QUALITY IN PROJECTS CONSTRUCTION

RCC WORKS

Presented by:
Ajay Kumar Sharma L&T-ECCD, Delhi

AGENDA

INTRODUCTION FORMWORK REINFORCEMENT CONCRETE POST CONCRETE CHECKS

WHAT IS QUALITY ?

TRADITIONAL DEFINITIONS OF QUALITY

FITNESS FOR PURPOSE CONFORMANCE TO SPECIFICATION

VALUE FOR MONEY

CUSTOMER SATISFACTION DOING IT RIGHT THE FIRST TIME AND EVERY TIME JUST IN TIME REDUCTION OF VARIABILITY

STANDARD DEFINITION OF QUALITY

The degree to which a set of inherent characteristics ( distinguishing feature) fulfils requirements. (need or expectation that is stated, generally implied or obligatory). ( AS PER ISO 9001-2008)

QUALITY CONTROL
INTEGRAL PART OF QUALITY ASSURANCE IT IS A PHYSICAL CONTROL ACTION INSPECTION MEASUREMENT QUALIFICATION TESTS ETC. HELPS TO PROVIDE THE EVIDENCE THAT QUALITY

REQUIREMENTS ARE BEING ACHIEVED

QUALITY ASSURANCE
Part of Quality Management focused on

providing confidence that the Quality requirements will be fulfilled.

It is a method by which an organisation

generates confidence in the mind of the customer by assuring and demonstrating the Quality Management System vide Plans, Procedures and Specific work instructions.

PRESENT PRACTICE OF QUALITY IN CONSTRUCTION

ESTABLISHING METHODOLOGY IMPLEMENTATION OF THE APPROVED METHODOLOGY AT ALL LEVELS TESTING AND INSPECTION OF INPUT MATERIALS AND PROCESS POST CONSTRUCTION CHECKS QUALITY ASSESMENT AND RATING (CONQUAS)

FORMWORK

MATERIAL FORMWORK SCHEME

DIMENSIONS
LINE LEVEL VERTICALITY/PLUMB RIGHT ANGLE CLEANLINESS

FORMWORK

DISTANCE BETWEEN ADJACENT MEMBERS COLUMN AND BEAM JUNCTIONS GABDI SHUTTERS LEAK TIGHT JOINTS CLEANLINESS OF FORM SURFACE APPLICATION OF FORM RELEASE AGENT

FORMWORK
Sl. Component/ No. Process Nature of Check / Test Method of Check Quantum of Check Reference Document Format of Record Agency File L&T Client Ref 1 Form Work Ensure formwork scheme drawing prepared for all structures a. Check for staging, if any

Inspection

All works

IS 456/Drgs/ Scheme Drgs

Check list based on drg/ FormatC-04/F02 -do-

b. Check for formwork fixing (Check list for Inspection/ -dostagewise control to be prepared based Measurement on drawing for all major activities) c. Ensure stripping time Inspection -do-

Drawings

As per Clause 11.3 Formatof IS 456 C-04/F02

FORMWORK
DO Follow the schemes given in Formwork manual strictly and avoid misuse of components. Apply form work releasing agent to the form work surface,to prevent absorption of water from concrete and adhesion of concrete and damage when shuttering is removed. The form work releasing agent should be applied before reinforcement is fixed in position. Provide tight joints use foam sheets to prevent leakage of grouts. Remove shuttering slowly and avoid sudden application of load. Allow specified time before removing shuttering.Follow the deshuttering time specified in contract / Indian standards.

COLUMN FORMWORK SYSTEM

WALER

TIE ROD

PROP

WALL FORMWORK SYSTEM

CODES GOVERNING REINFORCEMENT BARS

IS 1786 BS 4449 EN 10080

-2008 - 1997

ASTM A 615 1984 RUSSIAN (GOST)

REINFORCEMENT

MATERIAL CHEMICAL PROPERTIES (TC) TENSILE STRENGTH ELONGATION

BEND & REBEND

MEAN PROJECTED AREA

SECTIONAL WEIGHT
WELDABILITY

CHEMICAL COMPOSITION OF REBARS AS PER IS 1786 - 1985

Constituent Carbon Sulphur Phosphorus Sulphur Phosphorus & Percent, Maximum Fe 415 Fe 500 Fe 550 0.30 0.32 0.3 0.32 0.3 0.32 0.060 0.065 0.055 0.060 0.055 0.060 0.060 0.065 0.11 0.12 0.055 0.060 0.105 0.115 0.050 0.055 0.10 0.11

MECHANICAL PROPERTIES OF REBARS AS PER IS 1786 - 2008

Grade Fe 415 Fe 500 Fe 550 Yield stress/ 0.2% proof stress, Min. N/Sq.mm 415 500 550 Ultimate Tensile strength, Min. N/Sq.mm 485 545 585 Elongation, percent, Min 14.5 12 12 Bend for bars upto & including 22mm 3d 4d 5d Bend for bars over 22mm 4d 5d 6d Rebend for bars upto & including 10mm 5d 5d 7d Rebend for bars over 10mm. 7d 7d 8d Note: d diameter of the mandrel used for bend/ rebend test

Property

ALLOWABLE TOLERANCE ON NOMINAL MASS OF BARS AS PER IS 1786 - 2008

Nominal size (mm) Tolerance on nominal mass, Batch Individual Individual sample sample for coils only +7 -8 +8 +5 -6 +6 +3 -4 +4

Up to & including 10 10 16 Over 16

By

using bars of negative tolerance effective savings in cost can be achieved. (The design & construction is based on specific theoretical bar diameter, but the bars are supplied by weight)
If

the bars are with plus weight, it means reduced geometrical properties of ribs, which in turn reduces the bond between concrete & steel. And also leads to increase in the project cost.

