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Transcript of 1.Quality System
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CONSTRUCTION ENGINEERS
OF
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BIO - DATA
NAME : C. RAMANAIH
QUALIFICATION : 1. M. E (in Highway & Transportation)
2. Diploma in Construction Management.
3. Diploma in Transport Economics.
EXPERIENCE : 15 Years exclusively in the field of Highway
Design & Construction.
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Sl. No. Date Time Topic 1 23rd August 2005 9.00 to 11.00 Quality system for Highway projects 2 23rd August 2005 11.15 to 13.00 Material and Material testing. 3 23rd August 2005 14.00 to 16.00 DBM/ BC Mix designs
4 23rd August 2005 16.10 to 18.00 DBM/ BC laying and compaction.
5 24th August 2005 9.00 to 11.00 Construction procedure and acceptance criteria.
6 24th August 2005 11.15 to 13.00 Discussions on lessons learnt.
SCHEDULE OF TRAINING PROGRAMME
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Welcome
To
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C. RAMANAIAH M.Tech, DCM, DTE
Presented By
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What is „Quality‟?
The word ‘Quality’ is derived from Latin word Qualities‟ Which means ‘What Something Really Like’.
ISO 8402 defines ‘Quality’ as “The totality of features and
characteristics of a product or service that bear as its ability to satisfy stated or implied need”
Quality Control on Highways
QUALITY
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Shall specify…
Quality Control on Highways
QUALITY SYSTEM
WHAT - Designer Wants WHEN - It is to be defined
WHERE - It is to be controlled
HOW - It is to be controlled/done
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Quality Control on Highways
WHAT
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Quality Control on Highways
WHEN - It is to be defined
- Pre - Design Stage- Design Stage
WHERE - It is to be controlled
- Construction Stage- Maintenance Stage
HOW - It is to be controlled/done
- Construction Manual- Quality Control Manual- Systematic approach- Knowledgeful Staff
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A Document which describes the things (Q.C) to do. Manual
should describe the following…
DUTIES & RESPONSIBILITIES OF STAFF
OPERATIONAL PROCEDURES DESIGN PROCEDURE
SAMPLING & TESTING PROCEDURE
CALIBRATION PROCEDURE
SAMPLE FORMATS
ACCEPTANCE CRITERIA OF TEST RESULTS
STAFF TRAINING SCHEDULERS
Quality Control – Manual
Quality Control on Highways
HOW
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Quality Control is required to ensure the achievements of thedesired quality in a product.
Unsatisfactory Riding Quality Failure of Pavements & Bridges Reduced Service Life
Mounting Maintenance Bills Increased VOC
LACK OF QUALITY LEADS TO…
QUALITY CONTROL REQUIRED?
Quality Control on Highways
WHY
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WHO IS RESPONSIBLE FOR QUALITY
THE DESIGNER
THE OWNER
THE SUPERVISOR
THE CONTRACTOR
Quality Control on Highways
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Quality Control on Highways
THE DESIGNER
In the designer stage project shall be taylored, by considering the following things…
Size of the Project
Availability of Raw Material
Available Quality of Raw Material
Past history of Road behaviour in the region
Cost of the Project (Economical Feasibility)
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Periodic Revision of Specifications ?? Documents of QA for Bridges & Roads
Manuals for Design, Construction & Maintenance System for Pre Qualification Engagement of Consultants for design & Construct supervision
Steps taken for Quality improvement in
Indian Highway Construction…
Quality Control on Highways
THE OWNER
Steps to be Taken…
Regional based specifications Performance based Tendering Procedure Training to the Project Staff before start of Project In-time handing over
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Knowledge of Contract Management
Construction Procedure
Thorough knowledge of Technical Specifications
Good Education & Experience
Practical exposure
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THE SUPERVISOR
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WHAT IS REALITY?
In Reality it is the contractor on whom 75% of
Quality Depends….
