QCP Concrete Works

Galfar Engineering Contracting SAOG.
Page 1 of 13
QUALITY CONTROL PLAN
Customer : Ministry of transport & Communications, Director General of Roads & Land Transport.
Project: Construction of Batinah Expressway,Package-3 (Job# 6158) Concreting / Form Work & Shuttering
Consultant: Persons International & Company LLC
Contractor: Galfar Engineering & Contracting SAOG. CONCRETE WORKS
Legend: H - Hold; W - Witness; R - Review; S - Surveillance
Consultant
Contractor
Sl. Resp. Person
Activity Controlling Document Nature & Extent of Insp./Test Acceptance Criteria
at Location
Record
No.
1 Quality control of Std. spec.for Roads & - Routine Tests - Concrete production shall be in accordance with ACI 304. W W Mtls. Engr. Batch plant computer printouts
concrete mixes Bridge Constn 2010 -One set of sample per every - Ready mixed concrete shall comply with the requirements of ASTM C94 or BS EN20 QCI Concrete Pour Card
during production & Special spec. for BEW, 100 cu.m production - Batching of concrete ingredients shall be by weight and all weighing equipment Lab Tech. Compressive strength of
testing Package-3 ,Feb-2011 Freequency of routine test as shall be calibrated. Concrete cubes/Cylinders
Sec 5.1.4 per special specification - No concreting operation shall be carried out if Ambient temperature is of 40oC or more.
Sec 5.1.4.5 Table 5.1.2.3 - When air temperature is above 32oC, delivery time shall not exceed 45 minutes.
Sec 5.3.3.10 - Temperature of fresh concrete shall not exceed 32oC at the time of placement,
Sec.5.3.3.9 recorded in accordance to ASTM C 1064,
ASTM C 143 - Slump test of fresh concrete shall be performed in accordance to ASTM C 143.
ASTM C 94 - A minimum of one test shall be be conducted at pouring point for each day & type of
BS EN 206 concrete.
- Additional slump test shall be performed when concrete consistency appears to have
changed.
-The addition of water mixing at the point of discharge from Transit Mixture shall be
strictly prohibibited.
Galfar Engineering Contracting SAOG. Page 2 of 13
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
2 Quality control of - A sample shall consist of six numbers of 150x150 mm cube mould for each 7 day &
concrete mixes 28 day test.
during production & -The frequency of cube sample are as follows:
testing Structure Type
Sample represent a
Volume(m3)
(contd…) 1.Critical Structure e.g.masts,cantilevers,columns 10
2.Intermidiate structure e.g.beams,slabs,bridge decks 50
3.Heavy conc. construction e.g. breakwaters,solid rafts 100
- 3 cube mould are testing at 7 day and 3 for 28 days .
- A test result shall be mean of three cubes forming the sample set. Individual result
shall be within 15% of the mean result. Any individual result fails to comply with
the above shall be discarded from the mean calculation and the mean shall be
derived from the remaining results from the two entries. The number of total
accumulated results below the specified CCS shall not be more than 5% and no result
shall fall below the characteristic strength minus 3N/mm². 'If the above criteria are
not satisfied, actions shall be taken as specified in special spec. clause 5.14.5 -
sub clause 1(XV).
Air content BSEN 12350-7 (At mix design /As required by Engineer)
Flexural Strength (Prism) BSEN 12380-5 (At mix design /As required by Engineer)
Split Tensile Strength ASTM C 496 (At mix design /As required by Engineer)
- No production test for Blinding or Plain cement concrete are required.
each 7 day and 28 day test.
- Casted cube at site shall be cover with wet Hessian and Plastic sheet on the top.
- Curing of cubes sample shall be done in a temperature controlled curing tank.
-Cube samples shall be protected from damage and evaporation losses during storage,
transportation and handling.
- Concrete production operation shall be re-evaluated, If compressive strength
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
result of field cured Cubes are less than 85% of laboratory result.
3 Quality control of - The 28 day cube strength results shall be grouped consecutively in groups of
concrete mixes 40 samples and each group shall have a standard deviation less than 3.4 Mpa.
during production & - Concrete production shall be investigated if Standard deviation found greater
testing or equal to 3.5 MPa in each group.
(contd…) -The mixing time of concrete with microsilica shall be min 60sec and for normal
concrete is 30 sec minimum.
-When instructed by the Engineer concrete shall be tested for drying shrinkage and
wetting expansion on 75 x 75mm prisms prepared and tested in accordance with
BS EN 12350 and BS EN 12390. Maximum acceptable limits shall be:
* Drying shrinkage 0.05% * Wetting expansion 0.03%
-Air content of air entrained concrete shall be determined for every 200m³ for each
batch produced until consistency has been achieved. The maximum value shall not
shall not exceed 2%.
-Tolerance in batching (proportioning) shall be:
* 1% throughout the range of use for cement and water.
* 2% throughout the range of use for aggregates.
* 3% throughout the range of use for admixtures.
- IN NO CIRCUMSTANCES SHALL WATER BE ADDED TO CONCRETE
IN TRANSIT.
ISAT-BS 1881P-208 Each 500 cum of concrete
Depth of water penetration BSEN 12390 Part 8-Each 200 cum
RCPT-BSEN 12350 P1 each 200 cum
4 Concreting in Std. spec.for Roads & Visual 100% - When hot weather condition exist, concrete placement shall comply with W W QCI Concrete Pour Card
Hot weather Bridge Constn 2010 ACI 305 guidelines. Lab Tech.
Special spec. for BEW, -Aggregates, Mixing plant, Water tank, Trucks and Cement silo shall be in Shade. Site Engr.
Package-3 ,Feb-2011 - Insulated water supply pipeline shall be ensured in concrete production plant. Supvsr.
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
Sec 5.3.3.10 - Concrete temperature shall be maintained to 32oC at the time of placement.
ACI 305 - Concrete ingredients shall be cooled before mixing to maintain Concrete temperature
Concreting in at time of placement to below 25oC.
Hot weather - Water for concrete shall be used of chilled and/or chopped ice mixture
(contd….) - Reinforcement and formwork shall be kept in the shade so that steel temperature not
exceeding the ambient temp.
- Formwork, construction joint, etc. shall be sprinkled with cool water immediately
before the placement of concrete.
- Protect concrete during pouring and formwork from direct sunlight by use of shades.
- Concrete placing shall be completed as quickly as possible to reduce transit time.
- Curing of exposed concrete shall be immediately carried out.
-When the rate of evaporation of surface moisture from concrete is approach to
1 kg/m2/hr and shade air temperature is 35oc and rising then special care shall be taken
at site as well as concrete batching plant.
5 Curing of Concrete Std. spec.for Roads & - Curing shall commence immediately after the free water has left the surface and W W
Bridge Constn 2010 finishing operations are completed.
Special spec. for BEW, - The moisture on the surface of the concrete shall be continuously maintained
Package-3 ,Feb-2011 without any gaps during the curing period
Sec 5.3.3.12 - Continuous wet curing shall be conducted for a period of 7 days for ordinary conc.
and 14 days for microsilica concrete.
- The water cure shall be applied not later than 4 hours after completion of Deck slab
surface finishing.
- During period of hot weather, water shall be applied to concrete surfaces for curing
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
by liquid membrane method or by forms-in-place method, if required as directed by

