Qulaity Control of Bridges and Grade Separators.ppt

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1. Construction, Maintenance and Quality
Control of Bridges and Grade Separators
“Quality Control of Bridges and Grade Separators”
Er.M.Anandaraj,M.E.,
Assistant Divisional Engineer,(H)
Quality Control Subdivision,
Chennai

2. •Concrete is a versatile construction
material.
•It is plastic and malleable when newly
mixed, yet strong and durable when
hardened.
•These qualities explain why concrete
can be used to build skyscrapers,
bridges, sidewalks, highways, houses
and dams.

3. Why Concrete?
•Safety
•Cost
•Strength
•Durability
•Availability

4. CONCRETE – Constituents
Cement
14 - 21 %
Fine
Aggregate
20 – 30 %
Coarse
Aggregate
40 – 50 %
Water
7 - 15 %

5. QUALITY
MATERIALS
CONCRETE STRUCTURES
QUALITY
PRACTICES+

6. MATERIALS
CEMENT
AGGREGATES
WATER
ADMIXTURES
PRACTICES
BATCHING
MIXING
TRANSPORTING
PLACING
COMPACTING
PROTECTING
CURING

7. CONCRETE – Code of Practice
Bureau of Indian Standards
published the code of
practice for concrete (IS : 456)
in 1953
- Fourth Revision in 2000
- Fifth Amendment in 2019

8. CONCRETE – Specifications
Standard Specifications for Roads and Bridges
Published by
Ministry of Road Transport and Highways (MORTH)
- First publication in 1973
- Fifth Revision 2013

9. CONCRETE – Guidelines
Guidelines
Published by
Indian Roads Congress

10. CEMENT
•Factory made material
• Checking Grade, Type and
Brand
• Checking manufacturing
week & Year
• Checking storage place –
IS 4082

11. STANDARD SPECIFICATION FOR
ORDINARY PORTLAND CEMENT
PHYSICAL REQUIREMENTS
1. Fineness
2. Consistency
3. Setting Time
4. Soundness
5. Compressive Strength

12. Fineness of Cement IS 4031 I
• Finer cement offers greater surface area for
hydration and faster strength development.
• Fineness is a measure of particle size of Cement
• Particle size between 3 to 32 microns are optimum
for cement performance
• Fine Cement reacts quickly with water
• Faster setting & High early strength depends on
fineness

13. Fineness of Cement IS 4031
Test in two ways
 By Sieving (90 mic) % retained shall not more than
than 10% for Ordinary Cement.
Air Permeability method (represented as Specific
surface area -m
2
/kg)

14. Fineness of Cement : IS 4031 - Part 2
Determination of Specific Surface of Cement
Blaine Air Permeability apparatus
Specific Surface of Cement
shall not be less than
225 m
2
/kg

15. Consistency of Cement : IS 4031 – Part 4
Aim :Determination of Quantity of Water
required to produce standard cement
paste
Apparatus : Vicat apparatus with Plunger
(Plunger-10mm dia and 50mm length)
Percentage of water corresponds to a
consistency which will permit the
plunger to penetrate to 5 mm – 7
mm from the bottom of mould

16. VICAT APPARATUS

17. Initial Setting Time : IS 4031 – Part 5
Aim :Determination of Initial Setting Time
Apparatus : Vicat apparatus with Needle
The time elapsed between the moment that the
water is added to the cement, to the time that the
paste starts losing its plasticity.
• Initial Setting Time shall not less than 30 minutes

18. Final Setting Time : IS 4031 – Part 5
Aim :Determination of Final Setting Time
Apparatus : Vicat apparatus and needle with
Annular Attachment
Final Setting Time shall not more than 600 minutes
( 10 hours )

19. FOR FINAL SETTING TIME

20. Soundness of Cement : IS 4031 - Part 3
Aim :Determination of Soundness
Apparatus : Le Chatelier apparatus
(30mm dia & 30mm High)
•It Is very important that the cement after
setting shall not undergo any appreciable
change of volume.
•The unsoundness in cement is due to the
presence of excess of lime combined with
acidic oxide at the kiln.
•Expansion not more than 10 mm

21. Compressive Strength : IS 4031 – Part 6
Aim :Determination of Compressive Strength
Apparatus : Compression testing machine
• This is most important properties of hardened cement.
• Due to excessive shrinkage and the cracking the strength
test are not made on heat cement paste.
• Standard sand is used for finding the strength of the
cement.