The rates at which contractor gets the work
Time delay due to QC
Availability of Necessary Equipments
Knowledge of importance of QC
Education/Training
Cost to do Quality Control
Quality Control on Highways
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Production
Q u a t i t y
Q u a t i t y
Production
M a x . E
f f i c i e n c y
Modern EquipmentQuality control process
Relation Ship between Production Vs Quality
Relation Ship between Production Vs Quality
(Conventional method)
(By adopting modern techniques)
Production Vs Quality
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TIME SAVING TECHNIQUES OF ROUTINE TESTINGS
One point method of MDD & OMC
One point method of LL & PI
Use of Penetration Chart to find grade of Bitumen
Nuclear Density Gauge for field compaction control
Nuclear Asphalt content gauge
Electronic Water Testing kit Sieve Analysis by dry sieving.
Quality Control on Highways
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ONE POINT METHOD FOR DETERMINING MDD & OMC
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
0.0 5.0 10.0 15.0 20.0 25.0
Moisture Content
D r y D e n s i t y
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PENETRATION - TEMP CHART FOR BITUMEN
1
10
100
1000
0 5 10 15 20 25 30 35 40 45 50
Temperatureoc
P e n e t r a t i o n i n 1 / 1 0 m m
Pen-30 Pen-39 Pen-60Pen-70 Pen-80 Pen-103Expon. (Pen-30) Expon. (Pen-39) Expon. (Pen-60)
source: Indian Highways No vember' 19 97
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Rapid verification of asphalt content
(%AC) of paving mixtures sampled at
the asphalt plant, lab or paving site,
prior to placement and compaction.
Asphalt Content Gauge
Portable Water Quality Tester
Provides completely portable
method of water quality testing.
Quality Control on Highways
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Things that influence the quality of Work?
1. Material
2. Machinery 3. Man
Correctness of results depends on:
1. Correctness of Equipment Used
2. Level of Test Method Followed
3. Person Doing The Test
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Correctness of equipment being used
Some of the equipment that need calibration
Quality Control on Highways
CALIBRATION
All weights and balances
Measuring jars
Thermometer
Dial gauges & Proving rings
All weighing sensors of plants like WMM, HMP,BP All Nuclear devices, Field Density Operations, etc.
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Level of Test Method Follows
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Person doing the Test
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What Stages Quality Control is to be done?
1. Material Selection Stage
2. Processing Stage3. Finished Stage
TYPES OF QUALITY CONTROL
PROCESS CONTROL
END RESULT CONTROL
Quality Control – Stages & Types
Quality Control on Highways
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Registration
Test Requests
Sampling Field Testing
Preparation
Testing Distribution of Test Results
Storage of Samples
Decision
Filing/Computer Database
Laboratory Operational Procedure
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MATERIALS
ACCEPTABL
E
(Q.C)
SUITABILITY
OTHER WORKS
MIX DESIGN
(IF REQUIRED)
PROCESS
ACCEPTABLE
(Q.C)RECTIFIABLE REJECT/
REMOVE
END
PRODUCT
REJECT
Yes
Yes
Yes
Yes
No
No
No
No
QUALITY CONTROL PROCESS
Flow Chart
Quality Control on Highways
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Selection of soils
Suitability of foundation soils
Field compaction soils
Major Item of Road Works and their
KEY QUALITY CONTROL POINTS…
a. Embankment & Sub Grade
Quality Control – Road Works
Quality Control on Highways
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Soil Compaction
The basic factors that determine
compaction results in soils are… • The type of soil
• Its water (moisture) content
• The compaction method & applied
energy
A soil material consists of
three elements:
Soil Particles, Water and Air.
