Proper storage, stacking, and handling of construction materials is crucial to prevent deterioration and the intrusion of foreign matter, and to maintain their quality and suitability for use in the construction process. It is important to segregate materials based on their type, size, and length, and to stack them in a neat and orderly manner to avoid any accidents caused by falling materials.
When stacking materials to a considerable height, it is necessary to ensure that they are stacked at suitable intervals to avoid any undue stresses on walls or other structures. Additionally, a passageway of at least one meter in width should be left between the piles or stacks for inspection or removal purposes.
It is also essential to stack construction materials on a well-drained, firm and unyielding surface to prevent any damage caused by moisture or instability. Care should be taken to ensure that the materials are not stacked in a way that could impose any undue stresses on walls or other structures.
In this article, we have outlined the specifications for the proper storage, stacking, and handling of major construction materials at the construction site. By adhering to these guidelines, we can ensure the safe and efficient use of materials and prevent any accidents or damage that may occur during the construction process.
1. Cement
A. Storing and Stacking of Cement
The proper storage of cement is critical to ensure its quality and usability. To achieve this, the cement must be kept in a building or shed that is dry, moisture-proof, and leak-proof. The structure used for storage should have a minimal number of windows and close-fitting doors that should be kept closed as far as possible. This will prevent moisture from getting in and damaging the cement.
When cement is received in bags, it is essential to keep the bags free from dampness or moisture. Therefore, the bags should be stored off the floor on wooden planks. A clearance of 150 to 200 mm from the ground must be provided, and a space of at least 450mm should be left between the exterior walls and the stacks. Stacking the bags close to each other will reduce the circulation of air, preventing moisture from entering.
To prevent lumping of cement under pressure, the height of the stacks should not exceed more than 15 bags. Additionally, the width of the stack should not exceed four-bag length or three meters. For stacks that are higher than eight bags, the cement bags must be arranged alternately lengthwise and crosswise to tie the stacks together and minimize the danger of toppling over.
During monsoon or when storing cement for an extended period, extra safety measures are necessary. The stack should be completely enclosed by a waterproofing membrane such as polyethylene, which should close on top of the stack. This will prevent moisture from entering the stack, ensuring that the cement remains usable.
Finally, it is important to note that drums or other heavy containers of cement should not be stacked more than two layers high. This will prevent the containers from toppling over and causing injury or damage.
B. Handling of Cement
It is prohibited to use hooks for the handling of cement bags. Workmen who handle bulk cement must wear protective clothing, respirators, and goggles to prevent dermatitis. Additionally, workers must be provided with hand cream, petroleum jelly, or a similar preparation to protect exposed skin.
If a workman needs to enter a silo or bin for cleaning or other purposes, the ejection system installed must be shut down and locked out. In such cases, the workman entering the storage area must wear a lifeline, and another workman must attend the rope from outside the silo or hopper. This is to ensure the safety of the workman and to prevent any accidents from occurring.
2. Masonry Units- Bricks
A. Storing and Stacking of Bricks
The recommended method for handling bricks at a construction site is to avoid dumping them and instead stack them on dry and stable ground in a neat and orderly manner. This helps to minimize the risk of damage and defacement to the bricks during unloading. To facilitate easy inspection and counting, the stacks should consist of 50 bricks placed on edge and 10 bricks high. It is also preferable that the width of each stack be two bricks. The distance between adjacent stacks should be at least 0.8 meters to allow for adequate space and proper ventilation.
In the case of bricks made from clays containing lime Kankar, it is important to soak them in water (docked) to prevent lime bursting. This soaking process helps to prevent damage to the bricks and ensure their structural integrity.
For storing concrete blocks, stone blocks, and other similar materials, it is important to stack them in a way that does not cause damage to the blocks in the lower layers. Additionally, there should be no fear of the stack toppling over. It is recommended that the height of the stack be carefully considered to prevent damage and ensure stability.
B. Handling of Bricks
When it comes to loading or unloading bricks, there is a specific recommendation that should be followed. It is suggested that bricks should only be loaded or unloaded in pairs, unless they are palletized. This means that bricks should be handled in sets of two, as a standard practice. The reason behind this suggestion is to ensure safety during the process of loading and unloading bricks. By handling bricks in pairs, it becomes easier to maintain balance and stability while transporting them. This reduces the risk of bricks falling or causing damage to equipment or personnel. However, if bricks are palletized, then they can be handled as a unit, as the pallet provides the necessary stability and balance. In such cases, handling them in pairs is not necessary. Overall, the recommendation to handle bricks in pairs when they are not palletized is a safety measure that should be followed to avoid accidents and maintain a safe work environment.
