QUALITY CONTROL ON CONCRETE

Quality
• Quality means it should meet the
specifications

• Quality is closely related accidents and safety.

 Quality Assurance (IS 456:2000)
• Quality assurance in construction activity
relates to proper design, use of adequate
materials and components to be supplied by
the producers, proper workmanship in the
execution of works by the contractor and
ultimately proper care during the use of
structure including timely maintenance and
repair by the owner.
 Quality Assurance Measures
• The job of quality control and quality assurance would involve
quality audit of both the inputs as well as the outputs. Inputs
are in the form of materials for concrete; workmanship in all
stages of batching, mixing, transportation, placing,
compaction and curing; and the related plant, machinery and
equipments; resulting in the output in the form of concrete in
place. To ensure proper performance, it is necessary that
each step in concreting which will be covered by the next step
is inspected as the work proceeds.
Production and Control of Concrete

• A competent person (Certificate issued

by Divisional Engineer/Senior Engineer)
shall supervise all stages of production
of concrete
BATCHING
 BATCHING
– Cement and aggregates be proportioned by mass
– Water either by volume or weighed
– Solid admixture by mass and liquid or pastes admixture
by volume or mass
– Batching plant should as per IS:4925
– Uniform quality of aggregate be maintained
– Coarse aggregate of different sizes, grading be controlled
by blending in right proportion
– Different aggregates should be stock piled separately
– Grading of fine and coarse aggregate as per IS:383
– Moisture content of fine and coarse aggregate be
accounted for to obtained correct w/c ratio.
Mixing
 MIXING
• Mixing should ensure that mass becomes
– Homogeneous
– Uniform in colour
– Uniform in consistency
• Types of mixing
– Hand mixing (generally not recommended.
If used then 10% extra cement to be used)
– Machine mixing – efficient and economical
•MACHINE MIXING
Batch mixer
Continuous
Mixers as per IS : 1791 – 1968
 MIXING TIME
25 to 30 revolution @ 15-20 rpm is
minimum required for proper mixing.
Therefore 2 minute mixing is
desirable.

 Mixing is faster in natural aggregates

 MIXING

• Concrete shall be mixed in a mechanical

mixer
• Mixer should comply with IS:1791
• Mixing should be continued till distribution
of material and mass is uniform
• Mixing time generally is 1.5 to 2min for
normal mixture and 45 to 60 sec for high
rated batching plant
WORKABILITY
 WORKABILITY
• Compactibility- or ease with which
concrete can be compacted.
• Mobility- or ease with which concrete
can flow into formwork & around
reinforcement.
• Stability- or ability of concrete to
remain stable, cohesive and
homogeneous mass while handling,
vibrating without segregation
 Categories of Workability
Category CF Slump Vee Bee
mm sec
Extremely 0.68 0 > 20
low
V. Low 0.78 0-10 7-20
Low 0.85 10-25 5-10
Medium 0.92 25-50 3-5
High 0.95 50-125 2-3
V. High 0.97 125-200 0-2
 SLUMP TEST

• Vessel shape – frustum of cone of 30 cm ht.

10 cm. dia at top & 20 cm at bottom
• Concrete filled in four layers each
compacted with 25 strokes of bullet points
16 mm dia, 60 cm long, steel rod.
• Cone is removed & concrete allowed to
settle vertical settlement is ‘SLUMP.’
 COMPACTION
FACTOR TEST

• Here workability
is the amount of work required
to place concrete and to compact it thoroughly
• Two hoppers are one above other and cylindrical
mould 30 cm. high, 15 cm dia at bottom to collect
concrete. Wt. Of concrete collected in cylinder
divided by theoretical wt. of concrete gives CF.
 VEE BEE TEST

• Vibrating table 36 x 26 cm, with fixed

cylindrical container & a transparent disc.
• Ordinary slump test done by putting cone
into the cylinder. Slump measured with
plastic disc.
• Then vibration started with disc resting on
concrete,
• Time required for the concrete to take
horizontal surface in sec. is Vee Bee degree.
 FACTORS AFFECTING WORKABILITY

• Water
• Size of particles
• CA/FA ratio
• Particle interference – gap grading helps
• Shape of aggregates
• Admixtures – Air entraining agents,
pozzolanas.
 Effect of inadequate
workability

• Honey combing
• Less strength
• Less durability
 WORKABILITY- Provisions of CBC

• Should be controlled by direct

measurement of water content with or
without admixture
• Should be checked at frequent intervals
(refer to IS:1199)
PLACEMENT
 Methods of transportation
1. Mortar pan
2. Wheel barrow/hand cart
3. Bucket & rope way
4. Truck mixer & dumper
5. Belt conveyor
6. Chute
7. Skip & hoist
8. Pump & pipe line ( 8-70 cum concrete/ hr)
8-20 cm pipe, mix should be truly plastic
COMPACTION

