Krishna Buildestates Pvt. Ltd. Element: Laboratory Manual

KRISHNA BUILDESTATES
ELEMENT: LABORATORY MANUAL

PVT. LTD.
Title : Standard Operating Procedure

DOC: KBE/HO/LAB/ 01
Laboratory Manual
Rev: 1.0 Date: 25.09.13 Page: 1
Where this page is over stamped with the word “controlled copy” this means:
1. Distribution is centralized from the head QA/QC

2. Each copy is issued to a particular person or organization. If no longer required it should be
returned.
3. It is not to be photocopied either in whole or in part. Additional copies are available on request.
4. Copy holder will automatically issue with any amendment. Responsibility for incorporating such
amendments rest with the copy.
Mr. Subhash Kumar Mr. Rakesh Bahl
REV. NO. 1 Prepared & Reviewed by Approved by

AGM QA/QC Director
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1.0 INTRODUCTION
1.1 GENERAL – Project Detail
1.2 Quality
Quality is culture that ensures the safety standard, compliances, process and
method within the company to achieve the quality standard.
Quality control:
Quality control refers to the technical processes that gather, examine, analyze and
report the projects and conformance with performance requirement.
 Valuating material, working methods, and productivity through appropriate

tests/ procedures and inspection etc.
 Appraising failures to these standards and acting when acting are not being
adhere to.
 Planning improvements in the standards and specifications.
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Title : Standard Operating Procedure Laboratory

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Various stages of QC are:
 Incoming material control

 Pre-construction and planning control
 Construction process control
2.1 Scope and Application

The present project quality plan is developed for execution for civil work
2.2 OBJECTIVE
The fundamental objectives of the PQP related to construction activities are
1. To ensure correct setting out of work

2. To ensure that the construction work are done in accordance with the appropriate
procedures.
3. No material is incorporate in the work unless tested and accepted.
4. To achieve the desired workmanship
5. To prevent any damage or deterioration of the work partially completed till the final
completion of the entire job.
6. To ensure maintenance of quality records conforming to the required quality and effect
operation of the quality system.
7. To monitor the implementation of the PQP by regular surveillance schedules audit and where
necessary, to suggest corrective act.
8. To carry out analysis of non- conformances and to implement corrective actions when
required
9. To monitor all performance in line with legislation, regulation and code of practice.
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RESPONSIBILITY: Process owner : Head QA/QC

Process operator : QA/QC
Involvement of : Project Manager and QA/QC
Process star : Raw material testing
Process end : Product testing
Part II
MATERIAL TEST PROCEDURE

CEMENT
PHYSICAL AND MECHANICAL PROPERTIES OF CEMENT AND TEST MENTHODS
General
The object of testing of physical and mechanical properties of cement has been to ascertain the
values of those properties which are found to be bare minimum and satisfactory in practice as
fixed by standard specification. Standard specification has adopted stain fixed values of these
properties beside on experience and requirement in the practice. Any deviation from such
standards indicates the presence of interior material of inferiority in process manufacture.
1.1 Consistency
The test is to used to determine the quantity of water required to produce a cement paste
of standard consistency. A neat cement paste is considered to be normal consistency when
300 gm plunger of vacate apparatus having rod of 1cm diameter is placed gently on surface
of the paste filled in vacate would settles to a point 5-7 mm from bottom on the mould the
amount of water needed to prepare paste having this consistency and expressed as
percentage.
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This test is carried out in laboratory having controlled environment with temperature of 27 +2 and
relative humidity 65+ 5 in most tests which are to performed after mixing cement with water such
mixing and casting has to be carried under standard condition of temperature and humidity.
1.2 Initial And Final Setting Time:
Initial Setting Time
The initial setting is time elapsed between gauging and partial loss of plasticity, this measured by an
instrument called vacate needle apparatus. Here a plunger having weight of 300gm and needle with1
millimeter square cross section is dropped on a cement paste of consistency 0.85P(where p is % of water
for standard consistency) into cylinder mould the initial set is set to reached when needle is no longer
able to pierce the test block within 5mm to bottom shall initial setting time.
Final Setting Time:
Final setting is the time required for gauged cement to acquire sufficient firmness to resist a certain
definite pressure to initial set out fitted with metal attachment hollowed out so as to leave circular
cutting edge 5mm in diameter. Final set is said to be achieved or attained when needle gently lowered
to the surface of the test block, make a impression on it but the circular edge on it fail to do so. The time
elapsed between the time of adding of water to the cement and attainment of final set is called the final
setting time.
The major chemical factors that affect setting of cement are presence of larger alumina and ferric oxide.
1.3 Compressive Strength of Cement
Any hydraulic cement is expected to give a minimum strength at the specified age when test in a
standard manner. The test specimen shall be on the form of cement mortar cub e having an area of
50cm, height of mould is 7.06cm, the cement mortar is prepared by mixing the cement with standard
sand (sand IS650:1966) is proportion 1:3. With quantity of water given by {p/4=3.0} percent combined.
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Process operator : QA/QC

Involvement of : project manager and QA/QC
Process start : raw material testing
Process end : product testing
PART -I
LABORATORY OPERATION
PURPOSE AND SCOPE
For the project it is felt necessary to achieve very high degree of quality. This procedure applies to
testing of all construction materials including aggregate, concrete, reinforcement, earthwork in the site
laboratory.
Action and Responsibilities
Site QA/QC in charge engineer is overall responsible for operation of laboratory testing of material,
material, reports, documentation, maintenance & calibration of laboratory equipment.
References
Bureau of India standard specification and project quality plan (PQP) referred for all the materials
sampling and tests sampling and tests including water as well as in construction.
Site Laboratory
The site lab shall be equipped with testing facilities for earth work, aggregate concrete, and other
permanent work construction materials for structure work. The area allotted as per project
requirement. This shall have-
1. Lab office room for keeping of test records & files.

