SDL INTERNATIONAL CERTIFICATION EDUCATIONAL ACADEMY - SDLINC, CHENNAI.

COURSE OFFERED SDLINC CERTIFIED CIVIL QA QC

INSPECTOR ( Duration –30 days )

Course syllabus

Module 1 – Roles & responsibilities of QA/ QC Inspector

Module 2 - Introduction to the Company QMS ISO 9000 and ISO 14000 standards

Module 3 - International codes and standards

Module 4 - Concept of Quality Inspection

Module 5 - Classification of Civil work

Module 6 - Materials/specifications

Module 7 - Process Flow Diagram PFD

Isometric Drawings

Module 8 - Types of Civil constuction

Module 9 - Preparation of Inspection procedures

Module 10 - NDT methods

Module 11 – Calibration of instrument / equipment, IMTE

Module 12 – Project Quality plan

Module 13 – Inspect as per inspection test plan (ITP’s ) and Preparation

Module 14 - Specific quality procedures and Preparation

Module 15 – Quality Control QC Job Brief on Receiving, In-process, Final Inspection

Module 16 - Implementation and Monitoring QA/QC system

Module 17 -Traceability, Punch list

Module 18 - Stage wise inspection B31.1/B31.3 / API 570 )

Module 19 - Final documentation, Inspection Report, Non Conformance Report, QA/QC

For any clarification please feel free to contact the undersigned at this e mail id
sdlincacademy@gmail.com and in mobile +91 9600162099

Warm regards,

V Umashankar

Director ( Training, Recruitment Assistance & Corporate Relations)

Sridurgha Lakshmi Inc,

SDL INC Educational Society, 16, Netaji Colony, 1st cross street,

Velachery, Chennai - 600042, Tamilnadu ,India

Mobile/Cell : +919600162099

E Mail : sdlplacement@gmail.com

ndt@outlook.com, qaqc@outlook.com

http://www.indiamart.com/sridurgha-lakshmi-incorporation

http://in.linkedin.com/pub/v-umashankar-ceo-sdl-hr-academy-ndt-qa-qc-
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Table of Contents

1. Tests on Cement
1.1 Fineness 1
1.2 Consistency 3
1.3 Initial and final setting time 5
1.4 Soundness 7

2. Tests on Aggregates
2.1 Sieve analysis 9
2.2 Water absorption 13
2.3 Aggregate abrasion value 15
2.4 Aggregate impact value 18
2.5 Aggregate crushing value 21

3. Tests on Fresh Concrete

3.1 Workability 23
3.1.1 Slump 23
3.1.2 Compacting factor 25
3.1.3 Vee-Bee 27

4. Tests on Hardened Concrete

4.1 Non-destructive tests 29
4.1.1 Rebound hammer 29
4.1.2 Ultrasonic pulse velocity 31
4.2 Compression test 34
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5. Tests on Soil
5.1 Water content 38
5.1.1 Oven drying method 38
5.1.2 Calcium carbide method 41
5.2 Particle size distribution 44
5.3 Liquid limit 47
5.4 Plastic limit 50
5.5 Free swell index 52
5.6 Specific gravity 54
5.7 Maximum dry density and optimum moisture content 57
5.8 In-situ dry density 61
5.8.1 Core cutter method 61
5.8.2 Sand replacement method 63

6. Tests on Blanket Material 68

7. Tests on Bitumen
7.1 Bitumen content 72
7.2 Specific gravity 74
7.3 Marshall stability 76
7.4 Penetration 78
7.5 Flash point and fire point 80
7.6 Softening point 83
7.7 Ductility 86

ANNEXURES 89 to 99
List of suppliers of material testing equipments
alongwith their addresses 100
 1. TESTS ON CEMENT
1.1 FINENESS

AIM

To determine the fineness of cement by dry sieving as per

IS: 4031 (Part 1) - 1996.

PRINCIPLE

The fineness of cement is measured by sieving it through a

standard sieve. The proportion of cement, the grain sizes of
which, is larger than the specified mesh size is thus determined.

