QUALITY CONTROL MANUAL

Transcription

1 GOVERNMENT OF RAJASTHAN WATER RESOURCES DEPARTMENT QUALITY CONTROL MANUAL March 2011 Chief Engineer Water Resources Department Rajasthan, Jaipur

2

3 PREFACE Status of water in Rajasthan is critical and complex. Ground water table is depleting at fast rate across the state due to over exploitation. The availability of water is also decreasing regularly due to abnormal growth of population. After independence, major concentration was extended to water sector and 90% of state's water is utilized by irrigated agriculture. But the major concerns in water sector are sustainability, productivity, water management, pricing etc. It will be our endeavor that the works are executed with strict quality standards confirming to technical specifications with deployment of good construction modalities. To achieve the objectives of an effective Quality Control Monitoring and Quality Assurance Management System, an independent quality control unit has been established and made operational. The important aspect is to develop quality concept and capacity of field engineers to be continuously vigilant on quality control. Accordingly a manual to promote procedure and guidelines of quality control systems on the works of Water Resources Department has been prepared, after detailed discussions and feedback experience from the prevailing practices. The manual shall provide in depth understanding of the need of quality control, including prescribing the tests required to be conducted for the materials during construction and placement activities along-with post construction scenario. The manual is designed to introduce various formats to be followed at various stages or construction to achieve proper quality control and to transmit necessary reports. It also provides an opportunity for the engineering personnel for deployment of their skills in quality control procedures to increase useful life of structures being constructed in confirmation with the international standards. Although every care has been taken to check mistakes and misprints, yet it is difficult to claim perfection. Any errors, omissions and suggestions for the improvement and corrections in the Quality Control Manual are most welcome from all the quarters, which may please be sent to the undersigned.

4 Quality Control Manual for Water Resources Department has been made under valuable guidance and support of the Committee officers Sh.P.L.Solanki, Chief Engineer Quality Control & Vigilance, Jaipur and Sh.G.R.Bhansali, Chief Engineer SWRPD, Jaipur.Their valuable support for the finalization of Quality Control Manual applicable to the construction works of Water Resources Department by Sh. Narendra Mertia SE & TA and his team is thankfully acknowledged. Date: 17th March, 2011 Place: JAIPUR (Kundan Lal) Chief Engineer Water Resources Department Rajasthan, Jaipur

5 INDEX CHAPTER NO. PARTICULARS PAGE NO. LIST OF INDIAN STANDARDS CHAPTER-I QUALITY ASSURANCE AND CONTROL 1 CHAPTER-II ORGANISATIONAL SET-UP 5 CHAPTER-III GENERAL FUNCTIONS OF LABORATORIES 8 CHAPTER-IV CHAPTER-V DUTIES OF STAFF INCHARGE OF LABORATORIES DUTIES OF FIELD STAFF IN RELATION TO QUALITY OF WORKS (i)-(iii) CHAPTER-VI CO-ORDINATIONS 24 CHAPTER-VII QUALITY ASSURANCE 27 CHAPTER-VIII O.K. CARDS 29 CHAPTER-IX TESTS TO BE PERFORMED ON MATERIALS 39 CHAPTER-X LIST OF EQUIPMENT FOR CEMENT AND CONCRETE TESTING CHAPTER-XI FORMATS OF TEST RESULTS 43 CHAPTER-XII IMPORTANT SPECIFICATIONS 58 CHAPTER-XIII FREQUENCY OF TESTING 96 CHAPTER-XIV MONITORING THROUGH CONTROL CHARTS 102 CHAPTER-XV COMPILATION OF QUALITY CONTROL DATA CHAPTER-XVI PROCEDURE FOR EXECUTING EARTH WORK 108 CHAPTER-XVII CHAPTER-XVIII CHAPTER-XIX CHAPTER-XX CHAPTER-XXI CHAPTER-XXII ANNEXURE-I PROCEDURE FOR EXECUTING CONCRETE LINING PROCEDURE FOR EXECUTING RCC WORK & CONCRETE FOR STRUCTURES PROCEDURE FOR SHOT-CRETING AND GUNITING DETERMINATION OF FIELD MOISTURE & DRY DENSITY OF COMPACTED EARTH FILL DETERMINATION OF FIELD DENSITY BY SAND REPLACEMENT METHOD CHECK LIST FOR QUALITY CONTROL UNIT SKETCH SHOWING THE ROLES AND RESPONSIBILITY MATRIX ANNEXURE-II ORGANISATIONAL CHART 142 ANNEXURE-III SKETCH SHOWING CONSTRUCTION JOINT IN LINING

6 ANNEXURE-IV INSPECTION OF TESTING ACTIVITIES 144 ANNEXURE-V-A SKETCH SHOWING AIR WATER GUN 145 ANNEXURE-V-B AIR MORTAR GUN 146 ANNEXURE-VI ANNEXURE-VII ILLUSTRATIVE SKETCH SHOWING TREATMENT OF CANAL PRISM IN EXPANSIVE SOILS WITH CNS MATERIALS TYPICAL CROSSECTION OF A DISTRIBUTARY WITH C.N.S. SUB GRADE ANNEXURE-VIII ANNEXURE-IX ANNEXURE-X ANNEXURE-XI ANNEXURE-XII ANNEXURE-XIII ANNEXURE-XIV ANNEXURE-XV CURVE SHOWING RELATION BETWEEN SPECIMEN SIZE AND STRENGTH OF CONCRETE CORE DATA OF THE CORES TAKEN FROM IN SITU CONCRETE CANAL LINING ILLUSTRATION OF PREPARATION OF CONTROL CHARTS FOR CEMENT AND CONCRETE GRAPH SHOWING CORRECTION FACTOR FOR HEIGHT/ DIAMETER RATIO OF A CORE STATEMENT SHOWING CAPACITY OF PAVER AND MECHANICAL TRIMMER GOVERNMENT OF RAJASTHAN,IRRIGATION DEPPARTMENT ORDER OF DATED GOVERNMENT OF RAJASTHAN,WRD ORDER OF DATED PHOTOGRAPHS OF KEY/CRITICAL EQUIPMENTS

