2012

CONSTRUCTION
QUALITY
MANAGEMENT
SODE-NCP28
You have been selected as a project manager for a
prestigious high rise building Mumbai which will be housing
very rich personalities from industry and film world. Your
company management has asked you to formalize Quality
Management System (QMS) for interior finishes, Plumbing and
prevention of ram water seepage so that the overall quality
standard and image of company is raised.

SUHAIB JUWALE
QUALITY - It’s MEANING IN CIVIL WORK PROJECTS

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.

4. Quality is experience, so it should be done with complete management.

5. Quality management is responsibility of project authority.

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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 Planning Designing Procurement Construction Finished

Facility
Management
Technical

Managerial

Organizational

Manpower

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.

Various stages of quality control are listed below.

 Incoming material control

 Pre-Construction and Planning Control.

 Construction Process Control.

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 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 Quality Quality Manpower

Assurance

Manpower Manpower

Determine Performance
Standards of a facility

Design Option Set up

Select a Design Design tests

Formalize Specification

Plant & Diode Construction Organizational

Machinery Methods

Test Records Q Control Test Records

and Reports and Reports
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 Procurement Procurement

Vendor Material Process Finished

control Product

STANDARDS & SPECIFICATIONS FOR MAKING & TRANSPORTING CONCRETE

Introduction

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.

Standards and Specification

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

The project authorities prepare the process of working out specification of various

facilities where concrete will be used. However, the standards and specifications for

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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. IS Title
No. No.

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 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 Standard

Code for plain and reinforcement (IS:456)

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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

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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

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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.

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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.

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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.

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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

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 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

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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

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 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

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 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

TABLE-2

Tests Conducted on Concrete and its Ingredients (As per IS: 2386-1963)

Sr Cement Pozzolona Aggregates during Aggregat Admixtures for Concrete

No sources selection e site lab
Coiners Fine Product Perform Fresh Harde
Unlomity ance State ned
State
Setting Grading
Moisture Gradin Unit Unit Streng
1 Time (Initial Fitness Grading Density
Content g Weight Weight th
& final) Modules
Air Air
Pozzolona Specific Specific Specify Densit
2 Faise Set Colour Conten Conten
Activity Gravity Gravity Gravity y
t t
Akali Water
Akali Volum
Aggreg Water Cemen
Temperatu Temperatu Aggregat Moisture e
3. ate PH Value Require t
re re e content Charg
Reactivi ment Require
Reaticity e
ty ment
Modul
Water
Soundn Soundnes Soundnes Setting e
4 Soundness Requireme Chloride Temp.
ess s s time Elastic
nt
ity
Strain
Impact Organic Impact Bleedin Bleedin
5 Fitness Fitness Dissolved Capa
value Imperils Value g g
city
Self and Suspend
Compressi Relative Crushin Crushing
6 day ed Creep
ve Designee g Value value
content Matter
Strengt Therm
Material
Loss of Loss on Abrasio Abrasion h al
7 Finer
Ignition Ignition n Value Value Develo Prope
Than
pment rties

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 Crushin Abrasi
Chemical
g Rock Building Volume on
8 Compositio
Strengt sand Charge Resist
n
h ance
Deleterio
Particle us Durabili Durab
9
Shape Substanc ty ility
e
Patrograph
ic
10
examinatio
n
Unit
11 Unit Weight
Weight
Water Water
12 Absorpt Absorptio
ion n
Mica
13 Conten
t

TABLE 3

FREQUENCIES OF TESTS TO BE CONDUCTED

Sr. Small Concrete Jobs and

Name of Test Mass Concrete Remarks
No. R. C. C. Works
Also carry out
tests as
mentioned in
1 Adulteration of cement One every 50 of cement One every 50 of Cement Appendices
M. N. P. and O
at this
frequency
i) Once a day
Particle size analysis of
2 ii) Additional in
aggregates
source is charge
Flakiness index of
3 As per above As per above
coarse aggregate
i) Once a day i) Once a day
Still test o line
4 ii) Additional it ii) Additional if
aggregate
source is charged sources if charged
Clay, line slit and line
dust in aggregate
5 Once a week Once a fornight
(sedimentation
method)
Surface moisture One per shift per stock One per shift per stock
6
content in fine pile pile

