SOUTH EASTERN RAILWAY Office of the Chief Engineer, Garden Reach, Clacutta-43. Dated: 18.10.79 CEs Circular No.

24 Sub: Low cost Housing. Copy of extracts from the Central Building Research Institutes (CBRI) Data sheet No.1 is enclosed herewith giving the details with regard to the use of thin pre-cast RCC lintels in brick walls. Since the adoption of thin lintels results in about 50% saving in materials and overall costs compared to lintels based on conventional designs, it has been decided that in all future construction of staff quarters only thin precast RCC lintels should be used. The reinforcement details are also given in the attached ferro. Receipt of this letter may kindly be acknowledged. Encl: As above. Max. Clear span opening (c,m.) 120 120 120 150 150 150 180 180 180 Width of Lintel (C.M.) 20/23 10/11.5 30/35 20/23 10/11.5 30/35 20/23 10/11.5 10/35 Min. crushing Strength of Brick in wall (Kg./Cm2) 40 40 40 70 70 70 100 100 100 Main Reinforcement

2 2 3 2 2 3 2 2 3

Nos. Nos. Nos. Nos. Nos. Nos. Nos. Nos. Nos.

10 10 10 10 10 10 12 12 12

mm. mm. mm. mm. mm. mm. mm. mm. mm.

DIA. DIA. DIA. DIA. DIA. DIA. DIA. DIA. DIA.

M.S.Bars M.S.Bars M.S.Bars M.S.Bars M.S.Bars M.S.Bars M.S.Bars M.S.Bars M.S.Bars

THIN PRECAST RCC LINTELS IN BRICK WALLS (CBRIs Data Sheets No.1 Extracts) Factors Affecting Composite Action. Composite action of lintel with masonry above is a complex phenomenon and the following are the major factors affecting it.

(a)

Bond/friction at the interface of lintel and masonry:

The masonry above the lintel acts like an arch and transmit the load to the support of the lintel and the lintel acts like a tie for the arch. For the lintel to act as a tie, it is necessary that the bond of friction between the masonry and lintel near support is more than the horizontal shear stress caused by the thrust of the arch. (b) Crushing strength of masonry.

The arch action developed in the masonry causes vertical stress concentration in the masonry near supports. When this stress exceeds the crushing strength of masonry, failure sets in. (c) Shear strength of masonry:

Once the shear stress developed in masonry near the support exceeds the shear resistance of masonry, failure sets in. (d) Weight of masonry above Lintel:

If the height of masonry above the lintel is very less, physically it may not be possible for an arch to be formed in the masonry and hence composite action will be less. (e) Whether the masonry is already stressed to the limit, then there will be no reserve strength left for accommodation the peak vertical stresses demanded by composite action. (f) Whether the masonry is already stressed to the limit or not.

In case, the masonry is already stressed to the limit, then there will be no reserve strength left for accommodation the peak vertical stresses demanded by composite action. (g) Reinforcement in lintel:

Normally, this is not a controlling factor. If the area of reinforcement provided is extremely low and the masonry above is comparatively strong, failure of composite action by yielding of reinforcement could be excepted. Conclusions: (a) There is composite action of lintels with brick work above, even when brick masonry is of low strength and the height of brick work above lintel is 45 or 30 cm. Only.

(b) (c) (d) (e)

For a given masonry, the load carrying capacity increases with increase in the height of brick work above lintel. For a given height of brickwork, the load carrying capacity increases with strength of masonry above lintel. When the height of brickwork above lintel is less than 0.37 span and the masonry of low strength, failure occurs by shearing of masonry over supports. Compared to deep panel, vertical stress concentration in brickwork is less in case of shallow panels.

