and non-negotiable required under MGNREGA will be

followed in engaging MGNREGA workers under these guidelines,

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• It is necessary to ensure that prescribed quality standards are adhered to. If the building material production is not of the quality required, not only should the field trial be discontinued, such building material should not be used for construction at all.

QUALITY ASPECT

• Sizes, strength required and tests to be performed as prescribed in IS code by Bureau of Indian Standards (BIS)

• States must deploy all required inspection/monitoring processes so as to ensure that building material produced are of acceptable quality.

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In building material production cost, un-skilled labour component (shall not be less than 33%) and skilled/ semi-skilled/ material component, will be worked out by the State, based on actual costs of inputs, wage rates and work output.

COSTING

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Procurement of capital items should be avoided. If it is absolutely necessary to procure small items, then the same can be procured following procurement procedures laid down by the State Government. However, it is advised that a decision for procuring capital items shall not be a level below that of DPC.

CAPITAL INVESTMENT

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On every building material production site all accountability arrangements as prescribed under MGNREGA will be followed. Material at site (MAS) register with details of raw material and produced material will be maintained in the format as detailed Format-1 & Format -2 respectively.

ACCOUNTABILITY ARRANGEMENT

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S.

NO.

RAW

MATERIAL

UNIT QUANTITY SOURCE DATE OF

RECEIPT

AMOUNT

SPENT (RS.)

DATED SIGNATURE

OF THE VERIFYING

AUTHORITY

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

FORMAT-1: MATERIAL AT SITE (MAS) REGISTER FOR RAW MATERIAL PROCURED FOR PRODUCTION OF BUILDING MATERIAL FOR MGNREGA WORKS (pg 215 of the manual)

Name of Site/ GP/ Block/ District: Name of building material to be produced: Name of the implementing agency producing building material:

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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

FORMAT-2: MATERIAL AT SITE (MAS) REGISTER FOR BUILDING MATERIAL PRODUCED (pg 216 of the manual)

Name of Site/ GP/ Block/ District: Name of building material to be produced: Name of the implementing agency producing building material:

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COMPLIANCE WITH RULES/ REGULATIONS AND ENVIRONMENTAL LAWS

• All other conditions such as compliance with Rules / Regulations including those relating to Environmental aspects should be strictly adhered to.

• All building material shall follow ‘green’ (environmental friendly) technology and processes.

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MISCELLANEOUS

Building materials produced under

MGNREGA

For Construction of Buildings permitted under MGNREGA only

It needs to be re-iterated here that building material production is not permitted as a “stand alone” activity meaning thereby that building material production cannot be made under MGNREGA and used for works other than the works taken up under MGNREGA or for sale in the open market.

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BUILDING MATERIALS MAY BE PRODUCED AT SITE

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1. COMPRESSED STABILISED EARTH BLOCKS (CSEB) FOR MASONRY

S. N. Details Limiting value

a Clay Fraction (< 0.002 mm) 5% - 18%

b Silt fraction (0.002 - 0.075 mm) 10% - 40%

c Sand fraction (0.075 - 4.75 mm) 50% - 80%

d Gravel fraction (4.75-6mm) 0% - 10%

CSEB blocks are made by compressing earth/ soil mixed with Suitable stabilizer (cement/ lime) at optimum moisture content by simple mechanical means. Raw material required: • Suitable soil with the following specifications in the

required quantity.

• Sand or quarry dust. • Suitable stabiliser lime or cement. Equipments required : • Block press machine (e.g. Mardini block press, Auram

block press, Balram block press, etc.

CSE Blocks

Block Press machine 15

Production:

• Site (i.e. borrow pit) identification for source

of raw material.

• Beating and sieving of soil.

• Sand or quarry dust to be mixed to correct

the clay sand percentage in the soil.

• Suitable stabiliser to be added (cement or

cement and lime) in appropriate proportions

and mix thoroughly in dry condition.

• Moisture to be sprinkled on to the mixture

and further mixed thoroughly till the mixture

is homogenous. Test for optimum moisture.


Sedimentation test

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Production:

• The correct quantity of moist soil to be weighed such that a fresh block density of

2.05 gm/cc can be achieved. The weighed soil is to be poured in a soil

compaction press, and moulded in a CSEB.

• Blocks are then stacked in a five or six block high stack and cured for next 21 days

to complete the block making process.

• Blocks thus produced ready to be used for masonry with cement mortar 1:6,

cement-lime-mortar 1:1:6.

