Embed Size (px)
Citation preview
ASSIGNMENTNICMAR / CODE OFFICE
1. Name Rajesh Narayanan
2. Reg. No. …………………….
3. Course No. IDM 22
4. Course Title CONSTRUCTION QUALITY,
SAFETY AND ENVIRONMENT
1 | P a g e
QUALIT Y - It’s MEANING I N CI VIL WORK P ROJEC TS
Quality is a norm, sticking to which produces a good product which fulfills all
the requirements and standards. As such, civil work is a multi faced activity
and it requires very detailed and careful inspection of quality at every stage
of construction. A small point missed/ overlooked may result a disaster. It is
therefore necessary that all the engineers concerned with construction
industry should be aware of quality norms, substandard material,
malpractice as well as shoddy workmanship. There is an urgent need for
observance of quality in all aspects of construction viz quality of material,
quality of workmanship and a proper balance in
quality viz the quality desired with the increased competition, timely
completion and sound construction. The management has to have an
actual role in the process of quality construction whether it is a road, an
airport a multi stored residential, an office building or an industrial structure.
So quality management is highly needed.
Quality Management refers to all plans, process and activities that are
developed to achieve the intended degree of conformance in design and
execution of any project. The quality management system concept focuses
attention on the following aspects of the construction process:-
1. Construction is a one time activity.
2. Construction is becoming more & more competitive.
3. Quality in construction starts from designing process to completion.
2 | P a g e
4. Quality is experience, so it should be done with complete management.
5. Quality management is responsibility of project authority.
3 | P a g e
Quality management encompasses various project phases of planning
procurement construction & finished structure. It mobilizes technical
managerial organization all and manpower aspects of construction. The
result QMS matrix is
presented in the chart below:
Quality
Management
Planning Designing Procurement
Construction
FinishedFacility
Technical
Managerial
OrganizationalManpower
Quality Control Concept:
Quality control refers to the technical process that gather, examine, analysis
and report the project is in progress and in conformance with the
performance requirement. Quality control mainly relates to four basic
functions.
i. Setting up of standards and specifications.
ii. Evaluating materials processes and outputs through appropriate
tests, inspection etc.
iii. Appraising failures to these standards and acting when standard
are not being adhered to.
iv. Planning improvements in the standards and specification.
4 | P a g e
Various stages of quality control are listed below.
Incoming material control
Pre-Construction and Planning Control.
Construction Process Control.
The detailed steps in the procedure depend upon the scope and type of work and owners policy decision.
Quality Management System
Technical Technical
Organizational Organizational
Manpower QualityAssurance
Quality Manpower
Manpower Manpower
Determine PerformanceStandards of a facility
Design Option Set upSelect a Design Design tests
Formalize Specification
Plant & Machinery
Diode ConstructionMethods
Organizational
Test Records and Reports
3 | P a g e
Q Control
Q- Assurance Q -Audit
Test Records and Reports
4 | P a g e
Procurement Procurement
Vendor Material Process Finished
ST ANDARDS & S PECIFICAT IONS FOR MAKI NG & T RANSP ORTING CONCRET E
I ntroduct ion
Concrete is the most versatile construction material used in civil
engineering structures. Its growing use in modern complex and large
projects including river valley projects merits the closest attention of
designers and constructors in order to achieve durability and design level
serviceability over the life span of the structure with minimum
maintenance and repairs. The need for quality management system
becomes an obvious and essential requirement.
St andards a nd Specificat ion
The quality of construction depends upon right materials used, the correct
methods followed ad produce and product of acceptable performance.
Quality control attempts to ensure just that much. The means of quality
control are tests, inspection supervision and analysis of date etc. quality test
are conducted in laboratories and inspection and supervision are carried
out on the site and the date analysis in done by experts in office.
Specification
5 | P a g e
The project authorities prepare the process of working out specification of
various facilities where concrete will be used. However, the standards and
specifications for
concrete and its various ingredients are Universally standardized and
they are required to be in ingredients viz cement aggregates coarse
and fine, water admixtures and various aspects of concerning its
placement & final acceptance should be as per IS specification.
Sr. No.
IS No.
Title
1. IS 226 Specification for structural steel
2. IS 269 Specification for ordinary and low heat port land cement
3. IS 383 Specification for coarse and fine aggregates
4. IS 432 Specification for mild steel and medium tensileSteel bars for concrete reinforcement
5. IS 456 Code of practice for plain and reinforcement
6. IS 650 Specification for standard sand for testing
7. IS 1489 Specification for Portland Pazzolona Cement
8. IS 1786 Specification for cold wanted steel high strength deformed barms for concrete reinforcement
9. IS 2502 Code of practice for bending and fixing of bars for concrete reinforcement
10. IS 3025 Methods of sampling and test (Physical and Chemical)for water used in industry
11. IS 4082 Recommendations on stocking and storage of construction materials at site
12. IS 9103 Specification for admixtures for concrete
13. IS 10262 Recommended guidelines for concrete mix design
14. SP 22 Handbook on concrete mixes
15. SP 24 Explanatory handbook on Indian StandardCode for plain and reinforcement (IS:456)
Coarse Aggregate
Stone:- This shall be crushed or broken from hard stone obtained from
approved quarry. It shall, be hard strong dense and durable, clean and
fee from soft friable, thin, flat elongated dirt and any other foreign matter.
However, the total amount of deleterious substances such as coal, lignite,
clay lumps, soft fragments, foreign materials and other deleterious
materials in the stone aggregate shall not exceed
5% of its weight.
Gravel:- In can either be river bed shingle or pit gravel. It shall be sound,
hard, clean, suitably graded in size with or without some broken fragments.
This shall be free from flat particles of shale, powered clay, slit, loam and
other impurities, however pit gravel shall have to be washed if it contains
soil material adhering to it.
Brick: It shall be obtained by breaking well burnt or over burnt dense
brick bats. It shall be homogenous in texture, roughly cubical in shape, clean
and free from dirt or any other deleterious matter.
Stacking: When stack piling, the aggregate shall not form pyramids
resulting in segregation of different sized materials. It shall be stacked
separately according to nominal sizes of coarse aggregates in regular
stacks of height not exceeding 150 cm.
