CONSTRUCTION MANUAL

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CIVIL WORK MANUAL

BORAK REAL ESTATE (PVT.) LTD.

CIVIL WORKS MANUAL

OF
ENGINEERING DEPARTMENT

BORAK REAL ESTATE (PVT.) LTD

45, Unique Oval, Kemal Ataturk Avenue
Banani, Dhaka - 1213

PREPARED BY:

ENGR. A.H.K. MAMUN

GENERAL MANAGER (CONSTRUCTION)
BORAK REAL ESTATE (PVT.) LTD.

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Mobilization

Mobilization is made when PM (coordination) hands over corrected

and checked Architectural, Structural, Plumbing and Electrical
drawings as well as complete BOQ and Project Master Schedule to
the concerned project manager or project in-charge. Mobilization
work includes following points:

Fencing of the project.

Making a boundary gate with pocket system.

Establishing all utilities services i.e. water, electricity,

gas lines and sewerage.

Preparing two toilets, one for labourers and the other

one for the site staffs.

Preparing labour sheds, guard sheds and storage area.

Deploying security guards and site staffs at sites.

Arranging to bring all the equipments, tools, and

plants necessary for the jobs at site.

Bringing all the people who will carryout the jobs.

Arranging to bring material and establishing material

management system.

Establishing site administrative system.

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Bringing all the office equipments and stationeries.

Layout Setting
Layout setting consists of following works:
1.

Property line identification.

1.

Finding one reference line, assuming line AD along X

axis.

2.

From
CAD,
get
the
value
Y1,X1,Y2,X2,Y3,X3..Yn, Xn.

3.

One perpendicular line CM, on the said reference line,

is to be established physically at ground with the help
of these values getting from CAD.

of

X,

X4

X3
Y4
Y3

X2
Y2

X1
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4.

Determining level of the land with reference to

adjacent road crest, drain top or any other reference
point shown in the drawing. Fix required number of
level points along the four perimeter line of the land.

5.

Once line AD and line CM are established and required

level points are taken, grid lines along reference line
AD and grid lines along reference line CM will be fixed
with the help of these lines, points and distances are
taken from drawings in a way that all grid lines
intersect in the same horizontal plane.

6.

Providing a preliminary layout and checking whether

all set backs are possible to be maintained in
accordance with the layout drawing.

7.

Measuring the land by triangulation and check

whether land size is exactly the same as given in the
drawing and mentioned in the landowners deed.

8.

Each string as a grid line is laid along its both lines of

reference maintains uniform level and extended its
ends up to the wall or any permanent structure
around the perimeter of the land. Mark these points of
intersection of string and walls by permanents paint.

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9.

Check all the diagonals of the squares or rectangles

formed by the placement of the strings as grid lines as
mentioned above.

10.

Pegs are made permanent by casting concrete around

them and grid points are marked by drop of paint or
tip of permanent marker pen on them.

11.

Verification of all the grid lines and set backs as well

as the land area are done and found out whether any
adjustment is necessary.

12.

Prepare and submit the report to DGM (Engineering)

or VP (Engineering).

Piling

Purpose:
Piling is done where our foundation drawings shows they are
required
There are three kinds of pile:
1) Driven pile Wooden, RCC (pre-cast), and Steel
piles.
2) Bored pile - Cast in situ piles.
3) Sheet pile Wooden, Steel and RCC.
But usually for our works, we use bored pile using percusion method of
boring (Wash boring).
Scope:
Applies to foundation footings, pile caps and raft etc.
Description:
This work covers pile centering, boring, washing of bore holes,
rebar fabrication by welding, placement of rebar cage in the bored
hole and concreting the cage and bored hole.
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Equipments:
i. Pile rig (Tripod, winch machine, boring pipe, trime pipe,
cutting chisel of different diameter, bucket etc.
ii. Mud pump of 12 HP.
iii. Water pump of 2 HP.
iv.
Mixture machine.
v.
Welding machine.
vi.
Rod cutting and rebar spiral making instrument.
Materials:
i. Cement.
ii. Rebar.
iii. Coarse sand.
iv.
Medium coarse sand.
v.
Stone chips/ Shingles.
vi.
Welding rod
vii.
24 SWG wire.
viii.
Electricity.
ix. Water.
x. Level pipe.
xi. Admixture (for increasing slump).
Responsibility:
APE, SPE/PE, DPM/PM, Manager Q&C, Audit & Quality Inspection
Team.
Work Procedure:
1. Complete the layout as per architectural column layout plan.
2. Check the layout in accordance with structural column layout and
pile layout plans.

3. Complete the layout of piles under each column.

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4. Identifying the pile points permanently by inserting 10mm rebar of

one and half feet length in the each pile point and concreting the
same in a way that only the tip of the 10mm rebar remain visible.

5. Once the pile points are fixed in accordance with above, select a
suitable space for preparing mud tank of double chamber.
6. Mobilize all the pilling instruments and materials at site.