 Expulsion of entrapped air

 Each 1% entrapped air reduces
6% strength
 Methods of compaction

• Rodding
• Ramming
• Tamping
• Internal vibration
• External vibration/Surface vibration
• Platform or table vibration
 Proper Internal
Vibration
• Increase compressive strength & bond
• Decrease permeability
• Decrease honeycombing
• Decrease excessive entrapped air
• Decrease segregation
 Transportation, Placement, Compaction
(CBC Provisions)
• Transportation
– Should be as rapidly as possible
– Should prevent the segregation or loss of
ingradients
• Placing
– Shall be placed before setting has commenced
and shall not be disturbed there after
– Should be as rapidly as possible
– Should prevent the segregation or loss of
ingradients
• Compaction
– No concrete shall allowed without vibration except
under water concreting or tremie concreting
– Vibrating points should be prefixed
– Vibrators shall be inserted in an orderly manner and
distance between insertion shall be 1.5 times the radius
of area visibly affected by vibrations.

• Construction Joints
– Position and arrangement shall be predetermined by
design
– Concreting be done continually upto construction joint.
Curing
 CURING OF CONCRETE
• Curing is a procedure used for
– Promoting the hydration of cement
– Control of temp and humidity
• As a result of curing
– Strength is improved
– Durability is improved and permeability of
concrete is reduced.
 METHOD OF CURING

• Replenishing lost water

– Immersion
– Ponding
– Sprinkling
– Saturated covering i.e. Jute bags
• Preventing moisture loss
– Curing compounds
– Impermeable membrane covering.
 PERIOD OF CURING
• As per IS : 456 for OPC – 7 days
• At least 10 days where mineral
admixtures or blended cement are used.
• As per IRS : CBC for OPC – 14 days
Curing mainly depends upon
– Type of cement
– Ambient atmospheric condition
– Mass to surface area ratio
 CURING (cont..)

• The process of curing shouldn’t be

interrupted, because partial hydration
makes capillaries discontinuous & on
curing again water may not enter the
concrete
• High strength concrete should be
cured at an early stage.
 PRACTICAL ASPECTS IN RELATION TO
CURING
• Widespread belief that humid climate is
sufficient for curing
• Generally the person responsible for
curing is most unskilled. He doesn’t
appreciate the importance & therefore
doesn’t care much
• Curing is not a measurable item in the
agreement.
 CURING (cont..)

• It is better to
– Use curing compounds
– Curing be kept as a separately payable item in
bill of payment
– Keep a set of cube in vicinity of structure & let it
be cured in the same way as the structure.
Strength & Permeability test on these cubes will
reveal the history
– Educate the person responsible for curing.
                                                                                                             

       
 CURING
– Concrete should be kept constantly wet
for a minimum period of 14 days.
– Approved curing compound may be use
in lieu of moist curing with permission of
Engineer provided test are done to
ascertain Loss of moisture in connection
with and without curing compound
– Steam curing can be used
advantageously in case of saving time for
transfer of prestress
False Work and Form Work
 False Work and Form Work
(CBC Provisions)
• False work
– To be designed to meet requirement of permanent
structure
– Attention be paid to detailing of connections
• Loads
• Dead load of wet concrete and reinforcement
• Weight of form work
• Plant and equipment including impact
• Impact due to deposition of concrete
• Construction personal
• Prestressing loads
• Lateral loads
• Wind loads
• Forces due to water current, if any
• Form work
– Shall confirm to shapes, line and dimensions as
per drawing and should give finished concrete
with specified tolerances
– Shall remain sufficiently rigid during placement
and compaction of concrete
– Shall be sufficiently water tight to prevent loss
of water or mortar
– Finished surface should be smooth and mortar
tight
• No surface finishing be normally provided
• The required finish be obtained by use of properly
designed form work of closely jointed boards
• Cleaning and Treatment of Forms
– All rubbish and unwanted material to be removed
– Form work in contact with concrete be cleaned and
thoroughly wetted or treated with an approved release
agent. Care shall be taken that such release agent is kept
out of contact with reinforcement
– Stripping time
• Forms shall not be struck until concrete had reached a
strength at least twice the stress to which concrete
may be subjected at the time of removal of form work
• Where possible form work may be left longer as it
would assist the curing
• Normal stripping time for ordinary portland cement
may be
– Walls, columns and vertical face of structural members:
24 to 48 hours
– Slabs (Props left under): 3 days
– Beam soffits (Props left under): 7 days
– Removal of props under slab
• Spanning upto 4.5m : 7 days
• Spanning over 4.5m : 14 days
– Removal of props under beam
• Spanning upto 6m : 14 days
• Spanning over 6m : 21 days
 PLACEMENT OF
REINFORCEMENT
 REINFORCEMENT
• Any reinforcement bent should not be
rebent at original location
• Below 5o C , special precaution be taken
• Straightening, cutting and bending
– Shall be bent, cut & fixed as per IS:2502
– All reinforcement be cold bent
– Shall not be straightened in a manner injurious
to material.
• Special precaution like coating of bars be
taken for reinforcement exposed to severe
and very severe exposure conditions
• Welded joints or Mechanical Connections
– Be used with the approval of Engineer
– For important connections, test shall be made to prove
that joints are full strength of bars connected
• Proper care should be taken for reinforcement
projecting for construction joints.
• No concreting shall be done unless reinforcement is
inspected and approved by engineer
Recommended test on material as per
USSOR
 Water requirement in concrete
 Water fit for drinking purpose can be used for concrete.

