CONSTRUCTION

MATERIALS 2(QUALITY
CONTROLS) (ECCOM2A)
QUALITY CONTROLS
LEARNING OUT COMES
In this section quality control the learning outcomes will be as
follows:
• Understanding what overview of quality control,
• Knowing some of the quality terminologies,
• Understanding allocation of quality responsibilities
• Appreciation of highway construction material specification
standards,
• Understanding quality control processes, and
• Understanding various high way construction materials tests.
Understanding what overview of quality control
Quality control is an essential part of any construction
project, regardless of the type of contract. The
responsibility of determining quality standards in a high
way construction project is with the consulting engineer.
The consulting engineer will administer the contract,
monitor and ensure that the contractor constructs the
works as designed, complies with the specified
requirements, in terms of materials specifications and
good workmanship practice up to the completion of the
project.
Understanding what overview of quality control (cont’d)

The contractor on the other hand when appointed

by the client to construct the works as designed by
the consulting engineer is merely required to
ensure that he monitors ,constructs the works as
designed, complies with the specified
requirements, and follows good workmanship
practice.
Understanding what overview of quality control Management vs
Control (cont’d)
Quality management (Contractor) Quality control (engineer)

Prevents problems Reacts to problems

Does the right things Does the right things

Controls activity Provides end inspections

Involves all people in the organization Relies on quality control specialists

Responsibility is with people who the work Engineer is responsible to client

Know quality terminologies (cont’d)
Quality system: A documented system in which the
organizational structure, responsibilities, procedures,
processes and resources for implementing quality
management are defined. ISO 9000 and SANS 17025
provide an excellent framework and point of
departure for the development and implementation
of an organizational quality system. A quality system
is implemented in a project by the preparation and
use of a quality plan.
Know quality terminologies (cont’d)
Quality Plan
For every project, a project specific Quality Plan
should be compiled by the supervising team,
temporary (site) laboratory and the contractor. The
plan should set out the specific quality practices,
resources and sequence of activities relevant to the
project.
Know quality terminologies (cont’d)
Supervising Team
Quality control carried out by the supervisory engineering staff is
defined in the Standard Specifications as Acceptance Control. It is
the supervisory engineers' responsibility to institute a quality
control system that conforms strictly to the contractual
requirements, as prescribed in the appointment, as well as the
Standard Specifications and relevant project specifications.
Procedures not prescribed in the above documentation are carried
according to the requirements contained in the quality manual,
this guideline, or any other systems relating to current best
practise.
Quality control responsibilities
The Resident engineer is responsible for timeously informing
the engineer and, if necessary, the client, of any contractual
and or technical problems experienced or expected in a
highway construction site. On site the resident engineer
should be expected to perform these responsibilities:
 Sampling
 Visual assessment
 Dimensional work assessment
 Laboratory tests interpretations for acceptance of the
mix and constructed layer
Quality control responsibilities (cont’d)
The consulting engineer will administer the
contract, monitor and ensure that the contractor
constructs the works as designed, complies with
the specified requirements, in terms of materials
specifications and good workmanship practice up
to the completion of the project. His responsible
for design and supervision qualities.
Quality control responsibilities (cont’d)
The contractor on the other hand when appointed
by the client to construct the works as designed by
the consulting engineer is merely required to ensure
that he monitors ,constructs the works as designed,
complies with the specified requirements, and
follows good workmanship practice.
In this way he becomes responsible for workmanship
qualities only.
Quality control responsibilities (cont’d)
The responsibilities of the resident engineer sometimes also known as
materials supervisory staff, cover a wide range of activities, including
aspects such as:
 Knowledge of project requirements and specifications
 Evaluation of raw materials properties
 Materials selection and utilisation
 Assessment of of materials design properties and sensitivity to
changes and variations
 Suitability of construction plant and equipment
 Appropriateness and consistency of construction processes and
techniques
 Adhere to prescribed environmental limitations, e.g., weather and
Quality control responsibilities (Cont’d)

 Visually inspect completed elements of works

 Test materials properties in place
 Level, width and layer thickness control
 Smoothness and surface finish
 Report results and final assessment of completed work
 Knowledge of SANS 17025
 Knowledge of laboratory quality and auditing procedures
 Record as-built data
Quality control responsibilities (Cont’d)
SANS 17025 is a South African National
Standards reference number for the General
requirements for the competence of testing and
calibration laboratories.
Quality control responsibilities (Cont’d)

