International Standard | Oil & Gas

QA/QC _ Civil
Batching Plant Inspector
Qualification Guideline [Vol-3]

Batching Plant Questions & Answer

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Concrete batching plants provide the highest quality of concrete for every single
project. Depending on the project, jobsite and required capacity, stationary,
mobile, compact and on-site concrete batching plants are available.

Difference between QA and QC, Quality Manual and quality plan , Documents and records.
Just go through Table -2 of SAES-Q-001

Q1. What are the minimum concrete cylinders should be cast for each set to be
tested for compression strength as per Saudi Aram co standard?

Answer: 4

Q2. What is the maximum allowable fresh concrete temperature until used as per
Saudi Aramco standard?

Answer: 32 OC

Q3. What are the requirements of water to be used for curing concrete specimens
as per ASTM specification?

Answer: SWEET WATER , MAX TDS =1000 ppm

Q4. In what temperature range should concrete specimen be cured as per ASTM
specification?

Answer: (23 +- 2_ OC)

Q5. At what age concrete cylinders should be tested for Saudi Aram co projects?

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Answer: (3,7,28 Days)

Q6. How frequent shall concrete capping material is tested?

Answer: (Every lot should be tested)

Q7.How many minutes does it take to complete temperature measurement after

obtaining sample?

Answer: (2-1/2 Minute)

Q8. The molding of strength test specimens shall begin within

---------- minutes after fabricating the composite sample.

Answer: ( 15 min )

Q9. The slump test is filled in ( 3 ) layers. And each layer shall be rod for

Answer: ( 25 strokes).

Q10. The diameter of standard tamping rod casting six inches diameter cylinder
is 5/8"

Answer: (16mm) and its length approximately is 24"(600mm)

.
Q11. How many seconds does ASTM specifies to remove the slump cone?

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Answer: ( 5 +- 2 sec)

Q12. The number of blows, layers, and size of proctor molds depends
on of soil?

Answer: Gradation

Q13. How many layers do you apply during standard proctor compaction?

Answer:
A: (Mold dia 4" 3 layers, 25 Blows/layer B: Mold dia 6" 3 Layers, 56 blows/layer

Q14. How many layers does the modified proctor consist of?

Answer: ( 5 Layers ( 56 Blows )

Q15. How many points (as minimum) does modified proctor test should be
consisted of?

Answer: Minimum (4 Points), Preferred 5 Point.

Q16. How many hours should CBR samples be soaked?

Answer: ( 96 Hrs )

Q17. What sieve size do you need to obtain a sample for liquid/plastic limits?

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Answer: ( # 40 )

Q18. At what temperature do you dry soil sample that is prepared for gradation
only?
Answer: (110 + 5 0C)

Q19. Briefly explain how to prepare a soil sample for gradation?

Answer:
a: Quartering the sample
b: Keep the sample in oven for dry at 110 + 5 degree centigrade
c: Sieve the material on specified meshes and note the retained weight on each sieve.
d: Calculate the percent passing for each sieve.

Q20. At what sieve size do you wash soil sample in order to determine the % of fine
materials?

Answer: ( # 200 ) sieve.

Q21. What are the Safety equipment do you need when you perform field density
test using nuclear gauges?

Answer: ( TLD, 3 meter away from Nuclear )

Q22. Briefly describe how to conduct field density test using a nuclear gauge?

Answer:
Take standard count for density and moisture to confirms the counts as per
calibration Certificate
Select the location at least 10 meter away from structure and make hole by rod
minimum 2'' more deeper the testing depth.
Keep the Nuclear at hole in position so that the soil not disturbed by rod.

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Check DD, moisture content and percentage compaction.

Q23. Briefly describe how to run CBR test as per ASTM procedures (compaction
and penetration)?

Answer:
Prepare 3 specimen molds for compaction as follow: 10-Blows5 Layers
25-Blows''
56-Blows''

After compaction soak the specimen for 96 Hrs, drain for 15 minute after soaking and crush
taking reading @ 1", 2" penetration.