2. Big hall for testing equipments (approx 8900 Sft.).
3. One water tank.
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Determination of workability of concrete
Slump Test- AS PER IS: 1199
PROCEDURE
 Clean the internal surface of slump mould thoroughly.

 Fill the concrete sample in the mould in four layers, each layer approximately ¼ of the height of
the mould.
 In case of the concrete containing aggregate of maximum size more than 38mm, the concrete
shall be wet sieved through 38mm screen to exclude aggregate particles bigger then 38mm.
 Tamp each layer 25 times by tamping rod.
 When the mould is filled, cut off the excess concrete, to the level of the cone.
 Immediately remove the mould by raising it slowly in vertical direction, allowing the concrete to
subside.
 Place the mould by side of subsided concrete.
 Measure the difference in level between the height of the mould and highest point of the
concrete in millimeter and record it as slump.
 Inspect the type of slump and record it.
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Compressive Strength of Concrete Cubes
AS PER IS: 516
PROCEDURE
 Fill the mould with freshly mixed concrete in three equal layers, compact it with tamping rod
giving 35 blows in each layer uniformly and finally level off with trowel.
 Mark the date of casting, cube no and identification of member.
 Keep the specification in moist air of at least 90% relative humidity and at a temperature of 27
plus minus 2 degree Celsius for 24 hours. Alternatively cover the moulds with wet gunny bags.
 After period of time, period is over remove the specimen from the moulds and submerge it in
afresh clean water, maintained at a temperature of 27 plus or minus 2 degree till the cube is
ready is for test.
 Take out the cube for 7, 28, days as required and wipe off the surface water with cloth.
 Note down dimension and weight the cube and place in compression testing machine.
 Apply the load on the cube at the rate of 140kg/sqm/min till it fail. Record the maximum load
applied.
 Inspect the type of failure and record it.
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SIEVE ANALYSIS OF AGGREGATES
AS PER IS 2386 PART-I
PROCEDURE
 Bring the sample to an air dry condition either by drying at room temperature or heating at a
temperature of 100 to 110 degree Celsius.
 Take the weight of the sample (maximum weight of the sample should be taken as per IS 2386
part-I)
 Clean all the sieve and sieve the sample successfully on the appropriate sieve starting with
largest.
 Shake each sieve separately over a clean tray until not more than a trace passes, but in any case
for a period of not less than two minute.
 Shake a sieve with a varied motion, backwards and forwards left to right, circular clockwise and
anticlockwise, and with frequent jerking, so that the material is kept moving over the sieve
surface in frequently changing direction.
 Do not force the material through the sieve by hand, except for sizes coarser than 20mm.
 Break the lumps of fine particles, if any with fingers against the side of the sieve.
 Light brushing with soft brush on the underside of sieve may be used to clear the surface.
 On completion of sieving note down the weight of material retained on each sieve.
 Report the results as cumulative percentage by weight of sample passing each of the sieves.
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AGGREGATE CRUSHING VALUE
AS PER IS: PART-IV
APPRATUS
I. Cylindrical Measure and Plunger

II. Compression Testing Machine
III. IS Sieves of sizes- 12.5mm, 10mm, and 2.36mm
PROCEDURE
 The aggregate passing through 12.5mm and retained on 10mm IS sieve are oven dry at a
temperature of 100 to 110 degree Celsius for 3 to 4 hrs.
 The cylinder of the apparatus is filled in 3 layers each layer temped with 25 strokes of
temping rod.
 The weight of Aggregates is measured (weight A)
 The surface of the aggregate is leveled and plunger is inserted. The apparatus is then placed
in compression testing machine and loaded at a uniform rate so as to achieve 40 tone loads
in 10 minute. After this the load is released.
 The sample is then sieved through 2.36mm IS sieve and then fraction passing through the IS
sieve is weight (B).
 Two tests should be conducted.
REPORTING OF RESULTS
Aggregate crushing value =B/A
Where,
B=weight of fraction passing the appropriate sieve
B=weight of surface dry sample
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Determination of flakiness and elongation index
AS PER IS: 2386 PART III
APPARATUS
Flakiness and Elongation Gauge, IS sieve 40mm, 25mm, 20mm, 16mm,12.5mm,10mm, and 6.3mm,
weight balance, Sieve Shankar etc.
PROCEDURE
 Take a representative sample and sieve the sample through is sieve 63,50,40,31.5mm,
25mm,20mm,16mm,12.5mm,10mm,6.3mm.
 Separate the flaky material which passes through standard gauge.
 Take the material which passes through standard gauge.
 The Flakiness Index=Wt of material passing the gauge/ total wt of sample x100=F.I
 Take the non Flaky portion of the sample tested and Weight (W2gm)
 Separate Elongated material by using standard Elongation gauge and take weight.
 The Elongation Index=wt of Elongated particle / sample tested
REPORTING OF RESULTS
The results should be calculated and reported and reported as-
1. the cumulative percentage by weight of total sample

2. The percentage by weight of the total sample passing through one sieves and retained on
next smaller sieve to the nearest 0.1 percent.
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SAMPLING OF AGGREATESS
SAMPLING FROM STOCK PILE
PROCEDURE
 Divide the quantity of aggregate into a suitable no. of lots of approximate equal size
 Scope out aggregate at various points of sub-lot
 Take minimum no. of 10 increments from the exposed side of stock pile. Each increment not less
than1 kg no of increment being equally distributed over the sub-lot
 Collect it in a sampling bag to from a cross sample representative of sub-lot.
 The no of increments is taken equally from the top third at the middle point and at the bottom
third of the volume of the pile.
 The size of the field sampling may be taken as per it.
REDUCTION OF GROSS SAMPLE
Divide the aggregate that have been collected by any methods explain below-
REDUCTION BY RIFFLE DIVIDER
1. Keep the collector boxes on either side of riffle divider.

