Concrete Construction Part 23

The miscellaneous expenses of the work comprised:

Watchman, tools, telephone, etc. $ 722.48 Shanties, furnishings, supplies, etc. 829.04 --------- Total. $1,551.52

To this has to be added $1,134.28, the cost of excavating the cofferdams. The total and unit costs of the different items of the concrete substructure work can now be summarized as follows:

Item. Total. Per cu. yd.

Machinery and supplies 1,594.86 $ .69 Cofferdams 3,672.49 1.60 Forms, etc 821.30 .36 Concrete materials 7,980.45 3.47 Mixing and placing concrete 3,490.87 1.53 Excavating cofferdams 1,134.28 .49 Miscellaneous 1,551.52 .67 ---------- ----- Total $20,245.74 $8.81

~COST OF PERMANENT WAY STRUCTURES KANSAS CITY OUTER BELT & ELECTRIC RY.~--The following cost of concrete work including retaining walls, abutments and box culverts, for the permanent way of the Kansas City Outer Belt & Electric Ry., is given by Mr. W. W. Colpitts. These figures are of particular interest, for the variation in prices of materials during the two-year period while work was in progress and as giving the average cost of the work on the whole line as well as for individual structures. The culverts were all box culverts with wing walls and the abutments were for girder bridges. Walls and abutments were of L section with triangular or trapezoidal counterforts at the back between base slab and coping. The form work was thus rather complex.

All work was reinforced concrete, and was done by contract under the following conditions: The work of preparing foundations, including excavation, pile driving, diversions of streams, etc., was done by the railroad company, which also bore one-half the cost of keeping foundations dry while forms were being built and concrete placed. The railroad company also furnished the reinforcing bars at the site of each opening. The concrete work was let at $9 per cu. yd., which figure covered all the labor and materials necessary to complete the work, other than the exceptions mentioned. The concrete proportions were 1-3-5. The cement used was Iola Portland and Atlas Portland. The sand was obtained from the bed of the Kansas River in Kansas City. The rock used was crushed limestone, pa.s.sing a 2-in. ring and freed from dust by screening. Corrugated reinforcing bars, having an elastic limit of from 50,000 to 60,000 lbs. per sq. in., manufactured by the Expanded Metal & Corrugated Bar Co. of St. Louis, Mo., were used exclusively. The concrete in the smaller structures was mixed by hand, in the larger by a No. 1 Smith mixer. In the first structures built 2-in. form lumber was used, with 2 by 6-in. studs placed 3 ft. on centers. This was abandoned later for 1-in. lumber with 2 by 6-in. studs, 12 ins. on centers, and was found to be more satisfactory in producing a better face. The structures were built in the period from April, 1905, to May, 1907.

The cost of materials and the wages paid labor were as follows:

Cement-- Per barrel at structure, April, 1905 $1.25 Per barrel at structure, April, 1907 1.92 Average cost per barrel at mill 1.42 Freight per barrel 0.21 Hauling 1 miles and storage 0.12 Average cost at structure 1.75 Average cost per cu. yd. concrete (1.1 bbls.) 1.93 Sand-- Per cu. yd. at structure, April, 1905 $0.625 Per cu. yd. at structure, April, 1907 0.75 Average cost per cu. yd., river bank 0.30 Freight per cu. yd 0.22 Hauling 1 miles 0.20 Average cost at structure 0.72 Average cost per cu. yd. concrete ( cu. yd.) 0.36 Stone-- Per cu. yd. at structure, April, 1905 $1.10 Per cu. yd. at structure, April, 1907 1.75 Average cost per cu. yd. at crusher 0.65 Hauling 4 miles 0.84 Average cost at structure 1.49 Average cost per cu. yd. concrete (0.9 cu. yd.) 1.34

Lumber--

Per M. ft. at structure, April, 1905 $15.00 Per M. ft. at structure, April, 1907 22.50 Average cost per M. at structure 19.00 Average cost per cu. yd. concrete 0.49

Labor-- Max. Min.

Common labor, cts. per hour 20 17 Carpenters, cts. per hour 40 30

With these prices and wages the average cost of concrete work for the whole line was:

Item. Per cu. yd.

Form building and removing $1.98 Mixing and placing concrete 0.74 Placing reinforcement 0.10 Wire, nails, water, etc. 0.20 1.1 bbls. cement at $1.75 1.93 cu. yd. sand at $0.72 0.36 0.9 cu. yd. stone at $1.49 1.34 Lumber for forms 0.49 ------ Total $7.14

The following are the costs of specific structures built at different times:

Example I.--Indian Creek Culvert. 1415 ft., 250 long, completed November, 1905:

Per cu. yd.

Cement $1.37 Sand .34 Stone 1.10 Labor 2.48 Lumber .76 Miscellaneous .18

Total $6.23

Example II.--Third Street Abutments and Retaining Wall. Completed November, 1906:

Per cu. yd.