7 S. No. LIST OF INDIAN STANDARDS Short Title IS. to various Standards (A) Cement 1 Specification for 33 grade ordinary Portland cement IS: Specification for Rapid-hardening Portland cement IS: Specification for Portland pozzolona cement IS:1489 (Part 1&2) Methods of physical test for hydraulic cement IS: Method of chemical analysis of hydraulic cement IS: Method of sampling for hydraulic cement IS: Standard sand for testing of cement IS: Specification for 43 grade ordinary Portland cement IS: Specification for 53 grade ordinary Portland cement IS: (B) Coarse / Fine Aggregate 1 Specification for coarse & fine aggregates IS: Methods of test for aggregates for concrete IS:2386 (Part I)-1963 particle size and shape. 3 Methods of test for aggregates for concrete IS:2386 (Part II)-1963 estimation of deleterious materials and organic impurities. 4 Methods of test for aggregates for concrete specific IS:2386 (Part III) gravity, density, voids, absorption & bulking. 5 Methods of test for aggregates for concrete IS:2386 (Part IV)-1963 Mechanical properties. 6 Methods of test for aggregate for concrete IS:2386 (Part V) Soundness. 7 Methods of test for aggregate for concrete IS:2386 (Part VI)-1963 measuring mortar making properties of fine aggregates. 8 Methods of test for aggregates for concrete alkali aggregate reactivity. IS:2386 (Part VII) Methods of test for aggregates for concrete petrographic examination. IS:2386 (Part VIII) (C) Bricks 1 Method for sampling of clay building bricks IS: Method of tests of burnt-clay building bricks IS:3495 (Parts 1 to 4) Common burnt clay building bricks IS:

8 S. No. (D) Short Title IS. to various Standards Masonry Mortar 1 Specification for sand for masonry mortars IS: Code of practice for preparation and use of masonry mortar. IS: (E) Cement Concrete 1. Specification for coarse and fine aggregate IS: Specification for compressive strength, flexural IS: strength. 3 Code of practice for plain & reinforced concrete IS: Methods of sampling and analysis of concrete IS: Recommended guide lines for concrete mix design IS: (F) Curing Compound 1 Standard test method for water retention & day light reflection test on concrete. 2 Standard method of test for effect of organic materials in fine aggregate on strength of mortar. 3 Standard specification for liquid membranes forming compounds. ASTM-C ASTM-C ASTM- C (G) PVC Water Stops 1 Code of practice for provision of water stops IS: Procedure for Testing Parts of IS: Standard Test methods for Tensile properties of ASTM : D Plastics. 4 Standard Test methods for Thermoplastic Elastomers Tension. ASTM : D (H) HYSD BARS 1 Specifications for HYSD bars. IS: Specification for Mild Steel and Medium Tensile IS:432 (Part I) steel bars for concrete reinforcement. 3 Method for Tensile testing of steel wires IS: Hard drawn steel wire for concrete reinforcement IS:432 (Part II) Method for Tensile testing of Steel IS: Code of practice for bending & fixing of bars for concrete reinforcement. IS: (I) Precast R.C.C. Pipes 1 Specifications for precast concrete pipes IS: Methods of test for concrete pipes IS:

9 S. IS. to various Short Title No. Standards 1 Preparation of dry soil samples IS:2720 (Part I) Determination of water content (moisture content) IS:2720 (Part II) Determination of specific gravity of fine grained soils. IS:2720 (Part III) Sect/1 4 Determination of specific gravity of fine, medium & coarse grained soils. IS:2720 (Part III) Sect/2 5 Grain size analysis IS:2720 (Part IV) Determination of liquid and plastic limit IS:2720 (Part V) Determination of shrinkage factors IS: 2720 (Part VI) Determination of water content -dry density IS:2720 (Part VII) relation using light compaction. 9 Determination of water content -dry density relation using heavy compaction. IS:2720 (Part VIII) Determination of water content -dry density IS:2720 (Part IX) relation using constant weight of soil method. 11 Determination of unconfined compressive strength IS:2720 (Part X) Determination of shear strength parameters IS:2720 (Part XI) (tri-axial) without measurement of pore water pressure (tri-axial compaction). 13 Determination of shear strength parameters with IS:2720 (Part XII) measurement of pore water pressure. 14 Direct shear test IS:2720 (Part XIII) Determination of density index (relative density) of cohesionless soils. IS:2720 (Part XIV) Determination of consolidation properties IS:2720 (Part XV) Determination of permeability IS:2720 (Part 17) Determination of dry density of soils, in- place by IS:2720 (Part 28) the sand replacement method. 19 Determination of dry density of soils, in- place by IS:2720 (Part 29) core-cutter method. 20 Laboratory vane shear test. 1S:2720 (Part 30) Determination of the density in place by the ring IS:2720 (Part 33) and water replacement method. 22 Determination of free swell index of soils IS: 2720 (Part 40) Measurement of swelling pressure of soils IS: 2720 (Part 41) Classification and identification of soils for general engineering purposes. IS:

