Foundation Alternatives and Cost Evaluation

As noted earlier, the two major alternate foundation types are the shallow and deep foundations. Shallow foundations are discussed in this chapter. Deep foundation alternatives including piles and drilled shafts are discussed in the next chapter. Proprietary foundation systems should not be excluded as they may be the most economical alternative in a given set of conditions. Cost analyses ofall feasible alternatives may lead to the elimination of some foundations that were otherwise qualified under the engineering study. Other factors that must be considered in the final foundation selection are the availability of materials and equipment, the qualifications and experience of local contractors and construction companies, as well as environmental limitations/considerations on construction access or activities. Whether it is for shallow or deep foundations, it is recommended that foundation support cost be defined as the total cost of the foundation system divided by the load the foundation supports in tons. Thus, the cost of the foundation system should be expressed in terms of dollars per ton loadthat will be supported. For anequitable comparison, the total foundation cost should include all costs associated with a given foundation system including the need for excavation or retention systems,environmental restrictions on construction activities, e.g., vibrations, noise, disposal of contaminated excavated spoils, pile caps and cap size, etc. For major projects, if the estimated costs of alternative foundation systems during the design stage are within 15 percent of each other, then alternate foundation designs should be considered for inclusion in contract documents. If alternate designs are included in the contract documents, both designs should be adequately detailed. For example, if two pile foundation alternatives are detailed, the bid quantity pile lengths should reflect the estimated pile lengths for each alternative. Otherwise,material costs and not the installed foundation cost will likely determine the low bid. Use of alternate foundation designs will generally provide the most cost effective foundation system. A conventional design alternate should generally be included with a proprietary design alternate in the final project documents to stimulate competition and to anticipate value engineered proposals from contractors.

NATIONAL BUILDING CONSTRUCTION CORPORATION PROFILE

YEAR OF INCORPORATION NBCC was incorporated in November 1960 as a wholly owned Government of India undertakingunder the erstwhile Ministry of Works, Housing & Supply ("MoWHS"), which is now known as the Ministry of Urban Development ("MoUD"). AN ISO COMPANY ISO 9001:2008 Certification has been awarded to NBCC for its Project Management and Consultancy Divisions. ISO 9001:2008 certification issued by Bureau of Indian Standards is valid up to March 2014. AUTHORISED CAPITAL The authorized, issued and paid-up equity share capital is Rs. 120 crore. This includes Rs. 30 crore of fully paid-up bonus shares to the existing share holder s as on 30-09-2011. PERFORMANCE RECOGNITION On October 14, 2008, the Government granted NBCCSchedule "A" PSU status. NBCC has also been awarded ISO 9001:2008 from the Bureau of Indian Standards in respect of our consultancy and project management division. NBCC has also received "Excellent" rating from MoUD for each of the Fiscal years from 2004 to 2010 and Ministry of Heavy Industries & Public Enterprises has awarded us with an "Excellence Award". MoUD grants us "Excellent" rating if all the targets set out in the MoU with MoUD for the respective Fiscal year are acheived. Further, in 2011, for one of our PMC projects, we were awarded an "Appreciation Shield" for quality and timely completion of NSEZ Noida Project by the Ministry of Commerce & Industry and the Development Commissioner, NSEZ.

AREAS OF OPERATION
NBCC is one of the few public sector companies engaged in the business of (i) (ii) project management consultancy services for civil construction projects ("PMC") civil infrastructure for power sector and real estate development.

NBCC is headquartered in New Delhi and in addition has 10 regional / zonal offices across India. The projects undertaken by our Company are spread across 23 states and 1 union territory in India. In addition, NBCC has also have also undertaken projects overseas. NBCC's PMC business segment includes providing management and consultancy services for a range of civil construction projects including residential and commercial complexes, redevelopment of buildings and colonies, hospitals, educational institutions; infrastructure works for security personnel, border fencing as well as infrastructure projects such as roads, water supply systems, storm water systems and water storage solutions. NBCC's civil Infrastructure for power sector segment includes providing engineering and construction services for power projects, including design and execution of (i) civil and structural works for power projects (ii) Cooling towers (iii) Chimneys. NBCC's real estate development segment focuses on principally two types of projects, namely, (i) residential projects, such as apartments and townships and (ii) commercial projects, such as corporate office buildings and shopping malls.

