QA/QC OF CONCRETE FOR BRIDGE CONSTRUCTION

QA/QC of Concrete for Bridge Construction

What is Quality Assurance/ Control?
Some Basic Definitions

QUALITY :
Degree to which a set of inherent characteristics fulfils requirements.

QUALITY CONTROL:
Part of quality management focused on fulfilling quality requirements.

QUALITY ASSURANCE :
Part of quality management focused on providing confidence that the relevant quality requirement will be
fulfilled.
Why is Quality Necessary?
Why is Quality Necessary?
A Loud applause please!
We are the Watch Dogs!
Quality Control of Concrete in Bridge

How Critical is a Bridge Structure

 Of all the major structural failures of the world, 52% cases are of bridges.
 Bridges are exposed to most Harsh environment leading to faster corrosion of
Steel Parts
 Repair of bridge structures usually costs higher than it’s original construction
cost.
 Revision of IS:456 in 2000 was actually a consequence of a bridge failure in
Goa. In this Code Cover of reinforcement was increased, clause on durability
was added.
 Most of the bridges are strategically very important as they play a vital role in
improving economy by connecting places, which otherwise would have been
very difficult.
Quality Control of Concrete in Bridge

To Achieve Quality,
 The Top most man in the organisation must be convinced that Quality must be
had.
 Quality Must be given preference over Speed and economy.
 Timely inspection and timely correction are the key to successful
implementation of QC systems. Delay in inspection/ correction leads to failure
of QA/QC system.
 Occurrence of Mistakes may not be necessarily a failure of QA/ QC system, but
repeating of mistakes is a failure of QA/QC system.
 QC Auditor should be able to recommend suggestions in addition to pointing
out of non- conformities. It is very necessary that he/ she should not go as
others say, and should only believe, what he/ she sees.
Quality Control of Concrete
Quality Control of Concrete

Characteristics
to
denote quality
of concrete

Temperature Economy

Workability Workmanship Strength Durability

Quality Control of Concrete- Material & Mix
INSPECTION AND TEST PLAN
Frequency of
Inspection and Testing Verifying MoRTH 5th rev. ref. /
Sl. No. Controlling Specification Person Responsible Time Line When to control Inspection / Record
Description Document Acceptance criteria
Testing
1 COARSE AGGREGATE (MoRTH 1007)
i Specific Gravity IS:383, IS:2386 - Part III ILR Site- Material Engineer/ Lab Technician 2 days At the time of Source Approval/ vendor finalization 1 test / source - ITR
Upon receipt of goods/ Each truck load for Daily once (or) as
ii Gradation/Sieve Analysis IS:383,IS:2386 – Part 1 ILR Site- Material Engineer/ Lab Technician 1 day As per table 1000-1 ITR
Routine Tests Acceptance/Rejection and when required
Upon receipt of goods/ Each supplier once in a 1) One per source 1007; IS:383 clause
iii Aggregate Impact Value IS:383, IS:2386 Part IV ILR Site- Material Engineer/ Lab Technician 1 day ITR
Routine Tests week 2) Weekly 5.4.2 AIV <30% for
1007; IS:383:2016
iv Los Angeles Abrasion Value IS:383, IS:2386 Part IV ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source clause 5.4.3 LAA TC
<30% for wearing
Each supplier once in a 1) One per source MoRTH clause No.
v Flakiness Index IS:383,IS:2386 P-1 ILR Site- Material Engineer/ Lab Technician 1 day Upon receipt of goods ITR
week 2) Weekly 1007; < 35%
Water absorption of
vi IS383,IS:2386 P-III ILR Site- Material Engineer/ Lab Technician 2 days At the time of Source Approval/ vendor finalization 1 test / source - ITR
Aggregate
Soundness (Magnesium and IS:383:2016
vii IS:383,IS:2386 P-V ELR Site- Material Engineer/ Lab Technician 15 days At the time of Source Approval/ vendor finalization 1 test / source TC
sodium sulphate) clause5.5.1, <12
viii Alkali-Aggregate reactivity IS:383,IS:2386 P-VII ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source IS:383:2016 clause TC
ix Deleterious Material IS:383, IS:2386 P-II ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source Table 2 of IS:383- TC
2 FINE AGGREGATE (MoRTH 1008)
IS:383,
i Specific Gravity ILR Site- Material Engineer/ Lab Technician 3 days At the time of Source Approval/ vendor finalization 1 test / source - ITR
IS:2386 Part-III
Gradation/Sieve Analysis, IS:383, Each truck load for Daily once (or) as 1008; As per table
ii ILR Site- Material Engineer/ Lab Technician 1 day Upon receipt of goods ITR
Fineness Modulus IS:2386 Part III Acceptance/Rejection and when required 1000-2, Fineness
iii

