Construction Materials E-Book

7/26/2019 Construction Materials E-Book

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All rights reserved to Civil EngineeringDepartment Ports, Customs & Free Zone

Corporation, Dubai. No parts of this

publication may be reproduced, stored

in any retrieval system, or transmitted in

any form or by any means, electronic,

mechanical, photocopying, recording orotherwise, without the prior consent of

the copyright owner.


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CONSTRUCTION MATERIALS

QUALITY CONTROL GUIDELINES

Ports, Customs & Free Zone Corporation, DubaiUnited Arab Emirates


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Al rights reserved to Civil Engineering Department Ports, Customs & Free Zone Corporation, Dubai. No parts of this publication may

be reproduced, stored in any retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying,recording or otherwise, without the prior consent of the copyright owner.

First Edition-2007

Construction Materials Quality Control Guidelines

This edition was issued in March 2007

Jebel Ali, Dubai, United Arab Emirates

P.O. Box 17000, Ports, Customs & Free Zone Corporation, DubaiTel.: 00971 4 8819444E-mail: [email protected]://ced.dubaitrade.ae


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CONSTRUCTIONMATERIALS

QUALITY

CONTROL

GUIDELINES

First Edition-2007

Ports, Customs & Free Zone Corporation, DubaiUnited Arab Emirates


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ACKNOWLEDGEMENT


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ACKNOWLEDGEMENT

The publication of this book could not have been possible but

for the ungrudging efforts put in by the Quality Section of the

Civil Engineering Department. We would like to acknowledge

contributions made by Group Internal Audit and Quality

Director, Nakheel Contracts and Procurement Manager,

Nakheel Quality Assurance Manager, Concrete Readymix

Suppliers, Materials Testing laboratories and many engineers

from different organizations.

Our thanks go out to all of those who contributed, whether

through their comments, feedbacks, edits or suggestions.

As there is always room for improvement, Civil Engineering

Department welcomes comments on this Book, and will

consider all that are received. Your comments will continue the

development of this book leading to its ultimate acceptance.

As always it has been a great joint effort..

Nazek Al Sabbagh

Chief, Civil Engineering Officer

Ports, Customs & Free Zone Corporation CED


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Page

Chairman Quality Policy Statement-------------------------------------------- 11

Section 1: Introduction------------------------------------------------------------------ 13

Section 2: Quality Control (General)----------------------------------------------- 15

2.01 Quality Policy -------------------------------------------------------- 15

2.02 Submittals ---------------------------------------------------------------- 15

2.03 General Quality Control Requirements------------------------------- 16

2.04 Quality Control Plans--------------------------------------------------- 19

2.05 Inspection Procedures--------------------------------------------------- 20

2.06 Inspection and Test Plan------------------------------------------------ 222.07 Document and Submittal Control------------------------------------- 22

2.08 Identification and Control of Items and Materials------------------- 23

2.09 Inspections and Tests---------------------------------------------------- 24

2.10 Measuring and Test Equipment---------------------------------------- 26

2.11 Non-Conformance Monitoring---------------------------------------- 26

2.12 Personnel Qualifications------------------------------------------------ 28

2.13 Quality Control Reports/Audits---------------------------------------- 28

2.14 Equipment/Material Handling and Storage-------------------------- 29

2.15 Quality Control Records------------------------------------------------ 292.16 Workmanship------------------------------------------------------------ 30

2.17 Protection of Property--------------------------------------------------- 31

2.18 QA/QC Induction Training--------------------------------------------- 32

Section 3: Recommended Practices Before and During Concreting----- 33

3.01 Formwork ---------------------------------------------------------------- 33

3.02 Concrete Consolidation ----------------------------------------------- 33

3.03 Concreting -------------------------------------------------------------- 333.04 Hot Weather Concreting----------------------------------------------- 34

Section 4: Schedule of Tests and Inspections-------------------------------- 37

a. Cast In-Situ Concrete (Ready-Mixed Concrete) ----------------------- 37

Laboratory and Plant Trial Mixes ------------------------------------ 37

Concrete Production & Site Deliveries ------------------------------- 39

Site Laboratories ------------------------------------------------------- 42

Aggregates ------------------------------------------------------------- 44

Water --------------------------------------------------------------- 46

Cementitious Materials and Admixtures ---------------------------- 47

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b. Bored In-Situ Piles & Drilled Shafts ------------------------------------- 48

c. Reinforcing Steel -------------------------------------------------------- 49

d. Epoxy-Coated Steel ------------------------------------------------------- 50

e. Earthwork ------------------------------------------------------------------ 51

f. Precast Concrete -------------------------------------------------------- 52

g. Glass Reinforced Cement (GRC) Elements ---------------------------- 53

h. Blocks ---------------------------------------------------------------------- 54

Concrete Blocks-------------------------------------------------------- 54

Autoclaved Aerated Concrete Blocks -------------------------------- 55

Normal Weight Polystyrene Sandwich Blocks----------------------- 56

Light Weight Masonry Units ------------------------------------------ 57 Clay Masonry Blocks with Polystyrene Insert ----------------------- 58

i. Lath and Plaster ----------------------------------------------------------- 59

j. Polystyrene Thermal Insulation ------------------------------------------ 60

k. Painting -------------------------------------------------------------------- 61

Section 5: QC Forms ------------------------------------------------------------- 63

a. Non-Conformance Report ----------------------------------------------- 63

b. Status of Non-Conformance Reports ----------------------------------- 64

c. Field Memorandum ------------------------------------------------------- 65d. Material Inspection Report ----------------------------------------------- 66

e. Notification of Material Receipt ---------------------------------------- 67

f. Inspection and Test Plan------------------------------------------------- 68

g. Concrete Pour Record --------------------------------------------------- 69

h. Inspection Record for Structural Repairs ------------------------------- 70

i. Pile Record ----------------------------------------------------------------- 71

Section 6: QC Checklists -------------------------------------------------------- 73

Introduction -------------------------------------------------------------------- 73

a. Pre-Concrete Checklist --------------------------------------------------- 74

b. Pile Cap -------------------------------------------------------------------- 75

c. Footings -------------------------------------------------------------------- 76

d. Tie Beams ------------------------------------------------------------------ 77

e. Slab on Grade ------------------------------------------------------------ 78

f. Walls ----------------------------------------------------------------------- 79

g. Columns ------------------------------------------------------------------- 80

h. Slabs ----------------------------------------------------------------------- 81

i. Reinforced Concrete Water Tanks--------------------------------------- 82

j. Water Proofing ------------------------------------------------------------ 83

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k. Back Fill ------------------------------------------------------------------- 84

l. Block Work --------------------------------------------------------------- 85

m. Plastering ----------------------------------------------------------------- 86

n. Roof Water Proofing ----------------------------------------------------- 87

o. Swimming Pool ----------------------------------------------------------- 88

p. Ceramic Tiles ------------------------------------------------------------- 89

q. Marble/Granite ---------------------------------------------------------- 90

r. Aluminium ---------------------------------------------------------------- 91

s. Painting (Metal Surfaces)------------------------------------------------ 92

t. Painting (Concrete/Plaster Surfaces) ----------------------------------- 93

u. Painting (Timber Surfaces) ---------------------------------------------- 94

v. False Ceiling ------------------------------------------------------------- 95w. False Ceiling Closure ---------------------------------------------------- 96

TABLE OF CONTENTS


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CHAIRMAN QUALITY POLICY STATEMENT


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The need for and use of a Quality control function can not be

overemphasized. Quality cannot be tested nor inspected into a product,

it must be built in. This manual outlines the basic and minimumrequirements for building a simple but effective system for controlling

the quality of work and basic materials used in construction. This manual

is based on the belief that:

Quality is controlled by adequate advance planning, coordination,

supervision, and technical direction; proper definition and a

clear understanding of job requirements and procedures; and

the employment of appropriately skilled personnel.