Cement $1.78 Sand .35 Stone 1.35 Lumber .74 Labor 2.75 Miscellaneous .16 ----- Total $7.13

Example III.--Abutments, Overhead Crossing with Union Pacific and Rock Island. Completed May, 1907:

Per cu. yd.

Cement $1.92 Sand .32 Stone 1.74 Lumber .98 Labor 2.96 Miscellaneous .16 ----- Total $8.08

~COST OF PLATE GIRDER BRIDGE ABUTMENTS.~--The following record of the construction of 20 abutments for 10 four-track plate girder bridges over streets in Chicago, Ill., are given by Mr. W. A. Rogers. The work was done between May 1 and Oct. 1, 1898, in which time 8,400 cu. yds. of concrete were placed, all the work being done by company labor. The forms were made of 2-in. plank and 66-in. posts bolted together at the top and bottom with -in. rods. The lumber was used over and over again.

When the dressed plank became too poor for the face it was used for the back. The concrete was 1 Portland cement, 3 gravel and 4 to 4 limestone (crusher run up to 3-in. size). A mortar face 1 ins. thick was built up with the rest of the concrete. The concrete was made quite wet, and each man ramming averaged 18 cu. yds. a day rammed. The concrete was mixed by a machine of the Ransome type, operated by a 12-HP. portable gasoline engine. The load was very light for the engine, and 8 HP. would have been sufficient. The engine made 235 revolutions per minute, and the pulley wheels were proportioned so that the mixer made 12 revs, per minute. One gallon of gasoline was used per hour, and the mixing was carried on day and night so as not to give the concrete time to set. The time required for each batch was 2 to 3 mins., and about cu. yd. of concrete was delivered per batch. The average output was 70 cu. yds. per 10-hr, shift, with a crew of 28 men; but as high as 96 cu. yds. were mixed in 10 hrs. The concrete was far superior to hand mixed concrete.

The water for the concrete was measured in an upright tank and discharged by a pipe into the mixer. The sand and stone were delivered to the mixer in wheelbarrows, and the concrete was taken away in wheelbarrows. No derricks were used at all. Each wheelbarrow of concrete was raised by a rope pa.s.sing over a pulley at the top of a gallows frame, one horse and a driver serving for this raising. A small gasoline hoisting engine would have been more satisfactory than the horse which was worked to its full capacity. After the barrows were raised (12 ft.), they were wheeled to the abutment forms and dumped. The empty wheelbarrows were lowered by hand, by means of a rope pa.s.sing over a sheave and provided with a counterweight to check the descent of the barrow. The cost of the concrete (built by company labor) was as follows:

Per cu. yd.

Cement, gravel and stone delivered $3.28 Material in forms (used many time) .11 Carpenters building and taking down forms .34 Labor 1.18 ----- Total per cu. yd $4.91

The labor cost includes moving plant from one bridge to the next, building runways, gasoline for engine, oil for lights at night and unloading materials, as well as mixing, transporting and placing concrete. Wages were $1.75 per 10-hour day for laborers and $2.50 for carpenters.

~COST OF ABUTMENTS AND PIERS, LONESOME VALLEY VIADUCT.~--Mr. Gustave R.

Tuska gives the following on the concrete substructure of the Lonesome Valley Viaduct, near Knoxville, Tenn. There were two U-shaped abutments and 36 concrete piers made of a light limestone that deteriorates rapidly when used for masonry. Derricks were not needed as would have been the case with masonry piers, and colored labor at $1 for 11 hrs.

could be used. The piers were made 4 ft. square on top, from 5 to 16 ft.

high, and with a batter of 1 in. to the foot. The abutments average 26 ft. high, 26 ft. long on the face, with wing walls 27 ft. long; the wall at the bridge seat is 5 ft. thick, and the wing walls are 3 ft. wide on top. Batters are 1 in. to the foot.

The forms were made of 2-in. tongued and grooved plank, braced by posts of 210-in. plank placed 3 ft. c. to c. for the abutments, and at each corner for the piers. At the corners one side was dapped into the other, so as to prevent leakage of cement. The posts were braced by batter posts from the earth. For the piers a square frame was dropped over the forms and spiked to the posts. The abutment forms were built up as the concreting progressed. The north abutment forms were made in sections 6 ft. high, held by -in. bolts buried in the concrete. The lower sections were removed and used again on the upper part of the work, thus saving plank. The inside of forms was painted with a thin coat of crude black oil. The same form was used for several piers.