Testing: Coarse aggregate shall be tested for the
following a. Determination of particle size and
shale
b. Estimation of organic
impurities c. Surface moisture
d. Determination of ten per cent fines Value
Measurement The aggregates shall be measured in stacks and paid for after
making a deduction of 7.5 of the gross measurements of stacks in respect of
aggregates of nominal size 40mm and above. In respect of aggregates of
sizes below 40mm, no deduction shall be made from the gross
measurements of stacks.
Admixtures: When required, admixtures of approved quality shall be
mixed with concrete, as specified.
Transportation of Concrete
Concrete from the mixer should be transported to the point where it
has to be placed as rapidly as possible by a method which prevents the
segregation of loss of ingredients. The concrete has to be placed before
setting has commenced. Attempts have been made to limit the time
to time between mixing and compaction within the forms. The
specifications however permit a maximum of two hours between the
introduction of mixing water to the cement and aggregates, and the
discharge if the concrete is transported in a truck mixer or agitator. In the
absence of an agitator, this figure is reduced to one hour only. All these
however presume that the temperature of concrete when deposited is not
less than 5 C or more than 32 C. it has now been established that delays in
placing concrete after the so-called strengths provided the concrete
retains adequate to allow full compaction.
The requirements to be fulfilled during transportation are:
(i) No segregation or separation of materials in the concrete and
(ii) Concrete delivery at the point of placing should be uniform and of
proper consistency
The prevention of segregation is the most important consideration in
handling and transporting concrete. The segregation should be
prevented and not corrected after its occurrence. The concrete being a
non-homogenous composite of materials of widely differing particle sizes
and specific gravities is subjected to internal and external forces during
transpiration and placing tending to separate the dissimilar constituents.
Segregation can be prevented by ensuing that the direction of fall
during the dumping or dropping or concrete vertical. When the discharge
it at an angle, the larger aggregate is thrown to the far side of the
container being charged and the mortar is collected at the near side thus
resulting in segregation.
The plant required for transporting the concrete varies according to the size
of the job and the level at which the concrete is to be placed. The
principal methods of transporting concrete from the mixer are:
i) Barrows
a) Wheel barrows and handcarts
b) Power barrows or powered buggies or dumpers
ii) Tippers and Lorries
iii) Truck mixers and agitator
lorries iv) Dump buckets
v) The monorail system or trolley or rails.
SQC
Q. C. Functions in Concrete
The qualify control of concrete comprises of the following four functions:
i. Control of ingredients of concrete viz, cement, coarse and fine
aggregate, water and admixtures.
ii. Concrete mix proportioning or concrete mix design to attain the
required strength specifications.
iii. Concrete production and placement
operations. iv. Acceptance.
The responsibility of all the four functions is shared by contractor, the
department or client and the quality control staff. The functions are
discharged through an intricate network of testing, supervision and
inspection procedures performed in the prescribed manner.
Quality assurance in concrete includes are following basic programmes;
i. Preparation of concerning manuals for workers, supervisors and engineers.
ii. Providing training to all those involved in the concerning
function to discharge their responsibility and duties in the manners
prescribed.
iii. Preparation of a schedule of job description and job
specification and organizing charts focusing on the interface
between all persons and parties in concrete construction.
iv. Making quality a joint responsibility and accountability by
creating appropriate organizations for the purpose.
v. Setting up on internal and external quality audit systems.
Establishing and monitoring a good MIS (Management Information
System) procedure and computersing the same wherever possible.
vi. Providing the necessary resources physical, financial and personnel
as and when required.
The concept of quality assurance assumes that the contractor
is best qualified to perform, supervise and verify the work assigned to
him. Clients and authorize direct their efforts mainly to the audit function
whereby they make certain that the intended quality is in all respects
obtained and well documented. Where a client chooses to be involved
directly or indirectly, the degree of involvement is clearly formalized
through established and agreed Co ordination procedures. This may be for
the day to day control and monitoring of acceptance procedures.
Quality management system is based on the concept of
Engineering for quality rather than inspection of quality. It believes that
quality starts from design stage itself and permeates throughout
procurement, construction and acceptance stages. I hold that the quality
can neither be departmentalized nor compartmentalized and that it is a
matter of joint accountability and responsibility of everyone involved in the
construction process. For this purpose it integrates the quality control
processes and quality assurance program into one unified plan of action.
Tests
Tests are used to determine the various properties of the materials, which
help in their selection as well as for ascertaining the quality of final product.
The test results are compared with the prescribed standards and
specification and judgments are arrived at. Proper methods of sampling,
prescribed procedures of testing, well qualified and trained personnel for
testing work and properly equipped laboratories are necessary.
What to test
The manufactured goods such as cement and steel carry their suppliers
warrantee but this does not mean that they are not to be tested. In case
of materials like aggregate and water the properties may vary widely
over time and space and proper selection has to done to meet the
engineering requirements.
The raw materials are processed to obtain the final product. The processing
need to be tested and supervised carefully. Some intermediate process
may not be having tests and they cannot be tested and the inadequacies
if any can be known only when the final product is tested. In such
situation the testing of final product is important.
This helps to ascertain:
i. Conformity to Specification
ii. Validity of design assumption
iii. Need of modification due to any error
iv. Comparative position of work at different sites.
The data analysis and interpretation becomes meaningful only if
observations are adequate and frequencies are numerous in relation to the
volume and importance of work.
All tests prescribed under ASTM, BS and IS for judging various quality
parameters of cement aggregates water and admixtures and the final
concrete are presented in table 1 and 2 The frequencies of tests and
samples required are shown in table 3 and 4
TABLE 1
Tests for adjusting various parameters of cement aggregate and concrete.