Quality is verified through checking, reviewing and monitoring

of work activities, with documentation by experienced, qualified

individuals who are not directly responsible for performing the

work.

Quality is achieved by providing proper training of personnel

and ensuring that all personnel remain current on the knowledge

and skills needed for their positions.

Quality is achieved by focusing on preventing problems or errors

rather than reacting to them.

Quality control should ensure that the work is done correctly the

first time.

This manual requires the attention and cooperation of all consultants,

contractors and production personnel to assure quality production and

material. It shall be implemented by all concerned parties in the field of

construction. All involved parties shall comply with quality issues in other

regulatory agencies having jurisdiction over the project.

Section 1: INTRODUCTION


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2.01 QUALITY POLICY

A. The Port, Customs and Free Zone Corporation Quality Policystatement signed by the Chairman will be adopted for allProjects.

B. The Project shall prepare a Statement of Commitment to thePort, Customs and Free Zone Corporation Quality Policy thatshall be signed by the Project Manager/Contractor Managerand Sub-Contractor Manager.

2.02 SUBMITTALSA. Contractors Quality Control Plan (QCP).

1. Submit to Employer Representative no later than 7 calendardays from issue of the commencement date.

2. No work covered by the Contractors QCP shall beginuntil the plan has been approved.

3. Plan shall describe all of the Contractors quality controlprocedures that will be used throughout the project.

4. Include an Internal and External Audit Schedule

a. Minimum requirements shall be as specified herein.

B. Quality Control Organization Plan

1. Show organization of Contractors quality control team.

2. Provide the name, qualifications, and experience of theQuality Control Manager and key QC support staff forapproval by the Employers Representative.

a. Once approved, the Contractors Quality ControlManager shall have full authority to represent and act forthe Contractor on all quality related matters.

b. Notify the Employer Representative in writing priorto re-assigning any of the designated quality control

personnel.c. Obtain Employer Representatives approval for

replacement prior to re-assigning or re-locating approvedquality control personnel.

C. List of Proposed Suppliers and Sub-Contractors QC Staff

1. List shall include the following:

a. Items to be supplied by each supplier and sub-contractor

b. Model or catalogue numbersc. Specifications

d. Inspection and test requirements

Section 2 : QUALITY CONTROL (GENERAL)


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e. Performance data

f. Anticipated inspection and test dates

g. Name and location of quarries and procedures forwork in quarries

2. List other pertinent information as appropriate.

D. Submit inspection and test results, certificates of compliance, andcertified material test reports to the Employer Representative.

E. Inspection and Test Plan

1. Submit to Employer Representative no later than 7 calendardays from the commencement date.

2. No work covered by the inspection and test plan shallbegin until the plan has been approved.

F. Quality Control Procedures and Instructions

1. Submit to Employer Representative no later than 3 calendardays prior to using such procedures or instructions.

2. Do not begin work governed by Quality Control Proceduresuntil such procedures have been approved by the EmployerRepresentative.

G. Records Index

1. Prepare an index of all project records which will bedeveloped and maintained during progress of the Work.

2. Submit to Employer Representative no later than 7 calendardays from the commencement date.

H. Inspection and Test Results

1. All materials delivered to the site shall be sampled andtested; test results to be submitted at least 7 calendar daysprior to incorporating items into the Work.

2. Report results to the Employer Representative indicatingcompliance or failure immediately upon receipt.

2.03 GENERAL QUALITY CONTROL REQUIREMENTS

A. Develop, implement and maintain a quality control programconsistent with the requirements of this Section.

1. Ensure equipment and material conform to applicablerequirements of each section of the specifications.



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2. Maintain specified quality in all areas of the Work includingbut not limited to:

a. Design and construction of temporary structures

b. Inspection

c. Testing

d. Packaging, shipping, handling and storage ofequipment and materials

e. Site construction activities

B. Establish procedures to prevent deficiencies from occurring.

1. Identify discrepancies when they do occur and then takecorrective action.

2. Instruct workmen, sub-contractors, material suppliers,and other personnel involved in the project on the correctprocedures to follow.

C. Assign specific responsibility for implementing the qualitycontrol program.

D. Systematically verify compliance with the specified requirementsusing quality control audits for sub-contractors and suppliers.

1. Record results in formal reports.

2. Establish corrective action logs to track all actions.

E. Assist Employer Representative in auditing quality controlactivities.

1. Employer Representatives audits may be either pre-

planned or random as warranted by general qualitytrends.

F. Inspect and test all work under this Contract.

1. Maintain records of such inspections and tests.

2. Prepare and submit signed checklists for all work offeredfor the approval of the Employers Representative.

G. Arrange for factory inspections and tests when required by theContract Documents.



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H. Provide equipment, instruments, qualified personnel, andfacilities necessary to inspect the work and perform the testsrequired by the Contract Documents.

I. Repeat tests and inspections after correcting non-conformingwork until all work complies with the contract requirements.

1. All re-testing and re-inspections shall be performed at noadditional cost to the Employer.

J. The Employer Representative may elect to perform additionalinspections and tests at the place of the manufacture, the

shipping point, or at the destination, to verify compliance withapplicable Specifications.

1. Inspections and tests performed by the EmployerRepresentative shall not relieve the Contractor of hisresponsibility to meet the Specifications.

2. Inspections and tests by the Employer Representative shallnot be considered a guarantee that materials delivered ata later time will be acceptable.

K. Non-conforming materials, whether in place or not, will berejected by the Employer Representative.

1. Contractor shall be notified in writing to correct or removethe defective material from the Works.

2. If the Contractor fails to respond, the EmployerRepresentative may order correction, removal, and/orreplacement of defective materials by others.

a. Contractor shall bear all costs for such work.

L. Materials accepted on the basis of a Certificate of Compliancemay be sampled and inspected/tested by the EmployerRepresentative at any time.

1. The fact that the materials were accepted on the basis ofa certificate of compliance shall not relieve the Contractorof his responsibility to use materials which comply with theSpecifications.

M. Contractor shall impose all of the specified QCP requirements(including inspection and test procedures) upon Suppliers andSub-Contractors.



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N. Failure to Perform

1. In the event the Contractor fails to adequately performany or all of the provisions of this Section, the Employer, athis sole discretion, reserves the right to have the EmployerRepresentative perform any or all of the provisions of thisSection and back-charge the Contractor for the actualcost of such work and any administrative charges deemednecessary.

2. This remedy for Contractors failure to perform shall be inaddition to any other right or remedy available under theContract.

2.04 QUALITY CONTROL PLAN

A. Provides detailed description of procedures, instructions,and reports used to ensure compliance with the ContractDocuments.

B. No construction shall begin and no requests for payment shallbe processed until the Contractors Quality Control Plan isapproved.

C. Contractors QCP shall include the following as a minimum:

1. Statement of Commitment to Ports, Customs & Free ZoneCorporation Quality Policy signed by all parties in theproject.

2. Organization chart identifying all personnel responsiblefor quality control.

a. Identify the manager of the QC program showing thatthe position is independent of the job supervisory staff

with clear lines of authority.

b. The QC manager shall report directly to the Contractorscorporate management and he shall liaise andcoordinate directly with the Employer Representative.

c. Show area of responsibility and authority of eachindividual in the quality control system.

d. Describe in detail the area of responsibility and authorityof each individual in the quality control system.

e. The QC manager or designated substitute shallbe present at the project site at any time work is inprogress.



