Professional Documents
Culture Documents
Quality Control Program
Quality Control Program
• MATERIALS TESTING
• QUALITY CONTROL
WHAT IS MATERIALS TESTING ?
The Manager
J.D. LEGASPI CONSTRUCTION
202 A. Luna Street, Brgy. Greenhills
Mandaluyong City
Metro Manila
Sir:
This is to inform you that samples taken from your stock pile submitted at the
Regional Laboratory Office failed to meet the Grading requirements and Wash on Sieve No.
200 as per attached photocopy of test result for coarse and fine aggregates.
ANTONINO R. ZINGAPAN
Project Engineer
WHAT IS THE IMPORTANCE OF MATERIALS
TESTING
So without testing even in the field or in the laboratory, no one can state
definitely if the quality of materials is satisfied or not, even the expert.
What is Quality ?
What is to be checked?
1. Program of Works
5. Inspection
PROJECT : RECONSTRUCTION OF MINANGA BRIDGE ALONG NAGUILIAN - BENITO SOLIVEN - SAN MARIANO ROAD
LOCATION San Mariano, Isabela
LIMIT :
TEST TO BE PERFORMED:
QUANTITIES MINIMUM NO. OF TEST
ITEM NO. DESCRIPTION UNIT
PROGRAM REQUIRED
<:> A. BRIDGE
103 - 2 Structure Excavation (AOWL) 5.00 cu.m. No Test Required
GPC 2.0
104 - 1 Embankment 1,805.00 cu.m.
D 57.0
400- 23a 1400 mm. Diam. Bored Pile (16500mm) 33.00 ln.m.
CLASS "AA" (Substructure, 28 Mpa) 50.80 cu.m. # 2.0
12 a) Cement 610.00 Bags Qt 1.0
0.44 b) Fine Aggregate 22.35 cu.m. Qt 1.0
G 1.0
cu.m
PROJECT : RECONSTRUCTION OF MINANGA BRIDGE ALONG NAGUILIAN - BENITO SOLIVEN - SAN MARIANO ROAD
CONTRACTOR : J.D. LEGASPI
LIMIT :
TEST TO BE PERFORMED:
<:> C. MISCELLANEOUS
SPL 10 Progress Photographs all L.S. No Test Required
SPL 11 Rent to Own two (2) units Service Vehicle for the Engineer 2.00 units No Test Required
SPL 12 Field Office/ Engineers Quarters Rental & Maintenance 10.00 mos. No Test Required
SPL 13 Provision of Furniture, Fixture, Equipment, & Appliances for Engineer's Office all L.S. No Test Required
SPL 14 Warning/Traffic Signs all L.S. No Test Required
714 – Water
715 – Geotextiles
SCHEDULE OF MINIMUM TEST REQUIREMENTS GOVERNING ITEMS OF WORK OF
THE DPWH STANDARD SPECIFIC ATIONS FOR HIGHWAYS, BRIDGES AND AIRPORTS
(VOLUME II)
Part C - EARTHWORK
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
Item 100 - Clearing and Grubbing None
Item101 - Removal of Structures & Obstruction None
Item 102 - Excavation Same tests as for Items 103, 104 and 105, whichever is
applicable.
Item 103 - Structure Excavation
If excavated materials are incorporated into the work:
For every 1,500 cu.m. or fraction thereof:
If excavated materials are wasted, the volume
involved shall be reported so that Quality 1-G, Grading Test
1-P, Plasticity Test (LL, PL)
Control requirements may be adjusted
1-C, Laboratory Compaction Test
accordingly. Submit Project Engineer
Certificate of Waste For every 150 mm layer in uncompacted depth:
1-D, Field Density
For every 1,500 cu.m. or fraction thereof:
Item 104 - Embankment 1-G, Grading Test
1-P, Plasticity Test (LL, PL)
1-C, Laboratory Compaction Test
For each 500 sq.m of each layer of compacted fill or
fraction thereof at least one group of three in-situ
density tests. The layers shall be placed not exceeding
200 mm in loose measurement or based on the result of
compaction trials.
Item 200 - Aggregate Subbase Course For every 300 cu.m. or fraction thereof:
1-G, Grading Test
1-P, Plasticity Test (LL, PL)
For every 1,500 cu.m. or fraction thereof:
1-Q, Quality Test for Grading, Plasticity, Abrasion
and Laboratory Compaction Test
For every 2,500 cu.m. or fraction thereof:
1-A, Abrassion 1 -CBR, California Bearing Ratio
For every layer of 150 mm of compacted
depth/based on the results of compaction trials:
At least one group of three in-situ density
tests for each 500 sq.m or fraction thereof.