• In case of exposed SCEB masonry, the joints should be pointed with 1:3 mortar or

1:1:2 (cement-soil-fine sand) mortar to prevent water leakage through joints.


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Production of Compressed Stabilised Earth Block (CSEB)

Source: Auroville Earth Institute 18

Unskilled Man days: 9 nos. for the production of 1000 nos CSEB (230X108X76mm) National Standard: IS 1725-Stabilzsed soil blocks used in general building construction- Specifications


• Data for producing 1000 numbers of Compressed Stabilised Earthen Blocks

based on Hand Book of Vidyalayam:

• Size: 230 X 108 X76mm

Sr. No. Materials Quantity

1. Soil 3.5 cum 2. Cement 212 kg

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20


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Advantages:

• Can be very cost effective, especially when the blocks are produced at the site of use

• Provides good thermal comfort provides aesthetical wall finish, no plaster required

• Creates additional local employment in block production

• Can be made with locally available earth which makes it cost effective.

Limitation:

• Requires a good understanding of the type of soil available for block

production and how it can be improved/ stabilized.

• Availability of soil in adequate quantity from a single source, can be a

limitation.

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2. PRECAST CONCRETE STONE MASONRY BLOCKS

• This Technology has been developed by Central Building Research Institute (CBRI), Roorkee.

• Concrete Stone masonry blocks are made of large size stone spalls bonded together with lean cement concrete mix.

• Stones spalls replace 25% - 30% of Cement concrete from the total volume of the block.

Raw material required: • Stone spalls: Broken stone pieces of size

ranging from 50mm to 250mm. • Coarse aggregate: 10mm and down graded

confirming IS383. • Cement: confirming to IS455/ IS269/ IS1489). • Sand: Well-graded, confirming to IS383

Equipments required: • Trovel • External vibrator: Plate vibrator/ Mason’s tool • Mould: Fixed type or Split type

Precast concrete stone masonry blocks

Fixed type mould for PCSMB 26

Production:

• Preparation of concrete. The cement concrete mix for blocks shall not

be richer than 1:3:6 and shall not be leaner than 1:5:8.

• Placing of stone spalls in the mould, with inter spacing minimum 10-15

mm. Large size stone spalls of 100mm and above shall be placed in the

bottom.

• Pouring of concrete all around the stone spalls and filling up of the

mould.

• Concrete shall be tamped with suitable tamper from the top.

• Top surface of the block shall be finished with a trovel to the edge of

the mould


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Unskilled Man days:

• 50 nos for the production of 1000 blocks

(290X190X140mm).

National Standard:

• IS 12440 - Specifications for Precast

concrete stone masonry blocks

Production:

• Demoulding shall be done 5-10 minutes after compaction.

• After demoulding, the blocks shall be protected until they are sufficiently

hardened to permit handling without damage.

• Curing for 14 days and then drying for 2 weeks.

• Ready to use for construction.

Production Site: Precast concrete stone Masonry blocks


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3. PREFABRICATED RCC PLANKS AND JOISTS

• Precast reinforced cement concrete joists are beams and the planks are small reinforced cement concrete slab units.

• The joists are placed across walls or beams, then the planks are placed between the joists and gaps are filled with concrete to form roof or intermediate floor.

Raw material required:

1) RCC Plank: • Concrete: M-15 grade (1:2:4) as per IS456 • Reinforcement steel: Mild Steel bar 6mm diameter • Well graded aggregate of maximum size 10mm.

2) RCC Joists: • Concrete: M-15 grade (1:2:4) as per IS456 • Reinforcement steel • Well graded aggregate of maximum size 20mm.

Equipments required: • Moulds for RCC planks and joists • Mechanized vibrating table (Optional)

RCC Planks

RCC Joists 29

Production:

1) Production of RCC Plank:

• Inner sides of the mould shall be applied with

a suitable bond releasing agent.

• Mould to be kept on Smooth concrete floor

applied with bond releasing agent.

• Reinforcement cage shall be placed inside the

mould, in such way that it will get cover of

15mm.

• Concrete shall be poured to a depth such that

after compaction with a plate vibrator shall

become 30 mm.

Mould for RCC Plank

Isometric view: RCC Planks


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1) Production of RCC Plank:

• The upper sides of the longitudinal members of the mould and the two tapering

members shall then be placed over the mould.

• Concrete shall be then poured in the middle and the sides and compacted with

tamping or plate vibrator.

• Concrete shall be finished with mould and the top surface shall be made rough

by trowel marking.

• After 2 hours demoulding shall be done.