TESTS
A. TESTS FOR CEMENT CHARACTERSTICS
1. Setting Time
2. Soundness
3. Strength
4. Fineness and Grading
5. Chemical Composition
6. Specific gravity
7. Heat evolution
8. Water retention
9. False set
10. Adulteration
B. TESTS FOR EVALUATION OF CHARACTERISTICS OF AGGREGGATES
1. Petrography examination
2. Grading and surface area
3. Bulk unit weight
4. Specific gravity
5. Absorption and surface moisture
6. Chemical stability
7. Resistance to freeze and thaw
8. Abrasion resistance
9. Crushing
10. Impact Value
11. Sampling Aggregate
C. TESTS FOR WATER FOR CONCRETE MAKING (Test for impurities)
1. Organic
2. Inorganic
3. Sulfates (as SO4)
4. Chlorides
5. Suspended matter
6. Hydrogen ion concentration
7. Sea water
8. Sugar
D. TESTS FOR EVALATION OF CONCRETING PRACTICES
1. Bathing of concrete constituents
2. Proportioning
Sampling of fresh concrete
Analysis of fresh concrete
3. Mixing
Unit weight of concrete
Air content
Cement
Content Yield
4. Transporting
Moisture
Content
Segregation
Setting time
5. Placing
(Workability) Slump
test
Flow test
Ball penetration test
6. Compaction Vee
bee test
Compaction
factor Bleeding
E. DESTRUCTIVE TESTS FOR CONCRETE STRENGTH
1. Standard for making test specimen
FieldLaboratory
2. Method of capping test specimen
3. Drilled core and sawed concrete specimen
4. Compressive strength test
5. Flexural Strength
test Third Point
Loading Center
Point loading
6. Splitting Strength (indirect tension)
7. Bond strength
F. NON DESTRUCTIVE TESTS FOR CONCRETE STRENGTH
1. Rebound hammer test
2. Penetration probe test
3. Vibration sonic
test Longitudinal
Flexural
Torsion
4. Ultrasonic Pulse velocity test
5. Pull out test
G. TESTS FOR PHYSICAL PROPERTIES ON CONCRETE
1. Durability test
2. Shrinkage and moisture test
3. Abrasion resistance test
4. Permeability test
5. Static modules of elasticity and Poission’s ratio
6. Alkali reactivity test
7. Creep of concrete in compression
T ABLE -2
Tests Conducted on Concrete and its Ingredients (As per IS: 2386-1963)
SrNo
Cement Pozzolona Aggregates during sources
Aggregat e site lab
Admixtures for Concrete
Coiners Fine ProductUnlomity
Perform ance
FreshState
Harde ned
1Setting
Time (Initial
MoistureContent
Gradin g
Grading Fitness
Grading Density UnitWeight
UnitWeight
Streng th
2 Faise Set Pozzolona
Activity
SpecificGravity
SpecificGravity
SpecifyGravity Colour
Air Conten t
Air Conten t
Densit y
3. Temperatu re
Temperatu re
Akali Aggreg ate Reactivi ty
Akali Aggregat eReaticity
Moisture content
PH ValueWater Require ment
Water Cemen t Require ment
Volum e Charg e
4 SoundnessWater Requireme nt
Soundn ess
Soundnes s
Soundnes s
Chloride Setting time
Temp.
Modul e Elastic ity
5 Fitness Fitness Impact value
OrganicImperils
ImpactValue Dissolved Bleedi
n gBleedi
n g
Strain Capa city
6 Compressi ve
RelativeDesignee
Crushin g Value
Self and day
Crushing value
Suspend ed Matter
Creep
7 Loss ofIgnition
Loss onIgnition
Abrasio n Value
Material Finer Than
AbrasionValue
Strengt h Develo
Therm al Prope rties
8Chemical Compositio n
Crushin g Rock Strengt
Building sand
VolumeCharge
Abrasi on Resist ance
9 ParticleShape
Deleterio us Substanc e
Durabili ty
Durab ility
10
Patrograph ic examinatio n
11 Unit Weight UnitWeight
12Water Absorpt ion
Water Absorptio n
13Mica Conten t
T ABLE 3
FREQUENCIES OF TESTS TO BE CONDUCTED
Sr. No. Name of Test Mass Concrete Small Concrete Jobs
andR. C. C.
Remarks
1 Adulteration of cement
One every 50 of cement
One every 50 of Cement
Also carry out tests as mentioned in AppendicesM. N. P. and Oat this
2 Particle size analysis of aggregates
i) Once a day ii) Additional in
3 Flakiness index of coarse
As per above As per above
4 Still test o line aggregate
i) Once a day ii) Additional it
i) Once a day ii) Additional if
5
Clay, line slit and line dust in aggregate (sedimentation
Once a week Once a fornight
6 Surface moisture
One per shift per stock pile
One per shift per stock pile
aggregate (Hot place method)
7
Surface moisture content in line aggregate (Laboratory method)
Once a week Once a for Night
8 Bulking of fine
One per shift per stock pile
9
Specific gravity and water absorption for aggregate’s up to
One a week
10
Specific gravity and water absorption for aggregates above 10 mm size)
Once a week Once a for night
11 Slump of cement
One per every two hours working per
One a for night
12 Slump of cement
One per every two hours working per
One per every two hours working per
13Density and air contents of fresh concrete
i) One per mixer per week
ii) Additional ifsource of aggregate
i) One per mixer per mouth
ii) Additional ifsource of aggregate is changed
14 Compressive strength of drilled
As directed by design office
As directed by design office
15
LaboratoryPermeabilitya) Moulded Specimen b) Drilled
One per month for every mix proportion One per month per 3m depth
Nil
Nil
16 In-situ permeability
One hole at 20m, distance per working season for full depth duly
T ABLE 4
Size of Sample Required for Various Tests
Sr No. Purpose of test MaterialWeight of sample
Remarks
1 Adulteration of Cement 1
About 100 kg of thesamples shall be per served in air light
2 Tests on aggregate such
CoarseAggregate
100
flakiness index, surface moisture, bulking specific gravity and water
Fine aggregates
40
3 Complete mix design of concrete/mortar
Cement Coarse aggregate Surkhi
Details of Tests
The detail information on the tests for measuring various characteristics types
of test, test specimen apparatus parameters derived significance /
application and
relevant ASTM, BS and IS standards is given as per list below.
Sr. No.