2. Mix the aggregates and pour into the riffle.
3. Repeat this process using deferent size riffles according to the size of aggregates, till the
required quality of aggregate is obtained.
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SAMPLING OF FRESH CONCRETE
AS PER IS: 1199
PROCEDURE
 From mixture: at least from 3 portion of the batch, collect the sample so that the composite
sample will be .02 cum approximately.
 From concrete at the time and place of deposition. Collect the increments of sample from not
less than five well distributed position.
 Avoid the edge of mass where segregation may occur.
 Mixed the composite sample.
 After collection the composite sample either of the above described methods
 Mix it thoroughly with it shovel to obtained a uniform sample and shall be used immediately for
the purpose of carrying out the test.
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Laboratory Manual
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Job Responsibilities
Reporting to : Quality Head

Reporting for : Quality Engineer / Lab Technician
Duties & Responsibilities:
 Checking quality raw material at source and laboratory as per frequency

 Sample collection for testing and for approval.
 To ensure that proper methodology and instruction are followed in execution of various activities of central
laboratory.
 Issued NCR to site project manager.
 Monitoring overall activities in project laboratory.
 To impart training and coordinate for technical and functional subject.
 Preparation for MIS Report.
1.0 Job Title: Lab In charge
2.0 Job Title : Lab Engineer
Reporting to : Lab In charge

Reporting for : Lab Technician
 To maintain laboratory and keep equipment in good condition.

 Checking and preparing test result as per IS code and specification.
 To maintained all laboratory record.
 To check all site activities that conformed as drawing and specification.
 Sample collection and checking of raw materials.
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3.0 Job Title : Lab Technician
Reporting to : Lab Engineer
 To maintain QC lab in good condition.

 To carried out lab test and field testing.
 To maintained laboratory records.
 To ensure calibration of all equipment should conduct as per desired time.
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Frequency of calibration of laboratory
S. no. NAME OF EQUIPMENT FREQUANCY OF CALIBRATING AGENCY

CALIBRATION
1
2 CTM 2000kn Yearly Third party
3 Third party
4 Digital vernier calipers 0.150 Yearly Third party
5 Cube Mould 150*150*150mm quarterly Third party
6 Rapid Moisture Meter 0-25% Half yearly Third party
7 Wire Gauge Yearly Third party
8 Hot air Oven 250 C Yearly Third party
9 Digital Balance 2 kg Yearly Third party
10 Digital Balance 100kg Yearly Third party
11 IS sieve brass, 20cm dia complete set Yearly Third party
12 IS sieve GI, 4cm, dia complete set Yearly Third party
13 Digital PH Meter 0-14 PH Yearly Third party
14 Digital Thermometer with SS Stem(50 to 300) Yearly Third party
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MATERIAL TESTING
LIST OF TEST FOR VARIOUS MATERIALS
1. AGGREGATE
1. Sieve analysis
2. Aggregate Crushing Value
3. Aggregate Impact Value
4. Specific Value
5. Water Absorption
6. Flakiness & Elongation
7. Determination of Clay, Slit, and fine Dust
8. Bulk Density
2. COURSE SAND
1. Sieve Analysis & finesses Modulus

2. Determination of clay, Silt and fine, Dust
3. Specific Gravity
4. Water Absorption
5. Bulk Density
3. STEEL
1. Ultimate Tensile Strength

2. Yield Stress
3. Elongation, Bend Re-Bend
4. Rolling Margin.
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MATERIAL TESTING
LIST OF TEST FOR VARIOUS MATERIALS
4. CONCRETE
1. Cube compression Test

2. Mix Design
3. Workability
5. WBM
1. Sieve Analysis
2. Water Absorption
3. AIV
6. SOIL
1. Standard Proctor Test

2. Field Density Test
3. Gradation & Moisture Content
7. BRICK
1. Dimension Test
2. Shape and Visual Test
3. Water Absorption
4. Compressive Strength
5. Efflorescence
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MATERIAL TEST PLAN

S.No. MATERIAL TEST REQUIRED SPECIFICATION/RELIVENT ACCEPTANC FREQUANCY
IS CODE E CRITERIA
1 sand Particle Size Analysis IS : 2386 part I -1963 IS Every load
specification
Specific Gravity & IS 2386 Part – 3-1963 IS weekly
Water Absorption specification
Bulk Density IS 2386 IS weekly
specification
Silt Content IS 2386 , 1S 1542-1992 IS Every load
specification
2 Aggregate Sieve Analysis IS : 2386 PART I - 1963 IS weekly
specification
Crushing Value IS : 2386 Part -4-1963 IS weekly
specification
Specific Gravity & IS 2386 Part- 3 -1963 IS weekly
water Absorption specification
Silt, Clay Content, & IS : 2386 Part- I- 1963 S specification 50cm
Fine
Flakiness & Elongation IS : 2386 Part- I- 1963 IS 50cm
Index specification
Bulk Density IS : 2386 Part- I- 1963 IS Weekly
specification
Impact Value IS: 2386 Part-IV- 1963 IS weekly
specification
Consistency test IS: 8112 IS weekly
specification
cement Compressive strength IS: 8112
Initial & final setting
time
3 Steel Physical IS: 1786-1985, IS: 1599- IS Every lot test
Reinforcement 1963 specification report
Concrete Design Mix IS: 456,10262 & SP- 23 IS Every source
specification change
Workability IS: 456 2000, IS-1199 IS Every load
specification
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S.No. MATERIAL TEST REQUIRED SPECIFICATION/RELIVENT ACCEPTANCE FREQUANCY

IS CODE CRITERIA
Procter Test IS 2720- IS One set for 200m2
specification
Gradation & Moisture IS 2720 IS 200m2
Content specification
4 Earth Work Compaction Test IS 2720 Should not be 300m
less than 95%
5 Brick Visual Inspection IS: 1077- 1992 IS specification Every load