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3. Procedures for reviewing shop drawings, samples,certificates, and other submittals necessary for contractcompliance.

a. Include the name of all personnel authorized to signthe submittals for the Contractor certifying that theycomply with the Contract requirements.

4. Procedures used to ensure compliance with the ContractDocuments, as well as problem identification, reportingand resolution.

a. Include a copy of forms and reports used to documentquality control operations.

b. Include a submittal status log listing required submittals

and action required by the Contractor and EmployerRepresentative or Project Manger.

5. A description of the services provided by outsideorganizations such as testing laboratories, architects, andconsulting engineers.

6. A test and inspection schedule keyed to the constructionschedule and following the order of the Specification.

Indicate the following:

1. Inspections and tests required.

2. Names of responsible personnel for each segment ofthe Work.

3. Schedule for each inspection and test.

4. Acceptance criteria for any tests carried out.

7. Document and submittal control procedures.

8. Procedures to identify and control use of items andmaterials.

9. Sample forms to be used (Stop Work Order, NCR, etc.)10. A control chart for both production facilities and field

operation to provide a visual indication of whether aprocess is under control.

11. Internal and External Audit Program for the duration of theproject.

2.05 INSPECTION PROCEDURES

A. As a minimum, inspect work before beginning each worksegment and after completing a representative portion of thework.



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B. Perform follow up inspections as necessary to ensure compliancewith the contract documents.

C. Preparatory inspection shall include:

1. Review of the contract requirements

2. Review of approved shop drawings and submittal data.

3. Check availability of required control testing.

4. Ensure materials and equipment conform to approvedshop drawings and submittal data.

5. Ensure the necessary preparatory work has been completedand is of acceptable quality.

D. Perform an initial inspection as soon as a representativesegment of the particular item of Work has been completed.

1. This inspection shall include the following:

a. Conduct scheduled tests.

1. Results shall cite the Contract requirements, the testor analytical procedures used, and the actual testresults.

2. State whether item tested or analyzed conforms orfails to conform.

3. Test reports shall be signed by the laboratoryrepresentative authorized to sign certified testreports.

4. Immediately deliver all documents to the EmployerRepresentative.

b. Examine quality of workmanship.

c. Check for omissions or dimensional errors.

d. Approve or reject initial work.

E. Provide follow-up inspections as necessary.

1. Include continued testing and examinations to ensurecontinued compliance with the Contract requirements.

F. Prepare and attach to the Inspection procedures copies of

checklists to be used to cover all aspects of the works.



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2.06 INSPECTION AND TEST PLAN

A. Contractor shall develop an Inspection and Test Plan foreach Specification Section and for the design/production/testprocesses for each item of manufactured equipment.

1. Identify the following:

a. All required inspections and tests required by thatSpecification Section

b. Required testing frequency

c. The accept/reject criteria

d. Records required to document compliance

e. Procedures or instruction to be used for control of eachactivity

g. Establish procedures to ensure that test results aresubmitted on time

B. Provide sufficient detail to allow the Employer Representativeand other agencies having jurisdictional authority over thework to identify operations to be inspected by that organization(i.e. Ports, Customs & Free Zone Corporation - CED, DubaiMunicipality, etc).

1. Such operations shall not be bypassed by the Contractor,unless a written waiver is given by the witnessingorganization.

2.07 DOCUMENT AND SUBMITTAL CONTROL

A. Establish written procedures for processing all documents andsubmittals associated with this project.

1. Procedures shall address receipt, filing, safe guarding,processing and transmitting.

2. Establish procedures to ensure documents are preparedand transmitted or distributed in a timely manner.

3. Procedures shall also ensure documents contain therequired technical information.

B. Provide quality control procedures, methods, and currentdocuments at the locations where they are to be used.

C. Maintain separate files for quality related documents andmake such files available to the Employer Representative uponrequest.



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1. Retain all quality related records for not less than tenyears.

2. Protect all records from damage, deterioration, and loss.

D. Contractor shall not change or alter approved submittals,procedures, shop drawings or any other pertinent documentationwithout the Employer Representatives written authorization.

E. Establish document registers to verify the approval status ofITPs, Method Statements and Drawings.

2.08 IDENTIFICATION AND CONTROL OF ITEMS AND

MATERIALS

A. Contractor shall establish control procedures to ensure thatitems or materials accepted through shipping or receivinginspection are properly used and installed.

B. Contractor shall identify all items and materials so that theyare traceable throughout all inspections, test activities, andrecords.

1. For stored items, the identification method shall beconsistent with the expected duration and type of storage.

C. Contractor shall record equipment and material identificationsand ensure that they are traceable to the location where theyare incorporated into the work.

D. Contractor shall develop and maintain a receiving/inspectionlog containing at least the information itemized below:

1. Purchase order number

2. Item number

3. Suppliers name

4. Quantity

5. Item description

6. Reference to applicable Contract requirements

7. Date received

8. Heat number, serial number or other Identification, asapplicable

9. Verification of receipt of all required supportingdocumentation



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10. QC acceptance sign-off and date

11. Non-conformance number, if applicable.

2.09 INSPECTIONS AND TESTS

A. Contractor shall use an approved material testing laboratoryfor testing required by these specifications.

1. An on-site approved independent laboratory accreditedby Dubai Municipality Construction Quality Control &Research Section (DM CQC & RS) and staffed by qualifiedpersonnel shall be used.

a. Submit name and qualifications of independent testinglaboratories to Employer Representative for approvalnot less than 7 calendar days prior to the date thelaboratories are to be used.

b. Once approved, dismissal and replacement of theapproved independent testing laboratory shall requirewritten authorization by the Employer Representative.

B. All inspections, sampling and testing of materials shall beconducted in accordance with the specified standards.

1. Contractor shall have adequate QC personnel on siteduring all production shift operations.

2. Test procedures submitted for approval shall include thefollowing, as a minimum:

a. Prerequisites for the given test

b. Required tools, equipment, and instrumentation

c. Necessary environmental conditions

d. Acceptance criteria

e. Data to be recordedf. Test results reporting forms

g. Identification of items tested

C. Inspection work shall be performed by personnel designatedby the Contractor.

1. Such personnel shall not be the same as those performingthe work.

D. Approved procedures and instructions shall be on hand andused by inspection and test personnel at the time of inspectionor test.



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1. All revisions shall be approved prior to being used toinspect or test the work.

2. No deviations from approved work procedures and

instructions shall be allowed without written authorizationfrom the Employer Representative.

E. Provide the Employer Representative with not less than 24 hourswritten notice of the occurrence of an assigned hold point.

1. Any hold point inspected by outside agencies shall requirea minimum of 14 days prior written notification.

F. Submit inspection/test results to the Employer Representativeprior to incorporating the item(s) into the work.

1. Report inspection/test failures to the EmployerRepresentative immediately upon receipt.

2. Submit certificates of compliance 7 days prior toincorporating a product to the Works.

G. Inspections and tests conducted by persons or agencies otherthan the Contractor shall not in any way relieve the Contractorof his responsibility and obligation to meet all Specificationsand referenced standards.

H. Inspection and test records shall, as a minimum, identify thefollowing:

1. Name of items inspected/tested

2. Quantity of items

3. Inspection/test procedure reference

4. Date

5. Name of inspector/tester

6. Observations/comments

7. Specified requirements

8. Acceptability

9. Deviations/non-conformances

10. Corrective action

11. Evaluation of results

12. Signature of authorized evaluator

I. Inspection and Test Status

1. Contractor shall clearly document and identify theinspections and test status of materials and equipment

throughout construction.