Q24. What is the minimum weight of fine aggregate for sieve analysis as per ASTM
C136?

Answer:

1. 100g
2. 300 g
3. 1000g
4. 1500g
5. 2000g

Q25. After the soundness cycles, what sieve sizes do you use to determine fine
aggregate loss?

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Answer:
a. # 4'' b. # 1/4'' c. 5/16'' d. ( In the same sieve on which it was retained before the
test.)

Q26. After the soundness cycles, what sieve sizes do you use to determine coarse
aggregate loss?

Answer:
a. # 4''
b. # 1/4'' c. # 5/16''d. (depends on aggregate fraction size.)

Passing 2 1/2'' Retain 1/2'' Washing # 1 1/4'' # 5/8'' # 5/16''

1/2'' 3/4'' #5
3/4'' 3/8''
3/8'' # 4''

For fine than same size will be used.

Q27. What is the minimum weight of coarse aggregate for sieve analysis as per
ASTM C 136?

Answer:
Size 2'' Kg 20
1 1/2'' 15

1'' 10
3/4'' 5
1/2'' 2
3/8'' 1
a. 2000g b. 100g c. 1000g

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d. 1500g

e. (Depend upon the maximum aggregate size) .

Q28. How many cycles are there for soundness test?

Answer: ( 5 cycles )

Q29. What is the ASTM specified reading requirement of specific gravity of

soundness solution?

Answer: ( MgSo4> 1.2951.308 )

Q30. What type of solution shall be used to perform soundness test as per Saudi
Aram co requirements?

Answer: (MgSo4, Sodium Sulphate )

Q31. Clay lump samples shall be soaked for:

Answer:
a. 12 +/- 4 hours.b. 300g
c.( 24 +/- 4 hours )d. 48 +/- 4 hours.

Q32. To prepare Clay Lump fraction as per ASTM C 142, the mass of aggregate
should be:

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Answer:
a. 500g b. 300g c. 10,000g d. (Depends on the aggregate)

Q33. Prior running liquid limit, you should place the prepare material in its
mixing dish and cover to prevent moisture loss for at least

Answer: (16 ) hours.

Q34. Explain in brief how you perform Maximum Index Density and Unit weight of
soil using a Vibrating Table (using wet method)?

Answer:
1. Take Minimum density loose
2. Keep mold on vibrating table surcharge weight on it
3. Remove water from top of mold with sponge.
4. Sample should be in SSD conditi
Bar Bending Schedule, commonly referred to as “BBS” is a comprehensive list that
describes the location, mark, type, size, length and number, and bending details of each
bar or fabric in a Reinforcement Drawing of a Structure.

This process of listing the location, type and size, number of and all other details is called
“Scheduling”. In context of Reinforcement bars, it is called bar scheduling. In short, Bar
Bending Schedule is a way of organizing rebars for each structural unit, giving detailed
reinforcement requirements.

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General guidelines to be followed in preparing BBS:

 · The bars should be grouped together for each structural unit, e.g. beam, column, etc.

 · In a building structure, the bars should be listed floor by floor

 · For cutting and bending purposes schedules should be provided as separate A4 sheets

and not as part of the detailed reinforcement drawings.

 · The form of bar and fabric schedule and the shapes of bar used should be in accordance

with BS 8666.

 · It is preferable that bars should be listed in the schedule in numerical order.

 · It is essential that the bar mark reference on the label attached to a bundle of bars refers

uniquely to a particular group or set of bars of defined length, size, shape and type used on the job.

 · This is imperative as a bar mark reference can then point to a class of bar characteristics.

Also, this helps steel fixers and laborers keep track of the type and number of bars needed to

complete a certain work.

