QUALITY CONTROL AND INSPECTION

INTRODUCTION:

The Quality Control Unit of I & CAD Dept., of Telangana state is Headed by a Chief Engineer,

Quality Control with Head quarters at Hyderabad with Two Circles One at Hyderabad and another at

Warangal.

The Quality Control / Quality Assurance in execution is a prime requisite to ensure longevity and

performance of any Engineering work. The Quality of work can be realized through stringent Quality

Control measures jointly by Team of Members comprising of Contractor, Construction Engineers and

Quality Engineers.

The Quality Control Unit is responsible for the Quality checks of all the Major, Medium and

Minor Irrigation Projects In order to achieve the required degree of quality, it not only

requires proper coordination among the Quality Control Staff, Construction Staff and the

Contractors but also the availability of a Comprehensive Handbook on the Quality Control

and Quality Assurance aspects becomes a dire necessity which proves handy for one and all

involved in the Construction Activity.

The importance of Quality Control of Construction Works of Irrigation Projects needs no emphasis.

Irrigation Projects involve heavy expenditure and contribute to the prosperity of State. They are time

bound programmes and require assistance from various technical bodies for investigation, design,

planning and execution. To have a safe durable structure, it is necessary that the materials and

Standard of execution fully satisfy the specifications. It is to be recognized that while the ultimate

efficiency of the performance of a project will depend upon proper layout and designs, the ultimate

health of the project during life scale of its operational phase will depend largely on the quality

achieved during its construction. Projects have to be there for generations to come. We must take all

the steps to ensure the top class quality is maintained and there should be no compromise on this

The handbook now prepared has been arrived at after careful study of various Quality Control

Manuals of the past and guidance for its users.

 DUTIES
1.DUTIES OF ASSISTANT EXECUTIVE ENGINEER

ASSISTANT EXECUTIVE ENGINEER/ ASSISTANT EXECUTIVE ENGNEER/

ASSISTANT ENGINEER ASSISTANT ENGINEER QUALITY
CONSTRUCTION CONTROL

1. Shall see that the markout of the area to be 1. Shall check the markout foundation/
tackled is properly given, shuttering, prelevels and centering/shuttering
centering, reinforcement are done as per reinforcement arrangements and inform the
drawings and technical specifications, to Assistant Executive Engineer / Assistant
record the Pre levels/foundation levels, and to Engineer construction to rectify the defects if
see that mark-out for canal excavation is any. Shall certify the markout of canal
perfectly given as per drawings. Prelevels, excavation as per drawings. Prelevels,
classification levels and final levels of canal classification levels and final levels of canal
shall be taken as per specification and got shall be checked.
verified by Quality Control Assistant
Engineer/Assistant Executive Engineer. 2. Shall check the adequacy of the
construction equipment and curing / watering
2. Shall see that the construction equipment arrangements.
like mixers, vibrators, rollers, pumping
arrangements for water curing/curing 3. Shall conduct the field tests on input
compound are arranged before starting of any materials and record the results and to inform
work. the Assistant Executive Engineer/Assistant
Engineer construction to rectify the defects if
3. Shall see that sufficient quantities and any. To send the samples of input materials to
quality of input materials as per agreement central lab as and when required. To conduct
specifications are made available at site of core tests and other field tests as per IS codes
work and to arrange testing equipment, men in case of Embankment works.
and material required for conducting field tests
on input materials or for sending samples of 4. Shall check and write the O.K. card and
input materials to central lab. record the deviations, defects if any or
otherwise to record the final OK and to inform
4. Shall write O.K. Cards after area is ready to the Deputy Executive Engineer/Executive
start the work and to inform the Asst. Engineer quality control and to permit to start
Executive Engineer /Assistant Engineer the work.
Quality Control and Deputy Executive
Engineer construction and take permission to 5. Shall make constant checks of the feeding
start the work on O.K. Card. of input materials mixing time and suggest the
quantity of water depending on the moisture
5. Shall supervise and ensure that correct content of sand as and when required.
quality and quantities of input materials as per
mix design communicated by the central 6. Shall conduct slump test, record
laboratory are fed into the mixers/batching temperature of concrete, core tests, proctor of
plants etc., and shall ensure adequate mixing concrete, proctor density etc., and to extract
time field samples of finished product to be sent to
central laboratory later.
6. Shall ensure proper vibration, rolling etc.. 7. Shall assist the Assistant Engineer /
during course of day to day work and to Assistant Executive Engineer Construction in
provide men and material required for Proper handling/ transport of samples to
central lab.

extracting samples of finished product for 8. Shall check and see that the preparation of
quality control staff. the surface is adequately done for starting the
next lift.
7. Shall ensure proper curing of samples
extracted till the curing time is over and to 9. Shall check the adequacy of curing /
make arrangements to send the samples to watering and see that the final surfaces are
central lab. finished neatly plumb/straight lines etc.

10. Shall maintain registers of field tests

8. Shall ensure timely green cutting of conducted.
concrete with proper air - water gun: nicking
& chipping (wherever so warranted) so as to
prepare the surface for next concrete lift for
effective bend at the lift/construction joints.

9. Shall ensure proper curing/watering and

allow removal of centering only after the time
limit prescribed in the specifications and to see
that the surfaces are finished to the
plumb/straight lines etc., after removal of
shuttering.

10. Shall maintain (1) mark-out register (2)

OK Card files (3) Load Register.

The AEE.s/A.Es working at tunnel both in construction and Q.C. staff shall pay special attention on
1. Marking / checking the center line after every head blasting & mucking.
2. Monitoring oxygen and carbonmonoxide levels in the tunnel as well as lighting.
3. Checking the alignment of concrete placement Gantry.
4. Monitoring Safety measures.
2. DUTIES OF DEPUTY EXECUTIVE ENGINEER

DEPUTY EXECUTIVE ENGINEER DEPUTY EXECUTIVE ENGINEER

(CONSTRUCTION) (QUALITY CONTROL)

1. Shall exercise proper check over all the 1. Shall exercise proper check over all the
activities of Assistant Engineer / Assistant activities of Assistant Engineer / Assistant
Executive Engineer, Construction. Executive Engineer/ Quality Control.

2. Shall verify the foundation/ pre-levels, 2. He shall invariably check foundations of

check the mark-out, reinforcement centering all components of works. Final OK is to be
etc., invariably for all works. recorded before the work is started. Where
heavy reinforcement is involved the same
3. Shall check feeding of input materials, also should be checked invariably and final
mixing, placing, vibration rolling etc. OK is to be recorded.
3. Shall check at random feeding of input
4. To ensure that the cement used at site of materials, mixing, placing, vibration rolling
work is tested in the central laboratory. etc.
4. Shall check the test reports of cement,
5. Shall write the OK cards after satisfying date of manufacture etc., and satisfy before
about the arrangements made for starting of starting of the work.
the work and report to the Executive 5. Shall write O.K. cards as and when
Engineer/ Construction. Executive required and inform the Executive
Engineer / quality control accordingly. Engineer/Quality Control accordingly.
6. Shall see that samples of finished
products are transported to the central 6. Shall conduct the field tests like slump,
laboratory. temperature of concrete at random.
7. Shall personally supervise the 7. Shall intimate the defects if any to the
rectifications pointed out by Executive Executive Engineer Construction and
Engineer Construction, Executive Engineer Executive Engineer Quality Control, Check
Quality Control. and verify whether rectifications are done as
per the norms laid down in the contract
8. Should arrange to get the foundations of specifications.
soil tested in case of weak soil over which
heavy Embankments are proposed. 8. Shall assist the Deputy executive
9. He should send soil samples in various Engineer Construction in conducting these
reaches well in advance to central tests.
laboratory and get the soil tested for various 9. Shall assist the Deputy Executive
properties and obtain OMC and MDD Engineer Construction in sending the
values. samples to central laboratory.

10. Shall order temporary suspension of 10. Shall order temporary suspension of
work if any serious defects are noticed and work if any serious defects are noticed and
shall intimate immediately to Executive shall intimate immediately to Executive
Engineer Construction and Executive Engineer Construction and Executive
Engineer quality Control. Engineer Quality Control.

