1.Quality System

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CONSTRUCTION ENGINEERS

OF



BIO - DATA

NAME : C. RAMANAIH

QUALIFICATION : 1. M. E (in Highway & Transportation)

2. Diploma in Construction Management.

3. Diploma in Transport Economics.

EXPERIENCE : 15 Years exclusively in the field of Highway

Design & Construction.



Sl. No. Date Time Topic 1 23rd August 2005 9.00 to 11.00 Quality system for Highway projects 2 23rd August 2005 11.15 to 13.00 Material and Material testing. 3 23rd August 2005 14.00 to 16.00 DBM/ BC Mix designs

4 23rd August 2005 16.10 to 18.00 DBM/ BC laying and compaction.

5 24th August 2005 9.00 to 11.00 Construction procedure and acceptance criteria.

6 24th August 2005 11.15 to 13.00 Discussions on lessons learnt.

SCHEDULE OF TRAINING PROGRAMME



Welcome

To



C. RAMANAIAH M.Tech, DCM, DTE

Presented By



What is „Quality‟?

The word ‘Quality’ is derived from Latin word Qualities‟ Which means ‘What Something Really Like’.

ISO 8402 defines ‘Quality’ as “The totality of features and

characteristics of a product or service that bear as its ability to satisfy stated or implied need”

Quality Control on Highways

QUALITY



Shall specify…


QUALITY SYSTEM

WHAT - Designer Wants WHEN - It is to be defined

WHERE - It is to be controlled

HOW - It is to be controlled/done




WHAT




WHEN - It is to be defined

- Pre - Design Stage- Design Stage

WHERE - It is to be controlled

- Construction Stage- Maintenance Stage

HOW - It is to be controlled/done

- Construction Manual- Quality Control Manual- Systematic approach- Knowledgeful Staff



A Document which describes the things (Q.C) to do. Manual

should describe the following…

DUTIES & RESPONSIBILITIES OF STAFF

OPERATIONAL PROCEDURES DESIGN PROCEDURE

SAMPLING & TESTING PROCEDURE

CALIBRATION PROCEDURE

SAMPLE FORMATS

ACCEPTANCE CRITERIA OF TEST RESULTS

STAFF TRAINING SCHEDULERS

Quality Control – Manual


HOW



Quality Control is required to ensure the achievements of thedesired quality in a product.

Unsatisfactory Riding Quality Failure of Pavements & Bridges Reduced Service Life

Mounting Maintenance Bills Increased VOC

LACK OF QUALITY LEADS TO…

QUALITY CONTROL REQUIRED?


WHY



WHO IS RESPONSIBLE FOR QUALITY

THE DESIGNER

THE OWNER

THE SUPERVISOR

THE CONTRACTOR





THE DESIGNER

In the designer stage project shall be taylored, by considering the following things…

Size of the Project

Availability of Raw Material

Available Quality of Raw Material

Past history of Road behaviour in the region

Cost of the Project (Economical Feasibility)



Periodic Revision of Specifications ?? Documents of QA for Bridges & Roads

Manuals for Design, Construction & Maintenance System for Pre Qualification Engagement of Consultants for design & Construct supervision

Steps taken for Quality improvement in

Indian Highway Construction…


THE OWNER

Steps to be Taken…

Regional based specifications Performance based Tendering Procedure Training to the Project Staff before start of Project In-time handing over



Knowledge of Contract Management

Construction Procedure

Thorough knowledge of Technical Specifications

Good Education & Experience

Practical exposure


THE SUPERVISOR



WHAT IS REALITY?

In Reality it is the contractor on whom 75% of

Quality Depends….