Bar Bending Schedule is used by the:

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 · Detailer

 · person checking the drawing

 · contractor who orders the reinforcement

 · organization responsible for fabricating the reinforcement

 · steel fixer

 · clerk of works or other inspector

 · the quantity surveyor

Quantity surveyor is responsible for estimation and costing operations of a

project. This kind of surveying demands a high level of precision. Bar Bending
Schedule helps the quantity surveyor to consolidate the number of bars required
of each bar type.
This leads to an estimation of the quantity of steel, which translates to the cost
requirements for steel work. Hence, BBS is used by the contractor who orders
the reinforcements as well. Unit cost of steel is charged by weight of steel
purchased.
Clerk of works and other inspectors refer to the BBS to make sure that the
reinforcement work in the site is in tandem with the design requirements as per
drawings. It is used as a frame of reference by the steel fixers firsthand. They can
easily make note of the number and kind of rebar needed for a structural unit.
In essence, Bar Bending Schedule subsumes all necessary information
on reinforcements, used by professionals at various stages of the construction
process, right from procurement to finish.

How to prepare a BBS?

Necessary Columns

Bar number/Bar Mark

Reference Bar shape

Diameter

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Spacing

Length of bar

Cutting Length

Number of bars

Most of the information in a BBS can be found in reinforcement drawings of the structural unit. Bar shape, diame

Number of bars:
Suppose the spacing of stirrups is 150 c/c and the length along which they are placed is 6800 mm,

we can find the number of bars by the formula below

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[ Length / Spacing ] + 1 = number of bars

[ 6800 / 150 ] + 1 = 46.33

In this case, we always round up. Hence, we require 47 stirrups.

Cutting Length:
We must remember than steel is ductile in nature and is subject to elongation. Hence, the length of a

bar is increased when bends or hooks are introduced. Hence, certain deductions are needed to offset

this increase in length.

Cutting Length = True Length of a bar – Deductions

For 45 degree

Cutting length = Total length – 1 x Dia of bar x No. of bends

For 90 degree
Cutting length = Total length – 2 x Dia of bar x No. of bends
For stirrups:
90 degree hook:
Length of stirrup = (2A + 2B) + 20 x dia
135 degree hook:
Length of stirrup = (2A + 2B) + 24 x dia

Example BBS of RCC BEAM Calculation:

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schedule for slab,bar bending schedule for column,bar bending schedule format,bar bending

schedule example,bar bending schedule calculation for footing,bar bending schedule software

free download,how to prepare bar bending schedule in civil engineering pdf,rebar detailing, bar

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reinforcement, circular slab.bar bending schedule for beam, rcc beam.

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QUE 37- How will trucks be checked on-site when receiving concrete?

Answer: - A. Revolution Counter

B. Ticket Checked for Concrete Batching time and Slump Value at the plant.

C. Slump Test.

D. Temperature Test (32 C maximum @ Site).

E. Assure Lab Technician is present at the site and performs testing.

F. 6 Cubes or 4 Cylinders should be taken per 50cum or recommended in the project

specification.

QUE 38 - What is the purpose of the slump test?

Answer: - To determine the consistency of the workability of the concrete mix and to check for

the required slumps.

QUE 39 - What are allowable slumps?

Answer: - 2.5cm to 7.5cm (for vibrated structure and without admixture ) and If with

admixture and plasticizer, Slump depends upon the project specification.

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QUE 40 - What is plasticizer?

Answer: - Usually applied at a low water-cement ratio concrete to make it workable.

QUE 41 - What is the maximum temperature of concrete that can be poured into a

concrete structure?

Answer: - 32 Degrees C.

QUE 42 - Min and Max atmospheric (ambient) temperature prior to paving?

Answer: - Min is 5 Degree C in cold weather and 45 degrees C max for hot weather.

QUE 43 - Min and Maximum temperature of concrete at the site prior to pouring?

Answer: - Min Concrete temp is 10 degree, and Max is 32 degrees C

QUE 44 - What is the purpose of curing?

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Answer: - 1. To maintain the amount of water in the concrete mix.