10

11 CHAPTER I QUALITY ASSURANCE AND CONTROL 1. INTRODUCTION Evaluation of water resources projects involves enormous expenditure. They are time bound programme and require assistance from various technical bodies for investigation, design, planning and execution. To have a safe durable structure, it is necessary that the materials and standard of execution fully satisfy the specifications. It is to be recognized that the ultimate efficiency of the performance of a project will depend upon proper layout and designs, the ultimate health of the project during life scale of its operational phase will depend largely on the quality achieved during its construction. Each and every job whether big or howsoever small shall require to be executed to acceptable construction quality duly confirming to sound design principles, specifications and deployment of good methodology or modern technique and procedures. To achieve the requisite objectives, it is essential to introduce a result oriented quality management system. This system is planned to orient the whole range of quality effort on a continuous basis covering quality assurance and quality control, broadly out lined below including steps initiated for its meticulous implementation. 1.1 Orientation and training of construction supervision/quality control staff A capable and functional construction supervision (CS) and quality control / quality assurance team is needed to ensure implementation of contract specifications. To achieve this objective intensive training will be given to all related staff of construction / quality control in suitable batches covering specifications for the works to be executed and also the procedure to conduct various tests in the field and laboratories. Recommendation of I.S. codes will be explained in the training so as to cover key construction and QC / QA aspects. 1

12 1.2 Laboratory system for testing of Input and Outputs Looking to the overall quantum of work and the scattered area in different zones, establishment of laboratories at different levels and places forms an important link of project organisation for quality control. The system is required to provide reliable and accurate testing support to fulfill the objectives. Accuracy and reliability in testing will depend upon the competence of testing personal, accuracy of apparatus, quality of reagents used, and maintenance of requisite environmental conditions. Introduction of "Mobile testing laboratory system" will prove to be highly result-oriented. This can be supplemented by adequate nos. of site labs, field laboratories and zonal laboratories. 1.3 O.K. Card System It provides a systematic approach towards assuring quality construction and has proved to be practical mechanism for enforcement of technical specifications. For the purpose, each work is divided in various activities in proper sequence/order of construction and listed in chronological order of occurrence in O.K. Card. The cards are maintained in 2 colors (Pink and Green) to be operated by construction and quality control units separately. During execution of work both cards are operated simultaneously and will be kept on record by Executive Engineer concerned. 2. OBJECTIVES AND SCOPE OF QUALITY CONTROL The objective of quality control management is to collect, process and then communicate the data related to the quality of inputs and outputs as well as finished item of work to those who are responsible for the quality. Any programme of quality control seeks to ensure adequacy and uniformity of quality through the following operations. 1. To ensure that the works are being executed in conformity with the prescribed specification. 2

13 2. Inspection of storage, handling and processing facilities for all materials in conformity with accepted or specified practice. 3. Monitoring the variation in specification of the materials and quantities used in the operation of production and in the final product by suitable observation, measurements or tests. 4. In order to achieve the common goal Construction quality in the execution of project, the roles and responsibility matrix, as depicted in Annexure-I shall be broadly followed by : 1. GOR 2. Contractor 3. Project Construction Team 4. Project QC/QA Team and 5. Project Design Team 5. Analysis of the observed variations by statistical or other techniques. 6. Feed-back of the results of analysis for exercise of control at each stage and to take corrective steps for maintaining the variations within specified limits. 7. Indicating expeditiously the possible remedial measures, wherever warranted to ensure execution of works as per drawings / specifications. 8. Rejecting, where warranted, the material or the product at any intermediate or final stage in case acceptance criteria is not satisfied. The rejected material should be removed from work site immediately. 3. QUALITY CONTROL MANUAL It is very important constituent of the quality management system. It is a document encompassing specific requirement, which if fulfilled, shall help in effectively implementing the quality control system to achieve the objective of good construction quality. It covers broadly, the objectives, functions and operations of the Q.C. organisation; duties and responsibilities of Q.C. personnel; Q.C. Laboratory System; O.K. Cards; Monitoring through Control Charts; Control on workmanship; Tests on materials; Important specifications; Standards to be adopted for materials and works; Frequency of testing and reporting; Compilation of Q.C. Data and Statistical Analysis etc.; Documentation and Feed-back; Inspection etc. 3

14 4. CONFIGURATION OF QUALITY MANAGEMENT SYSTEM QUALITY MANAGEMENT SYSTEM Quality planning, Q.C. Manual; Training of Q.C./Q.A. Staff, Infrastructure etc. Quality Control Quality Assurance 5.1 QUALITY CONTROL: (Q.C.) The operational techniques and activities that are used to fulfill the requirements for quality. 5.2 QUALITY ASSURANCE: (Q.A.) All the planned and systematic activities implemented within the quality system and demonstrated as needed to provide adequate confidence that an entity will fulfill requirements for quality; and making sure that the quality of a product is what it should be. Purpose of Quality Assurance is to prevent problems before they occur, to identify and correct them swiftly if they occur and to uncover the root cause. 5.3 QUALITY MANAGEMENT All activities of the overall management function that determine the quality policy, objectives and responsibilities, and implement them by means such as Quality Planning, Quality Control, Quality Assurance, and Quality Improvement within the quality system. The QUALITY CONTROL MANUAL being adopted for Water Resources Department (the salient requirements of which are being outline in the various chapters) aims at a System Approach to ensure that upon implementation, the quality levels as set and defined in the specifications and contract documents and relevant Indian Standards would be met in the execution of project works. 4