iv
Water absorption of
Aggregate
Deleterious Material
Soundness (Magnesium and
IS:383,IS:2386 P-III
IS383,
IS:2386 Part II
ILR

ELR
Site- Material Engineer/ Lab Technician

Site- Material Engineer

2 days

15 days
At the time of Source Approval/ vendor finalization

At the time of Source Approval/ vendor finalization

1 test / source

1 test / source
-
1008; Table2 of
IS:383:2016
1008; IS:383:2016
ITR

TC ITP- Materials
v IS:383,IS:2386 P-V ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC
Sodium Sulphate) clause5.5.1 Sodium
3 ORDINARY PORTLAND CEMENT (Ref. IS: 8112 , IS : 12269 & MoRTH 1006)
ELR / ILR / 2 days for ILR and 1 test/each
i Standard Consistency (%) As per IS: 4031 Site- Material Engineer Upon receipt of goods/ Routine Tests - ITR/TC/MTC
MTC 15 days for ELR Consignment

ELR / ILR / 2 days for ILR and 1 test/each

ii Initial Setting Time (Minutes) As per IS: 4031 Site- Material Engineer Upon receipt of goods/ Routine Tests IS:269:2015 Table 2 ITR/TC/MTC
MTC 15 days for ELR Consignment

ELR / ILR / 2 days for ILR and 1 test/each

iii Final Setting Time (Minutes) As per IS: 4031 Site- Material Engineer Upon receipt of goods/ Routine Tests IS:269:2015 Table 2 ITR/TC/MTC
MTC 15 days for ELR Consignment