Item Table
1 Cement 5
2 Aggregate 6
3 Water 7
4 Admixtures 8
5 Evaluation of concrete properties 9
6 Destructive tests for concrete strength 10
7 Non destructive test for concrete strength 11
8 Physical properties of concrete 12
T A B L E 5
SrNo
Type ofTest
Test Specimen/Apparat us
Parameter
Derived
Significanc e/ Applicatio n
Remarks ASTM BS IS
1 SettingTime
Vicat apparatus orGull more needle
Time available for concrete
Quality control on cement supplied
Different Type of needles for initial andfinal
C191C266
4550 (3)
4031
2 SoundnessLe Chattier, Part and Autoclave test methods
Expansion in dimensions
Presence of excess gypsum, lime or magnesi
Checks for development of serve cracks
C-15 4550 (3)
4031
3 Strength Briquettes and cubes
Load per unit area
Strength of cement
Loss of strength due to
C190C109C917
4550 (3) 4031
4 Fitness andGrading
Air permeability or photo electric
Specific surface
Uniformity in quality of
Rate of gain in strength
C114 4550 (3) 4031
5Chemical Compositio n
Chemical Analysis
Percent of various cement constituent s
Quality of cement
Classification of cement
C114 4550 (3)
4032
6 Specificati on Gravity
Le Chattier flaskWeight per unitvolume
Uniformity in cement
C118 4550 (3)
4031
7 Heat evolution
Heat of solution method
Calories of heat evolved
Mass connectin g cold weather concernin g
Simple Laboratory Test
4550 (3)
269
8 Water retention
Mortar made with cement in standard manner
Percent of water suction
Masonry cement
Workability of mortar mix
C91
9 False set Vicat’s ApparatusDepth of penetratio n
False setting, premature, stiffening
Rate of setting of cement
C359
T ABLE 6
Tests for Evaluation of Characteristics of Aggregate
S. No.
Tests Characteristic s
Significance of Importance
Test methods
Specification requirement
ASTM BS IS
1 PetrographyExamination
Presence ofImpurities
Visual Examinati on
C295D75 882 2386
(vi)
2 Grading andSurface area
Workability of fresh concrete Economy
StateAnalysis
Max. and Min. percent passing standards
C136C125C33
812(I)4101134
2386 *I)
3 Bulk unit
Mix design calculation
Weighing
Max. and Min. Unit
C29 812(2) 2386(I)
and classificatio n
4 SpecificGravity
Mix design calculation of ensure uniform
Batting method
C127C128
812(2) 2386(I)
5Absorption and Surface moisture
Quality control of concret
DryingMethod
Min. Percent of water
C70C127C128C566
812 (4) 2386*vii)
6 ChemicalStability
Strength and durability of all structures To delete harmful inorganic
ChemicalAnalysis
Max. expansion of motor bar. Not reactive with cement alkalies
C27C289C586C88C117C40
7Resistance to freeze and thaw
Decides the porosity structures subject to
Icing and deciding test
Max. expansion of motor bar Not reactive with cement
C290, C291,
8 Abrasion resistance
Index of agg. quality Soundness and crushing
Mechanic al Test Max. percent loss C131 812(3) 2396(iv
)
9 CrushingStrength
Index to agg. Quality Soundness and crushing value
Std. Load applied test
Minimum value 812 (3)882
2396 (iv)
10 Impact Value
Index to impact value soundness incompassion
Std. Impact load test
Minimum Value 812 (3) 2396(iv)
11 Sampling aggregate
Influences on test result
Sampling technique s
Max. & Min. samples
D75C702 812(I) 2430
20 | P a g e
21 | P a g e
T A B L E 7 Tests for Water for Concrete
Making(Tolerance Limit and Effect of Ingredients)
Sr. No.
Ingredients
Tolerance Limit (IS 456)Influence and effect in Concrete(Higher Value(H)/Lower value (L)
Reinforced Concrete
MassConcrete Max
1 Organic 200 mg/I 200mg/I Adversely affect hardening of cornet
2 Inorganic 3000mg/I 3000mg/I Greatly retard both setting and strength
3 Sulphates(as SO4)
500 mg/I 500 Mg/I Reduces the 28 day strength (H).
4 Chlorides(as CI) 1000 mg/II 2000 Mg/I
Enhances both hardening and strength rate. Result in Corrosion and deterioration
5 SuspendedMatter
2000 Mg/I 2000 Mg/I Adverse effect on strength
6Hydrogen concentratio n
More than 6 More than 6 Result for corrosion of steel (H)
7 Sea Water 35,000 ppm Reduction in strength (H)
8 Sugar 0.25 0.25%Repaid setting but, reduction in strength, Retards setting time (H & L value)
T A B L E 8 Code of Practices for Admixtures and its influence
Sr. No.
Classification Purpose/Influences ASTM BS IS
1 Air entraining admixture
Improves durability to freezing and thawing, surface scaling Reduces segregation and
C260 C233C226 C175
5075(2) 9103
2 Water reducing admixture
Increases strength and slump of concrete increase in drying shrinkage
5075(1) 9103
3 Retarding AgentsRetarding and setting time of concrete and grout
5075(1) 9103
4 AcceleratingAdmixture
To accelerate the setting time and strength development early removal of forms increase the drying
D98, D345 5075(1) 9103
5 Pozzolona
Fine particles combines with CalciumHydroxide to form comentitious properties, control internal temperature
C219, C618 3892 3812,1344
6 Workability agents
Improve slump, reduce, water comment ratio, facilitated, placing and finishing
C618 4887
7
Damp Proofing/Permeab ility reducingagent
Reduce the capillary flow of moisture through concrete thatis in contact with
743 2645
8 Grouting agents
To alter the properties of grout for specific like stabiles, foundation, crack, fill joints, seal oil walls
C937
9 Forming Agent
To entrain gas form in concrete before hardening applied for grouting in post tensioning
C869, 796
T A B L E 9 Destructive Tests for Concrete Strength
Sr. No. Type of Test
Type Specime n
ParameterMeasured
Significance/Applicati on
ASTM BS IS
1
Standard for making test specimen a Field b.
Influences to test result
C31
1881 (4)
1881 (4)
1199
1199
2Method of capping test
Uniform loading in test C617 1881 (4)
516
3
Drilled core and sawed concrete
Cube and Cylinder
Field Application C42 1881 (4)
1199
4 CompressiveStrength test
Cube and Cylinder
Ultimate failure load
Strength in compression
C39, C513, C873, C116
1881 (4)
516
5
Flexural strength test
a. Third point loading
b. Center
Beam
Beam
Ultimate failure load
Ultimate failure
Module of repute
Module of repute quality control
C78, C683, C293
1881 (4)
1881
516
6. Splitting strength
Cylinder Splitting load
Tensile strength of concrete
C496 1881 (4)
5816
7 Bond StrengthCubes and Prisms
Bond Strength between steel and
Comparing ConcreteMixes
C234 2770
T ABLE 1 0
Non Destructive Tests for Concrete Strength
S N o.