15 CHAPTER II ORGANISATIONAL SET-UP GENERAL I. Anyone connected with quality control work, should possess adequate knowledge and experience of quality control works and be well conversant with testing of construction materials. The object of quality control should be clearly understood by them in letter and spirit so as to help in construction and achieve high order of quality as laid down in specifications for works by controlling various factors responsible for deterioration in quality, investigating reasons therefore and suggesting ways and means for improvement. II. III. To have proper and independent quality, quality control formation shall consist of an independent unit headed by Chief Engineer Quality Control. The C.E. shall have three S.E.'s in-charge of Quality Control Circle for the various construction activities of different zones and the S.E.'s shall have a team of E.E.'s to look after the work of different circles. Thus there will be separate streams of construction and quality control assurance respectively up to the level of C.E. (Organisational Chart attached at Annexure-II). Every Q/C Circle shall be divided in number of division and each division shall be headed by the Executive Engineer for the purpose of effective quality control, every divisional jurisdiction shall be sub-divided in number of units and each unit is to be put under the charge of A.En. The E.E. quality control shall make all arrangements for the demarcating the areas of operation of every quality control staff and issue a duty chart for each member after approval from the C.E / S.E. Field Laboratory will be situated at important nodal points which shall cover all the adjoining works and incharge will be T.A. to Executive Engineer. Site Laboratories as per requirement in field shall be maintained by concerned site in-charge (construction) and also utilized by Assistant Engineer Q/C for carrying out necessary tests whenever site is inspected by him. 5

16 IV. One of the fundamental principles to be understood and kept in mind is that the overall responsibility for achieving construction quality in each subproject rests with the execution unit and construction staff shall be fully responsible for quality of work. Requisite assistance is to be provided by the Q.C. Staff for ensuring construction quality. Functions of Quality Control Units The main function of Q.C. units is to have independent checking and control of works. Since the works in the zones are of scattered nature, the quality control units can not exercise concurrent quality control, but it has been planned that these units should act in such a manner that necessary quality control requirements are fulfilled jointly with the execution staff. It will be the responsibility of quality control staff to ensure that all-requisite test as per IS / relevant standards and specifications are carried out in site / field / zonal or central laboratories. The quality control units will carry out periodic inspections of works and conduct field tests so that any deficiencies in the execution of works are properly brought to the notice of concerned authorities and execution staff for taking corrective measures. The following broad indications of functions of quality control units are given which may be supplemented by issue of any further instructions by the Chief Engineer, Quality Control, Jaipur from time to time. (1) They should monitor that all required tests are carried out before start of work as well as during execution. At least 10% tests are to be conducted by the quality control units for reliability of the results and counter checking. (2) They should ensure that all arrangements for carrying out routine field tests in the field laboratories and site laboratories are duly made including provisions and up-keeping of equipments, personnel etc. and record of these field tests in prescribed formats are maintained. They should check this record and also sign in the relevant registers in token of their inspection. They should conduct field tests whenever they visit site of construction work and record results of such tests in the registers maintained for the purpose. 6

17 (3) They shall be empowered to order the suspension of work if deficiencies or defects are noticed during execution. Order for stoppage of work if given by the officer below the rank of S.E. should be got examined and confirmed by S.E. Q.C. very promptly, preferably within 24 hours. However, order for suspension of work can only be passed by the Chief Engineer Quality Control. (4) Inspection Book should be maintained at site wherein remarks should be recorded by quality control staff whenever they visit site which should be noted for compliance by the construction unit. They should specifically record any deficiency noted to bring the same to the notice of appropriate authority through remarks in the inspection book or inspection note. The execution staff shall ensure the compliance of such deficiency and intimate to the concerned officer of Quality Control Unit. (5) The Chief Engineer, Quality Control shall ensure at least one test check of all the works costing more than Rs lacs in a year. This does not preclude him for conducting more than one test check of any work for important works; frequent checking is to be carried out. The test check shall be thorough to ensure the quality of work and shall include - a. Observation of DBD and moisture contents of earthwork in filling reaches. b. Fineness modulus of sand, grading of sand and coarse aggregate. c. Checking of water cement ratio for concrete. d. Checking of lining work / masonry work / concrete work. e. Any other requisite tests as per case. 7

18

19 CHAPTER III GENERAL FUNCTIONS OF LABORATORIES The laboratory system, in addition to evaluate and monitor the inputs and outputs, would also evaluate and monitor the workmanship as well as construction plant, machinery and equipment. This would, thus, be accompanied by testing as well as inspection. FUNCTIONS OF CENTRAL LABORATORY AT JAIPUR I. To conduct laboratory tests on samples of sand, coarse aggregate, stone, cement and steel for use in masonry and concrete works. II. III. IV. To conduct laboratory tests for foundation soil, and for selection of soils from proposed borrow areas, for use in the various zones of embankment as per specifications, proctor density & optimum moisture content of soils before start of earth work. For masonry and concrete, the strength of mortar and concrete has to be as specified in agreement. Laboratory has to design the proportions of different ingredients through tests for the specified strength. The proportioning shall be done by weight. It should be co-related with volume for volumetric batching of concrete where quantity of concrete to be placed is of small magnitude. Volume batching may be allowed by the Engineer-in-charge where weight batching is not practical and provided accurate bulk densities of materials to be actually used in concrete have been established. Allowance for bulking shall be made in accordance with IS: 2386 (Part III) The mass volume relationship shall be checked at periodical frequency to ensure that specified grading is maintained. For concrete and mortars where strength is not given and only proportions have been specified, the strength should be treated as standard for execution. V. When controlled concrete is specified, it is essential that mix design is to be done. VI. Since the strength of cement varies from batch to batch in a cement factory itself, it is essential that a relation between strength of cement versus strength 8

