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JMC Projects (I) Ltd.

Laboratory
Manual

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Reference: Matrix of Documents, Rev no: 14,
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Issued Date: 27th August, 2011.
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Management Representative: ______________________


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JMC Projects (India) Limited


Registered & Corporate Office
A-104, Shapath-4
Opp. Karnavati Club
S.G. Road, Ahmedabad - 51
JMC Projects (I) Ltd.

JMC PROJECTS (I) LTD


QUALITY POLICY
We, at JMC are totally committed to customers’

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expectations in terms of quality of work and services.

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We strive for excellence through continual
improvement in all areas of operations.

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QUALITY OBJECTIVES
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1. Continual improvement in business processes to meet with ever
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changing expectations of customer.
2. Complete projects within stipulated time schedule with desired
quality.
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3. Enhance capabilities of our people through continuous training and


development programs at all levels.
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4. Observe and adhere to Environmental, Health and Safety standards


with the goal as “Zero-Accident” on site.
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5. Allocate and utilize financial and physical resources in the most


efficient & effective manner.
6. To develop our vendors and sub-contractors to enhance their
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capabilities with a view to providing Quality services.

Suhas Joshi Hemant Modi


Managing Director Vice Chairman

Date: 9th July, 2008


JMC Projects (I) Ltd.

Laboratory Manual
INDEX
Document No. Contents Page Number
QMP-LB-01 Scope 2
QMP-LB-02 Activity Flow Chart 1
QMP-LB-03 Standard List Of Lab Equipments 1
QMP-LB-04 Standard List Of IS Codes at sites 1
QMP-LB-05 Calibration of Laboratory equipments 3
QMP-LB-06 Checking Procedure for Theodolite 1
QMP-LB-07 Temporary / Permanent adjustment of Theodolite 3
QMP-LB-08 Calibration Procedure for weight Batcher 1
QMP-LB-09 Calibration Procedure for Batching Plant 1

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QMP-LB-10 Frequency of Calibration of Equipments 1
QMP-LB-11 List of test to be carried our for various materials 1

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QMP-LB-12 Determination of specific gravity 2
QMP-LB-13 Dry Density by Core Cutter Method 1
QMP-LB-14 Dry density using proctor apparatus 1
QMP-LB-15 Sieve Analysis of Aggregate 1
QMP-LB-16 Determination of silt content in sand 1

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QMP-LB-17 Aggregate impact value 1
QMP-LB-18 Aggregate Crushing Value 1
QMP-LB-19 Flakiness Index 1
QMP-LB-20 Compression test of bricks
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QMP-LB-21 Water absorption for bricks 1
QMP-LB-22 Compression test of blocks 1
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QMP-LB-23 Water absorption for blocks 1
QMP-LB-24 Density of blocks 1
QMP-LB-25 Compressive strength test for concrete 1
QMP-LB-26 Slump test 1
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QMP-LB-27 Fineness of Cement 2


QMP-LB-28 Standard Consistency of cement 1
QMP-LB-29 Setting time of cement 1
QMP-LB-30 Soundness of cement 2
QMP-LB-31 Compressive strength test of cement 2
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QMP-LB-32 Calibration procedure for Level Machine 1


FCN-LB-01 Record of Calibration of Measurement & test equipments 1
FCN-LB-02 Record of Calibration of Batching Plant 1
FCN-LB-03 Record of Calibration of Weigh Batcher 1
FCN-LB-04 Determination of Specific Gravity 1
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FCN-LB-05 Determination of Dry Density by Core Cutter method 1


FCN-LB-06 Determination of OMC / MDD by proctor test 1
FCN-LB-07 Determination of Fineness Modulus of Sand 1
FCN-LB-08 Test Report for Coarse Aggregate – F.M, I.V., C.V., F.I. 2
FCN-LB-09 Test Report for Brick – Water Absorption , strength 1
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FCN-LB-10 Determination of Compressive Strength of Concrete 1


FCN-LB-11 Record of Verification of Material used prior to inspection 1
FCN-LB-12 Test Report of Cement 1
FCN-LB-13 Test Report for Solid / Hollow Block 1
FCN-LB-14 Record of verification of customer supplied product 1
FCN-LB-15 Rolling Margin of Steel 1
FCN-LB-16 Weekly Review Report 1
FCN-LB-17 Frequency of test / checks 3
FCN-LB-18 Material Submittal For Approval 1
FCN-LB-19 Analysis of Cost of Quality 1
FCN-LB-20 Standard Deviation 1
FQM-XX-08 Communication Channel – QC Dept. 3
JMC Projects (I) Ltd.
Doc. No. QMP-LB-01 (R1) Date: 18/03/2009 Page 01 of 02

Scope :-

This manual covers procedure to establish site laboratory, testing procedures, calibration
procedures, Steps for preparing PSQP, approved material list, sample approval, identifying
nonconforming material and its disposition, etc.

Establishing Site Laboratory:

1. Study the requirements related to testing equipments if given in tender by customer. If any

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test equipment is not in our standard list, raise indent for the same.
2. Check the condition of lab. equipments received at site and arrange for minor purchase /

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repair if require.
3. Install all equipments at appropriate location.
4. Display laminated work instructions for each test activity.
5. Provide instruction board to write lab test and sample to be collected from site.
6. Construct water tank to facilitate at least 126 cubes for 7 days and 504 cubes for 28 days test

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or according to the no. of sample to be cast for entire site.
7. Maintain laboratory always clean and dust proof.
8. Collect printed stationery books from RO.
9. Establish filing system as required for inspection & testing.
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10. Collect reference manuals and IS codes from RO.
11. Collect / carry out initial calibration reports for instruments.
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Preparation of Quality plan / Approved Material List / Sample approval:

1. Prepare Project Specific Quality Plan. It shall include approved material source / brand
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mentioned in contracts. It should cover frequency of check of each activity at various stage of
work. Procedure of site specific activities / general activities etc should be covered in PSQP.
For important / critical / special activities Method Statement to be prepared.
2. Visit all near by sources and collect / test samples for material approval.
3. Prepare the list of approved source of material based on test conformance.
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4. Prepare approved brand list as mention in contract and include RO approved brand, which is
not specified in contract document, for approval from client.
5. Collect sample of all approved material progressively and keep it in identified sample room /
laboratory.
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6. Collect literature /catalogues for special materials / construction chemicals, etc,.

Mix Design:

1. Identify grades of concrete for which mix design is required and collect related data from the
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tender specifications / IS codes, etc.


2. Discuss about mix design establishment procedure with client / consultants.
3. Take trials at site for verification.
4. Establish mix design based on trial mix results.
JMC Projects (I) Ltd.
Doc. No. QMP-LB-01 (R1) Date: 18/03/2009 Page 02 of 02

Testing of Incoming Material:

1. When ever store receives any material, they will inform or send materials to laboratory. Store
person will get concurrence for visual or instant check based on the test report / visual
inspection by QC staff.
2. Signature for Quality check shall be done randomly on material receipt which is to be used
for project site. Brand material like steel, cement etc. shall be checked with approved brand
list and manufacturer test results. In case of not receipt of any TC, it shall be got tested at
external / internal laboratory for verifying its conformance.

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Regular Material Test / Identify nonconforming materials

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1. Plan and display test status on instruction board daily for monitoring purpose.
2. Carry out building materials tests as per the set frequency.
3. Follow all test procedure / instruction given in display and manual.
4. Display the status of test to identify the approved materials at site and store by means of using

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display board like ‘MATERIALS TO BE TESTED’ / ‘REJECTED’ or ‘SCRAP’, if there is
no such display it means that material lot is approved for use.
5. Collect and send samples to external laboratory if testing facility is not available for some
materials at our site laboratory. d
6. Collect information about quantity of material received from the store and conduct test as per
the established frequency.
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7. Inspect and collect test report or conduct test for special work vendors’ material purchased by
them.
8. Conduct test for construction activities like concreting, filling etc.
9. Conducting tests for raw material of intermediate product (like RMC) supplied by the
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suppliers on random basis.

Monitoring of High Performance Concrete (M-40 & above)

1. At any project where M 40 and above grade of concrete is applicable prior approval of Mix
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Design from Management Representative is to be taken. M 40 grade concrete shall be


initiated only after approval for Mix design by Management Representative.

2. A fortnightly report of all cube results for concrete grade above M-40 to be sent to MR and
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RO-QA/QC dept.

In case of failure of any grade of concrete cube results

1. Incidences of cube failures for any kind of grade of concrete must be highlighted immediately
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and action for expert opinion / NDT must be initiated within 24 hours for applicable
component of structure. Incidence of cube failure shall be informed to Regional head & MR
without fail within 24 hours.

2. After 3rd recurring failures of test results of compressive strength of cubes, production of that
grade of concrete shall be immediately suspended and thorough investigation of the case shall
be started immediately. The production shall be started only after resolving the problems.
JMC Projects (I) Ltd.
Doc. No. QMP-LB-02 (R0) Date: 18/02/2003 Page 01 of 01

Activity Flow Chart for Laboratory

Receipt of Lab Equipment

Source Approval for Bldg Prepare approve material /

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Material Brand list – by study of tender

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documents / client approval

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Mix Design (Out side /
Internal) as approved by
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Calibration of lab.
Equipments / Measuring
equipments after receipt
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Material Receipt by Testing of incoming material


Store dept
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Sampling / Testing of
materials receipt at site as
per set frequency
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Identify Non conforming


material & maintain trace-
ability at site in case of any
non conformance / Inform to
store dept for action
JMC Projects (I) Ltd.
Doc. No. QMP-LB-03 (R3) Date: 09/10/2010 Page 01 of 01

Standard List of Laboratory Equipment

Sr. Name of Equipment


No.
1 Electronic Balance – Capacity 10 Kg , Accuracy – 1 gm
2 Platform Balance – Capacity 100 Kg , Accuracy – 50 gm
3 Concrete Cube Moulds (30 Nos) with tamping rod Size – 150 mm X150 mm 30 nos
4 Vicat Apparatus
5 Mortar cube moulds (9 Nos) with base plates – Size 70.6 mm X 70.6 mm

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6 Aggregate impact test apparatus
7 Aggregate Crushing test apparatus – 150mm dia

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8 Measuring cylinder – 1000 ml
9 Measuring cylinder – 500 ml
10 Measuring cylinder – 100 ml
11 Flakiness index gauge

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12 Slump Cone apparatus with measuring rod
13 Sieves for Coarse Aggregate – G.I. 18” dia. (63 mm, 50 mm, 40 mm, 31.5 mm, 25 mm,
20 mm, 16 mm, 12.5 mm, 10 mm, 8 mm, 6.3 mm, 4.75 mm, 2.36 mm) - Set of 13.
14 Sieves for Fine Aggregate – Brass sieve (4.75mm, 2.36mm, 1.18mm, 600 micron,
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300micron, 150 micron, 75 micron, lid & pan) - Set of 8.
15 Pycnometer bottle
16 Electric Oven O/S M.S. & I/S Aluminum - Size – 18” X 18”
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17 Cube testing machine - Capacity 2000KN or 200MT
18 Thermometer 00 -- 250 0 C
19 G.I. Tray – 45 cm X 45 cm
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20 G.I. Tray – 45 cm X 60 cm
21 Dolly & Rammer for core cutter
22 Core cutter -03 Nos
23 Procter compaction mould with light rammer of 2.4 Kg
24 Vernier caliper – 200 mm X 0.02 mm
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25 Wire Gauge
26 Le –Chatelier’s mould – (Optional)
27 Vibrating machine for cement cube moulds – ( Optional)
28 90 micron sieve for cement test
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JMC Projects (I) Ltd.
Doc. No. QMP-LB-04 (R5) Date: 27/08/2011 Page 01 of 01

STANDARD LIST OF IS CODES AT SITES

27th August 2011

Sr. Code No. Name of IS Code Year Rev. Amen-


No. No. dment
No.
1. IS 383 Specification for coarse and fine aggregates from natural 1970 2 -
sources for concrete

