, / Quality control procedure of

concrete, supplied by the manufacturer

: Northern
Capital Highway

:
IV V / Project: Construction of Western
High Speed Diameter, stage IV and V

ICA-WHSD-PPPCQCP-000 . 0

/ 1/12

,
- / QUALITY
CONTROL PROCEDURE OF CONCRETE,
SUPPLIED BY THE MANUFACTURER
WESTERN HIGH-SPEED DIAMETER PROJECT
STAGE IV & STAGE V /

, IV V
ST. PETERSBURG /RUSSIAN FEDERATION
- /

REVISION DESCRIPTION:

The revisions indicated by red highlighted colour in the related texts

Controlled Copy: _____

00

21.02.2013

Assigned to: ______________________________

Ufuk
Dogandemir

Victor Ignatiev

Mete Demir

Quality

Chief Engineer

PMO Director

____________________________________________________________________________________
ICA-WHSD-PPP-CQCP-000 .0 21/02/2013


, / Quality control procedure of
concrete, supplied by the manufacturer
: Northern
Capital Highway

Rev.

DATE

ICA-WHSD-PPPCQCP-000 . 0

:
IV V / Project: Construction of Western
High Speed Diameter, stage IV and V
Manager (QM)

(CE)

PREPARED BY

APPROVED BY

,

ICA ASTALDI IC ICTAS WHSD INSAAT
ANONIM SIRKETI
. ICA ASTALDI IC
ICTAS WHSD INSAAT ANONIM SIRKETI

- IV V .

/ 2/12

APPROVED BY

.
Confidential
This
document
contains
proprietary
information, which is owned by ICA
ASTALDI IC ICTAS WHSD INSAAT ANONIM
SIRKETI and is subject to copyright. ICA
ASTALDI IC ICTAS WHSD INSAAT ANONIM
SIRKETI has contributed such information
for the purpose of performance of the
Western High Speed Diameter Project
Stage IV & Stage V Project only, and any
use or reproduction for any other purpose
is strictly prohibited.

____________________________________________________________________________________
ICA-WHSD-PPP-CQCP-000 .0 21/02/2013


:

,

,

.

: 3-
-

6-
.

.
:
1) (
, , )

(
,

:
-

Program has foreseen control at all the

stages: compliance verification of the
technological requirements of concrete mix
production by manufacturer, loading and
transportation of concrete mix to the
construction site, receiving concrete mix
and its incoming inspection, concreting
process and control of poured concrete. The
responsible representatives of Quality
control department of General contractor,
who are at least 3 engineers and 6
laboratory assistants, participate to control
procedures.
General contractor with assistance of his
own engineer, who will be constantly at the
manufacturer mill, provide control at the
concrete mix preparation stage.
Here are that engineers functions:
1) batch inspection according to its
weight (for concrete, aggregate, and
sand) and its volume (for water and
liquid admixture). Inspection should
be
performed
to
testify
that
metrological inspection of batch is
executed timely by laboratory of
State Supervision.
There will be done control inspection of
batch correction. In case of 8 weighing from
10, the difference of actual and target
weight of batch must not exceed valid
value. Weighing accuracy of batchers of
periodic action shall not exceed the
following values:
-2% for cement and active mineral
admixtures;
-2,5% for aggregates;
-2% for water and water based liquid

 2%
- 2,5%
-
2%

admixtures;
Weighing
accuracy
of
batchers
of
continuously action is tested on samples,
selected
during
30sec.
of
batcher
continuously action. In case the accuracy of
batcher exceeds the valid value, then it is
required to be corrected.

, 30.
.

2) The inspection of liquid additive

,

concentration. Concentration of liquid

.
additive is controlled at least 1 time
2)
per shift before each filling times of
.
feed tank.

The methods, selected by laboratory of

manufactures laboratory and based on test
concerning tightness, electrical conduction
.
or color, are applied for this purpose.

,

3) Concrete mix quality is depended on
,
mixing operation quality.