Compressive Strength IS: 1077-1992,IS: 3495- 75kg/cm2 Every load
1992 Part -1
Dimension Inspection IS: 1077 - 1992 Length:4600+/- Every load
80mm
Width: 2200+/-
Water Absorption IS: 1077 -1992, IS:3495- 20% Every load
1992 Part- 2
Efflorescence IS 1077-1992,IS 3495 Part moderate Source change
-2
6 Wood Moisture content
Visual Inspection
Brick work Line, level, Groove As per contract & As per contract As per RFI
7
specification & specification
plastering Line, Level, Thickness As per contract & As per contract AS PER RFI
8
specification & specification
Tile Line, level, Thickness As per contact & drawing As per contact AS PER RFI
9 specification & drawing
specification
Plumbing & Pressure,Testing, As per contact & drawing As per contact AS PER RFI
10 fire fighting Dimension,Fitting, specification & drawing
Fixture specification
electrical Material
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LABORATORY EQIPMENT
S NO. NAME OF EQIPMENT
Pan balance – capacity 2kg, accuracy- 0.5gm

1
Platform balance –capacity
2
Concrete cube mould (50 N0) with temping rod size 150*150mm
3
Aggregate impact test No
4
Aggregate crushing value apparatus 1 NOS
5
Measuring glass cylinder – 1000ml, 500, 250ml, & 100ml
6
Measuring plastic cylinder – 1000ml, 500ml, 250ml,
7
Density basket -2 No
8
Slump cone apparatus with measuring rod – 4 No
9
Sieves for course aggregate – GI 18”dia, 100mm, 80mm, 63mm, 31.5mm, 25mm, 20mm, 16mm, 12.5mm,
10
10mm, 8mm, 6.3mm 4.75mm, Lid& pan) set of 13
Sieves for fine aggregate – brass sieve ( 2.36mm, 1.18, 500micron, 425micron, 300micron, 212micron,
11
150micron, 150micron, 90micron, 90mic, 75mic, 45mic, 45mic, lid & pan –set of 10
Electric oven size 455mmx455mmx455mm 1 No
12
Cube testing matching – capacity 2000KN 1 No
13
Digital thermometer ( -50 to 300 C 1No
14
Concrete mixture drum( .003m3 1 No
15
16 Vacate apparatus 1 No.
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COARSE AGGREGATE SPECIFIC GRAVITY

(IS: 2386 PART III)
SAMPLE FROM: JOB ID NO:

REF LETTER NO: TEST REF NO:
SOURCE: DATE:
LOCATION: TESTED BY:
SIZE/ TYPE OF AGGREGATE: 20 mm/10 mm TIME OF TESTING:
S.No DETERMINATION 1 2
1 Weight of saturated in water, gms (A)
2 Weight of SSD aggregate in air, gms (B)
3 Weight of oven dried aggregate in air (C)
4 Specific Gravity IS 2386(Part III) = C/(B-A)

Average
Remarks: Confirms/Does not confirm to IS 2386(PART III)
KBE Representative
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DETERMINATION OF SPECIFIC GRAVITY (USING PYCNOMETER)
(IS: 2386 /PART III)

SOURCE: DATE:
SIZE/ TYPE OF AGGREGATE: TIME OF TESTING:
DETERMINATION 1 2
Weight of Empty Pyconometer (W1) gms
Wt. of PYC + Sample (W2) gms
Wt. of PYC + Sample + Water (W3) gms
Wt. of PYC + Water (W4) gms
Specific gravity= (W2-W1)/(W4-W1)-(W3-W2)
Specific gravity Average
Remarks:
KBE Representative
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DETERMINATION OF IMPACT VALUE
(IS: 2386 /PART 4)

SOURCE: DATE:
LOCATION: Project Field Laboratory TESTED BY:
SIZE/ TYPE OF AGGREGATE: PASSING 12.5 mm TIME OF TESTING:
RETAINED ON 10 mm
SL No DETERMINATION 1 2
1 Weight of Dry Aggregate (W1) gms.

2 Weight of Aggregate retained on 2.36 mm
3 Weight of Aggregate passing through 2.36 mm sieve (W2) gms
4 Impact Value = W2/W1X100 %
5 Average Impact value %
Limit: As per IS: 383-1970 (i) for wearing surfaces -30% (max.)
As per IS: 383-1970 (ii) for non wearing surfaces - 45% (max.)
Result: Confirms / does not conform to IS 383-1970
Remarks:
KBE Representative
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DETERMINATION OF SILT CONTENT TEST
(IS: 2386 / IS 383)

SOURCE: DATE:
1 Weight of Rep. sample (in grams)
2 Weight of Sample after oven drying (in grams)
Oven dried weight of sample retained on 75 micron sieve after

3
washing (in grams)
4 Percentage of silt / clay (2-3) / (2) x 100
Average
Result: Confirms/Does not confirms to 4.1 (Table-2) of IS:383-1970
Limit: 3 % as per IS: 383-1970
Remarks:
KBE Representative
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WATER ABSORPTION TEST

(IS: 2386 / PART 3) Documents No:
Coarse Aggregate / Fine Aggregate

SOURCE: DATE:
S.No DETERMINATION 1 2
1 Weight of saturated surface dry sample in air, (gm)
2 Weight of oven dry sample in air,(gm)
3 Water absorption, % (1-2) / 2 x 100
Average %
SIZE/ TYPE OF AGGREGATE: 10mm

S. No DETERMINATION 1 2
1 Weight of saturated surface dry sample in air, (gm)
Average %
Result: Confirms/does not confirm to IS 383 - 1970.
Remarks:
KBE Representative
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WATER ABSORPTION TEST

(IS: 2386 / PART 3) Documents No:
Coarse Aggregate / Fine Aggregate

SOURCE: DATE:
SIZE/ TYPE OF AGGREGATE: River Sand/Crushed sand
Weight of saturated surface dry sample in air,
1
(gm)
Average %
KBE Representative
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SIEVE ANALYSIS PLASTER FOR SAND
Source: Date Sampled:

Location at Site: Sampled by:
W.T. of Sample (GMS): Date Tested:
Moisture Content: Tested by:
DRY/WET Grading:
Lab Job No.