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2. Identification may be by means of stamps, tags, or other

control devices attached to, or accompanying, the material

or equipment.

2.10 MEASURING AND TEST EQUIPMENT

A. Provide measuring and test equipment necessary to ensureconstruction conforms to the requirements of the specification.

B. Maintain the accuracy of all measuring and test equipment.

1. Provide a unique identification number or markpermanently affixed to each item of measuring and test

equipment.2. Calibrate each item of measuring and test equipment at

intervals recommended by the manufacturer and submitcalibration certificates.

3. Develop a log of all measuring and test equipment andrecord:

a. Equipment description

b. Identification number

c. Date of the last calibration

d. Due date of the next calibration

2.11 NON-CONFORMANCE MONITORING

A. Contractor shall develop a system to identify, document, controland process non-conforming material and equipment.

1. A non-conformance exists when either material andequipment, documentation, or construction do not complywith the requirements of the Contract Documents.

2. The monitoring system shall apply to material andequipment as well as documentation, installation andconstruction which fail to conform to the ContractDocuments.

B. Contractor shall provide the Employer Representative with thefollowing information for each non-conformance:

1. Identification of non-conformance

2. Description of non-conformance

3. Evaluation of non-conformance to establish the cause4. Recommended corrective action

5. Date non-conformance was identified



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6. Date corrective action was completed

7. Description of final corrective action

8. Consultants Approval

C. Contractor shall develop and maintain a non-conformanceaction tracking log to track all non-conformances.

1. Log shall contain the following information as a

minimum:

a. Sequential reference number

b. Date issued

c. Originator

d. Description of item deemed to be in non-conformance

f. Description of non-conformance

g. Recommended and final disposition

h. Date closed

i. QC Managers initials

j. Remarks, as applicable

D. Contractors QC personnel shall have the authority to stop thatportion of the work which does not comply with the Contractrequirements.

E. The dispositions for non-conforming items and materials shallbe subject to approval by the Employer Representative.

F. Contractor shall clearly identify each non-conforming item witha status tag or other distinguishing mark.

1. Establish procedures for installing, monitoring, and

removing these status tags.2. Identify personnel authorized to remove status tags.

G. Corrective Actions

1. Contractor shall take prompt action to identify the causesof each non-conformance and the corrective actionnecessary to prevent recurrence.

a. The results of failure and discrepancy report summaries,supplier evaluations, and any other pertinent applicable

data shall be used for determining corrective action.

b. Information developed during construction, tests, andinspections that support the implementation of required



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improvements and corrections shall be used to supportthe adequacy of corrective action taken.

2.12 PERSONNEL QUALIFICATIONS

A. Contractor shall identify activities requiring qualified production,inspection, and test personnel and establish their minimumcompetence level.

B. Personnel inspecting and testing special operations (e.g.,welding, brazing, etc.) shall have the experience, training, andcurrent certification commensurate with the scope, complexity,or nature of the activity.

1. Such personnel shall be approved by the EmployerRepresentative.

C. Contractor shall submit the following for all such production,inspection and test personnel:

1. Qualifications description

2. Orientation

3. Skill evaluation

4. Certification credentials

D. Contractor shall maintain records of personnel qualifications asquality records.

2.13 QUALITY CONTROL REPORTS/AUDITS

A. The Contractors Quality Control Manager shall provide adaily Quality Control Report to the Employer Representative.This report shall be comprehensive and it should include all

Q.C. activities on the project.

B. Contractor shall perform regularly scheduled internal audits toverify that his quality control procedures ensure total compliancewith the Specifications and referenced standards.

1. Schedule quality control audits not less than monthly anddocument findings in a report.

2. Maintain records of internal audits as quality records andmake them available to the Employer Representative uponrequest.

3. Provide the Employer Representative with access to theaudit records upon request.



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4. Allow the Employer Representative to observe theContractors internal audit upon request.

5. Provide the Employer Representative with a copy of theaudit report.

C. Contractor shall perform regularly scheduled external auditson his main Suppliers and Sub-Contractors to verify that theirquality control procedures ensure total compliance with thespecifications and referenced standards.

1. Schedule quality control audits not less than monthly.

2. Maintain records of internal audits of contractors andsubcontractors as quality records and make them available

to the Employer Representative upon request.3. Provide the Employer Representative with access to the

audit records upon request.

4. Allow the Employer Representative to observe theContractors internal audit upon request.

5. Provide the Employer Representative with a copy of theaudit report.

2.14 EQUIPMENT/MATERIAL HANDLING AND STORAGEA. Contractor shall be responsible for handling, storing and

preserving equipment and material from the time of receipt tothe time of acceptance by the Employer.

B. Contractors storage and handling procedures shall bedesigned to prevent damage, deterioration, distortion of shapeor dimension, loss, degradation, loss of identification, orsubstitution.

C. The handling procedures shall address the use, inspection

and maintenance of special devices such as crates, boxes,containers, dividers, slings, material handling and transportationequipment and other facilities.

D. Contractor shall identify equipment and material requiringspecial handling or testing.

2.15 QUALITY CONTROL RECORDS

A. Contractor shall develop a complete records index based onthe requirements for document and data submittals in each

Section of the Specifications.1. Indicate all quality control records, documentation,

submittals and data required by the Contract.



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2. Supplement these records as necessary to monitor qualitythroughout the project.

3. The records identified in the index shall provide objective

evidence that quality control program activities conform tothe contract requirements.

a. Include evidence that required verifications have beenperformed

b. Establish the basis for key project decisions.

B. Authenticate all records.

1. Only complete and properly authenticated documentsshall be maintained as records of material and equipment

quality.

C. Quality records shall be indexed, filed and maintained in amanner that provides for timely retrieval; traceability, easyidentification and the latest status (acceptability) of equipmentand material.

D. Protect Quality Control records from deterioration anddamage.

E. As a minimum, records shall include:1. Name of equipment/material inspected/ tested

2. Specification reference by section and paragraph (whereapplicable)

3. Quantity of items

4. Location and installation

5. Inspection/test procedure reference

6. Date

7. Signature of inspector

8. Observations/comments

2.16 WORKMANSHIP

A. Comply with industry standards except when more restrictivetolerances or specified requirements indicate more rigidstandards or more precise workmanship.

B. Perform work by persons qualified to produce workmanship ofthe specified quality.

C. Secure products in place with positive anchorage devicesdesigned and sized to withstand stresses, vibration, andracking.



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D. Comply with manufacturers published installation instructionsin full detail, including each step in sequence.

1. Should instructions conflict with Contract Documents,

request clarification from Employer Representative beforeproceeding.

2.17 PROTECTION OF PROPERTY

A. Do not load or permit a structure to be loaded in a manner thatwill endanger the structure.

B. Do not subject Work or adjacent property to stresses or pressures

that will endanger it.

C. Existing Surfaces and Facilities:

1. Take positive action to protect existing surfaces and facilitiesfrom damage resulting from construction operations unlessmodifications to the surfaces or facilities are required aspart of the Contract.

2. Protect paving, landscaping, and utility facilities fromdamage caused by mobile and stationary equipment,including vehicles delivering materials to the project site.

3. Protect finished surfaces, including jambs and soffits ofopenings used as passageways through which materialsare handled, against possible damage resulting form theconduct of the work by trades.

4. Provide and maintain adequate protection for adjacentstructures.

a. When required by law or for the safety of the Work;shore, brace, underpin, or otherwise protect thoseportions of adjacent structures that may be affected by

the Work.