TMT BARS

Enhancement of rebar strength is achieved by Thermo Mechanical Treatment as a part of rolling process. The bar is rapidly cooled / quenched in high-pressure water jacket / spray system as it emerges from the finishing strand of the rolling mill. This quenching process the surface layer to hardened structure called Martensite & while the core remains comparatively hot and Austenitic. Tempering begins as the bar leaves the water cooling section. The heat supplied from the core tempers outer Martensite layer. The core Austinitic transforms to a ductile Ferrite Pearlite core. The finished bar has a grain structure comprising a Tough outer layer & ductile core which imparts excellent yield strength with superior ductility.

ADVANTAGES OF TMT BARS

TMT bars contain lower carbon content & thus exhibit better ductility & weldability (can be butt welded or lap welded) TMT bars have better yield strength, tensile strength, and elongation than CTD bars of same grade. TMT bars display easy bendability and thus requires less energy for bending & rebending alongwith superior reverse bending properties. They possess in built ability to resist loss of strength when exposed to higher temperatures. They display better corrosion resistance than CTD bars due to absence of cold twisting stresses. TMT bars are also available in higher strength levels than those listed in the Indian Standard. Use of Fe 500 grade TMT bars can result in saving of more than 15% in steel consumption when compared to CTD bars.

REINFORCEMENT
Sl. Component/ No. Process Nature of Check / Test Method of Quantum Check of Check Reference Document Format of Record Agency File L&T Client Ref

1 Steel Ensure steel for works from only approved Reinforcement source Conduct the following tests wherever required and ensure that the material is as per standard a. For HYSD Bars (Fe415) Mild Steel - Tensile strength, proof stress & elongation - Bend - Rebend b. Ensure fabrication is done as per details given in drgs and approved / verified Bar Bending Schedule - Ensure tieing of reinforcement by 20 gauge annealed wire - Spacer bocks - Check for placement of reinforcement bar

Review of TC Every batch IS 1786 -do-do-do-doMeasurement 100%

MTC MTC MTC FormatC-04/F01

C C C C

R R R W

IS 2502 Drawings

Inspection Inspection

100% 100%

Drawings Bar bending Schedule

FormatC-04/F02

C C

R R

REINFORCEMENT

BAR BENDING SCHEDULE CUTTING/BENDING TO REQUIRED DIMENSIONS SPACING AS PER REQUIREMENT LAPS TYING COVER/CHAIRS

CUTTING & BENDING

Jigs used for manual bending for correct dimensions before going for mass production. Cutting schedule. Use of latest revision of drawings & bar bending schedules. Check bent shape for dimensional accuracy (against a template), bent radius & for signs of fracture. Always bend the bars by Cold. Bars larger than 25mm in size may be bent hot at cherry red heat (not exceeding 8500C) except those bars which depend for their strength on cold working. Hot bars shall not be cooled by quenching. ( Clause 6.1.1 of IS 2502 1963) Bundling & labeling bars of identical size, shape & type.

REINFORCEMENT COVER
Cover to reinforced concrete member is the minimum thickness of concrete provided over the reinforcement steel measured from the exposed concrete surface to the closest reinforced steel. The role of concrete in the cover region can be compared to the role human skin plays in protecting the flesh & other parts of the body. Concrete in the cover region protects steel reinforcement in two ways: By providing dense, strong, impermeable barrier against ingress of moisture, oxygen, chlorides, sulphates, carbon dioxide, & other aggressive gases & chemicals. By providing passive coating on steel surface. Due to alkaline nature of concrete, this coating prevents corrosion of steel.

FACTORS INFLUENCING REINFORCEMENT COVER

Exposure conditions of the structure
Concrete grade specified. Maximum aggregate size used in the concrete.

Diameter & spacing between reinforcement steel

Likely exposure to fire.

REINFORCEMENT COVER AS PER IS 456 - 2000

Exposure Mild Moderate Severe Very severe Extreme Nominal concrete cover in mm not less than 20 30 45 50 75

PERMISSIBLE TOLERANCE FOR COVER

Unless specified, actual concrete cover should not deviate from the required nominal cover by +10mm & there is no negative tolerance.

PROTECTION OF REBARS
If the work is suspended for a longer period, then the dowel bars left in the first phase have to be protected. The protection can be done by the following methods

By applying a firm coat of neat cement slurry to the exposed reinforcement bars leaving no point untouched.

Apply suitable anti corrosive chemical to guard against corrosion.

Encase the dowel bars in concrete either fully or partly.

Reinforcement
DO
Conduct applicable tests for the reinforcement bars for every lot / as stipulated in the specification Store reinforcing bars under cover, until required to use, kept clear of mud, dirt and oil and preferably stacked by sizes on racks. Use only bars that are free from mud, dirt, oil, grease, paint, loose rust, mill scale and pitting due to corrosion, Slightly oxidized bars are not good for adhesion with concrete;

DONT Dont use bars with mud and dirt sticking to them. Mud and dirt can be easily washed off with water.
Dont use bars with oil, grease and paint sticking to them. These should first be dissolved in suitable solvents. Dont use bars with loose rust and mill scale. These can be removed with a wire brush.