• After 24 – 30 hours to be cured for 2 weeks

• Ready for construction.

RCC Planks


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2) Production of RCC Joists: • The mould shall be assembled. • Application of bond releasing agent from

inside. • Placing of reinforcement cage with the gap of

25mm from the bottom for cover, with the stirrups projecting out as shown in figure “X-Section RC joist”.

• Cement concrete with well graded aggregate with maximum size of 20mm shall be poured in the mould and compacted using needle vibrator.

• Mould may be dismantled in about 3 to 4 hours after casting.

• After 48 -72 hours joist to be cured at least for 2 weeks.


X-Section RC joist 32


Modular planning: Room sizes to be derived from the dimensions of RCC Planks and joists

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Installation of beams and planks : • Before installing planks and joists, their accurate positioning for a given room size

should be ascertained. • Cement concrete / roof band to be casted for placing of the joists. • Placing of joists. • Placing of planks one beside the another.

Step-1 Step-2 Step-3 34


In-situ Concrete Placing of RCC Planks

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Advantages: • Reduces overall roof cost by 15-20% because of reduction in both cement and

steel consumption. • Saves construction time – the space can be ready in 2 days as compared to 14

days which are needed before shuttering can be taken off in case of conventional RCC slab

• Creates employment as the roof components can be locally produced and delivered through

• a micro level enterprise • Much better quality control can be maintained during pre-fabrication Limitations • Not financially viable for a single dwelling unit, if the precast elements are not

available from an enterprise/ supplier • The many joints in the roof can lead to water leakage if the in-situ concrete

and subsequent flooring on top is not done with good quality control

National Standard: IS 13994.1994

4. PRE-FABRICATED BRICK PANELS FOR FLOOR OR ROOFING

• Roofing system consist of prefabricated Brick panels and RCC joists and in situ

concreting.

• Prefabricated brick panels are made by a combination of concrete, bricks and

reinforcement.

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Raw material required:

• Good quality bricks

• M.S. bars 6mm Diameter

• Reach cement mortar 1:3 (cement ,

coarse sand)

Equipments Required:

• Mould

• Trovel


Production: • The mould for the brick panel should be made with well seasoned timber. For

mass production, moulds may also be made with mild steel or other rigid, non-absorbent and non-corrodible material such as FRP.

• The moulds which are open at bottom are kept on a levelled ground having a thin layer of sand or pucca floor or platform.

• Wet the bricks before placing in the mould. Then arrange the bricks in the mould with outer most bricks touching the sides of the mould and keeping specified gaps in between bricks for joints.

• The frogs of the brick should face upwards to provide shear key to concrete which is laid in situ on top of the panel.

• 2 reinforcing bars of 6mm diameter are placed on the two longitudinal joints. • M20 concrete is placed in the longitudinal joints, each about 35mm thick • The remaining joints between bricks are filled with rich cement mortar of 1:3

ratio. • The mould can be removed just after casting the panel. • Cure the panel with water for 14 days and let it dry for another 14 days before it

can be used for roof construction. 38


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• IS 14143.1994_Specifications_Prefabricated brick panel and partially precast concrete joist for flooring and roofing 40


National Standard: • IS 14143.1994 Specifications Prefabricated brick panel and partially precast

concrete joist for flooring and roofing

Panels shall be assembled on the joists (beams) and concrete is poured (35mm) with M20 grade concrete.

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5. Extraction of laterite stones

Unskilled labours may be employed at Stone quarry in the extraction of stone for the construction.

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6. PRECAST DOOR AND WINDOW FRAMES

• IS 6523.1983: Specification for precast reinforced concrete door and window frames 43

State Group (Nodal Person)

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1 Shri Ram Newasj (Trnasffered)

Sr. DY commsioner MGNREGA, UP [email protected] 9411851687

2 Shri V. K. Bhagwat DY COMMISIONER, R.D. UP [email protected] 9415424754

3 Shri T. N. Singh (Transferred) Engineer, T.A.C, R.D, U.P. [email protected] 9411851687

Masons trained on Appropriate Technologies

1 Ramanand Pathakhaulee, Jigna mirzapur Chhanbe, Mirzapur, Uttar Pradesh 7897034931

2 Maya Shanker Bind Jodhipur, Chanbe, Mirzapur, Uttar Pradesh 9793498581

mailto:[email protected]

mailto:[email protected]

Rural Housing Knowledge Nentwork

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Thank you

production of building materials under mgnregs · 2015. 5. 17. · mord, goi pankaj s. duberkar...

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