IS WEIGHT PERCENTAGE CUMULATIVE IS CODE
SIEVE RETAINED RETAINED PERCENTAGE PERCENTAGE PASSING FOR REF.
DESIGNAT (gm) RETAINED
ON
AS PER IS:REQUIREMENT FOR
TEST
4.75MM 100 IS: 1542
2.36MM 90-100
1.18MM 70-100
600MIC 40-100 IS: 2386

(Part I)
300MIC 5-70 -1963
150MIC 0-15
MAXM
PASSING 75 MIC SIEVE

Remarks:
KBE Representative
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PROJECT NAME: PERIOD:
CONTRACTOR'S NAME: DATE:
OBSERVATIONS
S.No. WORK DESCRIPTION REMARKS
Poor Average Good N/A
A FORM WORK
1 QUALITY OF PLY BOARD USED
2 QUALITY AND QUANTITY OF SHUTTERING OIL
USE OF MASKING TAPE FOR SEALING THE JOINTS OF
3
PLY BOARD
FORIGN MATERIAL USED IN SHUTTERING TO AVOID
4
SLURRY LEAKAGE
CLEANING OF SHUTTERING/ FORMWORK WITH AIR
5
COMPRESSOR OR WATER JET
6 QUALITY OF SCAFFOLDING USED
7 OVERALL WORKMANSHIP
B REINFORCEMENT WORK
QUALITY AND SIZE OF REBAR USED AS PER APPROVED
8
DRAWING
9 LAPPING OF REBARS IN RESPECTIVE LAP ZONE
10 BINDING OF REBARS WITH BINDING WIRE
11 QUALITY AND EXTRA LENGTH OF BINDING WIRE
ADEQUATE CLEAR COVER TO THE REINFORCEMENT
12
BAR
OVERALL WORKMANSHIP IN CUTTING, BENDING &
13
FIXING OF REBAR
C STRUCTURE
ALIGNMENT OF HORIZONTAL AND VERTICAL
14
COMPONRNT AS PER DRAWING
15 HONEYCOMBING/ SEGRAGATION IN CONCRETE
16 QUALITY OF FINISHED SURFACE(RCC)
17 SHRINKAGE CRACKS ON CONCRETE SURFACE
18 IMPROPER REPAIRING
19 BEARING PLASTER PROVIDED
STATUS OF CURING AND DATE OF CASTING ON THE
20
STRUCTURE COMPONENTS
21 QUALITY OF CONSTRUCTION JOINTS IN CONCRETE
29
KRISHNA BUILDESTATES PVT.
LTD.

DOC: KBE/HO/LAB/ 30
Manual
Rev: 1.0 Date: 25.09.13 Page: 30
D BRICKS MASONRY
22 CHICKEN WIRE MESS PROVIDED AS SPECIFIED
23 QUALITY OF BRICKS USED IN MASONRY WORK
24 HACKING DONE ON CONCRETE SURFACE
25 THICKNESS OF MORTAR BED IN BRICK WORK
26 6mm STEEL BAR PROVIDED IN HALF BRICK WALL
PROPER FILLING AND RAKING OF VERTICAL AND
27
HORIZONTAL JOINTS
28 PROPER MIXING RATIO AS PER WORK ORDER
29 MIXING OF MORTAR AT SITE
30 OVER ALL BRICK WORK QUALITY
E FINISHING
31 CRACKS IN WALL PLASTER
32 UNDULATION/ WAVINESS IN PLASTER WORK
33 SEEPAGE OBSERVED IN PLASTER
34 QUALITY OF FLOORING / TILING WORK
35 THICKNESS OF STONE AND JOINTS
36 NOSING/MOULDING ON STONE WORK
37 SLOPE CHECKED AND RECORDED
38 SEQUENCING OF ACTIVITY FOLLOWED
39 ROOM SIZES OF UNITS
40 DIMENSIONS OF JAMBS/SOFFIT/DOOR/ WINDOW
41 DOOR HINGES AND MAKE
WORKMANSHIP IN FIXING OF ELECTRICAL AND
42
SANITARY ITEMS
WORKMANSHIP IN EXTERNAL DEVELOPMENT
43
WORK
44 THICKNESS AND UNIFORMITY OF WAIST SLAB
45 SIZE OF LANDING,TREAD,RISER OF STAIR CASE
46 DESIGN FAULTS, IF ANY
30
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DOC: KBE/HO/LAB/ 31
Manual
Rev: 1.0 Date: 25.09.13 Page: 31
F PLUMBING, SANITARY & BUILDING ELECTRIFICATION
QUALITY OF PIPES, FIXTURE & OTHER ACESSARY AS PER
47
APPROVED BRAND
VISUALS OBSERVATION OF PIPES, FIXTURE & OTHER
48
ACESSARY
49 PRESSURE TESTING AS SPECIFIED
JOINTING OF PIPES AND SANITARY APPLIANCES ARE AS
50
APPROVED METHOD STATEMENT
ALL ELECTRICAL CABLE, WIRES USED AS PER APPROVED
51
BRAND & SPECIFICATION
STATUS OFAPPROVED BRAND OF ALL ELECTRICAL
52
MCB's, SWITCH BOARD, AND OTHER APPLIANCES
BACK BOX OF SWITCH BOARD PROPERLY CONNECTED
53
WITH EARTHING
G SAFETY AND HOUSEKEEPING
53 PPE's USED BY THE WORKERS/ STAFF
BARRICADING OF OPEN CUT- OUTS AND TEMPORARY
54
HAND RAILS FOR STAIRE CASE
55 HARD BARRICADING OF THE EXCAVATED AREA
THIRD PART INSPECTION OF CRANE AND OTHER
56
LIFTING MACHINE
HEIGHT OF LIVE ELECTRICAL CABLE IN THE WORK
57
AREA
EARTHING OF ALL ELECTRICAL MACHINE AND
58
EQUIPMENT
59 REVERSE HORN IN ALL MOVING VAHICLE
STATUS OF EMERGENCY CONTACT NUMBERS,
EMERGENCY ASSEMBLING POINT AND EMERGENCY
60
ACTION PLAN ARE WELL DISPLAYED ON THE NOTICE
BOARD IN THE WORK AREA
SAFETY SIGN AND AWARENESS DISPLAY BOARD
61
DISPLAYED AT REQUIRED LOCATIONS
62 STATUS OF SAFETY PARK AND FIRST AID ROOM AT SITE
31
LTD.