Quality Control on Highways
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Selection of Aggregates Blending of Aggregates
Checking for suitability of blended Aggregates
Compaction
Line & Level Checks
b. Granular Sub Base & Wet Mix Macadam
Quality Control on Highways
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AGG. %
SIZE 37.5 26.5 13.2 4.8 2.4 0.3 0.1 BLEND 37.5 26.5 13.2 4.8 2.4 0.3 0.1
40 100.0 73.8 2.3 0.0 0.0 0.0 0.0 15.00 15.0 11.1 0.3 0.0 0.0 0.0 0.0
20 100.0 99.6 11.3 0.3 0.0 0.0 0.0 23.00 23.0 22.9 2.6 0.1 0.0 0.0 0.0
12 100.0 100.0 97.3 2.8 1.4 0.0 0.0 20.00 20.0 20.0 19.5 0.6 0.3 0.0 0.0
q/d 100.0 100.0 100.0 82.9 55.3 18.6 1.9 38.00 38.0 38.0 38.0 31.5 21.0 7.1 0.7
Filler 100.0 100.0 100.0 100.0 100.0 99.0 49.7 4.00 4.0 4.0 4.0 4.0 4.0 4.0 2.0
TOTAL 100.0 96.0 64.4 36.2 25.3 11.0 2.7
AVEG. 100.0 95.0 68.0 44.0 32.0 11.0 4.0
SPEC. L/L 100 90 56 29 19 5 1
SPEC. U/L 100 100 80 59 45 17 7
SIEVE SIZE (in mm) SIEVE SIZE (in mm)
DBM BLENDING HOT BIN PROPORTION
Aggregate blending chart For DBM
0
10
20
30
4050
60
70
80
90
100
110
0.0 0.1 1.0 10.0 100.0
Sieve size in mm
% P a s s i n g
upper limit lower limit design gradation max density gradation
Quality Control on Highways
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Sieve Analysis
Sieves are used to analyze the gradation
(grain size distribution) of a sample.The amount of material remaining on
Each sieve is calculated as a percentage
Of the total weight of the sample.
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Type of Material (Cut back/Emulsion) Property of Material
Application Temperature
Rate of Spreading
Penetration/Bonding
c. Prime Coat & Tack Coat
Quality Control on Highways
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Selection of Materials
d. Bituminous Works
Aggregate Bitumen (Plain Bitumen/CRMB/PMB) Filler (Recycled/Lime/Cement)
Design of Job Mix Formula
Stability Flow
VMA VFB Air Voids Density Loss in Stability
KNR – PATEL (JV)
Quality Control on Highways
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KNR – PATEL (JV)
TEST PROPERTY CURVES FOR HOT-MIX DESIGN DATA BY MARSHALL METHOD
Stability Vs Bitumen Content
500
900
1300
1700
3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1
Bitumencontent in %
S t a b i l i t y i n k g
Unit Wight Vs Bitumen content
2.400
2.450
2.500
2.550
2.600
3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1
Bitumencontent in %
U n i t w e i g h t i n g / c c
Flow vs Bitumen content
2.00
2.50
3.00
3.50
4.00
4.50
5.00
3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1 5.4Bitumencontent in %
F l o w i n
m m
Air Voids Vs Bitumen content
1.4
2.4
3.4
4.4
5.4
6.4
3.3 3.6 3.9 4.2 4.5 4.8 5.1 5.4
Bitumencontent in %
A i r V o i d s i n %
VMA vs Bitumen content
12.00
13.00
14.00
15.00
16.00
3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1 5.4Bitumencontent in %
V M A i n %
VFB Vs Bitumen content
40.00
50.00
60.00
70.00
80.00
90.00
3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1 5.4Bitumencontent in %
V F B i n %
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KNR – PATEL (JV)
Bitumen
content by
wt. of total
mix %
Stability
in Kgs
Unit
Wight
in g/cc
Flow
in
mm
VMA
in
%
VFB
in
%
3.60 1322 2.477 2.8 13.80 53.99
3.90 1599 2.494 3.2 13.46 59.29
4.20 1681 2.499 3.5 13.56 66.00
4.50 1700 2.501 3.6 13.76 70.28
4.80 1480 2.508 4.0 13.80 75.72
5.10 1428 2.518 4.6 13.72 81.78
VFB
VMA
Air Voids
Flow
Stability
%Bitumen 3.6 3.9 4.2 4.8 5.1
2.50
Selection Of The Narrow Range Of Acceptable Bitumen Contents
Abstract of Marshal Mix Design Test Values
Air Voids
in %
6.40
5.50
4.5
Passes all criteria
4.60
4.10
3.40
Index:
Low
High
Passing
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Influence of Gradation on Mix
Segregation More Air Voids
High VMA Low VFB
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Coarser grading leads to
More flow Slippery Surface
Blending Low Stability Low Air Voids
Finer grading leads to
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Things to Remember while doing Job Mix Formula
Select proper grading advisable slightly coarser side
Air Voids shall not be too low, should not be high(by considering Secondary Compaction)
VFB (Voids Filled with Bitumen)
Stiffness Factor
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Quality Control on Highways
PLANT CONTROLS
Bitumen Content
Temperature of Aggregate
Temperature of Bitumen
Mixing Temperature
Type of Mixing
Type of Loading
l l h
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Quality Control on Highways
SITE CONTROLS
Laying Procedure
Laying Temperature Compaction Procedure
Degree of Compaction
Rolling Temp
Q li C l Hi h
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MIX SEGREGATION
If the material level is too high,it will slope towards the outeredges where stones can separate.