7. Prepare the rebar cages as per structural design of the pile.

8. Place the covering round blocks already cured and prepared.

9. Weld the spiral of 10mm dia alternatively.

10. Place the tripod of the rig on a pile ensuring precautionary
measures.
11. Start boring until 12-15 is bored.
12. Place MS caging of dia 2 higher then the pile dia.
13. Continue boring until required depth is reached (usually 2 feet
extra boring beyond the length of pile cage).
14. Wash the bored hole using clearer water of the mud chamber.
15. Take out all the drilling pipes including chisel from the bored
hole.
16. Continue washing until the same water without lump of clay stops
coming. At least 30 minutes is required for washing.
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17. place rebar cage in the pile hole in a way that the tip of the rebar
remains at least 1-6 from the bottom of the hole while top of the
rebar cage will remains above the cut-off level.
18. Place tremie pipe and bucket in the pile hole.
19. Prepare concrete in the way described in the general notes of
structural drawing.
20. Place the concrete in the pile hole through tremie pipe.
21. Start compacting the concrete of the pile by making up and down
motion of tremie pipe with the help of winch machine after placing at
least two batch of concrete.
22. Complete the casting of each pile in the way described above.
23. Take precaution so that two successive piles under a pile cap are
not cast in a day.

Inspection:
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Make following check during casting:

a.) One batch of concrete (Mixture machine capacity one
bag) covers vertical length H of a pile of dia D,
H= 8.75
* 4/3.14*D*D.
Therefore ones two batches of concrete covers 2H distance
vertically of a pile.
b.) Ups and down movement of trime pipe must be less
than a vertical distance of H, so that muds surrounding
the pile can not enter into the concrete.
c.) A pile having length L, starting from cut-off level to
bottom of the pile plus 1 extra) will cover complete
volume of concrete
(3.14*D*D)*(L+2.5)/4.
d.) After completion of boring of each pile take the
measurement of the pile whether actual length is bored or
not.
e.) Colour the pile number whose concreting is done in
the pile plan.
f.) Take concrete cylinders as prescribed by departmental
management.

Earth Excavation
Purpose:
Excavation of earth upto required level is done for all kinds of
foundations of a building.
Scope:
Applies for all sorts of footings, pile caps, raft and basements of a
building.
Materials:
ii. Excavating plants and tools.
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iii.
iv.

v.
vi.
vii.
viii.
ix.

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Mud pump/ Water pump (Diesel and electric both) with

drainage pipe.
Shore protection materials ( shall bolli, steel beams, joists,
channels, drum sheet, plain sheet, bamboo, G.I wire, nail,
rope etc.
Welding machine with electrode.
Drill machine with different drill bit.
Grinding machine.
Polythene, tarpaulin.
Shovel, crowbar, spade and pickaxe, earth carrying busket.

Responsibility:
APE, SPE/PE, PM/DPM, Manager Q&C, Audit & Quality Inspection
Team.
Description:

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Complete excavation upto required level of foundation.

Once excavation is complete, check the soil whether it
is loose or strong by pocking a rebar of 16mm dia upto
one feet into the ground.
If a man can take out the 16mm bar easily pocked into
the soil in the way described above, the soil is said to
be loose. But if the man can not take out the 16mm
rebar from the soil, the soil is strong and compacted.
Observe the cut marks of the space during the
excavation to examine the soil whether it is compacted
enough or not.
Ask the labours who are excavating soil by hand how
is their feel about soil.
Show the soil to the foundation designer or the team of
our departments responsible for this works.
Once you are sure proper strength of soil, take
preparation for sliding concrete or brick flat soling.
Check whether water is coming out from underlying
soil or from the side of the cut.

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If the soil is loose or if enough seepage water coming

into the foundation hole continuously, there is
possibility of sliding of the shore.

Inspection:
Take proper shore protection arrangement by consulting with
your seniors.

BRICK FLAT SOLING

Purpose:
To make the concrete bed smooth. This work is lying of Bricks on
top of the earth or sand bed.
Scope:
Applied to foundation and Ground level floor.
Materials:
1st class solid Bricks, fine sand.
Responsibility:
APE, SPE/PE, DPM/PM, Manager Q & C, Audit & Quality
Inspection Team.
Description:
Compact the surface by hand rammer and sprinkling water.
Level the surface.
Lay the Bricks flat in surface contact with each other with frog
marks upwards.
Keep Brick joints in the subsequent row of Bricks in English Bond
pattern so that joints not be in the same line.
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Use broken Bricks. If any, at the edge of the area.

Fill small gaps or joints between the Bricks with fine sand (FM=
minimum 0.5).
Do not use water for flushing in of sand to the gaps.

Inspection:
Check the finish surface is leveled both longitudinally and
transversely.