Recommendations: The composite action of lintel with brickwork above is governed by a number of parameters. The design of composite lintel is some what complicated and not easily amenable to calculation. For the ready use of site engineers, design chart for thin precast lintels in brickwalls of normal residential buildings is given in Table 1. It is applicable only when the load on the composite lintel is a uniformly distributed one. The brickwork over the lintel shall be not less than 45 cm. In height and shall be constructed in a mortar not leaner than 1:6 cement: sand mortar or 1:1:6 cement lime: sand mortar. Thin lintels shall not be used in brickwalls made in mud motors. It shall be noted that there is no composite action in continuous lintels at intermediate supports, where the top portion of the lintel is in tension. The thickness of the lintel shall be the thickness of the brick, i.e. 7 cm. In case of traditional bricks and 9 cm. In case of modular bricks and the width shall be the width of the wall. The lintel shall preferably have a bearing of 23 cm./20 cm. On either support. Details of thin precast lintel in a single brick thick wall over an opening of span 120 cm. Is shown in Fig.1. Lintels can be cast over a concrete topped casting platform, finished level and smooth after applying a coat of used engine oil or any other bond- breaking material. Simple timber/steel mould duly oiled can be used for the casting. The main reinforcement as given in Table 1 shall be placed at the centre of the thickness of the lintel and 6 mm. Dia M.S. Distribution bars shall be spaced @ 30 cm. C/c above the main reinforcement and tied with it with G.I. wires. The concrete used shall be grade M-150 with coarse aggregate of 20 mm. And down size and shall be compacted by vibrators. The top of the lintels shall be finished rough with chequered lines while the bottom and sides shall be finished smooth. The lintel shall be water cured for two weeks and air dried for another two weeks before using them in any construction. During construction, in case the lintels are not resting on door/window frames, they shall be supported to a length of 0 cm. At the mid-span, before the wall above is built and for at least a weeks time after the wall is completed.

In case, the lintel is having a chajja projection, both may be precast together. A detail of lintel with chajja is shown in Fig. 2. Alternatively, the lintel portion may be precast with the reinforcement for the chajja projecting. The chajja projection has to be kept propped up till the wall above is built to provide sufficient counterweight against overturning. Where two lintels cross each other at the bearing portion the lintels may be precast upto the bearing portion only with the reinforcement for the bearing portion exposed. This portion shall be cast-in-situ. Alternatively, both the lintels may be cast completely in situ. Lintels have to be kept propped in either case, till the concrete and masonry above attain strength. Advantages: Use of precast lintels speeds up the construction of walls, besides eliminating shuttering and centering. Adoption thin lintels result in about 50 % saving in materials and overall cost, compared to lintels based on conventional design. PRE-CAST STONE MASONRY BLOCK WALLING 1. Stone forms the Chief walling material in some parts of this Rlys. It is being mostly used in the form of random rubble masonry for constructing walls of thickness ranging from 38 cm to 45 cm although 30 cm thick walls are also being used of late. They require excessive materials and are undesirably massive. Further the construction is time consuming and calls for more skilled labour. 2. CBRI under lock study to reduce the thickness of the walls as also the level of skills normally required in the traditional method of construction. Accordingly, the scheme of producing masonry units in the form of pre-cast stone masonry blocks was developed such that the stone texure is maintained on the external face and the internal face to have a minimum thickness of plaster. These blocks can be produced easily with the semi skilled labour without any special equipment. 3. The normal length and height of the block is kept 30 cm and 15 cm respectively with 3 widths as 20 cm, 15 cm and 10 cm. The actual block dimensions are short by 1 cm to accommodate mortar joint thickness. These blocks weight from 9 kg. To 18 kg. To get the stone texure on the outer face of the wall these blocks are cast such that the bottom face during casting forms the exposed face when laid in wall. 4. The above books are used both for load bearing and non-load bearing walls. The permissible stresses in the masonry are given in the I.S. Code 1905-1969 Structural Safety of Buildings Masonry