Type ofTest
Type Specime n
Paramete r
measure d
Paramete r derived
Applicatio n/ Significanc e
Advantag es
Disadvan tages
ASTM BS I S
1 Rebound Hammer Test
Test Specime n or in sills concrete
Degree of rebound received
Strength through calibratio n
Testing of concretruc tual members
Payable simple in operation
Variable results only quality of surface
C805 4408 (4)
2 Penetratio n
Test Specime n or in silu concrete
Dimensio n of indentati on
Testing concrete stractual
Portable simple in operation
Variable results only quality of surface concrete
Variable result onlyquality ofsurface of concret
C803 4408 (4)
3 VibrationSonic test
a. Longit
Beams Cylinders Beams Cylinders Beams
Resonant frequenc y of elasticity
Quality control, deteriora tion of concret
Single specimen simple accurate and
Limited to specially made specime
C215
Do
1881
--do--
b. Flexura l
c. Torsion
Cylinders dynamic modules of modules of elasticity in
--do—
--do--
resproducti y
--do—
as above Poisson’s
--do--
4 Ultrasonic Pule velocity test
Test cubes concrete members
Velocity of pulse time
Compres sive through calibratio n
Laboratory test, testing ofconcrete in silu for strength
Variability of concrete strength can be measured
Special preparati on required, Access to two opposite faces of memberisrequired
C597 4408 (5)
5 Pull OutTest
Pull PutInterest
Failure load fractur
T ABLE 1 1
Tests for Physical Properties of Concrete
Sr. No.
Types of test TestMethods
ParameterDerived Significance
or applications
ASTM BS IS
1 DurabilityTest
Freeze and thaw cycles
Strength to withstand standard
Strength of concrete for special condition
C666C671C672
2Shrinkage and moisture
Wet and dry process
Dimensions measuremen ts
Relatives shrinkage in structural
C157C827
1881 (5)
6441 (11)
3Abrasion resistance test
Dry abrasion testabrasiontools
Depth of abraded material
Industrial flooring hydraulic channel etc.
C944, C779, C148
9284
4 Permeability test
Water absorption method
Amount of water absorbed
Water tank, fluid, retaining C642 1881
(5) 3085
5
Static modules of elasticity and
Strain measureme nts
Stress and strain values
Quality of concrete
C469 1881 (5)
ratio
6 Alkali reactivity test
Mortar bar method
Elongation in length
Performance of cement and
C227
7Creep of concrete in Compressio
Longitudinal compressio
Strain values Performance of concrete structure
C512
INSP ECT ION & CH ECKLIST S
Inspection
Inspection is the act of physical verification of the subject work on the site
and under normal day-to day working conditions. The inspection for quality is
done by quality control inspectors who are posted at al active sites and who
should be persons at deputy engineer and above levels. They are a member
of the quality control team and unrelated to the production process directly.
The duties of quality control inspectors are as under:
1. Check that the working is proceeding in accordance with the
specifications and bring the substandard work to notice of
concerned authorities.
2. Inspect personally and regularly the work in progress at sites.
3. Review the previous days “Daily QC” reports filed by the Field Quality
Control units and convey immediately to the concerned site in
charge and any adverse results and recommendation for
rectification.
4. Verify that the results of the tests received from labs have been duly
attended to and send them to seniors in the department.
5. Prepare daily report of inspection on the prescribed forms and send to
seniors in the department.
6. Check to ensure that QA manual for workers and supervisors are
available at hand at work stations that they are not in torn stage, that
they are easily accessible and that they are being referred to.
7. Check to ensure that copies of contract conditions particularly
regarding specifications and related matters are available at site
offices and are being referred to.
8. Check that all equipment plants are in proper working condition
and that they conform to IS specifications.
9. Investigate the case where the test results of input materials are
satisfactory but that of in process stage are not, or there is a
discrepancy in test results during in process and end product stage
and find out the causes of mishap. Investigate the human factor and
machine condition/capability more particularly.
Items to be Inspected
Following items must be covered during inspection of the inspectors:
Inspection of the constituent material cement, steel, aggregate, and
water and admixture. The test results of these materials and their
condition of storing needs to be checked.
Inspection of form work, embedded parts, ladder and gangway
plant and machinery.
Inspection of concrete making and placing.
Inspection of the end product.
Guidelines for concrete inspection are given below:
Sr. No.
IS No.
Title
1. IS 226 Specification for structural steel
2. IS 269 Specification for ordinary and low heat port land cement
3. IS 383 Specification for coarse and fine aggregates
4. IS 432 Specification for mild steel and medium tensile
Steel bars for concrete reinforcement
5. IS 456 Code of practice for plain and reinforced concrete
6. IS 650 Specification for standard sand for testing
7. IS 1489 Specification for Portland Pazzolona Cement
8. IS 1786 Specification for high strength steel
deformed bars for concrete reinforcement
9. IS 2502 Code of practice for bending and fixing of bars for concretereinforcement
10. IS 3025 Methods of sampling and test (Physical and Chemical)
for water used in industry
11. IS 4082 Recommendations on stocking and storage of
Construction materials at site
12. IS 9103 Specification for concrete admixtures
13. IS 10262 Recommended guidelines for concrete mix design
14. SP 22 Handbook on concrete mixes
15. SP 24 Explanatory handbook on Indian Standard
Code for plain and reinforcement (IS: 456)
Supervision of Concreting
Supervision is the third aspect of QC along with testing and
inspection. The supervision relates to the construction process and is to
be made by production group. It is the task of the engineers in charge of
construction that the contractors and workers executing the job know the
specifications, use the tested and certified materials are fully skilled to
do job they are engaged in and that tests are conducted at the
sated frequencies and according to prescribed procedures. The Supervisors
both from the side of contractors as well as the clients should be
conversant with above and know the techniques of supervision and of
preferring daily progress reports of work quality.
All resorts on QC activity eminating from laboratories, filed quality
control units, inspections of suppliers material stores, in process activity
finished product by QC inspectors and supervision as well as form the
corresponding personnel of contraction has to be as per procedure of MIS
laid down by authorities.
ASSU RANCE OF QUALITY
For assurance of quality following steps shall be taken:
1. PRELIMINARY
i. Plans and specifications availability at sites.
ii. Organization chart, job descriptions and work
assignments. iii. Permissible tolerance of measurements.
iv. Provision of records and reports.
v. Contractor’s plant calibrations, equipment organization and methods.