Mixing quality of concrete is depended on

.
mixer filling consequence. Good mixing
quality is achieved with the following order
3) of operations: firstly, the mixer is filled with

water (15-20% of the volume required for

.
batch), and then simultaneously the cement

and aggregates are added with non-stop

water filling up to the required level. Mixing

.
time is set by laboratory based on its
experience.
:
(1520% , ),

,
The minimal duration of concrete mixing
. with solid aggregates (SNiP III 15-76, table

1.7) in seconds

.
Volume
In gravity batch
In mixers of

of
mixer
at
enforced
action

finished
mixture
( III-15-76,

 1.7) .
batch, l

500

500

2-6
2
6
10
75
60
0
15
0

12
0

90

60
60

.
4)

,
,
.
,

,
,
:
- , ..
0,61%;
-

()

,
( 0,05)- 1%
;
- :
800 25-30;
1000 35-40;
1200 45 ;
-

:
5-10
25-40%
10-20
60-75%

Below
500
Above
500

mobility, cm
bel
abo
ow
2-6
ve
2
6
10
75
60
0
15
12
90
0
0

60
60

Firstly, the water based liquid additives are

added with wet method at injection time of
active mineral additives. And after shortterm mixing the cement is added.
4) Studying the mix design with test
reports related to mobility, porosity,
density, and temperature of mixture
at the mill laboratory. It is required to
be sure that all the regulation
requirements were followed:
-

Cement contains aggregate 06-1% as

max.

aggregate (granite) contains of dust,

silt and clay particles (below 0.05
mm) - below 1% by weight.
- Aggregate type according to its
strength is following:
800 as min. for concrete B25-B30
1000 as min.- for concrete B35-B40
1200as min.- for concrete B45 and
more
- Aggregate fraction is following:
f.5-10mm
25-40%
f.10-20mm
60-75%
GOST 26633-91 (table 5) should be followed
for the aggregate of different fractions.
5) Concrete mix preparation in
automatic mixer of concrete:
During the preparation of the concrete
mixture the mixing duration should be
controlled. Central mixer truck is filled with
dry mix. Duration control should begin no
later than 30 minutes after loading the


26633-91 (.5).
5)
:

,

30

70 300.
6)

.

(,
, )

aggregate. The number of turns in the

batch mixer must be at least 70 and no
more than 300.

6) When concrete unloads from the

mixer it is very important to protect it
from its segregation. Deflection
plates or pipes must be set as
mixture flow should be directed
vertically and in the center of
receiving container (hopper, bucket,
box truck).
7) Quality of concrete is inspected at
the construction site.
The initial quality indicator of concrete mix
is its workability, i.e. mixtures feature to fill
the form of concreting products and
condense it by gravity or under the
influence of mechanical vibrators.

Estimation of workability concludes in its

mobility and stiffness coefficients.
7)

The mobility of concrete mix is measured

.
with cone slump, molded from of concrete
mix, which subject to be tested.

Stiffness of concrete mix is characterized by

, .. time of vibration, which is required to align
and condensate molded cone in device for
determining its workability.

.
Classification of concrete mix according to

its workability (acc.to GOST 7473-94)

.

Type of
The standard of workability acc.to
workabilit
following indices:

,
Stiffness,
Mobility, cm
y
,
sec.
.
Cone
Cone flow
slump

.

( 747394)

,
, .

4
3
2
1

31-60
21-30
11-20
5-10

Harsh mix
H
H
H
H

4
3
2
1

31-60
21-30
11-20
5-10

Easily workable mix

W1
W2
W3
W4
W5

Below 4
-

1-4
5-9
10-15
16-20
Above 21

26-30
Above 31

8) In order to protect from concrete mix

segregation, plasticizers are added
by reducing the amount of water and
correctly picking the grain structure
of aggregates.

It is not allowed to increase water content

(under conditions of constant flow of

cement) because it leads to decreasing of
1
4
1-4
concrete strength, though it is reason of
2
5-9
increasing the mobility of concrete mix.
3
10-15
The mobility of concrete mix can be
4
16-20
26-30
5
21
31
increased by increasing the cement paste

content after concrete setting without any

inflection to its strength parameters. At any
8)

case, the proportions must be determined

by laboratory of concrete mix manufacturer.

,

9) Incoming control at construction site

has foreseen following:

.
9.1) the log of incoming control of concrete
mix should be filled including all the

incoming parameters of concrete mix,

which was loaded to the construction site.