20 of concrete may be worked out in the lab, well in advance of the starting of the work. This would facilitate in furnishing the proper proportion of the mix for adopting in the field and also it entails adding or reducing cement content based on the strength of the cement. VII. Results of tests performed in central laboratory should be documented in prescribed Performa pertaining to following tests. A. SOIL : Disturbed grain size analysis IS: 2720 (Part IV) Proctors compaction IS: 2720 (Part VII & VIII). Atterberg's limit IS: 2720 (Part V) Permeability IS: 2720 (XVII) (at OMC. MDD) Shear test (remoulded at OMC. MDD drained / undrained) IS: 2720 (Part XIII) Specific gravity IS: 2720 (Part III) Undisturbed density and natural moisture content, permeability, consolidation, shear test (drained/undrained) at OMC or saturation. Free swell index; Swelling pressure of soil sample. Dispersibility of soils. Total Soluble salts. Chemical test for carbonates & sulphates (Chlorides Gypsum test). B. SAND : For IS: Grading, IS: 2386 (Part I) Fineness Modulus, IS: 2386 (Part III) Bulkage, IS: 2386 (Part II) Organic and silt content. Deleterious material and mica content, and presence of organic impurities, if any. C. Cohesive Non-Swelling Soils Requirement should broadly confirm to IS: D. CEMENT Fineness, consistency, specific gravity, compressive strength, setting time, soundness by Le-Chatelier test. E. COARSE AGGREGATE : Grading IS: 2386 (Part I)

21 Soundness, crushing value, impact test. Abrasion, Absorption, Specific gravity IS: 2386 (Part III):1963 Flakiness. F. BOULDERS : Soundness, weight and size, absorption, specific gravity, weathering conditions (visual) abrasion after breaking to proper sizes. G. FILTER MATERIALS : Grading, uniformity co-efficient, weathering conditions (visual) and tests for fine and coarse aggregate fulfillment of filter criteria as per I.S.Code. H. WATER: ph value, silt content, soluble salts and any other impurities. H1. STEEL Ultimate tensile strength / Elongation. I. CONCRETE : Air Content Mix Proportions; Test on admixture (if used); Test on Super-plasticiser (if used) J. HARDENED CONCRETE AND MORTARS : Proportion by chemical analysis and compressive strength. K. BRICKS : Dimensions and physical properties including water absorption and compressive strength. L. TESTS FOR FOUNDATION INVESTIGATION AND INSITU PERMEABILITY BEARING CAPACITY : Other properties, if tested shall be reported in the remarks column or foot note. M. LDPE Film wherever used shall be tests. N. IMPROVED DEVICES FOR QUALITY CONTROL : It is planned to introduce improved devices for achieving speedy and efficient quality control. Monitoring the characteristics of fresh concrete is important from the point of view of quality control. The 28 days strength of concrete is the criteria for acceptance and is the basis of quality evaluation. 10

22 However, one has to wait for 28 days to get the results of compressive strength of concrete cubes / cylinders. Even the accelerated compressive strength tests take considerable time. The portable electronic devices, commercially available now, have made it possible for rapid on-site measurements of slump, temperature, water-cement ratio (the most important factor influencing the strength of concrete) and the likely 28 days strength of fresh concrete mixes. Software supplied with the electronic unit also produces 'quality control certificates' based on the measurements taken by this unit. This evidence of the properties of concrete gives the site Q.C. /Q.A. Engineer, the confidence to accept or, if necessary, to reject the concrete mix before it is placed. Central laboratory at Jaipur is planned to be equipped with such a portable electronic unit with software. On embankment construction and compacted earth fill placement it is planned to procure an engineering device of the type "Nuclear Guage" to enable much more rapid and economic compaction and quality control than the conventional methods, without any loss in accuracy. Such a device is capable of quickly computing and displaying wet density, moisture content, dry density, and percentage of compaction in terms of Proctor density. The central laboratory at Jaipur is planned to be equipped with two Nuclear Guage Device. Inspection of testing activities is illustrated in Annexure -IV. FUNCTIONS OF ZONAL LABORATORY To carry out tests of soils, filter materials, ingredients of concrete, tests of cement and mortar etc. of the samples collected by the quality control staff and also such samples collected by construction staff whose facility of testing is not available at site as well as field laboratories. Results of tests performed will be reported to Executive Engineer construction and Superintending Engineer and Chief Engineer of Quality Control unit in the prescribed Performa pertaining to the following tests: 11

23 SOILS: 1. Density, moisture content and compaction efficiency. 2. Sieve analysis 3. Proctor density & O.M.C. 4. Atterberg's limits 5. Specific gravity SAND: 1. Gradation analysis & silt content. 2. Presence of deleterious materials including organic impurities. 3. Bulkage COARSE AGGREGATE: 1. Grading 2. Specific gravity 3. Impact Value, Soundness, Crushing Value, Flakiness. FRESH CONCRETE & MORTAR: 1. Water cement ratio, slump test 2. Compressive strength of Concrete & Mortar 3. Mix Proportions BOULDER SAMPLE: 1. Absorption 2. Dimensions 3. Visual observation as regards weathering etc. 4. Specific gravity, impact value, soundness, specific gravity. CEMENT: 1. Setting time by Vicat needle test 2. Strength of cement BRICKS: 1. Dimensions and physical properties including compressive strength. WATER: 1. Chemical 2. Cl, SO 4, Organics & Inorganic Solids 3. ph value, Alkalinity, Acidity 12