BLINDING CONCRETE
Purpose:
To provide rigid impervious bed to RCC in foundation where the
earth is soft.
Scope:
Applies to foundation and Ground level floor work.
Materials:
Cement, 25mm down graded brick chips, Local sand (FM -1.2 to
1.5) and potable water (normally municipal supply water).
Responsibility:
APE, SPE/PE, DPM/PM, Manager Q & C, Audit & Quality
Inspection Team.
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Description:
Proportioning:
Mix cement, sand and brick chips in the ratio of 1:3:6 by
volume in foundation, basement and 1:2:4 in car park area.
Mixing:
Machine mixing:
Screen excessive dust from aggregate. Maximum
allowable dust is 3% by volume.
Measure the aggregates and sands as per proportion
by can equivalent to a sack of cement.
Dump the measured quantity of materials as per
proportion specified in the drawing in the drum of
mixer machine and thoroughly mix with required
quantity of water for period of not less than 2 minutes
after all material including the water are in the drum.
Control water quantity by measuring slump. Slump
not to exceed 50mm. One responsible person must be
in mixture machine point to control the quality of the
mix and ensure slump.
Hand mixing:
Mix the materials on a clean solid watertight masonry
platform.
Spread the measures quantity of sand evenly on
platform
Dump and distribute the cement evenly on sand.
Mix sand cement thoroughly until the mixture is of
even color.
Spread the measured quantity of brick chips in
another place of platform.
Spread sand cement mix on brick chips.
Thoroughly mix the above at least 3 times.
Add water gradually and turn the materials as above
till the each aggregate becomes coated with sand
cement mortar and becomes plastic to give a uniform
platform.
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Placing & Compaction:

Clean the area from dust or of foreign materials.
Take level pillars of fresh concrete in the area at
suitable intervals but more than 2mm C/c both ways.
Lay the concrete gently (not thrown) from one side. Use
the concrete mix within 45 minutes after the water is
added.
Use wooden rammer for compaction.
Roughen the surface for joining future work before
concrete becomes hardened.
Curing:
After 24 hours of laying of concrete moist the blinding concrete
surface by flooding the water or by covering with moist gunny bags
at least for 7 days.
Inspection & Testing:
Inspection the thickness level before casting by putting
steel pegs in the area of putting concrete level pillar at
intermediate distance of 1200mm c/c maximum.
Check random the finish level by thread fixing with
nails in form work.
Record quantity measure of material.
Record pre-inspection for level concrete.
Record blinding concrete pouring.
Basement Leakage:

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At least 6 thick sand filling to be under the cc casting.

Sand should be properly compacted.
Two layer polythene to be used over compacted sand.
2 thick C.C casting to be done over compacted sand.
Make C.C completely dry and then use liquid felt made
of Hydro Seal over C.C and over brief retaining wall.
Then allow in drying and making 1 C.C.

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The retaining wall should be 10 thick at least one

third of retaining wall flashed inside. The rest will be
5 brick wall. Outside of retaining wall should be
plastered with the proportion of 1:4.
RCC casting in floor to be 12 thick with two layers of
reinforcement. In case of any joint, water stopper may
be used.
Thickness of retaining wall of one third height from the
floor to be 2 more than the thickness shown in the
working drawing. Also the outside brick wall will be
10 thick up to one third heights from floor level and
the rest will be 5 thick.
Haunch with wall portion to be casted first then floor
to be casted.
Back filling will be done with earth laid in 12 layers
and well compacted by rammer.
During casting surrounding water table should be
below the basement level.

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FORM WORK
Purpose:
Form work is used to confine the concrete, mould and shape it to
the required lines and dimension as shown in the drawings.
Scope:
Applies to RCC work.
Description:
It includes all temporary or permanent forms or mould required for
forming the concrete together with all temporary construction
required for their support.
Responsibility:
APE, SPE/PE, DPM/PM, Manager Q & C, Audit & Quality
Inspection Team.
Material Requirement:
i.
Mango wood plank of various sizes.
ii.
Steel shutter.
iii.
MS plain sheet.
iv.
Steel metal lining Props.
Construction Methods:
i.
Use all column forms made of 16 SWG steel sheets with
holes for fixing & tightening. Height of form should not
exceed 2m.
ii.

Use wooden form for footing, beam and slab periphery made
of mango wood planks with minimum thickness of 25 mm
and include necessary battens, struts, runner & ties etc. Do
not use warp wood for shutter.

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iii.

Use steel shutter for beam where directed, made of 16 SWG

steel sheets with necessary holes & clamps and strong MS
Angle Frame.

iv.

Use 18 SWG sheet with 50mm over-lapping with each other

where necessary over wooden planks of size 125mm in width
& 25mm in depth minimum for slab form. Clear gap between
each plank should not exceed 150mm.

v.

Use thin metal 32 SWG sheet lining in between the joints of

wooden form & properly nailing it to make form watertight.

vi.

Clean the steel forms with steel scraper or steel brush to

make it free of rust, mortar and other foreign material.
Apply oil to the form either mobil or thin tar to avoid sticking
of the concrete with form without excess form oil.

vii.

viii.

Tighten the column with nuts & bolts at every holes and
with T-bolts.

ix.

Check the vertical alignment both transverse and

longitudinal & after proper vertically fixing steel shutter with
turn bolt and tie bolt. Then again check vertical alignment by
adjusting turn bolts.

x.

xi.

Level the form of slab with water level in all direction.

Fix the end of sheet with wood by nails.

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xii.

Check there is any gap /holes in the form & close with paper
or with thin metal that not to permit leakage of cement
grout.

xiii.

Use camber in beam and slab 4mm per meter to counteract

the effects of deflection.

xiv.

Use props @ 600mm C/C for slab.

xv.

Tight the props at both ends, no loose props should be used.

xvi.

Use horizontal bracing at 1200mm level for height more than

3 meter.

xvii.

In addition to turn bolt & T bolt fixing in the column

shutter use bamboo/steel as strut in inclined.

xviii.