2. To minimize hairline cracks

QUE 45- Types of Curing?

Answer: Water Curing - as in ponding, spraying, wet sand and wet earth

Membrane Curing - as in plastic film, liquid membrane curing compound, and reinforced paper

Steam Curing.

QUE 46- When will you apply the curing of the concrete?

Answer: - After the concrete has initially set (35 to 40 minutes is the initial setting time of

concrete)

QUE 47 - For how many days are you going to cure a structure?

Answer: - Seven days (in some cases like PPC types of cement, 14 days of curing are

recommended)

QUE 48 - What is hydration?

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Answer: - It is the formation of a compound by the combination of water and other substances

or in concrete; it is the chemical reaction between water and cement.

QUE 49 - How many times do you apply the curing membrane?

Answer: - At least two times. The second application is perpendicular to the first and applied

after the first application has set.

QUE 50 - Concrete Curing Water shall not have more than.......................Of total

dissolved solids (TDS).

Answer: - 1000 ppm

QUE 51- Concrete can be dropped freely at a height of …………

Answer: - 1.5 meter

QUE 52 - Max and min slope of chutes used in pouring concrete?

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Answer: - Max slope is 1:2 (Vertical to Horizontal), Min slope is 1:3

QUE 53 - Advantages of reducing the water-cement ratio of concrete mix?

Answer: - Increased strength, Increase water tightness, Lower absorption, Increased resistance

to weathering, a better bond between concrete and reinforcement.

QUE 54 - What are the two basic types of concrete?

Answer: - Structural and nonstructural concrete.

QUE 55 - How would you compare 7 days and 28 days compressive strength of

concrete?

Answer: - 70 to 75 % of that of 28 days strength.

QUE 56- What is a composite structure?

Answer: -It is a structure composed of two materials as in steel and concrete.

QUE 58 - What is a non-composite structure?

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Answer: - It is a structure made of either concrete or steel.

QUE 59 - What are the reasons behind the cracks?

Answer: - Poor Curing Practice, Poor design, Poor Vibration which results in segregation, less

rebar covering, poor quality of concrete, movement of falsework or forms, higher water-cement

ratio, Severe atmospheric attack which shows the effect on the heat of hydration with water

initially

QUE 60 - What are the concrete samples?

Answer: - The cylinder and the cubes for the compressive strength test.

QUE 61 - Within how many hours should concrete mix be discharged after leaving

the batching plant or after all the aggregates, cement, and water are in the mixer?

Answer: - Within one hour if the mixer is an agitated mixer (Also depends on the design mix)

And Within 30 minutes if the mixer is a non-agitated mixer.

QUE 62 - What is the initial setting time of Concrete Mix?

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Answer: - 35 to 40 minutes.

QUE 63 - What is the mixing time of a stationary or central batching plant

(concrete)?

Answer: - 50 to 90 seconds

QUE 64 - What is the agitating speed of the mixer?

Answer: - 2 to 6 revolutions per minute (rpm)

QUE 65 - What is the mixing speed of the mixer?

Answer: - 6 to 18 rpm

QUE 66 - What is concrete fatigue?

Answer: - It is the weakening of a material caused by repeated loads.

QUE 68 - What is creep?

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Answer: - It is deformation due to the sustained load.

QUE 69 - How would you know if the concrete has gained its initial set?

Answer: - If there is no more water seen (brightness) on the surface of the concrete, or if there

is no water on the surface of the concrete.

QUE 70 - If agitated concrete is discharged after more than one hour, what will

happen?

Answer: - The concrete is over mixed, becomes hot, and the strength is reduced

QUE 71 - How many layers are in the concrete cube?

Answer: - Concrete Cube is cast in 3 layers.

QUE 72 - How many strokes are done in one layer in a concrete cube?

Answer: - 35 Strokes in one layer.

QUE 73 - What is the size of rode used in concrete cube casting and slump test?