COMPUTERIZATION AND TRANSPARENCY NBCC makes extensive use of information and communication technologies for the execution and management of its projects. NBCC has implemented Enterprise Resource Planning ("ERP") system in some business processes related to accounting, salaries, HRM system and e-Bidding system. In addition, NBCC's team has access to domain controller and additional domain controller, cluster servers, IT security management, network management etc. IT security management is also utilized for the continuous upkeep of security products , solutions, products, tools. The online computer maintenance services ensures accurate management of the organizations hardware and software complaints electronically, including hardware management, complaint tracking, minimum problem rectification time, better reports management and optimal performance. NBCC also hascentralised its database and has begun digitising its records and has business continuity servers to protect the electronic data and ensure maximum uptime.

PROJECT MANAGEMENT CONSULTANCYFOR CIVIL CONSTRUCTION PROJECTS ("PMC")

Our PMC business segment includes providing management and consultancy services for a range of civil construction projects including residential and commercial complexes, redevelopment of buildings and colonies, hospitals, educational institutions; infrastructure works for security personnel, border fencing as well as infrastructure projects such as roads, water supply systems, storm water systems and water storage solutions. Some of our clients in this segment are or have been, ESIC, Ministry of Defence, Ministry of Home Affairs (including Security forces like CRPF, CISF, NSG, BSF), Ministry of External Affairs, MoUD, Ministry of Commerce and Industry, Ministry of Corporate Affairs, Ministry of Finance, Haryana Urban Infrastructure Development Board, IIT Roorkee, IIT Kharagpur, IIT Patna, SVNIT, amongst others. Our key completed projects during the period April 01, 2006 tillSeptember 30, 2011, based on the total contract value, include road works at Agartala, construction of defence campus at Jaipur, Jodhpur, Ahemdabad, Ambala, Sulur, CBI headquarters at New Delhi, Extension of campus of MDU university and IIT Roorkee. Our key domestic PMC Ongoing Projects based on the total outstanding contract value, include Indo Bangladesh Border Fencing Works at Meghalaya, ESIC Hospital, Parel (Mumbai). We presently have one overseas PMC Ongoing Project at Male, Maldives for construction of India - Maldives Friendship Faculty of Hospitality & Tourism Studies.

As of September 30, 2011 Number of Projects Contract Value (in million) Outstanding Contract Value / Order Book (in million)

PMC Projects Ongoing Projects Forthcoming Projects 130 59 162,764.24 23,786.40* 79,240.52 23,786.40*

REAL ESTATE DEVELOPMENT

Our real estate development segment focuses on principally two types of projects, namely, (i) residential projects, such as apartments and townships and (ii) commercial projects, such as corporate office buildings and shopping malls. Our Company has undertaken real estate projects which are spread across 10 states in India. As ofJanuary 15, 2012, our Land Reserves aggregate approximately 127.918 Acre. Our Land Reserves are located in Delhi, Uttar Pradesh, Patna, Gurgaon, Kolkata, Kochi, Alwar and Lucknow. As on January 15, 2012, our completed commercial projects include commercial complex at Vadodara, Cuttack, Agartala, Ghaziabad (Uttar Pradesh) and at BhikajiCama Place, PragatiVihar and PushpVihar in New Delhi. Further, some of our key real estate development Ongoing Projects include residential complex at "NBCC Heights" at Sector-89, Gurgaon, Haryana; Khekra (Phase-I), Baghpat, Uttar Pradesh; residential-cum-commercial complex at Bahadurpur, Phase-I, Patna; New Delhi,Sukias Lane at Kolkata and Hemanta Basu Sarani Complex. The following table represents details for types of real estate projects, as of January 15, 2012:

Type of Real Estate Developm ent

Completed Projects

Ongoing Projects

Forthcoming Projects

No. of Developa No. of No. of Developa Saleabl Leasab Projec ble Projec Projec ble Area e Area le Area ts Area ts ts Residentia 3,410,4 Nil 4 3,732,053 0 6 l 03 Commerci 8 1,076,65 3 407,633 239,560 66,624 6 al 3,649,9 Total 8 1,076,65 7 4,139,686 66,624 12 63

Developa Saleabl Leasab ble Area e Area le Area 4,878,8 147,58 82 5 1,724,1 290,78 2,323,908 01 6 6,602,9 438,35 7,879,729 83 3 5,555,821

CIVIL INFRASTRUCTURE FOR POWER SECTOR

Our civil Infrastructure for power sector segment includes providing engineering and construction services for power projects, including design and execution of (i) civil and structural works for power projects (ii) Cooling towers (iii) Chimneys. Some of our clients in this segment include NTPC Limited, BHEL, APGENCO Limited, Uttar Pradesh RajyaVidyutUtpadan Nigam Limited, MAHAGENCO Limited and Karnataka Power Corporation Limited. Our completed key projects, during the period April 01, 2006 till September 30, 2011based on the total contract value, include construction of civil, structural and architectural works for 2x250 MW at Korba, Chattisgarh;Rihand Main Plant , Civil Works in Uttar Pradesh our key On-going PMC Projects, based on the total outstanding contract value, include cooling tower, chimney at Farakka Super Thermal Power Project, West Bengal, ,Koderma Thermal Power Project at Jharkhand, Durgapur, Thermal Power Project at West Bengal, Rihand Super Thermal Power Project, Uttar Pradesh, Barh Super Thermal Power Project, Patna, Mauda and Vindhyachal Super Thermal Projectat Maharashtra & Madhya Pradesh respectively.

As of September 30, 2011 Number of projects Contract Value(` in million) Outstanding Contract Value / Order Book(` in million)

Civil Infrastructure for power projects (Ongoing Projects) 14 7,875.43 3,199.49

PROBLEMS FACED AT SITE

There were numerous problems which were faced at site. Some of these were purely due to the human errors and poor workmanship but some were due to unseen factors. 1. There was a problem in providing beams at one location as per the standard drawings so the drawings were changed by consulting the structural designers and architect 2. There was problem pouring concrete in one beam due to small area available for pouring and compacting. The solution to this problem was that the size of steel was increased but the number of steel bars was decreased so as to provide the total area same.

3. No window was there in staircases which lead to complete darkness, so it was decided to change the drawing by consulting the concerned authorities.

4. The depth if beam above the door was 35 earlier but to keep the size of the door as per the standard it was changed to 3.

5.Frequent power cuts lead to increase in the cost of construction as generators were used to meet the power requirements 6.Laying of foundations was postponed by 1 month due to the rainy season.

Unit Weight of Materials Used at Construction Site

Following table shows unit weight of materials used at construction site. Please note this is for reference purpose only and may vary from place and type of material. We are thankful to Engineer Prince Saha for submitting this very useful information to us.

S.No

Material

Theoretical Weight in(KG/M) 1440 7850 1600 1840 2850 to 2960 1000 2240 2420 1600 to 1920 1920 1760 1800 2080 1760 640 2530 670 to 830 990

Approx Weight at Site Remarks in Kg 50 d/162 50 to 55 57 to 63 48 to 52 1 8.24 to 8.5 Per Bag d -dia in mm farma farma farma liter Cube mould no no cft cft no cft cft bag sft cft cft no no 1 farma=1.25cft 1 farma=1.25cft metal 12mm to 20mm cube mould size=15x15x15cm 9x4x2 3/4 9x6x3 3/4 Black cotton 30x15x20 cm 30x10x20 cm