24 FUNCTIONS OF FIELD LABORATORIES To carry out daily routine tests of soils, filter materials, ingredients of concrete and mortar of the samples collected by the construction staff and report the results to concerned J.En., A.En. & Executive Engineer of construction. The results will also be reported to the quality control unit in the prescribed Performa pertaining to following tests: SOILS & EARTH WORK: 1. Density, moistures content and compaction efficiency. 2. Sieve analysis. 3. Proctor density & OMC. CNS: 1. Gradation analysis 2. Shear Parameters 3. Index properties SAND: 1. Gradation and Fineness Modulus. 2. Bulkage 3. Organic impurities through quick "Colour test". CEMENT: Casting of cubes for strength; Fineness by Sieve. COARSE AGGREGATE: 1. Grading 2. Physical Properties FRESH CONCRETE & MORTAR: 1. Water cement ratio & slump test 2. Physical properties of ingredients & silt content of sand. 3. Casting of concrete & mortar cubes. BOULDER SAMPLE: 1. Water absorption 2. Dimensions 3. Physical properties including weathering etc. 13

25 BRICKS: Dimensions & physical properties including water absorption. SITE LABORATORIES: To carry out daily routine tests of soils, filter material, ingredients of concrete and mortar for the on-going works and material carted at site before use. Results will be recorded in registers kept at site for inspection purposes and will be reported to J.En. & A.En. Construction and Quality Control, in the prescribed Performa pertaining to the following: SOILS & EARTH WORK: 1. D.B.D. & Moisture content layer wise. SAND: 1. Gradation analysis & Fineness Modulus. 2. Bulkage COARSE AGGREGATE: 1. Gradation analysis 2. Physical properties CEMENT: Casting of cubes for strength FRESH CONCRETE & MORTAR: 1. Slump test 2. Physical properties of Ingredients; Proportion of cement and sand in mortar. 3. Casting of concrete / mortar cubes. BOULDER SAMPLE: 1. Dimensions & physical properties including weathering etc. 2. Water absorption BRICKS: 1. Dimension & physical properties 2. Sampling of bricks for testing. 14

26 Record of daily activities / tests will be maintained at site in the registers such as:- 1. Inspection Register 2. D.B.D. Register 3. Cement Consumption Register 4. Slump Test Register 5. Daily progress register progress to be compared with consumption of various ingredients including cement. FUNCTIONS OF MOBILE LABORATORY (FIELD TESTS) (i) (ii) (iii) To carry daily routine tests on compaction efficiency. Field density and moisture content determination test. To carry out daily routine tests like silt content, fineness modulus and gradation of fine aggregates and coarse aggregates. To carry out slump test, unit weight and temperature of concrete by using fresh concrete in-situ testing equipment, and to take fresh concrete as per the required frequency. 15

27 CHAPTER IV DUTIES OF STAFF INCHARGE OF LABORATORIES DUTIES OF ASSISTANT ENGINEER / A.R.O. INCHARGE OF LABORATORY i) To ensure proper up-keep and maintenance of laboratory equipment in laboratory. ii) iii) iv) To ensure proper up-keep of records of all samples being tested in the laboratory as per prescribed norms and communication of the results to the concerned. To supervise the testing works of Junior Engineer, Laboratory Assistants and personally to check the tests to the extent of 25%. To prepare fortnightly review of all the tests results and submit to the Executive Engineer, Quality Control & Construction. v) To conduct any research work as may be assigned by the Executive Engineer. vi) vii) viii) The Central Laboratory & Zonal Laboratories have to conduct tests for the suitability of materials proposed from various quarries, well in advance of the actual execution of work, for which the construction staff shall send the material to the lab well in advance. Steel rods as proposed to be used shall be tested for ultimate tensile strength elongation and bond etc. as per standards. Samples of welded rods, welded at site shall be collected and tested to the quality of welding. DUTIES OF ASSISTANT ENGINEERS / A.R.O. / S.R.A. (LABORATORY) Shall perform important tests as mentioned below: A) CEMENT : 1. Fineness by Blaine 2. Normal Consistency 3. Setting time 16

28 4. Soundness 5. Specific gravity 6. Compressive strength 7. Adulteration test B) SAND : 1. Sieve Analysis & Fineness Modulus 2. Test for organic impurities silt & clay 3. Decantation test for silt 4. Specific gravity 5. Unit weight and bulkage factor C) COARSE AGGREGATE : 1. Sieve Analysis and gradation 2. Specific gravity 3. Water absorption 4. Examination of deleterious materials 5. Crushing strength 6. Impact 7. Abrasion 8. Flakiness index 9. Alkali Silicate reactivity D) CONCRETE : 1. Consistency slump or compaction factor 2. Compressive strength 3. Air content 4. Yield per unit quantity of cement 5. Mix design test 6. Cement content E) MORTAR : 1. Consistency 2. Compressive Strength 3. Yield per unit quantity of cement 4. Cement Content 17