The rates at which contractor gets the work

Time delay due to QC

Availability of Necessary Equipments

Knowledge of importance of QC

Education/Training

Cost to do Quality Control




Production

Q u a t i t y

Q u a t i t y

Production

M a x . E

f f i c i e n c y

Modern EquipmentQuality control process

Relation Ship between Production Vs Quality

Relation Ship between Production Vs Quality

(Conventional method)

(By adopting modern techniques)

Production Vs Quality



TIME SAVING TECHNIQUES OF ROUTINE TESTINGS

One point method of MDD & OMC

One point method of LL & PI

Use of Penetration Chart to find grade of Bitumen

Nuclear Density Gauge for field compaction control

Nuclear Asphalt content gauge

Electronic Water Testing kit Sieve Analysis by dry sieving.




ONE POINT METHOD FOR DETERMINING MDD & OMC

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

2.1

2.2

2.3

0.0 5.0 10.0 15.0 20.0 25.0

Moisture Content

D r y D e n s i t y




PENETRATION - TEMP CHART FOR BITUMEN

1

10

100

1000

0 5 10 15 20 25 30 35 40 45 50

Temperatureoc

P e n e t r a t i o n i n 1 / 1 0 m m

Pen-30 Pen-39 Pen-60Pen-70 Pen-80 Pen-103Expon. (Pen-30) Expon. (Pen-39) Expon. (Pen-60)

source: Indian Highways No vember' 19 97




Rapid verification of asphalt content

(%AC) of paving mixtures sampled at

the asphalt plant, lab or paving site,

prior to placement and compaction.

Asphalt Content Gauge

Portable Water Quality Tester

Provides completely portable

method of water quality testing.




Things that influence the quality of Work?

1. Material

2. Machinery 3. Man

Correctness of results depends on:

1. Correctness of Equipment Used

2. Level of Test Method Followed

3. Person Doing The Test




Correctness of equipment being used

Some of the equipment that need calibration


CALIBRATION

All weights and balances

Measuring jars

Thermometer

Dial gauges & Proving rings

All weighing sensors of plants like WMM, HMP,BP All Nuclear devices, Field Density Operations, etc.



Level of Test Method Follows



Person doing the Test



What Stages Quality Control is to be done?

1. Material Selection Stage

2. Processing Stage3. Finished Stage

TYPES OF QUALITY CONTROL

PROCESS CONTROL

END RESULT CONTROL

Quality Control – Stages & Types




Registration

Test Requests

Sampling Field Testing

Preparation

Testing Distribution of Test Results

Storage of Samples

Decision

Filing/Computer Database

Laboratory Operational Procedure




MATERIALS

ACCEPTABL

E

(Q.C)

SUITABILITY

OTHER WORKS

MIX DESIGN

(IF REQUIRED)

PROCESS

ACCEPTABLE

(Q.C)RECTIFIABLE REJECT/

REMOVE

END

PRODUCT

REJECT

Yes

Yes

Yes

Yes

No

No

No

No

QUALITY CONTROL PROCESS

Flow Chart




Selection of soils

Suitability of foundation soils

Field compaction soils

Major Item of Road Works and their

KEY QUALITY CONTROL POINTS…

a. Embankment & Sub Grade

Quality Control – Road Works




Soil Compaction

The basic factors that determine

compaction results in soils are… • The type of soil

• Its water (moisture) content

• The compaction method & applied

energy

A soil material consists of

three elements:

Soil Particles, Water and Air.