DOC: KBE/HO/LAB/ 32
Manual
Rev: 1.0 Date: 25.09.13 Page: 32

H DOCUMENTATION & RECORDS

QUALITY
63 TEST REGISTER MAINTAINED
64 SITE ORDER BOOK
65 RMC STOCK REGISTER
66 APPROVED DESIGN MIX BEING USED AT SITE OR NOT
67 POUR CARD RECORDS MAINTAINED
68 CALIBRATION OF EQUIPMENTS DONE(NABL LAB)
RECORD OF REJECTED MATERIALS.(LOCATION TO BE
69
CHECKED)
70 CUBE REGISTER MAINTAINED
STEEL TEST RECORD MAINTAINED -(TENSILE + ROLLING
71
MARGIN)
72 RECORDS OF ATT POURING
FREQUENCY IS FOLLOWED FOR MATERIAL TESTING(AS
73
PER IS CODES)
74 TESTING OF MATERIALS DONE BY EXTERNAL AGENCY
75 MTC OF MATERIAL TESTING , IF ANY
76 RECORDS OF PRESSURE TESTING IN PLUMBING LINE
77 EARTH COMPACTION TESTING RECORD
SAFETY & HOUSEKEEPING
78 TOOL BOX INDUCTION RECORD
79 FIRST AID RAGISTER
80 MONTHLY ACCIDENT STATICS RECORD
81 SAFETY INSPECTION REPORT
HAZARD IDENTIFICATION AND RISK ASSESMENT
82
RECORD OF ALL ACTIVITY
I MISC. DEFECTS
J REBOUND HAMMER TEST ON ATLEAST 25 Nos. OF COLUMNS AT DIFFERENT LOCATIONS.
32
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DOC: KBE/HO/LAB/ 33
Manual
Rev: 1.0 Date: 25.09.13 Page: 33
NAME OF PROJECT:
Quality Assurance & Quality Control Report for the Month
1. Site Abnormality Report (NC Internal - During the month)

S. NC ID Raised on Dept. Description of Non Conformance NC Date Status Remarks
No.
Total No of NC Raised
Total No of NC Closed up-to-date
2. Testing of Cement
No of Type of Batch No. Observed

Test Make Remarks
Tests Cement Limit Value (Avg.)
MTC Review
Initial Setting Time
Final Setting Time
General observation
Total No of NC Raised
Total No of NC Closed up-to-date
33
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DOC: KBE/HO/LAB/ 34
Manual
Rev: 1.0 Date: 25.09.13 Page: 34
3. Testing of Steel Reinforcement Bars
No of Type of Dia. (mm) Observed

Test Make Remarks
Tests Steel Limit Value (Avg.)
- TMT
MTC Review
Physical Observations - Within limit

Unit Weight - AS PER IS:1786
Physical Test -
Chemical Test -
4. Testing of Flyash
No of Min (%) Observed

Test Source Max. (%) Remarks
Tests Limit Value (Avg.)
MTC Review
Material Retained <34%
45 mic Sieve
34
LTD.

DOC: KBE/HO/LAB/ 35
Manual
Rev: 1.0 Date: 25.09.13 Page: 35
5. Testing of Concrete Admixture
No of Dia. (mm) Observed

Test Source Batch No. Remarks
Tests Limit Value (Avg.)
MTC Review
PH Value
Specific Gravity
Trial Mix
Physical Test as per IS
9103
Chemical Test as per IS
9103
6. Brick Test
S.No. No of Tests Description Acceptance Standards as per Results Remarks

IS:3495 , 1077 & 12894
Compressive Strength Class I: 10 Mpa (min) &
1
Class II: 7.5MPa(min)
2 Water Absorption 20% Maximum
Dimension (Non Modular) Length 4568 to 4680mm, Width
3 for 20 No. 2240 to 2160mm,
Height 1440 to 1360mm
4 Efflorescence Nil to Slight (Not more than 10%)
35
LTD.

DOC: KBE/HO/LAB/ 36
Manual
Rev: 1.0 Date: 25.09.13 Page: 36
7. Testing of Course Aggregates (Flakiness & Elongation Index)
Type of Aggregate No of Tests Flakiness Limit Elongation Limit Remarks

Index(Average) Index
20mm coarse Max 35% Max 35%

Aggregate
10mm coarse Max 35% Max 35%
Aggregate
8. Testing of Coarse Aggregates (Sieve Analysis)
Type of Aggregate No of Tests Limit as per IS 383-1970 Physical Observation Remarks
Sieve 40mm -100%Passing,

20 mm Coarse Aggregate Sieve 20mm -85-100, Sieve10mm -
0-20,Sieve 4.75mm - 0-5%Passing.
Sieve 12.5mm -100%Passing,
Sieve 10mm -85-100,
10 mm Coarse Aggregate
Sieve4.75mm - 0-20,Sieve 2.36mm
- 0-5%Passing.
Sieve 40mm -100%Passing,Sieve
Combined Coarse Aggregate 20mm -95-100, Sieve10mm - 25-
55,Sieve 4.75mm - 0-10%Passing.
9. Testing of Coarse Aggregates (Impact Value Test)
Type of Aggregate No. Of Impact Value % IS: Limit Limit as per IS:383-1970 & IS:2386 (PartIV)-1963
Test
20 mm Coarse Aggregate Max. 45%
10 mm Coarse Aggregate Max. 45%
36
LTD.