29 F) SOILS : 1. Gradation (Grain size analysis) 2. Consistency limits 3. Porosity & Voids ratio 4. Specific gravity 5. Swell pressure DUTIES OF LABORATORY TECHNICIANS / JUNIOR RESEARCH ASSISTANTS i) To assist Assistant Engineer / Executive Engineers whenever required in laboratory and field work. ii) To perform tests in laboratory such as : a) Compaction tests b) Limit tests c) Analysis of fine & coarse aggregates d) Silt in fine aggregate e) Slump test f) Collection of samples of concrete and mortars for filling moulds for compaction test. DUTIES OF LABORATORY ATTENDANTS a) To keep instruments clean. b) To assist Assistant Engineer / Executive Engineer and Laboratory Technicians in conducting tests. c) To prepare samples for test. d) To arrange samples systematically. CONTROL OF INSPECTION, TESTING AND MEASURING EQUIPMENT The identification, calibration, and adjustment of all inspection, measuring and test equipment and devices will be done at prescribed intervals as stated below against certified equipment having a known valid relationship to nationally recognised standards. The equipment will be capable of controlling the delivery of material for weighing so that in accuracies in feeding and measuring during normal operation 18

30 will not exceed 1% for water and 3% for all aggregates. Periodical test will be made at least once in a month in case of equipment for measuring water, cement, admixtures, sand and coarse aggregate. Other measuring equipments will be tested once in a year unless some defects are noticed earlier, in which case these will be attended immediately. Documents will be established and calibration procedures will be maintained including details of the following: 1. Equipment type 2. Identification number 3. Location 4. Frequency of Checks 5. Check method 6. Acceptance criteria 7. Action to be taken for unsatisfactory results, to ensure that the inspection, measuring, and test equipment are capable of the required accuracy and precision. 19

31 CHAPTER V DUTIES OF FIELD STAFF IN RELATION TO QUALITY OF ASSISTANT ENGINEER CONSTRUCTION WORKS DUTIES OF ASSISTANT ENGINEER 1. Shall see that the markout of the area to be tackled is properly given, shuttering, centering, reinforcement are done as per drawing and technical specifications, to record the Pre levels / foundation levels, and to see that mark-out for canal excavation is perfectly given as per drawings. Pre levels, classification levels and final levels of canal shall be taken as per specification. 2. Shall see that the construction equipment like mixers, vibrators, compaction equipment, pumping arrangements for curing / watering are arranged before starting of any work. 3. Shall see that sufficient quantities of input materials as per agreement specifications are made available at site of work and to arrange testing equipment, men and material required for conducting field tests, sending samples of input materials for testing to central lab, field laboratories as per norms. 4. Shall write O.K. Cards after area is ready to start the work and to inform the Assistant Engineer Quality Control and Executive Engineer construction and take permission to start the work on O.K. Card. Shall also permit OK in case quality control A.En. is not available. 5. Shall supervise and ensure that correct quantities of input materials as per mix design communicated by the ASSISTANT ENGINEER QUALITY CONTROL 1. Shall check the markout of foundation and centering/ shuttering reinforcement arrangement and inform the Assistant Engineer construction to rectify the defects if any. 2. Shall check the adequacy of the construction equipment and curing/ watering arrangements before start of work and during excavation. 3. Shall conduct / get conducted by different laboratories the field tests on input materials and record the results and to inform the Assistant Engineer construction to rectify the defects if any. 4. Shall check and write the O.K. card and record the deviations, defects if any or otherwise to record the final OK and to inform Executive Engineer quality control and to permit to start the work. 5. Shall make regular checks of the feeding of input materials mixing time and suggest the quantity of 20

32 ASSISTANT ENGINEER CONSTRUCTION central laboratory are fed into the mixers/batching plants etc., and shall ensure specified mixing time. (minimum 2½ minutes) ASSISTANT ENGINEER QUALITY CONTROL water depending on the moisture content of sand as and when required. 6. Shall ensure proper vibration, rolling etc., during course of day to day work. Shall conduct D.B.D. test of earth work, gradation of material, slump test, core drill test and to extract field samples of material and finished products to be sent to different laboratories also provide men and material required for extracting samples of finished product for quality control staff. 7. Shall ensure proper curing of samples extracted till the curing time is over and to make arrangements to send the samples to central lab or other suitable lab. 8. Shall ensure timely green cutting of concrete with proper air water gun; nicking & chipping (wherever so warranted) so as to prepare the surface for next concrete lift for effective bond at the lift / construction joints. 9. Shall ensure proper curing / watering and allow removal of shuttering only after the time limit prescribed in the specifications and to see that the surface are finished to the plumb/straight lines etc., after removal shuttering. 6. Shall ensure slump test, core tests, proctor density etc., conducted as per norms by the construction and quality control staff and to extract field samples of finished product to be sent to central laboratory later. 7. Shall assist the Assistant Engineer in Proper handling / transport of samples to central lab. 8. Shall check and see that the preparation of the surface is adequately done for starting the next lift. 9. Shall check the adequacy of curing/watering and see that the final surfaces are finished neatly plumb/straight lines etc. 10. Shall maintain (1) mark-out register (2) OK Card files (3) Load Register. 10. Shall maintain registers of field tests conducted. 21