Selection of Aggregates Blending of Aggregates

Checking for suitability of blended Aggregates

Compaction

Line & Level Checks

b. Granular Sub Base & Wet Mix Macadam




AGG. %

SIZE 37.5 26.5 13.2 4.8 2.4 0.3 0.1 BLEND 37.5 26.5 13.2 4.8 2.4 0.3 0.1

40 100.0 73.8 2.3 0.0 0.0 0.0 0.0 15.00 15.0 11.1 0.3 0.0 0.0 0.0 0.0

20 100.0 99.6 11.3 0.3 0.0 0.0 0.0 23.00 23.0 22.9 2.6 0.1 0.0 0.0 0.0

12 100.0 100.0 97.3 2.8 1.4 0.0 0.0 20.00 20.0 20.0 19.5 0.6 0.3 0.0 0.0

q/d 100.0 100.0 100.0 82.9 55.3 18.6 1.9 38.00 38.0 38.0 38.0 31.5 21.0 7.1 0.7

Filler 100.0 100.0 100.0 100.0 100.0 99.0 49.7 4.00 4.0 4.0 4.0 4.0 4.0 4.0 2.0

TOTAL 100.0 96.0 64.4 36.2 25.3 11.0 2.7

AVEG. 100.0 95.0 68.0 44.0 32.0 11.0 4.0

SPEC. L/L 100 90 56 29 19 5 1

SPEC. U/L 100 100 80 59 45 17 7

SIEVE SIZE (in mm) SIEVE SIZE (in mm)

DBM BLENDING HOT BIN PROPORTION

Aggregate blending chart For DBM

0

10

20

30

4050

60

70

80

90

100

110

0.0 0.1 1.0 10.0 100.0

Sieve size in mm

% P a s s i n g

upper limit lower limit design gradation max density gradation




Sieve Analysis

Sieves are used to analyze the gradation

(grain size distribution) of a sample.The amount of material remaining on

Each sieve is calculated as a percentage

Of the total weight of the sample.




Type of Material (Cut back/Emulsion) Property of Material

Application Temperature

Rate of Spreading

Penetration/Bonding

c. Prime Coat & Tack Coat




Selection of Materials

d. Bituminous Works

Aggregate Bitumen (Plain Bitumen/CRMB/PMB) Filler (Recycled/Lime/Cement)

Design of Job Mix Formula

Stability Flow

VMA VFB Air Voids Density Loss in Stability

KNR – PATEL (JV)




KNR – PATEL (JV)

TEST PROPERTY CURVES FOR HOT-MIX DESIGN DATA BY MARSHALL METHOD

Stability Vs Bitumen Content

500

900

1300

1700

3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1

Bitumencontent in %

S t a b i l i t y i n k g

Unit Wight Vs Bitumen content

2.400

2.450

2.500

2.550

2.600

3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1

Bitumencontent in %

U n i t w e i g h t i n g / c c

Flow vs Bitumen content

2.00

2.50

3.00

3.50

4.00

4.50

5.00

3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1 5.4Bitumencontent in %

F l o w i n

m m

Air Voids Vs Bitumen content

1.4

2.4

3.4

4.4

5.4

6.4

3.3 3.6 3.9 4.2 4.5 4.8 5.1 5.4

Bitumencontent in %

A i r V o i d s i n %

VMA vs Bitumen content

12.00

13.00

14.00

15.00

16.00


V M A i n %

VFB Vs Bitumen content

40.00

50.00

60.00

70.00

80.00

90.00


V F B i n %




KNR – PATEL (JV)

Bitumen

content by

wt. of total

mix %

Stability

in Kgs

Unit

Wight

in g/cc

Flow

in

mm

VMA

in

%

VFB

in

%

3.60 1322 2.477 2.8 13.80 53.99

3.90 1599 2.494 3.2 13.46 59.29

4.20 1681 2.499 3.5 13.56 66.00

4.50 1700 2.501 3.6 13.76 70.28

4.80 1480 2.508 4.0 13.80 75.72

5.10 1428 2.518 4.6 13.72 81.78

VFB

VMA

Air Voids

Flow

Stability

%Bitumen 3.6 3.9 4.2 4.8 5.1

2.50

Selection Of The Narrow Range Of Acceptable Bitumen Contents

Abstract of Marshal Mix Design Test Values

Air Voids

in %

6.40

5.50

4.5

Passes all criteria

4.60

4.10

3.40

Index:

Low

High

Passing




Influence of Gradation on Mix

Segregation More Air Voids

High VMA Low VFB


Coarser grading leads to

More flow Slippery Surface

Blending Low Stability Low Air Voids

Finer grading leads to



Things to Remember while doing Job Mix Formula

Select proper grading advisable slightly coarser side

Air Voids shall not be too low, should not be high(by considering Secondary Compaction)

VFB (Voids Filled with Bitumen)

Stiffness Factor





PLANT CONTROLS

Bitumen Content

Temperature of Aggregate

Temperature of Bitumen

Mixing Temperature

Type of Mixing

Type of Loading

l l h




SITE CONTROLS

Laying Procedure

Laying Temperature Compaction Procedure

Degree of Compaction

Rolling Temp

Q li C l Hi h



MIX SEGREGATION

If the material level is too high,it will slope towards the outeredges where stones can separate.