22. Compressive Strength : IS 4031 – Part 6
Aim :Determination of Compressive Strength
Apparatus : Compression testing machine
DAYS
COMPRESSIVE STRENGTH
(N/mm
2
)
3 23 27
7 33 37
28 43 53
43 GRADE 53 GRADE

23. AGGREGATES
COARSE AGGREGATES : AGGREGATES RETAINED ON
4.75 MM SIEVE
FINE AGGREGATES : AGGREGATES PASSING THROUGH
4.75 MM SIEVE

24. AGGREGATE
Properties
• Specific Gravity
• Water absorption
• Bulk Density
• Gradation

25. COARSE AGGREGATE
• Particle size distribution
• Crushing value
• Impact value
• Abrasion value
• Soundness
• Flakiness index
• Elongation index

26. FINE AGGREGATE
GRADING REQIREMENT - IS : 383 TABLE 4
SIEVE SIZEZONE - IZONE - IIZONE - IIIZONE - IV
10 mm 100 100 100 100
4.75 mm 90 – 100 90 – 100 90 – 100 95 – 100
2.36 mm 60 – 95 75 – 100 85 – 100 95 – 100
1.18 mm 30 – 70 55 – 90 75 – 100 90 – 100
600 micron 15 – 34 35 – 59 60 – 79 80 – 100
300 micron 5 – 20 8 – 30 12 – 40 15 – 50
150 micron 0 – 10 0 – 10 0 – 10 0 – 15
FINE AGGREGATE

28. •Iron slag
•Copper slag
•Steel Slag
•Recycled Aggregate
Types of Aggregates

29. COARSE AGGREGATE

30. GRADED COARSE AGGREGATE
IS : 383 TABLE 2
IS SIEVE DESIGNATIONPERCENTAGE PASSING
40 mm 100
20 mm 90 – 100
10 mm 25 – 55
4.75 mm 0 – 10
FOR 20 mm NOMINAL SIZE

31. AGGREGATE CRUSHING VALUE
IS : 2386 PART - IV
AGGREGATE CRUSHING VALUE SHALL
NOT EXCEED :
30 % FOR WEARING SURFACES SUCH
AS ROADS & PAVEMENTS
30 % FOR OTHER THAN WEARING
SURFACES

32. AGGREGATE IMPACT VALUE
IS : 2386 PART - IV
AGGREGATE IMPACT VALUE SHALL NOT
EXCEED :
30 % FOR WEARING SURFACES SUCH AS
ROADS & PAVEMENTS
45 % FOR OTHER THAN WEARING
SURFACES

33. AGGREGATE ABRASION VALUE
IS : 2386 PART - IV
AGGREGATE ABRASION VALUE SHALL
NOT EXCEED :
30 % FOR WEARING SURFACES SUCH
AS ROADS AND PAVEMENTS
50 % FOR OTHER THAN WEARING
SURFACES

34. SOUNDNESS TEST
IS : 2386 PART - V
•This test is intended to study the resistance of Coarse and
fine aggregates to weathering action.
•Loss in percentage not more than =10 for Sodium
sulphate, 15 for Magnesium sulphate

35. •Combined flakiness and Elongation shall not exceed = 40%
25mm- 20mm
20mm- 16mm
16mm- 12.5mm
12.50mm - 10mm
10mm- 6.3mm
Flakiness and Elongation Test

36. Water
• Clean and free from injurious amount of Oil,
Acid, Alkali, Sugar, Salt, and Organic materials
• Potable water is good for concrete
• Sea water is not permitted

37. Test Reference CodesAcceptance Standards
PH Value IS 456 2000 6 to 8
Chlorides IS 3025(Part 24) 500mg / l. (RCC & PSC)
Sulphate IS 3025(Part 24) 400 mg / l.
Neutralization with NaOH IS 3025
Maximum = 5 ml. of 0.02
Normal NaOH to
Neutralize 100 ml. of water
Neutralization with H
2 SO
4 IS 3025(Part 23)
Maximum = 25 ml. of 0.02
Normal H
2 SO
4 to
Neutralize 100 ml. of water
Suspended matter IS 3025 (Part 17) 2000 mg./l. max
Organic matter IS 3025 (Part 18) 200 mg /l. max
Inorganic matter IS 3025 (Part 18) 3000 mg / l. max
Water

38. Steel (IS 1786)
•To determine the ultimate tensile stress, proof stress and
elongation using the universal Testing Machine
•Use Primary Steels (as per Cl 1009.3.1 Morth Vth)

39. Steel (IS 1786)
•TMT
•CRS
•CTD
•EQR
•TMX
•HCRM
Quenching and tempering : a two-stage heat-treatment process.
Stage one includes hardening (900°C) and then quickly cooled with
water or oil. Stage two consists of tempering the material to
obtain the desired material properties.