 PH value should be between 6 to 8. PH value less than 6 is

acidic in nature and causes corrosion.

 It should be free from organic matters and impurities i.e. Oil,

acids, alkalis, salts, sugar, organic materials and other
harmful substances.

 Compressive strength and initial setting time tests should be

carried out in case of doubt.
 Sea water contains salinity of 3.5% and causes corrosion
and reduction in strength of about 10-15%.
47
 Permissible Limit for Solids
(IS 456:2000)
Sl.No. Tested as Per Permissible Limit, Max

i) Organic IS 3025 (Part 18) 200 mg/l

ii) Inorganic IS 3025 (Part 18) 3000 mg/l

iii) Sulphates (as SO3) IS 3025 (Part 24) 400 mg/l

iv) Chlorides (as Cl) IS 3025 (Part 32) 2000 mg/l for concrete not
containing embedded steel and
500 mg/l for reinforced concrete
work
v) Suspended Matter IS 3025 (Part 17) 2000 mg/l

48
 Recommended tests on Materials
Material Para Test Field/ Test Minimum Frequency of
Laboratory Procedure quantity testing
of
material
for
carrying
out test

Water 26.1.1 i. pH value Lab IS:3025 Water from each

source shall be get
ii. Limits of Lab tested before the
Acidity commencement of
iii. Limits of Lab work and thereafter
once in every three
Alkalinity months till the
iv. Percentage of Lab completion of the
solids work. Water from
municipal source
a)Chlorides need be tested only
b)Suspended matter once in six months.
c)Sulphates Tests for each
source shall be 3.
d)Inorganic solids
e) Organic solids

49
 Recommended tests on Materials
Material Para Test Field/ Test Minimum Frequency of
Laboratory Procedure quantity of testing
material
for
carrying
out test

Cement 26.1.2 Physical Lab (i) IS:4031 Each Lot Every 50

Requirement (Part II ) tonnes or part
i. Fineness ,, (ii) IS:4031 thereof
ii. Soundness ,, (Part III)
iii. Setting ,, (iii) IS:4031
time(Initial & (Part V)
Final)
iv. Compressive ,, (iv) IS:4031
Strength (Part VI)
v. Consistency of ,,
standard
cement paste

50
 Recommended tests on Materials
Material Para Test Field/ Laboratory Test Procedure Minimum Frequency of
quantity of testing
material for
carrying out
test

Sand 26.1.4.1 Organic Field Annexure 26.2 20 cum Every 20 cum or

impurities part thereof or
more frequently as
decided by the
engineer

26.1.4.2 Silt content Field Annexure 26.3 20 cum -do-

26.1.4.4 Particle size Field or Lab as Annexure 26.4 40 cum 40 cum or part
distribution a, b, c, d decided by the thereof
&e Engineer

26.1.4.8 Bulking of sand Field Annexure 26.5 20 cum Every 20 cum or

part thereof or
more frequently as
decided by the
engineer

51
 Test Results of Sample(Cube)
• The test results of the sample shall be the
average of the strength of three specimens.
• The individual variation should not be more (+
or-) 15 percent of the average.
• If more, the test results of the sample are
invalid.
 Acceptance Criteria As per IS-456:2000
(Para 16,table 11)(Latest Amendments)
a. Characteristic Compressive strength Compliance
Requirement
Specified Mean of the group of 4 non overlapping Individual test results in
Grade consecutive test results in N/mm2 N/mm2

M-15 ≥ fck + 0.825 x established standard ≥ fck - 3 N/mm2

And above deviation(rounded off to nearest 0.5 N/mm2)
or

fck + 3 N/mm2, whichever is greater.

Note: 1. In the absence of established value of standard deviation, the values given table 8
may be assumed, the attempt should be made to obtain results of 30 samples as early as
possible to establish the value of standard deviation.
2.For concrete of quantity up to 30m3, (where the number of sample to be taken is less than
four as per the frequency of sampling given in 15.2.2)the mean of the test result of all such
samples shall be fck+4 N/mm2 ,minimum and the requirement of minimum individual test
results shall be fck-2 N/mm2 , minimum. However when the number of sample is only one as
per 15.2.2, the requirement shall be fck+4 N/mm2 ,minimum .
 Testing
• In case of doubt regarding the grade of
concrete used, either due to poor
workmanship or based on results of cube
strength tests, compressive strength test of
concrete on the basis of Core Test or Load
Test or Non – destructive Test.