The concrete was 1-2-5, the barrel being the unit of measure, making about cu. yd. of concrete per batch. The mortar was mixed with hoes, but shovels were used to mix in the stone. By pa.s.sing the blade of a shovel between the form and the concrete, the stone was forced back and a smooth mortar face was secured. Rammers weighing 30 to 40 lbs. were used for tamping. Two days after the completion of a pier the forms were removed. The concrete was protected from the sun by twigs, and was watered twice a day for a week. It was found by actual measurement that 1 cu. yd. Of concrete (1-2-5), the ingredients being measured in barrels, consisted of 1 bbls. of Atlas cement, 10 cu. ft. of sand, and 26 cu. ft. of stone. The total amount of concrete was 926 cu. yds. of which two-thirds was in the two abutments. The work was done (in 1894) by contract, for $7 per cu. yd., cement costing $2.80 per bbl., sand 30 cts. per cu. yd., and wages $1 a day. A slight profit was made at this price. A gang of 15 men and a foreman would mix and lay about 40 cu.

yds. in 11 hrs. when not delayed by lack of materials. The cost of making the concrete, with wages at $1 a day, was:

Cts. per cu. yd.

1 man filling sand barrels and handling water 2.7 2 men filling rock barrels 5.4 4 men mixing sand and cement 10.6 4 men mixing stone and mortar 10.6 2 men wheeling concrete 5.3 1 man spreading concrete 2.7 1 man tamping 2.7 1 foreman 5.0 ---- Total labor 45.0

~COST OF HAND MIXING AND WHEELBARROW WORK FOR FOUR BRIDGE PIERS.~--The following figures of the cost of hand-mixed concrete for bridge piers and abutments are given by Mr. Fred R. Charles of Richmond, Ind. The figures cover three jobs. All concrete was mixed by hand and with one exception noted below was moved to place in wheelbarrows. The concrete was a 1-2-5 mixture. In this connection it is well to note that in one or two of the jobs where the proportion of the aggregate seems too small for the yardage of concrete the difference is accounted for by the fact that large stones were placed in the foundations, these stone being on the ground and costing nothing but the labor to throw them in.

_Job I._--The first job consisted of the construction of one abutment and six piers for a bridge over the Miami River at Fernald, O. The stone was procured on the site and crushed by a portable crusher run by a traction engine. The rough stone cost 10 cts. a cubic yard, and this, with the cost of handling, fuel and hire of engine and crusher, made the cost of crushed stone about $1 per cu. yd. Sand was obtained close to the work, but the cement had to be teamed 10 miles. Labor was paid $1.75 per day. The cost of materials and labor per cubic yard of concrete in place was as follows:

Item. Per cu. yd.

1.16 bbls. cement at $2.10 $1.58 Sand 0.35 Stone 0.75 Lumber 0.64 Tools, hardware, etc. 0.20 Labor (including 15 cts. per cu. yd. for pumping) 2.78 ----- Total materials and labor $6.30

_Job II._--The second job was the construction of two abutments containing 434 cu. yds. of concrete for a viaduct at Ernst Street, Cincinnati, O. The abutments were constructed at the street and the excavation was clay and shale. Labor received $1.75 per day. The cost of materials and labor per cubic yard of concrete in place was as follows:

Materials-- Per cu. yd.

376 bbls. cement at $1.70 $1.48 224 cu. yds. sand at $1.20 0.64 255 cu. yds. stone at $1.55 1.00 Lumber 0.40 Tools, hardware, etc. 0.06

Total materials $3.58

Labor-- Clearing and excavating $1.12 Mixing and placing concrete 1.13 Building forms, etc. 0.25 ----- Total labor $2.50 Total labor and materials $6.08

_Job III._--This job consisted in placing 570 cu. yds. of concrete in the pedestals for a viaduct at Quebec Avenue, Cincinnati, O. The pedestals were 5 ft. square on top and from 8 to 20 ft. high. The location of the work was very inconvenient for the delivery of materials, all materials having to be teamed or wheeled. Labor was paid $1.75 per day. The cost of labor and materials per cubic yard of concrete in place was as follows:

Item. Per cu. yd.

500 bbls. cement at $1.60 $1.40 239 cu. yds. sand at $1.25 0.53 560 cu. yds. stone at $1.88 1.84 Lumber 0.38 Tools, hardware, etc. 0.05 Labor 2.96 ----- Total labor and materials $7.16

_Job IV._--This job consisted in placing 2,111 cu. yds. of concrete in a railway viaduct at Cincinnati, O. For one pier 56 ft. high the concrete was raised to place by a derrick; for the remainder of the work it was wheeled or teamed to place. Labor was paid $1.75 per day. The cost of labor and materials per cubic yard of concrete in place was as follows:

Item. Per cu. yd.

1,908 bbls. cement at $1.60 $1.44 1,105 cu. yds. sand at $1.95 0.50 1,468 cu. yds. stone at $1.48 1.03 Lumber 0.54 Tools, hardware, etc. 0.25 Water 0.03 Labor 3.44 ----- Total labor and materials $7.23