DUTIES OF EXECUTIVE ENGINEER

EXECUTIVE ENGINEER EXECUTIVE ENGINEER QUALITY

CONSTRUCTION CONTROL

1. Shall supervise, check, advise, and instruct 1. Shall supervise, check, advise and instruct
the A.E/A.EE/ D.EE Construction regarding the A.E/A.E/D.EE Quality control regarding
discharge of their functions properly. discharge of their functions properly.
2. Shall intimate the Executive Engineer 2. Shall maintain copies of approved Designs,
quality control regarding signing of reports, contract document, drawings,
agreement for starting of any new work, duly construction programme, extracts of
endorsing a copy of work order. Shall supply inspection notes etc., and shall see that his
copies of contract documents, drawings subordinates go through the above
Construction programme etc., to Executive documents.
Engineer Quality Control. and Superintending
Engineer Designs and Inspection Circle. 3. Shall remind, ensure and verify whether
3. Shall see that all ingredients of concrete, test results are available or not before starting
masonry are got tested before use. Shall see up of any new work.
that the soils are tested for various properties
like OMC, MDD. etc. before starting of 4. Shall assist in upkeep and calibration of
Embankment work. equipment.
4. Shall see that all the Machinery/ equipment
being used by the contractor is got 5. Shall inspect and sign on O.K. Cards
periodically calibrated during field visits.
5. Shall see that OK Cards are written and
kept at site of work before starting of any 6. Shall order the suspension of work if any
work. defects are noticed or reported by quality
6. Shall order the suspension of work if any control staff and intimate his counterpart to
defects are noticed or reported by quality see that defects are rectified. If not rectified
control staff and resume the work only after the matter is to be reported to the S.E./Quality
rectification of defects in the presence of Control.
quality control staff. 7.Foundations and reinforcement, shuttering,
7. Foundations and reinforcement, shuttering, centering where heavy reinforcement is
centering where heavy reinforcement is involved is to be checked by Executive
involved is to be checked by Executive Engineer invariably before starting the work.
Engineer invariably before starting the work.. 8. Shall jointly inspect the site with
8. Shall jointly inspect the site with quality Construction Executive Engineer in case
control Executive Engineer in case variation variation in classification is less than 10%
in classification is less than 10% (+/-) and (+/-) and finalise the classification.
finalise the classification. 9. Shall pursue and keep track of sending of
9. Shall personally see that the samples samples to T.S.E.R.L/N.C.C.B. and to keep
proposed to be sent to the laboratories like record of results received.
T.S.E.R.L/N.C.C.B. are sent regularly as per 10. Shall co-ordinate with the
the need, obtain the results and communicate EE/Construction division render assistance in
the same to Executive Engineer, Quality resolving the issues referred to technical
Control. expert.
10. Shall take the help of quality control
Executive Engineer whenever a dispute is
referred to Technical Expert.

FREQUENCY OF TESTS
Sl.
Material Tests Frequency Range
No
 One test for each
a) Fineness Modulus The Permissible Value of FM of
150m³ of sand
IS: 2386-Part-I-1963 Sand- 2.20 to 3.20.
used in concrete
1 Fine Aggregate
One test for each not >3% for natural fine aggregate
b) Silt Content
150m³ of sand and not >5% for crushed fine
IS:2386 (Part-II)-1963
used in concrete aggregate

One test for each

a) Sieve Analysis % Passing as per
150m³ of sand
IS: 2386-Part-I-1963 IS 383-1970
used in concrete

Coarse The Permissible Value of Flakiness

2 b)Elongation Index and Elongation Index should be
Aggregate
IS 2386 (part I)-1963 less than 15%.
One test whenever
Quarry changes
c) Flakiness Index
IS 2386 (part I)-1963

a) Weight per m For each

3 Steel -
length IS-1786-1985 consignment

a) Fineness The Permissible Value of Fineness

For each
4 Cement IS: 4031 (Part 1) - of Cement less than 10%.
consignment
1996
Quantity of
Concrete in No.of Samples
m³
1 to 5 1
6 to 15 2
16 to 30 3
a) CC Cubes As per clause
31 to 50 4
IS:456-2000 15.2.2 of IS 456
4 +1
additional sample
51 and for each
5 Concrete above additional
50m³ or part
thereof
-
b) Slump
IS:1199-1959 One test in each
shift on at frequent
intervals to check
-
workability
c) Temperature
 Field Dry density(FDD)
For each layer or
by Core cutter
6 Soil for every 1500 cum Compaction Efficiency- 95% to 98%
Method IS:2720(part-
of soil
29)-1975

QUALITY CONTROL FIELD TESTS

Field Tests on Earthwork:
 1. Field Dry Density (FDD)
2. Permeability Test (Japanese Method)
3. Standard penetration Test (SPT)

Field Tests on Cement:

1. Fineness of cement

Field Tests on Fine Aggregates:

1. Fineness Modulus (FM) of sand

2. Silt content in sand

Field Tests on Coarse Aggregates:

1. Sieve Analysis of Coarse Aggregate

2. Flakiness and Elongation Index of Coarse aggregate.

Field Tests on Cement Concrete:

1. Compressive strength of Cement concrete cubes

2. Slump and Temperature of concrete.

Field Tests on Steel:

1. Weight of steel per 1 metre length

Field Tests on Pipe Line:

1.
2. Hydrostatic Test (HT)
3. Ultrasonic Test (UT)
4. Radioactive Test (RT)

Field Tests on Tunnel:

1. Grouting
2. Pull out Test

Field Tests on Earthwork

 1. DETERMINATION OF FIELD DRY DENSITY BY CORE CUTTER
METHOD
Aim: To determine the Field moisture and dry density of compacted Earth Embankment by core
cutter method.

Principle: Core Cutter Method of Field density test is conducted to know whether the specified
compaction is achieved. Core cutter method is used for finding field dry density of cohesive/clayey
soils placed asfill.

Density, γ = 𝑤/𝑣
The density (γ) is defined as the total weight of soil (w) per unit of its total volume (v)

The water content w, also called the moisture content is defined as the ratio of weight of water (Ww)
to the weight of solids (Ws) in a given mass of soil.

Water content, w = 𝑊𝑤/𝑊𝑠 ×100%

The dry density (γd) is the weight of soil solids per unit of total volume of the soil.

Dry density, γd = γ/ 1+𝑤

Reference: IS:2720 (part-29)-1975

APPARATUS: 1) Cylindrical core cutter of steel, 2) Steel rammer, 3) Steel dolly, 4) Palette knife,
5) Steel rule, 6) Straight edge, 7) Balance, 8) Container for water content determination, 9)
Thermostatically controlled oven

PROCEDURE:
1. Measures the height and internal diameter of core cutter, then find the volume and Weigh the
empty core cutter (W1).
2. Clean the area in the field where the test is to be carried out, put the dolly on the top of the core
cutter and drive the core cutter into the soil.
3. Dig out the container from the soil and trim off both the sides of the cutter.
4. Weigh the core cutter filled with soil (W2).
5. Remove the soil from the core cutter and take representative Sample of soil in the container for
the water content determination and weight it (Ws).

7. Heat the sample and then weight it again (Wd).

8. Find the water content and repeat the procedure from step 5 to step 8 as required.

EXAMPLE:

D = Inner diameter of core cutter in cm =

H = Height of core cutter in cm =

V = Volume of core cutter (πd2h/4) in cm3 =

Weight the empty core cutter in gms =W1 =

Weight of core cutter + wet soil in gms = W2 =

Weight of wet soil in gms (W2-W1) =W 3=

Field density in gms /c.c. = W3 / V =

Moisture container No.1

Wet soil in gms (Ws) =

Dry soil in gms (Wd) =

Weight of moisture in gms (Ws-Wd) =

% Water content (M.C.) =

Dry density in gms /c.c.= (Field density/1+W.C)=

Maximum Dry Density from laboratory.(MDD) in gms /c.c=

Optimum moisture content from laboratory (OMC) =

Compaction Efficiency = (Dry density/ Maximum Dry Density)*100

Weight Weight
of the of the Weight of
Location Volume Wet
empty empty the soil Weight of Weight of
Date of the R.L of the density
core core W3=W2- the wet the dry
test soil (V) (W3/V)
cutter cutter+s W1 soil ( Ws) soil ( Wd)
W1 oil W2
 Weight of the Water content Dry density OMC MDD Compaction Efficiency=
water Ww=Ws- (Ww/Wd)*100 F.D/(1+ W.C) (FDD/MDD)X100
Wd

LIMITATIONS: The Compaction Efficiency should be 98% as per the specifications.