The segregated strip in the
middle of the lane is caused by the auger drive unit located atthe centre of the augers.
Quality Control on Highways
Q li C l Hi h
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Temperature of the Bituminous mix during differentoperations are to be checked to control them withinthe following specified limits…
Sl.No Operations Range
1 Temperature of Binder at the time of mixing 150o C to 163o C
2 Temperature of Aggregate at the time of mixing 155o C to 163o C
3 Difference in aggregate & Bitumen <14 o C
4 Discharge temperature of mix from the mixer 130o C to 160o C
5 Temperature of mix at the time of laying 120o C to 135o C
6 Minimum temperature of mix at the time of rolling 100o C
Quality Control on Highways
Q lit C t l Hi h
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ROLLING PROCEDURE A rolling pattern consisting of three parallel rolling lanes divided into zones,normally 30-50 m long. In each zone the roller moves forward and backwardthe required no.of passes.
The roller strokes (the distance the roller movesfrom the point at which it changes direction
behind the paver to the change in direction at theend of the lane) thencover two zones.
Quality Control on Highways
Q lit C t l Hi h
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Compaction is a process by which the Soil/Aggregate particles an
artificially rearranged and packed together into a closer state of
contact by mechanical means in order to decrease the porosity
(on Air Voids)
• Static Roller
• Vibratory Roller
• Pneumatic Roller
• Tampers
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COMPACTION
Type of Compaction available
Q lit C t l Hi h
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STATIC Compaction• Static compaction uses the dead weight
of the machine to apply pressure.
• Static equipment will normally achieveadequate compaction in the upperlayers.
• Owing to the bridging of the soilparticles it is limited in depth effect.
In the static compaction,only pressure is exerted on
the underlying surface
Quality Control on Highways
Qu lity Control on Highw ys
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VIBRATORY Compaction• Vibratory compactors deliver a rapid
succession of impacts to the underlying surface.
• This virtually eliminates the internalfriction and facilitates therearrangements of the particles intopositions that result in as low a void
space and as high a density as possible
• The increase in the no.of contactpoints between particles leads to highstability and strength.
Vibratory compaction
combines static pressure and
dynamic force
Quality Control on Highways
Quality Control on Highways
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PNEUMATIC TYRED ROLLER
The compaction effect of pneumatictyred roller is primarily determinedby two parameters…
- Wheel Load
- Ground contact pressure of Tyre
Pressure contact area overlap. A part from the individual pressure bulbs,
there is an interaction of the pressure bulbs to give greater depth effect
Tyre overlap
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Quality Control on Highways
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Compaction On Minor Jobs
There is a wide range of light compaction equipment available for
use on minor jobs and in confined spaces. These vibratory plate
compactors, vibratory tampers, double-drum walk behind rollers
and lightweight tandem Rollers also complement larger types of
rollers where these machines do have full access.
few more…
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Quality Control on Highways
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Compaction On Minor Jobs
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Quality Control on Highways
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Core Drilling Apparatus
Nuclear Gauge
The normal method for field density
control is to remove a core sample with
a diamond drill. Density and air void
content are determined on the samplecores in Laboratory.
Nuclear gauges gives a rapid
reading of the density of an asphalt
surfacing
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TESTING OF DEGREE OF COMPACTION
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Riding Quality (unevenness)
Skid Resistance
Avoid Core Cutting in finished layer toavoid potential Pot Holes
Quality Control for Finished Work
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Quality Control on Highways
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The surface evenness is measured by running a straight edge over
the finished surface. Irregularities are shown up on the gauge
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“Quality Is Not Outcome Of Accident;
It Is The Resultant Of Persistent Hard Work By Conscientious People”
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T h a n k Y o u