2. PROPORTIONING
i. Tests of aggregates
ii. Proportioning of
mix iii. Mix
computations
iv. Grading of mixed aggregates; batch quantities;
yield, air v. Content
3. MATERIALS
i. General (applies to all materials)
ii. Identification; quantities (Used on hand); acceptability;
Uniformity; storage conditions, handling methods, waste;
schedule of testing
iii Cement
iv Sampling for laboratory
test v Protection from
dampness vi. Aggregates
vii. Acceptability tests
viii. Gradation; organic matter; deleterious undesirable substance;
soundness, resistance to abrasion; other
tests. ix. Control tests
x. Moisture; absorption; specific gravity; unit weight; voids
4. STOCKPILING:
i. Water
ii. Admixture
iii. Reinforcing Steel
iv. Size, Bending, surface
condition v. Accessories
vi. Fixtures
vii. Other materials
5. FORMWORK
i. Specified type of forms
ii. Excavation; foundations location, dimensions, shape,
drainage, preparation of surfaces.
6. FORMWORK
i. Specified type of
forms ii. Location
iii. Alignment provision for settlement
iv. Stability (bearing, shores ties and spaces)
v. Inspection of
openings vi. Preparation
of surfaces. vii. Final
clean up
7. GATEWAY AND LADDERS
i. Working platforms; location width, guardrails with no.
ii. Scaffoldings of adequate strength supported, properly
braced. iii. Suitable guards on all gangway and stairs.
iv. Ladders securely fixed
8. PLANT AND MACHINERY
i. Availability of Spare concrete mixers vibrators and other
machines. ii. Adequate electric and petromax lamps for
concerning at night.
iii. Adequate quantity of tarpaulin to cover concrete in case of rains.
9. BATCHING AND MIXING OF CONCRETE
i. For each batch check the quantity of coarse aggregate,
find aggregate, cement and water quantity of water being
corrected from
the viewpoints of dry wet conditions of the coarse and
the fine aggregate.
ii. Periodical checking of accuracy, serviceable condition
and cleanliness of all the measuring equipment.
iii. Checking that water/cement ratio is maintained at the
stipulated value. Further control over the amount of water
used shall be exercised in terms of slump/compaction factor
value.
iv. Physical checking of the quantities of the constituents per
batch periodically.
v. Checking of workability of concrete at frequent
intervals. vi. Checking cleanliness of the mixer
machine drum.
vii. Checking cleanliness and adequacy of chairs in the
area of concerning.
viii. Checking cleanliness and adequacy of chairs in the
area of concerning.
ix. Checking that concrete is placed and compacted before the
expiry of initial setting time of cement and left undisturbed
afterwards.
x. Checking that concrete is placed in even layers, each layer
being compacted before placing the next layer.
xi. Ensuring that concerning is carried out continuously
upto the construction joint.
xii. Ensuring that while concerning an old work, the surface is
chipped, cleaned with wire brush and wetted with a coat of
cement slurry, before laying new concrete.
xiii. Ensuring that while connecting an old work, the surface is
chipped, cleaned with wire brush and wetted with a coat of
cement slurry, before laying new concrete.
10. EMBEDDED PARTS:
i. Inspection of embedded parts and embedment
of lugs ii. Position and level of embedded parts
iii. Precautionary measures to keep the embedded parts in
position iv. Position, depth and size of bolt holes.
11. REINFORCEMENT IN PLACE.
i. Size (diameter; length; bends; and anchorage)
ii. Location (number of bars; minimum clear spacing minimum cover)
iii. Splicing
iv. Stability (binding by wire; chairs and spacers)
v. Cleanliness (no loose rust, no oil, paint dried mortar etc.)
vi. Fixtures (location, stability,
cleanliness). vii. Opening shown on
plans
viii. Calibration of batting devices.
ix. Conditions of mixer speed of
operation x. Provision for continuous
placement
xi. Provision for curing
xii. Provision for protection against sun, rain, hot or cod
weather xiii. Adequate tools and men for compaction,
finishing and curing
12 CONCRETING
i. Working Conditions
Whether preparations completed, specified interval since
previous placement, lighting for night work, covering and
protection.
ii) Batching
Cement; aggregates; water; admixtures
Check batching devices
Check yield of
concrete iii) Mixing
Minimum Time, batches delayed in mixer maximum time
loading number of revolutions of drum water used mixing
capacity of drum amount of concrete.
iv. Control of consistency
a. Observations of concrete being placed; tests;
adjustments of water or admixtures in mix.
b. Monitoring of air content
c. Concrete temperature
check d. Conveying
e. No segregation of materials; no excessive stiffening or
drying out time limits.
v. Placing uniform and dense concrete; continuous
operation; preparation of contract surface mortar bedding,
vertical drop, no dropping against forms or reinforcement;
little or no flow after depositing depth of layers water
gain rock pockets removal of temporary ties and spacers
disposal of rejected batches placing concrete under water.
vi. Contraction
joints a.
Location
b. Forming or tooling
c. Dowels of ties (if any) in place and
aligned vii. Construction and hinge joints
a. Location preparation of surface
b. Dowels or ties (if any) in place and
aligned c. Expansion and isolation joints
d. Joint filler material location, alignment stability freedom,
from interference with subsequent movement.
viii. Finishing of formed surfaces shallow surface layer of mortar
water gain no over working first floating alignment of surface,
final hard trawling plastic shrinkage cracks; rain.
ix. Schedule of testing
13. AFTER CONCRETING
i. Protection from damage impact overloading of
surfaces ii. Time of removal of forms
iii. Curing surface continuously moist; time of beginning curing;
length of curing period, in cold and hot weather required
precaution.
iv. Joints Clean and seal
v. Tests of concrete; Detailed
elsewhere vi. Records and reports
a. Records; materials mix computations, batching and
mixing, placing and cutting.
b. Reports; daily;
summary c. Diary
d. Photographs & video recording
14. SPECIAL WORK
i. Cold whether concerning
Limiting temperatures and times outdoor, air enclosure,
materials, concrete Heating materials, contact surfaces,
and enclosures, Protection from drying carbonation and
carbon monoxide Tight enclosure or insulated forms
Removal of forms protection from too repaid cooling.
ii. Hot weather concerning
Cooling materials presetting aggregates and contact
surfaces protecting concrete. Limiting combinations of wind
relative humidity and ambient temperature.
iii. Filling under base plates
Preparation of base; proper mix; complete; filling of voids
iv. Pressure grouting
Holes (depth, spacing, freedom from clogging) Material
(acceptability quantities used) injection (sequence, pressure
times, completeness of penetration no damage to structure)
v. Shotcrete.