DO’s DO NOT’s

1. Clean the Core cutter and dolly thoroughly 1.

2. Before lifting the core cutter, the soil 2.
should be removed around the properly.

Video Link: For detailed Information Visit https://youtu.be/8kwYcdrVWQU

DETERMINATION OF PERMEABILITY (INSITU) METHOD

( By Japanese Method)

Aim: To determine the Permeability of soil (Insitu) by Japanese Method.

PRINCIPLE: The permeability test is the measure of the flow of a liquid through a soil sample.

REFERENCE:

PROCEDURE:

1. Scrap all the top loose material at the desired area for an extent of 6’X6’.
2. Make a trench of bottom dimensions 4’X2’ and 1’-9” deep with sides.1/4:1 slope.
3. A can calibrated in 1/10 gallons from which water can be fed into the trench.
4. Fill up the trench with water to a depth of 2” from the top and go on feeding water into the
trench from the top calibrated can, so that the water level is maintained constant at a depth of
3” from the top surface.
5. Record the water in-take every one hour.
6. The experiment should be continued till the in-take readings are steady say for a period of 4
hours.
7. Extend the pit to the dimensions of 4’X4’ at the bottom by cutting an extra width of 1 foot on
either side of the shorter sides of the trench.
8. Feed the trench with water as in the previous case maintaining the water level in the pit 3”
from top.
9. Measure the in-take every one hour for a period of 2 hours or more till the in-take is constant.
10. Determine the extra amount of water required to maintain the level in the pit after it has been
extended.
If the extra amount of water is 1/100 gallon per hour permeability is 1 ft/year.
If the extra amount of water is 1/10 gallon per hour permeability is 10 ft/year.

Suppose: =1/100 G.P.H Then K= 1 ft/year

=1/100 G.P.H. to 1/10 G.P.H. is in the limits of 1-10 ft/year.

=1/10 G.P.H. to 1 G.P.H.K is in the limits of 10-1000 ft/year.

1 Gallon = 4.536 litres

1/10 Gallon = 453.600 C.C

1/100 Gallon = 45.360 C.C

Note: 1. After excavating the pit, the bottom and sides may be searified with an iron nail
before water is fed into the pit.
2. The bottom of the trench should not be allowed to be trampled under the feet and
after dewatering the pit and before extending the width from 2’ to 4’ it shall be
covered by polyethylene cloth or tarpaulin or empty gunny bags. Only one man
should be allowed to work in the pit.
3.while extending the width of bottom of trench from 2’ to 4’ all precautions shall be
taken to remove the excavation material with minimum disturbance to the
foundation soil in the trench.
DETERMINATION OF STANDARD PENETRATION TEST

AIM: To determine the Standard Penetration Test.

REFERENCE: IS -2131:1963

APPARATUS:

1. Standard Split Spoon Sampler

2. Drop Hammer weighing 63.5kg
3. Guiding rod
4. Drilling Rig.
5. Driving head (anvil).

PROCEDURE

The test is conducted in a bore hole by means of a standard split spoon sampler. Once the
drilling is done to the desired depth, the drilling tool is removed and the sampler is placed inside the
bore hole. By means of a drop hammer of 63.5kg mass falling through a height of 750mm at the rate
of 30 blows per minute, the sampler is driven into the soil.
This is as per IS -2131:1963. The number of blows of hammer required to drive a depth of 150mm is
counted. Further it is driven by 150 mm and the blows are counted. Similarly, the sampler is once
again further driven by 150mm and the number of blows recorded. The number of blows recorded for
the first 150mm not taken into consideration.. The number of blows recorded for last two 150mm
intervals are added to give the standard penetration number (N).
 N = No: of blows required for 150mm penetration beyond seating drive of 150mm

Teng’s Formula,

qns = 5.54*0.6(N-3)((B+0.3)/2*B))^2

Where, qns = Net safe bearing pressure, kN/m2

N = SPT value corrected for overburden pressure

RW = Water table correction factor

Rd = Depth correction factor = 1 + 0.2Df/B ≤1.2

Field Tests on Cement:

• Observe the Manufacture date of the cement on the bag.
• See the Grade of the cement.
• Should not contain any lumps.
• Should have homogeneous colour and texture.
• When a handful of cement is thrown in a bucket full of water it should float on
the surface of water before sinking.

DETERMINATION OF FINENESS OF CEMENT

AIM: To determine the Fineness of Cement.

PRINCIPLE: The fineness of cement is a measure of the size of particles of cement and is expressed
in terms of the specific surface area of cement.
The fineness of cement is measured by sieving it through a standard sieve, The proportion of cement
is measured as the % weight retained on a 90µm IS sieve over the total weight of the sample.

REFERENCE: IS - 4031(Part 1)-1996

APPARATUS
i) 90μm IS Sieve
ii) Balance capable of weighing 10g to the nearest 10mg
iii) A nylon or pure bristle brush, preferably with 25 to 40mm bristle, for cleaning the
sieve

PROCEDURE
 1. Weigh approximately 10gof cement (W1) to the nearest 0.01g and place it on the sieve.
2. Agitate the sieve by swirling, planetary and linear movements, until no more fine material
passes through it.
3. Weigh the residue of cement (W2) on the sieve to the nearest 0.1percent.
4. Gently brush all the fine material off the base of the sieve.
5. Repeat the whole procedure using a fresh 100g sample. Then calculate the mean of obtained
fineness values of cement, expressed to the nearest 0.1 percent.

Note: When the results differ by more than 1 percent absolute, carry out another sieving and
calculate the mean of the three values.

IS 90Microns Sieve

EXAMPLE:

S Weight of the Weight retained % of Fineness Mean of the total

S.No Cement (in gms) after Seiving (in of cement obtained fineness values
(W1) gms))W2) (W2/W1)*100 (M)
1 10 0.65 6.5
2 10 0.7 7.0 (6.5+7+7.8)/3=7.1%
3 10 0.78 7.8

REPORTING OF RESULTS

Report the value of Mean, to the nearest 0.1 percent, as the residue on the 90μm sieve.

Limitations: The Permissible Value of Fineness of Cement less than 10%.

DO’s DO NOT’s

1. Clean up the apparatus thoroughly before 1. Cement lumps should be avoided.

testing.
2.Cement sample should be dry
3. The sample tested for fineness should be
free of lumps.
4. The weighing should be done accurately.
5. Sieving should be done holding the sieve in
both hands.
6. The underside of sieve will be lightly
brushed with a 25 or 40 mm bristle brush.
7. Make sure that the sieving operation is
done in all directions for a minimum of
15min.

Video Link: For detailed Information Visit https://youtu.be/eP8_yrP8xc0

Field Tests on Fine Aggregates:

1. DETERMINATION OF FINENESS MODULUS OF FINE AGGREGATE

Aim: To determine Fineness modulus(F.M) of Fine Aggregate(Sand).

Principle:
Fineness modulus of Sand is a measure of average particle size of sand particles.
Fineness modulus is an empirical factor obtained by adding the cumulative percentages of
aggregate retained on each of the standard sieves ranging from 80 mm to 150 micron and dividing
this sum by 100.

 Fineness modulus is generally used to get an idea of how coarse or fine the aggregate is. More
fineness modulus value indicates that the aggregate is coarser and small value of fineness
modulus indicates that the aggregate is finer.
 Fineness modulus of different type of sand is as per given below.

Type of Sand Fineness Modulus Range

Fine Sand 2.2 – 2.6

Medium Sand 2.6 – 2.9

Coarse Sand 2.9 – 3.2

 Generally sand having fineness modulus more than 3.2 is not used for making good concrete.

REFERENCE: IS 383-1970

APPARATUS: Sieve Set (10 mm, 4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron,
150 micron, 75 microns& Pan), Weighing Balance.