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Answer: - Dia - 12mm and 600mm length.

QUE 74- What is the size of a concrete cube?

Answer: - 150mm X 150mm X 150mm.

QUE 75 - What is the size of slump cones?

Answer: - Height - 20cm, Top of Cone - 10cm, and Bottom of cone - 20cm.

QUE 76 - How many layers are in the slump test??

Answer: - 3 Layers in ASTM and BS but 4 Layers in Indian standard.

QUE 77- How many strokes are done in one layer in a slump test?

Answer: - 25 Strokes

QUE 78 - What are the essential elements of Concrete placement?

Answer: -

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A. The maximum height of the concrete drop is less than or equal to 1.5 meters.

B. Segregation must be prevented by ensuring transit mixture is approved, has operating

revolution counter, no adding water after batching, and concrete is placed in such a manner to

prevent segregation (only shovels can be used to move concrete around inside the forms no

raking allowed. Vibrators should not be used for that purpose.

C. Proper vibration must be implemented (proper vibrating - dropping the vibrator under its

own weight until it gets to the desired drop height, then leaving it there for 3-7 seconds then

pulling at the count of 3 to 4 seconds. When vibrating subsequent layers, vibrator must

penetrate a centimeter into the older layer.

D. Some labors must be continuously watching the forms in case a wall is being poured, proper

height of each concrete lift must be observed, such as the usual 600mm stated normally in

project specifications. Also, tamping on the wall is necessary to assist in the consolidation

process.

E. The concrete temperature and the slumps are two strong indicators of the inspector's

knowledge. A slump between 75mm and 125mm is normal for normal pours. The maximum

allowed temperature for concrete when arriving at the project site is 32 degrees celsius.

79) Brackish Water: what is the

TDS Answer: ( 10,000ppm or more)

80) Clean Sand: what is the max % to be passed in no. 200 sieve?

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Answer: 10%

81) A geotechnical investigation as per SAES-A-113 is required for excavation

depths greater than------m

Answer: (6M)

82) General Fill Material shall consist of gravel, sand and/or marl. The
maximum size of the fill material shall be one-half the lift thickness or mm),
whichever is less

Answer: ( 75mm)

83). The portion of Select Fill material passing the No. 40 sieve shall have a
maximum liquid limit of ----- and a maximum plasticity index of--------per ASTM
D4318

Answer: ( 35 and 12)

84) what is CLSM-

Answer: Controlled Low Strength Material

Refer to flowable soil

85) Select sfill hall be used Within--------------m of the bottom elevation of

foundations, spread footings, slabs-on-grade and pavements when fill is required
to achieve final grade

Answer: ( 0.6 m)

86) In no case shall compaction be allowed on slopes greater than ----- (V) to -------
(H)

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Answer:.( 1V 5 H)

87) The moisture content of the material being compacted shall be within ------------
-, of the optimum moisture content as determined by ASTM D1557.

Answer: (+/- 3)

88) Tests shall be performed for Select Fill Material under all foundations,
buildings and process areas - one test every------------of each lift.

Answer: (100 m2)

89) APCS-10 is not suitable for direct --------- and ---------- as per SAES-H-003

Answer: ( sunlight ,hydrocarbon)

90) Paving slabs subject to vehicular traffic shall be a minimum thickness of --------
------- mm of reinforced concrete

Answer: ( 150mm )

91) The minimum 28 day design compressive strength of non structural

concerte(ASTM C39) shall be-------------MPa

Answer: (14)

92) What is the minimum strength of the concerete for S2 type exposure as
per SAES Q-001 table 2

Answer: ( 32 MPa)

93) Minimum concrete cover in sulfur pits shall not be less than-----------mm

Answer: ( 75mm)

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94) Saudi Aramco shall be notified before proceeding with repair if the defect is
the following: Depth is greater than---------mm at the maximum point and surface
area is greater than------------mm

Answer: ². (75 and 100,000)

Thank You

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