the Engineer.
6 Falsework & Forms W W

Falsework System / Std. spec.for Roads & - Examination of all Drawings - Proposed system of falsework shall be checked & approved for safety and adequacy Engrs. Rep. - Approved drawings of falsework
Forms for Bridge Constn 2010 & Design Calculation to support the loads to which it'll be subjected. Site IC & Design calculation documents
Concreting works Special spec. for BEW, documents - Forms shall be watertight & rigid. QA/QC Engr. - Concrete Pour Card
Package-3 ,Feb-2011 - Check safety of Design, - Forms shall be designed to permit easy removal. CED-QC-000-005-F/01
Sec.5.3.2.1 Manufacture & Assembly - Only approved material (plywood / steel) shall be used for formwork. - RFI (approval for Falsework &
Sec.5.3.3.1 - Verification for Shape, - Forms shall be maintained to eliminate bending,warping & shrinking. Formwork)
ACI 301 Dimensions & Rigidity-100% - Dimension, shape & profile shall be as shown on the approved drawings.
ACI 117 - Visual-condition of forms, - Forms shall not show signs of sagging or bulging.
ACI 347R lining, etc. -100% - Form lining shall be used in the largest possible size to minimize joints.
- Manufacturer Specs. - Forms shall be oiled with suitable release agent prior to placement of concrete
- Approved Drawings reinforcement.
& Design Calculation - Different release agents shall not be used in the formwork to concrete.
documents - Form bolts, rods or ties shall be made of steel.
QC Procedure - - All ties, props, scaffold fittings shall be secured against vibration before & during
Formworks concrete operations.
CED-QC-000-026 - Formwork shall be correctly levelled & aligned.
- All exposed edges shall be bevelled by using dressed, mill-cut, triangular moulding
having 20mm sides, unless otherwise provided on the drawing or directed by the
Engineer.
- All formwork shall be inspected & approved by the Engineer before placement of
concrete.
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
- For Post Tensioned Concrete Box Girder following points shall be abided:
^ Formwork shall be marine plywood for all superstructures.
Falsework & Forms ^ Treated commercial plywood may be used for internal vertical & inclined web surface.
Falsework System / ( 3 coats of polyurethane varnish or similar approved materials),
Forms for ^ Prior to erecting falsework for the deck superstructure the following shall be confirmed:
Concreting works 1. Bearing capacity.
(contd…) 2. Expected amount of settlement of the supporting ground.
^ the shop drawings & design calculations for the forms / falsework shall be
approved by the Engineer prior to concreting works.
-Stay-in-place deck form shall be used for the deck slab of concrete box girder
provided they galvenized steel or otjer non-combustible material acceptable by
the Engineer.
-A 3cm slip joit shall be placed transversly in the deck forming between each diaphragm
to eliminate resistance of the deck forms to deck shortening during prestressing.
7 Striking Formwork Std. spec.for Roads & - Time elapsed from end of - The concrete shall be of sufficient age & strength at the time of striking form to W W Engrs. Rep. - Compressive strength of
Bridge Constn 2010 pour or Age of concrete (for withstand the effects of striking (includes thermal shock, loss of surface durability & Site IC concrete cubes
Special spec. for BEW, each pour) resulting stresses). Lab IC - Concrete Pour Card
Package-3 ,Feb-2011 -Design,erect,shore,brace and maintain formwork according to ACI 301,to support QA/QC Engr. CED-QC-000-005-F/01
ACI 301 vertical lateral,static,and dynamic loads and construction loads that might be applied
Sec.5.3.3.1 until concrete structure can support such loads.
ACI 301 -Construct formwork so that concrete members and structures are of size,shape,
ACI 117 alignment,elevation and position indicated within tollerance limits of ACI 117.
ACI 347R -Limit concrete surface irregularities,designated by ACI 347R as abrupt or gradual.
-Chamfer exterior corner and edges of concrete receiving applied waterprofing
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
membrenes, unless otherwise indicated,provide 20x20 mm chamfer on all exposed