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2. IS 456 Plain and Reinforced Concrete - Code of Practice 2000 4 3
3. IS 516 Method of tests for strength of concrete 1959 - 2

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4. IS 1077 Common burnt clay building bricks – Specification 1992 5 1
5. IS 1199 Methods of sampling and analysis of concrete 1959 - -
6. IS 1489 Specification for Portland pozzolana cement Part 1 Flyash 1991 3 5
(PART - 1) based

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7. IS 1542 Specification for sand for plaster 1992 2 -
8. IS 1786 High strength deformed steel bars and wires for concrete 2008 4 -
reinforcement- Specification
9. IS 2212 Code of practice for brickworksd 1991 1 -
10. IS 2250 Code of Practice for Preparation and Use of Masonry 1981 1 -
Mortars
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11. IS 2386 Methods of Test for Aggregates for Concrete - Part I : 1963 - 4
(PART-1) Particle Size and Shape
12. IS 2386 Methods of test for aggregates for concrete Part 3 Specific 1963 - -
(PART-3) gravity, density, voids, absorption and bulking
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13. IS 2386 Methods of test for aggregates for concrete Part 4 1963 - 3
(PART-4) Mechanical properties
14. IS 2386 Methods of Test for Aggregates for Concrete - Part V : 1963 - -
(PART-5) Soundness
15. IS 2386 Methods of test for aggregates for concrete : Part 6 1963 - 2
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(PART-6) Measuring mortar making properties of fine aggregates


16. IS 2502 Code of Practice for Bending and Fixing of Bars for 1963 - -
Concrete Reinforcement
17. IS 2720 Methods of Test for Soils - Part 29: Determination of Dry 1975 1 -
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(PART-29) Density of Soils In-place by the Core-cutter Method


18. IS 3495 Methods of tests of burnt clay building bricks: Part 1 1992 3 -
(PART-1 Determination of compressive strength Part 2
to 4) Determination of water absorption Part 3 Determination of
efflorescence Part 4 Determination of warpage
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19. IS 3535 Methods of sampling hydraulic cement 1986 1 -


20. IS 4082 Recommendations on stacking and storage of construction 1996 2 -
materials and components at site
21. IS 4926 Ready-Mixed Concrete - Code of Practice 2003 2 1
22. IS 8112 Specification for 43 grade ordinary Portland cement 1989 1 9
23. IS 9103 Concrete Admixtures - Specification 1999 1 2
24. IS 10262 Guidelines for concrete mix design proportioning 2009 1 -
25. IS 12269 Specification for 53 grade ordinary Portland cement 1987 - 9

Note: These codes are available at all sites. Additional project specific codes are issued from
Regional / Head Office as per requirement.
JMC Projects (I) Ltd.
Doc. No. QMP-LB-05 (R2) Date: 27/08/2011 Page 01 of 03

Calibration of Laboratory Equipment

The calibration of equipments means comparison of the accuracy of the equipments with the
approved standards. This includes validation.
The calibration of equipments to be done in-house is:
• Compression testing machine
• Weigh Batcher

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The equipments to be used for the purpose of calibration will be vernier calipers, measuring tape,
calibrated weights, etc. These equipments must be calibrated against National Indian standards

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which in turn will calibrate equipments at various sites.

The equipments which require calibration from outside agency are as under:
• Weights

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• Proving ring / Dial gauges
The external agencies which will carry out calibration are Bureau of weights and measures,
ERDA, NPL & other government authorised laboratories.
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1. IS 516 & 10086

Cube moulds - 15x15x15 cm3


Height & distance + 0.2 mm, angle 90o + 0.5o
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Internal plane face variation - + 0.03 mm


Tamping bars - 16mm dia & 0.6meter long & bullet pointed
Testing machine - metal bearing plates < 6.5mm > 19mm thk (10x10cm2)
2. IS 2386 (Part 3)
Pycnometer - Capacity 0.5 to 1 kg jar
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Accuracy + 0.5 ml , 6mm dia hole at apex


3. IS 1199
Slump cone - Bottom dia - 20 cm
Top dia - 10 cm
Height - 30 cm
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Thick - at least 1.6 mm


Tamping rod - 16mm dia & 0.6m long rounded at one end

4. IS 2386 (Part 1)
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Thickness gauge
Length Depth Length Depth
100 33.90 50 10.80
90 27.00 40 8.55
80 19.50 35 6.75
70 16.95 25 4.89
65 13.50
1.6 mm thick sheet rolled over 8 mm dia handle
JMC Projects (I) Ltd.
Doc. No. QMP-LB-05 (R2) Date: 27/08/2011 Page 02 of 03

5. IS 5640
Aggregate Impact Value
Total wt not more than 60 kg not less than 45 kg. Machine with metal base - weighing 22 to 30
kg, Cylindrical steel cup (internal dimension) - 6.3 mm thk, 102 mm dia, 50mm deep
Hammer - 13.5 to 14 kg
100 mm dia
50 mm long
2 mm chamber
Drop height - 380 + 5.0 mm
Cylindrical measure - 75mm dia, 50 mm deep

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Tamping rod - 10 mm dia, 230 mm long

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6. IS 9198
Compaction rammer
Light rammer - 2.6 kg + 25 gm fall height - 310 + 0.5 mm
Heavy rammer - 4.9 kg + 50 gm fall height - 450 + 0.5 mm
Mould for modified proctor test - 100 mm dia & 1000 cm3, 150 mm dia & 2250 cm3

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7. IS 10080
Mortar cubes - 70.6 mm x 70.6 mm
Tamping rods - 10 mm dia, 600 mm long, Hemispherical tip with 10mm dia
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8. IS 2720 (Part 29)
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Core cutter - 130 mm long,
10 cm dia - internal diameter
3 mm thickness
Dolly - 2.5 cm high
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100mm internal diameter


108 mm dia
115 mm dia
Rammer - Staff length - 900 mm
Height - 75 mm
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Diameter - 140 mm
9. Balance Sensitivity
Tolerance
10 kg - 100 gm
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1 kg - 1 gm
250 gm - 0.01 gm

10. IS 9376 - Aggregate crushing value


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Cylindrical cell
Internal dia - 150 mm +/- 0.5 mm
Height - 130 to 140 mm
Wall thickness - 15 mm ( min )
Plunger
Dia. Of piston - 148 +/- 0.5 mm
Dia of stem - 100 to 145 mm
Height - 100 to 115 mm
Depth of piston - 25 mm
Dia of hole - 20 mm
JMC Projects (I) Ltd.
Doc. No. QMP-LB-05 (R2) Date: 27/08/2011 Page 03 of 03

11. IS 5513

Vicat apparatus

Needle for determining initial setting time


Dia - 1.13 mm +/- 0.05 mm
Effective length – 50mm +/- 1 mm
Needle for determining final setting time
Dia - 1.13 mm +/- 0.05 mm
Effective length – 30 +/- 1 mm

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Circular cutting edge – 5 +/- 0.1 mm

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Plunger dia – 10 +/- 0.05 mm

Vicat mould – internal dia – 70 +/- 5 mm at the top


- 80 +/- 5 mm at the bottom
height – 40 +/- 0.2 mm

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Thickness of the mould – min. 4 mm

12. Oven : Oven is used at site for drying purpose only , So No calibration / Validation is
required. d
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JMC Projects (I) Ltd.
Doc. No. QMP-LB-06 (R1) Date: 09/10/2010 Page 01 of 01

CHECKING PROCEDURE FOR THEODOLITE :

HORIZONTAL CIRCLE CHECK AS UNDER:

1. Set circle reading 0 - degree, 0 - minute, 0 - second.


Point sighted ‘x’ approx. 30 meters away from instrument.

2. Telescope reversed, point sighted ‘y’ approximately 15 meters away from the instrument.

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3. Alidade rotated through 180 degree 0 - minute, 0 - second sighted point ‘x’
again.

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4. Telescope reversed, it automatically sighted point ‘y’. Error - nil.

VERTICAL CIRCLE CHECK AS UNDER

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1. Sighted telescope at a clearly defined object. (Point ‘x’ approximately 30 meters away
from the instrument )

2. Vertical circle reading was 90 degree, 0 - minute, 0 - second.


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3. Reversed telescope, rotated Vertical circle through 180 degree, sighted same point.
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Vertical circle reading was 270 degree 0 - minute, 0 - second, hence error - nil.

CHECK BY INCLUDED ANGLES OF A TRIANGLE


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1. Set Theodolite at point ‘A’ of a triangle.


2. Sight point ‘B’ & set reading of horizontal plate to 0 ° 0 ′ 0 ″.
3. Rotate Theodolite to point ‘C’. Measure included angle ‘A’
Lets call it ∠ A.
4. Set Theodolite at point ‘B’ of the triangle.
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5. Sight point ‘A’ & set reading of horizontal plate to 0 ° 0 ′ 0 ″.


6. Rotate Theodolite to point ‘C’. Measure included angle ‘B’.
Lets call it ∠ B.
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7. Same way measure angle ‘C’. It is ∠ C.


8. Now ∠ A + ∠ B + ∠ C should be 180 ° 0 ′ 0 ″.
9. Tolerance of 1 least count of Theodolite can be allowed. So, in case of 20 second
Theodolite
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∠ A + ∠ B + ∠ C ≅ 180 ° 00 ′ 00 ″ +/- 00 ′ 20 ″.
= 179 ° 59 ′ 40 ″ to 180 ° 00 ′ 20 ″

in case of 1 second Theodolite


∠ A + ∠ B + ∠ C ≅ 180 ° 00 ′ 00 ″ +/- 00 ′ 01 ″.
= 179 ° 59 ′ 59 ″ to 180 ° 00 ′ 01 ″
JMC Projects (I) Ltd.
Doc. No. QMP-LB-07 (R0) Date: 18/02/2003 Page 01 of 03

TEMPORARY ADJUSTMENTS OF THEODOLITE

There are three temporary adjustments of a Theodolite as follows:


1. Setting up the Theodolite as follows:
2. Leveling up
3. Elimination of parallax

1. Setting up
This adjustment includes the following 2 operations

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a. Centering the Theodolite over a station
b. Approximately leveling it by the tripod legs only

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To setup the instrument over a station:

i. Place the instrument over the station by spreading the legs of the tripod well apart, in such
a way that the telescope is at a convenient height, the plumb bob is approximately over

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the station mark and the leveling head is approximately in level.
ii. Lift the instrument bodily without disturbing the relative positions of the legs and move it
so that the plumb bob hangs about 2 cm above and within 1 cm horizontally of the station
mark. d
iii. Now, to bring the plumb bob exactly over the station mark and to approximately level the
instrument, move each leg radially as well as circumferentially. Press the legs firmly into
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the ground.
iv. The instrument is said to be centered over the station when the plumb bob hangs exactly
over the station mark. If the instrument has a shifting head, the plumb bob should hang
about 2 to 3 mm above the station mark.
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2. Leveling up
Leveling up the instrument means to level it accurately with reference to the plate levels
by means of leveling screws so that the vertical axis is truly vertical. Leveling up is done
as follows;
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i. Turn the instrument about one of its axes so that the longer plate level is parallel to any
pair of leveling screws. The other plate level will then be parallel to the line joining the
third screw and the mid point of the line joining the first pair.
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ii. Bring the bubble to the center of its run by turning both the leveling screws uniformly.
iii. Similarly, bring the other bubble to the center of its run by turning the third leveling
screw.
iv. Repeat the process until both the bubbles are exactly centered.
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v. Now rotate the instrument about the vertical axis through a complete revolution. If the
plate levels are in correct adjustment each bubble will remain in the center of its run. The
vertical axis will be then truly vertical.
JMC Projects (I) Ltd.
Doc. No. QMP-LB-07 (R0) Date: 18/02/2003 Page 02 of 03

3. Elimination of parallax
The parallax is said to be eliminated if the image formed by the objective lies in the plates
of the cross hairs. It is done in two steps as follows:

i. By focusing the eye piece.