Procedure:

 Bring the sample to an air dry condition either by drying at room temperature.
 Take the weight of the sample.
 Sieve the aggregate using the appropriate sieves (10 mm, 4.75 mm, 2.36 mm, 1.18 mm, 600
micron, 300 micron, 150 micron, 75 microns& Pan)
 Record the weight of aggregate retained on each sieve.
 Calculate the cumulative weight of aggregate retained on each sieve.
 Calculate the cumulative percentage of aggregate retained.
 Add the cumulative weight of aggregate retained and divide the sum by 100. This value is
termed as fineness modulus of fine aggregate.

Example:-

Wt. of Sample taken= 1000 g

WEIGHT CUMULATIV %PASSIN
SIEVE SIZE IN %WEIGHT %
S.N0 RETAINED IN E %Wt. G AS PER
MM RETAINED PASSING
GRAMS RETAINED IS
383-1970
100%
1 10 - - - 100
ZONE-II
2 4.75 25 2.5 2.5 97.5 90-100%
3 2.36 75 7.5 10 90 75-100%
4 1.18 245 24.5 34.5 65.5 55-90%
5 600 micron 240 24 58.5 41.5 35-59%
6 300 micron 225 22.5 81 19 8-30%
7 150 micron 185 18.5 99.5 0.5 0-10%
8 Pan 5 0.5 100 0 -
1000 1000 286

F.M =(∑ Cumulative %Wt. Retained)/100 2.86 Zone-II

Reporting of Results: The Fineness Modulus obtained is 2.86 which indicates Zone-II.

Limitations: The Permissible Value of FM of Sand- 2.20 to 3.20.

DO’s DO NOT’s

1. Clean up the apparatus thoroughly before 1. Sample should be dry and free of lumps.
testing.
2.The weighing should be done accurately.
3. Sieving should be done holding the sieve in
both hands in one direction.
4. Make sure that the sieving operation is
done in all directions for a minimum of
10min.

Video Link: For detailed information visit the link https://youtu.be/UcpQllsu0r8

DETERMINATION OF SILT CONTENT IN FINE AGGREGATE

Aim: To determine the percentage of Silt Content in Sand.

Principle: Silt content is a fine material which is less than 150 microns.
The Excessive quantity of silt reduces the bonding of cement and fine aggregate and also
affects the strength and durability of work. So it is important to find out the silt content in sand.
Reference: IS:2386(part-II)-1963
Apparatus: 250ml measuring Cylinder, Sand and Tray.
Procedure:
 First, we have to fill the measuring cylinder with 1% solution of salt ( increase the settlement
time of silt) and water up to 50 ml. Add sand to it until the level reaches 100 ml. Then fill the
Solution up to 150 ml level.
 Cover the cylinder and shake it well (as shown in video)
 After 3 hours, the silt content settled down over the sand layer
 Now note down the silt layer alone volume as V1 ml (settled over the sand).
 Then note down the sand volume (below the silt) as V2 ml
 Repeat the procedure two more times to get the average.

Example:If V1comes out to be 4 and V2 is 100, then

Silt Content = (4/100)*100 = 4%

Limitations: The Permissible Value of Silt Content in Sand should be less than 6%.

DO’s DO NOT’s
1. Clean up the apparatus thoroughly before 1. Sample should be dry and free of lumps.
testing.
2.

Video Link: For detailed information visit the link https://youtu.be/qz0-nF_2hH8

Field Tests on Coarse Aggregates:

DETERMINATION OF GRADATION OF COARSE AGGREGATES

Aim: To determine Gradation of Coarse Aggregates by Sieve Analysis.

Principle: The sieve analysis is conducted to determine the particle size distribution of
aggregates. The particle size distribution of coarse aggregate is termed as gradation.
Reference: IS: 383-1970
Apparatus: Sieve set (63mm, 40mm, 20mm, 10mm, 4.75mm, 2.36mm, Receiver), tray,
metal brush Weighing balance.

Procedure:
 Bring the sample to an air dry condition either by drying at room temperature or in
oven at a temperature of 100°C and 110°C. Take the weight of the sample.
 Clean all the sieves and sieve the sample successively on the appropriate sieve starting
with the largest.
 Shake each sieve separately over a clean tray.
 On completion of sieving note down the weight of material retained on each sieve.
 Report the results as cumulative percentage by weight of sample passing each of the
sieves.
Example:

40 MM Metal Weight of the Sample : 5 Kg

%
Weig %
Weight ht Cumulative Passing
Sieve Size in Retained Retai % Weight Cumulative as per IS Remark
Sl No mm in kgs ned Retained % Passing 383-1970 s
1 63 mm - - 0 100 100%
2 40 mm 0.55 11 11 89 85-100 %
3 20 mm 3.87 77.4 88.4 11.6 0-20 %

4 10 mm 0.58 11.6 100 0 0-5 %

5 Receiver 0 0 100 0

Weight of the Sample : 5

20 MM Metal Kg
% %
Weight Weight Passing
Sieve Size in Retaine Retaine Cumulative % as per IS
Sl No mm d in kgs d % Retained Passing 383-1970 Remarks
1 40 mm - - 0 100 100%
2 20 mm 0.46 9.2 9.2 90.8 85-100 %
3 10 mm 4.42 88.4 97.6 2.4 0-20 %
4 4.75 mm 0.12 2.4 100 0 0-5 %
5 Receiver 0 0 100 0

10 MM
Metal Weight of the Sample : 5 Kg
%
% Passing
Sieve Weight Weight Cumulativ as per IS
Size in Retaine Retaine e% % 383-
Sl No mm d in kgs d Retained Passing 1970 Remarks
12.5
1 mm 0 0 0 100 100%
85-100
2 10 mm 0.24 4.8 4.8 95.2 %
4.75
3 mm 3.82 76.4 81.2 18.8 0-20 %
2.36
4 mm 0.94 18.8 100 0 0-5 %
Receive
5 r 0 0 100 0

Limitations: Percentage of passing of aggregates should be as per specifications.

DO’s DO NOT’s
1. Clean up the apparatus thoroughly before 1.
testing.
2.Cleaning and drying of sample before the
test.

Video Link: For detailed information visit the link https://youtu.be/MuhpE0Sk4EI

DETERMINATION OF FLAKINESS AND ELONGATION INDEX

Aim: To determine Flakiness and Elongation Index of Coarse aggregate.

PRINCIPLE:
Flakiness index of aggregate test is conducted on coarse aggregates sample to estimate the shape of
aggregates. The Surface texture and aggregate shape influence the properties of freshly mixed
concrete more than the properties of hardened concrete. Rough-textured, angular and elongated
aggregates require more water to produce workable concrete than smooth, rounded compact
aggregates.
Consequently, the cement contents must also be increased to maintain the water-cement (W/C) ratio.
Generally, flat and elongated aggregate particles are avoided or limited to about 15 % by weight of
the total aggregate.
FLAKINESS INDEX:
The Flakiness index is the percentage by weight of particles whose least dimension (Thickness) is
less than 3/5th of their mean dimension.
ELONGATION INDEX:
Elongation Index of an aggregate is the percentage by weight of particles whose greatest dimension
(length) is greater than 9/5th times their mean dimension.

REFERENCE: IS: 2386(part-II)-1963

APPARATUS:
1. Metal Gauge – Thickness Gauge & Length Gauge
2. IS: Sieve of size 63,50,40,31.5,25,20,16,12.5,10,3.6 mm
3. Balance of Accuracy of 0.1% of the Total Aggregate
Test

Procedure for Flakiness index:

1. The Sample shall be sieved through the sieves Specified.

2. At least 200 Pieces shall be taken from each fraction and the flaky samples shall be weighed
to an accuracy of 0.1 % of the test sample
3. Then to separate the Flaky materials, gauge each fraction for thickness on a thickness gauge
of the pattern in bulk on sieves having elongated slots.
4. Weigh the total amount of flaky aggregate retained by the thickness gauge to an accuracy of
at least 0.1 percent of the weight of the test sample.

Calculate the Flakiness index = Wt. of Flaky Sample(Passing) X 100

Wt. of the Sample Taken for test

Test Procedure for Elongation index:

1. The Sample shall be sieved through the sieves Specified.

2. At least 200 Pieces shall be taken from each fraction and the elongation samples shall be
separated from the total sample taken.
3. Then to separate the elongated materials, gauge each fraction for length on a length gauge of
the pattern or in bulk on sieves having flaky slots.
4. Weigh the total amount of elongated aggregate retained by the length gauge to an accuracy of
at least 0.1 percent of the weight of the test sample.