40. CorrosionCorrosion

41. Coating of Reinforcing Bars
•Fusion Bonded Epoxy Coated Rein. – IS 13620
•Hot Dipped Galvanized Bars
– IS 12594
Coating of reinforcing bars

42. Properties of Steel bars
PropertiesFe 415Fe 415 DFe 500 Fe 500 DFe 550Fe 550D
Proof Stress
Minimum
(Mpa)
415 415 500 500 550 550
Ultimate
Strength
Minimum
(Mpa)
485 500 545 565 585 600
Elongation
Percentage
Minimum
(%)
14.5 18 12 16 10 14.50
Steel (IS 1786)

43. Seismic Zone Map for Tamil Nadu

44. Steel Reinforcement for Structures
•As per IRC 112 for Zone III &Zone IV area it is necessary to
use HYSD bars having minimum elongation of 14.5%

45. •Shall be furnished by the contractor and got approved by
the Engineer before start of work.
•Bars shall be bent cold to the specified shape and
dimensions or as directed by the Engineer using a proper
bar bender, operated by hand or power to obtain the
correct shape and radii of bends.
Bending of Reinforcement

46. Form work (IRC 87)

47. Welding and Mechanical Coupler

48. CONCRETE – Strength development
Fresh Stage
Concrete is Plastic, workable
capable of being moulded
Transition Stage
Workability reduces, process
of setting begins
Hardened Stage
Concrete becomes stiff and
gains enough strength to
support load

49. CONCRETE – Strength
Number refers to
Compressive strength of
150 mm cube, cured in
water for 28 days expressed
in N/mm
2
(Mpa)
Concrete is designated by its
compressive strength only
M 30
M refers to Mix
Eg :

50. Ordinary Concrete
Cement Fine Aggregate
Coarse Aggregate
Ordinary Concrete
+
+
Water
+

51. Applications of Ordinary Concrete (M 10,M 15,M 20)
• Plain concrete works
• Lean concrete works
• Simple foundations
• Foundation for masonry walls
• Temporary RCC constructions
• Non load bearing structures

52. Standard Concrete
Ordinary Concrete
Chemical Admixture
Standard Concrete
+
(High range water reducers)

53. Applications of Standard Concrete (M 25 to M 50)
• Reinforced concrete works
• Pre stressed concrete works
• Prefabricated concrete
elements
• Load bearing structures

54. Achieving High Strength Concrete
Conventional
Concrete
Mineral
Admixture
Chemical
Admixture
High Strength Concrete
+
+

55. Applications of High Strength Concrete (M 50 – M 100 )
• High Rise Buildings
• Offshore Structures
• Nuclear Power Plants
• Spill ways of Dams
• Long span Bridges
• Ultra-thin whitetopping

56. MINERAL ADMIXTURES
RECOMMENDED BY IS : 456
•Fly Ash
•GGBS
•Silica Fume
•Rice Husk Ash
•Metakaolin

57. Chemical Admixtures IS 9103
•Compatibility of the admixtures with the cement and any
other pozzolans or hydraulic addition shall be ensured by
avoiding the following problems.
Requirements of large dosage of super plasticizer for
achieving the desired workability.
Excessive retardation of setting
Excessive entrainment of large air bubbles
Rapid loss of slump
Excessive segregation and bleeding
Chemical Admixtures (IS 9103)

58. •Transported by the transit mixes
or properly designated buckets or
by pumping.
•Transported within 2 hrs., if
excess the time use retarder type
admixtures
•During hot or cold weather,
concrete shall be transported in
deep containers
RMC (IS 4926)

