Rengali Irrigation

Project,
Department of
Water Resources,
Government of
Odisha

QUALITY
CONTROL
AND
ASSURANCE
Report presented by

Group 1
Ajita Gupta (UM18005)
Aritra Mitra (UM18013)
Charusmita Tamrakar (UM18021)
Nirgun Nirakar Dash (UM18032)
Pallav Nayak (UM18034)
Raunaq Saraogi (MG18002)
 INTRODUCTION
Aim of the Project:
Quality Control and Assurance in Government Irrigation Projects.

About the Site:

Rengali Irrigation Project, Department of Water Resources, Government of Odisha

What is Quality?
Quality is meeting the requirement, expectation and needs of the customer being free from
defects, lacks and substantial variants. They are standard needs that need to be followed to satisfy
the customers’ requirements.
Quality can also be defined as “Conformance to requirements or specifications”. It begins
with the design of the product and also involves the general measurement standards, the use of
proper materials, selection of suitable manufacturing process and so on. Quality is a relative term
and is generally used with reference to the end use of the product.

What is Control?
Control can be defined as setting standards, testing or verifying actual performance,
comparing them with the standards and taking corrective actions.

What is Quality Control?

Quality Control (QC) may be defined as a system/process that is used to maintain a desired
level of quality in a product or service. It is a systematic control of various factors that affect the
quality of the product. It depends on materials, tools, machines, type of labor, working conditions
etc. QC involves inspection at a particular and also places emphasis on quality future production.
Quality control aims at prevention of defects at the source, relies on effective feedback system and
corrective action procedure. It uses inspection as a valuable tool.

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CONSTRUCTION OF CONCRETE WORK
Extreme care is necessary for preparation of transport and placing and finishing of concrete
in construction works. A bit of care and supervision can make a great difference between quality
and bad concrete. The cement, aggregates and water to be used in the work are to be tested as per
relevant specifications in Government laboratories and Design Mix reports are also required. The
test reports need to be registered in the Quality Control Register.
The Engineer-in-Charge should ensure that there are sufficient approved quality
construction materials stacked at construction sites. Prior information needs to be provided over
the concerned quality control staff while executing any major work so that random checks can take
place.

CONSTRUCTION EMBANKMENT
The earth needs to be laid in suitable layers not exceeding 30 kms for construction
embankments in a way that pebbles, gravels and small size boulders, not exceeding 100 mm are
well distributed and not nested in any position within or under the embankment. The root, grass
and rubbish are to be removed from the filling and the compaction is achieved with a Dry Density
of 95% under OMC.
When the embankments are constructed with black cotton soil, a layer of cohesive non-
swelling soil is to be provided to the bed and the side of the canal. Consolidation of CNS soil is
done at 90% of Maximum Dry Density (MDD) at OMC.
Preparation of Ground Surface for Embankment:
1. The top soil is cleared of all perishable materials and any soil which may become unstable
on saturation or may interfere in the development of proper bond between the foundation
and embankment. The depth of stripping for soil containing light grass cover is 5 cm to 7.5
cm and for agricultural land is 15 cm to 22.5 cm. (IS 4701 – 1982)
2. The ground surface under all canal embankments where it is below the maximum water
level in the canal shall be scarified making open furrows not less than 20 cm below the
natural ground surface at intervals not more than 1 m.
Pre-Construction Stage:
1. Visually inspect the borrow area for suitable earth for construction of embankment.
2. Collection of composite disturbed soil sample from nodal points of 50 m and testing them
in the central laboratories for their engineering properties.
3. Collection of undisturbed soil sample from the embankment base area in a grid of 50 m x
30 m to a depth of 6 m and testing them for their engineering properties.
4. Conduct the In-situ Density & Moisture content test, Grin Size analysis for classification,
Specific Gravity test, Atterberg’s Limit test, Standard Proctor Test, Permeability Test, Tri-
Axial sheer test and Consolidation test.

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 FIELD TEST DETAILS
1. CEMENT

a. Storage of Cement:
Cement needs to be stored in a damp-proof place. No cement is stored for more than 120
days counted from the date of dispatch by the manufacturer. Cement that is stored from between
120 days to 180 days

b. Field Test:
i. The cement bag needs to be inspected and there should not be any visible lump. The color
is expected to be greenish grey.
ii. When we thrust our hand into the cement bag, it needs to feel cool.
iii. The texture of the cement needs to be smooth.
iv. When a handful of cement is thrown into a bucket of water, the particles must float for a
while before sinking.
v. Make a stiff paste with about 100 gm of cement and a bit of water. Form a cake from the
paste and put it under water in a bucket. The shape of the cake should not be disturbed
while the cake goes to the bottom. In 24 hours, the cake should retain its original shape and
also attain some strength.
If a sample of cement satisfies the above field tests, we can conclude that the cement is suitable
for our use.
N.B.- The field tests aren’t an indication that the cement is good for every important work. To use
a cement for any important or major work, the user needs to test the cement in a Government
certified laboratory to confirm the requirements of the IS specifications with respect to its physical
and chemical properties.

2. AGGREGATE

a) Storage of Aggregates:
It is ensured that the aggregate is stored in a clean surface to avoid contamination with dirt,
clay and foreign materials. The aggregates are also separately stored as per their size required for
grading

b) Quality of Aggregates:
Aggregate shall consist of naturally occurring (Crushed or Uncrushed) stones, gravel and
sand or combination thereof. They shall be hard, strong and durable and free from veins and other
adherent coating and free from amounts of disintegrated pieces, alkali or vegetable matter. As far
as possible, flaky coriaceous and elongated pieces should be avoided.