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 aggregate (Hot place
method)
Surface moisture
content in line
7 Once a week Once a for Night
aggregate (Laboratory
method)
Bulking of fine One per shift per stock
8
aggregates pile
Specific gravity and
water absorption for
9 One a week
aggregate’s up to 10
mm size)
Specific gravity and
water absorption for
10 Once a week Once a for night
aggregates above 10
mm size)
Slump of cement One per every two hours
11 One a for night
concrete working per mixer
Slump of cement One per every two hours One per every two hours
12
concrete working per mixer working per mixer
i) One per mixer i) One per mixer per
per week mouth
Density and air
ii) Additional if ii) Additional if
13 contents of fresh
source of source of
concrete
aggregate is aggregate is
changed changed
Compressive strength As directed by design As directed by design
14
of drilled cores office office
Laboratory One per month for
Nil
Permeability every mix proportion
15
a) Moulded Specimen One per month per 3m
Nil
b) Drilled Core depth
One hole at 20m,
distance per working
16 In-situ permeability
season for full depth
duly staggered

TABLE 4

Size of Sample Required for Various Tests

Weight of
Sr No. Purpose of test Material sample Remarks
required
About 100 kg of the
samples shall be per served
1 Adulteration of Cement 1
in air light container in case
of doubt about it quality
Tests on aggregate Coarse 100
2
such as particle size, Aggregates

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 flakiness index, surface
moisture, bulking Fine 40
specific gravity and aggregates
water absorption
Cement
Complete mix design Coarse
3
of concrete/mortar aggregate
Surkhi Lime

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.
Item Table
No.
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

TABLE 5

Significanc
Test
Sr Type of Parameter e/
Specimen/Apparat Remarks ASTM BS IS
No Test Derived Applicatio
us
n
Time
Quality Different Type
available
Setting Vicat apparatus or control on of needles for C191 4550
1 for 4031
Time Gull more needle cement initial and C266 (3)
concrete
supplied final setting
forming

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 Presence
Checks for
Le Chattier, Part Expansion of excess
development 4550
2 Soundness and Autoclave test in gypsum, C-15 4031
of serve (3)
methods dimensions lime or
cracks
magnesia
Strength of Loss of C190
Briquettes and Load per 4550
3 Strength cement strength due C109 4031
cubes unit area (3)
used to storage C917
Specific Uniformity
Fitness and Air permeability or Rate of gain 4550
4 surface in quality C114 4031
Grading photo electric in strength (3)
area of cement
Percent of
Chemical various
Quality of Classification 4550
5 Compositio Chemical Analysis cement C114 4032
cement of cement (3)
n constituent
s
Weight per Uniformity 4031
Specificati 4550
6 Le Chattier flask unit in cement C118
on Gravity (3)
volume supplied
Mass 269
connectin
Calories of Simple
Heat Heat of solution g cold 4550
7 heat Laboratory
evolution method weather (3)
evolved Test
concernin
g
Mortar made with Percent of
Water Masonry Workability of
8 cement in standard water C91
retention cement mortar mix
manner suction
False
Depth of Rate of
setting,
9 False set Vicat’s Apparatus penetratio setting of C359
premature,
n cement
stiffening

TABLE 6

Tests for Evaluation of Characteristics of Aggregate

S. Tests Significance Test Specification ASTM BS IS

No. Characteristic of methods requirement
s Importance
Visual
Petrography Presence of C295 2386
1 Examinati 882
Examination Impurities D75 (vi)
on
Workability
Max. and Min. C136
Grading and of fresh State 812(I)
2 percent passing C125 2386 *I)
Surface area concrete Analysis 4101134
standards sieves C33
Economy
Bulk unit Mix design Weighing Max. and Min.
3 C29 812(2) 2386(I)
weight calculations method Unit weight

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 and
classificatio
n
Mix design
calculation
Specific Batting C127
4 of ensure 812(2) 2386(I)
Gravity method C128
uniform
supply
C70
Absorption Quality
Drying Min. Percent of C127 2386
5 and Surface control of 812 (4)
Method water C128 *vii)
moisture concrete
C566
Strength
and C27
durability of Max. expansion C289
Chemical all structures Chemical of motor bar. Not C586
6
Stability To delete Analysis reactive with C88
harmful cement alkalies C117
inorganic C40
compounds
Decides the
Max. expansion
Resistance to porosity Icing and C290,
of motor bar Not
7 freeze and structures deciding C291,
reactive with
thaw subject to test C682
cement
weathering
Index of
agg. quality
Abrasion Soundness Mechanic 2396(iv
8 Max. percent loss C131 812(3)
resistance and al Test )
crushing
value
Index to
agg.
Quality Std. Load
Crushing 812 (3) 2396
9 Soundness applied Minimum value
Strength 882 (iv)
and test
crushing
value
Index to
impact
Std.
value 2396(iv
10 Impact Value Impact Minimum Value 812 (3)
soundness )
load test
in
compassion
Influences Sampling
Sampling Max. & Min. D75
11 on test technique 812(I) 2430
aggregate samples C702
result s

