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    19 views46 pages

    Materials Engineering Reviewer Bureau of Research and Standards Part 1 PDF

    Uploaded by

    Juan Ako

    Copyright:

    © All Rights Reserved
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    of 46
    il. TX. VI. VIL VIL. IX Table Of Contents Introduction eee Soil and Soil Aggregates = ------—- Conerete Technology Miscellaneous Products Asphalt Technology sips, DPWH Minimum Requirement -~--——- DPWH Flyers Review Questions Answer Key 30 66 7 119 148 DUTIES OF A MATERIALS ENGINEER 1. To ascertain that all materials incorporated into the work poss the requirement of DPWH Standard Specification for Highways, Bridges and Airports and to strictly comply with the schedule of rainimum testing requirement. 2. To advise tl 2 project engineer on the acceptance or rejection of construction materials intended to use in the project. 3, Recommend to the project engineer remedial measures for the correction of unsatisfactory condition of materials. 4, To prepare design mixes for concrete and bituminous mixtures. 5. Tocnsure the samples are properly cured by standard procedures 6. To fully acquaint himself with the standard procedures of sampling, testing and quality control of materials. 7. To see that the field laboratory is adequately equipped such that the progress of work will not impeded to laboratory testing and that non-pecformance of test should not be the cause of delay in the prosecution of project. 8. To keep 2 record logbook of his daily activities ready for inspection at anytime. 9. To submit within the required time frame test reports and other pertinent papers. 10. To sce-to it that quality of completed projects are attained as per DPWH standards. MATERIALS QUALITY CONTROL DOCUMENTATION & TERMINOLOGIES Quality Control Program- a program of quality control works prepared by the Materials Quality Control Division of the Regional Office and the MQC Section of the District Office to be complied by the contractor. Contents: Ttems af Work 10 be done Description of work Units and quantities, Number of test in each item of work Sample Cards Prepared by the DPWH, District or Regional MQC Field Density Test Report if pavement is being constructed | Prepared by the Contractor's project engineer concurred by the DPWH PE and verified correct by j the MQC Concrete Pouring Permit/Pouring Slip Prepared by the Contractors project engineer and approved by the Project Engineer. Dept. Order No. 211 ser 2000 states that in order to ensure that all concreting works are done in accordance with the approved plans and specifications, it is hereby directed that no contractor shall start eny concreting without a pouring permit duly approved and issued by the Project Engineer. Concrete Pouring Report Prepared by the contractor's PE, To be submitted every time concreting activity is done, Do not forget to fill up the portion where information is given if cylinder or beam samples are taken. 1 Testing Refers to the process of making tests to determine the degree of compliance of delivered or constructed materials with the specifications. Test Results- conducted either at the regional or district level. Reinforcing bars, cement, angle bars, paints, galvanized sheets, pipes Monthly Materials Report To be prepared by the contractor and submitted every 25" of the month, Contents: Summary report of laboratory and ficld tests (grading, FDT, complex tests, inspection report, certification) submitted to MQC with transmitial letter. Materials Logbook Contents: Materials activity during the day (pouring and sampling) Information on samples taken Information if samples are tested Materials delivered on site MATERIALS QUALITY CONTROL POLICIES/ADMINISTRATIVE ISSUANCES Onder No. Date | Subject 1.DONo.206 | ‘00 Amendment to DO 184, series of 1999, re-Guidelines on the Accreditation of Contractors’ & Consultants Materials Engineer 2.DONo.14 | 199 Adoption of DPWH Standard Specifications for Public Works and Highways 1995 Edition Vol Il in the implementation of all Infrastructure Projects 3, DO No. 184 99 Guidelines on the Accreditation of Contractor's and Consultants’ Materials Engineers 4.DMCNo.03 | 99 Standard Specification for Chemical Admixtures for Concrete $.DONO.14 = [99 Adoption of DPWH Standard Specifications for Public Works and Highways, 1995 edition 6,DONo. 127 |97 Guidelines for Re-coring of Concrete Pavement and Concrete Structures for Strength Determination 7T.DONO.115 | 195 Use of High-Early Strength Concrete in the Construction of National