D. Utilities

1. Known utilities and related facilities are shown on thedrawings.

a. Location of these facilities are not guaranteed, noris there any guarantee that other utilities are notpresent.

b. Unless otherwise specifically provided, protect utilitiesand related facilities from damage and cause nointerruption of service.

2. Establish and maintain direct contact with the Employer



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Representative or operator of each utility that may beaffected by the Work.

a. Proceed with Work that may affect a utility only withthe cooperation and approval of the EmployerRepresentative or operator of the utility.

b. Immediately inform the Employer Representative ofany agreement with the utility operator concerning the

Work under this Contract.

3. Verify the location of all utilities in the vicinity of the workbefore commencing construction.

a. Submit a plan for performing the work to the EmployerRepresentative for approval.

b. Include evidence of approval by the utility owner oroperator.

E. New Work

1. All finished surfaces shall be clean and un-marred uponacceptance of the area.

2. Do not permit traffic or material storage on finishedsurfaces.

a. Where some activity must take place on the finishedsurface in order to perform the Work, provide andmaintain adequate protection.

3. Provide and maintain adequate protection against theweather at all times so as to preserve Work, materials,equipment, apparatus, and fixtures free from damage.

4. Do not use items of equipment that are intended to forma part of the completed work as construction equipmentwithout specific approval from the Employer Representativein each instance.

2.18 QA/QC INDUCTION TRAINING

A. Prepare and carry out QA/QC Induction Training for all QCstaff, Engineers, Inspectors and Foremen on the project QCplan, procedures, Inspection and Test Plan, method statementsand checklists to be used during the construction of theproject.

B. Prepare and carry out QA/QC Induction Training for all Sub-Contractors staff as noted in A.



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Section 3 : RECOMMENDED PRACTICES BEFORE AND DURING CONCRETING

3.01 FORMWORK

All forms should be perfectly cleaned

Release agent applied correctly Correct position

Line and level

Accuracy within tolerances

Verticality (plumb)

Correct angles for batters

Finishing heights (mark off)

Joints flush and tight

Joints sealed as required

No nails protruding into the concrete

3.02 CONCRETE CONSOLIDATION

Make sure you can see the concrete surface

When inserting the poker, its head should be put in quickly andallowed to penetrate to the bottom of the layer as quickly as

possible under its own weight. If done slowly, the top layer willbe compacted first, making it more difficult for the entrappedair in the lower part of the layer to escape to the surface.

The head should be inserted vertically. This minimizes the voidscreated by inserting the head, and allows air bubbles to rise upunimpeded by a sloping vibrator.

The poker should be left in the concrete for about 10 seconds,and withdrawn slowly.

The poker should not touch the form face.

The poker should extend 100mm into any previous layer.

The maximum depth of the new layer equals the vibrator headlength minus 100mm. If the depth of concrete is greater, thenthe new part will not be fully compacted.

It should be noted that where finish is important, extra vibrationcan reduce the number of blowholes.

3.03 CONCRETING Someone experienced in the construction of formwork should

always be present at site when the concrete is being placed.


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Grout loss is an indication that joints were not tight or somemovements have occurred during placing.

In walls and columns no layer should be more than about450mm thick. With layers thicker than 450mm, the weight ofconcrete on top makes it impossible even with vibration to getthe air out from the bottom of the layer.

Make sure that each layer of concrete has been fully compactedbefore placing the next one.

Fully compacted concrete will be dense, strong, durable andimpermeable. Badly compacted concrete will be weak, nondurable, honeycombed and porous. The air must be removed.

For maximum compaction, preferance should be given to the

use of self compacting concrete.

3.04 HOT WEATHER CONCRETING

The American Concrete Institute Hot Weather Concreting, ACI305R-99, defines hot weather as any combination of high ambienttemperature, high concrete temperature, low relative humidity,high wind speed, and excessive solar radiation that can impair thequality of fresh or hardened concrete. These factors individually orcombined, can accelerate moisture loss and cement hydration.

Concrete mixed and placed during hot weather is subject toconditions that can adversely affect the properties and serviceabilityof the hardened concrete. Some of these conditions are:

Increased water demand

Increased rate of slump loss

Increased rate of setting

Increased tendency of plastic shrinkage cracking anddrying shrinkage cracking

Low ultimate strength

Decreased durability Increased permeability

Increased potential for reinforcing steel corrosion

Successful hot weather concreting requires careful planning andclose coordination among all members of the construction team.Best results will be achieved if the following important proceduresare recognized.

A. Production at Batching Plants

1. Shading the aggregates.

2. Cooling the mixing water before use.3. Approved water cementitous material ratio should be

respected.



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4. Set retarding admixtures can be added to slow setting ofconcrete and reduce water demand.

5. Cement extenders, such as Fly Ash and GGBS.

B. Transport

1. Steady flow of concrete

2. Drum rotation should be at the lowest agitating speed

3. Major placement of concrete should be scheduled duringevening or night times and periods of lower traffic.

4. The dispatching of trucks should be coordinated with therate of placement to avoid delays in arrival or long waiting

periods.5. Traffic arrangement at site should ensure easy access of

delivery units to the unloading points.

6. Site traffic should be coordinated for a quick turnaroundof concrete truck.

C. Placement of Concrete

1. Have adequate manpower and equipment (plus stand-byunits) available to handle the concrete at the desired rate

of placement and to unload the concrete trucks promptly.2. Water should be available in sufficient quantities. The

temperature of water used for curing must be as close aspossible to that of the concrete to avoid thermal shock (notmore than 11 C than that of concrete).

3. Erect temporarily windbreaks and shades to protect freshconcrete from hot sun and drying winds.

4. Arrangement should be made for the ready availability ofbackup equipment for placing, vibrating and material for

curing.5. Dampen the sub grade, forms and reinforcing steel the

night before, do this again thoroughly before placingconcrete.

6. Cover concrete as soon as it is placed, until final finishingcan be started.

7. Water curing should start immediately after finishing andit should be continuous as per specified period of curing.

8. Temperature of concrete should be as per specified limit.

9. For mass concrete a method statement should be givenaddressing the logistical and technical issues.



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D. Testing

1. An approved trained technician should perform all tests.

2. Leaving the samples of fresh concrete exposed to sun,wind or dry air is not acceptable.

3. Samples of fresh concrete shall be provided withan impervious cover, cured and stored in a shadedenvironment (temperature of shaded environment shouldbe as per relevant standards). Record temperature usingmaximum minimum thermometer.)

4. Prevent moisture loss of samples during transportationby wrapping them in plastic wet burlap. Be sure to avoidexcessive rough handling during transportation to the

laboratory.