DOC: KBE/HO/LAB/ 37
Manual
Rev: 1.0 Date: 25.09.13 Page: 37
10. Testing of Fine Aggregates (Silt content)
Type of Aggregate No of Tests Fineness F.M .Limit Zone Average Silt Silt Limit Remarks
Modulus Content
coarse sand 2.4 to 3.5 ll 3% by Wt.
11. Testing of Fine Aggregates (Sieve Analysis)

Type of Aggregate No of Limit as per IS Zone Physical Remarks
Tests Observation
22 Sieve 10mm -100%Passing,Sieve
River Sand 4.75mm -90-100, Sieve2.36mm - 75- IS 383;1970 Wash sand
100,Sieve 1.18mm - 55-90, 600Mic.- zone II
35-59,300Mic.- 8-30,150Mic.- 0-
10%Passing.
2 Sieve 4.75mm -100%Passing,Sieve
Sand for Masonry Mortar 2.36mm -90-100, Sieve1.18mm - 70- IS ;2116;1980 fine sand
100,Sieve 600Mic.- 40-100,300Mic.- TABLE 1
5-70,150Mic.- 0-15%Passing.
1 Sieve 4.75mm -95-100%Passing,Sieve

Sand for Plastering 2.36mm -95-100, Sieve1.18mm - 90- IS:1542 Yamuna sand
100,Sieve 600Mic.- 80-100,300Mic.-
20-65,150Mic.- 0-15%Passing.
12. Testing of Sp Gravity & Water Absorption of Aggregates
Type of Aggregate No of Tests Acceptance Standard SP Gravity Source Water Absorption Observed
Observed Value Value
20 mm Coarse Aggregate 1 Limit as per IS:383-1970
& 2386-1963
10 mm Coarse Aggregate 1 Limit as per IS:383-1970

& 2386-1963
Sand 1 Limit as per IS:383-1970

& 2386-1963
37
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DOC: KBE/HO/LAB/ 38
Manual
Rev: 1.0 Date: 25.09.13 Page: 38
13. Water for construction
source No of Tests As per IS 456: 2000 Remarks
14. Materials Tested and Rejected
S. No. Description Status
1 Coarse Aggregate -20mm

2 Coarse Aggregate -10mm
3 Sand
4 Bricks
15. Site Batching Plant Concrete Production/ RMC Supply Details
Grade of Concrete Consumption factors of Site Batching Plant

S No Concrete Unit Produced from RMC for the month
Site Branching
Qty for Cum Qty for Cum Cement Micro Flyash Admixture Total
the Qty the month Qty Silica Concrete
month Qty.
1 M-7.5 Cum
2 M-15 Cum
3 M-20 Cum
4 M-25 Cum
5 M-30 Cum
6 M-35 Cum
7 M-40 Cum
8 slurry Cum
Total
38
LTD.

DOC: KBE/HO/LAB/ 39
Manual
Rev: 1.0 Date: 25.09.13 Page: 39
16. Monthly average of Standard Deviation & Comp. Strength of Concrete Cubes
Concrete Cube Compressive Strength & Standard Deviation (Monthly Average)
S.No. Month Grade of No. of 7 days Comp. No. of 28 days Comp. S.D. for S.D. Limit as per
2
of Concrete Tests for Strength N/mm2 Tests for Strength N/mm 28 days IS:456-1978 &
Casting 7 days 28 days Strength IS:10262-1982
Min. Max. Ave. Min. Max. Ave.
1 M-20
2 M-25
Sep-11
3 M-30
4 M-35
5 M-40
Remarks:
17. Cumulative average of Standard Deviation & Comp. Strength of Concrete Cubes
S.No. Cubes Casted up Grade of No. of Tests for 7 days Cum. No. of 28 days Cum Avg S.D. for S.D. Limit
2
to Concrete 7 days Avg. Strength Tests for Strength N/mm 28 days as per
2
N/mm 28 days Strength I:456-1978
& IS:10262-
1982
1
2
3
4
5
6
7
8
9
10
Note:
KBE Representative
39
KRISHNA BUILDESTATES PVT. LTD. ELEMENT: LABORATORY MANUAL

DOC: KBE/HO/LAB/ 40
Manual
Rev: 1.0 Date: 25.09.13 Page: 40
Sr.No Dia Invoice No. MTC No. Make Supplier Date Length Actual Actual Standard Varianc % Toleranc Qty.
. of & Name of (mm) Weigh Weigh Weight e (kgs) Varianc e Limit Recd.
Bar Type Receip t (kgs) t (kgs (kgs/m) e (MT)
(mm) t
,, ,, ,,
,, ,, ,,
Average
,, ,, ,,
,, ,, ,,
Average
,, ,, ,,
,, ,, ,,
Average
Tested by KBE Project Limited QA/QC Witness by Client
Signature Signature
Name Name
Date Date
40
LTD.