The object of focusing the eyepiece is to make the cross hairs distinct and clear. To focus
the eyepiece directs the telescope towards the sky or holds a piece of white paper in front
of the object glass. Now move the eye piece in and out until the cross hairs are seen quite
distinctly and clearly.

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ii. By focusing the object glass
The object of focussing the object glass is to bring the image of the object formed by the

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object glass in the plane of the cross hairs. To focus the object glass directly the telescope
towards the object and turn the focussing screws so that the image appears sharp and clear
lying in the plane of cross hairs.

PERMANENT ADJUSTMENT OF THEODOLITE

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1. To make the axis of each plate level perpendicular to the vertical axis.

Test. d
Rotate the instrument about the vertical axis until each level tube is parallel to a pair of
opposite leveling screws. Center the bubbles by means of leveling screws. Rotate the
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instrument end for end (by 180 degree) about the vertical axis. If the bubble remains
centered the axis of each plate level is perpendicular to the vertical axis.

Correction.
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If the bubbles do not remain centered, then bring them half way back by means of
adjusting screws. Level the instrument again and repeat the process to verify the result.

2. To make the line of collimation at right angles to the horizontal axis.


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Test.
Level the instrument and sight on a point A about 200 m away with the telescope normal.
By clamping both the horizontal motions of the instrument, plunge the telescope and set
another point B on the line of collimation and about the same distance away on the
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opposite side of the instrument. Unclamp the upper motion, rotate the instrument end for
end about the vertical axis, and again sight at A with the telescope inverted. Clamp the
upper motion. Plunge the telescope as before. If B is on the line of collimation, then the
line of collimation is at right angle to the horizontal axis.
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Correction.
If B is not on the line of collimation then set a point C on the line of collimation beside B.
Mark a point D one quarter of the distance from C to B and adjust the cross hair ring until
the line of collimation passes through D.
JMC Projects (I) Ltd.
Doc. No. QMP-LB-07 (R0) Date: 18/02/2003 Page 03 of 03

3. To make the vertical cross hair lie in a plane perpendicular to the horizontal
axis

Test.
Sight the vertical cross hair on the well-defined point at a distance of 60 m approximately.
Clamp both the horizontal motion of the instrument and swing the telescope through a
small vertical angle, so that the point traverses the length of the vertical cross hair . If the
point appears to move continuously on the hair, the cross hair lies in a plane
perpendicular to the horizontal axis.

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Correction.
If the point appears to depart from the cross hair, loosen the two adjacent capstan screws

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and rotate the cross hair ring in the telescope tube until the point traverse the entire length
of the hair. Now tighten the two screws.

4. To make the line of sight coincide with the optical axis:

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Test.
Set two pegs, one about 10 m and the other about 100 m from the instrument. Clamp the
vertical motion and take a rod reading on the distance point, and without disturbing the
vertical motion read the rod on the near point. Plunge the telescope, rotate the instrument
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about the vertical axis and set the horizontal cross hair at the last rod reading with the rod
held on the near point. Sight to the distant point. If the first and last reading on the distant
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rod is the same, the line of sight coincides with the optical axis.

Correction.
If the first and last readings are not the same, then move the horizontal cross hair by
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means of the upper and lower adjusting screws until it has apparently traversed over
several times the apparent error. Repeat the process, gradually reducing the movement of
the cross hair as the rod reading to the distant point approach each other, until by
successive approximations the error is reduced to zero.
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5. To make the vertical circle read zero when the telescope bubble is centered.

Test.
This adjustment is only for those transits, which have fixed vertical verniers, with the
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plate bubbles centered, center the telescope bubble and read the vernier of the vertical
circle.

Correction.
If the vernier does not read zero, loosen it and move it until it reads zero. Care should be
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taken that the vernier will not bind on the vertical circle as the telescope is rotated about
the horizontal axis.
JMC Projects (I) Ltd.
Doc. No. QMP-LB-08 (R0) Date: 18/02/2003 Page 01 of 01

CALIBRATION PROCEDURE FOR WEIGH BATCHER

1. Clean weigh bucket properly.

2. Check weigh batcher is leveled.


ƒ The lever would rest at the zero mark in the perfect horizontal level. If lever does not
remain against the zero mark, check the level of the unit by placing spirit level on the
frame.
3. Put known weight of 50 kg (calibrated) in the weigh bucket.

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4. Note down the reading on the lever arm by adjusting the indicator (jockey weight) to set
lever arm horizontally.
ƒ The difference between the actual weight noted down & 50 kg should not be more
than 1 % of 50 kg i.e. 500 gms.

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5. In case of more variation bring it with in limit (i.e. 1 % of the weight ) by adjusting nuts
provided in the weigh batcher.

6. The weigh batcher then shall be checked for least count by putting known weight
d
equal to its least count.
lle
7. The weight batcher shall also be tested for sensitiveness by adding equal loads of 5 kg
and then ascertaining that an additional load equals to this weight i.e. correctly indicated.

8. Check the calibration up to the weight equal to normally put for a batch of cement ( i.e.
tro

approx. 150 – 200 Kgs. )

9. Carry out the same procedure for both the weight bucket and lever system.
on
nc
U
JMC Projects (I) Ltd.
Doc. No. QMP-LB-09 (R1) Date: 18/03/2010 Page 01 of 01

CALIBRATION PROCEDURE FOR BATCHING PLANT

BHAI BATCHING PLANT

Weighing system of aggregate, sand and cement is cumulative in weigh hopper and reading
display through dial gauge. Water is measured through in line water meter.

1. Clean the weigh hopper and ensure the knife edges and levers are free from cement, dust etc.
Ensure that the weigh hopper is resting on the knife edges freely and no external supports.

y
2. Read the dial gauge and set to zero.
3. Place the standard weigh of 50 kgs x 2 Nos and read the dial gauge and record the same.

op
4. Add the standard weights in the same denomination up to the required cumulative weight and
record the dial gauge readings.( loading )
5. Remove the weights of same denominations one by one and record the reading up to zero.
( unloading )
6. The setting of correct weighment can be adjusted by the adjusting screw provided in the rear

C
of the dial gauge.

OTHER BATCHING PLANTS


d
Weighing system is independent for aggregate & sand in skip cum weigh hopper, cement in
cement weigh hopper on the top of plant and water in weigh hopper on the top of plant.
lle
All the weigh hoppers are resting on the load cells separately and the reading will be displayed in
the Electronic Panel Board inside the operating cabin.
tro

1. Clean the weigh hopper and ensure that the same rests freely on the load cells.
2. To have visual check on load cells and ensure that the position and electrical connections
are intact.
3. Energise the electronic control panel inside the operating cabin.
4. Place the standard weights of 50 kg x 2 nos in the skip cum weigh hopper for sand &
on

aggregates and read the display in the Electronic Panel. (loading)

5. Add the standard weights in the same denominations up to the required weights for
aggregates and sand and record the readings.
nc

6. The correct weighment setting can be adjusted from the Electronic Control Panel Chord
by feather touch operations of the relevant keys on the respective panel.
7. Remove the weights of same denominations one by one and record the readings up to
zero. ( unloading )
8. Repeat the same procedure for cement and water separately with 20 kgs and 10 kgs
U

standard weight respectively.


9. The weighment display as per the standard weights kept in the concerned weigh hopper
should be within the tolerance limit. If erratic display is shown even after resetting, it is
to be taken up and rectified by the manufacturer.
JMC Projects (I) Ltd.
Doc. No. QMP-LB-10 (R4) Date: 27/08/2011 Page 01 of 01

FREQUENCY OF CALIBRATION OF EQUIPMENTS

Sr. Name of the equipment Elements for Calibration Frequency of calibration


No. calibration Agency
1 Theodolite Vernier plates Site Yearly
2 Leveling Instrument -- Site Yearly
3 Measuring Weights / Weighing External Agency Yearly

y
instruments capacity
4 Cube Testing Machine Pressure/ load HO/RO / Yearly or change of site

op
gauge External Agency
5 Batching plant Dial gauge / load Site Monthly or change of
shell site
6 Weigh Batcher Weighing scale Site Monthly or change of

C
site
7 Total Station -- External Agency Yearly

Note: These frequencies are indicative. In case of intermediate deviations or repairs,


d
immediate calibration shall be undertaken.
lle
tro
on
nc
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JMC Projects (I) Ltd.

Doc. No. QMP-LB-11 (R0) Date: 18/02/2003 Page 01 of 01

List of test to be carried out for various materials

Sr. Material List of tests


No.
1 Soil For building works
1) Maximum dry density and optimum moisture content
by proctor test if applicable

y
2) Field density by core cutter test if applicable
3) Specific gravity if applicable

op
2 Coarse Aggregate 1) Specific gravity if applicable
2) Fineness modulus
3) Crushing value
4) Impact value
5) Flakiness Index

C
6) Water absorption if applicable
3 Fine aggregate 1) Fineness modulus / gradation
2) Silt content

4 Bricks d
3) Bulkage if applicable
4) Specific gravity if applicable
1) Dimension
lle
2) Compressive strength
3) Water absorption
5 Concrete 1) Slump Value
tro

2) Compressive strength
6 Concrete Block 1) Compressive strength
2) Water absorption
3) Density of Block
7 Cement 1) Fineness
on

2) Standard consistency
3) Setting time
4) Soundness
5) Compressive strength
nc

8 Steel 1) Rolling margin


2) Elongation (external agency )
3) Ultimate tensile strength (external agency )
4) Proof stress (external agency )
U

5) Bend test if applicable (external agency )


6) Rebend test if applicable (external agency )

This list is tests which are carried out generally, actual test requirement should be decided by site
qc engineer as per project requirement.
JMC Projects (I) Ltd.

Doc. No. QMP-LB-12 (R1) Date : 09/10/2010 Page 01 of 02

Determination of specific gravity

Ref. : IS 2386 (PART III), 1963

Purpose : To find out specific gravity of aggregate

y
Aggregate between 40 mm & 10 mm

op
Salient features of apparatus :

(a) Balance, capacity of not less than 3 kg with least count of 0.5 g
(b) Oven
(c) Glass vessel or jar of 1.5 litre capacity

C
(d) Tray

Procedure :

d
(a) Screen the sample on 10 mm IS sieve, wash it thoroughly to remove fine
lle
particles of dust.
(b) Immerse the sample in glass vessel for 24 +/- ½ hours between 220 to 320 C.
(c) Soon after immersion and again at the end of the soaking period, gently rotate
the vessel in clockwise and anticlockwise direction, so that air entrapped in or
tro

bubbles on the surface of the aggregate gets removed.


(d) Overfill the vessel by adding water and slid glass disc over the mouth.
(e) Dry the vessel from the outside and weigh (weight A).
(f) Empty the vessel. Refill it with only water. Slid the glass disc in position as
on

before. Wipe out water from outside wall of vessel and weigh (weight B).
(g) Difference in temperature in vessel during 1st and 2nd weightings should not be
more than 20 C.
(h) Surface dry the aggregates using dry cloths. When it appears that aggregate
nc

are completely surface dry, take weight (weight C)


(i) Place the aggregate in the oven in shallow tray, at a temperature of 1000 to
1100 C for 24 +/- ½ hours. Cool them and weigh (weight D)
U

Calculation : Specific Gravity G = D / (C – (A – B))


JMC Projects (I) Ltd.