BAR BENDING AND FIXING

DO Cut and bend bars according to detail schedules, paying special attention to bends and hooks. Join wires securely at crossings with soft iron wire of 18 or 20 S.W.G. or with galvanized wire clips specially made for this purpose or by spot welding. Carry out bending of bars cold in the normal course. In certain circumstances, such as bars of large diameter, heating to cherry red ( 1550 F ) may be permitted and after bending, the bars allowed to cool naturally , quenching by dipping in oil should not be allowed. To maintain adequate cover to the steel reinforcement, use concrete spacer blocks or concrete rings of thickness equal to the cover required preferably wired to bars to prevent their displacement.

CONCRETE
CONSTITUENTS
CEMENT (10 15%) AGGREGATES (60 80%) WATER (15 20%)

ADMIXTURE

LIST OF COMMONLY USED CODES FOR RCC CONSTRUCTION WORKS

S.No Description Cement Specification for Ordinary Portland cement-33 Grade Specification for Ordinary Portland cement-43 Grade Specification for Ordinary Portland cement-53 Grade Specification for Portland Slag cement Specification for Portland Pozzolana cement (fly ash based) Specification for Sulphate resisting Portland cement Method of physical test of hydraulic cement Method of test for Chemical analysis of hydraulic cement Specification for standard sand for testing of cement Admixture: Specification for concrete admixture Specification for Fly ash as pozzolana and concrete Standard

1 2 3 4 5 6 7 8 9

IS IS IS IS IS

269 8112 12269 455 1489-Part 1

IS 12330 IS 4031 Part 1 to Part 15 IS 4032 IS 650

1 2

IS 9103 admixture for IS 3812

1 2 3

Aggregates Specification for aggregates from natural concrete Method of sampling of aggregates Method of test of aggregates for Concret Water: Water for concrete

sources

for IS 383 IS 2430 IS 2386-Part I to Part VIII

1 1

IS 456 & SP 23 IS 456

Concrete Design and construction: Code of practice for Plain and reinforced concrete

1 2 3

Concrete T esting : Method of test for strength of concrete IS 516 Method of sampling and analysis of fresh concrete IS 1199 Method of making and curing and determining IS 9013 compressive strength of accelerated concrete cured test specimen

CONCRETE MIX DESIGN

GRADE OF CONCRETE EXPOSURE CONDITION TYPE OF CEMENT / CEMENT CONTENT WATER CEMENT RATIO SLUMP / WORKABILITY AGGREGATE SIZE ADMIXTURE BRAND & DOSAGE

CONCRETE MIX DESIGN

Nature of Check / Test Method of Quantum Check of Check Lab. Test at client Lab. Test Reference Document Format of Agency File Record L&T Client Ref Client record R C

Sl. Component/ No. Process

1 Mix Design Mix design by IS code method

a. Source and grade of cement b. Cement content (Tech.Spec. / IS 456) c. Water / Cement ratio d. Maximum size of Aggregate e. Exposure condition f. Design slump g. Admixtures - Brand & dosage (Brand and spec. shall be submitted to client for approval. Dosage to be decided at site as per manufacture's spec.)

Once for IS 456, 10262 brand of IS516, IS 1199 cement and grade

CEMENT
VERIFICATION OF MTC FINENESS CONSISTENCY INITIAL SETTING TIME FINAL SETTING TIME COMPRESSIVE STRENGTH

INSPECTION & TEST PLAN - CIVIL WORKS

Sl. Component/ No. Process 1 CEMENT Nature of Check / Test a. Chemical composition

CEMENT
Review of MTC Lab. Test at Client's Lab.

Method of Check

Quantum of Check Once per batch Once per batch

Reference Document IS8112/ IS12269 IS 4031 IS 12269

Format of Record MTC

Agency File L&T Client Ref C R

b. Physical - Fineness by dry sieving - Consistency of cement - Initial and final setting time - Compressive strength - 3, 7 & 28 Days Note: Ensure that material is stored properly to avoid deterioration due to moisture and contamination by various impurities - Covered storage is provided - Material is stored on raised platform - Not more than 10 bags are stacked on one heap with proper access for inspection - Cement will be stacked consignment wise, type & gradewise for clear identification.

FormatC-04/F07

Inspection

Monthly

SIR

Inspection

Monthly

SIR

COMMONLY USED CEMENTS

1. Specification for Ordinary Portland cement-33 Grade - IS 269 2. Specification for Ordinary Portland cement-43 Grade - IS 8112 3. Specification for Ordinary Portland cement-53 Grade - IS 12269

4. Specification for Portland Slag cement

5. Specification for Portland Pozzolana Cement (fly ash based) 6. Specification for Sulphate resisting Portland cement Note :

- IS 455
- IS 1489 PART 1 - IS 12330

Sl.No 1 to 5 - Used for Sub-structure & Super structure - Ref. IS 456 2000 Table 4 & 5 Sl. No. 6 Used for Sub-Structure - Ref. IS 456 2000 Table 4

DOS AND DONTS

FOR GOOD CONCRETE
CEMENT DO Use cement complying to customer specification Conduct applicable tests for cement for every batch to ensure conformity. Storage of cement as per standard requirement. Follow First in First out system for the usage of cement.

DONT Dont use cement that has Set. Set cement can be recognized from its lumpiness and when the lumps cannot be easily broken up with the fingers.