Item 201 - Aggregate Base Course For every 300 cu.m. or fraction thereof:
1-G, Grading Test
1-P, Plasticity Test (LL, PL)
For every 1,500 cu.m. or fraction thereof:
1-Q, Quality Test for Grading, Plasticity,Abrasion
and Laboratory Compaction Test
For every 2,500 cu.m. or fraction thereof:
1-CBR, California Bearing Ratio
For every layer of 150 mm of compacted
depth/based on the results of compaction trials:
At least one group of three in-situ density
tests for each 500 sq.m or fraction thereof.
Part D – SUBBASE AND BASE COURSE
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
Item 202 - Crushed Aggregate Base Course For every 300 cu.m. or fraction thereof:
1-G, Grading Test
1-P, Plasticity Test (LL, PL)
For every 1,500 cu.m. or fraction thereof:
1-Q, Quality Test for Grading, Plasticity, Abrasion
and Laboratory Compaction Test
For every 2,500 cu.m. or fraction thereof:
1-CBR, California Bearing Ratio
1 – F, Fractured Face
For every layer of 150 mm of compacted
depth/based on the results of compaction trials:
At least one group of three in-situ density
tests for each 500 sq.m or fraction thereof.
Item 300 - Aggregate Surface Course For every 300 cu.m. or fraction thereof:
1-G, Grading Test
1-P, Plasticity Test (LL, PL)
For every 1,500 cu.m. or fraction thereof:
1-Q, Quality Test for Grading, Plasticity,Abrasion
and Laboratory Compaction Test
For every 2,500 cu.m. or fraction thereof:
1-CBR, California Bearing Ratio
1 – F, Fractured Face
For every layer of 150 mm of compacted
depth/based on the results of compaction trials:
At least one group of three in-situ density
tests for each 500 sq.m or fraction thereof.
Part E – SURFACE COURSE
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
Item 307- Bituminous Plant-Mix Surface A. Aggregates
Course General For every 75 cu.m./200 t or fraction thereof:
1-G & P, Grading and Plasticity Tests for every
Item 310 – Bituminous Concrete Surface 1,500 cu.m. or fraction thereof:
1-Q, Quality Tests for: (Grading, Plasticity,
Course, Hot-Laid Abrasion, Stripping and Bulk Specific Gravity) 1-
F, Fractured Face
B. Bituminous Materials
Quantity: 5.0 to 8.0 mass % of total dry aggregate
Tests: 1-Q, Quality Tests for each 40 t or fraction
thereof
C. Mix
For every 75 cu.m./130 t or fraction thereof:
1-G, Grading Test
1-Ext., Extraction
1-Sty., Stability
1-C, Laboratory Compaction
D. Hydrated Lime
For every 100 t or fraction thereof
E. Mineral Filler
For every 75 cu.m. or fraction thereof:
1-G & P, Grading and Plasticity Tests (LL, PL)
F. For each full day’s operation:
D & T (Density and Thickness Tests) – at least one
(1) but not more than three (3) samples shall be
taken.
Part E – SURFACE COURSE
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
A. Cement
Item 311 - Portland Cement Concrete Quality: 9.1 bags cu.m. (40 kg/bag)
Tests: For every 2,000 bags or fraction thereof:
Pavement 1-Q, Quality Test
B. Fine Aggregate
Quantity:
1. 0.50 cu.m./cu.m. concrete (if rounded
coarse aggregate is used)
2. 0.54 cu.m/cu.m. concrete (if angular
coarse aggregate is used)
Tests: For every 1,500 cu.m. or fraction thereof:
a. For a source not yet tested, or failed in
previous quality tests:
1-Q, Quality Test for: Grading, Elutriation
(Wash), Bulk Specific Gravity, Absorption
Mortar Strength, Soundness, Organic
Impurities, Unit Weight, % Clay Lumps and
Shale.
b. For a source previously tested and passed
quality test:
1-Q, Quality Tests for: Grading, Elutriation
(Wash), Bulk Specific Gravity, Absorption
Mortar Strength
For every 75 cu.m. or fraction thereof:
1-G, Grading Tests
Part E – SURFACE COURSE
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
H. Concrete
I. Completed Pavement
Five (5) holes per km per lane or five (5) holes per
500 m when 2 lanes are poured concurrently.