Doc. No. QMP-LB-12 (R1) Date : 09/10/2010 Page 02 of 02

Aggregate smaller than 10 mm

Salient features of apparatus :

(a) Balance, capacity of not less than 3 kg with least count of 0.5 g
(b) Oven
(c) Pycnometer bottle
(d) Glass vessel or jar of 1.25 to 1.50 litre capacity

y
(e) Tray

op
Procedure :

(a) Take sample of about 1 kg (10-4.75 mm ) or 500 g (finer than 4.75


mm). Place in the tray and immerse in water at temperature of 220-

C
320 C for 24 +/- ½ hours.
(b) After immersion, gently agitate with rod to remove entrapped air
bubbles on the surface of aggregate.
(c)
d
Drain the sample carefully thru a filter paper. Return any material
retained on filter paper to the sample. Expose the aggregate
lle
including any solid matter retained on the filter paper to evaporate
moisture. Stir the sample at frequent intervals. Weight the
saturated and surface dry sample. (weight A)
(d) Place the aggregate in pycnometer which filled with water.
tro

Eliminate any trapped air by rotating pycnometer on its side,


covering hole of apex with finger.
(e) Top up pycnometer with water so that surface of the water in the
hole should be flat. Wipe out water from outside of pycnometer
on

and weigh (weight B)


(f) Empty the contest of pycnometer in to tray, take care that all the
aggregate are transferred. Refill pycnometer with water to the same
level, wipe out water from outside of pycnometer and weigh
nc

(weight C). Difference in temperature of water in the pycnometer


during 1st and 2nd weighing should be more than 20 C.
(g) Drain water from sample thru filter paper. If any material retained
on filter paper, return to sample. Place the sample in oven at a
U

temperature of 1000 to 1100 C for 24 +/- ½ hours. Stir occasionally


them to facilitate drying. When cooled in air tight container, weigh
(weight D)

Calculation : Specific Gravity G = D / (A – (B – C))


JMC Projects (I) Ltd.

Doc. No. QMP-LB-13 (R0) Date : 18/02/2003 Page 01 of 01

Dry Density By Core Cutter Method

Ref. : IS 2720 (PART XXIX), 1975

Purpose : To find out the dry density of compacted soil in field.

y
Salient Features Of Apparatus :

op
(a) Dolly : Inner Diameter : 100 mm
Outer Diameter : 115 mm
Height : 25 mm

(b) Cutter : Inner Diameter : 100 mm

C
Outer Diameter : 106 mm
Height : 130 mm

(c) Rammer :
d Length
Diameter
:
:
900mm
140mm
lle
Procedure :

(a) Find the volume in cm3 and weight of the cutter in gms.
tro

(b) Expose about 30 cm2 of ground area and level it.

(c) Put the dolly on the top of the core cutter and drive assembly into
the soil with the help of the rammer until top of the dolly protrudes
on

about 1.5 cm above the surface. Detach the core cutter from the
surrounding soil.

(d) Trim flat end of the cutter.


nc

(e) Keep some representative specimen of soil for moisture content


determination.
U

(g) Find out dry density by using the following formula :

γb
DRY DENSITY γ d = ------------
1+ω
Where :
γ b = Bulk Density
ω = Moisture Content
JMC Projects (I) Ltd.

Doc. No. QMP-LB-14 (R1) Date : 09/10/2010 Page 01 of 01

Dry density using proctor apparatus

Ref. : IS 2720 (PART VII-1980/VIII-1983)

Purpose : To find out moisture- density relationship of soil .

Salient features of apparatus :

y
(a) Mould for compaction: Diameter : 100 mm

op
Height : 127.3 mm
(b) Rammer : Diameter : 50 mm
Length : 310 mm
Weight : 2.60 kg + 25 g
(light)

C
4.90 kg + 50 g
(heavy)
Procedure :

(a)
d
Weigh 5 kg of air dried soil sample .
lle
(b) Add 10% water less than estimated optimum moisture content
(O.M.C.) in the soil.
tro

(c) Keep in air tight container for 16 hours.

(d) Fill the soil in mould in three layers.


on

(e) Each layer should be compacted with 25 blows with the help of
rammer dropped from height 310 mm (light) / 450 mm (heavy).

(f) Remove the collar and trim off the surplus soil.
nc

(g) Weigh the mould and calculate bulk density.

(h) Repeat the procedure with addition of 2% more water upto the
U

estimated value of O.M.C.

(i) Calculate dry density and draw a curve showing the relationship
between moisture content and dry density.

(j) Mark the points of maximum dry density (M.D.D.) and O.M.C. on
the curve.
JMC Projects (I) Ltd.

Doc. No. QMP-LB-15 (R0) Date : 18/02/2003 Page 01 of 01

Sieve Analysis Of Aggregates

Ref. : IS 2386 ( PART I) , 1977

Purpose : To determine the gradation of aggregates / fineness modulus of


aggregates.

y
Procedure :

op
(a) Prepare the sample for testing from a larger sample by quartering
or by mean of the sample divider.

(b) Weigh the air dried sample and successively sieve on the
appropriate size starting with the largest.

C
(c) Shake each sieve separately over a clean tray until not more than a
trace passes.

(d) d
Brush lightly with a fine camel hair brush on the 150μ (micron)
lle
and 75μ sieves to prevent blocking of the apertures.

A typical format for tabulating the result is given below:


tro

IS. Sieve size Retention % Cumulative Cumulative


weight in g Retention % retained % passing
63 mm
40 mm
on

20 mm
10 mm
4.75 mm
2.36 mm
nc

1.18 mm
600 μ
300 μ
U

150 μ
PAN

Sum of cumulative % retained


FINENESS MODULUS =
100
JMC Projects (I) Ltd.

Doc. No. QMP-LB-16 (R0) Date : 18/02/2003 Page 01 of 01

Determination of silt content in sand

Purpose : To determine the silt content in sand.

y
Procedure

op
(a) Fill the jar with 100ml water.

(b) Add to it 3 - 4 tablets of NaOH and prepare NaOH solution.

(c) Add sample of sand in the measuring jar up to height of 100 ml

C
approximately.

(d) Fill the jar with additional 100 ml water.

(e)
d
Stir the contents in the jar thoroughly and allow it to settle for 10 -
lle
15 minutes.

(f) Measure the height of sand layer (d1) and height of silt layer (d2) in
the jar.
tro

Calculation :

d2
on

Silt content ( % ) = x 100


d1
nc

Note : In case of non availability of NaOH, only water is used in the test and the soil
solution is allowed to settle for 2 - 3 hours
U
JMC Projects (I) Ltd.

Doc. No. QMP-LB-17 (R1) Date: 18/03/2010 Page 01 of 01

Aggregate impact value

Ref. : IS 2386 (PART IV), 1963

Purpose : To determine the aggregate impact value.

y
Preparation of test sample :

op
(a) Take a sample of aggregate passing through 12.5 mm is. sieve and
retained on a 10 mm sieve.
(b) Dry the aggregate sample in an oven for a period of four hours at a

C
temperature of 100oC to 110oC and then cool it.

(c) Fill the measure in three layers and tamp each layer by 25 strokes
of tamping rod.
d
lle
(d) Determine net weight of aggregate (A) in the measure.

Test procedure:
(a) Place the test sample in the cup.
tro

(b) Compact the sample by subjecting it to 25 strokes with a tamping


rod.

(c) Compact the sample by subjecting it to 15 blows of hammer at an


on

interval of not less than one second. Raise the hammer 380 mm
above the upper surface of the aggregate and allow it to fall freely
nc

on to the aggregate.
(d) Remove the crushed aggregate from the cup.

(e) Sieve the aggregate on the 2.36 mm sieve.


U

(f) Weigh the aggregate passing through sieve (B).

(g) Weigh the aggregate retained on the sieve (C).

(h) Discard the result if the total weight (B + C) is less than the initial
weight (A) by more than one gram and make a fresh test sample.
repeat the test twice.
Calculation:
Aggregate Impact Value (%) = B x 100
A
JMC Projects (I) Ltd.

Doc. No. QMP-LB-18 (R0) Date : 18/02/2003 Page 01 of 01


Aggregate Crushing Value
Ref. : IS 2386 (PART IV)

Purpose : To determine crushing value of aggregate.

Significance : The aggregate crushing value gives relative measure of the


resistance to crush under a gradually applied compressive load.

y
Definition : It is defined as the ratio of the weight of fines to the total sample

op
weight expressed as a percent when tested as per the IS procedure.
Apparatus : Steel cylinder with open ends, Cylindrical measure, Steel tamping
rod, Balance, Compression testing machine
Preparation of Sample:

C
(a) Take a sample of about 6.5 kg aggregate for 150 mm diameter
cylinder and 1 kg for 75 mm diameter cylinder, passing through
12.5 mm and retained on 10 mm sieve for 20 mm down aggregate
& passing through 6.3 mm sieve and retained on 4.75 mm sieve for

(b) d
10 mm down aggregate, to provide two test samples.
Dry the aggregate at the temperature of 100oC to 110oC and then
lle
cool at room temperature.
(c) Fill up the cylindrical measure in three equal depth layers by
tamping each layer 25 times by tamping rod.
tro

(d) Take weight (A) of aggregate sample.

Procedure:
(a) Add the test sample in three layers. Compact each layer by 25
strokes of tamping rod.
on

(b) Level the surface of the aggregate and insert the plunger.
(c) Place the apparatus with the test sample and plunger in position
between the platens of the testing machine.
(d) Apply uniform load, so that load is reached in 10 minutes. The
nc

total load shall be 40 tonnes for 20 mm down aggregate and 10


tonnes for 10 mm down aggregate.
(e) Release the load and remove the whole material from the cylinder.
(f) Sieve the material on 2.36-mm sieve for 20 mm down aggregate
U

and on 1.18-mm sieve for 10 mm down aggregate.


(g) Take weight (B) of material passing through is. 2.36 mm sieve for
20 mm down aggregate and 1.18 mm sieve for 10 mm down
aggregate.
Calculation:
B
AGGREGATE CRUSHING VALUE (%) = ---------------- x 100
A
NOTE: IN ALL THESE OPERATIONS TAKE CARE TO AVOID LOSS OF THE FINES. MAKE TWO
SETS.
JMC Projects (I) Ltd.

Doc. No. QMP-LB-19 (R0) Date : 18/02/2003 Page 01of 01


Flakiness Index

Ref : IS 2386 (Part-1)

Purpose : To determine the Flakiness index of the coarse aggregate.

Significance : Coarse aggregate having more flaky particles will adversely affect
the strength of concrete.

y
Definition : The flakiness index of the aggregate is the percentage by Weight
of particles in it, whose least dimension (thickness) is less than

op
three-fifth of their mean dimension.

Apparatus : Balance, Metal Gauge, Sieves Set

C
Procedure :
a) Take a sample of about 3 Kg.
b) Divide the sample into four quadrants.
c) Select two opposite quadrants and sieve them through the sieves

d
arranged in the following order 63 mm, 50 mm, 40 mm,31.5 mm,
25 mm, 20mm, 16mm, 12.5 mm, 10 mm, 6.3 mm.
lle
d) Take the aggregate sample sieved through 63 mm and retained on
50 mm sieve. Find the weight W1 gm.
e) Pass that sample through 63-50 mm size of thickness gauge.
f) Find the weight of the aggregate passing through the respective
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slot ( i.e through 63 – 50 mm ) of the gauge w1 gm


g) Repeat the same procedure with 50-40 mm, 40 – 25mm, 31.5 -25
mm, 25-20 mm, 20-16 mm, 16-12.5 mm, 10-6.3 mm size of the
thickness gauge.
on

Observation table ( As per clause 4.5 & Table V of IS 2386 – Part I )


Size of aggregate(I.S sieve) Individual weight (W) Weight of aggregate (w)
retained between sieves (gm) passing through respective
slot of the gauge (gm)
nc

63 mm- 50 mm W1 = w1 =
50 mm- 40 mm W2 = w2 =
40 mm- 31.5mm W3 = w3 =
31.5 mm- 25 mm W4 = w4 =
U

25 mm-20 mm W5 = w5 =
20 mm-16 mm W6 = w6 =
16 mm-12.5 mm W7 = w7 =
12.5 mm- 10 mm W8 = w8 =
10.0 mm- 6.3 mm W9 = w9 =
Calculation :
Flakiness index = ( w1+w2+w3+……… ) X 100
( W1+ W2+ W3+ ……)
JMC Projects (I) Ltd.