Calculate the Elongation index = Wt. Elongated Sample(Retained) X 100

Wt. of the Sample Taken for test
 Dimension of thickness and length gauges
SIZE OF Thickness Length Remarks
AGGREGATE Gauges(*) (mm) Gauge(#) (mm)
Passi Retained on
ng Through IS IS Sieve
Sieve
1 2 3 4 5
63m 50mm 33.90 -
m
50m 40mm 27.00 81.0
m
40m 31.5mm 21.5 64.4
m
31.5m 25mm 16.95 -
m
25m 20mm 13.50 40.5
m
20m 16mm 10.80 32.4
m
16m 12.5mm 8.55 25.6
m
12.5m 10mm 6.75 20.2
m
10m 6.3mm 4.89 14.7
m
 * This Dimension is equal to 0.6 times the Mean Sieve Size
 # This Dimension is equal to 1.8 times the Mean Sieve Size

Note: Flakiness and Elongation test is not applicable for aggregate sizes less than 6.3 mm

Example:

FLAKINESS INDEX: A Particle is said to be flaky if its thickness is less than 0.6 times mean
dimension
Ex: 20mm pass and 16mm retained
20mm + 16mm =36(mean dimension 36/2=18mm)
18mm * 0.6=10.8mm
If sample pass through 10.8mm than sample is FLAKY
= Weight of flaky samples (passing) * 100
Weight of total sample taken for test
= 0.95/8.4*100
= 11.30%

ELONGATION INDEX: A Particle is said to be elongated whose length is 1.8 times more than
mean dimension
Ex: 20mm pass and 16mm retained
20mm + 16mm =36(mean dimension 36/2=18mm)
18mm * 1.8=32.4mm
If sample retained through 32.4mm than sample is ELONGATED
= Weight of elongation samples (Retained)*100
Weight of total sample taken for test
= 0.85/8.4*100= 10.11 %

Limitations: The Permissible Value of Flakiness and Elongation Index should be less than 15%.

DO’s DO NOT’s

1. Cleaning and drying of sample before the 1.

test.
2. Collect 200 random pieces from the
sample.

Video Link: For detailed information visit the link https://youtu.be/acfJIG9o8iw

Field Tests on Cement Concrete:

DETERMINATION OF COMPRESSIVE STRENGTH OF CEMENT
CONCRETE CUBES

Aim: To determine the compressive strength of Cement concrete cubes, Casting and Testing of CC
Cubes.
Principle: The Compressive strength is the Capacity of structure to resist or withstand under
compression. It is determined by the ability of the material to resist failure in the form of cracks and
fissure.
Reference: IS: 456-2000
 Apparatus: 150*150mm CC moulds, Tamping rod, trowel, Compressive Testing Machine.

PROCEDURE:
CASTING:
 Take required quantity of samples as per the Design Mix provided and take random sample
from the mix in ghamela while concreting.
 Pour concrete into the cube mould in 3 layers , compacting each layer with 35No. of strokes
with tamping rod.
 Finish the top surface by trowel after compaction of the last layer.
 After 24 hours remove the specimen from the mould and submerge the specimen in a
clean/fresh water until the time of testing.
 Test 3 specimens for 7days and 3 specimens for 28days.
TESTING:
 Remove the specimens from the water before testing for its Compressive Strength.
 Weight of the cubes is noted in order to determine its density.
(Concrete density is 2400Kg per cubic meter).
 Place the cube in the testing machine, and load is applied and record the maximum load
applied to the specimen.
 Calculate the Compressive strength of the Cubes.(Load/Area of Cube).

S DESCRIPTION M DATE OF D A A ULTIMATE LOAD COMPRESSI R

SL AND MIX CASTING DATE OF AGE ARE IN KN VE REMAR
No LOCATION TESTING IN A OF STRENGTH KS
. DAY CUB 1 2 3 a IN N/MM2
S ES avg
1

Frequency of Testing:
 Quantity of Concrete in m³ No. of Samples
1 to 5 1
6 to 15 2
16 to 30 3
31 to 50 4
4 plus one
additional sample
51 and above
for each additional
50m³ or part thereof
DO’s DO NOT’s

1. Clean the moulds thoroughly without dead 1. Load should not be applied on uneven
concrete. surface of casted cubes.
2. Apply the lubricant properly. 2.
3. The top surface of specimen should be
made even and smooth.

Video Link: For detailed Information Visit https://youtu.be/e8bH26-3PCw

DETERMINATION OF SLUMP AND TEMPERATURE OF CONCRETE

Aim: To determine the slump and temperature of freshly mixed concrete.
Principle: The slump test is to determine the workability or consistency of concrete mix.
Reference: IS:1199(part-II)-2018
Apparatus: Slump cone, tamping rod, trowel, Thermometer.

Procedure:
 Clean the internal surface of the mould and apply lubricant.
 Place the mould on a smooth horizontal non-porous base plate.
 Find out the temperature of concrete mix using thermometer and fill the mould with the
prepared concrete mix approximately in 3 equal layers.
 Tamp each layer with 25 strokes of the rounded end of the tamping rod in a uniform manner
over the cross section of the mould. For the subsequent layers, the tamping should penetrate
into the underlying layer.
 Remove the excess concrete and level the surface with a trowel.
 Clean away the mortar or water leaked out between the mould and the base plate.
 Raise the mould from the concrete immediately and slowly in vertical direction.
 Measure the slump as the difference between the height of the mould and the height point of
the specimen being tested.

When the slump test is carried out, following are the shape of the concrete slump that can be
observed:
 EXAMPLE:

S LOCATION DATE MIX SLUMP TEMPERATURE REMARKS

S/No. OBSERVED IN 0 c
IN mm

S
Limitations: The Slump obtained should be as per the Design mix and temperature of the mix should
be between 15°C to 35°C.

DO’s DO NOT’s

1. Clean the Slump cone and base plate 1.

thoroughly without dead concrete. 2.
2. Apply the lubricant properly.
3. The top surface of slump cone should be
made even and smooth.

Video Link: For detailed Information Visit https://youtu.be/ERnKVQcOfJU

Field Tests on Steel:

1. Weight of steel per 1 metre length

 1.STEEL TEST

Aim : To determine the weight of steel per 1 metre length.

Principle: The unit weight of steel bars is the weight per unit length of a given size of steel
bar. The unit weight of steel bars is typically expressed in kilograms per meter (kg/m).The
steel bars are majorly used as reinforcement to strengthen the tensile property of concrete
structures. The formula used to calculate the unit weight of steel bars is D²/162. Where, D =
Dia. Of steel bars, 162 is a constant value.

Reference: IS:1786-1985
Procedure:
 Take 3 No.’s of bars of same diameter of 1m length each and weigh the bars individually.
 Calculate the average weight of 3 bars and average weight should be as per the below table.

Weight of Steel per 1metre length :

Weight per 1 m length

Sl.No. Diameter of Bar (mm)
Kg/m Min Req.

1 8 0.395

2 10 0.617

3 12 0.888

4 16 1.578

5 20 2.466

6 25 3.854

7 32 6.313

Example:
 Sample Avg of For Dia unit
Dia of Sample 1 Sample 2
S.No. 3 (in Sample Wt.Per 1m
Rod (in Grms) (in Grms)
Grms) 1, 2 & 3 length(Kg/m)

1 8 0.400 0.410 0.410 0.407 0.395

2 10 0.615 0.630 0.625 0.623 0.617
3 12 0.880 0.900 0.900 0.893 0.888
4 16 1.580 1.590 1.580 1.583 1.578
5 20 2.540 2.500 2.560 2.533 2.466
6 25 3.880 3.850 3.860 3.863 3.855
7 32 6.280 6.310 6.460 6.350 6.313
Limitations: As per IS 1786-1985 Code, Table 2: Tolerance on Nominal Weight are as below

Field Tests on Pressure Mains:

Pressure Main
A pressure main is a pipeline that carries a fluid (typically water or sewage) at a pressure
greater than atmospheric pressure.
The water conductor system in a LI scheme is mainly through pipes. These pipes generally
are manufactured in a yard, near to the reach of pipe laying.
The pipe is manufacture by welding plates which form number of longitudinal and
circumferential weld joints.
Later these pipes will be transported to a site and joined by welding after placing in the
position to form the pipe line.
Before laying the pipe line, the BM stones/pillars shall be fixed in CC and DCBM register
shall be approved by the Engineer-In-Charge.