APPARATUS

FIG. 1 : IS SIEVE
i) 90µm IS Sieve

ii) Balance capable of weighing 10g to the nearest 10mg

iii) A nylon or pure bristle brush, preferably with 25 to 40mm

bristle, for cleaning the sieve

1
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 PROCEDURE

i) Weigh approximately 10g of cement to the nearest 0.01g and

place it on the sieve.

ii) Agitate the sieve by swirling, planetary and linear

movements, until no more fine material passes through it.

iii) Weigh the residue and express its mass as a percentage R1,
of the quantity first placed on the sieve to the nearest 0.1
percent.

iv) Gently brush all the fine material off the base of the sieve.

v) Repeat the whole procedure using a fresh 10g sample to

obtain R2. Then calculate R as the mean of R1 and R2 as a
percentage, expressed to the nearest 0.1 percent. When the
results differ by more than 1 percent absolute, carry out a
third sieving and calculate the mean of the three values.

REPORTING OF RESULTS

Report the value of R, to the nearest 0.1 percent, as the residue

on the 90µm sieve.

2
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CONTENTS
SRIDURGHA LAKSHMI INC
CHAPTER-1 NON - DESTRUCTIVE TESTING OF BRIDGES -
GENERAL

1.1 Introduction 1

1.2 Concrete Bridges 1

1.3 Steel Bridges 4

1.4 Masonry Bridges 5

CHAPTER-2 NON – DESTRUCTIVE TESTS FOR STRENGTH

ESTIMATION OF CONCRETE

2.1 Rebound hammer test (Schmidt Hammer) 6

2.1.1. Object 6
2.1.2 Principle 7
2.1.3 Methodology 8
2.1.4 Procedure for obtaining correlation 9
between compressive strength of concrete
and rebound number
2.1.5 Interpretation of results 10
2.1.6 Standards 11

2.2 Ultrasonic Pulse Velocity Tester 11

2.2.1 Object 11
2.2.2 Principle 12
2.2.3 Methodology 13
2.2.4 Determination of pulse velocity 17
2.2.5 Interpretation of Results 18
2.2.6 Factors influencing pulse velocity 19
measurements

2.3 Combined use of Rebound hammer and Ultrasonic 23

Pulse Velocity Method

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2.4 Pull Off Test 23

2.4.1 Object 24
2.4.2 Principle 24
2.4.3 Methodology 25
2.4.4 Advantages and Limitations 26
2.4.5 Standards 27

2.5 Pull out Test 27

2.5.1 Object 27
2.5.2 Principle 27
2.5.3 Methodology 28
2.5.4 Advantages and Limitations 29
2.5.6 Standards 30

2.6 The Break-off Test 30

2.6.1 Object 30
2.6.2 Principle 30
2.6.3 Methodology 33
2.6.4 Advantages and Limitations 35
2.6.5 Standards 35

2.7 Penetration Resistance Methods 36

2.7.1 Object 36
2.7.2 Principle 37
2.7.3 Methodology 37
2.7.4 Advantages and Limitations 38
2.7.5 Standards 38

CHAPTER-3 NON – DESTRUCTIVE TESTS FOR CORROSION

ASSESSMENT, LOCATION AND DIAMETER OF
REINFORCEMENT AND COVER THICKNESS OF
CONCRETE BRIDGES

3.1 Introduction 39

3.2 Half-cell Potential Measurement Method 39

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3.2.1 Object 41
3.2.2 Principle 41
3.2.3 Methodology 42
3.2.4 Interpretation of test results 43
3.2.5 Limitations 44
3.2.6 Standards 44