Doc. No. QMP-LB-20 (R0) Date : 18/02/2003 Page 01of 01

Compression test of bricks

Ref. : IS 3495 (PART I), 1992

Purpose : To determine the compressive strength of bricks.

y
Salient features :

op
(a) Compression testing machine

(b) The compression plate which shall have a ball seating in the form
Of portion of a sphere , the center of the plate , shall be used.

C
Preparation of sample :
(a) Grind the uneven bed faces to provide two smooth and parallel
faces.

(b)
d
Immerse the sample in water at room temperature for 24 hours.
lle
(c) Remove the sample from water and drain out any surplus water at
room temperature.
tro

(d) Fill the frog and all the voids in the bed face flush with cement
mortar .

(e) Store under the damp jute bags for 24 hours followed by
on

immersion in clean water for 3 days.

Procedure :
(a) Place the sample with flat faces horizontal and mortar filled face
nc

facing upwards between two 3mm thick plywood sheet and


carefully centered between plates of testing .

(b) Apply load axially at a uniform rate of 14 n/ mm2 / 140 kgf / cm2
U

per minute till the sample fails.

(c) Note the maximum load at failure.

Calculation :

Compressive strength (N / mm2) / ( kgf / cm2)

= maximum load at failure in N or kgf


Average net area of two faces under compression in mm2 or cm2
JMC Projects (I) Ltd.

Doc. No. QMP-LB-21 (R0) Date : 18/02/2003 Page 01of 01

Water absorption for bricks

Ref : IS 3495 (PART II), 1992

Purpose : To determine water absorption of bricks.

Salient features :

y
(a) Balance : Capable of weighing 0.1 % of mass of the sample

op
(b) Oven

C
Sample preparation :

(a) Dry the sample in the oven at room temperature of 105o C to 115o
C till it attains substantially constant mass.

(b)
d
Cool the sample at room temperature and record its weight (M1).
lle
Procedure :

(a) Immerse dried sample completely in clean water at a room


tro

temperature of 27o C + 2 o C for 24 hours.

(b) Remove the sample from water and wipe out any traces of water
with a damp cloth.
on

(c) Weigh the sample up to 3 minutes and records its weight (M2).

Calculation :
nc

Water Absorption = M2 - M1 x100


M1
U
JMC Projects (I) Ltd.

Doc. No. QMP-LB-22 (R1) Date : 27/08/2011 Page 01of 01

COMPRESSION TEST OF BLOCKS

Ref : IS 2185 (PART I), 2005


Purpose : To determine the compressive strength of blocks.

Salient Features :

y
(a) Compression testing machine

op
(b) The compression plate which shall have a ball seating in the form
of portion of a sphere, the center of the plate , shall be used.

C
Capping Of Sample :
(a) Prepare neat paste of high strength gypsum plaster having
compressive strength of not less than 25 N/mm2 at 2-hour age.

(b)
d
Coat the sample with oil and spread water evenly over it.
lle
(c) The capping surface must be rigid and plane within 0.075 mm in
40 cm.

(d) Form a rectangular mould on the casting surface plate consisting of


tro

four 25 mm square steel bars .

(e) Bring in contact the surface of the sample to be capped with the
capping paste, hold the sample with its axis at right angles to the
on

capping surface and press the paste firmly in single motion. The
thickness of the cap will not be more than 3 mm. Allow the cap to
age for two days.
nc

Procedure :
(a) Place the sample with the centroid of their bearing surface aligned
vertically with the center of thrust of the bearing block of testing
machine.
U

(b) Apply load upto one-half of the expected load and uniformly
increase the load at a convenient rate.
(c) Note the maximum load at failure.

Calculation :
Compressive strength (N / mm2) / ( kgf / cm2)

= maximum load at failure in N or kgf


average net area of two faces under compression in mm2 or cm2
JMC Projects (I) Ltd.

Doc. No. QMP-LB-23 (R1) Date : 27/08/2011 Page 01of 01

WATER ABSORPTION FOR BLOCKS

Ref : IS 2185 (PART I), 2005

Purpose : To determine water absorption of blocks.

y
op
Salient Features :

(a) Balance

(b) Oven

C
Procedure :

(a)
d
Completely immerse the test sample in clean water at a room
temperature for 24 hours.
lle
(b) Remove the sample from water and wipe out any traces of water
with a damp cloth.
tro

(c) Record its weight (M2).

(d) Dry the sample in the oven at temperature of 100o C to 115o C for
not less than 24 hours till it attains substantially constant mass.
on

(e) Weigh the sample immediately and record its weight (M1).
nc

Calculation :

Water Absorption = M2 - M1 x100


M1
U
JMC Projects (I) Ltd.

Doc. No. QMP-LB-24 (R1) Date : 27/08/2011 Page 01of 01

DENSITY OF BLOCKS

Ref. : IS 2185 (PART I), 2005

Purpose : To determination the density of block

y
op
Procedure :

1. Select three blocks at random.

C
2. Dry the samples to constant mass in a suitable oven heated to
approximately 100oC.

d
3. After cooling the blocks to room temperature, measure the dimensions
lle
of each block in centimeters (to the nearest millimeter) and the overall
volume computed in cubic centimeters.

4. Weigh the blocks in kilograms (to the nearest 10 g) and calculate the
tro

density of each block.

Calculation :
on

Mass of block in kg
Density = ----------------------------------- x 106 kg/m3
Volume of specimen in cm3
nc
U
JMC Projects (I) Ltd.

Doc. No. QMP-LB-25 (R3) Date: 09/10/2010 Page 01of 01

Compressive strength test for concrete

Ref. : IS 516, 1959

Purpose : To find out the compressive strength of concrete.

y
Salient features of apparatus:

op
(1) Compression testing machine

(2) Specimen : Dimensions : 150 mm x 150 mm x 150 mm.

C
Procedure for preparing cube specimen

a) Cube moulds should be 15 X 15 X 15 cm made of steel or cast Iron.

d
b) Clean the mould, assemble and give thin coat of mould release oil to the inner
surfaces.
lle
c) Fill the concrete in three layers, each roughly one-third of the height of mould.
d) Tamp each layer thirty five times with a 16 mm dia tamping rod.
e) Take care to distribute the tamping in a uniform manner. The rod while
tamping should penetrate in to the layer below.
tro

f) Use trowel to remove air bubbles from the concrete and finish the top surface
of concrete properly. Mark proper identification on the top surface by nail or
by marking pen after it dries.
g) Remove cubes from the moulds after 12 hours and place in the designated
on

curing tank. Pl. make sure edges of the cubes are not broken while handling.

Procedure:
nc

(a) Remove the cubes from water after curing period.


(b) Place the cube in the compression testing machine in such a way that the
load can be applied to the faces other than the top and bottom of the cube
as cast.
U

(c) Apply the load gradually without any shock at a rate of 31.50 t per minute
until cube fails to take any more load.

Calculation:
Compressive strength (N / mm2) / ( kgf / cm2)
Failure load in N or kgf
=
Surface area of cube in mm2 or cm2
JMC Projects (I) Ltd.

Doc. No. QMP-LB-26 (R0) Date: 18/02/2003 Page 01of 01

Slump test

Ref. : IS 1199
Purpose : To find out the workability of fresh concrete.

Salient features of apparatus:

y
(a) Mould Top diameter : 100 mm

op
Bottom diameter : 200 mm
Height : 300 mm
Thickness : 1.6 mm

(b) Tamping rod Diameter : 16 mm

C
Length : 600 mm
Shape : rounded at one end

Procedure :
d
lle
(a) Fill the mould in four layers.

(b) Tamp each layer 25 times with the rounded end of the tamping rod.
tro

(c) The tamping should be uniformly distributed and for the second
and subsequent layers, tamping rod shall penetrate in to the under
lying layers.
on

(d) Strike off the top level of concrete by trowel and tamping rod.

(e) Remove the mould in vertical direction.


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(f) Measure the difference in level between the height of mould and
that of the highest point of the subsided concrete.

(g) This difference in height in mm is recorded as the slump of


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concrete.
JMC Projects (I) Ltd.

Doc. No. QMP-LB-27 (R2) Date: 09/10/2010 Page 01 of 02

Fineness of Cement

Ref : IS 4031 – Part - 1

Purpose : To Determine the Fineness of Cement

Significance : The Fineness of Cement has an important bearing on the rate of

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hydration and hence on rate of gain of strength and rate of

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evolution of heat. Finer cement offers a greater surface area for
hydration and hence the faster and greater the development of
strength.

: The area of cement particles of particular cement weight.

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Definition

Apparatus : (a) IS sieve no. 9 (90 micron)


(b) Pan
(c)
d
Balance & Weights
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Procedures : (1) Disturb the sample of cement by shaking for 2 min to break
down the air set lumps. Wait 2 min.
(2) Stir the resulting powder gently using a clean dry rod in
order to distribute the fines throughout the cement.
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(3) Fit the pan under the sieve.


(4) Weigh correctly 10 g of cement (W1) gm.
(5) Take sample on an IS 90 micron Sieve.
(6) Break down the air set lumps.
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(7) Fit the lid over the sieve. Sieve the sample giving circular
and vertical motion continuously until no more fine
material passes through it.
(8) Weigh the residue left on sieve (W2).
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(9) Calculate the mass in percentage, R1, of the quantity first


placed in the sieve.
(10) Clean the pan. Repeat the whole procedure using a fresh
10g sample to obtain R2.
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(11) Then calculate the residue of the cement R as the mean of


R1, and R2, as a percentage.
(12) When the results differ by more than 1 percent absolute,
carry out a third sieving and calculate the mean of the three
values.

Calculation : Fineness of Cement, R = (W2/W1) x 100


JMC Projects (I) Ltd.

Doc. No. QMP-LB-27 (R2) Date: 09/10/2010 Page 02of 02

Observation Table :

Sample Wt. of Sample Wt. of the Residue Percentage Residue Average


W1 (gm) W2 (gm) (W2/W1) x 100 Percentage
1
2
3

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Frequency : For each batch received at site

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JMC Projects (I) Ltd.

Doc. No. QMP-LB-28 (R0) Date: 18/02/2003 Page 01 of 01

Standard Consistency of Cement

Ref : IS 4031 - Part-4


Purpose : To determine standard consistency for finding initial and final
setting time of Ordinary Portland Cement.
Apparatus : (a) Vicat apparatus, (Mould dia.: 80 mm, Height: 40 mm)
(b) Weights & Balance

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(c) Trowel

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(d) Plunger (10mm dia. & 50 mm long)
Significance : It is a parameter which is used to find out initial & final setting
time and soundness of cement. This gives percentage of water
required to produce a cement paste of standard consistency.
: (1) Take about 400 gm of cement and prepare a paste with a

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Procedure
weighed quantity of water. (Say, 25% to 35% by weight of
cement)
(2) The paste must be prepare d in a standard manner and filled in

d
to the vicat mould within 3 to 5 minutes.
(3) After completely filling the mould, shake the mould to expel
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air.
(4) A plunger attached and brought down to touch the surface of
the paste in the test block and quickly released allowing it to
sink in to the paste by its own weight.
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(5) Take the reading by noting the depth of penetration of the


plunger.
(6) Similarly, conduct trials with higher and higher W/C ratio till
such time the plunger penetrates for a depth of 5 to 7 mm
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from the bottom.


(7) That particular percentage of water which allows the plunger
to penetrate only to a depth of 5 to 7 mm from the bottom is
known as the percentage of water required to produce a
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cement paste of standard consistency.


