Construction Materials

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What is Quality in Construction?

1. Fulfillment of Requirements Material Requirements Process Requirements Equipment Requirements End Product Requirements 2. Fitness for Purpose Riding comfort at design speed Ability to serve till the end of design life at design level of serviceability

Quality is generally to mean compliance with specified requirements Quality control is a means to control quality i.e. to verify compliance of materials, equipment, process and final product to predetermined requirements.

Material Specifications
1. Embankment /GWC
No.
1 2 CBR 3 4 5 6 7 8 9 Percent swell Liquid limit Plasticity index Maximum Dry Density (MDD) AASHTO T-193 AASHTO T-89 AASHTO T-90 AASHTO T-180

Inspection and Testing Description

Maximum particle size

Testing method
Visual AASHTO T-193

Acceptance Frequency of Test criteria

<2/3 of layer At random >4% for Fill One sample per 3000m3 >15% for Capping > 30% for GWC <1.5% One sample per 3000m3 <60% <30% for GWC <30% 8-15% for GWC Lab .value Lab. value >95 % >97% for GWC Omc+2% One sample per 3000m3 One sample per 3000m3 One sample per 3000m3 One sample per 3000m3 4 per lot or One sample per 1500m2 4 per lot or One sample per 1500m2

Optimum Moisture content (OMC) AASHTO T-180 Field Dry Density (FDD) Field Moisture Content (FMC) AASHTO T-191 AASHTO T-191

Fine Aggregates (Sand)

No.
1

Inspection and Testing Description

Testing method
AASHTO T-27

Acceptance criteria
Sieve(mm) % pass 10 100 4.76 95-100 2.38 68-86 1.19 47-65 0.59 27-42 0.3 9-20 0.15 0-7 0.075 0-2.5 <0.05% by weight < 0.4 % <10% < 3% < 75%

Frequency of Test
One sample per 1500 m3

Grading

2 3 4 5 6

Soluble chlorides Soluble sulfates SSS % passing 0.075mm SE

BS 812 BS 1377 AASHTO T-104 AASHTO T-27 AASHTO T 176

One sample per 3000m3 One sample per 3000m3 One sample per 3000m3 One sample per 1500m3 One per source

Rapid field Technique to Estimate silt content

River or pit sand should be sharp, angular, hard, clean uncoated particles free from clay and organic impurities. Well graded sand must be used for all cement work.

Coarse Aggregate (Gravel)

No. Inspection and Testing Testing method Description 1 AASHTO T-27 Grading 2 3 4 5 6 7 8 LAA ACV FI Specific gravity SSS Water absorption % passing 0.075mm AASHTO T-96 BS 812-1990 BS 812-1990 AASHTO T-85-94ASH AASHTO T-104 BS 812 or AASHTO T182 Acceptance criteria Different for different nominal sizes <40 to 50% <35% <35% <40% for grades lower than 15 <12% < 2.5% < 1% Frequency of Test One sample per 1500 m3 One sample per 3000m3 One sample per 3000m3 One sample per 1500m3 One sample per 1500m3 One sample per 3000m3 One sample per 3000m3 One sample per 3000m3

Aggregates must be clean and free from clay, loam, vegetable and organic material. A well graded crushed rock or gravel that contains both sand and stones should be used for concrete work. The size of aggregates should not be larger than 30 mm. The aggregates should be washed at least once in clean water immediately before being used in concrete production.

Water
No. 1 2 3 4 5 Inspection and Testing Description Chloride content Sulfate content Alkali carbonates and bicarbonates TDS pH value Testing method Acceptance criteria ASTM D 512 ASTM D 512 <400ppm <500ppm <750ppm <2000ppm 7 to 9 Frequency of Test After each rainy season

ASTM D 1888

Potable water is Generally considered satisfactory for both mixing and curing In case of doubt, 28 days average compressive strength of at least three 150mm cubes prepared with water proposed to be used shall not be less than 90% of the average strength of 3 similar cubes prepared with distilled water

Cement
The cement to be used in the work should be ordinary Portland cement complying with ASTM C-150 or BS-12. Both Roads and Building specifications of UNOPS specify OPC, not PPC Hardened cement will not be permitted in the works and is to be removed from site at the contractors expense.