Before concreting check the props are intact and during

casting keep two carpenter/shuttering man for constant
watch on prop and take immediate remedial measure as
soon as any of props get loosened.
Removal of Form Work:

xix.
xx.

Remove the formwork as per time elapse after concreting:

Columns, walls, vertical members

: after 36 hours.

xxi.

Soffits of slabs and beams (upto 4.5m span) : after 14 days.

xxii.

Soffits of slabs and beams (above 4.5m span): after 21 days.

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xxiii.

Gradually and uniformly lower the props to avoid shock or

vibration and damage to concrete. Operation should go from
middle for slab bounded at all sides for cantilever from free
end.

xxiv.

First open the sides of beam, then gradually from middle

sides of slab and then underside of beam each as per
elapsed time period shown earlier.

xxv.
xxvi.

Through clean all shutters after stripping for reuse.

Pull from wood all nails. Do not allow nail bending by
hammering against the face of wooden from board.

Inspection & Test:

xxvii.

Reject woods having knots, warping, splits, check thickness.

xxviii.

Check the thin metal sheet lining in the joints of wooden

from board.

xxix.
xxx.

Check the forms are cleaned & oiled.

Check the vertical alignment of column, proper, tie &
bracing.

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Check the horizontal & vertical level & alignment of beam &
slab.
Detect the leaks & close.

xxxiii.

Check the tightness & spacing of props.

xxxiv.

Record as per Formwork Inspection Format.

Reinforced Cement Concrete

Purpose:
For use in all RCC work to increase its strength in bending and in
tension.
Scope:
Applies to RCC wall, column, floor, foundation and beams i.e. for
all structural concrete.
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Description:
This item consist of straightening, Cutting, Bending and placing
reinforcing steel of quality, size, shape and dimension shown on
the drawings or as specified herein.
Materials Required:
MS Deformed Reinforcing Bars of 40/60 grade.
Ordinary Portland Cement
Stone/Brick Chips (25 mm down graded)
Sylhet Sand (FM from 1.8 to 2.5)
Coarse Sand (FM from 1.2 to 1.5)
Lap Lengths:

Column

30D

Beam, Grade Beam, Slab

35D
(Where D is the Diameter of Rod)

Equipments:

Concrete mixture machine

Vibrator with nozzles (one 1" diameter and the other 2"
diameter)
Batching Box (15"x12"x12")
Slump Cone
Cylinder Mold
Water pumps
Weighing scale

Items to be checked before Concreting:

Form Work
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Forms are cleaned and oiled.

Horizontal and vertical level as well as alignment.
Spacing & size of planks and runner (plank spacing
maximum 7" c/c, runner spacing 2-0" c/c).
Peripheral forms are in same line & level.
Joints and leakages are properly closed.
Spacing of props is within 2'-0" to 2'-6" c/c.
Props are strong and properly tight.

Rebar
Rebar are rust free and straight
Size and spacing of rebars are as per drawing
All crossing points are tightly fixed with binding wire of 24 SWG
Extra tops are properly placed.
Clear coverings and spacer blocks/chairs are properly placed.
Concrete Mix Proportions:
Mix proportion which is normally mentioned in the drawing by the
Consultant must be maintained strictly (usually mixing ratios are 1:1:3
and 1:2:4).

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Construction Joints:
Construction joints in grade beam: beam or slab will not be left at the
support. It will be left at minimum shear point of grade beam, beam or
slab. Bar schedule will be prepared before fabrication of reinforcement.
No casting of any structural member can be done with aggregates mixed
with foreign materials. At the same time casting will not be allowed in
any place which is water logged.

L/3

L/3

L/3

Construction joints must be left within the black region, if

necessary.

Curing for RCC Works:

RCC curing will be started after 24 hours of casting for normal condition;
but if the weather is dry and hot, it may be started earlier. The columns,
walls and the footings will be wrapped by the hessian cloth and the
hessian cloth will always remain in wet condition by sprinkling water.
Slab top will be ponded with water until curing period is over. RCC
surface will be cured for at least 21 days after casting.

Materials Consumption :
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i) For 100 cft of RCC works (1:1:3), requirement is as follows:

Cement
22 bags
Sylhet sand
21 cft
Medium coarse sand
21 cft
Stone chips/ brick chips84 cft

ii) For 100 cft of RCC works (1:2:4), requirement is as follows:

Cement
18 bags
Sylhet sand
22 cft
Medium coarse sand
22 cft
Stone chips/ brick chips88 cft

iii) For 100 cft of RCC works (1:3:6),

Cement
Sylhet sand
Medium coarse sand
Brick chips

requirement is as follows:
12 bags
22 cft
22 cft
90 cft

Brickwork

Materials Required:
a) 1st class brick
b) Portland cement
c) Local coarse sand (FM 1.2 to 1.5)
Mortar (Cement Sand Mixture) Proportion:
a) For 250 mm or more thick brickwork, cement-sand mortar ratio is
1:6.
b) For 125 mm or less thick brickwork, cement-sand mortar ratio is
1:4.