(8) This percentage is usually denoted as `P’
Observation Table :
Weight of Percentage of water by Penetration
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Cement Weight of Cement of Plunger, mm


400 gm 24%
400 gm 25%
400 gm & so on.
400 gm
400 gm
400 gm

Range : General range of standard consistency is 25% to 35%.


Frequency : Every batch received at site.
JMC Projects (I) Ltd.

Doc. No. QMP-LB-29 (R1) Date : 09/10/2010 Page 01 of 01

Setting Time Of Cement

Ref : IS 4031 - Part 5

Purpose : To determine initial and final setting time of Cement.

Significance : This test gives a judgement about the available time for

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transportation, placing of concrete, commencement of curing and

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stripping.

Apparatus : (a) Vicat apparatus, (Mould dia.: 80 mm, Height: 40 mm)


(b) Weights & Balance
(c) Trowel

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(d) Initial & Final setting time needle
(e) Time Watch

Procedure :
d
(1) Take 400 gm of cement and 85% water required for making
cement paste of normal consistency.
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(2) The paste shall be gauged and filled into the vicat mould in
specified manner within 3-5 minutes.
(3) Start the time watch the moment water is added to the cement.
The temp of water and that of the test room at the time of
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gauging temperature shall be within 27 +/- 2 °C.


(4) When the needle for Initial setting time, brought in contact
with the top surface and released quickly, fails to penetrate the
paste block for 5 to 7 mm measure from the bottom of the
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mould is taken as Initial setting time.


(5) When the needle for Final setting time, placed gently on the
surface makes an impression on the paste but the circular
cutting edge of the attachment fails to do so, is taken as Final
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setting time.
Observation Table :

Weight of Cement Water Initial Setting Time Final setting


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gm gm Minute Time Minute

Limit : As per IS 269-1989, 8112-1989, 12269-1987, 1489 (Part 1)-1991


(1) Initial setting time not less than 30 minutes.
(2) Final setting time not more than 600 minutes.
Frequency : For every batch received at site
JMC Projects (I) Ltd.

Doc No. QMP-LB-30 (R0) Date : 18/02/2003 Page 01 of 02

Soundness of Cement

Ref : IS 4031 - PART- 3

Purpose : To determine the soundness of Ordinary Portland Cement

Significance : It is essential that the cement paste, once it has set, does not undergo

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large changes in volume, i.e., there should not be appreciable expansion,

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which under conditions of restraint could result in disruption of hardened
cement paste. By soundness test this property of volume change can be
checked.

Apparatus : (a) Weighing balance & weights

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(b) Le-Chatelier moulds
(c) Vicat apparatus
(d) Plunger
(e)
(f)
d
Trowels, Tray, Time Watch
Water bath
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(g) Glass sheets and oil

Procedure: (1) Take 400 gm of cement and find its standard consistency.
(2) Place the lightly oiled Le-Chatelier mould on a lightly oiled glass
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sheet.
(3) Prepare a cement paste formed by gauging cement with 0.78 times
the water required to give a paste of standard consistency.
(4) Fill the Le-Chatelier mould with this cement paste made in Step 3
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of procedure.
(5) Cover the mould with another piece of lightly oiled glass sheet.
(6) Place a small weight on this covering glass sheet and immediately
submerge the whole assembly in water at a temperature of 27 ± 2
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°C and keep it there for 24 hours.


(7) Measure the distance between the indicators to the nearest 0.5mm.
Submerge the mould again in water at temperature of 27 ± 2 °C.
(8) Bring the water to boiling temperature in 25 to 30 minutes and
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keep it boiling for 3 hours.


(9) Remove the mould from water, allow it to cool and measure the
distance between the indicators. The difference between these two
measurements, i.e., in step (7) & step (9) of procedure indicates the
expansion of cement.
JMC Projects (I) Ltd.

Doc No. QMP-LB-30 (R0) Date: 18/02/2003 Page 02 of 02

Observation table:

Sr. No. Distance between Distance between Expansion


indicators after indicators after final = (3) – (2)
initial submergence submergence in
in water for 24 boiling water for 3
hours at 27 ± 2 °C hours and cooling

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(mm) (mm) (mm)

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(1) (2) (3) (4)

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Limit : Maximum expansion 10 mm.

Frequency : For every batch received


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Note : (as per the same IS) In the event of cement failing to meet the test for soundness, a
retest may be made after aeration. For this purpose, spread out the cement in a layer of
75 mm thickness and store it for 7 days in an atmosphere maintained at 27 ± 2 °C and
relative humidity of 50 to 80%. Retest this cement as per the above procedure.
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JMC Projects (I) Ltd.

Doc No. QMP-LB-31 (R1) Date: 27/08/2011 Page 01 of 02

Compressive Strength Test Of Cement

Ref : IS 4031 - PART - 6

Purpose : To determine the compressive strength of cement.

Significance : Compressive strength of cement helps in determining grade of cement,

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in calculations of mix designing proportioning of concrete etc.

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Apparatus : (a) Vibration machine
(b) Poking rod
(c) Cube mould of 70.6 mm size
(d) Gauging Trowel

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(e) Balance, Weights & Tray
(f) Graduated glass cylinder

Procedure
d
: (1) Take cement 200 gm, standard sand 600 gm and water = ( P/4 + 3.0)
percent of combined mass of cement and sand, where P is the
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percentage of water required to produce a paste of standard
consistency determined as described in IS:4031 (PART IV)-1988.
(2) Place mixture of above cement and sand (1:3) on a tray, mix it dry
with a trowel for one minute and then with water (as per step (1) of
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procedure) until the mixture is of uniform colour.

Note : The time of mixing shall in any event be not less than 3 minutes and should the
time taken to obtain a uniform colour exceed 4 minutes, the mixture shall be rejected and
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the operation repeated with a fresh quantity of cement, sand and water.

(3) Properly oil the interior faces and bottom of mould which should be
water tight.
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(4) Place the assembled mould on the table of vibration machine and hold
it firmly in position by means of a suitable clamp. Attach a hopper of
suitable size and shape securely at the top of the mould to facilitate
filling and this hopper shall not be removed until the completion of
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vibration period.
(5) Immediately after mixing the mortar as in step (2) of procedure, place
the mortar in the cube mould and rod with the poking rod 20 times in
about 8 seconds to ensure elimination of entrapped air to prevent
honey combing. Place the remaining quantity of mortar in the hopper
of the cube mould and rod again as done for the first layer.
(6) Compact the mortar by vibration machine for 2 minutes at the
specified speed of 12000 ± 400 vibrations per minute.
JMC Projects (I) Ltd.

Doc No. QMP-LB-31 (R1) Date: 27/08/2011 Page 02 of 02

(7) At the end of vibration remove mould together with the base plate
from the machine and finish the top surface of the cube in the mould
by smoothening the surface with the blade of trowel.
(8) Keep the filled mould in moist cloth for 24 hours after completion of
vibration.
(9) At the end of this period remove them from the mould and
immediately submerge in clean fresh water.
(10) Test sets of three cubes for compressive strength at 3, 7 & 28 days in

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compression testing machine. The cubes shall be tested on their sides

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without any packing between the cube and the steel platens of the
testing machine. Load shall be steadily and uniformly applied at
the rate of 35 N/mm2 per minute.
(11) The load when the cube fails shall be noted and divided by cross
sectional area of the cube and record the results.

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Observation table:

Sample no Date of casting


d
Date of testing Days Strength in
kg/cm2 or
Average
strength
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N/mm2
1 3
2 3
3 3
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4 7
5 7
6 7
7 28
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8 28
9 28

Limit: Minimum compressive strength in N/mm2 for different types of cement at different
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ages:

Age in days PPC 43 grade OPC 53 grade OPC


3 16 N/mm2 23 N/mm2 27 N/mm2
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7 22 N/mm2 33 N/mm2 37 N/mm2


28 33 N/mm2 43 N/mm2 53 N/mm2

Frequency: For every batch received at site


JMC Projects (I) Ltd.

Doc. No. QMP-LB-32 (R0) Date: 01/05/2003 Page 01 of 01

Checking Procedure For Leveling Machine:

1. Set leveling machine at location point ‘A’ & level it perfectly.

2. Take reading at temp or Permanent Bench Mark & shift the reading at
location X & Y.

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3. Set Level machine at ‘B’ & ‘C’ and verify the level of ‘X’ & ‘Y’ with respect

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to the concerned bench mark.

4. Level at ‘X’ & ‘Y’ should match while taking readings from ‘A’, ‘B’ & ‘C’
Points.

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5. Deviation of level from each level station should be with limit of (+) / (-) 5
mm (Acceptable limit).

6.
d
If it is more than acceptable limit, it shall be get repaired by Specialize
Agency and recheck for accuracy.
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JMC Projects (I) Ltd.

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FORMATS
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JMC Projects (I) Ltd.

Doc. No : FCN-LB-01 (R0) Date : 18/02/2003 Page 01 of 01

RECORD OF CALIBRATION OF MEASURING AS WELL AS TEST EQUIPMENT

Site :______________________

Sr. Name of Equipment Date of Calibration Reference Initials of officials


No. Equipment I.D. No. calibration agency Equipment present
used for

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calibration
Last Due Company Client

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JMC Projects (I) Ltd.

Doc. No : FCN-LB-02 (R1) Date : 18/03/2009 Page 01 of 01

CALIBRATION REPORT FOR BATCHING PLANT


SITE:

JMC CODE NO :

PLANT MAKE :

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DATE OF CALIBRATION :

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READINGS :

SENSOR / GAUGE FOR :

Applied load Dial gauge/Panel Average Applied load Dial gauge/Panel Average

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In kg display reading in kg In kg display reading in
kg
Loading Unloading Loading Unloading

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Remark, if any : __________________________________________________________

CALIBRATED BY WITNESSED BY
JMC Projects (I) Ltd.

Doc. No : FCN-LB-03 (R0) Date : 18/02/2003 Page 01 of 01

Calibration Report For Weigh Batcher

Project:

JMC Code No :

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Plant Make :

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Date Of Calibration :

Readings :

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Applied load Lever arm reading Average Applied load Lever arm reading Average
In kg in kg In kg in kg
Loading unloading loading unloading
5 100
10
15 d 110
120
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20 130
25 140
30 150
35 160
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40 170
45 180
50 200
60
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70
80
90
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Remarks, if any : ________________________________________________________


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CALIBRATED BY WITNESSED BY
JMC Projects (I) Ltd.

Doc. No : FCN-LB-04 (R1) Date : 09/10/2010 Page 01 of 01

Project : _______________________________________
Client : _______________________________________
Consultant : _______________________________________

DETERMINATION OF SPECIFIC GRAVITY


IS 2386 (PART III) -1969

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Date of receipt : _______________ Date of testing :___________

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Room temp : _______________ Material : ______________

Aggregate between 40 mm & 10 mm

Sample No. I II III

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Weight of glass jar + plate + Sample + Water (A), g

Weight of glass jar + plate + Water (B), g

d
Weight of saturated surface dried aggregate (C), g
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Weight of oven dried aggregate (C), g

Specific Gravity at room temperature


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D
G= C - (A - B)
Aggregate smaller than 10 mm
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Sample No. I II III


Weight of saturated surface dried aggregate (A), g

Weight of pycnometer + sample + water (B), g


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Weight of pycnometer + water (C), g

Weight of oven dried aggregate (C), g


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Specific Gravity at room temperature


D
G= A - (B - C)

Checked by Tested by
QC Engineer/Site In-charge QC Lab In- charge
JMC Projects (I) Ltd.