corners and edges of concrete.
Striking Formwork -The tollerence and level of form works shall be as follows:
+25 mm,-12 mm. And for concrete surface
(contd…) that are to be waterproofed,abrupt
For all Buried Concrete
irregularities in the suface finish shall not
exceed 3mm
For soffit edge beams and sides of ±3mm but not more than 3mm in 3.5m.
parapet plinths
For all other Concrete ±6mm but not more than 3mm in 3.5m.
- The concrete shall be of sufficient age & strength at the time of striking form to
withstand the effects of striking (includes thermal shock, loss of surface durability &
resulting stresses).
-The formwork shall be retained for a minimum period before striking as under:
CONCRETE ELEMENT MINIMUM TIME
Sides of beams,walls and columns 2 days
Soffits of beams and slabs(props left in) 7 days
Removal of props(beams and slabs) 14 days
Soffits of precast beams 7 days
8 Supplying & Fixing Std. spec.for Roads & - Material Test Certificate - Reinforcement shall be in accordance with BS 4449 & shall conform to the requiremen W W Engrs. Rep. - Material Test Certificate of
Concrete Reinforcing Bridge Constn 2010 verification for deformed High Yield Steel bars grade 500 TypeB or equivalent as shown on the Matls. Mngr. Reinforcement steel.
Steel Special spec. for BEW, - Outside laboratory Testing approved drawings. Matls. Engr. - Water absorption test record for
Package-3 ,Feb-2011 in accordance with BS 4449- ^ Range of bar sizes shall be from 6mm to 50mm. Site IC concrete spacers.
Sec.5.2.1.2 2005,clause E.3.2: ^ The deviation of any cross-sectional dimension from its nominal size QA/QC Engr. - Bar Bending Schedule (BBS)
Sec.5.2.2.1 (for each test unit of 100 ton) (other than those of ribs) shall not exceed 8%. - Approved drawings of
Sec.5.2.2.2 ^ 3 specimens from different ^ Requirements for cross-sectional area & mass:AS per BS 4449:2005 steel reinforcement.
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
X-sectional
Sec.5.2.3.1 bars for tensile strength, yield Nominal Size area (mm2) Mass/metrerun (kg) - Approved RFI (reinforcement
- Approved Drawings & strength, elongation after 6 28.3 0.222 check)
8 50.3 0.395
Bar Bending Schedule fracture, total elongation at
Codes: BS 4449-2005, max. force, rebend, deviation 10 78.5 0.616
Supplying & Fixing BS 4483, BS 8666, from the nominal cross- 12 113 0.888
Concrete Reinforcing BS 5315, AASHTO M section & bond tests. 16 201 1.58
Steel 284M. ^ 02 specimens from different 20 314 2.47
Mfrs. MTC bars for chemical composition. 25 491 3.85
ACI 315 - Verification (100%) 32 804 6.31
ACI 318 - Visual (100%) 40 1257 9.86
50 1963 15.4
Nominal Size (mm) ≤8 >8
Tolerance on mass/metre run (%) ±6.0 ±4.5
^ Requirements for chemical composition: AS per BS 4449:2005
Deviation above the %
Element % max.
specified max.
Carbon 0.22 0.02
Sulfur 0.05 0.005
Phosphorus 0.05 0.005
Nitorgen 0.012 0.002
Copper 0.80 0.05
Carbon Equivalent Value 0.50 0.02
^ Requirements for mechanical properties:
(a) * Yield Strength - 500MPa
(b) Stress Ratio (min.) - 1.08 for B500B.
(c) Elongation at fracture % (min.) - 12, 14 for 460A & 460B resp.
(d) # Total elongation at max. force % (min.) - 5 for B500B.
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
* => For routine testing the yield strength shall be considered a minimum value.
- For the long term quality level, the values given shall be for the characteristic strength.
#
Values obtained below the minimum values specified shall not be a cause for
non-conformity with this BS.
(e) Redend test - Specimens shall show no sign of fracture or irregular bending