COARSE AGGREGATES
SOURCE VERIFICATION ABRASION,CRUSHING AND IMPACT VALUE SIEVE ANALYSIS (GRADATION) SPECIFIC GRAVITY BULK DENSITY WATER ABSORPTION

COARSE AGGREGATES
Sl. Component/ No. Process Nature of Check / Test Method of Quantum Check of Check Lab. Test Reference Document Format of Record Agency File L&T Client Ref C C C R R R

1 COARSE a. Los Angles Abrasion Value AGGREGATEb. Crushing Value (Crushed Stone) c. Impact Value d. Water absorption e. Sieve Analysis f. Specific gravity g. Bulk density

Once for each IS 383 source IS 2386 -doMonthly Monthly Monthly

LTR LTR Client record

Lab. Test by client -do-

FINE AGGREGATE
SILT & CLAY CONTENT SIEVE ANALYSIS SPECIFIC GRAVITY FINENESS MODULUS DENSITY WATER ABSORPTION ORGANIC IMPURITY

FINE AGGREGATE
Sl. Component/ No. Process Nature of Check / Test Method of Quantum Check of Check Reference Document Format of Agency File Record L&T Client Ref

1 FINE - Ensure that the following tests are AGGREGATEconducted for each source of supply (SAND) and check whether the material is as per standards a. Silt & clay content Lab. Test b. Sieve Analysis by client c. Bulking of sand d. Specific gravity e. Water absorption f. Organic Impurity

Monthly IS 383 Monthly IS 2386 Weekly Monthly Once per source

Client record R Register Client record R

Aggregate
DO
Test aggregates as stipulated in the specification Stacking of aggregates of different sizes separately in the stack yard. Stack on leveled surface and higher elevations than the surroundings.

DONT
Mixing of different sizes of aggregate in stack yard. Mixing of aggregates with dirt, mud & other unwanted materials.

WATER
CHLORIDE & SULPHATE CONTENT

INORGANIC AND ORGANIC SOLIDS

PH VALUE (NOT LESS THAN 6)

SUSPENDED MATTER.
ACID & ALKALINE NEUTRALIZATION

WATER
DO Check water to its suitability to concrete purpose. Measure water in litre. DONT Dont use contaminated water for mixing concrete.

Dont measure and add water by guess

CHECK FOR CONCRETE

SLUMP/WORKABILITY
COHESIVENESS/SEGREGATION AIR CONTENT COMPACTION FINISHING CURING COMPRESSIVE STRENGTH

YIELD (SOURCE CONSISTENCY)

TEMPERATURE CONTROL (Beyond 40 Deg.C)

WATER CEMENT RATIO

In a cement slurry, the ratio of water to cement expressed as percent, the number of parts of water used to mix with 100 parts of cement.
If all the water absorbed by the aggregate particles is neglected & just water on the surface is considered along with the water added to the mix, then the W/C is called Free water cement ratio.

If water absorbed by the aggregate particles is also considered in addition to the water on the surface of the particles as well as water added to the mix, then the W/C is called total water cement ratio.
In the concrete mixes, besides cement, if any cementitious materials like fly ash, silica fume, ground granulated blast furnace slag, etc is used, and then the ratio will be known as Water cementitious ratio.

SIGNIFICANCE OF WATER CEMENT RATIO

When the concrete is fully compacted, its strength is taken to be inversely proportional to water cement ratio.
Water cement ratio determines the porosity of the hardened cement paste at any stage of hydration & hence influences the durability & permeability of hardened concrete. When concrete is made using very high water cement ratio, large capillary pores in cement paste allows high permeability of water along with other chemicals like chlorides & sulphates, which cause deterioration of concrete. To have durable concrete structures, it is desirable to specify low water cement ratios.

MIN. CEMENT CONTENT & MAX WATER CEMENT RATIO AS PER IS 456 - 2000
a) Plain concrete: Exposure Min. grade of concrete Mild Moderate Severe Very severe Extreme --M 15 M 20 M 20 M 25 Min. cement content (Kg/cum) Max. Free Water cement ratio

220 240 250 260 280

0.6 0.6 0.5 0.45 0.4

b) Reinforced concrete: Exposure Min. Min. cement Max. Free grade of content (Kg/cum) Water cement concrete ratio Mild M 20 300 0.55 Moderate M 25 300 0.5 Severe M 30 320 0.45 Very severe M 35 340 0.45 Extreme M 40 360 0.4

PRODUCTION AND PLACEMENT

MIXING PLACE WITHIN INITIAL SETTING TIME

VIBRATION
CURING SUPERVISION CONSTRUCTION JOINT PREPARATION

CHECK FOR CONCRETE

Sl. Component/ No. Process Nature of Check / Test Method of Quantum Check of Check Reference Document Format of Record Agency File L&T Client Ref 1 Concreting Ensure the following Area to be concreted to be free from debris and any extraneous matter or water logging - Pour card clearance - Construction joint adequacy check Visual Visual 100% 100% Drgs. Method Statement MS/C-07 Mix Design FormatC-04/F02 -doC C R C

- Moisture correction in Aggregates - Sampling for workability check - Placing and compaction - Sampling cubes 7 and 28 days

Lab Test

Everyday

Batch Sheet FormatC-04/F04 Nil FormatC-04/F04 Client record QA report

C C C

R R R

Measurement Min. 2 per IS 516 every pour Inspection Major pour Method Statement Lab. Test As per IS 456 IS 456 Lab. Test by client Inspection 7 & 28 daysIS 456 & IS 516 100% -

C R C

R C R

- Compression strength check - Curing

PREPARATION OF CONCRETE
Measurement of Ingredients DO CEMENT Measure cement in units of 1 bag. ( Remember 1 bag of cement contains 50 Kg and has a volume of approximately 1 cft.) AGGREGATES
Volume batch.
Measure aggregates in gauge boxes for specified mixes of dimensions, in terms of volume of one cement bag. Gauge boxes should be made of good timber or sheet metal with lifting arms for hand mixing. Make allowance for bulking of sand when it is damp. Remember, sand may bulk up 30% of its volume when damp and unless allowance is made or this, the mix may be under sanded and consequently harsh and unworkable. If accurate information is not available an average bulking of 25% may be assumed i.e., the quantity of damp sand to be mixed should be 25% greater than the quantity of calculated quantity of dry sand.