Doc. No : FCN-LB-05 (R0) Date : 18/02/2003 Page 01 of 01

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Project : _______________________________________
Client : _______________________________________
Consultant : _______________________________________

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DRY DENSITY TEST BY CORE CUTTER METHOD
IS 2720 (Part XXIX), 1975
W1 = Weight of cutter, g ω = Moisture content, %

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W2 = Weight of soil and cutter, g γb = Bulk density, g/cm3
W3 = Weight of soil, g γd = Dry density, g/cm3

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W4 = Weight of crucible, g V = Volume of cutter, cm3
W5 = Weight of crucible with wet soil, g
W6 = Weight of crucible with dry soil, g

Sample
No.
Date Location W1

g
W2

g
W1 g tro
W3 = W 2 - V

cm3
γb =
W3 / V
g / cm3
W4

g
W5

g
W6

g
ω (% ) =
W5 - W6
W6 -W4
x 100
γd = γb
1+ω
g / cm3
Tested
by
Checked
by
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Note : This is a sample format to be maintained in the register


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JMC Projects (I) Ltd.

Doc. No : FCN-LB-06 (R1) Date : 09/10/2010 Page 01 of 01

Project : _______________________________________
Client : _______________________________________
Consultant : _______________________________________

PROCTOR COMPACTION TEST


IS 2720 {Part VII-1980/VIII-1983}

Date : ______________
Source : _______________________________________

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Supplier : ______________________________________
Volume of mould (Vm) ______________________

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Weight of rammer, kg ______________________
Fall of rammer, mm ______________________

Sample No. I II III IV V VI

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Weight of mould + compacted soil, g (W)

Weight of mould, g (Wm) d


Weight of compacted soil, g, Wc = W - Wm
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Moisture content, ω (%) ( known )

Wet density, g / cm3 γb = Wc


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Vm
Dry density, g / cm3 γd = γb
1+ω
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Checked by Tested by
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_________________________ __________________
QC Engineer/ Site In - charge QC Lab In - charge
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JMC Projects (I) Ltd.

Doc. No : FCN-LB-07 (R0) Date : 18/02/2003 Page 01 of 01

Project : _______________________________________
Client : _______________________________________
Consultant : _______________________________________

FINENESS MODULUS OF SAND


IS 383, 1970
Date of receipt : _______________ Date of testing :________________
Source of sand : _______________ Location of
Name of Supplier : _______________ unloaded material :________________

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Weight of sample : _______________ g

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Sieve size Weight of sand retained Individual % of sand Cumulative % % Passing
on each sieve (Retained on each sieve) of sand

4.75 mm
2.36 mm

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1.18 mm
600 μ
300 μ
150 μ
Pan
d TOTAL :
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F. M. of sand = Total / 100 = ___________ ZONE:

DETERMINATION OF SILT CONTENT IN SAND


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IS 383, 1970

Sample No. 1 2 3
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Height of sand layer (d1)

Height of silt layer (d2)

Silt content (%) = d2 x 100


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d1

Sample approved / rejected :


Action taken, if any :
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Tested by Checked by

QC Lab In- charge QC Engineer/Site In-charge Client/Consultant


JMC Projects (I) Ltd.

Doc. No : FCN-LB-08 (R0) Date : 18/02/2003 Page 01 of 02

Project : ______________________
Client : ______________________ Consultant : ______________________

FINENESS MODULUS OF COARSE AGGREGATE


IS 2386 (Part I)

Date of receipt :___________ Date of testing :___________


Name of supplier : __________ Location of unloaded material:____________
Source of aggregate : __________ Weight of sample : _________________ g
Type of aggregate : ___________ (40mm down / 20mm down / etc.)

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Sieve size Weight of aggregate Individual % of aggregate Cumulative % of % Passing

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retained on each sieve (Retained on each sieve) aggregate
80 mm
63 mm
40 mm
20 mm

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16 mm
12.50 mm
10.00 mm
04.75 mm
2.36 mm
1.18mm
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600μ
300μ
150μ
TOTAL :
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F. M. of coarse aggregate = TOTAL / 100 = ___________

AGGREGATE IMPACT VALUE TEST


IS 2386 (Part IV)
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Sample No. I II Average


Weight of oven dry sample (A)
Weight of fraction of sample passing 2.36 mm I.S. sieve (B)
% of finer sample B/A x 100
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AGGREGATE CRUSHING VALUE TEST


IS 2386 (Part IV)
Sample No. I II Average
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Weight of oven dry sample (A)


Weight of fraction of sample passing 2.36 mm I.S. sieve (B)
% of finer sample B/A x 100

Tested by Checked by

QC Lab In- charge QC Engineer/Site In-charge Client/Consultant


JMC Projects (I) Ltd.

Doc. No : FCN-LB-08 (R0) Date : 18/02/2003 Page 02 of 02

FLAKINESS INDEX (THICKNESS) TEST OF COARSE AGGREGATE

IS 2386 (Part I)

Weight of sample (w) : __________ g

Size of aggregate(I.S sieve) Individual weight (W) Weight of aggregate (w)


retained between sieves (gm) passing through respective slot
of the gauge (gm)
63 mm- 50 mm W1 = w1 =

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50 mm- 40 mm W2 = w2 =
40 mm- 31.5 mm W3 = w3 =

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31.5 mm- 25 mm W4 = w4 =
25 mm-20 mm W5 = w5 =
20 mm-16 mm W6 = w6 =
16 mm-12.5 mm W7 = w7 =

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12.5 mm- 10 mm W8 = w8 =
10.0 mm- 6.3 mm W9 = w9 =

Calculation : d ( w1+w2+w3+……… )
Flakiness index = ____________________ X 100
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( W1+ W2+ W3+ ……)

Sample approved / rejected : ________________________________________________


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Action taken, if any : ____________________________________________________


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Tested by Checked by

______________________ ________________
QC Lab In- charge QC Engineer/Site In-charge Client/Consultant
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JMC Projects (I) Ltd.

Doc. No : FCN-LB-09 (R0) Date : 18/02/2003 Page 01 of 01

Project : _______________________________________
Client : _______________________________________
Consultant : _______________________________________

COMPRESSION TEST FOR BRICKS


IS 3495 (Part I), 1992
Date of receipt :___________ Date of testing :___________
Name of supplier : __________ Location of
Brand name : __________ unloaded material :__________________

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Sample Nos Maximum load at failure Average area Compressive strength
(N or kgf) ( mm2 or cm2 ) (N/ mm2 or kgf / cm2)

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1.
2.
3.
4.

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5.
Limit = compressive strength should be more than 35 kg/cm2

WATER ABSORPTION FOR BRICKS


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IS. : 3495 (PART II), 1992
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Sample Nos Weight of dry brick (M1) Weight of wet brick W.A(%)(M2 - M1)/ M1x
(M2) 100
1.
2.
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3.
4.
5.

Limit: W.A. should be less than 20 %


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Sample approved / rejected :


Action taken, if any :
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Tested by Checked by

QC Lab In- charge QC Engineer/Site In-charge Client/Consultant


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JMC Projects (I) Ltd.

Doc. No : FCN-LB-10 (R2) Date: 27/08/2011 Page 01 of 01

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Project : _______________________________________
Client : _______________________________________

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Consultant : _______________________________________

COMPRESSIVE STRENGTH OF CONCRETE

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IS 516, 1959

Sr. Location Grade Slump Date of Due date of testing Weight of Compressive strength Average strength Remarks
No of (mm) casting cube (N / mm2) or (kgf / cm2) (N / mm2) or ( kgf / cm2)

d
concrete (kg)
7 days 28 days 7 days 28 days 7 days 28 days

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Checked by Tested by
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Client/Consultant QC Engineer/Site In-charge QC Lab In- charge

Note : This is a sample format to be maintained in the register


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JMC Projects (I) Ltd.

Doc. No : FCN-LB-11 (R0) Date : 18/02/2003 Page 01 of 01

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RECORD OF VERIFICATION OF MATERIAL USED PRIOR TO INSPECTION

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Sr. Date Identification Lot Quantity Quantity Balanced Remarks Initials of Initials of Initials of
No. mark No. received consumed Quantity (conforms or non inspecting Client / vendor (in
before conforms) official Consultant case of return
of material)

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JMC Projects (I) Ltd.

Doc. No: FCN-LB-12 (R2) Date: 27/08/2011 Page 01 of 01

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TEST REPORT OF CEMENT
Sample no: Dt. of receipt:

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Name of site: Dt. of testing:
Batch no: Brand Name: Type of Cement (OPC/PPC): if OPC, Grade:

Sr. Test Result Ref. Limits as per specification of relevant IS code Remarks

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No. Testing
I.S. No.
A. Fineness Test 4031 -
% Residue on I.S. 90 Micron Sieve (I)

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B. Standard Consistency (%) - -

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C. Setting Time Test 4031
Initial Setting time (Minutes) (V) Not less than 30 minutes
Final Setting time (Minutes) Not more than 600 minutes
D. 4031

E.
Soundness Test
Expansion in Le-Chatelier test (mm)
Compressive Strength Test
( N / mm2 )
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4031
(VI)
Not more than 10 mm
43 Grade 53 Grade PPC
23 27 16
at 3 Days
on
at 7 Days 33 37 22
at 28 Days
43 53 33
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Action taken in case of Non conformity:


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( QA /QC Engineer ) Tested By


JMC Projects (I) Ltd.

Doc. No : FCN-LB- 13 (R0) Date : 18/02/2003 Page 01 of 01

Project :

Client :

Consultant :

TEST REPORT FOR SOLID/HOLLOW BLOCK

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IS 2185 (Part 1 & Part 2)
Date of receipt : Category of Blocks : A/B/C/D

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Name & Supplier : Size of the Block :
Date of testing :
Location of unloaded material:

[A] DENSITY TEST

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S.N. Wt. [Kg.] Volume [m3] Density [Kg./m3]
1.
2.
3.
d Avg.
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[B] WATER ABSORPTION TEST :

S.N. Wt. of dry block [M1] Wt. of wet block[M2] Water absorption
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[(M2-M1) /[M1 X 100]


1.
2.
3.
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Avg.

[C] STRENGTH TEST :

S.N. Max. load at failure[ kg. ] Avg. area [ cm2 ] Comp. Strength
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[ kg./cm2 ]
1.
2.
3.
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Avg.

Checked by Tested by

Client Q.C. engineer / Site in charge Q.C. lab. in charge


JMC Projects (I) Ltd.

Doc. No : FCN-LB-14 (R0) Date : 18/02/2003 Page 01 of 01

RECORD OF VERIFICATION OF CUSTOMER SUPPLIED PRODUCT

Name of work :________________________________


Client/Customer :________________________________
Material :

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Sr. Date of Batch No. / Quantity Source of Test Result of test Validity Remarks
No. Receipt Lot No. Certificate ( Approved / upto (Date)

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(In House / unapproved )
Laboratory)

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JMC Projects (I) Ltd.

Doc. No : FCN-LB-15 (R0) Date : 18/02/2003 Page 01 of 01

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ROLLING MARGIN OF STEEL

Name of the site ______________________

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Date Sr / Description Challan Length Actual Actual Theoretical Difference Initials Remarks
Sample No. (m). wt. wt. wt. %
No. (kg.) (kg/m) (kg/m) JMC Consultant
/ Client

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JMC Projects (I) Ltd.

Doc. No : FCN-LB-16 (R0) Date : 18/02/2003 Page 01 of 01

WEEKLY REVIEW REPORT (QA/QC)


Client : Site :
Consultant : Period :
(I) Quality of material :

Sr Description of Non conformity with Action taken on control of N.C.


No name of material
1
2

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3
(II) Workmanship :

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Description Approx. Description of Action taken on control of
Qty. Non N.C.
Executed Conformity

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1
2
3
4
5
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(III) Customer Complaints :

Description with date Action taken with date


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(IV) ISO system discrepancies: ( Self identified / NCR’s )


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Description Action taken / to be taken


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(V) Summary of pending / unresolved QC issues:


(VI) Requirement of technical assistance
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(VII) Activities to start within fortnight :


Prepared by Checked by Reviewed by

(QA / QC Engr.) (Project In charge) (RO – QA In charge )


Date: Date: Date:
Note: 1) Please attach extra sheets, wherever necessary
2) If sent through E – Mail , Mark copy to MR at HO
JMC Projects (I) Ltd.