Materials (acceptability quantities) condition of equipment
preliminary mixing, pressure (air, water) preparation of
surfaces application thickness no sagging, construction joints);
surface finish; surfing tests.
vi. Terrazzo
Thickness of layers; uniformity; curing dividing strips
vii. Stucco
Mortar; preparation of backing surface; bonding to backing surface;
uniform finishing curing each layer.
viii. Architectural Concrete
Location and neat joining of molds; surface coating to avoid
sticking or staining curing Reinforcement near surface
support location & material. Vibrating to minimize bugholes
Colour and texture mockup protection against drip stains
surface repair; hole filling.
ix. Coloured Concrete
Pigments; matching of colors; through and intimate mixing of
colour with cement uniform application and trawling, curing.
x. Painting
Cleaning surface; neutralizing surface (if needed); uniform application;
curing Portland cement paints.
xi. Mass Concrete
Times and rates of placement, avoidance of high or non
uniform temperatures instrumentation embodiment, after
embedment care monitoring, analysis and interpretation
thermal stresses and temperature control bonding of
liters prevention of aggregate breakage.
xii. Air entertaining
Accurate measurement of air entraining agent; tests for air
content of Concrete, regulations of air content adjustment of
mix of compensate for air avoidance of excessive mixing of
vibration ,avoidance of wet consistency; finishing.
xiii. Under water construction
Avoidance of flowing water; temperature; continuous placement,
operation of treme or bucket minimizing of wash; protection
from flowing water for several days.
xiv. Vaccum Concrete:
Final thickness of slabs; timing and duration of application of
vacuum uniformity of processing condition of mats.
xv. Prestressed Concrete;
Strength of concrete at time of prestressing;
sheathing of reinforcement, in specified, accurate
placing of reinforcement avoidance of obstruction of
excessive friction; measurement of tension by means of jack
pressure and/or lengthening of steel thoroughness of grouping, if
specified.
CREATING QUALIT Y ASSU RANCE ORGANIS AT ION/UNI T AT S IT E
The chart enclosed shows the persons for the organization of quality
assurance and their hierarchy.
FUNCTIONS AND DUTIES
The Superintending Engineer who is head of the Quality Management System
department may have the following duties and responsibilities.
i. Ensuring compliance by contractors with the plans,
specifications and contractual provisions regarding the quality in
selection and processing of materials, and during construction and
acceptance stages of work.
ii. Monitoring and where appropriate, ensuring that the quality in the
project construction is maintained, where it cannot, prompt action is
taken rectify the situation.
iii. Coordination and monitoring of reviews approvals, and tests as
required by the specifications and contract.
iv. Stopping work and progress when quality concerns
override other considerations or when continuation of work will result
in sub-standard work.
v. Preparing check lists, manuals and guidelines on quality for
personnel at various levels of vertical hierarchy of the project and
making them available to all concerned.
vi. Arranging training in Quality Control and Quality Assurance through
expert consultants on a continuous basis, promoting Quality Circles,
and undertaking other measures to create awareness that Quality is
everybody responsibility.
vii. Supervising the work of laboratories and Field Q. C. units, receiving test
results and reports and providing feedback to the executing
departments.
viii. Providing technical back stopping and interface with executing
departments regarding all matters pertaining to QMS.
ix. Preventing backsliding on quality by taking timely corrective actions
through guidance inspections, training, and other suitable methods.
x. To be responsible for QMS department, its operations,
budget and performance.
E.E. / Chief Training Officer
i. To carry out training needs assessment surveys of personnel at various
levels of the project organization, contractors and their staff and others
concerned.
ii. To appoint training consultants, approve training programmes and
supervise the conduct of training courses.
iii. To maintain stock of training materials, technical literature and
training equipment.
iv. To evaluate training programmes from time to time.
v. To promote quality circles in the project organization and contractors staff.
vi. To liaise with the other expert agencies in the subject and bring their
inputs to the project.
E.E. / Chief Research Officer
i. To ensure that the central laboratory and the Full QC Units carry out
specified laboratory tests and that test record sheets are filled in
ad registers are maintained.
ii. To ensure that sophisticated tests are got carried out in
specialized and expert laboratories
iii. To examine all test carried out at specified frequencies not
variances if any and report the same to appropriate authorities.
iv. To organize proper upkeep and account of the equipment and instruments.
v. To remain in constant touch with the execution of works, and
coordination relations with contractors
vi. To maintain and progress charts, submit daily placement reports to
higher authorities and suggest way and means to improvement the
standards of work.
Dy. E/ Inspector
Quality Control Inspector is the Project Authority contact with the job.
Through the inspection process he develops not only the knowledge of
specific problems but a general awareness of the attitude of contractors.
He can identity the problems areas and single out situations that require
Authority attention.
The organization proposed for the Quality Management department
recommends 5 inspectors each to look after materials, concerning
earthwork Rockwell and mechanical equipment. The Inspector must be
able to look upon and view critically
the particular phase of the project comprehend and interpret the
contract plans and specifications and prepare notices through his daily
inspections that certain phases of work are not begin done according to the
quality required or when other problems occur, he is to immediately report
these errors, violations or problems to the higher authority for further action.
The Guidelines for inspection have been given in Chapters 2, 3 & 4.
Deputy Engineer /Research Officer
i. To remain in constant touch with the execution of works of the
project by inspection and frequently.
ii. To suggest ways and means to improve the standards of work in case
the test results indicate falling standards.
iii. To organize proper upkeep and account and calibration of the
equipment in the central and field laboratory at proper intervals.
iv. To organize test procedures and to submit daily reports on the quality
of works to higher authorities.
v. To maintain copies of approved design, reports plants, and
estimates specifications, extracts of inspection notes and data of
machinery used on works.
vi. To carry out at least a few of the important tests in a month personally
so that the deficiencies, if any are brought to light.
vii. To approve the instrumentation detailed plan showing the cable
lengths etc. and check the installation of a few representatives
instruments personally.
viii. Periodically inspect the stores of the department and of
contractors for checking storage and issued procedures from the
quality point of view and submit reports to higher authorities.
ix. To assess whether shuttering and centering and proper and
whether steel is provided as per drawing and design and should
also check and advice proper cover of concrete over reinforcement.
x. To inspect all other related operations prior to placement, during
placement and after placement is properly exercised.