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c) Deleterious Materials:
Aggregate shall not contain harmful materials like pyrite coal, mica or similar materials
and organic impurities in such quantity as to affect the strength and durability of concrete.
Aggregate to be used for reinforced concrete shall not contain any materials liable to attack the
steel reinforcement. Aggregate which are chemically reactive with alkalis of cement are harmful
as cracking of concrete may take place. Limits of deleterious materials 5% by mass where in
crushed fine aggregate is 2% by mass as per I.S. 383 – 1970 when tested in accordance with I.S
2386 – 1963.

d) Coarse Aggregate:
For the purpose of the specifications of the term “Coarse Aggregate” designated clean- well
graded aggregate most of which is retained on 4.75 mm I.S. SIEVE and quoting only so much
finer materials as permitted for various types described under clause 2.2 of I.S 383 – 1970 i.e
i) Uncrushed gravel or stone which results from natural disintegration from rock
ii) Crushed gravel or stone when its results from crushing of gravel or hard stone
iii) Partially crushed gravel or stone when it is a product of the blending of(i) and (ii)
Grading – The testing of grading should be done for coarse aggregate before starting concreting,
it should be tested by the means of standard sieves of I.S 383 – 1970 i.e % passing for graded
aggregate of nominal size when tested in accordance with I.S 2386 – 1963. The coarse aggregate
shall have specific gravity of 2.60 minimum

e) Fine Aggregate:
The term sand is used to designate aggregate most of which passes 4.75 mm I.S sieve and
contains only so much coarser materials as permitted in clause (4) of I.S 383 – 1970. All sand shall
be natural and be furnished by the agency from approved sources specified in the contract. Sand
should have an uniform and stable moisture content which shall be determined by the engioneer-
in- charge according to the weather conditions
Grading – the sand as batched shall be well graded and when tested by means of standard sieves
shall confirm to the limits given in I.S 383 – 1970 and shall be describes as fine aggregate grading
zones I, II, III and IV. Sand complying with the requirements from the four grading zone is suitable
for concrete. The fine aggregate to be used shall have minimum specified grade of 2.60.

f) Field Test before Starting Concrete:

i) Bulkage of Sand – In case of wet sand, the bulkage is to be determined in the field and
accordingly extra quantity of sand should be used
ii) Silt content – Specific test shall be made at the site of the above test and result be
recorded
Slump Test – The water – cement ratio should be strictly followed at the site but workability shall
be checked by slump test and the slump observed should be equal to that of the design mix. In case
of nominal mix, the slump should be equal to the desired workability.The moisture content in the
aggregate, size of material and actual quantity of water should be analyzed from the initial load.

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3. DESIGN MIX

Design Mix of concretes must be prepared at Government Laboratories and the ingredients
of the mix must be sent to the laboratory well before execution of the concrete work. Design mix
for concrete should also be finalized for a particular grade of concrete under specific conditions,
like, exposure, workability, durability, minimum standard deviation, etc. it must be made a point
to record the slump observed, brand and grade of cement and water cement ratio. The design mix
report should be recorded in the Quality Control Register. The quantity of plasticizer, if used
should also be specified for the design mix. The density of the concrete also needs to be noted.

Testing of Design Mix:

The following guidelines, given by the Chief Engineer, Quality Control and Research,
Bhubaneswar should be strictly adhered to:

It is to say that, concrete for which grade designation is indicated in the approved
construction drawing must be done by “Design Mix Concrete”. In special cases, when the design
mix concrete is not practicable to use for some valid reasons, ‘nominal mix concrete’ may be
allowed taking prior approval of the competent authority with due intimidation to Quality Control
Executive Engineer. However, such nominal mix concrete is permitted in ‘ordinary concrete
construction’, which does not call for concrete grades higher than M20. The proportion of
materials for nominal mix concrete shall be done in accordance with CI 9.3 of IS 456 – 2000.
Anticipated contractual complications, if any in affording the aforementioned procedure may be
brought to the notice of the competent authority for taking an appropriate decision prior to
implementation.

To adopt the design mix concrete, the Field Executive Engineer may be instructed to take
appropriate steps to obtain the design mix from the concerned quality control Executive Engineer
much before the start of the start of the construction work as it normally takes two months to
formulate the same.

4. REINFORCEMENT

a. Storage of Reinforcement:
Reinforcement needs to be stored in a way such that the rusting of steel is minimized.

b. Testing of reinforcing steel:

The following guidelines from the Chief Engineer, Quality Control and Research,
Bhubaneswar needs to be strictly adhered to:

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 It is proposed to adopt following procedure for testing of reinforcing steel prior to use in
reinforced concrete construction work as well as when there is a change in either brand or batch
of product during construction.

Head Works of Projects and Major Structures:

Collection of samples of steel for varying diameter should be done involving quality
control staff from the stack arranged by the Agency/Contractor at the construction site is sent to
the Department of Quality Control Laboratory for testing.

All Other Small Structures at Isolated Locations:

The Field Engineer-in-Charge of work should collect the sample and send the same to the
nearby Department of Quality Control Laboratory for testing under intimation to concerned
Departmental Quality Control Executive Engineer.
In case of non-availability of testing facility in the laboratory, the test should be conducted
on a priority basis in any Government Laboratory under intimation to the concerned Quality
Control Division.
Brands of steel to be used, if not mentioned in the agreement needs prior approval of the
competent authority and should be made available at the site for verification by the inspecting
authority and quality control staff.

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