3. Aggregate
A. Storing and Stacking of Aggregates
In order to ensure the quality of construction materials, it is important to store aggregates properly at the construction site. Aggregates, both fine and coarse, should be stored on a hard, dry, and level platform. If such a platform is not available, alternative options such as planks, old corrugated iron sheets, a floor of bricks, or a thin layer of lean concrete can be used to prevent contamination of the material by clay, dust, or other foreign matter.
To prevent the intermixing of fine and coarse aggregates, they should be stored in separate stockpiles. These stockpiles should be sufficiently removed from each other or separated by dividing walls. By doing so, it is possible to maintain the integrity of each type of aggregate and ensure that they are used in the proper ratio during construction.
It is also important to take into account the effect of wind on fine aggregates. To minimize the loss of fine aggregates due to wind, they should be stacked in a location where the effect of wind is minimal. By taking these precautions, it is possible to ensure that the aggregates used in construction are of high quality and will contribute to the strength and durability of the final structure.
B. Handling of Aggregates
When withdrawing cement bags from stockpiles, it is not allowed to have any overhang. This means that the bags should not extend beyond the edge of the stockpile, which could pose a risk to workers and equipment.
For employees who need to enter hoppers, it is necessary to take appropriate safety measures. They must wear safety belts and lifelines, and they must be accompanied by another person who can help in case of an emergency.
To ensure the safety of workers who need to enter machine-driven hoppers, feeders, and loaders, it is essential to follow proper lock-out/tag-out procedures. This means that the equipment should be locked in the off position before anyone enters, to prevent accidental startup and potential injury. Taking these precautions can help to prevent accidents and ensure a safe working environment for everyone.
4. Steel
A. Storing and Stacking of Steel
To prevent corrosion and distortion, it is necessary to store steel reinforcement properly. Coating the reinforcement with a layer of cement wash before stacking is recommended to prevent scaling and rusting. It is also important to store bars of different classifications, sizes, and lengths separately. This makes it easier to issue the required sizes and lengths, minimizing wastage from cutting standard lengths.
In case of long-term storage or in coastal areas, it is essential to stack the reinforcement bars at least 15 cm above ground level. Additionally, a layer of cement wash should be applied to prevent rusting and scaling.
When it comes to structural steel, it should be stored separately based on different sections, sizes, and lengths. Furthermore, it should be stored above floor level, at least 150mm upon platforms or any other suitable supports, to avoid distortion of sections.
To make identification easier, the ends of the bars should be painted with separate nominated colors for different diameters of the rebar. By following these guidelines, the steel reinforcement can be stored properly and will remain in good condition for use in construction projects.
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B. Handling of Steel
When a crane is being used to handle reinforcements or structural steel, tag lines should be used to control the load. It is not safe for workmen to carry heavy steel bundles on their shoulders, so slings and tackles should be used to lift and carry the load instead. This will help ensure the safety of everyone involved in the operation.
5. PVC Pipes
A. Storage and Stacking of PVC Pipes
Proper storage is important for pipes to ensure that they are not damaged or distorted before use. To achieve this, it is recommended that the pipes be placed on a flat surface that is free from stones and other sharp objects. This will provide adequate support to the entire length of the pipe.
When storing pipes, they should not be stacked in large piles, especially in warm temperatures. Doing so can cause distortion in the bottom pipes, which can lead to difficulties when it comes time to joint them. Therefore, it is best to avoid stacking them too high.
For pipes with sockets and spigots, they should be stacked in layers with the sockets placed at alternate ends of the stacks. This will help to prevent lopsided stacks that can cause instability and increase the likelihood of damage.
It is not recommended to store pipes inside one another, as this can also cause damage or distortion. Additionally, pipes should not be stored in a stressed or bent condition, nor should they be kept near a source of heat.
Finally, when storing pipes in tropical conditions, it is important to keep them in the shade to prevent damage or distortion due to excessive heat exposure. By following these guidelines, pipes can be stored safely and securely, ready for use when needed.
B. Handling of PVC Pipes
During wintry weather conditions, it is crucial to exercise extreme caution when handling pipes as they can become brittle in very cold temperatures. This brittleness can lead to the pipes cracking or even breaking, causing significant damage and costly repairs.
Therefore, it is essential to ensure that pipes are adequately insulated to prevent them from getting too cold and becoming brittle. Proper insulation can help maintain the temperature of the pipes and prevent any cracks or breaks due to extreme cold.
Furthermore, it is advisable to avoid any sudden movements or impacts on pipes during freezing conditions, as this can also cause them to become brittle and crack. Instead, pipes should be handled gently and carefully to minimize any damage that may occur.
In summary, wintry weather conditions can be detrimental to pipes, causing them to become brittle and prone to cracking or breaking. As such, it is vital to handle them with care, ensure proper insulation, and avoid any sudden movements or impacts that could lead to damage.