2 ELR / ILR / 2 days for ILR and 1 test/each

iv Fineness (m /Kg) As per IS: 4031 Site- Material Engineer Upon receipt of goods/ Routine Tests IS:269:2015 Table 3 ITR/TC/MTC
MTC 15 days for ELR Consignment
ELR / ILR / 2 days for ILR and 1 test/each
v Soundness test As per IS: 4031 Site- Material Engineer Upon receipt of goods/ Routine Tests IS:269:2015 Table 2 ITR/TC/MTC
MTC 15 days for ELR Consignment
30 days for ILR
ELR / ILR / 1 test/each
vi Compressive Strength As per IS: 4031 Site- Material Engineer and 37 days for Upon receipt of goods/ Routine Tests IS:269:2015 Table 2 ITR/TC/MTC
MTC Consignment
ELR
1 test/each
vii Chemical Composition As per IS: 4032 ELR / MTC Site- Material Engineer 15 days Upon receipt of goods/ Routine Tests IS:269:2015 Table 2 TC/MTC
Consignment
4 FLYASH Grade-1 (Ref. IS: 3812 , IS : 1727 & MoRTH 1012)
i Chemical Requirements IS: 1727/ IS:4032 ELR / MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source IS:3812-1:2013 Table TC/MTC
ix Physical Requirements IS: 4031/4032 ELR / MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source IS:3812-1:2013 Table TC/MTC
xii Compressive Strength IS: 4031/4032 ILR Site- Material Engineer/ Lab Technician 35 days Upon receipt of goods/ Routine Tests 1 test / quarterly Not less than 80% of Test Results
5 GRANULATED SLAG (Ref. IS: 12089 & MoRTH 1012)
Proportion of lumps Max 5, Clause 3.1 of
i IS: 12089/4032 ILR Site- Material Engineer/ Lab Technician 1 day Upon receipt of goods/ Routine Tests 1 test / lot ITR
exceeding 50mm size, % IS:12089-1987
Insoluble residue of dried Max 5, Clause 3.4 of
ii IS: 12089/4032 ILR Site- Material Engineer/ Lab Technician 2 days Upon receipt of goods/ Routine Tests 1 test / quarterly ITR
samples IS:12089-1987
iii Glass content IS: 12089/4032 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source Min 85, Clause 3.4.1 TC/MTC
iv Manganese Oxide IS:4032 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source Max 5.5, Clause 3.2 of TC/MTC
v Magenesium Oxide IS:4032 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source Max 17, Clause 3.2 of TC/MTC
vi Sulphide Sulpher IS:4032 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source Max 2, Clause 3.2 of TC/MTC
CaO+Mg0+1/3 Al2O3 ≥1, Clause 3.3 of
vii IS:4032 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC/MTC
SiO2+2/3 Al2O3 IS:12089-1987
CaO+MgO+Al2O3 ≥1, Clause 3.3 of
viii IS:4032 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC/MTC
SiO2 IS:12089-1987
6 SILICA FUMES(Ref. IS: 15388& MoRTH 1012)
Min 85, IS:15338:2013
i SiO2 % by mass IS:1727/15388 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC/MTC
Table2
Max 3, IS:15338:2013
ii Moisture Content % by mass IS:1727/15388 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC/MTC
Table2
Loss on ignition in percent by Max 4, IS:15338:2013
iii IS:1727/15388 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC/MTC
mass Table2
Max 1.5,
iv Alkalies as Na 2O % IS:1727/15388 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC/MTC
IS:15338:2013 Table2
Min 15, IS:15338:2013
v Specific Surface (m2/g) IS:1727/15388 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1 test / source TC/MTC
Table2
Oversize % retained onon 45 Max 10,
vi IS:1727/15388 ILR Site- Material Engineer 1 day At the time of Source Approval/ vendor finalization 1 test / lot ITR
Micron Sieve IS:15338:2013 Table2
Oversize % retained onon 45
Max 5, IS:15338:2013
vii Micron Sieve, variation from IS:1727/15388 ILR Site- Material Engineer 1 day Upon receipt of goods/ Routine Tests 1 test / lot ITR
Table2
average
Compressive Strength at 7
Min 85, IS:15338:2013
viii days as percent of control IS:1727/15388 ILR Site- Material Engineer 10 days Upon receipt of goods/ Routine Tests 1 test / quarterly ITR
Table2
sample
7 WATER (MoRTH 1010)
To Neutralise 200ml sample MoRTH 1010; Should
of water, using not require more than
i IS:3025 -p22 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source TC
Phenolpthalein as an 2 ml of 0.1 normal
indicator NaOH
To Neutralise 200ml sample MoRTH 1010; Should
ii of water, using Methyl IS:3025 -p23 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source not require more than TC
Orange as an indicator 10 ml of 0.1 normal
iii Organic IS:3025-p18 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source MoRTH 1010; TC
iv Inorganic IS:3025-p18 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source MoRTH 1010; TC
MoRTH 1010;
v Sulphates (SO4) IS:3025-p28 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source TC
400mg/lit max
vi Chlorides (CI) IS:3025-p32 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source MoRTH 1010; TC
vii Suspended matter IS:3025-p17 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source MoRTH 1010; TC
viii pH IS:3025 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization 1/source MoRTH 1010; >6.0 TC
8 ADMIXTURE (MoRTH 1012)
MTC for each supply
MoRTH :1012.2
i Chloride Content IS:9103, IS:6925 ELR / MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization and one test for TC/MTC
,0.2% max
each source
MTC for each supply
ii Physical Requirements IS:9103 ELR / MTC Site- Material Engineer 7 days At the time of Source Approval/ vendor finalization and one test for IS:9103, Table 1A TC/MTC
each source
MTC for each supply MoRTH 1012.3.2Not
iii Air Content IS:1199 ELR/MTC Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization and one test for more than 2% higher TC/MTC
MTCeach supply than the corresponding
source
for each
iv Uniformity test IS:9103 ELR Site- Material Engineer 15 days At the time of Source Approval/ vendor finalization MoRTH 1012.3.2 Dry TC
and one test for
9 REINFORCEMENT STEEL
For all sizes - 1009.3; As per IS :
i Mechanical properties IS: 432 / 1786 MTC / ELR Site- Material Engineer 15 days Upon receipt of goods/ Routine Tests TC/MTC
2 per cast ( for 1786:2008 and
For all sizes - 1009.3; As per IS :
ii Mass per meter IS: 432 / 1786 MTC / ELR Site- Material Engineer 15 days Upon receipt of goods/ Routine Tests TC/MTC
2For
perall
cast ( for
sizes - 1786:2008
1009.3; Asclause
per IS6.2
:
iii Bend & Rebend IS: 432 / 1786 MTC / ELR Site- Material Engineer 15 days Upon receipt of goods/ Routine Tests TC/MTC
Quality Control of Concrete- Workmanship
INSPECTION AND TEST PLAN (During Execution)
Controlling Frequency of
Sl. Inspection and Testing Specification/ Inspection / Acceptance criteria Record
No. Description Method Testing
2 FORMWORK INSPECTION
Formwork
i design/drawing/sketch As per Approved All formwork IRC:SP:112-2017 B-1; IIR
approved including Drwaing Yes/No/NA
deshuttering arrangements?