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Section 4 : SCHEDULE OF TESTS AND INSPECTIONS

CAST IN-SITU CONCRETE

Ready-Mixed Concrete

LABORATORY & PLANT TRIAL MIXES

Schedule of Tests and Inspections

DESIGNATION NORMATIVE DOCUMENT FREQUENCY NOTES

A. Composition/Selection Each Grade Before Production Starts

Concrete Temperature ASTM C 1064 Each grade

Slump

BS 1881-102,

EN 12350-2 Initially and every 15 minutes

Flow Table(1) EN 12350-5 Initially and every 15 minutes

Slump Flow(2) ASTM C 1611 Each grade

T-50 cm Slump Flow(2) ASTM C 1611 Each grade

V-Funnel(2)European Guidelines

for SCCEach grade

V-Funnel at T5minutes(2)

European Guidelinesfor SCC

Each grade

L-Box (h2/h

1)(2)

European Guidelinesfor SCC

Each grade

J-Ring(2) ASTM C 1621 Each grade

Fresh Concrete Density& Yield

BS 1881-107, EN12350-6, ASTM C 138

Each grade

Air ContentBS 1881-106,

EN 12350-7Each grade

Bleeding ASTM C 232 Each grade

Setting Time ofConcrete

ASTM C 403 Each grade

Compressive StrengthBS 1881-116,EN 12390-3

At 7 and 28 days for eachgrade

Tensile/FlexuralStrength

EN 12390-5&6At 7 and 28 days for grades

where flexural govern

Drying Shrinkage ASTM C 596 Each grade of structuralconcrete


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Sulfate and Chloride

ContentBS 1881-124 Each grade (3)

Rapid ChloridePenetration

ASTM C 1202At 28 days for each grade of

structural concrete

Water Absorption BS 1881-122At 28 days for each grade of

structural concrete

Water Permeability EN 12390-8At 28 days for each grade of

structural concrete

Initial SurfaceAbsorption Test

BS 1881-208At 28 days for each grade of

structural concrete

(1) Where flowable concrete is used

(2) Where Self Compacting Concrete is used

(3) Whenever the source of any ingredient changes

Notes:

1. Designed concrete shall conform to the requirements specifiedin EN 206 and BS 8500

2. Additional testing will be conducted at the request of theEngineer and/or Authority

3. Contract Specifications are to be implemented if more or othertests are required

4. Follow the recommendations of the following codes/standards:

ACI 311.5: Guide for concrete plant inspection and testing ofready-mixed concrete

ACI 304R: Guide for measuring, mixing, transporting and

placing concreteASTM C94/C94M: Standard Specification for Ready MixedConcrete

The European Guidelines for Self Compacting Concrete

SECTION 4 : SCHEDULE OF TESTS AND INSPECTIONS


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Ready-Mixed Concrete

CONCRETE PRODUCTION & SITE DELIVERIES



A. Composition/Selection Structural Concrete

Concrete Temperature ASTM C 1064 Each load

SlumpBS 1881-102,EN 12350-2

Each load

Flow Table(1) EN 12350-5 Each load

Slump Flow (2) ASTM C 1611 Each Delivery650 - 750 mm

and visually

J-Ring (2) ASTM C 1621As per projectspecifications

0 - 10 mm

Fresh Concrete Density& Yield

BS 1881-107,EN 12350-6,ASTM C 138

With each set of compressivestrength cubes

Air Content (3)BS 1881-106,

EN 12350-7

Each load

Compressive StrengthBS 1881-116,EN 12390-3

1. Critical Structures (columns, cantilevers...): One set every 10m3or

fraction thereof

A setconsistsof atleast 6cubes

2. Intermediate Structures: One set every 50m3or

fraction thereof

3. Mass Concrete (rafts): One set every 100m3for

pours less than 2000m3

One set every 150m3forpours less than 2000m3

Tensile/FlexuralStrength

EN 12390-5&6At 7 and 28 days for grades where

flexural govern

Evaluation of StrengthTest Results of Concrete

ACI 214,ACI 363.2R

Biweekly for each grade of structuralconcrete:1. The overall variation class of

operation for general constructiontesting shall be at least Good.

2. The within-test variation class ofoperation for field control testingshall be at least Very Good.



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Visual Examination of

Aggregates (by washing)

Project Specifications At the request of the Engineer

Sulfate and ChlorideContent

BS 1881-124 As per project specifications

Rapid ChloridePenetration

ASTM C 1202 As per project specifications

Water Absorption BS 1881-122 As per project specifications

Water Permeability EN 12390-8 As per project specifications

Initial SurfaceAbsorption Test

BS 1881-208 As per project specifications

(1) Where flowable concrete is used

(2)Where Self Compacting Concrete is used

(3) Where air-entrained concrete is used

Notes:

1. A strength test is the average strength of concrete specimens sampled

from the same batch or load.2. A load is the quantity of concrete transported in a vehicle comprising

one or more batches.

3. A batch is the quantity of fresh concrete produced in one cycle ofoperations of a mixer or the quantity discharged during one minutefrom a continuous mixer.

4. Follow the recommendations of ACI 305R during hot weather.

5. Follow the recommendations of the following codes/standards:

ACI 311.5: Guide for concrete plant inspection and testing of ready-

mixed concrete

ACI 304R: Guide for measuring, mixing, transporting and placingconcrete

ASTM C94/C94M: Standard Specification for Ready Mixed Concrete

6. Each load shall be accompanied by a computer controlled nonsimulated printout listing all the information related to the mix.

7. Each truck mixer/agitator, when it arrives at site, shall have its watercontainer full. If that container is not full or field test results are outsidethe specified limits, the load shall be rejected.

8. Additional testing will be conducted at the request of the Engineer and/or Authority



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9. Contract Specifications are to be implemented if more or other tests arerequired.



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SITE LABORATORIES

Requirements for Concrete Testing Laboratories

A. Human Resources:

a. The testing lab services shall be provided under the technicaldirection of a professional engineer with relevant experiencein construction material testing, or a supervising lab technicianwith relevant experience in construction material testing andcurrent technician certification.

b. The testing field and/or lab technician shall possess currenttechnician certification or have undergone a training programcovering all the relevant tests performed by the technician.

B. Test Methods and Procedures:

a. The site testing laboratory shall be capable of performing therequired tests as per standard methords, guides or practices.

b. The laboratory shall use the latest version of each referencedmethod within one year of its publication unless an earlier

version of the standard is required by the client.

c. Laboratory personnel shall have convenient access to applicablestandards.

C. Facilities, Equipment and Supplemental Procedures:

a. The laboratory shall have facilities and equipment conformingto the requirements of the applicable test methods.

b. All equipment and instruments shall be verified and calibrated

before being placed in service and at the frequency set by thepertinent standards and local regulations.

c. All balances and scales shall be calibrated annually or wheneveraccuracy is in doubt.

D. Preparations and Conditions:

a. Proper sampling of fresh concrete shall be conductedin accordance with the pertinent standards and project

specifications.b. The required field tests shall be performed at the frequencies

stated in the project specifications.



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c. The floor, where tests are preformed and compressive strengthspecimens are stored, shall be levelled and free of anyvibrations.

d. Concrete test specimens shall be protected from evaporationand damage.

e. Proper tagging of the specimens shall be done specifying thedate, time, location, grade of concrete and name of technicianmoulding the specimens.

f. Initial curing temperatures for the concrete specimens shall bemaintained between the limits set in the pertinent standards.

g. De-moulding of the concrete specimens shall be done withinthe time limitations stated in the relevant standards.

h. Curing tanks shall be of sufficient size and controlledtemperature. Temperature shall be verified with recordingthermometers.

E. Laboratory Records and Reports:

The laboratory shall maintain a system of records that permitsverification of any issued report. The records shall include:

a. Standard operating procedures

b. Calibration certificates of the equipment and instrumentsused

c. Records on laboratory personnel that document workexperience, competency and certification

d. Current standard test methods

All testing reports shall include the information requiredand stated by the pertinent standards and test methods.

All testing reports shall state the acceptance criteria of the testbeing carried out as well as a statement on whether the test

results passed or failed.