No. 1 1.1 1.2 1.3

Inspection and Testing Description cement Consistency test Initial setting time Final setting time

Testing method AASHTO T131

Acceptance criteria AASHTO M-85 AASHTO M-85 AASHTO M-85 AASHTO M-85

Frequency of Test Every lot Every lot Every lot Every lot

Brick
Brick must have correct size, shape and sharp edges. Bricks shall not break when dropped from 1m height, shall give ringing sound when struck with each other and leaves no impression with finger nail 1. Mortar joint thickness shall not exceed 10mm in the class bricks and 12mm in second class bricks 2. Crushing strength (shall not be less than 35kg/sqcm for ordinary bricks) and water absorption (shall be less that 20%) water absorption dry the bricks and weigh (w1), immerse in water for 24 hours and weigh again (W2). Then WA=(w2-w1)/W1*100 or A Brick shall not absorb more than 1/6th of its weight of water after being soaked for one hour 3. Bricks shall be soaked at least for 1 hour before use 4. Bricks work should be raised uniformly and height of work in a day shall be less than 1.5m. Difference in height between two different portions shall be less than 1m

Blocks
Shall be regular and uniform in size and shape with sharp square edges and parallel faces. They shall be free from flaws, cracks and chips. should have the following dimensions: 400mm x 200mm x 200mm. There should be a longitudinal groove with 10mm depth and 20mm width on each block in order to provide place for horizontal steel reinforcement for the masonry work. Sample shall be collected randomly and tested every 10m3 of blocks produced. Three samples (blocks) shall be selected at random from every batch. The crushing strength of blocks shall be tested in a laboratory and the average crushing strength of blocks shall not be less than 15MPa (10 MPa) ??? (N/m2) and the water absorption of the blocks shall be not more than 240kg/m3 of concrete.

TIMBER Timber shall be free from twists, knots, splits and other visual or physical defects

Examples of Poor Materials

Process Control
The assistant engineers shall always be at site to inspect and control the contractors work processes. Contractors always give priority for profit than for quality. Therefore, will go for cheaper materials .  When you do process control, strictly adhere to the Specifications A number of factors should be controlled during construction as a vital part of process Control: Material - is the contractor using approved material? Mixing is the contractor using proper mix ratios? Proper mixing techniques? Moisture content is the contractor applying proper water content? Thickness / Lift what is the maximum thickness or lift specified for earth work, brick work, concreting etc? Compaction what equipments are used during compaction? What are the number of passes? What is the sequence/direction passing during compaction? etc General finish what is the quality of the final product?

Examples of Poor Process Control

Top soil and Overburden were not removed properly due to weakness in process Control

Removal of overburden of the same borrow pit after PM and ME instruction

Poor Process Control Excessive material spreading with out clearing the road bed

The maximum allowed thickness was 200m The road bed should have been cleared properly before dumping

Poor workmanship, Substandard work, and poor Masonry stones due to Poor Process Control during Culvert apron construction

Excessive Back Fill and Dry Compaction by Contractor Lack of Process Control

Maximum allowed thickness of compaction at a time was 150mm but contractor is filling 1000mm at a time Contractor is supposed to apply optimum moisture to the back fill, but prefer to compact it dry

Improper Soaking of CBR test specimens Poor Process Control

Equipment Specification/Control What type of equipments are specified in the contract? e.g. for compaction, mixing, excavation etc

End Product Specification e.g. Road

Is the surface free from compaction planes, ridges, cracks, loose material and movement under construction equipment? Has the loose, segregate and otherwise defection areas made good to full depth? Is the thickness of the layer in limits? The size of the coarse material does not exceed 2/3 of layer thickness? Does the rolling pattern confirm to specification? Does survey results conform confirm to requirements grade, cross fall, side , surface levels, slopes etc Moisture content prior to compaction ok? Is Degree of Compaction acceptable? Is the thickness as per the design? Then Approve the layer!

How can we control Quality of Construction Materials in Particular and construction activities in General?
1. 2. 3. 4. By Inspection and Process Observation By Random sampling By Testing By Measuring

Inspection Inspection of Storage of Construction Materials

SI. No Material/pr oduct 1 Rebar Location open Storage Method Store on timber Runners or concrete beam Precaution(Do`s and Donts)` 1. Dont mix different dais. 2. Cover with polythene sheet in rainy season 3. Dont block access to vehicle Placed on pallets lifted 1. Dont allow contact with 300mm above ground. moisture or side walls 2. Dont exceed 12 bags stacking Open Stack yard Proper ramp is made for loading & unloading