Steel Cylindrical Pipes with Concrete Lining and Coating Manufacturing at Yard :

( IS 1916 – 2018 )

Materials :

The steel cylinder shall be manufactured from steel plates conforming to IS 2062 or its equivalent.
Stiffening bands and flats, where used, shall also conform to IS 2062 or its equivalent.
Electrodes for Welding:
The electrodes used for welding of steel plates shall conform to IS 814

The pipes with lining and coating shall be straight and free from cracks, except craze cracks.
The ends of the pipes shall be square with their longitudinal axis so that when placed in a straight line
in the trench no opening between ends in contact shall exceed 3 mm in pipes up to 600 mm diameter
(inclusive), and 6 mm in pipes larger an 600 mm diameter.
Marking on Pipe:
The following information shall be clearly an dindelibly marked on the each pipe
1.The Indication of the source of manufacture.

2)Size of pipe,

3)Class of pipe

4)Date of manufacture

Design Parameters:
1. Steel cylinder shall be designed such that the maximum tensile stress in steel under the specified
hydrostatic test pressure does not exceed 200 MPa, assuming that no tension is taken up by the
concrete.
2. The thickness of the plate used for steel cylinder shall be not less than the thickness specified
in Table1.

Table :1 Minimum Thickness of Plates for Steel Cylinders

Internal Diameter Nominal thickness Internal Diameter Nominal thickness
of finished Pipe in of plate in mm of finished Pipe in of plate in mm
mm mm
200 - 450 3 3200 -3300 15
500 - 900 5 3400 - 3500 16
1000 - 1100 6 3600 - 3700 17
1200 - 1500 8 3800 - 3900 18
1600 - 1800 9 4000 - 4100 19
1900 - 2100 10 4200 - 4300 20
2200 - 2400 11 4400 - 4500 21
2500 - 2700 12 4600 - 4700 22
2800 - 2900 13 4800- 4900 23
3000 - 3100 14 5000 24

MANUFACTURE
The steel cylinder shall be formed by shaping and welding together steel plates of specified
thickness. Either lap welding or butt welding shall be adopted for all longitudinal and
circumferential welds. All welds shall be made down-hand by the manual welding or automatic
shielded arc welding process.
Welding shall be done so that there shall be thorough fusion and complete penetration. Prior
to welding, the plates shall be fitted closely and during welding they shall be held firmly. For
guidance on metal arc welding, reference may be made to IS 816.
The ends of the steel cylinder shall be square with its longitudinal axis.

HYDROSTATIC TEST at Yard

Each steel cylinder shall be subjected, before concreting, to hydrostatic test under a water pressure
equivalent to the test pressure given in table
Type of Steel cylinder Pipe Test pressure
Class 1 0.5 Mpa ( or 50m Head)
Class 2 1.0 Mpa( or 100m Head)
Class 3 1.5 Mpa( or 150m Head)
Class 4 2.0 Mpa( or 200m Head)
Class 5 2.5 Mpa( or 250m Head)
Special class Above 2.5 Mpa ( or above 250m Head)
exact test pressure being specified by the
Purchaser

The steel cylinder shall be kept under pressure by pumping water for a period of not less than
1 min, and while under pressure, the cylinder shall be moderately hammered with a 1 kg hammer
throughout its length. The steel cylinder shall withstand the pressure test without showing any
leakage. Cylinders which show leakage may be rewelded at the points of leakage and subjected to a
repeat hydrostatic test and may be accepted, if it does not show any leakage.

Lining and Coating:

Reinforcement:
All cage reinforcement used in the pipe shall conform to IS 432 ( Part 1 ) or IS 432 (Part 2) or IS
2062 or its equivalent.

Concrete and Mortar

The concrete mix shall have a minimum cement content of 450 kg/m3 and a characteristic
compressive strength of 25 N/mm2 at 28 days. If mortar is used, it shall have a minimum cement
content of 600 kg/m3 and a characteristic compressive strength of 25 N/mm2 at 28days.
NOTES
1. Compressive strength test of concrete shall be conducted on150 mm cubes in accordance with
IS 516 and compressive strength test of mortar shall be conducted on 70.6 mm cubes in
accordance with IS 4031 (Part 6).
2. The water-cement ratio shall be the least that will produce a workable mix. No limit
has been set for the water-cement
ratio because the optimum ratio depends on the mix proportions, the diameter of the pipe to
be lined and coated, and the method of applying concrete or mortar to the pipe

THICKNESS AND COVER

Lining and Coating Thickness
The minimum thickness of lining and coating shall be as given in Table 2

Table 2 Minimum Thickness of Lining and Coating

S/No. Internal Diameter of Finished MinimumThickness MinimumThickness

Pipe of Lining of Coating
mm mm mm

1 200 - 250 6 25
2 300 - 500 8 25
3 600 - 900 10 25
4 1 000 - 5 000 13 25

Cover
The clear cover to the reinforcement whether steel cylinder or cage shall not be less than 9 mm for
lining and 12 mm for coating.
Cage Reinforcement
Minimum reinforcement in the coating shall be 3 percent of the quantity of steel cylinder of
minimum plate thickness given in Table 1.
The reinforcement shall be wire, wound spirally or wire fabric. The coating shall be applied b
efore any rusting occurs to thereinforcement. Longitudinal reinforcement is required in case coating
is done by vibration.
Wire
Anchoring of ends and splices in the wire shall be by welding or by other suitable means. The wire
reinforcement may be given a tension of 50 to 75 MPa while wrapping on the shell before the coating
is applied.
Wire Fabric
Splices shall be made by welding or other suitable means. The fabric shall be wrapped on the shell by
tack welding

Lining and Coating

Lining shall always be done at the manufacture’s works. While coating shall be done later either at
the manufacturer’s works or at site.
Lining shall be done by spinning or spinning combined with vibrations or vibrations.
Coating shall not commence before the expiry of three days after the completion of the lining unless
otherwise it is established that the lining has attained a works cube strength of not less than 10 MPa
earlier than this period. During this entire period the lining shall be under curing. The coating shall be
either vibrated or applied under pressure by rotary brushes or guniting.
The Elco meter is used for verifying the epoxy coating thickness.
Curing
After completion of concreting, the concrete or mortar shall be kept wet by any suitable means such
as immersion in water, covering by wet gunny bags or by mechanical sprinklers.
Note:
Curing for a period of not less than 14days when cement conforming to IS 269 (33 Grade), IS 455,
IS 1489 (Part 1 and 2), IS 8043 and IS 6909 isused; not less than 7 days when cement conforming
toIS 269 (43 Grade) and IS 8041 is used; not less than 3days when cement conforming to IS 269 (53
Grade),and IS 6452 is used and not less than 21 days whencement conforming to IS 12330 is used.

Tests to be conducted in the Field:

1.Hydrostatic Test
2.Ultrasonic pulse velocity test
3.Radiography Test

HYDROSTATIC TESTING

Hydrostatic Testing means the use of water for pressure testing a pipeline to determine its integrity
Pressure tests are performed to ensure the safety, reliability, and leak tightness of pressure systems. A
pressure test is required for a new pressure system before use or an existing 158 pressure system after
repair or alteration. There are two methods for pressure tests
1. Hydrostatic: Each steel cylinder shall be subjected to Hydrostatic test, before concreting as per IS
Code 1916: 1989 is performed by using water as the test medium.
2. Pneumatic: A Pneumatic test uses air, nitrogen, or any non-flammable and non- toxic gas.
Pneumatic tests are potentially more dangerous than hydrostatic because of the higher level of
potential energy.

Pneumatic tests may be performed only when at least one of the following conditions exists:
1. When pressure systems are so designed that they cannot be filled with water.
2. When pressure systems are to be used in services where traces of the testing medium cannot be
tolerated.