walls. Depending upon the load coming over it the thickness of the walls is decided. There are certain important construction. These are:(i) They can be used up to 3 to 4 storied constructions as load bearing walls. The thickness of the wall is decided based on the strength of the blocks and the load coming over it. (ii) As cutting of these blocks is not recommended the building should be planned to suit the block dimension, i.e. all lengths of walls, openings, spaces between the openings etc. shall be multiple of 10 cm. And all height shall be in multiples of course height, i.e. 15 cms. (iii) The proportion of the cement mortar should not be leaner than 1:6 for laying these blocks. Where good quality of time is available pozzolanic mortar may be used. (iv) The blocks should be dry at the time of laying in the masonry. If the climate is dry the blocks may be wetted on the surface only in order to reduce their section from mortar. However, wetting is neither necessary nor desirable. (v) For breaking of vertical joints in alternate course smaller length blocks are used (depending upon wall length). (vi) The hold-fasts of doors, windows and ventilators are fixed by embedding in M-100 cement concrete. (vii) The bearing of lintel is kept 10 cm. On either side. To match the top level of the lintel with the course height in situ concrete of required thickness is provided at the bearing. (viii) Only double face be finished with any desirable points and the internal face may or may not be allowed. (ix) The external face be finished with any desirable points and the internal face may or may not be plastered. (x) Blocks for fixing service pipes and electrical fittings etc. be preferably inserted at the joints of the masonry. Where large openings are required to be kept for sanitary fittings, full block be taken out and the gaps filled with lean concrete after taking the fittings through the walls. Space for switches or for fixing electric switch boards etc. is created by using thin blocks. It is destrable to pre-plan the services and make provision during construction of walls. (xi) At T junction of 20 cm with 20 cm and 15 cm thick walls, a vertical joint at the centre line of cross wall is provided in alternate course by providing 1/3 and or 2/3 size blocks in case of 20 cm thick walls and 1/4 and or 3/4 size block in case of 15 cm thick walls.

In case of T junction of 20 cm X 10 Cm X 10 cm thick walls, joints are staggered by using 1/3rd and 2/3rd length block in alternate courses. (xiii) For 20 cm to 15 cm to 10 cm wall junctions the bonding is achieved by providing 20 cm long 6 mm dia. Bar in alternate courses. Only cement mortar is used for embedding the metallic ties. 5. It has been estimated that this system of construction using pre-cast stone blocks provides an economy of the order of 15% to 30% in the walling cost against the conventional methods of construction. 6. ADVANTAGES WALLING. (1) (2) (3) OF PRE-CAST STONE MASONRY BLOCK

(xii)

(4)

(5) (6) (7) 7.

The use of stone walls saves cement consumption and provides strength even with lean concrete mix which works as a binder only. It also reduces the cost of block. The stone masonry blocks can be produced at site or at factory by semi-skilled workers on a mass scale. The wall provides a more uniform strength and as such the thickness is reduced to 20 cm and 15 cm thereby saving in cubical content of materials both in foundation and in super-structure masonry and also gives larger floor area for the same plinth area. One face of the block being in stone texture the external wall face is flush pointed which saves in cement and also gives natural stone appearance of coursed rubble masonry at a lesser cost, apart from saving in cement. Even if plaster is done the thickness required is only 12 mm against the 20 mm to 25 mm in brick and random rubble masonry respectively. This provides improved performance to rain water penetration/seepage which is not attainable in random rubble masonry. Productivity in laying is increased and the wall can be built by ordinary masons.

Method of production:

7.1 Moulds: These moulds consist of rectangular boxes made from 3 mm thick m.s. sheet, open from top and bottom and having two handles of 6 mm diameter bars welded on both sides across the widths. For fabrication of the mould, all welding is done from outside so that the internal edges are sharp and free from welding flux. It is estimated that for production of 500 blocks per day about 8 to 10 moulds are sufficient. Smaller size blocks required for breaking bond

can be cast by partitioning these moulds with G.I. Sheets or alternatively separate moulds, one for each type may be made. 7.2 Casting platform: This may consist of 30 mm thick 1:3:6 cement concrete finished smooth with neat cement on a base of either brick slopping or lean concrete. For a production rate of 500 blocks a day it is estimated that casting area of 80 Sq.m. is required. 7.3 Material: The blocks are made of large size stone pieces binded together with lean cement concrete mix of 1:5:8: using cement sand and stone aggregate of 10 mm size and less. The stone pieces used are as large size as can be accommodated in the mould. These can be from 5 cm to 26 cm size and obtained either from quarry or breaking the river boulders to provide rough surface for better bond and also a flat surface for stone texture. The save on the cement consumption, cement concrete is used as binding material instead of cement mortar. Since the proposed concrete mix is very lean it lacks in the fine particles to impart it plasticity and workability. The sand, therefore, should be well grades. 7.4 Casting of blocks:

7.4.1 Clean the platform and moulds properly. Apply any lubricating oil inside the moulds once a day. Place the moulds side by side in a row after oiling the platform or placing waste paper at their bottom. 7.4.2 Arrange as large size stones as possible in the mould. The number of stone pieces may be one or two depending upon their size which may be of any length from 10 cm to 26 cm in width upto 12 cm and in height from 7 cm to 16 cm. There should be a minimum gap of 1.5 cm between any two stone pieces and between stones and the mould to provide proper cover of the binding material all around. 7.4.3 Fill up the gaps between the stone pieces and the mould in its lower portion with lean cement concrete by trowelling to cover the stones already placed. The slump of the concrete is to be kept 3 cm to 4 cm. The remaining portion on the mould should be filled with stone pieces of 5 cm to 7 cm size. Maximum quantity of this stone pieces is to be used taking care that adequate concrete cover is available around every stone piece. Fill concrete and compact by masons trowel and also by tamping the mould and finish the top level and smooth. 7.4.4 When 6 to 8 blocks have been filled up, the demoulding is started from the block cast firm by placing timber piece on top and keeping it pressed by thumb while pulling the mould up in case of box type mould or by removing the pins and separating the sides in case of split type of moulds. The demoulding is to be done soon after the casting i.e. 3 to 7 minutes depending upon the weather to avoid setting of the concrete and its adhesion with the mould.

7.4.5 The moulds are rearranged in a row and subsequent casting continued in the same way as described above. The casting of special blocks are also done in the same manner by using special moulds or thin sheet partition and timber block for making recess of cut-out. 7.4.6 The next day of casting or after 48 hours, depending upon weather the cast blocks are slightly pushed to break bond and lifted. These are placed on level ground having layer of sand cured by frequent sprinkling of water over the stacks for 2 weeks and air cured for another 2 weeks before laying them in wall. 7.4.7 It may be desirable to test 2 blocks out of every 500 blocks for its compressive strength after providing proper capping as per procedure laid down in I.S.2185-1967. 8. Compressive Strength: The average compressive strength in Kg. Per cm2 ranges from 182 in the case of 1:2:4 concrete mix to 50 for 1:6:12 concrete mix. The value of the same is 69 for 1:5;8 concrete mix and 65 for 1:5;10,78 for 1;4:8 and 114 for 1:3;6 concrete mix for block of size of 29 cm X 19 cm X 14 cm. 9. In view of the reported economy both in cement and also in the cost of walling as brought out by the CBRI it is desirable to go in for the use of pre-cast wall technique in masonry works where at present random rubble masonry is being resorted to particularly ob Khurda Road and Waltair Divisions. Singlestack System of building Drainage. The normal drainage systems in use of two separate pipes, the soil pipe taking discharge from water closet and urinals while the waste pipe from baths, sinks and wash basins. In addition vent pipes are filled with both the stocks to prevent unsealing of the traps of different appliances. A recent development is the single stack system, wherein all the appliances are connected to one pipe which itself provides all the vent requirements. It is simple, economical and functionally efficient. For Indian conditions, CBRI have conducted studies. It has been seen that the ratio Q/D should not exceed 2.5, where Q is the peak flow rate in litres per minute through the main stack and D is the diameter of stack in millimetres. U.C. branch pipe should be directly connected to main stack with 100-mm. Dia pipe, generally referred to as stack. The connections should be swept in the direction of flow. The W.C. trap