DOC: KBE/HO/LAB/ 41
Manual
Rev: 1.0 Date: 25.09.13 Page: 41
Particle Size Analysis
Project ………………………………………………. Sample No. ………………………………………
Location …………………………………. Tested by ……………………………………………….. Date ………………....
Mass of Soil
% Mass retain on Cumulative %
Sieve No. Sieve Opening retained on each % finer 100-∑Rn
each sieve Rn retained ∑Rn
sieve (Wn)g
41
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DOC: KBE/HO/LAB/ 42
Manual
Rev: 1.0 Date: 25.09.13 Page: 42
Determination of Dry Density of soil by the core cutter meted.
Project ………………………………………………. Sample No. ………………………………………
Location …………………………………. Tested by ……………………………………………….. Date ………………....
Sr.No. Description of soil 1 2 3

1 Wt of Core cutter +wet soil (Ws) g
2 Wt of Core cutter (Wc) g
3 Wt of wet soil (Ws-Wc) g
4 Volume of core (Vc)Cm3
5 Bulk Density Yb=Ws-Wc / Vc
6 Water can no
7 Wt of can and lid (W1)
8 Wt of can and lid + wet soil (W2)
9 Wt of can and lid +dry soil (W3)
10 Water content (W)
W=(W2 – W3)/ (W3 – W1) x 100
11 Dry Density Yd =Yb/1+W/100
42
LTD.

DOC: KBE/HO/LAB/ 43
Manual
Rev: 1.0 Date: 25.09.13 Page: 43
Agency __________________________ _ Report No. ____________________

Location __________________________ Date of Sampling _______________
Class of brick ______________________ Sampled by ____________________
Mark of brick ______________________ Date of Testing _________________
WATER ABSORPTION
S.No. Wt. of Brick Over dry in Wt of brick in wet M2-M1 Efflorescence Remarks
(M1) Kg condition kg. (M2) W. A. =
M1
Average of
1 water
absorption
2
COMPRESSIVE STRENGTH AND DIMENSION
S.No. Dimension in mm (20 Nos.) Area in Sq. mm Crushing Strength Average Remarks
2
Load In N/mm Strength
2
Length Breadth Height KN N/mm
43
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DOC: KBE/HO/LAB/ 44
Manual
Rev: 1.0 Date: 25.09.13 Page: 44
DETERMINATION OF CRUSHING VALUE OF COURSE AGGREGATE
Agency __________________________ _ Report No. ____________________

Location __________________________ Date of Sampling _______________
Source of Sample______________________ Sampled by ____________________
Date of Testing _________________
S.No. CRUSHING VALUE I II MEAN
a) Weight of Oven Dry Sample (A) gms
b) Weight of Fraction passing (B) gms

B
c) Crushing Value= x 100
A
Note :
44
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DOC: KBE/HO/LAB/ 45
Manual
Rev: 1.0 Date: 25.09.13 Page: 45
DETERMINATION OF CONSISTENCY OF CEMENT PASTE
Date of Testing:
Reading recorded by analyst Requirements according to IS: 4031 (1968)
Temperature : _____ oC 27o ± 2oC
RH : _____ % > 65%
Weight of sample_____ g 500 g for 80mm diameter vicat mould
Quantity of water _____ml
Time of gauging: _____ min 3 – 5 min
Penetration of plunger of 5 – 7 mm from the bottom of the mould

10mm diameter :__ mm
Water added x 100

Formula :
Weight of Cement
Consistency : _______ %
45

Krishna Buildestates Pvt. Ltd. Element: Laboratory Manual

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KRISHNA BUILDESTATES

ELEMENT: LABORATORY MANUAL

Title : Standard Operating Procedure

1. Distribution is centralized from the head QA/QC

Mr. Subhash Kumar Mr. Rakesh Bahl

REV. NO. 1 Prepared & Reviewed by Approved by

Title : Standard Operating Procedure

1.1 GENERAL – Project Detail

 Valuating material, working methods, and productivity through appropriate

Title : Standard Operating Procedure Laboratory

Various stages of QC are:

 Incoming material control

2.1 Scope and Application

1. To ensure correct setting out of work

Title : Standard Operating Procedure Laboratory

RESPONSIBILITY: Process owner : Head QA/QC

MATERIAL TEST PROCEDURE

PHYSICAL AND MECHANICAL PROPERTIES OF CEMENT AND TEST MENTHODS

Title : Standard Operating Procedure Laboratory

1.2 Initial And Final Setting Time:

Initial Setting Time

Final Setting Time:

1.3 Compressive Strength of Cement

Title : Standard Operating Procedure Laboratory

Process operator : QA/QC

PURPOSE AND SCOPE

Action and Responsibilities

1. Lab office room for keeping of test records & files.

Title : Standard Operating Procedure Laboratory

Determination of workability of concrete

Slump Test- AS PER IS: 1199

 Clean the internal surface of slump mould thoroughly.

Title : Standard Operating Procedure Laboratory

Compressive Strength of Concrete Cubes

AS PER IS: 516

Title : Standard Operating Procedure Laboratory

SIEVE ANALYSIS OF AGGREGATES

AS PER IS 2386 PART-I

Title : Standard Operating Procedure Laboratory

AGGREGATE CRUSHING VALUE

AS PER IS: PART-IV

I. Cylindrical Measure and Plunger

Aggregate crushing value =B/A

Title : Standard Operating Procedure Laboratory

Determination of flakiness and elongation index

AS PER IS: 2386 PART III

The results should be calculated and reported and reported as-

1. the cumulative percentage by weight of total sample

Title : Standard Operating Procedure Laboratory

SAMPLING FROM STOCK PILE

REDUCTION OF GROSS SAMPLE

REDUCTION BY RIFFLE DIVIDER

1. Keep the collector boxes on either side of riffle divider.

Title : Standard Operating Procedure Laboratory

SAMPLING OF FRESH CONCRETE

AS PER IS: 1199

Title : Standard Operating Procedure

Reporting to : Quality Head

 Checking quality raw material at source and laboratory as per frequency

1.0 Job Title: Lab In charge

2.0 Job Title : Lab Engineer

Reporting to : Lab In charge

 To maintain laboratory and keep equipment in good condition.