1 2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Cement Steel SandDry River Stone(basalt) Water PCC RCC 2% Steel Bricks Brick Masonry Soil(damp) Cement concrete block(solid) Cement Mortar Lime Mortar Lime Glass Teak Wood Sal Wood Marble mosaic tile

1.9 to 2 4.8 to 4.9 50 to 55 18 to 20 10 to 11 57 to 62 48 to 52 30 0.9 to 0.95 18 to 20 22 to 24 2.8 to 3.2 4.8 to 5.2

4mm tk plain

25x25x22mm 30x30x25mm

19 20 21 22 23 24 25 26 27

Chequered tile Glazed tile15x15cm Marble Stone Granite Stone Coddappa A.C.sheet corrugated Bitumen Window frame (simple design) Door Frame a)30070 b)26x70

2620 2460-2800 2720 16 1040

2.5 to 2.8 0.20 to 0.25 5.1 5.35 6.4 1.2 220 1.9 to2.1

no no sft sft sft sft Drum sft

25x25x22mm 5mm tk 3/4tk 3/4tk 1 1/4tk 200liter drum

25 to 27 24 to 26

no no

section 4x2 1/2 section 4x2 1/2

PORTLAND CEMENT:
Joseph Aspdin, a mason at Leeds prepared a cement in 1824 by heating a mixture of finely-divided clay and hard limestone in a furnace until CO2 had been driven off; this temperature was much lower than that necessary for clinkering. The prototype of modern cement was made in 1845 by Isaac Johnson, who burnt a mixture of clay and chalk until clinkering, so that the reaction necessary for the formation of strongly cementitious compound took place. The name Portland Cement was given due to the resemblance of the colour and quality of the hardened cement to Portland stone- a limestone quarried in Doset. The process of manufacturing of cement consists essentially of grinding the raw materials ( calcareous materials such as limestone or chalk and argillaceous materials such as shale or clay), mixing them intimately in certain proportion and burning in a large rotary kiln at a temperature of upto about 14500C when the material sinters and partially fuses into balls known as clinker. The clinker is cooled and ground to a fine powder, with some gypsum added, and the resulting product is the commercial Portland Cement so widely used throughout the world.

MAKING CONCRETE:
Just mix cement, aggregates and water, cast this mix in a mould, open the mould next day. A uniform hard mass will be found, which is known as concrete, any body can make

it. The simplecity in making concrete make this material to be look like very simple in its production, yet it as not so simple. Due to ignorance about concrete no other building materials ever mis-used as concrete in the construction. In India concrete is being used in the construction since the last 70 years. Yet 80% of the builders have no proper understanding of this materials. Go to any construction site (except big construction sites) you will find that sand and aggregates are being taken in iron tasla or cane baskets to charge the mixer without the consideration of site aggregates actual grindings, moisture content and bulking of sand. The water is poured in the mixer without any measured quantity. It could be well imagine what sort of concrete structure will be made with the concrete being produced in this crude method. Most of the contractors, builders, masons etc. still follow 1:2:4 or 1:1.5:3 mixes they are not aware of Design Mixes and Concrete Admixtures. This paper described how Design Mixes can be converted into volume with 1 Bag Cement, 2 Boxes of sand and 4 Boxes of Aggregate. The site practical problem is the dispersion of water and liquid admixtures into the mixer. For this the site should fabricate a plastic circular graduated measuring container of 30 lit capacity with a tap fitted at its bottom. This container is to be fitted on top of the mixer. From this container water and liquid admixtures can conveniently poured direct into the mixer in a measured quantity.