The segregated strip in the

middle of the lane is caused by the auger drive unit located atthe centre of the augers.


Q li C l Hi h



Temperature of the Bituminous mix during differentoperations are to be checked to control them withinthe following specified limits…

Sl.No Operations Range

1 Temperature of Binder at the time of mixing 150o C to 163o C

2 Temperature of Aggregate at the time of mixing 155o C to 163o C

3 Difference in aggregate & Bitumen <14 o C

4 Discharge temperature of mix from the mixer 130o C to 160o C

5 Temperature of mix at the time of laying 120o C to 135o C

6 Minimum temperature of mix at the time of rolling 100o C


Q lit C t l Hi h



ROLLING PROCEDURE A rolling pattern consisting of three parallel rolling lanes divided into zones,normally 30-50 m long. In each zone the roller moves forward and backwardthe required no.of passes.

The roller strokes (the distance the roller movesfrom the point at which it changes direction

behind the paver to the change in direction at theend of the lane) thencover two zones.


Q lit C t l Hi h



Compaction is a process by which the Soil/Aggregate particles an

artificially rearranged and packed together into a closer state of

contact by mechanical means in order to decrease the porosity

(on Air Voids)

• Static Roller

• Vibratory Roller

• Pneumatic Roller

• Tampers


COMPACTION

Type of Compaction available

Q lit C t l Hi h



STATIC Compaction• Static compaction uses the dead weight

of the machine to apply pressure.

• Static equipment will normally achieveadequate compaction in the upperlayers.

• Owing to the bridging of the soilparticles it is limited in depth effect.

In the static compaction,only pressure is exerted on

the underlying surface


Qu lity Control on Highw ys



VIBRATORY Compaction• Vibratory compactors deliver a rapid

succession of impacts to the underlying surface.

• This virtually eliminates the internalfriction and facilitates therearrangements of the particles intopositions that result in as low a void

space and as high a density as possible

• The increase in the no.of contactpoints between particles leads to highstability and strength.

Vibratory compaction

combines static pressure and

dynamic force





PNEUMATIC TYRED ROLLER

The compaction effect of pneumatictyred roller is primarily determinedby two parameters…

- Wheel Load

- Ground contact pressure of Tyre

Pressure contact area overlap. A part from the individual pressure bulbs,

there is an interaction of the pressure bulbs to give greater depth effect

Tyre overlap





Compaction On Minor Jobs

There is a wide range of light compaction equipment available for

use on minor jobs and in confined spaces. These vibratory plate

compactors, vibratory tampers, double-drum walk behind rollers

and lightweight tandem Rollers also complement larger types of

rollers where these machines do have full access.

few more…





Compaction On Minor Jobs





Core Drilling Apparatus

Nuclear Gauge

The normal method for field density

control is to remove a core sample with

a diamond drill. Density and air void

content are determined on the samplecores in Laboratory.

Nuclear gauges gives a rapid

reading of the density of an asphalt

surfacing


TESTING OF DEGREE OF COMPACTION




Riding Quality (unevenness)

Skid Resistance

Avoid Core Cutting in finished layer toavoid potential Pot Holes

Quality Control for Finished Work





The surface evenness is measured by running a straight edge over

the finished surface. Irregularities are shown up on the gauge






“Quality Is Not Outcome Of Accident;

It Is The Resultant Of Persistent Hard Work By Conscientious People”



T h a n k Y o u