) ..,
9.2) production of concrete mix by
,
manufacturer is performed in compliance

with requirements of GOST 7473-94, and

.
control of concrete mix parameters is
executed based on GOST 10181-2000, they

are following:

-concrete mix workability;

,
- concrete mix temperature;

-transportation time of mixture from


. ,

- .
9)

.
:
9.1)

,
..
9.2)

-

7473-94,

10181-2000:
-
10181.01- 10181.4;
- ;
- ;
-
.
9.3) :
9.3.1)

20 30 (
18-20)

2-1
1
2
3-5

, /
30
30
30
30

, .
210
210
150
90

manufacturer to its implementation place;

9.3) incoming control content;
9.3.1) concrete mix receiving is started only
after its delivery time test.
The maximum acceptable duration of
transportation of finished concrete mixture
at the air temperature from 20 to 30C (at
mixture temperature 18-20C) is given in the
following table:
Mixture type
according its
workability
H2-H1
W1
W2
W 3-W5

Average speed of
transportation,
km/h
30
30
30
30

Duration of
transportatio
n, min.
210
210
150
90

9.3.2) Consistency test of concrete mixture

Concrete mix consistency is estimated
based on cone slump(CS) or cone flow (CF),
which was formed from concrete mix. Cone
flow describes W4-W5 concrete workability.
The concrete mix samples are selected from
middle part of batch in order to consistency
test before concreting.
At the continuosly supply of concrete mix,
the samples should be selected with 3
acceptance at randomly chosen time during
10min.as max.
Volume of selected samples should be at
least 2 volume of cone.
9.3.3) Order of preparation and test
9.3.3.1) The surface conducted with
concrete mix should be cleaned and wet at
the stage of cone and other tools
preparation.

9.3.2)

9.3.3.2) Cone is set on the smooth plate

() (not wood) and filled with concrete mix of

(), W1,W2 or W3 types through the funnel with

4-5.

.

.



10.

.
9.3.3)

9.3.3.1)


.
9.3.3.2)

( )

1, 2 3
.
:
1.

.
2.

()
,
10.
.
9.3.3.3)

16:
-25, -56

3 layers of same height.

Note:
1. selected sample must be additionally
mixed before test;
2. preparation of concrete mix test and
control samples (cubes of concrete)
has to be started not late than in
10min.after sample selection.

9.3.3.3) Each layer is pressed with metal

core (f 16mm)by ramming: for standard
cone-25times; for extended cone-56
times.
Note:
1. Concrete mix of W4 &W5 are filled
into the cone at once and puddled 10
times.
2. Cone should be tightly pressed to the
plate during filling and puddling
operation
9.3.3.4) After the pressing the concrete mix,
funnel is taken out, the surplus of mix is cut
with trowel in order to make it as same level
as top borders of cone. The concrete mix
surface is smoothed.
9.3.3.5) Cone is smoothly taken out from
formed concrete mix in vertical way and put
cone next to it. Time is spent for taking out
the cone is to be 5-7sec.
Note:
1. Time from cone filling start to cone
taking out must be 3min.as max.
2. Temperature of concrete mix from
sample selection moment to test
finish moment must not be varied
more than 5C.
9.3.3.6) Slump cone of concrete mix is
determined by placing the smooth rod
along the height of form by measuring the
distance from the bottom surface to the top
part of concrete mix with an accuracy of 0.5

:
cm
1. 4 5

10 .
Note:
2.
1. If after the taking out the cone form,

concrete mix falls to ruin, then

.
measurement is not performed. Test
9.3.3.4)
is repeated with new sample of
,
concrete mix.
2. Slump cone of concrete mixture,

determined in a larger cone. It is

transformed into the standard cone

slump via multiplying cone by a
.
factor of 0.67
9.3.3.5) 9.3.3.7) Cone flow of concrete mix is
determined by measuring the diameter of
melted paste with metal ruler in two
. , mutually perpendicular directions with an
, accuracy of 0.5 cm as max.
5-7 .
:
1.

3.
2.


5.
9.3.3.6)

0,5.

9.3.3.8) Slump cone (or cone flow of

concrete) of concrete mix is determined
twice. General time of test, from filling the
cone with concrete at the first
determination to slump cone measure at
the second determination must be 10min.as
max.
9.3.4) Processing of test results
9.3.4.1) Cone slump of concrete mixture is
calculated, rounded up to 10 cm, as the
arithmetic mean of the two determinations
of the same sample, differing by no more
than:

For 1cm at cone slump 9cm

For 2cm at cone slump =10-15cm
For 3cm at cone slump 16cm

:
1.
,

In case there is big difference between
results, then evaluation is redone with new
sample once again.
.
2. ,

0,67
9.3.3.7)

0,5.
9.3.3.8) ( )
.




10
.
9.3.4)

9.3.4.1)
10,

,

:
1 9
2 =10-15
3 16
,
.