Roads and Major Exchanges 8, DONo. 29 9, DONo 83 10, DO No. 139 11, DONo, 119 12, DMC No $ 13. DO No. 57 14. DO No. 55 15, DO No. 34 16, DMC No. 83 17.DMC No, 97 18, DONo 13 19. MO No 28 20, MC No. 38 21, MC No. 33 22. MC No. 80 ‘92 ‘92 ‘92 “1 ‘91 ‘91 Utilizing first the services of the Bureau of Research and Standards, Regional & District Laboratories in testing of samples of construction materials Testing of construction materials intended for regular maintenance projects. Correcting projects with noted defects/deficiencies prior to partial or fall payment. Thickness determination for concrete and asphalt paversent Proper edging on Forms and joints of concrete pavement ‘Testing and acceptance of cement Use of different brands or same brand of cement in concrete constriction ‘Use of Fly Ash in Conerete Mix Proper construction and secling of join's of concrete pavement Borehole filling after core drilling operation on newly constructed concrete and asphalt pavement Sampling and Testing of Construction Materials Guidelines on the submission of samples Circular about certificate of Quality Control Assurance Contractor is required to provide quality control personnel and Cully equipped laboratory building Order for all materials men to keep 2 logbook on Materials Quality Control. MINIMUM REQUIREMENTS FOR SUBMISSION OF SAMPLES | 9. Conerete Hollow Blocks (complete) a. Strength b. Moisture ‘sontent Steel bar Steel Sheet (Galvanized) 12. Wire ~Strand Strap 13, Gabion 14, Paints 10, nL. 15, Joint Filler (Pre-mold) 16. Curing Compound 17. Concrete Cylinder 18. Conerete Beam 19. Conerete Core 20. Asphalt Cores 21. Water Analysis ‘a, Chemical analysis b. Sediment Load 22. Structural Stee! sheet (5) per 10,000 units 1 (3) per 10,000 kg or 10 tonnes. 1{3) per 1,000 sheets 1 set of 3 cylinders for @ 75 eum 1 stor beans fr Scot ny outing 6 cores for every kilometer 1 core for every 100 meters | (5) per 50 tonnes MATERIALS MINIMUM TESTING MINIMUM QUANTITY/VOL. OF REQUIREMENTS MATERIALS FOR EACH SAMPLE SUBMITTED 1. Cement 1 sample per 2000 bags 1okg 2. Asphaltic materials | 1 (s) per40 Tennes or 200 drums} §L 3. Asphat Mi 1,(s) per 130 Tonnes 20 kg (Complete) 4. Aggregates UG) per 1500 ev.m a. Coarse 70g, aggregate b. Fine 50 ke agree 3. Soil aggregate 1 (5) per 1500 cu.m a. Classification 20 ky b. Routinary 50 kg tests c. Moisture 50 kg density Relation & CBR 6. Non-reinfoxed 2 Pipes min/0.5% of No. of Pipes | 2 pipes Concrete Pipe 7. Reinforced Concrete | 1 (5)/50 pipesor 2% of No. pines | 1 pipe ( 1 m length) Pipe 8. Steel Pipe 1 (3) per 500 length 2 pes of 100mm long taken from both (Galvanized) ends w/o thread units 3 units 2 units I meter 1 gheet 2 meters Imx 2m 1 (41 cans) | @OL cans) 1(400 sm x 400 mum) titer 1 set of 3 cylinders (6" x 12") 500 mi 500 mi Reduced section as prescribed MINIMUM REQUIREMENTS FOR SUBMISSION OF SAMPLES ON SOILS, AGGREGATES & OTHER MISCELLANEOUS CON’ TRUCTION MATERIALS. MATERIALS MIN TESTING | MIN. QTY. SAMPLE REQUIRED TEST REQUIREMENTS FOR SUB Soil & Soil exzresates | Embankment V(s)per 1500eum | 20 kg. Grading, PL-LL,Compaction Aggregate Subbase | 1(3) pe 300cum — | 20 kg Grading & PL-LU | 16) per 1500cum — | 50 kg Grading, PL-LL, Compaction V(s) per 2500cum — | SO ke. CBR Test Aggregate Bare same as above- -same as above- -same as above excepi with course Abrasion Test Aggregate Surface | 1(s)per300cum — | 20 kg Grading & PLL Course 14s) per 1500eu. M_ | 50 kg Grading, PL+LL. & Abrasion Test Grading, PL-LL,Stripping & Bulk Composite 1(s) per 15¢0cu.m | 50 kg. Sp. Gr,Grading, Wash test, Sp.Gr, Aggregates ‘Absorption, Coarse Aggregate §— | 1(s) per 1500cum — | 70 kg ‘Abrasion, Soundness & Unit Weight ine aggregates, Hs} per 1500 cum — | 30 kg Same as above except with Mortar ‘Strength, Organic Impurities & % Clay Lumps Concrete & Conersie Products Gone, Beam Lacie banepe 7.1m | tastorateamedss6%20") | Flexural Strength Cone. Cylinder Lreiot ctindesper Ee! | tact of) eyinder (outcry | Compressive strength Cone, Hollow Blocks Conc, Pipes sce Materials Steel Bars(Doformed & Rounded) Guard raila( Structural Stoel) Gabion/Mauress wiros Gil shoots Pain 1 {s) per 20,000 units -do- 1 (5) per pipes (6) per 10,000 kg, 1 (5) per $0 tons Nis) per each, sourceist ipment 1 (3) per 1000 sheets 1 (5) per 100 cans 6 units 3 units 1 pipe I meter each size 1 Reduced section 1(s)of LOm x 2.0m sheet |-4L Cans OL Cans Sirengih Absorrton (ets & Dimension Strength test & Dimension Strength & Absorption Test ‘Tensile strength, Elongation, Vari Phosporous content ‘Tensile strength, Dimension & ine