6. Paints, Varnishes, and Thinners
A. Storage and Stacking of Paints
Proper storage and handling of paints, varnishes, lacquers, thinners, and other flammable materials are crucial for safety in any workplace. To ensure the safety of employees and the workplace, these materials must be kept in properly sealed or closed containers. These containers should be kept in a well-ventilated location that is free from excessive heat, smoke, sparks, or flame.
To further enhance safety, the floor of the paint store must be made up of 10 cm thick loose sand. This type of flooring helps to absorb any spills or leaks that may occur, preventing them from spreading and reducing the risk of fires.
It is also important to keep only the necessary quantity of paint materials for daily use in the work area. Any excess quantities should be stored in a regular storage place. This ensures that the paint store remains clutter-free and minimizes the risk of accidents.
Finally, it is important to be mindful of the electrical equipment used in the paint store. Temporary electrical wiring/fittings are not permitted in the paint store. If electric lights, switches, or electrical equipment are necessary, they must be of explosion-proof design. This will prevent electrical equipment from igniting any flammable vapors that may be present in the paint store.
B. Handling of Paints
Adequate ventilation must be provided in all areas where painting is carried out to prevent the accumulation of flammable vapors. In confined spaces where flammable or explosive vapors may develop, any necessary heat should be provided through ductwork that is remote from the source of flame.
It is not permissible to have sources of ignition such as open flame and exposed heating elements in the areas or rooms where spray painting is being done. Additionally, smoking is also not allowed in these areas. This is to prevent the risk of fire and ensure the safety of workers.
To prepare for the possibility of fire, buckets containing sand and fire extinguisher (foam type) must be kept ready for use.
For the safety and protection of workers who handle lead-based paints, each worker must be issued with ½-liter milk per day for their personal consumption. This is to help mitigate the harmful effects of lead on the body.
7. Tiles
A. Storage and Stacking of Tiles
Tiles should be stacked on a well-treated and hard surface, in layers and different tiers. The arrangement should be such that the mold surface of one tile faces that of another. It is recommended that the height of the tile stack does not exceed 1m to ensure the stability of the stack.
To facilitate easy removal for use in work, tiles of different qualities, sizes, and thicknesses should be stacked separately. This will help to avoid confusion and ensure that the right tiles are used for each task.
When manufacturers supply tiles in wooden crates, it is important to store them as such. The crates should be opened one at a time, only when required for use. This helps to maintain the integrity of the tiles and ensures that they are not damaged during storage. Proper storage of tiles is crucial to their longevity and functionality.
B. Handling of Tiles
When removing tiles, it is important to begin with the top layer and work downwards. Handling the tiles in pairs is also necessary, and it is important not to throw them during the removal process. By following these guidelines, the task of removing tiles can be completed safely and effectively.
FAQs on Storage, Stacking, and Handling of Construction Materials.
What is the importance of proper storage, stacking of construction material?
It is necessary to ensure the preservation of the quality and fitness of construction materials for the work. Therefore, proper handling, storage, and stacking techniques must be implemented to prevent their deterioration and the intrusion of foreign matter.
The construction materials must be handled carefully to avoid damage and to maintain their original condition. They should be stored in a manner that prevents moisture, heat, and other environmental factors from affecting their quality. The stacking of materials should also be done in a way that minimizes the risk of collapse and damage to the materials.
To prevent the intrusion of foreign matter, the construction materials should be stored in a secure location where they are protected from dust, dirt, and other debris. It is also essential to ensure that the materials are not exposed to chemicals or other substances that may cause damage.
By implementing these measures, the quality and fitness of the construction materials can be preserved, ensuring that they are suitable for use in the work. This, in turn, will help to ensure that the construction project is completed successfully and that the resulting structure is safe and of high quality.
How to stack cement bags at site?
When stacking cement bags, it is important to keep them off the ground by using wooden planks. To ensure proper clearance, they should be kept 150 to 200 mm above the ground. Additionally, it is important to maintain a minimum space of 450mm between the exterior walls and the stacks.
To reduce air circulation, the cement bags should be stacked as closely as possible to each other. The height of the stack should not exceed 15 bags, while the width should not exceed four bags. Following these guidelines will help ensure that the cement bags are stored in a safe and efficient manner.
How to stack steel at site?
In order to prevent distortion of structural steel sections, sizes, and lengths, it is necessary to store them separately. They should be stored above floor level by at least 150mm, either on platforms or other suitable supports. This practice ensures that the steel sections remain in their original shape and do not deform due to pressure or uneven surfaces. Proper storage is essential to maintain the quality and integrity of the structural steel, ensuring it is in optimal condition for use in construction projects.