EXAMPLE OF MIX DESIGN

1. For a construction site M-25 Grade of concrete is required to be designed as per IS: 456-2000. The mix will be taken by volume. Workability required is 50 mm slump. Normal Superplasticizer will be used in the mix. The materials will be mixed at site in a tilting drum mixer of one cement bag capacity. 2. For durability consideration, maximum free W/C ration = 0.50 minimum cement content 300 kg/m3 including Fly ash. 3. Test datas of aggregates are as given in table-1. 4. Cement will be used PPC, having 7 days average compressive strength of 37.5 N/mm2 5. Mean design target strength: 25 + 1.65 x 5 = 33.3 N/mm2 at 28 days age

Table-1 Test Data of Dehradun Aggregates: I.S. Sieve Size Percentage Passing River Sand 40 mm 20 mm 10 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron Specific Gravity Water absorption % Bulk density kg/lit 100 100 95 79 72 56 47 27 6 2.65 0.80 1.78 2.65 0.50 1.40 20 mm Crushed Aggregate 100 86 3 0

Note : The sand is not falling to any grading Zone of IS : 383-1970. The aggregate grading is 20 mm single sized as per IS: 383-1970. If 95% this sand passes on 4.75 mm sieve, then the sand will become of Zone-II as per IS : 383-1970. The following mix is worked out as per Zone-II sand. For detail calculations refer reference of No. 1. a) For the target strength and given cement and Aggregate W/C ration found to be = 0.49 b) Water for OPC 190 kg/m3. For PCC 5/100 x 190 = 9.5 , Say 10 190 10 = 180 kg/m3 to give 50 mm of Slump with the given aggregates. Normal

Superplasticizer at a dosages of 7 ml/kg cement will give 15% water reduction without loss of workability. Water = 180 27 = 153 kg/m3 c) Cement = 153/0.49 = 312 kg/m3 d) Density of OPC concrete = 2405 kg/m3 Density for PPC Concrete = 2405 24 = Say 2380 kg/m3 e) Aggregates = 2380 -153 312 = 1915 kg/m3 f) Sand (Zone-II) = 1915 x 0.36 = 689 kg/m3 g) 20 mm aggregate = 1915 689 = 1226 kg/m3 Mix. No. 1 On the basis of saturated and surface dry aggregatesWater =153 kg/m3 PCC=312 kg/m3 Sand=689 kg/m3 20 mm Aggregate=1226 ml/m3 Mix No. 2 95-79 = 16% oversized particles in the sand is to be adjusted in the above mix. The modified mix on the basis of saturated and surface dry aggregates is given below: Water=153 kg/m3 PCC=312 kg/m3 Sand=820 kg/m3 20 mm Aggregate =1095 kg/m3 Normal Superplasticizer=2184 kg/m3 Accordingly mix ratio by weight on the basis of saturated and surface dry aggregates is given below: Cement : Sand : 20 mm Agg. 1 : 2.63 : 3.51 W/C Ratio = 0.49 Mix ratio by volume on the basis of room dry aggregates is given below: Cement : Sand : 20 mm Agg. 1 : 2.14 : 3.63 Free W/C Ratio = 0.49 MIX RATIO BY VOLUME FOR ONE BAG OF CEMENT 1. Cement = One bag = 50 kg = 35 lit = 35000 cc

2. Sand (room dry) = 2.14 x 35 = 74.9 lit = 74900 cc 3. 20 mm Aggregate (room dry) = 3.63 x 35 = 127.05 lit = 127050 cc 4. Free Water = 24.5 lit 5. Normal Superplasticizer = 350 ml MEASURING BOXES TO BE MADE AT SITE 1. Cement = One bag = 50 kg 2. Sand (room dry) = 33 x 33 x 34.4 cm two boxes 3. 20 mm Aggregate (room dry) = 33 x 33 x 29.2 cm .. four boxes 4. Free Water = 24.5 lit 5. Normal Superplasticizer = 350 ml In the above example M-25 Design mix is converted to the familiar 1 bag cement : 2 boxes of sand and 4 boxes of aggregate. While making concrete at site the moisture content of site sand and aggregate must be taken into account in the mixing water and bulking of sand. In the field trial mixes are to be carried out to finalize the mix.