Supplying & Fixing deformation.
Concrete Reinforcing - Welded wire fabric if used shall conform to the following requirements:
Steel ^ size & dimension shall be that shown on the drawing.
^ shall conform to the requirements for "Welded Steel Wire Fabric for Concrete
Reinforcement" BS 4483 or equivalent. (see annexure )
^ The individual wires or bars used in the febrication of welded mesh shall as per
BS 4449:2005.
- A certificate shall be provided confirming that samples taken from the bars delivered
to the works pass all the required tests.
- Reinforcement received at site shall be legibly tagged showing manufacture's
test / lot number.
- Test samples provided shall be replicate bars of not less than 1m length.
- Uncoated reinforcement shall be grit-blasted before use to remove rust, oil, grease,
salt & other deleterious materials, if found.
- Partially set concrete adhered to exposed bars during concreting operations shall be
removed.
- Bars shall be cut & bend in accordance with ACI 315./BS8866
The tolerances in cutting & bending shall be as following:
^ cutting of straight lengths (including reinforcement for
+25mm , -25mm
subsequent bending)
^ bending < 1000mm +5mm, -5mm

> 1000mm to < 2000mm +5mm , -10mm
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
> 2000mm +5mm , -25mm

±25 or 0.5% of the
Length of wires in fabric
length(whichever is greater)
- Bar bending schedule shall show the weight of each bar, total weight of each bar
size & the total of weight of bars and bending diagrams in accordance with ACI 315/
BS 8866.
Supplying & Fixing - Welding may be permitted unless specified in drawing or approved by the Engineer .
Concrete Reinforcing - Cutting & Bending by the application of heat is not permitted.
Steel - Reinforcement shall be as shown on the drawing.
(contd…) into the main body of the concrete.
- Ties at intersections shall be made with 1.5mm diameter annealed wire.
- Cover to reinforcement on exposed faces of concrete shall be maintained by using
approved concrete spacers with the underlying requirements:
^ concrete shall be of similar grade to the main concrete & shall have non-metallic ties.
^ shall be water cured for a min. of 7days.
^ shall have a 30 minute absorption of less than 3.5% by weight.
^ Plastic spacers shall not be used and cover blocks shall only be of concrete.
- Metal supports (approved by Engineer) shall be provided & used to retain the
reinforcement at proper distances from the forms.
- All reinforcement shall be rigidly supported & fastened so that displacement will
not occur during construction.
- Splicing shall not be made except where approved by the Engineer in drawing.
- Laps shall be as indicated on the drawing.
9 Storage of -Reinforcement bars shall be handled and stored in a manner to avoid bending or W W Engrs. Rep.
Concrete Reinforcing Std. spec.for Roads & Visual (100%) other damage. Matls. Mngr.
Steel Bridge Constn 2010 -Bars shall be bundled,seperated in sizes and clearly marked by diameter size. Matls. Engr.
Special spec. for BEW, -Bars for seperate structures shall not be bundled together. Site IC
Consultant
Contractor
Sl. Resp. Person
at Location
Record
No.
Package-3 ,Feb-2011 -Metal tags or approved equal shall be provided with legible marking. QA/QC Engr.
Sec.5.2.3.2 -Reinforcement shall be stored 1 mtr above ground level on platforms,skids or other
approved supports and suitable spaced.
-Contact with the soil shall be avoid.
-Proper drainage & protection from the elements shall be provided to minimize
corrosion.
Galfar Engineering & Contracting SAOG. 12