coating Tensile strength, Dimension & mension, Zine costing & coating Bend Test Quality Test odo QUALITY CONTROL AND ITS SIGNIFICANT QUALITY CONTROL FORMULA HQ (M+W) = (HO+E) $ Where HQ 7 High Quality M-= Materials W > Work E= Economical $= Structure Introduction Quality Control is an essential part of engineering practice and is vital to the development of better public works, highways or other infrastructures. It is necessary when one party, the builder/contractor, does work for another party, the owner. ‘The owner is the individual or company who has need for a structure but does not have the ability it himself, So he hires another party 10 do it from him. The other party is the contractor, also an individual or company, who builds for others for a fee. The owner determines the standards of quality since he pays the bills. Quality requirements are zeflecied in the plans and specifications which are prepared by on engineer hired by the owner. The con:ractor is responsible to conform to the requirements set by the owner, ‘The two then enter into a contract, including the plans and specifications which contains, among others, the agreed-upon requirements and the compensation to be paid. The requirements are two-fold, fone involving the quslity and the other, quantity. In designing an engineering structure, the materials selected shall hi 'e the desired quality to withstand the forces to which the structure will be subjected during its life sy 1, In addition these moterials should be used in such quantity and in such a way that the cost of the t.ructure will be as small as possible, All steps taken during construction to ensure an end-production which will possess the agreed-upon quality constitute what is known as quality control. ‘What is Quality? Quality is degree of excellence. It is described by such general terms as stable, durable, rigid or flexible. Some equate it to cost, others to comfort or elegance. However, quality for different Individuals may vary since it is influenced by factors such us economics, esthetics, safely. oF performance level, Quality is a judgment by the customers or users of a product or service, it is the extent to which the customers or users fee! the product or service surpasses their needs and expectations. The terms Quality is that characteristic of a product that provides a level of performance in terms of service and life “quality” does not mean “perfect” ‘What is control? Control is to regulate. 11 is usually used in relation to weight, population, or prices it is instituted when. there is need to check or regulate due to some important, compelling reasons. What is Quality Control? Quality control is checicing for conformance to requirements. It is now widely and increasingly used in the construction industry itis instituted during the course of construction as a preventive tool, not as a conective measure, Preventive measures are always more economical What is Assurance? ‘Assurance is degree of certainty. Quality assurance is a function of the owner to verify that the work is done in accordance with specifications. Some call it acceptance inspection. Quality Contro! Work Quality control work consists of all work elements carried out by the manager or by those in this organization, which contribute to the quality of the output of the organization Quality Assurance Work Quality assurance work consists of all work elemenis carried out by the manager or by those in this organization, which contribute te the quality of the output of some other organtzation Purpose ‘The purpose of materials quality control is to ensure the highest quality of work and exiend the service life of any structure by constructing according to the prescribed plans and specifications. The plans indicate the specific type of the structure and the specifications present the characteristic in which it is to be bulld, as well as the materials that are to be incorporated into the work. thor purpose 1 to check: and regulate the use of construction materials, and to economize on the cost of conatructlan. Fulfilling these requires adequate control of materials prior t and after placing to thelr final posltlon In the structure, The extent of controlling the required materials depends on the nature and Imits of the work, the specification requirements and local conditions. Normally, every material should be subjected to testing, inspection and verification before accepiance. ‘The Modern Concept of Quality Contro! Jn the past, quality control inspection in a construction project was regarded as a police