59. Standard slump cone size
Top dia = l0 cm
Bottom dia = 20 cm.
Height = 30 cm
Standard tamping rod
Length = 0.6 m
Dia = 16 mm.
Test Procedure
Concrete shall be poured in three layers - each layer 25
blows. On removing the cone slowly, the slumped concrete height
has to be measured. The difference between this reading and the
original height of 30 cm is the slump of concrete.
Concrete Workability – Slump Cone IS 1199

60. Concrete workability – Slump Test (IS 1199)

61. Sl.No Type Slump (mm)
1.(a) Structures with exposed inclined surface
requiring low slump concrete to allow proper
compaction
25
(b) Plain Cement Concrete 25
2.RCC, structures with widely reinforcement eg. solid
column, piers, abutment footing, well steining
40 -50
3.RCC structure with fair degree of congestion of
reinforcement eg.Pier and abutment, Caps, Box
culvert well curb, well cap, walls with thickness
greater than 300 mm
50 - 75
4.RCC PSC structures with highly congested
reinforcement eg. Deck Slab Girders, Box Girders,
walls with thickness less than 300 mm
75 - 125
5.Under water concreting through tremie eg. Bottom
plug, cast- in-situ Pilling
150 - 200
Recommended Slump Value

62. Requirement of concrete for Different
Exposure Conditions

63. •The concrete shall be deposited
as nearly as practicable in its
original position to avoid
re-handling.
•The concrete shall be placed and
compacted before its initial
setting so that it is amenable to
compaction by vibration
•As a general guidance, the
permissible free fall of concrete
may not exceed 1.5 m
Placing of concrete

64. •Concrete shall be thoroughly compacted by vibration or other means
during placing and worked around the reinforcement , tendons or duct
formers, embedded fixtures and into corners of the formwork to
produce a dense homogeneous void free mass having the required
surface finish.
•When internal vibrators are used, they shall be inserted vertically to
the full depth of the layer being placed and ordinarily shall penetrate
the layer below for a few centimeters. The vibrator should be kept in
place until air bubbles cease escaping from the surface and then
withdrawn slowly to ensure that no hole is left in the concrete
•IS 2502, IS 2506, IS 2514
Compaction of Concrete

65. Compaction

66. •The temperature of the concrete at the
time of placement should be as low as
possible, but in no case more than 35°C.
•Use of chilled mixing water
•Use of crushed ice or flaked as a part of
mixing water.
•Sprinkling stockpiles of coarse aggregate
with water and keeping them moist.
• Limiting temperature of cement to be
preferably not in excess of 30°C at the
time of use
Concrete in hot weather

67. •Ensure that the temperature of the concrete does not drop below
 4
degrees Celsius
 in order to prevent this loss of strength
.
•Delayed setting and hardening, slower rate of gain of strength,
• Irreparable loss of strength and durability, if freezing of
concrete takes place at early ages, when it is still in plastic
state. Even one cycle of freezing of concrete during the
prehardening period may lower the compressive strength by
30 to 50 percent,
Concrete in cold weather

68. •Water Curing
•Steam Curing
•Curing Compounds
After placing and during the first stages of hardening, concrete shall
be protected from harmful effects of sunrays, drying winds, cold,
running water, shocks, vibrations, traffic including construction traffic
etc.
Curing of concrete

69. Strength of Concrete Sample
Strength of Concrete in
Structure
1 Sample = 3 Cubes
Acceptance Criteria for Strength of Concrete

70. Minimum Frequency of Sampling
Quantity of Concrete (m
3
)Number of Samples
1 - 5 1
6 – 15 2
16 – 30 3
31 – 50 4
51 and above
4 + 1 for each additional
50 m3 or part

71. Sampling of Fresh Concrete
• Collect Samples from not less than 5 well-distributed
positions immediately after discharge
• Quantity of sample shall not be less than 0.02 m
3
• Avoid edge of the concrete mass to avoid segregation

72. Making and Curing Test Specimen
• Mould shall be thinly coated with oil
• Concrete shall be filled in 3 layers
Each layer 5 cm deep
• Compaction with tamping bar
Number of strokes per layer : 35

73. Making and Curing Test Specimen
• Specimen shall be stored at safe place at 22
0
c to
32
0
c for 24 hours
• After 24 hours, specimen shall be stored in clean
water at 27
0
c ± 2
0
c until the date of testing

74. Testing of Concrete specimen
• Specimens stored in water shall be
removed from the water

• Surface water shall be wiped off
• Specimens shall be tested while they
are in the Saturated Surface Dry
condition