Part F – BRIDGE CONSTRUCTION
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
C. Coarse Aggregates
Item 405 - Structural Concrete Quantity: cu.m./cu.m. of concrete
For Rounded For Angular
Class A - - - - - 0.77 - - - - - - - 0.68
Class B - - - - - 0.82 - - - - - - - 0.73
Class C - - - - - 0.70 - - - - - - - 0.68
Class P - - - - - 0.68 - - - - - - - 0.65
Tests: For every 1,500 cu.m. or fraction thereof:
a. For a source not yet tested or failed in
previous quality tests:
1-Q, Quality Test for: Grading, Bulk Specific
Gravity, Absorption, Abrasion, Soundness and
Unit Weight
b. For a source previously tested and
passed quality test:
1-Q, Quality Test for Grading, Absorption, Bulk
Specific Gravity and Abrasion
For every 75 cu.m. or fraction thereof:
1-G, Grading Test
Part F – BRIDGE CONSTRUCTION
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
C. Stone
Item 505 - Riprap and Grouted Riprap
Tests: Inspection Report/Soundness Test
D. Water
Tests: 1 – Certificate from Project Engineer or
1 – Q, Quality Test, if source is
questionable
A. Cement
Item 506 - Stone Masonry
Quantity: 2 bags/cu.m. of concrete
Test: For every 2,000 bags or fraction thereof:
1-Q, Quality Tests
B. Fine Aggregate
Quantity: 0.17 cu.m./cu.m. of concrete
Tests: For every 2,000 bags or fraction thereof:
1-Q, Quality Test for: (Same as for Item 405)
Part G – DRAINAGE & SLOPE PROTECTION
ITEMS OF WORK MINIMUM TEST REQUIREMENTS
B. Rock Fill
Tests:
Tests:
MINIMUM TESTING
REQUIREMENTS
Quality Control Procedures
1. Program of Works
5. Inspection
464.45 Qt = 1, G -7
717.79 Qt = 1, G -7
FA/CA
P.E.C
RSB's , FHCBP
16mm dia. Grade 40 kgs 41,810.72 Qt = 5
25mm dia. Grade 40 kgs 10,110.88 Qt = 2
32mm dia. Grade 40 kgs 160,311.36 Qt = 17
ITEM NO. DESCRIPTION UNIT QUANTITY NO. OF TESTS(Min.)
400 -24b Permanent Steel Casing ln.m 144.00 Physical Test/Inspection Report
(2.00m dia., t=10mm)
GP-17,C-4,
200 (1) Agg. Subbase Course cu.m. 4811 Q-4, A – 2, CBR-2,
D-65
c. Stone
Next topic
Computation:
For every 300 cu.m. or fraction thereof 1 GP 4811/300= 16.03 say G,P = 17
For every 300 cu.m. or fraction thereof 1 GP 7474 /300 = 24.91 say G,P = 25
For every 1500 cu.m. or fraction thereof Qt 7474 /1500= 4.98 Q,C = 5
For every 2,500 cu.m. or fraction thereof 1 CBR & A ;7474 /2500=2.99 CBR = 3, A=3
* The measured cement content shall be within plus(+) or minus (-) 2mass% of the design cement
content
3. Materials Sampling and Testing
Sampling of Materials
Is the process of selecting a part (sample), which will be used to judge
the whole (lot). Sampling of construction materials should be done on the
delivered materials at the project site and not in the place where it was
purchase.
- Take all the increments from the roadway for the full depth of the material,
taking care to exclude the underlying material.
Sampling from a Roadway
Sampling from the Conveyor Belt
- Stop the conveyor belt while the sample increments are being obtained.
Insert two templates, the shape of which conforms to the shape of the
belt in the aggregate stream on the belt, and space them such that the
material contained between them will yield an increment of the required
weight.
10. Steel Bar 1 Sample per 10,000 kgs. 0.70 meter for tensile
0.60 meters for bending
11. Steel Sheet (Galvanized) 1 Sample per 1,000 sheets 1 sheet
All cement shall be stored, immediately upon delivery at the Site, in weather
proof building which will protect the cement from dampness. The floor shall be
raised from the ground.
Provisions for storage shall be ample, and the shipments of cement as received
shall be separately stored in such a manner as to allow the earliest deliveries to
be used first ( first in – first out ) and to provide easy access for identification
and inspection of each shipment.
Storage building shall have capacity for storage of a sufficient quantity of cement
to allow sampling at least twelve (12) days before the cement is to be used.
Proper Storage of Cement
Storage of Concrete Aggregates
In order to secure greater uniformity of concrete mix, the Engineer may require
that the coarse aggregate be separated into two or more sized. Different sized of
aggregate shall be stored in separate bins or in separate stockpiles sufficiently
removed from each other to prevent the material at the edges of the piles from
becoming intermixed.
Storage of Reinforcing Steel Bars
Steel reinforcement shall be stored above the surface of the ground upon
platforms, skids, or other supports and shall be protected as far as practicable
from mechanical injury and surface deterioration caused by exposure to conditions
producing rust.
When placed in the work, reinforcement shall be free from dirt, detrimental rust,
loose scale, paint, grease, oil, or other foreign materials. Reinforcement shall be
free from injurious defects such as cracks and laminations.
Rust, surface seams, surface irregularities or mill scale will not be cause for
rejection, provided the minimum dimensions, cross sectional area and tensile
properties of a hand wire brushed specimen meets the physical requirements
For the size and grade of steel specified.