Weigh batch. Incase of weigh batching the actual weight specified in approved mix design with suitable corrections shall be put in the concrete mixer.

MACHINE MIXING
DO Add the constituents of the mix as per the approved mixed design. DONT

Dont mix concrete on bare ground. Dont add extra quantity of water to achieve workability as this may result in reduced concrete strength.

PLACING CONCRETE
DO Place concrete in position before initial set occurs i.e., within 30 minutes of mixing. Fill all nooks and corners in formwork, surround all reinforcement with concrete using tamping rods or vibrators. Place concrete in horizontal layers ( 6 to 12 deep for R.C. work and 15 to 18 for mass concrete work) each of which should be compacted properly, before subsequent layers are placed. Place each layer before the previous layer has hardened, except, of course, where concreting of the previous layer was stopped at the end of the days work. In fact concrete placing should be continued without interruptions until the placement is completed to avoid intermittent cold joints.
DONT Dont place concrete during rains unless proper cover can be provided. Dont drop concrete from a height greater than 5 feet; to avoid segregation. Dont use concrete in which initial set of cement has already started.

CURING
What is Curing? Curing is the process of preventing loss of moisture from the concrete while maintaining a satisfactory temperature regime. Why curing is required? Concrete in its early life needs to be carefully looked after like parents looking after their newborn baby. If the concrete is not nurtured properly by carrying out the required curing & protected against wind & extreme ambient conditions, then the structure will loose its strength, & durability, the concrete will behave like a child born weak.

METHODS OF CURING
Water cure by flooding, ponding, mist spray. Water retaining method By using absorptive coverings such as sand, canvas, burlap or straw that are kept continuously wet. By mechanical barriers. By using chemical membranes.

MINIMUM CURING PERIOD AS PER IS 456 - 2000

1.For OPC or Super sulphonated cements Minimum Seven days

2.For concrete having blended cements like Portland pozzolana cement, Portland slag cement or mineral admixtures - Minimum 10 days. This may be extended to 14 days. 3. For concrete exposed to dry & hot weather conditions

- Minimum 10 days.

CURING
DO Keep all surfaces of newly laid concrete damp for 7 days. Damping can be done in several ways; by hosing or sprinkling of water; by wet sacking or matting ; by ponding of horizontal surfaces with raised edges in weak mortar and filling I 2 depth of water ; or by laying 2 3 thick layers of sand kept soaked in water. DONT Dont neglect curing. It is better to over cure than to under-cure. Undercuring results in loss of strength which is irreparable ; and water is cheap.

CONSTRUCTION JOINTS
Construction joints are surfaces where two successive placements of concrete meet. They are typically placed at the end of the days work. But may also be required when the concrete placement is stopped for longer than the initial setting time of concrete. The location of construction joints should be planned. It may be desirable to achieve bond & continue reinforcement through a construction joint. For monolithic concrete, a good construction joint might be a bonded interface that provides a water tight surface & allows for flexural & shear continuity through the interface.

METHODS OF PREPARATION OF CONSTRUCTION JOINTS

By using hand chisel & hammer By using pneumatic bush hammer By using water jetting By applying surface retarder over the concrete surface. Cement paste and laitance were brushed away when the concrete was initial set.

CONSTRUCTION JOINTS IN BEAMS & SLABS

Desirable location for construction joints placed perpendicular to the main reinforcement are at points of minimum shear or points of contra flexure. Construction joints are usually located at mid span or in the middle third of the span, but locations should be verified by the Engineer before placement. Horizontal construction joints in beams and girders are usually not recommended.Common practice is to place beams & girders monolithically with the slab. For the beams where the members are of considerable depth, it is advisable to place the concrete in the beam section up to the slab soffit, then placing the slab in separate operation. This is to avoid cracking of the interface because of vertical shrinkage in deep member if beam & slab concrete are placed monolithically.

 The main concern in joint placement is to provide adequate shear shear transfer & flexural continuity through the joint. Flexural continuity is achieved by continuing the reinforcement through the joint with sufficient length past the joint to ensure adequate splice length for the reinforcement. Shear transfer is provided by shear friction between old & new concrete or dowel action in the reinforcement through the joint.

SURFACE DEFECTS IN CONCRETE CAUSES AND REMEDIAL MEASURES

Any defects in the finished concrete surface observed after removal of form work Design and construction-related causes Difficult placement due to design of a member Improper design, construction and maintenance of forms Improper selection of concrete mixture proportions Failure to adjust concrete mixture proportions to suit Placement condition Improper placement practices Improper vibration and consolidation practices Improper steel detailing

Equipment-related causes Improper equipment Improper equipment maintenance Equipment failure (crane, pump, concrete plant) Interruption of utility service
Material-related causes Improper selection of release agent Cement characteristics Variation in mixture components Inappropriate use of admixtures Inappropriate use of release agents Environmental causes Extreme weather conditions

Types of surface defects

Surface defects which can result from ineffective consolidation procedures are discussed below. 1 Honeycomb Honeycomb is a condition of irregular voids due to failure of the mortar to effectively fill the spaces between coarse aggregate particles. Where bridging of the aggregate particles or stiffness of the mixture is a cause of honeycomb, vibration may assist in overcoming the bridging by increasing the flowability of the concrete. Causes congested reinforcement, insufficient paste content, improper sand-aggregate ratio, improper placing techniques, quick setting on hot concrete, and difficult construction conditions. Changes in mixture proportions to improve workability may assist in reducing or preventing honeycombing.