Assistant Research Officer in charge of Laboratory
i. To ensure proper upkeep and maintenance on laboratory,
equipment in laboratory, core library the curing room, the store yard
of destructively tested samples etc.
ii. To ensure proper upkeep of records of all samples being tested
in the laboratory and ensure submission of test results in
prescribed forms of the Research Officer.
iii. To supervise the testing works of Research Assistants and
Laboratory technicians and to personally check representative tests to
get an insight into the efficiency of the work.
iv. To ensure correct method of sampling and testing.
v. To prepare monthly review of all the test results, and submit to
the R. O. vi. To conduct such other work as may be assigned by R.
O.
Research Assistant (Posted in Laboratory)
Shall perform important tests as prescribed in relevant standards, and as
directed by the superiors.
Research Assistants Posted in Field
i. To regularly supervise the work to ensure that material as per
approved specification are received at the site and O. K. cards issued
accordingly.
ii. To collect samples as per norms and frequency for testing the
mortar concrete etc.
iii. To keep watch over weighing of cement use of materials
as per specifications; cement bag containing lumps and time
barred should be rejected.
iv. To check mixing time and water cement ratio and mixing of air
entraining agents in required quantity.
v. To check bulkage of sand as required and conduct water
content test. vi. To attend to any other duties assigned to him by
the R.O or A. R. O.
Laboratory Technicians/Field Assistant.
i. To assist, Research Assistant whenever required in laboratory and
field work. ii. To perform tests in laboratory such as
a) Analysis of fine
aggregates b) Sit in
aggregates
c) Bulking in fine
aggregates d) Slump test
e) Collection of samples of concrete and mortars for filling
moulds for compaction test.
f) Numbering samples etc.
METHODS OF QUALITY ASSURANCE
Already listed above under heading assurance of quality
CONCLUSI ON
Quality assurance refers to the managerial processes which
determine the organization design, objectives and resources, the project
team, funding agencies, performance standards and feedback on the
project’s performance appropriate actions to deal with deviations and
all steps necessary for promoting quality awareness at all levels and in all
parts of the project organization.
A typical quality assurance programme addresses itself to the following:
i. Organization structure of the project team and quality
assurance
department.
ii. Responsibilities and powers of the various personnel involved.
iii. Identification of the coordination personal.
iv. Quality and its Programs.
v. Quality education and awareness.
vi. Quality circles
vii. Training
viii. Setting up to MIS for quality
ix. Resolution of technical differences and disputes.
x. Preparation of quality assurance manuals and their checklists.
xi. Vendor survey procedure
xii. Vendor surveillance procedure.
Quality assurance provides protection against quality problems through
early warnings play an important role in the prevention of both internal
and external problems. The assurance is provided from objective
evidence but the type of
evidence but the type of evidence differs widely according to persons
requiring the assurance and the nature of the product.
It need not be emphasized that quality assurance is an essential
prerequisite for all construction projects. Over years the accent on quality
has graduated progressively from simple inspection to quality control to
quality assurance and to quality management. Whereas the limitations of
inspections are quite obvious, a quality control system includes testing of
raw materials at selection and processing stage, testing at various stages of
production, acceptance and the feed back.
Quality assurance goes much beyond the introduction of quality manuals,
auditing for quality and computerized MIS for it. It includes building
quality in the project design itself, planning and selection of equipment
performance maintenance of machines, improving worker skills and
technical/managerial Quality assurance demands on organizational
structure wherein co-ordination and interface between various parties to
constriction becomes possible from the lowest to the top
management level.
Quality assurance provides protection against quality problems
through early warnings to trouble ahead. Such early warnings play an
important role in the prevention of both internal and external problems.
The assurance is provided form objective evidence but the type of
evidence differs widely according to the person requiring the assurance and
the nature of work.
Table 3.14
L i s t o f E q u i p m ent / A p p a r a t us R e q u i r ed f or C o nc r e t e T e s t i n g L a b o r a t o r y
Sr. No.
Description
Laboratory
Class A
Laboratory
Class B
Remarks
1IS Sieve sets 300, 20080, 40, 25, 20, 10,6,2,4,5, 75 3.35, 2.36, 1.70 and 1.8 mm
2 Sieve Shaker
3 Cube Moulds 70.6, 100, 150 mm. *18) (12)
4 Cylinder Moulds 150/300mm
5 Beam Mould 100/100/500mm (6) (3)
6 Slump cone apparatus
7 Compaction factor apparatus
8 Flow tables
9 Air entertainment meter
10 Shrinkage tester
Sr. No.
Description
Laboratory
Class A
Laboratory
Class B
Remarks
11 Length compactor
12 Hot both
13 Vbee Consistometer
14 Table Vibrator
15 High frequency table vibrator
16 Vicat needle apparatus
17 Le Chaterlier Mould
18 Hot Plate
19 Graduated Mould
20 Concrete Placing and finishing tools
21 Trays, big (1000x500x50mm) and small
22 Mortar Cube testing apparatus 200
23 Beakers 100cc, 1000cc Balance in 1kg and 200 kg capacity
24 Crushing value apparatus for aggregate
25 Stop watch
26 Standard hand tools and gauges for metal work
27 Laboratory type concrete mixer
28 Curing tanks of various sizes
29 Blains air permeability tester
30 Cylinder Measures, metallic 3,15, 30 liter capacity
31 Capping apparatus for Cylinders
32 Electric oven 200 c 1mmx1mm1xmm
33 Electric oven 150, c, 0.5, 0.5, 0.5
34 Hydraulic jack with remote control5.20, 50, 2001
35 Concrete test hammers
36 Compression testing machine 2000
37 Transverse testing attachment
38 Universal testing machine 400
Bibliography
N I CMAR pub l ic a t i on le s son book on Constru c t i on Qu a l i t y M a n a g e ment
B ut t e r w o rth - H e ine m a nn publ i ca t i on, The Ma n a g e ment of Constru c t i on b y L a w re n c e B e nn e tt