Doc. No : FCN-LB-17 (R4) Date: 27/08/2011 Page 01 of 03


Frequency of Test / Checks
Sr. Title Doc. No. Frequency of Test / Check Relevant IS

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No. Codes
1. Soil IS 2720

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a) Core cutter test FCN-LB-05 • At every 100 m2 of compacted area for small plinth
filling
• At every 500 m3 of compacted earth filling for mass
filling work
b) Standard Proctor Test FCN-LB-06 •

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Once for each source of earth
2. Coarse Aggregate / Fine Aggregate
a) Specific gravity FCN-LB-04 • Once or Charge in source IS 2386
b) Bulkage of Sand - • In monsoon/Rainy season when concreting is done

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by volumetric batching this test is to be performed
daily and necessary Bulkage corrective to be applied
• As and when required

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c) Dry/Loose Bulk density -
d) Silt content in Sand FCN-LB-07 For each source
e) Aggregate impact value FCN-LB-08 • If the source explored between 501-1500 cum take
f) Sieve analysis of one gross sample at each 100 cum.
aggregate
g) Aggregate crushing value
h) Flakiness Index Thickness
Test
tro • If the source explored between 1501-5000 cum, take
one gross sample at each 200 cum.

3. Bricks IS 3495-1992
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a) Visual Check - • Total 20 Nos. of Bricks to be selected from three
b) Dimensioned Check - trucks (i.e.; 6 to 7 bricks from each Truck)
c) Water absorption FCN-LB-09 • For each source Random 3 Nos. to be tested from 20
d) Compressive strength Nos. of bricks as selected
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4. Solid / Hollow Block IS 2185


a) Visual Check - • Total 20 Nos. of Blocks to be selected from 5000 (Part 1-2005 &
b) Dimensioned Check - Nos. Blocks Part 2-1983)
c) Water absorption FCN-LB- 13 • For each source Random 3 Nos. to be tested from 20
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d) Compressive strength Nos. of blocks as selected


JMC Projects (I) Ltd.

Doc. No : FCN-LB-17 (R4) Date: 27/08/2011 Page 02 of 03

S r. Title Do c. No . Frequency of Test / Check R e leva nt IS Co des

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No.
5. Cement
i. Fineness of cement Manufacturer • I S4031(P-1)-1996

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For each batch received at site
ii. Standard consistency of Test certificate I S4031(P-4)-1996
cement or
iii. Setting time Outside laboratory or I S4031(P-5)-1996
iv. Compressive strength FCN-LB-12 I S4031(P-6)-1996

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v. Soundness I S4031(P-3)-1996
6. Reinforcement Steel IS 1786-2008
i. Rolling margin FCN-LB-15 • One sample for each lot received at site
• One sample consists of 03 Nos. of bars of at least 0.5m

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length
ii. Tensile Test Manufacturer Test • If MTC is received or steel supplied by client, one sample
iii. Elongation Certificate or Test for receipt of ten consecutive lots of each category at site.

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iv. Bend – Rebend test Report from outside • One sample consists of 3 Nos. of bars of at least 1m
laboratory length
• If MTC is not received, one sample for each lot received
at site.

7. Structural Steel
i. Rolling Margin
tro FCN-LB-15


One Sample consists of 03 Nos. of bars of at least 01 m
length.

One sample for each lot received at site


IS 2062-2006

• One sample consists of 03 Nos. of bars of at least 0.5m


on
length
ii. Tensile test Manufacturer Test • If MTC is received or steel supplied by client, one sample
iii. Elongation Certificate or Test for receipt of ten consecutive lots of each category at site.
iv. Bend test Report from outside • One Sample consists of 03 Nos. of sections of at least 1 m
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laboratory length
• If MTCs are not received, one sample for each lot
received at site.
• One sample consists of 03 Nos. of section of at least 1 m
length.
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JMC Projects (I) Ltd.

Doc. No : FCN-LB-17 (R4) Date: 27/08/2011 Page 03 of 03

Sr. Title Doc. No. Frequency of Test / Check Relevant

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No. document
8. Concrete IS 456-2000

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i. Slump Test - • For each concrete cube set
ii. Compressive strength FCN-LB-10 • The cube samples shall be taken for each grade of
concrete for following daily concrete quantity

Qty. of concrete in Cum Number of Samples

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(Daily)
1-5 1
6-15 2
16-30 3

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31-50 4
51 and above 4 plus one additional for each

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50 cum. of concrete
• One sample consists of six nos of cubes. Three for 7
days and three for 28 days strength. However where 7
days strength is not required the sample size may be
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reduced to three nos of cubes for 28 days strength only.
Standard deviation to be taken every month
The frequency is to maintain for initial period, till
consistent results are obtained. It may be reduced as per
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engineer in charge’s discretion
9. Calibration of test equipment FCN-LB-01 • As per frequency set in Laboratory Manual
10. Inspection and test status FCN-CC-01 • Daily Refer QMP-CN-03
11. Control of nonconforming FCN-CC-03 • On occurrence of Nonconformity Refer QMP-NP-01
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product
12. Weekly review report FCN-LB-16 • To be Submitted to RO QA/QC – Weekly
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JMC Projects (I) Ltd.

Doc. No : FCN-LB-18 (R0) Date : 18/02/2003 Page 01 of 01

MATERIAL SUBMITTAL FOR APPROVAL

PROJECT :
_______________________________________________________________________
FROM : JMC Projects ( India ) Ltd. Sample No. :
TO : Date :

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DESCRIPTION

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Material ( Sample / Catalogue ) : ____________________________________________

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Drawing / Specification / Reference : _________________________________________

Location of use __________________________________________

Manufacturer
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: _________________________________________
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Local Availability _________________________________________

Date of Requirement at site : ________________________________________


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Test Report if applicable : _________________________________________

________________________________________________________________________
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_______________________________________________________________________

Name : Sign :
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Comments of Client’s Rep. : ________________________________________

________________________________________________________________________
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________________________________________________________________________

Approved / Rejected :_____________________________________________________

Name : Sign :
JMC Projects (I) Ltd.

Doc. No : FCN-LB-19(R0) Date : 09/12/2006 Page 01 of 01

ANALYSIS OF COST OF QUALITY


Client: Site :
Consultant: Month :
Sr.No Parameters Jan Feb Mar Apr May Cumulative
1 Prevention Cost

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1.1
1.2

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2 Appraisal Cost

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2.1
2.2

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3 Internal Failure
3.1
3.2
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4 External Failure
4.1
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4.2
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5 Total COQ (1+2+3+4)


6 Total Work Done
7 % COQ = 5/6 x 100
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8 Total Failure Cost (3+4)


9 % Failure Cost = 8/6 x 100

Prepared by Checked by

QC Engineer Site In-charge


JMC Projects (I) Ltd.

Doc. No : FCN-LB-20(R0) Date : 18/03/2009 Page 01 of 01

Standard Deviation

Project :
Duration of Results: From : To :

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Sample Crushing Avarage. deviation square of deviation
number strength (x) Strength (x - x ) ( x - X )2

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kg/cm2 x = ∑x / n

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n = Total no of samples
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Average Strength = x = Total Crushing Strength


Total Sample Number

Standard Deviation = σ = ( X - x )2
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n–1

Coefficient of variation (%) = Standard Deviation /Average Strength X 100

Prepared by

QC engineer
JMC Projects (I) Ltd.
Doc. No: FQM-XX-08 (R4) Date : 27/08/2011 Page 01 of 03
Communication channel
Sr Description Doc. No Frequency Submission Originator Recipients Remarks

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No Date
1 Weekly Review Report FCN-LB-16 Weekly 8th, 15th, 22rd, QA-QC Engineer Regional ISO

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(QA/QC) 2nd of next Coordinator / MR
month
2 Cost Of Quality Analysis FCN-LB-19 Monthly 10th QA-QC Engineer Regional ISO
with MRS FCN-AA-12 Coordinator / MR

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FCN-AA-13
FCN-AA-14
3 Batching Plant Output -- Fortnightly 17th, 2nd of QA-QC Engineer Regional ISO
Report next month Coordinator / MR

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4 Attendance of participants FCN-JJ-01 Monthly Immediately QA-QC Engineer Training Dept HO
in Training Program after training

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5 Training Calendar -- Monthly 2nd QA-QC Engineer Training Dept HO
6 Inspection & Test Status FCN-CC-01 Daily -- QA-QC Engineer -- If any NCP is
(Bldg. Wise Bifurcation) found, same to

tro be reported to
Team leader /
AE / Project
In charge
7 Control of Non FCN-CC-03 After -- QA-QC Engineer Team Leader / AE / Compliances
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Conforming Product finding Supervisor are to verify by
NCP QA-QC
Engineer /
Project In
nc

charge
8 Project Performance FCN-CC-04 Monthly 10th QA-QC Engineer Regional ISO
Review Formats – I, II Coordinator / MR
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9 Record of Process FCN-XX-01 Monthly 10th Project Manager/ Regional ISO


Parameter QA-QC Engineer Coordinator /
Project Head / MR
JMC Projects (I) Ltd.
Doc. No. - FQM-XX-08 (R4) Date : 27/08/2011 Page 02 of 03

Communication channel

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Sr Description Doc. No Frequency Submission Originator Recipients Remarks

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No Date

10 Pour Card / Pile log sheet FCN-BB-03 Each Pour -- JE/AE/PE Client / Consultant /
FCN-BB-08 QA-QC Engineer /
QS Engineer

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11 Customer Complaints/ FCN-BB-04 After -- Project Incharge / At the end of Compliances
Instruction Register receiving QA-QC Engineer Project, Register to are to reflected
any / Team Leader be sent to MR by concerned

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complaint / person & to be
instruction verify by

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from client / QA-QC
consultant Engineer /
through Project
different Incharge
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written IOC
/ Verbal /
MOM etc.
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12 Compressive Strength of FCN-LB-10 As per due -- QA-QC Engineer If any NCP is
Concrete. date of -- found, same to
(Cube Register) testing be reported to
Fortnightly 17th, 2nd of QA-QC Engineer MR (Only in case Project In
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next month of grade above charge.


M-40)
Immediately -- QA-QC Engineer MR (Only in case
of cube failure)
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13 Standard Deviation FCN-LB-20 Monthly 10th QA-QC Engineer Regional ISO


Coordinator / MR
JMC Projects (I) Ltd.

Doc. No. - FQM-XX-08 (R4) Date : 27/08/2011 Page 03 of 03

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Communication Channel
Sr Description Doc. No Frequency Submission Originator Recipients Remarks

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No Date
14 Material Testing As per -- QA-QC Engineer ----- If any NCP is
a. Specific Gravity FCN-LB-04 PSQP found, same to
b. Dry Density by core FCN-LB-05 be reported to

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cutter Project In
c. Proctor Compaction test FCN-LB-06 Charge.
d. Fine Aggregate test FCN-LB-07
e. Coarse Aggregate test FCN-LB-08

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f. Brick Test FCN-LB-09
g. Cement Test FCN-LB-12

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h. Solid / Hollow Block FCN-LB-13
i. Steel Rolling Margin FCN-LB-15
15 Calibration Report As per due -- QA-QC Engineer ----- If any NCP is
a. Record of calibration
of measuring as well as
test equipment
b.Batching Plant
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FCN-LB-01

FCN-LB-02
date. found, same to
be reported to
Project In
charge
c. Weigh Batcher FCN-LB-03
on
16 Record of Verification As per -- QA-QC Engineer ----- If any NCP is
a. Material used prior to FCN-LB-11 PSQP found, same to
Inspection be reported to
b.Customer Supplied FCN-LB-14 Project In
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Product charge
17 Rolling Margin Report FCN-LB-15 Monthly 10th QA-QC Engineer Regional ISO
Coordinator / MR
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