75. Testing of Concrete specimen
• Load shall be applied perpendicular to Cast direction
•Rate of loading : 5.25 kN/sec
• Load shall be applied until the specimen breaks down
Load at Failure
•Compressive Strength =
Cross sectional area
Top
Top

76. Acceptance Criteria
F
c1
= Strength of
cube 1
F
c2
= Strength of
cube 2
F
c3
= Strength of
cube 3
F
c1
+ F
c2
+ F
c3



F
c mean
= -------------------
3

F
c mean > (F
ck + 3)

The values of F
c1
,

F
c2
and
F
c3
should be
within ± 15 % of F
c mean

77. Acceptance Criteria for M 30
F
c1
= 33 MPa
F
c2
= 36 MPa
F
c3 = 28 MPa
F
c mean
= 32.33 Mpa

15 % of 32.33 = 4.85 MPa
32.33 – 4.85 = 27.48 MPa
32.33 + 4.85 = 37.18 MPa
F
ck = 30 Mpa
F
ck
+ 3 = 33 MPa
F
c mean
is less than (F
ck
+ 3)
Not Accepted
F
c1, F
c2 and F
c3 are between
27.48 Mpa and 37.18 Mpa
Test Result is valid

78. Sample 1
Sample 2
Sample 3
Sample 4
Group - I
For 50 m
3
of Concrete 4 Samples are required

79. Factors affecting Strength of Concrete
•Water/Cement Ratio
•Cement Content
•Aggregate/Cement Ratio
•Type of Aggregate
•Placing & Compaction
•Curing condition
•Age of Concrete
•Environmental Condition

80. Strength of concrete in
structure
If cube strength fails ?

81. •Penetration method
•Rebound hammer method
•Pull out test method
•Ultrasonic pulse velocity method
•Radioactive methods
•Half Cell Potentiometer etc.,
Non Destructive Tests

82. •The probe test produces quite
variable results and should not be
expected to give accurate values of
concrete strength.
•It has, however, the potential for
providing a quick means of
checking quality and maturity of in
situ concrete.
Penetration Test

83. Rebound Hammer (IS 516 P5 Sec4)
POSITION OF REBOUND
HAMMER - VERTICALLY
UPWARDS

84. Rebound Hammer Test

85. Pull out Test Method
•A pull-out test measures, with a
special ram, the force required to
pull from the concrete a specially
shaped steel rod whose enlarged
end has been cast into the concrete
to a depth of 3 in.
• Although pullout tests do not
measure the interior strength of
mass concrete, they do give
information on the maturity and
development of strength of a
representative part of it.
Pull Out Test Method

86. Ultrasonic Pulse Velocity Test (IS 516 P5 Sec1)

87. Ultrasonic Pulse Velocity
Concrete Quality Grading
Pulse Velocity (km/s) Quality
Above 4.4 Excellent
3.75 to 4.4 Good
3.0 to 3.75 Doubtful
Below 3.0 Poor

88. •Radioactive methods of testing
concrete can be used to detect
the location of reinforcement,
measure density and perhaps
establish whether honeycombing
has occurred in structural
concrete units.
Radioactive Method

89. GPR & Profometer 650AI

90. Concrete Core Test (IS 516 P4)
Fixing the core
cutting machine
Drilling the
concrete

91. Concrete Core Test
Drilling in processDrilling completed

92. Concrete Core Test
Concrete core Levelling

93. Concrete Core Test
Curing

94. Concrete Core Test
Fixing in machine Testing

95. ACCEPTANCE CRITERIA
I ) AVERAGE EQUIVALENT
CUBE STRENGTH OF CORE =
II ) STRENGTH OF ANY
INDIVIDUAL CORE =
COMPRESSIVE STRENGTH OF CORES
85 % of CUBE STRENGTH
of SPECIFIED GRADE
75 % of CUBE STRENGTH
of SPECIFIED GRADE

96. ACCEPTANCE CRITERIA
If the Concrete is not able to meet any
of the STANDARDS OF ACCEPTANCE,
the Structure is to be Investigated

97. • Strength and durability of concrete
depends on many factors
• To achieve a strong and durable
concrete structure,
High Intention
Sincere Effort
Intelligent Direction and
Skillful Execution
are needed


Summary of main points

98. THANK YOU