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 TABLE 7
Tests for Water for Concrete Making
(Tolerance Limit and Effect of Ingredients)

Tolerance Limit (IS 456)

Sr. Influence and effect in Concrete
Ingredients Reinforced
No. Mass (Higher Value(H)/Lower value (L)
Concrete
Concrete Max
Max
Adversely affect hardening of
1 Organic 200 mg/I 200mg/I
cornet
Greatly retard both setting and
2 Inorganic 3000mg/I 3000mg/I
strength
Sulphates
3 500 mg/I 500 Mg/I Reduces the 28 day strength (H).
(as SO4)
Enhances both hardening and
Chlorides
4 1000 mg/II 2000 Mg/I strength rate. Result in Corrosion
(as CI)
and deterioration
Suspended
5 2000 Mg/I 2000 Mg/I Adverse effect on strength
Matter
Hydrogen
6 concentratio More than 6 More than 6 Result for corrosion of steel (H)
n
7 Sea Water 35,000 ppm Reduction in strength (H)
Repaid setting but, reduction in
8 Sugar 0.25 0.25% strength, Retards setting time (H &
L value)

TABLE 8
Code of Practices for Admixtures and its influence

Sr.
Classification Purpose/Influences ASTM BS IS
No.

Improves durability to
freezing and thawing, C260 C233
Air entraining
1 surface scaling C226 C175 5075(2) 9103
admixture
Reduces segregation C595
and bleeding
Increases strength and
Water reducing slump of concrete
2 5075(1) 9103
admixture increase in drying
shrinkage
Retarding and setting
3 Retarding Agents time of concrete and 5075(1) 9103
grout

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 To accelerate the
setting time and
Accelerating strength development
4 D98, D345 5075(1) 9103
Admixture early removal of forms
increase the drying
shrinkage
Fine particles combines
with Calcium
Hydroxide to form
3812,
5 Pozzolona comentitious C219, C618 3892
1344
properties, control
internal temperature in
mass concrete
Improve slump,
reduce, water
6 Workability agents comment ratio, C618 4887
facilitated, placing and
finishing
Reduce the capillary
Damp
flow of moisture
Proofing/Permeab
7 through concrete that 743 2645
ility reducing
is in contact with water
agent
or dampness.
To alter the properties
of grout for specific like
8 Grouting agents stabiles, foundation, C937
crack, fill joints, seal oil
walls etc.
To entrain gas form in
concrete before
9 Forming Agent hardening applied for C869, 796
grouting in post
tensioning

TABLE 9
Destructive Tests for Concrete Strength

Type
Sr. Parameter Significance/Applicati
Type of Test Specime ASTM BS IS
No. Measured on
n
Standard for
1881
making test 1199
(4)
1 specimen a Influences to test result C31
1881
Field b. 1199
(4)
Laboratory
Method of
1881
2 capping test Uniform loading in test C617 516
(4)
specimens

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 Drilled core
Cube
and sawed 1881
3 and Field Application C42 1199
concrete (4)
Cylinder
specimen
C39,
Cube
Compressive Ultimate Strength in C513, 1881
4 and 516
Strength test failure load compression C873, (4)
Cylinder
C116
Flexural
strength test
1881
Ultimate C78,
a. Third point Beam Module of repute (4)
5 failure load C683, 516
loading
C293
b. Center Module of repute 1881
Ultimate
point Beam quality control
failure load
loading
Splitting Splitting Tensile strength of 1881
6. Cylinder C496 5816
strength load concrete (4)
Bond
Cubes Strength
Comparing Concrete
7 Bond Strength and between C234 2770
Mixes
Prisms steel and
concrete