HYDROSTATIC TEST PROCEDURE :

1. Ensures the pressure gauges used have current calibration stickers.

2. Remove pressure relief valves or non-reclosing relief device from the vessel or test boundary
where the test pressure will exceed the set pressure of the valve.
3. Holds down each valve by means of an appropriate test clamp and pressurizes both sides of non-
reclosing relief devices.
4. Installs temporary, higher-rated devices where practical Installs the calibrated test gauge so it is
visible at all times.
5. Ensures the skillet blanks or test plugs or clamps are appropriate for use and are free of obvious
defects.
6. Fills and vents system as necessary to remove as much air as practical.
7. Ensures that water used for the test is at not less than ambient temperature, but in no case less than
70°F.
8. Pressurizes the system, raising the pressure in the system gradually until the designated test
pressure is achieved.
9. Maintains this test pressure for 10 minutes before inspection. Then, if test is above maximum
allowable working pressure (MAWP), reduces to MAWP while making a full thorough inspection for
leaks.
10. Ensures the metal temperature at the time of the hydrostatic test does not exceed 120°F.
11. If there is evidence of structural distortion, either rejects the system or repairs as advised by the
inspector.

12. If there is leakage in the system, Ensure for repairs or Rejects the system.
13. When the test is completed, vents the test pressure to atmosphere and returns relief devices to
normal configuration.
14. Maintain a pressure test record.
 Each section of the Steel Pipe line(including bends fabricated for field erection) Shall be tested
under hydraulic Pressure equal to 1.5 times design pressure however pressure for hydrostatic tests,
shall not exceed(i.e Pressure computed by the following formula straight pipes and bends:

P= (Yp * T) / R

P = Test Pressure in N/mm2 .

Yp = Yield Point Stress of Steel used in the Particular Coarse under test in N/mm2
T = Actual Minimum Wall Thickness of Pipe in “mm” in the Pipe Length tested.
R = Internal Radius of Pipe in “mm”

Each pipe shall be completely filled with water and Pressure shall be slowly and uniformly increased
until the required test pressure is reached. The test pressure shall be applied and released THREE
TIMES successively and after each application shall be held steady, for at least 15 Minutes or till
such time until all welded joint and plate can be examined for defects, leaks etc. Any defects in welds
or plates disclosed by the hydrostatic test shall be repaired by the Contractor to the satisfaction of the
Engineer-in-Charge. All repaired sections shall be again tested for Hydrostatically.

HYDRO TESTING OF FIELD JOINTS

Name of Work :

Date of Testing :

Joint No. From : to

Chainage From : to

Test pressure :

Remarks
Reading observed in
Time (Retention (if any leakage is identified,
Sl.No. Pressure gauge
Period) write location/joint ID)
(Kg/cm2)
From To

Calibration certificate No.:

Pressure guage No. :
Test Begin Date :
Test End date :
Validity till :
Time :

VISUAL INSPECTION OF WELD IN FIELD

 Date of Inspection:
Visual Inspection
Joint Fit
Sl.No. Chainage Pipe No. Inside Outside Remarks
No. up
welding welding

LEAKAGE TEST
This will be conducted by filling the pipeline with water from intake with the suitable types of valves
in the pump house closed. All the field joints and the expansion joints gland packing shall be
tightened with in permissible limits. If necessary, measures to prevent leakage at other location will
be taken by the Contractor.

ULTRASONIC TESTING (UT) IS 13311 (Part 1)

It is a Non-destructive testing techniques based on the propagation of ultrasonic waves in the object
or material tested. In UT applications, very short ultrasonic pulse-waves with centre frequencies
ranging from 0.1-15 MHz, and occasionally up to 50 MHz, are transmitted into materials to detect
internal flaws or to characterize materials.
A common example is ultrasonic thickness measurement, which tests the thickness of the test object,
to monitor pipe work corrosion. Ultrasonic testing is often performed on steel and other metals and
alloys, though it can also be used on concrete, wood and composites.
Ultrasonic waves are introduced into a material where they travel in a straight line and at a constant
speed until they encounter a surface. At surface interfaces some of the wave energy is reflected and
some is transmitted. The amount of reflected or transmitted energy can be detected and provides
information about the size of the reflector.
The travel time of the sound can be measured and this provides information on the distance that the
sound has travelled.

Ultrasonic inspection techniques

1. Pulse-echo and Through Transmission: Relates to whether reflected or transmitted energy is used
2. Normal Beam and Angle Beam: Relates to the angle that the sound energy enters the test article
3. Contact and Immersion: Relates to the method of coupling the transducer to the test article Note:
IS Code 4260: 2004 recommended practice for ultrasonic testing of butt welds in ferritic steel.
Ultrasonic testing and inspection of welds by direct contact pulse echo reflection method. This
method is applicable to material thickness over 5 mm.

RADIOGRAPHY (IS 1182)

Radiography is an imaging technique that uses electromagnetic radiation other than visible
light, especially X-rays, to view the internal structure of a non-uniformly composed and opaque
object (i.e. a non-transparent object of varying density and composition). To create the image, a
heterogeneous beam of X-rays is produced by an X-ray generator and is projected toward the object.
A certain amount of X-ray is absorbed by the object, which is dependent on the particular density and
composition of that object. The X-rays that pass through the object are captured behind the object by
a detector (either photographic film or a digital detector). The detector can then provide a
superimposed 2D representation of all the object's internal structures. The radiation used in
radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that
we see as visible light. The radiation can come from an X-ray generator or a radioactive source.

Note: Is Code 1182-1983 (Reaffirmed 2000 recommended- practice for radiographic examination of
fusion welded butt joints in steel plates.

RADIOGRAPHIC TECHNIQUES

Technique A -This technique is particularly intended for general application for radiographic
examination. Most applications are covered by the ‘use of this technique.
Technique B - This technique is intended for more important and critical applications, where
Technique A may not have enough sensitivity to reveal all the defects desired to be detected. In this
technique only fine-grained films or ultra-fine-grained films and lead screens shall be used. This
technique generally requires longer exposure time.

WELD SURFACE PREPARATION To simplify interpretation of radiographs, it is advisable to

remove surface irregularities before radiographic examination. In general surface preparation is not’,
necessary for radiography, but, where surface irregularities might cause difficulty in detecting
internal defects, the surface may be conditioned by any suitable process.

IMAGE QUALITY INDICATORS Image quality indicator sensitivity is a means by which the
quality of radiographic techniques used may be compared and is not a measure of Saw sensitivity as
the latter is a complex function of the geometry, absorption and location of the flaw.

IDENTIFICATION OF RADIOGRAPHS
Each section of weld radio graphed shall have suitable symbols affixed to it to identify
a) The job or work piece,
b) The joint,
c) The section of the joint,
d) Manufacturer’s name or trade-mark,
e) Date.
MARKING Permanent marking for the work piece shall be used to provide reference points for
accurate relocation of the position of each radiograph.

TECHNIQUES FOR MAKING RADIOGRAPHS Films and Screens Cassettes Alignment of

Beam Interception of Undesirable and Scattered Radiation Source-to-Film Distance/Focus-to-Film
Distance Size of Area Examined Density of Radiograph X-ray Tube Voltage and Type of Gamma-
Ray Sources Processing Viewing

RECORD OF TECHNICAL DATA Each radiograph or set of radiographs Information shall be

available on the radiographic technique used. In particular the following shall be recorded:
• Type of X-ray equipment, tube voltage and current or type of radioactive source together with its
strength and size;
• Time of ‘exposure, type of film and screen, and focus-to-film distance/source-to-film distance;
• System of marking used; and 4 position of IQI, whether source side or 5lm side.
 Do’s & Do Not’s
Sl.No Do’s Sl.No Do Not’s
1. Check for the device is having the 1. Do not allow if the required
required frequency. frequency is not available.
2. Check for the technique and use for 2. Do not deviate from the
the appropriate material. specifications
3. Check that ultrasonic instruments
and probes shall be capable of
being used without difficulty in
the temperature range of – 10 to +
50°C.
4. Check that screen height linearity
shall be measured and recorded in
accordance with IS 12666.
5. Check for ultrasonic apparatus shall
be adjusted for sweep range and
calibrated prior to inspection as
described in IS 12666
6. Check the temperature difference
between the examination and the
calibration block surfaces shall be
within 14°C
7. Check for nominal frequency
shall be in the range of 2 to 5
MHz.