3.3 Resistivity Test 44

3.3.1 Object 45
3.3.2 Principle 45
3.3.3 Methodology 47
3.3.4 Limitations 47

3.4 Tests for carbonation of Concrete 47

3.5 Test for chloride content of concrete 48

3.6 Profometer 48

3.6.1 Object 49
3.6.2 Principle 49
3.6.3 Methodology 50
3.6.4 Advantages and Limitations 51

3.7 Micro Covermeter 51

3.7.1 Object 52
3.7.2 Principle 52
3.7.3 Methodology 52
3.7.4 Advantages and Limitations 53

CHAPTER-4 NON – DESTRUCTIVE TESTS FOR DETECTION

OF CRACKS / VOIDS / DELAMINATIONS ETC. IN
CONCRETE BRIDGES

4.1 Introduction 54

4.2 Infrared thermographic techniques 54

4.2.1 Object 56
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4.2.2 Principle 56
4.2.3 Methodology 56
4.2.4 Advantages & Limitations 57

4.3 Acoustic Emission Technique 58

4.3.1 Object 60
4.3.2 Principle 60
4.3.3 Methodology 61
4.3.4 Limitations 61

4.4 Short Pulse Radar Method 62

4.4.1 Object 62
4.4.2 Principle 63
4.4.3 Methodology 65
4.4.4 Advantages and Limitations 65

4.5 Stress Wave Propagation Methods 65

4.5.1 Pulse Echo method 66

4.5.2 Impact Echo Method 67
4.5.3 Impulse Response method 68

CHAPTER-5 NON – DESTRUCTIVE TESTING OF STEEL

BRIDGES

5.1 Introduction 70

5.2 Liquid Penetrant Inspection 70

5.2.1 Methodology 71
5.2.2 Material Properties 72
5.2.3 Advantages and Disadvantages 73

5.3 Magnetic Particle Inspection 73

5.3.1 Principle 74
5.3.2 Equipments and Methodology 76

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5.4 Eddy Current Testing 78

5.4.1 Methodology 79
5.4.2 Advantages and Limitations 81

5.5 Radiographic Testing 81

5.5.1 Methodology 81
5.5.2 Advantages and Limitations 82

5.6 Ultrasonic Inspection 83

5.6.1 Principle 83
5.6.2 Calibration and reference standards 86
5.6.3 Application of Ultrasonic Testing Method 87

CHAPTER-6 NON – DESTRUCTIVE TESTING OF MASONRY

BRIDGES

6.1 Introduction 89

6.2 Flat Jack Testing 89

6.3 Impact Echo Testing 90

6.4 Impulse Radar Testing 91

6.5 Infrared Thermography 92

LIST OF FIRMS DEALING WITH NDT EQUIPMENTS 93

REFERENCES 94

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 CHAPTER

III

Planning, Controlling,
and Assuring Product
and Process Quality
PROCESSES FOR PLANNING PRODUCT AND SERVICE
DEVELOPMENT
All but the most simple products contain very large numbers of features. In theory,
every feature of every unit produced could be inspected and judged against the require-
ments. However, this would add considerable cost to the product while, for most features,
adding little or no value to the customer. The producer is faced with the need for estab-
lishing a hierarchy of importance for the various characteristics of the product. Which fea-
tures are so important that they deserve a great deal of attention? Which need only a
moderate amount of attention? Which need only a cursory inspection? The activity of
arriving at this determination is known as classification of characteristics.
In practice, characteristics are usually classified into the categories critical, major, and
minor. The terms can be defined in simple terms as follows:
Critical characteristic—Any feature whose failure can reasonably be expected to pres-
ent a safety hazard either to the user of the productor to anyone depending on the
product functioning properly.
Major characteristic—Any feature, other than critical, whose failure would likely result
in a reduction of the usability of the product.
Minor characteristic—Any feature, other than major or critical, whose failure would
likely be noticeable to the user.
Incidental characteristic—Any feature other than critical, major, or minor.
Of course, it is possible to develop classification schemes that are more detailed.
However, the above definitions suffice for the vast majority of applications. Most often
classifications of critical characteristics are noted on the drawing as well as in the manu-
facturing plan, as well as in such other ways as to give the user ample warning of poten-
tial hazards.
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