Cement Bag

Sheltered store

Concrete pipes

Curing tank for 7 days

Inspection for Different types of Construction Pipe Culvert Installation

Testing/Inspection Item Has the pipe culvert location been excavated as per the drawings Have the bed levels of the excavation been checked as per the drawings Has the type of bedding specified in the drawing or ordered by the engineer constructed Is the manufactured or imported pipe culvert is as per the Technical Specification Are the installed pipe culverts are free of defects like crack Have the jointing of the pipes done properly and collars satisfactorily grouted Has the pipe culvert invert elevation checked as per the drawings Does the pipe culvert bed slope conform to the drawings Have the pipes culvert been backfilled according to the Technical Specification Have the headwalls constructed as per the drawings and in conformance to the Technical Specification Yes No

Inspection Earth work/GWC

Testing/Inspection Item CBR as per AASHTO T-193 Percent swell as per AASHTO T-193 Maximum Dry Density (MDD) as per AASHTO T-180 Optimum Moisture content (OMC) as per AASHTO T-180 Field Dry Density (FDD) Field Moisture Content (FMC) Is maximum size of aggregate less than 2/3 of compacted layer thickness Yes No

Inspection for Bridges

Testing/Inspection Item Has the foundation location been excavated as per the drawings Have the bed levels of the foundation excavation been checked as per the drawings Have the form works and reinforcements of the Footing, Abutment, Piers, Girders and slab being properly spaced as per the drawings. Has the proportion of the concrete mix been as per the mix design proportion Have cube and/or cylinder samples taken for concrete compressive strength Has slump test taken frequently Has the minimum compressive strength obtained Has the slump test satisfactory Has backfilling at the abutment, piers and footings done properly Has the bearings, and filter media placed properly Have the pre cast Concrete beam placed properly on the abutments and piers Is the Expansion joint as per the drawings
Yes No

Testing/Inspection Item Working drawing checked and approved Latest revision being used Bar schedules approved Reinforcing steel material approved Bar bending and cutting satisfactory Corrosion treatment of bars, if required, satisfactory applied Bar size and spacing correct Bar lap length and location correct Bar tied as specified Bar assembly rigid and adequately supported Cover to bottom bars correct Cover to side bars correct Cover to top bars correct Cover blocks approved including fixing

Yes

No

Inspection for Concrete works

Description Method statement approved Batching plant mixers in working order(separate dispenser for admixture, if required, available) Stand by batchers in working order Water , sand, coarse aggregate, cement, admixture approved Water, sand, coarse aggregate, cement, cement stock sufficient. Concrete conveying arrangement (including transit mixers) available in working condition and of sufficient capacity Formwork approved Reinforcement approved Pre stressing sheathing approved Concreting equipment in working order Stand by crane, vibrators present Tremie in working order (for under water work) Concrete ganging present, including carpenter, steel fixer, mechanics and electrician Access provided Safety arrangements adequate Lighting provided Communication between various points provided arrangements for arranging suspension/stoppage of concrete provided curing arrangements made laboratory notified
Yes No Not available

Inspection for Building

Description Are the site, orientation and plan of the buildings approved? Is the site layout as per the drawings? Is the foundation material of the buildings acceptable for the superstructure load or need improvement? Is the foundation material compacted satisfactorily? Are the materials for masonry work like stone, sand and water approved? Is the stone for masonry work shaped and dressed satisfactorily? Is the mortar mix proportion as per the standard requirements of UNOPS? Is the hardcore and masonry works constructed as per the drawings and site condition? Is the backfill in foundation construction made with approved material? Is the back fill material compacted to satisfactory level? Is the reinforcement arrangement of the grade beam, beams and columns (if any) as per the drawings? Is the proportion of cement, sand and coarse aggregates for grade beam and column as per the UNOPS standards? Is the walls constructed with fiber cement or other approved material? Are the walls double and filled with insulating materials? Is the fittings of the buildings are provided as per the drawings, and UNOPS spec? Is the floor of the buildings as per the requirements of UNOPS spec? Is the building painted with approved paint? Is the paint work maintained regularly?
Yes No

Sampling
Procedures Quantity Location Time Representative sampling?

Testing Standards Common standards are ASTM, BS, AASHTO Laboratory management Joint Laboratory, Separate Laboratory, External Laboratory Contractors will manipulate results to their interest if there is no proper control during testing

Procedures for Materials Source Approval

The quantity of the sources Visual uniformity/variability of the sources Intended use (more critical materials require exhaustive testing) Quality of the sources (more tests will be made on marginal sources) Type of tests (more number of tests will be made for more important requirements) The minimum number of tests, however, will not be generally below three.

Problem soils in Construction

When we build Let us think that we build forever, Let it not be for the present delight!!!

Thank You!