9.3.4.2)
1,0,

,

3.

9.3.4.2) Cone flow of concrete is calculated,

rounded up to 1.0 cm, as the mean value of
the two determinations of the cone flow
concerning one sample, differ by 3 cm.as
max. In case there is big difference between
results, then evaluation is redone with new
sample once again.

9.3.5) The results of concrete quality

determination should be written in a log of
incoming control. The data indicated in that
log following:
-mixture producers name;
-concrete mix description (acc.to GOST
7473-94);
-quality parameter description, which is
subject to be determined;
-test date and time;
-sample selection place;
-concrete mix temperature;
-the test results of certain parameters of
concrete mix quality and mean values
concerning to each parameter.

9.3.6) The cover letter of manufacturer on

concrete mix quality must contains the
following (acc.to GOST 7473-94):
-manufacturer name;
-address, telephone, fax of manufacturer;
-concrete mix brand, its graphical symbol
(for instance, concrete strength class
regarding pressure-B25, workability typeW2, frost resistance F200, waterproof-W4);
- concrete mix content number;
- date and time of concrete mix delivery;
-required concrete strength, MPa (kgf/cm2);
-aggregate description and weight/volume,
kg/l;
- maximum aggregate size, mm
10. Determination of entrained air in the


.
9.3.5)

,
:
-
;
- (
7473-94);
-

;
- ;
- ;
- ;
-


.
9.3.6)

( 7473-94):
-
;
-, , ;
-
(.,
25,

2,

F200,
W4);
- ;
- ;
-
,
(/2);
- / ,
/;
- ,


, ,
.
.

concrete mix should be started immediately

after sampling.
Concrete mix in a bowl deep vibrators seal
device with parameters corresponding to
the construction of the vibrator. Packing
time of concrete in the bowl unit should
comply with the sealing mixture in place of
its installation.
Internal vibrator is gently lowered into the
center of the bowl of entrained air meter for
half the required time compression of the
mixture and gently raised in the same
period. Vibrator does not touch the sides
and bottom of the bowl.
After compaction the missing seal concrete
mix in a bowl filled with a new portion of the
concrete mix and seal it by horizontal
movement of the vibrator on top of the
bowl.
The volume of entrained air and placed
concrete should not be more that 6%. The
percentage of air is shown on the dial
indicator entrained air meter.
11. Concrete strength control shall be
carried out on the object of construction by
compression test of prepared samples.
11.1. The samples of concrete mix can be
prepared by its systematically selection.
Samples shall be taken at the place, where
mixture going to be laid. The number of
concrete samples series of each type, which
are subject to be tested, shall be fixed
based on one series (6 twin-samples) for 50
m3 of concrete mix.
11.2. At concrete pouring in winter and
curing at positive temperature, other than
required 6 samples, three of 6 additional
samples shall be tested on that day when
concrete temperature in the structure falls
down to 1-2C. The remaining samples shall
be reserved (GOST 10180-2000). In order to
sample preparation the portable steel forms
of the following sizes shall be used:

10.


.


,
.



.




.
.




.
,
,
6%.


.

- 10x10x10cm (fraction size below 30 mm)

- 15x15h15cm (fraction size below 40 mm)
- 30x30x30 cm (fraction size above 80 mm)

11.3. Packing of concrete in forms shall be

completed within 30 min after sampling.
Samples can be hold in form maximum 2
days at temperature +15C and 90% of
relative humidity. Then the samples shall be
removed from forms and kept in damp
sand, sawdust or in a concrete moist room.
The room for keeping samples shall have
temperature between 15 and 20 with
90% of humidity as min. Strength test of 3
concrete cubes shall be carried out after 7
days (~70% of strength, to ensure loading
possibility on poured concrete), 3 cubes
tested in 28 days after its sampling. Test
results shall be documented.
11.4 Lab posts on site shall carry out the
following functions:
- control of concrete quality by sampling;

- test of control samples concerning its

strength, waterproof, freeze resistance
parameters and issue the test conclusions;
- development of regulations in order to lab
11.

tests execution.

.
11.1.

.
.


(6 -)
50 3 .

11.2.

,
,

1-2 .
( 101802000).

:
- 101010 (
30 )
- 151515 (
40 )
- 303030 (
80 )
11.3.
30
.
2-

+15

90%.


, .
,

,
+15
20 90%.
3-
7
(~70% ,

),

28
.
.
11.4

:
-
;
-

, ;
-