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CAST IN-SITU CONCRETEReady-Mixed Concrete

AGGREGATESSchedule of Tests and Inspections

DESIGNATION NORMATIVE DOCUMENT FREQUENCY/ NOTES

A Composition/Selection Coarse Aggregate Fine Aggregate

Grading EN 933-1, BS 812-103

Daily Daily Material finer than0.075mm sieve

EN 933-1, BS 812-103

Water Absorption andSpecific Gravity

ASTM C 127, C 128,EN 1097-6

Twice a month

Elongation and FlakinessEN 933-3&4,BS 812-105

Monthly

Moisture Content in Sandby Moisture Tester (Speedy)

To be carriedout by

batching plant

Cleaning ofmoisture tester

regularly

Moisture Content ofwashed aggregates and ofaggregates in rainy seasons

ASTM C 566 At least three times a day

Clay Lumps and FriableParticles

ASTM C 14 Monthly

Light Weight Particles ASTM C 123 Every 3 months

Organic Impurities ASTM C 40 Monthly

Sand Equivalent ASTM D 2419 Monthly

Water Soluble Chlorides(Quantitative)

BS 812-117 Every three months

Acid Soluble Sulfates BS 812-118 Every three months

Soundness (MgSO4) - 5

cyclesASTM C 88 Every two months

Potential Reactivity ofAggregates

ASTM C 289, C 227 Every six months

Aggregate DryingShrinkage

EN 1367-4 Every six months

10% Fines Value (TFV)BS 812-111, EN

1097-2Every two months

Los Angeles Abrasion Test ASTM C 131 Every two months



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Notes:

1. All the tests shall be done before the start of the work and whenever

the source is changed.

2. Additional testing will be conducted at the request of the Engineerand/or Authority.

3. Contract Specifications are to be implemented if more or other testsare required.



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WATERSchedule of Tests and Inspections


A Composition/Selection

Chlorides (Cl) ASTM D 512

Initially, everythree

months, andwhenever

source changes

It shall complywith the

requirements ofASTM C1602 /

EN 1008

Sulfates (SO4) ASTM D 516

Alkali Carbonates andBicarbonates ASTM D 513

Total Dissolved Ions ASTM D 1888

pH value ASTM D 1293

Notes:





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CEMENTITIOUS MATERIALS & ADMIXTURESSchedule of Tests and Inspections


Cement EN 197, ASTM C 150 Initially and every three months

GGBS BS 6699, ASTM C 989 Initially and every one month

Pozzolanic Fly ash BS EN 450S Initially and every three months

Silica Fume ASTM C 1240 Initially and every three months

Liquid Admixtures ASTM C 494, C 260, C 1017 Initially and every three months

Notes:

1. All the cementitious materials shall conform to the physical andchemical requirements of the pertinent standard specifications. Therequired tests shall be made to verify compliance.

2. For cementitious materials, regular sampling shall be made fromeach delivery for random testing. All samples are to be stored until

28 or 56 day results are obtained and satisfactory.3. Additional testing will be conducted at the request of the Engineer

and/or Authority.




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BORED IN-SITU PILES AND DRILLED SHAFTS


DESIGNATION NORMATIVE DOCUMENT FREQUENCY / NOTES


Reinforcing Steel BS EN 10080Refer to frequency of testing of Steel in

this Manual

Concrete Concrete SpecificationsRefer to frequency of testing of Cast-

in-place Concrete in this Manual

Pile Load Test ASTM D 1143

Minimum 1% for each type (Dimensionof Piles Diameter and Length) or as

per project specifications ifmore tests are required

Pile Load Test ASTM D 4945Minimum 5% of Piles or as per

project specifications if more tests arerequired

Pile Integrity Test ASTM D 5882 All Piles

Cross Hole LoggingAnalyzer

ASTM D 6760Minimum 10% of Piles or as per

project specifications if more tests arerequired

Calliper Logging ASTM D 6167Minimum 10% of Piles or as per

project specifications if more tests arerequired (To be selected randomly)

Ultimate Load Test ASTM D 1143A minimum of one non-working pile

to be tested according to projectspecifications

Notes:

1. Additional testing will be conducted at the request of the Engineer

and/or Authority.2. Contract Specifications are to be implemented if more or other tests

are required.

3. For Diaphragm Wall the following instruments are to be fixed formonitoring purpose:

Inclinometer, Steel Strain gauges, concrete stress gauges, andpressure cells.



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REINFORCING STEEL


DESIGNATION NORMATIVEDOCUMENT

FREQUENCY NOTES


Grade 460 B & Other Grades BS EN 10080

Mechanical Properties

Yield Strength

Ultimate Strength

Elongation of Fracture

Mass / meter

Nominal Cross-sectionalArea

Bending

Re-bending

Chemical Properties

One (1) set of tests

for Mechanicaland ChemicalProperties for eachbar diameter at thestart of the job andevery 100 tons ofsteel delivered tothe site.(Refer to Notes)

1. Every consignmentof Steel shall haveMill Certificates tobe attached to theMaterial InspectionRequest for theEngineers review.Steel tags havingheat number are tobe provided with thesteel.

2. Tests are to berepeated wheneverthere is a change inthe source of supply.

Notes:

1. All steel reinforcement specified shall comply with BS 4449 or BS4483, and shall be cut and bent in compliance with BS 8666.


3. Contract Specifications are to be implemented if more or other tests

are required.4. Reinforcing steel, supplied by Cares or equivalent accredited

certification body approved mills, shall be tested at the start of theproject and every 200 tons delivered to site.

5. Reinforcing steel, supplied and processed by Cares or equivalentaccredited certification body approved steel mills and cutting &bending companies, shall be tested at the start of the work andevery 400 tons delivered to site.



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EPOXY-COATED STEEL



Coating Thickness

BS 7295 /ASTM A775

As per standard/project

specifications

Every consignment ofSteel shall have Mill& Test Certificates tobe attached to theMaterial Inspection

Request for theEngineers review.

Steel tags having heatnumber are to be

provided with the steel

Coating Continuity

Coating Flexibility

Coating Adhesion

Notes:





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EARTHWORK



Particle Size Analysisand Determination ofSoil Constants(Dry and Wet)

BS 1377 part 2

All tests shall becarried out at a

minimum rate of 3tests for every 300m3

of material

ProjectSpecifications

Atterberg Limits (LL,PL & PI)

BS 1377 part 2

Sand Equivalent ASTM D 2419

Chlorides andSulfates in Soil BS 1377 part 3

In-Situ Density of Soil

a. Trenches

BS 1377

a) Make at selected locations at leastone field density test for every 200m2area/layer, but in no case less thanthree(3) tests per day operation.

b. Walkways

b) Make at selected locations at least

one field density test of subgrade orfinish grade for every 200m2area,but in no case less than three (3) testsper day operation.

c. Pavement Layer(Subgrade, Subbaseand Base)

c) Make at selected locations at leastone field density test for every 200m2area/layer, but in no case less thanthree (3) tests per day operation

Moisture - DensityRelations of Soil using4.5 kg Rammer, 457mm Drop Method D

BS 1377 part 4 All required testsshall be carried outfor every 400 m3of

material


California Bearing

Ratio Test

BS 1377

Notes:





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PRECAST CONCRETE



1 Material TestingRefer to the requirements of the Cast-

in-place Concrete and Reinforcing Steelsections of this Manual


2 Testing finished Material

CompressiveStrength

BS 1881,BS EN 12390-3

As directed by theEngineer (Cores fromprecast units) Project

SpecificationsDurabilityRequirements

As directed by theEngineer (Cores fromprecast units)

3 Joint Sealant and Fillers

Cement Grout(Portland Cement)

BS EN 197As directed by theEngineer


Natural Sand BS EN 13139

Non-shrink GroutAs directed by theEngineer

Elastomeric SealantsASTM C 962,

ACI 504

4Inserts and OtherHardware

ASTM A 307, A 325,A490, A 108, A 496


Corrosion Protection ASTM A 276Project

SpecificationsExpansion Anchors ASTM E 448

Notes:



3. Follow the recommendations of the manuals published by pci,Precast/Prestressed Concrete Institute.



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GLASS REINFORCED CEMENT (GRC) ELEMENTS



1 Composition of GRC Elements

Glass ContentProject

Specifications

At the start of the

job, once a month

or as requested by

the EngineerWet Bulk Density

2 Testing finished Material

Modulus of RuptureProject

Specifications

At the start of thejob, once a month

or as requested by

the Engineer

ProjectSpecificationsLimit of Proportionality

JJ the EngineerLloyd T 5000/SS

Notes:



are required.