Storage and Protection of Steel Bars
TRANSPORTATION OF SPECIMENS TO TESTING LABORATORY
Concrete specimens such as beams and cylinders shall not be transported from
the field to the laboratory before completion of the initial curing.
PHYSICAL CHEMICAL
WHY WE NEED TO KNOW & LEARN TESTING
INTERPRETATION AND
FIELD APPLICATION
INTERPRETATION OF MATERIALS TEST
RESULTS
c. Any material that has been sampled and passed the standard
specifications may be re-sampled and re-tested anytime before,
during and after incorporation into the work.
COMMON ABUSES IN MATERIALS TESTING &
QUALITY CONTROL
This practice shows that relationship of personnel in the project are in poor
situation. Construction and Materials personnel have no harmonious
relation and do not cooperate to each other during the implementation of
the project.
• Incorporation of Materials into the works without
Quality Tests
Construction materials are being incorporated into the works
without the benefit of quality tests.
ACCEPTANCE TEST
The results of this test shall be the basis of acceptance of
the materials.
PRE-TESTING
Pre-testing of material is applicable to materials manufactured in bulk,
such as portland cement, asphalt reinforcing steel bars, etc…
Arrangement shall be made with the concerned implementing office to
assign a Materials Technician who shall obtain the necessary samples at
the plant.
If the result of the test is satisfactory, the Material Technician, upon
receipt of the test report, shall identify the stock represented, witness the
loading of the material and issue a Pretesting Certificate.
The material may be re-sampled at the point of delivery at the option
of the consignee especially if there are evidences of deterioration or
tampering. Otherwise, the Pretesting Certificate shall be the basis of
acceptance of the material.
5. Inspection
INSPECTION
Purpose of Inspection
b. Sieve analysis was conducted on screened coarse aggregates for use for Item 405 for checking of the
required gradation and the results was reviewed by me.
c. Checked the size and spacing of rebars installed at double culvert at Sta. 2+105.70 for compliance to
approved plans.
(SGD.) JUAN DELA CRUZ
Materials Engineer
7. Submission of Monthly Materials and
Quality Control Report
MONTHLY MATERIALS REPORT
The Materials Engineer shall prepare and submit to the Project
Engineer a Monthly Materials Report containing the tests conducted
and their results conducted on the materials placed or incorporated
based on the Quality Control Program.
The materials test and quality control report shall consist of the
following:
a. Status of tests performed and the balanced of tests as required
in the approved Quality Control Program
b. Summary of field and laboratory tests
_______________________ ______________________
Project Materials Engineer Project Engineer
1. Set of Sieves including cover Similar to Minimum Materials Similar to Minimum Materials
and brush, fine & wire sieve Testing Equipment of small Testing Equipment of medium
contractor plus:Vertical Capping contractors plus :
2. Mortar & Paste
Set
3. Liquid Limit Test Set including 1. Mechanical CBR Apparatus
Plate complete with accessories
4. Hammer, Modified 2. Volumetric Flask
Compaction
3. Sand Absorption Cone and
5. Compaction Mold Tamper
6. MC Can 4. Specific Gravity Test Set for
coarse aggregates
7. FDT Test Set
5. Los Angeles Abrasion Machine
8. Triple Beam Balance ( 0.01 g
and 0.1 g sensitivity ) 6. Thermostatic Controlled Oven
9. Heavy Duty Solution Balance 7. Core Drilling Machine complete
(20 kg capacity, 1 g with accessories
sensitivity)
8. Centrifuge or Reflex Extractor
10. Post Hole Auger
BASIC LABORATORY TESTING EQUIPMENT
MINIMUM MATERIALS TESTING EQUIPMENT
SMALL CONTRACTORS MEDIUM CONTRACTORS LARGE CONTRACTORS
The micrometer is used to accurately measure the diameters of six (6) inch-concrete
cylinders and the dimensions of six (6) inch-cubes ( or metric equivalent ).
It is used to measure the dimensions of concrete test samples to ensure compliance
with specifications.
BASIC FIELD TESTING EQUIPMENT
CONCRETE TEST HAMMER
EYEPIECE
SCALE - turn
to align with
crack direction
KNURLED
KNURLED KNOB - turn
RING - to focus the
loosen & twist microscope
to center
beam of light
then tighten
It uses an 8 kg
weight dropping
through a height of
575 mm and a
cone having a
20mm diameter.
The TRL DCP (DYNAMIC Cone Penetrometer) is an instrument designed for the
rapid insitu measurement of the structural properties of existing road pavements
constructed with unbound materials.
BASIC FIELD TESTING EQUIPMENT
SKID RESISTANCE & FRICTION TESTER