2- -Bugholes (Air surface voids) Bugholes on vertical faces are normally caused by air bubbles, but occasionally by water entrapped between the concrete mass and the form, especially in sticky or stiff concrete mixtures of low workability which may have an excessive sand and/or entrapped air content. Also, the use of vibrators of too large an amplitude or the lack of complete insertion of the vibrator head may result in increased air-void formation.

3--Form-streaking Form-streaking is caused by mortar leaking through form joints and may be aggravated by over vibration from vibrators that are too powerful, or by using forms that vibrate excessively during consolidation. Placing excessively wet or high-slump concrete mixtures will result in more mortar washing out through tie holes and loose fitting forms. Special care is sometimes required when superplasticizers are used, as they tend to increase leakage at form joints and in pump lines. 4 --Aggregate transparency Aggregate transparency is a condition characterized by a mottled coloring on the surface which results from deficiencies in the mortar. It may result when concrete mixtures have low sand content, dry or porous aggregates, or high slump with some lightweight and normal weight aggregates. Also, high density or glossy form surfaces may cause aggregate transparency.

5--Subsidence cracking Subsidence cracking results from the development of tension when the concrete settles after or near initial set. The cracks are caused because the upper concrete bridges between the forms while the lower concrete settles. These cracks may occur when there is an insufficient interval between placement of concrete in columns and placement of concrete for slabs or beams. They may also occur adjacent to block outs or over reinforcing bars with shallow cover. To prevent subsidence cracking, the concrete can be revibrated. Revibration is most effective when done at the latest time at which the vibrator head will penetrate the concrete under its own weight. Subsidence cracking over reinforcing bars can be controlled by increasing concrete cover during the design phase and by using wellconsolidated, low-slump concrete.

6--Color variation Color variation may occur within a placement if the concrete is not uniform or is incompletely mixed. Vibrators inserted too close to the form destroy the release agent or mar the form surface. External vibration used haphazardly may also cause color variation. Furthermore, color variations may result from nonuniform absorption and/or nonuniform application of the release agent. 7 --Sand streaking Sand streaking is a streak of exposed fine aggregate in the surface of the formed concrete caused by heavy bleeding along the form. It frequently results from the use of harsh, wet mixtures, particularly those deficient in 0.30 to 0.15 mm and smaller sizes. Sand streaking is controlled by the use of tight forms and proper mixture proportioning, using well-graded fines to minimize bleeding.

8- -Layer lines

Layer lines are dark horizontal lines on formed surfaces which indicate the boundary between concrete placements. Layer lines are caused by stiffening or insufficient consolidation of the lower level due to lack of penetration of the vibrator into the lower level.
9- -Form offsets Form offsets are usually caused by inadequate stiffness or anchorage of the forms and can be aggravated by too high a rate of placement and/or using too powerful a vibrator. 10--Cold joints Cold joints frequently occur in concrete for many reasons. Cold joints can often be avoided by contingency planning, back-up equipment, working to keep the concrete surface alive, and working to vibrate into lower lifts.

Summary of Primary causes of surface defects

Name Description Due to design Due to of member formwork Due to concrete Due to placement Excessive free fall, excessive travel of concrete in forms, too high a lift, drop chute omitted or insufficient length , too small a tremie, segregation Due to consolidation

Due tp construction conditions Honeycomb Stony surface Highly congested Leaking at High with air voids; reinforcement, joints, temperature, lacking in fines narrow section, severe wind, configuration grout loss reinforcement too internal close to forms, interference, accessibility reinforcement splices

Insufficient fines, low workability, early stiffening, excessive mixing too large an aggregate for placing conditions

Air surface Small individual Battered voids holes, irregular , interfering ranging up to construction 1inch (25mm)In diameter

or Form face Excessive release impermeab agent , high le, poor temperature wetting characteris tics, form work too flexible, use of improper form release agent

Low FM sand, lean , sand with a high FM, low workability, excessive cement content or pozzolana , particle degradation , excessive sand , high air content

Too slow , caused by inadequate pumping rate, undersized bucket

Vibrator too small , too low a frequency too small an amplitude , short immersion time, excessive spacing between immersions, inadequate penetration. Too large an amplitude , external vibration inadequate, head of vibrator partially immersed

Name

Description

Due to Design of member

Due to formwork

Due to Due to concrete Construction conditions

Due to Placement

Due to Consolidation

Sand or gravel textured areas lacking cement, usually associated with dark color on adjacent surface Aggregate Dark or light transparency areas of similar size and shape to that of the coarse aggregate, mottled appearance

Form streaking

Leaking at joints, tie holes, etc.

Excess water or high slump

Excessive amplitude or frequency

Too flexible, high density surface finish

Subsidence cracking

Short cracks Interference to Poor thermal Insufficient varying in access insulation, interval width, more irregular between often shape topout of horizontal restraining columns and than vertical settlement, placement of excessive slab or beam, absorbency low humidity

Low sand content, gapgraded, aggregate dry or porous , excessive coarse aggregate , excessive slump with light weight concrete Low sand, high water content

Excessive or external vibration; over vibration of light weight concrete

Too rapid

Insufficient vibration

Name

Description

Due to Design of member

Due to Formwork

Due to Due to concrete construction conditions

Due to placement

Due to consolidation

Variation in colour or shade due to separation of fine particles caused by bleeding parallel to the form face Layer lines Dark coloured zones between concrete layers Form offsets Abrupt to gradual surface irregularities