TABLE 10

Non Destructive Tests for Concrete Strength

Paramete Applicatio
S Type
Type of r Paramete n/ Advantag Disadvan I
N Specime ASTM BS
Test measure r derived Significanc es tages S
o. n
d e
1 Rebound Test Degree Strength Testing of Payable Variable C805 4408
Hammer Specime of through concretruc simple in results (4)
Test n or in sills rebound calibratio tual operation only
concrete received n members quality of
surface
concrete
2 Penetratio Test Dimensio Testing Portable Variable Variable C803 4408
n Specime n of concrete simple in results only result (4)
n or in silu indentati stractual operation quality of only
concrete on surface quality of
concrete surface
of
concrete
3 Vibration Beams Resonant Quality Single Limited to C215 1881
Sonic test Cylinders frequenc control, specimen specially
Beams y of deteriora simple made Do --do--
a. Longit Cylinders elasticity tion of accurate specimen
udinal Beams --do— concrete and --do—
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 b. Flexura Cylinders dynamic resproducti
l modules --do— y --do--
c. Torsion of
modules --do-- --do—
of
elasticity as above
in shear Poisson’s
ration
4 Ultrasonic Test Velocity Compres Laboratory Variability Special C597 4408
Pule cubes of pulse sive test, testing of preparati (5)
velocity concrete time through of concrete on
test members calibratio concrete strength required,
n in silu for can be Access to
strength measured two
opposite
faces of
member
is
required
5 Pull Out Pull Put Failure
Test Interest load
fracture

TABLE 11

Tests for Physical Properties of Concrete

Parameter
Sr.
Test Derived Significance or
No Types of test ASTM BS IS
Methods applications
.
Strength to
Strength of C666
Durability Freeze and withstand
1 concrete for C671
Test thaw cycles standard
special condition C672
cycles
Shrinkage Dimensions Relatives shrinkage
Wet and dry C157 1881 6441
2 and moisture measuremen in structural
process C827 (5) (11)
movement ts members
Dry abrasion
Abrasion Depth of Industrial flooring C944,
test
3 resistance abraded hydraulic channel C779, 9284
abrasion
test materials etc. C148
tools
Water Amount of
Permeability Water tank, fluid, 1881
4 absorption water C642 3085
test retaining (5)
method absorbed
Static
Strain
modules of Stress and Quality of 1881
5 measureme C469
elasticity and strain values concrete (5)
nts
Poisson’s

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 ratio

Performance of
Alkali Mortar bar Elongation in
6 cement and C227
reactivity test method length
aggregate
Creep of Longitudinal
Performance of
7 concrete in compression Strain values C512
concrete structure
Compression method

INSPECTION & CHECKLISTS

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.

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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.

26 | P a g e
  Inspection of the end product.

Guidelines for concrete inspection are given below:

Sr. IS Title
No. No.

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 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 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)

27 | P a g e
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.

ASSURANCE 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

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 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

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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

30 | P a g e
 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.

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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

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 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

33 | P a g e
 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

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 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.

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 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,

36 | P a g e
 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 QUALITY ASSURANCE ORGANISATION/UNIT AT SITE

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.

37 | P a g e
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.

38 | P a g e
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

39 | P a g e
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.

40 | P a g e
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.

41 | P a g e
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

42 | P a g e
CONCLUSION

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

43 | P a g e
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.

44 | P a g e
 Table 3.14

List of Equipment/Apparatus Required for Concrete Testing Laboratory

Sr. Laboratory Laboratory

Description Remarks
No. Class A Class B
IS Sieve sets 300, 20080, 40, 25, 20, 10,
1 6,2,4,5, 75 3.35, 2.36, 1.70 and 1.8 mm
850, 600, 300, 150, 90, 45 microns
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. Laboratory Laboratory

Description Remarks
No. Class A Class B

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

Beakers 100cc, 1000cc Balance in 1kg
23
and 200 kg capacity

45 | P a g e
 Crushing value apparatus for
24
aggregate
25 Stop watch
Standard hand tools and gauges for
26
metal work
27 Laboratory type concrete mixer

28 Curing tanks of various sizes

29 Blains air permeability tester
Cylinder Measures, metallic 3,15, 30
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
Hydraulic jack with remote control
34
5.20, 50, 2001
35 Concrete test hammers

36 Compression testing machine 2000

37 Transverse testing attachment

38 Universal testing machine 400

Bibliography

NICMAR publication lesson book on Construction Quality Management

Butterworth-Heinemann publication, The Management of Construction by Lawrence

Bennett

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