Construction Equipment and Method

Guidelines presents the nature and
requirements of construction equipment and
different methods of construction the
engineer always ensuring that both plant
and equipment are suitable for the task.
Appreciating of highway construction material standards

According to the English dictionary, standard is a

level of quality. The Botswana public procurement act
2002, describes quality standard work as follows:
Consisting of a type of materials and workmanship
that conforms to internationally recognised bench
marks as recognised by professional institutions,
which is executed in a manner that is healthy and
safe, environmentally friendly and also saves time
and costs.
Appreciating of highway construction material standards (cont’d)

Standards therefore has to do with level of

quality expected of high way constriction materials.
The standards will be kept and controlled by the
various materials tests recommended. This
includes applicable limits (minimum and maximum
values) for test results. Material classification
systems are given, as are the guidelines on mix
and composition of materials.
Appreciating of highway construction material standards (cont’d)

• All bitumen, binders and asphalt test methods and

standards are in the process of being adapted to
SANS 3001, 4001 and 4002 methods. As the
methods are published, they will be available from
the SABS webstore, www.sabs.co.za.
Appreciate quality control processes

Quality control processes of these highway materials include the

following:
 Sampling
 Visual evaluation
 Dimensional acceptance
 Laboratory tests for acceptance
 Interpretation of laboratory tests results for acceptance
control
 Assessment of non-conforming work
 As-built data sheets
Appreciate quality control processes (cont’d),

The following processes of sampling should be noted:

 All samples for testing should be taken in a random pattern, or as
prescribed in the contract. Where specified, stratified random sampling
methods should be followed. For the testing of layer works, stratified
random sampling methods are used for obtaining all the sample portions
and for determining the locations for in situ tests.
 The size of the test sample (a sub-portion of a field sample)
prescribed by the standard test method, is only adequate to carry out a
single test or to obtain a single test value. To evaluate the quality of the
material or process, the variability must also be known. The only way to
obtain the variability of a certain property, or process, is to take a large
enough number of field samples.
Appreciate quality control processes (cont’d),