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Work Procedure:
a) 1st class brick of good, sound, hard and well burnt with uniform
size, shape and colour and free from flaws and cracks are used.
b) Bricks should be fully submerged under clear water for at least
twelve hours and be used after one/two hours of taking out from
the submersion tank.
c) Keep mixing cement and sand in proper proportions and in
quantity under dry condition until the colour of the mixture is
uniform. Then add water gradually to produce workable mixture.
Cement-sand mortar should be mixed in such quantity that can be
used within 45 minutes of mixing.
d) Clean and chip the surface properly where the brickwork will be
done. Clean all debrises, dust, loose materials and laitance from
concrete surface.
e) Lay the bricks on a full bed of mortar to ensure proper adhesion of
bricks with the bed of mortar. Use English Bond pattern with frog
mark upward.
f) Check the horizontal alignment by thread or spirit level and
verticality by plumb bob.
g) All horizontal layers should be parallel and all vertical joints in
alternate course and be one layer above another. Fill all vertical
joints fully with mortar from top.
h) Thickness of joints should not exceed 12 mm and check that all
joints are properly filled with mortar.
i) Top surface of brickwork which meets with the RCC surface like
beam/slab etc., the joints between the brickwork and RCC work

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should be filled tightly with fully pressed mortar to avoid cracks in

the junction point i.e. between brick wall and RCC surface.
j) Keep face joints racked to a depth of 10 mm in the green mortar to
provide key for subsequent cement sand plastering.
k) In a day, do not construct a height exceeding 1.25m or 4 ft for 125
mm thick wall and 1.5 m or 5 ft for 250 mm thick wall. Clean the
face of brickwork on the same day after the brick laying is
complete.
l) The brick wall should be cured properly for at least 10 days.
Curing of brickwork will be started normally after 24 hours of
brickwork.

Material Consumption:
1) For 100 cft of 10" brickwork (1:6), material requirement is as follows:
Brick

1150 Nos.

Cement

4 bags

Medium coarse sand

33 to 36 cft

2) For 100 sft of 5 Brickwork (1:4), material requirement is as follows:

Brick

480 Nos.

Cement

2 bags

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Medium coarse sand

11 to 14 cft
st
Test of bricks The test of 1 class bricks is performed in the field in
the following way:

If two bricks are stricken with each other, then the sound
will be metallic for 1st class bricks.
The shape & size of 1st class bricks are uniform.
When broken, the whole inner part should be uniform in
colour with minimum pores.

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Plastering Work
Materials Required:
Ordinary Portland Cement
Local coarse sand (F.M from 1.2 to 1.5)
Work Procedure:

R.C.C. surface is properly chipped with pointed hammer in case

of plaster on RCC work.

Brush and scrap the surface to make it free from oil, greasy
spots, efflorescence and loose mortar (brick or RCC surfaces).

Wash the surface with clean water and keep the surface moist
before plastering.

For R.C.C. surface, proportion of mortar mix will be 1:4 and for
brick surface 1:6.

Sand is to be screened before use. Mix cement and sand in

specified proportion and in dry condition until mixture is
uniform. Water is to be added gradually till mixture is plastic.
All mixed mortar should be used within 45 minutes of mixing
with water. At least one responsible person should be present
during mixing of mortar.

Apply cement grouting on R.C.C. surface.

Make 3" x 3" level (paya) of plaster @ 6'-0" to 7'-0" c/c as

reference level.

For masonry surface, maximum thickness of plaster will be "

(average) and for R.C.C. surface (average). For thickness
more than 1", plaster is to be done in 2 layers. After the 1 st coat,

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the surface is to be kept rough and then 2 nd coat is to be applied

after minimum 8 hours of the 1st coat.

No dry mortar shall be applied/used on the prepared surface

during plastering.

Check the level of the plastered surface with Aluminium

Straight Edge (Patta), thread and with spirit level. For defective
plaster, correct immediately till the mortar is in green condition.

Groove in plaster around doorframe should be 6 mm wide and 8

mm deep. The same is applicable for SDB box. Groove for drip
course will be 12 mm wide and 12 mm deep.

Cure the finished plastered surface with water after 24 hours

for continuous 14 days.

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Patent Stone
Scope:
Applies to bedding layer or base layer over existing concrete slab to
support floor finish surface like Mosaic, Terrazzo or Marble or neat
cement or granolithic floor finish.
Description:
This item consists of constructing 25 mm to 38 mm thick concrete
depending on floor levels prepared by pie chips, sand and cement mixed
with water to make workable concrete mix.
Material Requirement:

Pie Chips

- Brick chips of 12 mm downgraded size.

Sand

- Coarse Sand (FM 1.2 - 1.5)

Cement

- Ordinary Portland Cement

Water
Construction Method:
Thickness
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Provide 25 mm to 37 mm depending on the finished level and existing

floor level.
Proportion

Mix cement, sand & pie chips in the ratio of 1:2:4 by volume.
Measurement: Follow specification of concrete.
Mixing of Materials

Mix the material in presence of Site Engineer to control the ratio,

quantity of mix and follow specification of concrete.
Placing & Compaction

Clean the old surface of by wire brush to make it free from dirt,
laitance and all loose materials. Wash with clear water.
Apply cement slurry on the concrete bed before placing patent
stone on it.
Take levels by concrete @ 2m c/c.
Lay the concrete gently from one side and spread evenly.
Compact by straight edge and wooden floats.
Rough the surface by broom for adherence of the finish surface
over it.
Curing

Moist and cure the patent stone concrete for at least 7 continuous days
before laying any finish over it.
Check :

Mark the top level of surface finish. Mark patent stone top level
with this reference after deducting finish thickness.
Check and keep the level of patent stone uniform by filling or
removing patent stone concrete which is still green to keep the
surface finish thickness equal.
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Check by Aluminum Straight Edge or Spirit Level.