action {0 ensure compliance and minimize neglect of the requirements. This concept is ironic considering that reat sos {8 placed on the importance of awarding a contract to the most qualified and Temponall |dder and then to itnply that he carot be relied upon to perform his obligation. Recently, a new concept of quality control has emerged. It is a joint effort of the two parties involved and it calls for a two-fold program, namely: 1, Quality control by the contractor 2, Quality assurance by the owner. In this concept, quality control is a system which involves the joint but independent efforts of the ‘owner and the contractor to achieve the level of quality desired by the owner as established in the project specifications. It is a check and balance system, The contractor's tesk is to regulate, test and inspect his procedures, equipment, materials, and ‘manpower so that the completed facility will comply with the requirements. ‘The owner's task is to verify thet the contractor's quality control system is functioning and the completed structure or part of the structures is of the specified quality ‘This concept Is to place basic responsibility for quality control in the contractor. It requires catablishment by each contractor of a working quality control organization with responsibility for rupervision and Inspection at all levels of the work. Control of the quality of work should be rocogalzed by any well-meaning contractor as his inherent responsibility whether or not itis steted in the contract doouments, Contractors should be willing to accept this responsibility, On the other hand, the owner or his representative should refrain ffom interfering with the contractor's. His work should ‘be confined {o check or verification tests or inspection only when it has been ascertained that there havo boen deviations from the quality control program and the specified quality is not being produced. Quality Control! Procedures 1, Selection of Materials Information regarding the lovation of materials sources that will be incorporated into the work may be represented by the following: fa. Raw materials such as soil, sand and bank or river gravel (with litle or no processing). b, Materials that are processed without basically changing their properties, such as washed manuftotured sand, crushed rock and gravel, and etc. 6, Manufactured materials such as bituminous materials, cement, paint, structural and telnforelng stoc!. 4, Combination of materials that may be partly or totally manufactured, such as bituminous and Portland cement concrete. Materials to be procured or obtained from selected portions of any area of materials sources such ‘ts tntntioned above should be known in advance so that the required test can be made or arrangement for tenting the materials involved may be done to avoid unnecessary delays in eomatruetten due to rejection of unacceptable quality of materials. Tinilag ‘and Storage of Materials ing and atorage of delivered construction materials should be carefully end properly planned 4@ avold damage and maintain the desired quality. It should be placed or deposited in a safe place from eontamination or the action of weather. The proposed source of materials to be thould be sooesslble to the project. Condition for acceptance of materials 2. No materials shall be incorporated into the work until tested and found satisfactory . The approval of preliminary saciples shall not be considered as a guarantee of acceptance of all materials from the same source, as to the quality or quantity of such materials © Any materials which had becn sampled and passed as satisfactory may be resampled and retested anytime before, during and after incorporation into the work 3. Sampling and Testing of Materials Quality control is checking for conformity to the requirements. That is, conformance to materials specifications and methods of construction, or workmanship. Quality control therefore, includes all Procedures which are necessary to insure that the materials used and workmanship employed conform to the standard of quality specified. & Quality Control Program (QCP} To facilitate quality control, a program of quality control works to be complied by the Contractor is prepared by the DPWH. The plan includes provisions on how the work and materials should be inspected and the nature and amount of testing to be done, An example of a quality control rogram is shown in Annex A, Likewise, the DPWH provides a team to monitor the quality control activities in the project, like: sampling, testing, laboratory procedures, equipment