Sand streaking

Low Low absorbency temperature, wet mixtures

Lean mixture, Too rapid for over sanded type of mix bleeding mix, sand deficient in fines, low air content

Excessive vibration , Excessive amplitude , Over manipulation

Internal interference

Insufficient Wet mixture planning, high with tendency temperature to bleed

Inadequate stiffness or anchorage, weak forming material, irregular lumber, poor carpentry -

Excessive retardation of mixes

Slow Lack of Placement, vibration, failure lack of to penetrate equipment or into previous manpower layer Rate too high Excessive amplitude, nonuniform spacing of immersion

Cold joints

Unintended discontinuity, off coloured concrete

Internal interference

Poor planning Too dry , early of insufficient stiffening backup equipment

Delayed delivery

Failure to vibrate into lower lift. Insufficient vibration

QUALITY STANDARDS FOR STRUCTURAL WORKS Part 1 : Reinforced Concrete Structures Item* 1 Formwork 1) 2) 3) Tolerance for cross-sectional dimensions of cast in-situ & precast elements: +12mm / -6mm Tolerance for penetration / opening for services: +10mm for size and 25mm for location Tolerance for length of precast members (major dimension of unit): Up to 3m: 6mm 3m to 4.5m: 9mm Additional deviation for every subsequent 6m: 12mm Tolerance for departure of any point from its position: 10mm Tolerance for plumb: 3mm / m, maximum 20mm Maximum deviation of mean level of staircase thread to temporary bench mark: 5mm For cast in-situ elements, the deviation of level of any point from the intended level: 10mm Formwork must be free from defects Before concreting, the interior must be free from debris All formwork joints must not have gaps to prevent leakage There must be adequate support, bracing and tie-back for the formwork to prevent bulging or displacement of structural elements Standards

1a Formwork dimensions and openings for services

1b Alignment, plumb and level

1) 2) 3) 4)

1c Condition of formwork, props & bracing

1) 2) 3) 4)

Reinforcement (cast in-situ & Precast) 2a Main & Secondary rebars 2

1) 2) 1) 1) 1) 2) 1) 2)

2b Anchorages & lap lengths 2c Cover provision 2d Links, stirrups and trimming bars 2e Rebar Condition

According to structural drawings (numbers / sizes) a. For effective depth of 200mm or less + 10mm. b. For effective depth more than 200mm + 15mm Required lap length not less than that specified +10mm / -0mm from specified. According to structural drawings (numbers / sizes) Spacing of links not more than specified Rebars must be securely and properly tied in place Rebars must be freed from concrete dropping, corrosion etc

Finished Concrete (cast in-situ & Precast) 3a Dimension for elements / opening for services 3

3b Alignment, plumb and level

3c Exposed surface

1) Tolerance for cross-sectional dimension of cast in-situ and precast elements: +10mm / -5mm 2) Tolerance for opening: +10 for size and 25mm for location 3) Tolerance for length of precast members (major dimension of unit): Up to 3m: 6mm 3m to 4.5m: 9mm Additional deviation for every subsequent 6m: 12mm 4) Straightness or bow (deviation from intended line) of precast member: Up to 3m: 6mm 3m to 6m: 9mm Additional for every subsequent 6m: 6mm 5) Squareness of precast member Difference between the greatest and shortest dimensions should not exceed the following: Length of shorter sides Up to and including 1.2m: 6mm Over 1.2m but less than 1.8m: 9mm 1.8m and over: 12mm 6) Twist of precast member Any corner should not be more than the deviation stated from the plane containing the other 3 corners: Up to 600mm wide and 6m in length: 6mm Over 600mm wide and for any length: 12mm 7) Flatness: 6mm per 1.5m 1) Tolerance for departure of any point from its position: 10mm 2) Tolerance for plumb: 3mm / 1m, maximum 20mm for floor to floor height and 40mm for the entire building height 3) Maximum deviation of mean level: 10mm 4) For cast in-situ elements, the maximum deviation of levels within the element: 10mm 5) Camber at mid-span: according to specifications 1) Should not have visual exposure of groups of coarse aggregates resulting from grout leakage 2) Cold joint & formwork joint must be smooth 3) No bulging of structural elements 4) All formwork, nails, zinc strips, etc must be removed

STRUCTURAL WORK ASSESSMENTWHAT TO CHECK ? Formwork Visual

Free from Defects. No gaps at joints. Interiors free from debris. Adequate support, bracing and tie-back

Dimensions

Cross-sectional dimensions as per drawing. Penetration / opening for services. Length of precast members (major dimension of unit). Departure of any point from its position. Verticality. Mean level of staircase thread to temporary benchmark. Level for cast in-situ elements.

Alignment

STRUCTURAL WORK ASSESSMENT- WHAT TO CHECK ?

Reinforcement (cast in-situ & precast)

Rebar Condition Main & Secondary rebars Anchorages & lap lengths Cover provision Links, stirrups and trimming bars 1. Free from concrete dropping, corrosion, etc. 2. Securely and properly tied in place. 1. According to structural drawings (numbers / sizes) 2. Spacing of bars not more than specified. 1. Required lap length not less than specified. 1. According to specifications 1. According to structural drawings (numbers / sizes) 2. Spacing of links not more than specified.

STRUCTURAL WORK ASSESSMENTWHAT TO CHECK ?

Structure Quality
Reinforcement (Rebar)
The required samples tested and confirm to standards. The welded steel fabric tested and confirms to specified characteristic strengths as per standards. No nonconforming rebar used in the structure.

REINFORCEMENT RUSTING

STRUCTURAL WORK ASSESSMENT- WHAT TO CHECK ?