Tiles Work
Materials Required
Tiles (homogeneous or glazed)
Portland cement
Local coarse sand (F.M from 1.2 to 1.5)
Pigment
Work Procedure
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Clean and chip the surface properly where the tiles work will be
done. Clean all the debrises, dust, loose materials and laitance
from concrete or brick surface where tiles are to be laid.
Check the horizontal level properly for floor tiles work.
Vertical alignment will be checked and leveled before fixing of
wall tiles.
Pressure test in PPR pipes will be done before fixing of bathroom
tiles.
Confirm about laying of all conduits which would be concealed
underneath the tiles.
The mortar will be mixed in dry condition as per proportion
(1:3).
The tiles will be kept in submerged condition for 2 hours and
the soaking will be discontinued before 30 minutes of tile fixing.
Tap the tiles with wooden mallet for checking whether there is
any void space under the tiles.
The joints shall be uniform and their width shall not exceed 2
mm.
Skirting will be 4" high.
The tiles should be of proper size, shape and defect free.
Joints should be properly filled with mixture of white cement
and suitable pigments.
Sectional size of bathroom and kitchen doorframe shall be 6"
x 2" to avoid exposure of tiles over doorframe.
Strip of tiles are to be left at locations which will remain beyond
direct eye sight.

Wood Work
Purpose:

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Wood is used in door frames and shutters, decorative wooden works and
various wood related works.`
Scope:
Applies to door frames and shutters.

Description:
The work covers manufacturing and fixing of door frames and door
shutters made of wood including sizing, rebating, joining the
wooden planks to give required shape and dimensions of frames
and shutter as per opening size and fixing, finishing, polishing the
same in the position with necessary fixtures and fittings.
Responsibility:
APE, SPE/PE, SPM/PM, Manager Q & C, Audit & Quality
Inspection Team.
Material Requirement:

Teak Chamble Wood or equivalent for frames (internal).

Chittagong Teak Wood for main doorframes.

Veneered Doors for internal shutters.

PVC/Laminated/Solid wooden doors for bathroom shutters.

Hardware

Locks

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Paint/Polish

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Work Procedure:

Use wood which is free from sap, knot, cracks, large holes or
any other defect affecting appearance and strength.
Work on dry timbers.
Make each timber frame consisting two vertical jambs and one
head with 6'' x 2'' or 6'' x 2'' cross section.
Smoothen each member plank by planner till raised grains are
not visible.
Make 12 mm x 37 mm rectangular rebate in the members of
the frame by groove cutting machine. Rebate will be straight
and uniform.
Rub the members by sand paper to remove roughness and
ensure plainness before assembling them. Joints must be well
matched and tight, properly glued and secured with hardware
screws/nails.
The finished surface should be free from :

disfiguring effects

raised grain

stain

dents of chisel

uneven planning

uneven sanding

tool marks

scratches

uneven trimmings and gouges

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Paint the unexposed face of the doorframe in contact with

masonry or concrete surface with two coasts of tar paint before
fixing.

Fix the frames truly vertical, check the vertical alignment with
spirit level and with plumb bob.

Shutter:

Use wood which is free from sap knots, cracks, large holes
visual defects for door shutters. Each plank must be straight
without any warp on bow.

Follow all procedures for rubbing, smoothening etc. mentioned

above.

Use planner machine with fine abrasive paper for smooth

leveling of the shutter. No grain should be detectable by touch
with hand and planning should continue till a smooth, highly
level surface is attained.

Before varnishing/ polishing, properly clean surfaces to make

those free from dust, dirt adhesives and other foreign
substances. Lightly polish. No excess polish or polish work
should be visible. Excess oil must be removed to avoid sticky
surface as it catcher dust. Evenly spread polish.

Use lacquer polish (either yacht varnish of Elite or Original

Chaina lacquer) as final touch over three coats of polish/
varnish.

Fix locks and other fastening only before fixing various

sanitary and electrical fixtures.
Procedures for Pre-Fabricated Doors Shutters:

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Properly store the door shutters in a dry, well ventilated

damp proof area. Do not store in area in area prone to
alternated wetting and drying. Prefabricated shutters
when in touch with water may swell, disfigure and warp.

Do not stack more then 8-10 shutters one above another

and do not give inadequate under support that cause
bending effect to the shutter. Provide bottom support at a
spacing of 1'-6'' centre to centre.

Trim ends of the shutters at a time by ensuring exact size.

Many trimmings may damage the frame of the board
inside.