calibration and quality control reporting Minimum Testing Requirements- are prescribed in each project based on estimated quantities. The requirements specify the kind and number of tests for each item of work. Testing is done as the materials are being incorporated into the work. [1 should be emphasized that what are specified arc the minimum number of testing only, The owner can therefore, require more test if he is in doubt of the quality of materials or the finished structure. ¢. Pretestin’: of manufactured materials such as cement, asphalt, and steel bar. Sample re obtained at the factory and tested at the laboratories. Upon verification, the protested materials are ready for used upon delivery at jobsite. 4, Proper Construction Methods/Procedures a, Establish a working quality contro! organization with responsibility for supervision and inspection at all levels of work. . Construction method should be done according to each item of work indicated in the design. ¢, To sce to it that materials used pass the required specification prior to incorporation to the project. d, Continuous quelity contro! inspection on all items of work shall be done as construction progresses . ; 8, To assign technical and capable personnel to oversee the implementation during construction mage ‘To p90 10 it that needed equipment is aveilable "To e¢o to it thet there is no scarcity of supplies to materials to be used in the project 6, Inspection and Monitoring Different types of construction deman¢ different types and degree of inspection, Emphasis on the initial and early operations is essential. One, the equipment and operations are producing the desired quality; occasional checking may be done to assure continuous satisfactory results, However, vertical structures demand more constant scrutiny or verification due to the greater variety of materials and worked involved, Future results are less predictable on this type of work, ‘Therefore, ins sectors assigned in the ficld should be competent, experienced, and committed to publie service. Thcy should also be familier with the approved plans and specifications and various DPWH issuances relative to quality control and construction, ‘The purpose of inspection is to ensure that the materials and workmanship provided by the contractor company with the requirements of the project. In general, properly applied inspection/monitoring the project will help in ensuring that: the requiremeats of the contract documents will be carried out. The use of unacceptable substitutes will be avoided. Making errors that might result to unnecessary maintenance cost will be avoided. Extra work will be minimized. Materials and workmanship that are guaranteed will be evaluated at the time of installation, panos Soll- refers to the unconsolidated mineral materials at or near the carth’s surface which consist of air moisture and other organic substance which maybe incorporated therein and which have resulted from natural process such as decay, weathering and other chemical action. 3 classes of Soil 1, Geological Class «2, Sedimentary or transported b residual Bill 2. Pedological Class 3. Engineering Class I is divided and classified into 3 groups: 1, Granular or coarse grained soil ‘a, Grevel or stone - rounded or anguler passing 7Smm (3") sieve retained in the 2.0mm (#10) sieve b. Sand = passing 2.0mm (#10) sieve retained in 0.075(#200) sieve 2. Fine-grained soil — passing 0.075 (#200) sieve .Silt- particles passing 0.075mrsm (1/200) sieve but larger than 0.002 mm sieve b. Clay- materials/particles passing 0.002 mm sieve but larger than 0.001 mm sieve c. Colloids — particles smaller than 0.001 mm sieve 3. Organic Soils - dark color, foul odor, due to the presence of decompose plant matter. ENGINEERING PROPERTIES OF SOIL, a. C anular or coarse grained. soil 1, Good load becring quality 2. Permeable ~ easy to drained, water easily absorb. 3. Comparatively incompressible under static load, however loose granular materials may Undergo a considerable change in volume, when subjected to vibratory load. 4. Not subjected to change in strength & volume due to variation to water content. b. Fine-grained soil 1. Poor load bearing quality 2. Impormeable 3. Compressible under sustained load 4, Subjected to change in strength & volume due to variation in water content. ¢. Organic Soil Inferlor than fine-grained soil as to the properties stated, natural M.-C. is 100% MS$7-80 (1996) Standard Specifications for Materials for Embankments and Subgrades

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