Project: Al Batinah Expressway,Package-3 (Job 6158)
Consultant: Parsons International & Company LLC External Ptotective coating for concrete
Contractor: Galfar Engineering & Contracting SAOG.
(Legend: H - Hold; W - Witness; R - Review; S - Surveillance)
Sl Project reference Method of check Nature & Extent Resp. Person at

Activity Requirements Frequency Contractor
Customer Records
No. document of Insp. / Test Location
Standard
specification 5.11.1.2
Pre construction & Special Project
1 Method statement is in place As per manufacture recommendation Once before start activity H R Approved Method statement
stage specification 5.11.1.2 Manager /QA/QC
and approved
drawings
2 Material Receiving Inspection and routine Inspection
2.1 Preapplication
Standard
a Surface Preparation RFI Visual As per manufacture recommendation Daily W R Site Engr RFI
& Special
Standard
Moisture content of specification 5.11.1.2 Mtrl Engr /
b lab test report Moisture test As per manufacture recommendation on newly application surfaces W R lab test report
surface & Special QA/QC
3 Post Application
Standard
Final clearance and
3.1 & Special RFI visual As per manufacture recommendation Day to day works W R Site Engr RFI
completeness
& Method statements
gr.: Site Engineer; Supvsr.:

Legends:
Supervisor; Land Surv.: Land Surveyor; Lab Mngr.: Lab Manager; Tech.: Technician; Engr. Rep.: Engineer's Representative;
Matl. Engr.: Material Engineer; API: Asphalt Plant Incharge; APF: Asphalt Plant Foreman
Galfar Engineering & Contracting SAOG. 13

Project: Al Batinah Expressway,Package-3 (Job 6158)
Consultant: Parsons International & Company LLC KERB PAINTING
Contractor: Galfar Engineering & Contracting SAOG.
(Legend: H - Hold; W - Witness; R - Review; S - Surveillance)
Sl Project reference Method of check Nature & Extent Resp. Person at

Activity Requirements Frequency Contractor
Customer Records
No. document of Insp. / Test Location
Standard
specification 12 &
Pre construction Project
1 Special specification Method statement is in place As per manufacture recommendation Once before start activity H R Approved Method statement
stage Manager /QA/QC
12and approved
drawings
2 Material Receiving Inspection and routine Inspection
2.1 Preapplication
Standard
a Surface Preparation RFI Visual As per manufacture recommendation Daily W R Site Engr RFI
& Special
Standard
Moisture content of specification 12.1.4.2 on newly application Mtrl Engr /
b lab test report Moisture test As per manufacture recommendation W R lab test report
surface & Special surfaces QA/QC
specification12.1.4.2
3 Post Application
Standard
specification 12.1.4.2 On completed cured Mtrl Engr /
3.1 Dry film thickness lab test report Dry film thcikness As per manufacture recommendation W R lab test report
& Special surfaces QA/QC
Standard
Final clearance and specification 12.1.4.2
3.2 RFI visual As per manufacture recommendation Day to day works W R Site Engr RFI
completeness & Special
gr.: Site Engineer; Supvsr.:

Legends:
Supervisor; Land Surv.: Land Surveyor; Lab Mngr.: Lab Manager; Tech.: Technician; Engr. Rep.: Engineer's Representative;
Matl. Engr.: Material Engineer; API: Asphalt Plant Incharge; APF: Asphalt Plant Foreman

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Galfar Engineering Contracting SAOG.

by liquid membrane method or by forms-in-place method, if required as directed by

6 Falsework & Forms W W

membrenes, unless otherwise indicated,provide 20x20 mm chamfer on all exposed

^ bending < 1000mm +5mm, -5mm

> 2000mm +5mm , -25mm

QUALITY CONTROL PLAN

Sl Project reference Method of check Nature & Extent Resp. Person at

2 Material Receiving Inspection and routine Inspection

gr.: Site Engineer; Supvsr.:

QUALITY CONTROL PLAN

Sl Project reference Method of check Nature & Extent Resp. Person at

2 Material Receiving Inspection and routine Inspection

gr.: Site Engineer; Supvsr.:

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