33 DUTIES OF EXECUTIVE ENGINEER EXECUTIVE ENGINEER CONSTRUCTION 1. Shall supervise, check, advice, and instruct the J.E.N. /A.E.N. Construction regarding discharge of their functions properly. 2. Shall intimate the Executive Engineer quality control regarding signing of agreement for starting of any new work, duly endorsing a copy of work order. Shall supply copies of contract documents, drawings construction programme etc., to Executive Engineer Quality Control, and Superintending Engineer. 3. Shall get all ingredients of concrete, masonry got tested before use. Shall see that the soils are tested for various properties like OMC, MDD, etc., before starting of Embankment work. 4. Shall see that all the Machinery/ Equipment being used by the contractor is got periodically calibrated. 5. Shall see that OK Cards are written and kept at site of work before starting of any work. Also will ensure rectification of work before releasing payments. 6. Shall order the suspension of work if any defects are noticed or reported by quality control staff and resume the work only after rectification of defects in the presence of quality control staff. 7. Foundations and reinforcement, shuttering, centering where heavy reinforcement is involved is to be checked by Executive Engineer EXECUTIVE ENGINEER QUALITY CONTROL 1. Shall supervise, check, advice and instruct the A.E.N. Quality Control regarding discharge of their functions properly. 2. Shall maintain copies of approved Designs, reports, contract document, drawings, construction programme, extracts of inspection notes etc., and shall see that his subordinates go through the above documents. 3. Shall remind and verify whether test results are available or not before starting up of any new work and during execution of work. 4. Shall assist in upkeep and calibration of equipment. 5. Shall inspect and sign on OK Cards during field visits. Defects of construction will be pointed out and remedies suggested for achieving good quality construction. 6. Shall order the stopping of work if major defects are noticed or reported by quality control staff and intimate his counterpart to see that defects are rectified. Also defects noted during construction are to be reported to the S.E./Quality Control & Construction. 7. Foundations and reinforcement, shuttering, centering where heavy reinforcement is involved is to be tallied by Executive Engineer 22

34 EXECUTIVE ENGINEER CONSTRUCTION invariably before starting the work. 8. Shall personally see that the samples to the laboratories are sent regularly, obtain the results and communicate the same to Executive Engineer quality control. 9. Shall take the help of quality control Executive Engineer whenever a dispute is referred. 10. Shall jointly inspect the site with quality control Executive Engineer in case variation in classification is less than 10% (+/-) and finalize the classification. EXECUTIVE ENGINEER QUALITY CONTROL invariably before starting the work, during his field visits. 8. Shall pursue and keep track of sending of samples various laboratories and to keep record of results received. 9. Shall co-ordinate with the EE/ Construction division render assistance in resolving the issues referred to him. 10. Shall jointly inspect the site with Construction Executive Engineer in case variation in classification is less than 10% (+/-) and finalize the classification. 23

35 CHAPTER VI CO-ORDINATIONS The construction staff and quality control staff must act in tandem to achieve good quality of the finished product and construction as per the contract specifications. Construction staff should make it a point to inform the quality control staff, the date of starting of any activities or component of the work well in advance so as to enable the quality control staff to schedule their work plan and attend the particular work on the particular date. In turn quality control staff should schedule their programme, so as to attend to the work on the dates required by the construction staff and ensure that, the progress of work is not hampered. The quality control staff shall be responsible for exercising the various field checks with reference to drawing and specifications laid down in respective I.S. code during construction and carrying out all the laboratory and field tests on materials used for construction and reporting through their higher officer, to the field staff for ensuring quality. The Assistant Engineer / Executive Engineer (Quality Control) can address Assistant Engineer / Executive Engineer construction regarding defects, rectification testing etc. As far as possible the defects are to be rectified in the presence of the Quality Control staff and the payment shall be effected only after the Quality Control Staff are fully satisfied with the rectification and quality of work. Any rectification done subsequently any intimation and presence of Quality Control Staff shall be at the sole responsibility of the construction staff. The defects, if any, noticed by the quality control staff during their course of inspection shall be brought to the notice of the construction staff then and there. It is the primary responsibility of the Quality Control & Inspections staff to draw the attention of the construction staff, whenever they notice defective work during their course of inspection. It is duty of the construction staff to attend to the rectification and maintain proper specifications as pointed out by their counter part of the Quality Control organisation. 24

36 Quality Control staff will monitor that all tests required as per agreement and I.S. Codes are carried out in different laboratories by the field staff they will also test check to the extent of minimum 10% (or as decided by Chief Engineer QC) of the required tests and co-relate with the other tests conducted in different laboratories. All observations regarding substandard or below specification work will be dully recorded in the inspection / visit books kept at site by inspecting officer. Such substandard or below specification works should be got stopped / dismantled immediately by execution unit. The defects pointed out by Quality Control Unit will be communicated to the execution unit for compliance immediately. The compliance report should be sent by execution unit within ten days. The quality control staff cannot supervise the placement of concrete on a mix to mix basis continuously. They can only conduct random check of input materials, mixing time, placement of concrete, vibration etc. It's the primary responsibility of the construction staff to ensure adequate supervision of mix to mix placement of concrete. The Operations of the Quality Control Staff shall not interfere in any way, with the executive powers vested with the officers in-charge of execution. They will also in no way diminish the responsibility of the officers in-charge of execution. The field officers in-charge of works are primarily responsible for the quality of all works and to carry out the work as per the technical specifications. In case of difference of opinion between quality control staff and construction staff, it should be sorted out by way of discussions in cordial atmosphere and mutual trust as per the guide lines indicated below. In case it involves any design feature / problem / aspect, the design office should be duly consulted and the advice given by the designer should be accepted. In case of difference of opinion between Executive Engineer, Construction and Executive Engineer, Quality Control it would be referred to Superintending Engineer, Construction, who would discuss the matter with Superintending Engineer, Quality Control and settle the issue. Similarly, when the Superintending Engineer, Quality Control is not readily available, the Superintending Engineer, Construction can over-rule after recording the reasons in writing. In such cases the 25