ii
Formwork alignment As per Approved
All formwork
IRC:SP:112-2017 B-1;
IIR
ITP- Works
Correct? Drwaing Yes/No
iii Formwork levels correct, As per Approved All formwork IRC:SP:112-2017 B-1; IIR
including screed? Drwaing Yes/No
Formwork Dimensions As per Approved IRC:SP:112-2017 B-1;
iv correct? Drwaing All formwork Yes/No IIR
Formwork member spacing As per Approved IRC:SP:112-2017 B-1;
v correct? Drwaing All formwork Yes/No IIR

vi Formwork member material Visual All formwork IRC:SP:112-2017 B-1; IIR

quality acceptable Yes/No
vii False work member sizes As per Approved All formwork IRC:SP:112-2017 B-1; IIR
correct? Drwaing Yes/No
viii False work member spacing As per Approved All formwork IRC:SP:112-2017 B-1; IIR
correct? Drwaing Yes/No
ix False work member quality Visual All formwork IRC:SP:112-2017 B-1; IIR
acceptable? Yes/No
x Gaps between primary and Visual All formwork IRC:SP:112-2017 B-1; IIR
secondary members closed? Yes/No
xi Shuttering Material Visual All formwork IRC:SP:112-2017 B-1; IIR
thickness correct? Yes/No
xii Joints between panels Visual All formwork IRC:SP:112-2017 B-1; IIR
closed? (No gaps) Yes/No
xiii Joints between panels flush? Visual All formwork IRC:SP:112-2017 B-1; IIR
(No steps/lips) Yes/No
IRC:SP:112-2017 B-1;
xiv Panel flatness acceptable? Visual All formwork Yes/No IIR

Gaps between secondary IRC:SP:112-2017 B-1;

xv members and face panels Visual All formwork Yes/No IIR
closed?
Quality Control of Concrete- Records and Documentation
Project Quality Records

When it will be Controlling

Sr. No. Activity Responsibilities Action to be taken done/updated Document

Within 7 days of
1 QAP Preperation and approval of QAP
Site Material Engineer and shared with [email protected]. commencementthe Approved Copy of
of QAP
work