Paint Work
Purpose:
Paint is provided on masonry and concrete surface for protection
against corrosion, wear, decay and dirt accumulation. It is used to
produce smooth surface finish with aesthetic appeal.
Scope:
Applies to interior and exterior walls and ceilings.
Description :
This item consists of applying 2 or 3 coats of ready mix paint over a coat
of priming on brick or concrete plastered surface.
Material Requirement :
Sealer or Primer
Putty
Paint
Thinner

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Work Procedure:
Plastic Emulsion Paint:
Do not apply paint on the surface which has not been cured for at
least 14 days and which is not at least 45 days old. Use only for
interior surfaces of walls/ceilings.
Do not use paint on wet or damp surface.
Brush surfaces of walls/ceilings thoroughly with stiff brush/sand
paper to remove loose surface contaminations and particles.
Scrape off hard dirt and cement splashes.
Rectify defects with cement-sand mortar and cure the patch. Let it
completely dry.
Coverage area will be of 300 sft/4 liter can for 3 coats of paint.
For M.S surfaces- Use Red oxide primer/Red Lead primer/AlKarim Primer.
For Galvanized surfaces Use Zinc Chromed primer.
For Wooden surfaces Use Aluminium Wood Primer.
For concrete/plaster/masonry surfaces Use Elite Water Based
Sealer/ Berger Water Based Sealer.

Outside paint:
Use Super Aclose Master Coat or Berger Weathercoat or other
approved paint. Use 2 coats with primer or 3 coats without primer.
Follow procedure stated for Plastic Emulsion Paint. Use primer if 2
coats of paint are used or otherwise 3 coats. 1 coat of Snowcem
may also be used as primer.
Thoroughly stir the paint and thin with 15% clean tap water.
Use outside putty.
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Apply 1st coat with roller.

Apply 1 coat of white cement/snowcem/durocem/seacem allpurpose primer with roller. Thin the primer with required quantity
of water..
Stir the contents properly.
Apply sheet putty for smoothening and leveling the surface.
Plastic Paint

- 1 gallon.

Enamel Paint

- 1 litre

Chalk powder

- 25 Kg.

Zinc oxide

- 1 Kg.

Water

- as per requirement

Let the surface dry for 2-4 days.

Apply by roller 1st coat of plastic emulsion after 2 days of putty
work. Mix 15% water with plastic paint and stir the contents
thoroughly before use.
Apply touch putty where the surface is not level. Cure the putty for
2-4 days.
Apply 2nd coat of paint thinned with 15% of water by roller.
Apply finish coat by brush/roller softly with no stain or brush
mark. Finished paint must be smooth, lustrous, good opacity and
spotless.
Ensure ventilation in the room/space at least for 1 month during
& after the final coat is over.
Coverage Area will be @ 260 sft/4 liter can per 3 coats in case of
Berger Weather Coat.
Enamel Paint :
Follow method stated above.

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Apply first coat of enamel paint after 2-3 days of putty work. Thin
with
maximum
st
5% T-6 thinner. 1 coat should be dried for at least 24 hours. Cut
1st coat with water proof emery paper No. 320.
2nd and 3rd coat same as 1st coat.
Do not smoke or fire during paint.
Keep the paint in a cold & dry condition.
Keep the tin caps tightly closed after use.
Before synthetic enamel use in steel structure, check that the
scales or rust are properly scrubbed. Check the application of red
lead primer before application of paint.
Check the opacity and density of paint after 2 nd coat. The plastered
surface should be completely hidden.
Ensure continuous curing of Snowcem for at least 4 days.

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Putty Making for All Projects

Apply sheet putty (2 coats at a time both horizontally and vertically) for
smoothening and leveling the surface. Make putty as per following
proportion :
For Plaster Surface (Coverage Area : 1000 1100 sft)
a) Plastic Paint
b) Chalk Powder
c) Enamel Paint
d) Zinc Oxide
e) Water

:
:
:
:
:

1 gallon
25 kg
1 litre
kg
As per requirement

Apply touch putty where the surface is not level and undulated. Dry the
putty for 2-4 days.
For Wooden Surface (Coverage Area : 220 225 sft)
a) French Powder :
c) Chalk Powder :
d) Zinc Oxide
:
e) Al-Karim Primer :

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5 kg
kg
kg
3 litre

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Lime Terracing
Purpose:
To provide impervious course of waterproof and adequate thermal
insulation to roof surface.
Scope:
Applies to concrete roof.
Description:
This item consists of constructing a water proofing course of lime
concrete of ratio 2: 2: 7 (Lime: Surki: Khoa) on roof slab.
Material Requirement:

Lime

- Slaked Lime.

Surki
- Made from 1st class bricks crushed or grinded to
sizes below 2mm.

Brick clips- Made from 1st class Bricks crushed to sizes 20mm
down graded.