ACCEPTANCE CRITERIA
Table: Characteristics compressive strength compliance requirements

Specified grade Mean of the group of 4 non- Individual test results in

overlapping N/mm2
consecutive test results in N/mm2

1 2 3
M15 ≥ fck + 0.825 x established ≥ fck – 3 N/mm2 or
standard deviation (rounded off to above
nearest 0.5N/mm2)
Or
fck + 3 N/mm2 whichever is
greater.

M20 ≥ fck + 0.825 x established ≥ fck – 4 N/mm2

standard deviation (rounded off to
nearest 0.5N/mm2)
Or
fck + 4 N/mm2 whichever is
greater.
 TECHNICAL SPECIFICATIONS
 FIELD DRY DENSITY BY CORE CUTTER METHOD

The Compaction Efficiency should be 98% as per the specifications.

 DETERMINATION OF FINENESS OF CEMENT

The Permissible Value of Fineness of Cement less than 10%.

 Fineness modulus(F.M) of Fine Aggregate(Sand).

Fineness modulus is generally used to get an idea of how coarse or fine the aggregate is. More
fineness modulus value indicates that the aggregate is coarser and small value of fineness
modulus indicates that the aggregate is finer.

Fineness modulus of different type of sand is as per given below.

Type of Sand Fineness Modulus Range

Fine Sand 2.2 – 2.6

Medium Sand 2.6 – 2.9

Coarse Sand 2.9 – 3.2

Generally sand having fineness modulus more than 3.2 is not used for making good concrete.

The Permissible Value of FM of Sand- 2.20 to 3.20.

 Percentage of Silt Content in Sand.

Silt content is a fine material which is less than 150 microns

 The Permissible Value of Fineness of Cement less than 10%.
 FLAKINESS AND ELONGATION INDEX

FLAKINESS INDEX:
The Flakiness index is the percentage by weight of particles whose least dimension
(Thickness) is less than 3/5th of their mean dimension.
ELONGATION INDEX:
Elongation Index of an aggregate is the percentage by weight of particles whose greatest
dimension (length) is greater than 9/5th times their mean dimension.

Generally, flat and elongated aggregate particles are avoided or limited to about 15 % by weight
of the total aggregate.

Flakiness and Elongation test is not applicable for aggregate sizes less than 6.3 mm

The Permissible Value of Flakiness and Elongation Index should be less than 15%.
 The Compressive strength of Cement concrete cubes

Quantity of Concrete in m³ No. of Samples

1 to 5 1
6 to 15 2
16 to 30 3
31 to 50 4
4 plus one
additional sample
51 and above
for each additional  The
50m³ or part thereof Slump obtained
should be as per the Design mix and temperature of the mix should
be between 15°C to 35°C.
Do’s and Dont’s for the Components of work
14.0.1 EXCAVATION OF CANALS:

DOS DO NOTS

1. Fix up the centre line and set the curves correctly. 1. Do not avoid approval of the deviation
2. Take working levels, real variation in ground statement.
levels and classification of soils as per Govt. Memo 2. Avoid over break and loosening of canal.
No. 1970-12/72-11, dated 4-7-1994.
3. Get top soil vegetation etc., removed. 3. Do not mixup useful soils with other soil of
cutting.
4. Provide treatment with C.N.S. soils in B.C. 4. Unsighty heaps should be avoided
reaches (Expansive soils)
5. Form spoil bank as per drawing and away from
side drain with suitable gaps for drainage into the
valley.
6. Form Dowel Bank, as per drawing.
7. Form Inspection path to a uniform longitudinal
gradient and with gentle transverse slope towards toe
drains.
8. Compact over excavation/breakage portion with
suitable soils, gravel, spalls.
 FORMATION OF EMBANKMENTS

DOS DO NOTS

1. Get the top spoil, vegetation and sand patches 1. Do not raise the bank in piecemeal
removed to complete depth.
2. Scarify the ground and wet properly. 2. Do not allow new layer without scarification and
wetting of old layer.
3. Obtain P.D OMC for the useful soils and borrow 3. Do not allow new layer unless required degree
soils. of compaction is achieved.
4. Don’t leave any loose layer unrolled at the end
4. Provide C.O.T.s according to height of bank. of the day in rainy season.
5. Raise embankment to full width with uniform 5. Don’t allow compacted layer to be more than
horizontal loose layer of 22.5 cm thickness or as per approved test section.
the approved test section/agreement.
6. Break clods, remove roots, big boulders other 6. No new layer to be laid unless the over moisture
materials etc., larger than 80mm from the soils used layer is either completely removed or allowed to
in embankment. dry.
7. Supplement deficit moisture whenever required. 7. Don’t dump soils in heaps.
8. Provide 0.45 Mtr. extra offset on both sides of
bank. 8. Don’t dump the soils in water and slush.

9. Compaction with 8 to 10 tonnes power 9. No. of roller passes shall be as per the field trial
roller/vibratory roller/sheep foot roller as the case tests to achieve required degree of compaction.
may be.
10. Do not forget to provide settlement allowance
10. Sheep foot roller compaction is mandatory for of 2.5cm/mtr. Height of bank for power roller
expansive soils, required in COT and hearting zones. compaction.
11. Conduct field compaction tests and determine 11. Don’t use expansive soils in banking.
compaction efficiency.
12. Check embankment profiles periodically.
13. Ensure 8 minimum No. of passes or no.
of passes as per the field trial tests.
14. Provide 10% allowance in setting profile of the
embankment or as per the agreement condition
LIST OF REGISTERS AND REPORTS TO BE MAINTAINED AT THE SITE

REGISTERS:

1) Site Order Register and Placement Register.

2) Register of Bench marks.

3) Register for Permeability.

4) Register for Grouting/Shot crete.

5) Register of Sieve analysis & Silt content for Fine Aggregate & Coarse Aggregate.

6) Register for Concrete Slump and Temperature,

7) Register for Compressive strength of Concrete Specimens

8) Register for Field Dry Density (FDD)

9) Level Field Books

10) Register for Reinforcement.

REPORTS:

1) Mix Designs and Test results for cement.

2) Soil Test Reports (OMC&MDD)

3) SPT Reports

4) Steel test Reports

5) HT/UT Test Reports

6) Geologists Reports

7) Acceptance Criteria for Cement concrete.

8) Standard Deviation and Control Charts.

9) Approved Drawings

10) Inspection Reports.

 LIST OF IS CODES
IS:456-2000 - Plain and Reinforced Concrete - Code of Practice

IS:516-1959 - Method of Tests for Strength of Concrete

IS:1199-2018 - Methods of sampling and analysis of concrete(Slump Cone Test)

IS:2770-1-1967 - Methods of testing bond in reinforced concrete, Part 1: Pull-out test

IS:4031-1-1996 - Methods of physical tests for hydraulic cement, Part 1: Determination of

fineness by dry sieving

IS:4031-2-1999 - Methods of physical tests for hydraulic cement, Part 2: Determination of fineness
by specific surface by Blaine air permeability method

IS:4031-3-1988 - Methods of physical tests for hydraulic cement, Part 3:Determination of

soundness

IS:4031-4-1988 - Methods of physical tests for hydraulic cement, Part 4: Determination of

consistency of standard cement paste

IS:4031-5-1988 - Methods of physical tests for hydraulic cement, Part 5: Determination of initial
and final setting times

IS:4031-6-1988 - Methods of physical tests for hydraulic cement, Part 6: Determination of

compressive strength of hydraulic cement (other than masonry cement)

IS:10262-2009 - Guidelines for concrete mix design proportioning

SP-23-1982 - Handbook on Concrete Mixes

IS:2720 -29 -1975 - Methods of Test for Soils, Part 29: Determination of Dry Density of Soils In-
place by the Core-cutter Method

IS:2386- 1-1963 - Methods of Test for Aggregates for Concrete, Part I: Particle Size and Shape

IS:2386 -2-1963 - Methods of test for aggregates for concrete, Part 2: Estimation of deleterious
materials and organic impurities

IS:2131-1981 - Method for standard penetration test for soils

IS:383-1970 - Specification for Coarse and Fine Aggregates From Natural Sources For Concrete

IS:1786-2008 - High strength deformed steel bars and wires for concrete reinforcement

IS:1916-2018 - Steel cylinder pipe with concrete lining and coating

For IS codes visit www.law.resource.org.bis