3. Works and Material shall comply with the following requirements:

a. PCI MNL 117 - Manual for Quality Control for Plants andProduction of Architectural Pre-cast Construction Products

b. PCI MNL 128 - Recommended Practice for Glass Fibre ReinforcedConcrete Panels

c. PCI MNL 130 - Manual for Quality Control



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CONCRETE BLOCKS


DESIGNATION NORMATIVEDOCUMENT

FREQUENCY NOTES

1 Masonry Blocks

Dimensions and CompressiveStrength

DubaiMunicipality

StandardEvery 20,000 blocksDensity

Chloride and Sulfate Content

2 Paving Blocks


DubaiMunicipality

StandardEvery 20,000 blocksDensity


3 Filler Blocks (Normal Weight)

Dimensions and CompressiveStrengthDubai

MunicipalityStandard

Every 20,000 blocksDensity


4 Filler Blocks (Light Weight)


Dubai

MunicipalityStandard Every 20,000 blocksDensity


Notes:



are required.3. Works and Material shall conform to Dubai Municipality and

International Standards.



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AUTOCLAVED AERATED CONCRETE BLOCKS


DESIGNATIONNORMATIVE

DOCUMENTFREQUENCY NOTES


AAC Blocks


Dubai Municipality

Standard

Every 20,000

blocks

Thermal Conductivity and DryDensity


Drying Shrinkage

Fire Rating ASTM E 119Project

Specifications

MortarProject

Specifications

As recommendedby the

manufacturer

Portland Cement:

Works below Ground Slab (SRC) BS 4248

Project SpecificationsWorks above Ground Slab (OPC) BS EN 197-1

Sand BS EN 13139 Project Specifications

AccessoriesAs directed bythe Engineer

Project Specifications

Notes:



3. Works and Material shall conform to Dubai Municipality andInternational Standards.



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NORMAL WEIGHT CONCRETE POLYSTYRENE SANDWICH BLOCKS





Dubai MunicipalityStandard

Every 20,000blocks

Thermal Conductivity


Apparent Density

Polystyrene Dimensions andDensity

Polystyrene Core ThermalConductivity

Fire Rating (Polystyrene)ASTM D 2863,BS EN 11925-2

As directedby the

Engineer


Mortar Project SpecificationsAs recommended

by the

manufacturer

Portland Cement:




AccessoriesAs directed by

the EngineerProject Specifications

Notes:






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LIGHT WEIGHT MASONRY UNITS






Every 20,000blocks


Gross Density


Drying Shrinkage

Fire Rating ASTM E 119As directed

by theEngineer



by themanufacturer

Portland Cement:




AccessoriesAs directed by

the EngineerProject Specifications

Notes:






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CLAY MASONRY BLOCKS WITH POLYSTYRENE INSERT






Every 20,000blocks

Thermal Conductivity of Block

Thermal Conductivity ofThermal Insulation

Density of Thermal Insulation

Water Absorption

Apparent Density

Block Efflorescence

Fire Rating (Polystyrene)ASTM D 2863,BS EN 11925-2

As directedby the

Engineer



by themanufacturer

Portland Cement:




Accessories As directed bythe Engineer Project Specifications

Notes:






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LATH AND PLASTER



Cement Plaster

Portland CementBS 12, 146, 215,

4027 and BS 5224

As directedby the

Engineer


Lime BS 890

Sand BS 1199

Aggregates BS 882

Water BS 3148

Ready Mix RenderingMaterial

BS 4721

Bagged RenderingMaterial

BS 5262

Plaster Accessories BS 5262

Pull-Off Test BS 1881-207

Notes:



3. Works and Material shall conform to the following codes:

Code of practice for External Rendered Finishes BS 5262Code of practice for Internal Plastering BS 5492

Code of practice for Plastering and Rendering BS 8000 Part 10



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POLYSTYRENE THERMAL INSULATION



Compressive Strength andDimensions

Project SpecificationsAs directed

by the

Engineer


Density

Water Absorption

Flexural Strength

Water Vapour Permeance

Dimensional Stability

Oxygen Index

Notes:

1. Additional testing will be conducted at the request of the Engineer

and/or Authority.





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PAINTING


DESIGNATION NORMATIVE DOCUMENT FREQUENCY / NOTES

Specific Gravity ASTM D 1650

Project Specification / asrequired by the Engineer

Solid Content ASTM D 2139

Drying Time ASTM D 1650

Adhesion Strength ASTM D 4541

Abrasive Strength ASTM D 4060

Impact ASTM D 2794

Hardness ASTM D 2240

Crack Bridgeability ASTM D 836

Non Volatile Matter ASTM D 2939

Fungus Resistance ASTM D 2734

UV Resistance ASTM 653

Salt Spray Resistance ASTM B117



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SECTION 5 : QC FORMS

NON-CONFORMANCE REPORT

Project : ___________________________________________________________________________

Client : _________________________________________ NCR No. : _____________________

Project Manager : _________________________________________ Date : _____________________

Consultant : _________________________________________

Contractor : _________________________________________ Location : _____________________

Sub-Contractor : _________________________________________ Category : _____________________

Non-Conformance:

____________________________________________________________________________________________

____________________________________________________________________________________________

____________________________________________________________________________________________

____________________________________________________________________________________________

Issued by: _________________ Signature: ___________________

Requirements

Specifications : ___________________________________________________________________________

Standards : ___________________________________________________________________________

Drawings : ___________________________________________________________________________

Other : ___________________________________________________________________________

Received by Contractor/Sub-Contractor:Name: ________________ Position: ________________ Signature: _____________ Date: ______________

Cause of Non-Conformance:

____________________________________________________________________________________________

Name: ________________ Position: ________________ Signature: _____________ Date: ______________

Proposed Corrective Action by Contractor/Subcontractor:

____________________________________________________________________________________________

____________________________________________________________________________________________

____________________________________________________________________________________________


Comments by Project Manager/Consultant:

Accept: Accept with comments: Reject:

____________________________________________________________________________________________

____________________________________________________________________________________________

____________________________________________________________________________________________


Corrective Action Completed/Verified:

QA/QC Manager Name: ________________ Signature: _____________ Date: ______________


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STATUSOFNON-

CON

FORMANCEREPORTS

Proje

ct

:______________________________________________________

_________________________________

____________________________________

Clien

t

:______________________________________________________

_

NCRReportNo.:________________________________

Proje

ctManager:______________________________________________________

_

Date

:_

____________________________________

Cons

ultant

:______________________________________________________

_

Cont

ractor

:______________________________________________________

_

Location

:_

____________________________________

Sub-Contractor:______________________________________________________

_

Category

:_

____________________________________

NC

RRef.

No.

Date

Issued

Description

Contractor

Consultant/ProjectManag

er

Date

Received

Date

Returned

Accepted/

Date

Rejected

/

Date

SECTION 5 : QC FORMS

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