Working Procedure:
Use lime, surki and brick chips at a proportion of 2:2:7. Average
thickness of lime terracing will be 100 mm.
Soak the brick chips at least for 3 hours before mixing and allow
standing.
Mix lime & surki in the specified ratio on a clean platform in dry
condition until a uniform colour comes.
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Add previously wetted khoa in the specified quantity over limesurki mix.
Turn over the whole mix once without adding water and kneading
the mix minimum three times daily by gradually adding small
quantity of water to make uniform lime concrete. During last
mixing operation, molasses and tamarind is used with it along
with water.
Continue above step for successive 5 to 7 days.
After allowing 5 to 7 days, a ball is to be prepared with the mix and
thrown on wall surface; if the ball is remains adhered with the wall
then the mix is ready for spreading.
Spread the mixture in single layer on roof evenly with proper slope
towards gutter/rain water pipe (slope minimum 1 in 50) and 20
mm thicker than that of specified thickness for consolidation.
Consolidate the lime concrete thoroughly by hammering the
surface with wooden mallets weighing about 1 to 2 kg and hammer
thoroughly for continuous 5 to 7 days starting from the next day of
laying lime concrete on roof.
Stop compacting the LCC when no mark of mallet is noticed when
struck to flat bed of LCC. Finally check the compaction using one
of the following ways:
1) Betel Nut Check: A nut is to be penetrated on the prepared
LCC surface with wooden mallet, if it is not possible to
penetrate; the compaction of LCC is satisfactory.
2) Core Check: 2X2X2 core is to be made on prepared LCC
surface and fill up the core with water, if water is not soaked by
the surface, the compaction of LCC is satisfactory.
Frequently sprinkle lime water (lime slurry) during consolidation to
keep lime concrete wet.
Soften the surface by sprinkling pure water to render the mortar to
smooth finish. Finish the surface using lime cement slurry with
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the help of trowel. Do not use cement mortar for finishing the
surface.
Fill up the surface pore by lime putty prepared from lime and surki
(1:1)
Round the lime concrete at the junction of roof slab and parapet in
the shape of a haunch or fillet.
Rub the surface with brush and finish the surface with limecement grout (3:1).
Keep the surface continuously wet for at least 10 days.
Note: For reference enclosed sheet must be maintained and preserved.

Safety and Security

Purpose:
To provide adequate measures and precautions at site to prevent accident
or injury to person and damage or loss of property and work and ensure
good and safe working environment.
Scope:
Applies to safety and security provision during works especially slab
casting, centering and shuttering, peripheral brickwork, outside plaster,
any work at high level, work related to fire and electricity, in underground
works and in any other works related to safety and security not covered
on above items.
Description:
This item consists of providing safely net around building, hanging and
tying hessian cloths around building with proper post and bracing by GI
pipe/bamboo at certain intervals, keeping first aid measures for instant
intervention of the hazardous situation and any other measures to
prevent probable cause of accident.
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Responsibility:

Sr. PE/ PE, DPE, APE, PA/APA.

Material Requirement:
Bamboo.
Nylon Net.
Jute/Hessian Cloth.
GI Pipe/MS Pipe.
Fire Extinguisher.
First Aid Box.
Buckets.
Construction Method:
Safety Net at Working Level
Hang safety net 6 feet above casting level to 6' or 10' below casting
level before casting with adequate post and bracing as per drawing.
Put horizontal net extending outside 6' to 8' from building
periphery.
Put hessian cloth above net and hang around building periphery to
prevent falling objects in adjacent boundaries.
Tie hessian cloth and net vertically and horizontally so that the
cover may be strong and rigid and do not sag at any point or level.
Remove worn-out hessian cloth and retie the sagged one to give
good aesthetic look as well as safety.
Check the condition of the hanging hessian cloth twice a week and
maintain them properly.
Safe Stock Pilling of Shutter:
Store all shutters and scaffolding materials at least 8'-0" away from
building periphery.
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Do not keep shutter haphazardly. Store all shutter stockpiles at

one place.
Allow skilled person to remove scaffold at periphery. Ensure proper
safety before removal of peripheral props and centering so that no
worker may meet accident for the object falling in adjacent
properties.
Do not stock pile shutters at passage.
Good Working Environment:
Keep working place calm and quiet. Do not allow the workers to
shout and make noise at night disturbing the neighbors.
Do not allow worker to make every place urinal. Provide temporary
urinal at 2 alternate floors for workers use.
Keep temporary toilet neat and clean with proper enclosure.
Keep drains unclogged due to construction waste and clean those
from time to time.
Properly stock the construction materials to give a decent look to
site.
Remove the debris from the floors after every days work and keep
clean where no work is done.

Fire Protection
Do not allow worker to smoke here & there.
Do not allow workers to use open fire for plumbing works. Allow
only blowlamps for plumbing works and only in bath areas.
Cooking areas should be well enclosed and check that the
burner/oven is placed far away from hessian cloth or flammable
objects.
PREPARED BY:

ENGR. A.H.K. MAMUN

GENERAL MANAGER (CONSTRUCTION)
BORAK REAL ESTATE (PVT.) LTD.

CONSTRUCTION MANUAL
File Name:
UNIT:

CIVIL WORK MANUAL

BORAK REAL ESTATE (PVT.) LTD.

Version #: 1.0.0

Provide one fire extinguisher and two buckets, one filled with sand
the other empty for solely fire fighting during work progress.
Other Protection
Do not keep temporary electric wire lying on floor and in water.
Replace/rectify the damaged wire and conduit to avoid accident.
Transmit the wire using temporary poles to the working place and
through PVC conduits.
Use plug and do not put the wire directly in the outlet.
Keep first aid box with first aid medicine easily accessible.
Immediately rush victim if severely injured to nearby hospital.
Conduct a bimonthly training for all workers and staffs on safety
and security matters.

PREPARED BY:

ENGR. A.H.K. MAMUN

GENERAL MANAGER (CONSTRUCTION)
BORAK REAL ESTATE (PVT.) LTD.