should bear a minimum water seal of 50 mm. And floor trap 35 mm water seal. All other appliances except W.C. should be connected to stock through a floor trap. It has been estimated that there is saving of 54 per cent in overall cost of piping by adoption of single stack system as compared to 2 pipe system in a 5 storeyed building having twin units on other side of stack. Hence in our Rly. Houses, these should be used economically on a large scale in 2, 3 or 4 storeyed blocks and in H/S blocks, in future. Safe guards for single stack system 1. 2. 3. 4. 5. The appliances should be grouped as closely as possible round the main stack as to keep branch pipe short and reduce the noise. Max. distance of V.C. branch pipe should be 1.5 M from the main stack. The V.C. branch should be of 100 mm. Dia and the waste branch from floor trap should be 75 mm. Dia. The slope of the branches should vary between 1 in 10 to 1 in 50 and no waste branch should be connected within 20 cm. Vertically below the centre line of V.C. branch. The depth of water seals in M.C. and flow traps should be 50 mm and 40 mm respectively. The other appliances like wash basins and sinks need not have seal trips, when connected through a floor trap. Otherwise, they shall have water seal traps of 75 mm deep. Large radius bend 92.5 or two bends of 135 should be used at the foot of the stack to avoid back pressure. The pipes shall be laid in straight lines as far as possible in both the vertical and horizontal planes. Anything that is likely to causes irregularity of flow, such as abrupt changes of directions shall be avoided. No bends and junctions whatsoever may be permitted in sewers except at manholes and inspection chambers. Sub: Use of lime in buildings. On this Railway lime is available from Katni for some areas on BSP Division. There will be saving in cement by the use of lime in building construction. Various types of building limes are classified according to I.S. 712-1956.

6. 7.

For residential buildings not more than 3 storeys high, the use of cement in foundation concrete can be eliminated except in areas with excessive soluble salts or in areas with high sub-soil water level. In areas with low average rainfall, foundations and plinth masonry of single storeyed building can be laid in well burnt bricks in lime mortar and pointed in cement mortar 1:6. The proportion of mix. For lime concrete, lime mortar etc. May be as under:Foundation concrete. (Thickness may be 100 to 150 mm)
(a) (b) Dry sub grade with sub soil water level never within 2.5 m of the foundation level. Proportion of Mix. Lime: Sand-1:2 or lime : Surkhi 1:6 (Coarse aggregate). Moist sub grade with high sub soil water Agregate Usually 2.5 m or less below foundation level. Cement:Sand 1 : 4 : or 1 : 3 : 6 or 1 : 5 : 10

Masonry mortars. (i) In foundations and plinth:

Lime: Surkhi : Sand 1:1:2 Lime:cement:Surkhi:Sand 1:1:2:4 Lime:Cement:Sand 1:1:6 Lime:Cement:Sand 1:1:6 Lime:Surkhi:Sand 1:1:1 to 2 Lime:Sand 1:1 Lime:Cement:Sand 1:1:6 Lime:Cement:Sand 2:1:9 or Lime:Surkhi:Sand 1:1:1 to 2 Lime:Surkhi:Sand 1:1:1 to 2 Lime:Cement:sand 3:1:12 or

(a) Dry subgrade (b) Moist, but no soluble sulphates present (C) Moist, soluble sulphates present (ii) Walls in superstructure with solid wall (iii) Pointing 3. Lime plasters (a) External plaster below D.P.C. (10 to 15 mm thick) (b) External plaster above D.P.C. (10 to 15 mm thick) (C) Internal plaster in all low or medium cost house

4.

Damp proof coarse.

2 cm thick cement lime plaster cement (Lime: 5 coarse sand) with one or two coats of bitumen to be adopted in areas with scanty rainfall with low water table. Asphaltic Corrugated Sheets. Asbestos cement (A.C.) sheets & G.I. sheets are commonly used for carrying platform shelters, sheds, institutes etc. Baths, Kitchen and V.C. in the case of improvements to substandard quarters. The sheets are quite costly now a days.