Performing tests as per specified

2 ITP Site Material Engineer frequency in attached ITP and Monthly Refer Doc. No. ATELLP
updating the same and shared -ITP-01, Rev.0 dated 1
with [email protected]. 1-12-20 Project Quality Records

Calibration of Laboratory Calibration to be performed as

3 per frequency ,schedule to be
Equipment and Batching Site Material Engineer updated Monthly Refer Doc. No. ATELLP
on monthly basis and -FM-01, Rev.0 dated 1
Plant shared with [email protected]. 1-12-20

Updation of Source approval

4 Source Approval Site Material Engineer status sheet and shared with Monthly Refer Doc. No. ATELLP
[email protected]. -FM-02, Rev.0 dated 1
1-12-20

Updation of Mix design approval

5 Design Mixes Site Material Engineer status sheet and shared with Monthly Refer Doc. No. ATELLP
[email protected]. -FM-03, Rev.0 dated 1
1-12-20

6 Standard Deviation of Site Material Engineer Cube register with S.D. sheet are
maintained and shared with Monthly Doc. No. ATELLP-FM-
Cocnrete cube strength 06, Rev.0 dated 11-12
[email protected]. -20

Post Inspection of Post Inspection of materials to

7 materials Site Engineer be done as per attached ITP Regularly/Daily Doc. No. ATELLP-ITP-0
2, Rev.0 dated 11-12-
20

MTC of all manufactured

Quality Control of Concrete- Non Destructive Tests
Quality Control of Concrete- Non Destructive Tests
Quality Control of Concrete- Workmanship

Workmanship

3 Ls
1) Line
Visual Appearance
2) Level
3) Length

Honeycomb Cracks Dusting, Blistering Finishing

Poor workmanship as a result of Improper workability Concrete
Bad Mix, Bad Workmanship, Bad Planning
Do We Need Concrete Here?
Which Concrete is done by a Reputed Company?
Do you like it?
Does Quality counts for gutters also?
You have pimples!

Voids between aggregates form a defect known as honeycomb

Make Up or a Proper Surgery?

Repair mix is rubbed into a section of honeycombing with a sponge like rubber trowel
A severe cold joint

A severe cold joint was formed when the lower section of concrete set before the next load was
poured in. The strength of the wall at this point is questionable.
Is it workable?

This high slump concrete has been watered down too much as evident by the way it dribbles
down the chute and off the sides of the shovel.
Is it workable?
Blisters! Not in Paint, its in Concrete this time!
Crazing makes me Crazy!
Plastic Shrinkage Cracks
Kya hua! chalta hai!
Are ye bhi chalta hai!
Some Problems and Solutions
 Unavailability of cement;

leading to use of non tested brands of cement.

What can be done

• Assume some suitable lower value of cement strength

at 28 days (usually curve- ‘d’) and adjust the mix
proportions for the required strength by varying water
cement ratio.

• Check the strength of concrete at 7 days and predict

the strength at 28 days considering 70% value of 28
days.

• Detect the curve from strength of 28 days and w/c

ratio, record same and change mix proportions again
as per the curve found.
De- shuttering of slabs needs to be done faster?
Faster Deshuttering!

THE WAY OUT!

1. Find out what strength is required in concrete so that

de-shuttering can be carried out!

2. From the test certificate find out the equivalent

strength of cement at the required age. Work out the
mix design for the required strength based on the
strength of cement.
Honeycomb at joints always?

Close the gap between shuttering and old Concrete.

• Usually flowing out of slurry, due to vibration, from the
gaps is the main reason.
• Pack the gaps with cement Mortar/ Proper Packing
Material. Play close attention during execution and track
any leackage of slurry, and get it packed.

Sir, we get honeycombs even when the shuttering is water tight!

• Increase fines content/ improve aggregate grading and
increase the workability, simple!
• Decrease the Maximum size of aggregate, if reinforcement
is dense.
Case Studies
THANK YOU