Finished concrete (Cast in-situ & Precast)

Dimension for elements / opening for services Cross-sectional dimension of cast in-situ and precast elements. Required opening for services. Precast members:
Length Straightness or bow (deviation from intended line) Squareness Twist Flatness

STRUCTURAL WORK ASSESSMENT- WHAT TO CHECK ?

Finished concrete (cast in-situ & Precast)

Alignment, plumb and level

Departure of any point from its position. Verticality Deviation from mean level. Camber at mid span

Exposed surface
No visual exposure of coarse aggregates. Cold joint & formwork joint must be smooth. No bulging of structural elements. Free from formwork, nails, zinc strips, etc.

STRUCTURAL WORK ASSESSMENT- WHAT TO CHECK ?

Lifting points / inserts

Free from Damages. Position / Placement

Precast

Sleeve System / Connections

Free from concrete droppings or corrosion. Sleeves, grout holes, grout tubes not congested with debris. Position / Placement. Bar protrusion length according to requirements. Bars should be free from bending, cracks or damages.

Interface / joint requirements

Alignment of horizontal and vertical joint. Joint taper alignment. Jog in alignment of matching edges Sitting of element as per specifications. Installation of sealant and waterproofing as per specifications.

STRUCTURAL WORK ASSESSMENT- WHAT TO CHECK ?

Precast
Cast-in steel items / welded & bolted connections
Position of cast-in steel items as per drawing. Position of openings for bolt connections. Other requirements as per drawing.

Patch works

Poor form finish

Patch works

Poor Expansion Joint

No curing

Patch Works

Poor formwork finish

Less slump

Poor formwork finish

QUALITY LAPSES - SAMPLES QUALITY MANAGEMENT REGION Sl. Activity No 1 Backfilling Quality Lapses / NCRs Potential Cause Preventive action To ensure that no of personal for spreading and compaction , no. of compaction equipment be proportinate to the volume/ rate of fill before start of filling operation. Every layer shall be tested and cleared for the compaction before start of subsequent

Backfilling in foundations & plinth upto Deviation from procedure 1.00 M without compaction observed, /technical specification. against requirement of filling in specified layers and testing for compaction.

Formwork

Column lifts done using conventional moulds found bulged by 12mm.

Formwork

Formwork

Formwork

Reinforcement

Reinforcement

Insufficient stiffners and non- Fabrication method / scheme to be standardised mould prepared and standardised for Timber making. Moulds to avoid failure of Joints / ties Honey Combs due to Seggregation Violation of drop height of Drop of concrete to be restricted to 2.4 M found in bottom 300mm Ht. Column concrete from code / and the workability of concrete to be lifts of 4.0M specification requirements increased to avoid seggregation. Level difference of 25mm at beam Painting clearance shall be Stage checks to be ensured to maintain bottom. Painting in progress without given only after corrections beam bottom levels within tolerance. rectification in stuctural works,if any. Form work system violated in slab and Deviation from Formwork drawings as per the sysyem beam shuttering works. recommended system by made and appreved by the Regional propritery formwork(DOKA). formwork competency cell shall be strictly adopted at site. Column Reinforcement Laps missed Failure to check Dowel as Dowels for floor extensions / beams to be out for Floor extension/ Dowels out of per drg. prior to floor/ checked and laps to be provided before position for beams column concreting clearing floor slabs / columns for concreting. Column Reinforcement cover found Cover check failure Reinforcement cover to be checked before 15mm against requirement of 40mm at concreting foundation level

Sl. Activity No 8 Reinforcement

Quality Lapses / NCRs Issue of BBS for fabrication after verification not evidenced Cement / Reinforcement Steel in site use without MTC (Client supply)

Potential Cause BBS issue not controlled, as required by procedure.

Preventive action

9 Material

10 Material

Moisture correction of aggregates for concrete not evidenced Reinforcement sampled for random testing has no correlation with batch no. / qty. it represents for. Sand used for plastering not as per specified grading Leakages at base slab and wall junction in overhead tank. Variation in strength beyond acceptable levels observed between cube samples cured in water and cubes cured with curing compound.

11 Material

12 Material

13 Construction joint preparation 14 Cube Testing

BBS issue for fabrication to be controlled. Only verified / approved BBS shall be issued for fabrication. Non-Compliance of Quality Client should be informed at the start of requirement by Vendors the project of the Quality system controlled by Client requirement that every batch to be supplied with MTC or we shall be testing at Third party lab and the charges shall be borne by the Client. Since products conformance is our resp Deviation from W/C control Mixing water to be corrected based on requirement daily moisture correction of aggregates to control W/C ratio Wrong sampling method. Any samples for testing needs to be identified with B.No. / Qty for traceability, as per IS1786. a. Checks for Grading a. Sampling to verify conformance. conformance not made. b. Use of right screen b. Damaged screen used. Failure to treat the Construction joint preparation to be construction joint. Deviation ensured as per procedure before from procedure. subsequent pours. Deviation from procedure for Any use of curing compound shall be only "Verification of purchased after confirmation by lab trials that the product" under section strength requirements are met by the 7.4.3. proposed product.

CORRECTIVE ACTION

Rectification of a concerned problem is not Corrective Action. Corrective action is the action taken to prevent further recurrences of the non-conformity at all times, at all places, by all people in the project. It shall plug all the loop holes that may trigger the nonconformance.

Corrective Actions towards Honey Comb problem

Correct QAP / Work Procedure Inspection / Supervision Plan Knowledge of Staff / Workmen Attitude of S/c / Workmen

Training
Negligence of individual Equipment un availability

Cost reduction measures

Poor Design