Corrugated sheets manufactured from asphalt and paper felt provide good substitute for asbestos cement and G.I. sheets because of their low cost (around Rs.1/- sft) and other useful properties. Asphaltic corrugated sheets are recommended to be used in temperatures not exceeding 44 C. They are completely waterproof, flexible non-conducting and are not attached by fungi or varmint. They are not susceptible to corrosion and leakage. These do not support combustion and provide moderate protection against fire. These also stand wind loads upto 192 kmph. Being light require lighter structural support. These are not brittle and could be nailed directly on supports. These are available in grades as ordinary, super and deluxe. Plastic emulsion and other paints may also be used to protect it and made it last longer. The life expectancy is about 8 to 10 years, but it may last longer if protected properly repainting etc. These sheets are recommended for low cost housing, temporary and semipermanent structures etc. The are particularly suitable for heavy rainfall, coastal area and hilly regions. Specifications: 1. 2. 3. 4. 5. Size Thickness Weight Asphalt content Heat insulation 4 X 2.5 (pitch of corrugation 1) 5 to 6 mm. 2.5 to 3.5 kg/sheet. 45% by weight. RCC slab 4 0.71 Asphalt roofing 0.44 A.C. sheets 0.21

In view of the low cost we may go in for usage of these asphaltic corrugated sheets on this railway on large scale for:(i) (ii) (iii) Covering over both kitchen and W.C. provided as improvements to S/standard quarters. Covering over temporary and semi permanent structures built in constructions. Covering over platform shelters as a trial measure on the East Coast regions where the temperature is moderate.

The following are the dealers and manufactures of the above sheets at present.

1. 2. 3. 4.

M/s. Modern Roofing Ltd. Tadimalla, A.P. 534305. M/s. Light Roofing Ltd. 125, Loyds Road, Madras-600086 M/s. Ajantha Roofings (P) Ltd. E-24, Chikalthana, Aurangabad. M/s. B.B.Bhardwa, Light Roofings Ltd., E-48, Anand Niketan, New Delhi. M/s. Bhiranga Electricals, (Bldg. Materials division), C-4/14, Model Town, Delhi-110009. M/s. Navrang Marble House, G.B. Road, Ajmere Gate, Delhi. M/s. Sood & Co., Timber Merchant, Lal Kuan, Delhi-110006. M/s. Shree Pal Vakil Chand Jain, 96, Sadar Timber Market, Delhi-110006.

5.

6. 7.

8.

New techniques for cost reduction in roofing/flooring-Pre-cast roofing/flooring techniques. The adoption of pre-cast concrete roofing/flooring system results in appreciable saving in the consumption of cement and steel and cost of construction as compared to conventional R.C.C. in situ slabs and increased speed of construction is also attained. This is made possible by the elimination of time consuming centring and shuttering which is necessary in the case of situ RCC slabs, where as the pre-cast components are hoisted and placed on the wall to build up the roof/floor. The pre-cast roofing/flooring system have been developed and their advantages are given below:1. Pre-cast channel units: These are pre-cast RCC units of trough shape. The units are nearly 30 cm to 80 cm wide and their length varies from 3 m to 4 m. The main advantages of this system of roofing/flooring are:(i) (ii) Upto 20% saving in the consumption of steel. 25% to 30% saving in the consumption of cement.

Pre-cast RCC channel units have been adopted by M.E.S., Utta Pradesh, P.W.D., Rajasthan Housing BOARD, S.E.R.C., CHRI/Roorkee, Calcutta Metropolitan Planning Organization, Madras Port Trust, Hindustan Housing Factory, New Delhi, etc. 2. Pre-cast cored units : these are pre-cast RCC structural elements having two or more circular hollow cores throughout their length with widths from 30 cm to 90 cm and length from 3 m to 4 m. Adoption of pre-cast R.C. Cored units has the following advantages: (i) (ii) (iii) Upto 20% saving in the consumption of cement. 5% to 10% saving in the cost of roofing. Good thermal and sound insulation.

This system has been used in building projects of M.E.S., Delhi Development Authority, L.I.C. of India, Bombay Municipal Corporation, I.S.I./New Delhi, Hindustan Housing Factory, New Delhi, Rajasthan Housing Board, CHRI/Roorkee, etc. 3. Pre-cast cellular units: This system of roofing consist of hollow cement concrete un-reinforced units which are supported on full or partially pre-cast R.C.C., beams and covered with deck concrete when the supporting beams are partially pre-cast. The advantages of this system are: (i) (ii) (iii) 15% to 30% saving in the consumption of steel. 20% saving in the consumption of cement. 10% to 15 % saving in the cost of roofing.

N.E.S. Himachal Pradesh P.W.D. Maharastra Housing Board, CBRI/Roorkee, Rajasthan and Hariana Housing Board, Amritsar improvement Trusts are some of the construction agencies/departments that have used cellular unit roof/floor. 4. Pre-cast battens and hollow blocks: This system of roofing consist of concrete hollow blocks supported on inverted T battons and finished with topping concrete. The main advantages of this type of roofing/flooring construction are: (i) (ii) (iii) (iv) Upto 50% saving in the consumption of steel. 10% to 15% saving in the consumption of cement. Upto 10% saving in the cost of roofing. Good thermal comfort and sound insulation.

Pre-cast batton and hollow block construction has been adopted by the Delhi Municipal Corporation and Bombay Port Trust. 5. Pre-cast RCC T beamed units: This system of roofing consist of T-Beamed units placed directly on the walls. A modification of the Tbeamed roof system is the hollow T-beamed roof wherein pre-cast

concrete tiles are used along with T beam to give a flush ceiling and more thermal comfort. The main advantages of this type of roofing system are:(i) (ii) Upto 20% saving in the consumption of cement. Upto 15% saving in the cost of roofing.

6. Doubly curved concrete tiles: This system of roofing is based on the use of roofing units comprising of pre-cast 70 cm square doubly curved tiles resting on partially pre-cast cement concrete beams or even on u/s rails. Those are used in place of solid RCC slabs. These are either of square or of rectangular shape. These lines are pre-cast with concrete grade M-150 using stone chips of size 10 mm and below collected from quarry dust. The size of the tiles is approximately 70 cm X 2.5 cm (thick). No reinforcement steel is used, which is the main saving in this type of roof. Another advantage is that the use of shuttering is totally eliminated. The size of the tile can be decided depending on feasibility of easy handling. Where unserviceable N.G. rails are available these are used as purlins. The doubly curved tiles are placed over N.G. rail purlins resting on supporting walls. These can also be used along with precast R.C. joints of rectangular section or of inverted T section or with timber section. The tiles are placed with their edges bearing on the foot of the rails on either side of the web to get a better view from the inside of the roofs. The rise of the tiles could be between 1/10 to 1/15 of the length of tile. The ordinates at different points can be calculated using the following formula:-

Z max. Z= --------------- (a2 x2) (b2 - y2) a2 b2 Where Z = vertical ordinate at nay required point x,y. Z max = maximum central rise. a=1/2 the length of the tile. b=1/2 the width of the tile.

x,y = co-ordinates of grid point from the origin which is taken as the centre of the shell.

It has been estimated that 1 Mason and 2 helpers can about 8 tiles a day. The N.G. rails are clamped down and fixed at their two ends into masonry and no fixing arrangement of these rails to the RSJs is required (in case RSJs are used in the roofing) as the doubly curved tiles are themselves acting as spacers and keeping the rails in position. The advantages achieved adoption this system are: (i) Upto 15% saving in the consumption of steel. (ii) Upto 25% saving in the consumption of cement. (iii) Upto 20% saving in the cost of roofing. Doubly curved tiled roof system has been adopted by the Madhya Pradesh P.W.D., Maharastra Housing Board, Uttar Pradesh P.W.D. CBRI/Roorkee, etc. To start with on this Railway we may adopted the technique of pre-cast channel units and doubly curved concrete tie units for roofing/flooring systems in single storied quarters till sufficient experience is gained in such techniques.