 Anincrease in the size of a statistical sample, i.e.,

number of test values, which represents a lot, improves
the confidence level in estimating the variation of a
certain material property or process.
 The various statistical sample sizes required to
assess various quality parameters are addressed in the
Standard Specifications and/or the project specifications.
 Normally, the minimum statistical sample size to
assess material properties or processes is six.
Appreciate quality control processes (cont’d)
Sampling Plan
 The completed layer is judged using lots. The lot must also be visually
homogeneous regarding grading, moisture, soil binder, surface texture,
and with no segregation. Any isolated, non-homogeneous areas, such as
wet patches or rough unfinished surfaces, must be excluded from the test
section and treated separately as a lot. The width of the layer is normally
divided, so that there is a high probability that the test points fall in zones
that experience heavy wheel movement. The test points are determined
in a stratified random manner.
 3.1.1.1 Number of Test Points
 The minimum number of test points for sampling will usually be given in
the spec.
Appreciate quality control processes (cont’d)
Appearance and Finish
The following aspects must be taken care of for the appearance and finish of
granular layers.
  The test section must be visually homogeneous regarding grading,
density and moisture content. Any isolated non-homogeneous areas, e.g., wet
patches, must be excluded from the test section and treated separately.
  The completed layer should be firm and stable, free from areas of
segregated material, laminations (loose, soft, thin layers), or corrugations.
  During compaction, care should be taken not to roll the surface out of
shape and disturb the cross fall. Flat or dished shapes may act as a water trap
for water coming from the upper layer during compaction, or from seepage
water during rainy seasons.
  The completed base should also be firm and stable with a closely knit
surface of aggregate exposed in the mosaic, and free from nests of
segregated material, laminations and corrugations.
Appreciate quality control processes (cont’d)
Dimensional Acceptance Control
The completed selected, subbase and base layers should comply
with the construction tolerances for:
 Level
 Layer thickness
 Grade
 Width
 Cross-section
 Surface regularity
Appreciate quality control processes (cont’d),
Testing Frequency
 The test frequency should be a minimum of one test per 200
metres per lane, taken early in the morning. A minimum of six
tests per unit or section must be tested. The basic test points
should be randomly selected. In addition, the tester shall
actively seek any areas in the lane or shoulders that show any
signs of moisture in excess of the typical surface. In particular,
any low-lying areas where moisture, could migrate should be
checked. The purpose of the testing procedure is to ensure that
no portion of the base layer investigated has moisture contents
greater than 50% of Optimum Moisture Content (OMC).
Appreciate quality control processes (cont’d),
Testing Frequency (cont’d)
Whenever isolated values in excess of the minimum
occur, such areas are further assessed by locating
an additional six test points randomly selected, in
close proximity to the isolated spots. The mean
value of the six results obtained for such an
isolated area is used to determine the accepted
moisture content for the isolated area. This also
assists in defining the limits of local damp areas.
Understanding various highway materials tests
Tests on bituminous materials
There are a number of tests to assess the properties of bituminous
materials. The following tests are usually conducted to evaluate
different properties of bituminous materials.
1. Penetration test-(composition)
2. Ductility test- (composition)
3. Softening point test- (composition)
4. Specific gravity test- (binder composition test)
5. Viscosity test- (consistency)
6. Flash and Fire point test-Distillation (consistency)
7. Float test- (composition)
8. Water content test- (composition)
Understanding various highway materials tests (cont’d)
Penetration test
It measures the hardness or softness of bitumen by
measuring the depth in tenths of a millimetre to which a
standard loaded needle will penetrate vertically in 5
seconds. The penetrometer consists of a needle assembly
with a total weight of 100g and a device for releasing and
locking in any position. The bitumen is softened to a
pouring consistency, stirred thoroughly and poured into
containers at a depth at least 15 mm in excess of the
expected penetration. The test should be conducted at a
specified temperature of 25o C
Understanding various highway materials tests (cont’d)
Penetration test set up apparatus
Understanding various highway materials tests (cont’d)
Ductility test
Ductility is the property of bitumen that permits it to undergo great
deformation or elongation. Ductility is defined as the distance in cm, to
which a standard sample or briquette of the material will be elongated
without breaking. Dimension of the briquette thus formed is exactly 1 cm
square. The bitumen sample is heated and poured in the mould assembly
placed on a plate. These samples with moulds are cooled in the air and
then in water bath at 27o C temperature. The excess bitumen is cut and the
surface is levelled using a hot knife. Then the mould with assembly
containing sample is kept in water bath of the ductility machine for about 90
minutes. The sides of the moulds are removed, the clips are hooked on the
machine and the machine is operated. The distance up to the point of
breaking of thread is the ductility value which is reported in cm.
Ductility test apparatus
Understanding various highway materials tests (cont’d)
Softening point test
Softening point denotes the temperature at which the bitumen
attains a particular degree of softening under the specifications of
test. The test is conducted by using Ring and Ball apparatus. A
brass ring containing test sample of bitumen is suspended in liquid
like water or glycerine at a given temperature. A steel ball is placed
upon the bitumen sample and the liquid medium is heated at a rate
of 5o C per minute. Temperature is noted when the softened
bitumen touches the metal plate which is at a specified distance
below. Generally, higher softening point indicates lower
temperature susceptibility and is preferred in hot climates.
Bitumen melting point set up
 Understanding various highway materials tests (cont’d)
Specific gravity test
In paving jobs, to classify a binder, density property is of great use.
In most cases bitumen is weighed, but when used with aggregates,
the bitumen is converted to volume using density values. The
density of bitumen is greatly influenced by its chemical composition.
Increase in aromatic type mineral impurities cause an increase in
specific gravity.
The specific gravity of bitumen is defined as the ratio of mass of
given volume of bitumen of known content to the mass of equal
volume of water at 27o C. The specific gravity can be measured
using either pycnometer or preparing a cube specimen of bitumen
in semi solid or solid state. The specific gravity of bitumen varies
from 0.97 to 1.02.
Understanding various highway materials tests (cont’d)
Viscosity test
Viscosity denotes the fluid property of bituminous material and it is a
measure of resistance to flow. At the application temperature, this
characteristic greatly influences the strength of resulting paving mixes. Low
or high viscosity during compaction or mixing has been observed to result in
lower stability values. At high viscosity, it resists the compactive effort and
thereby resulting mix is heterogeneous, hence low stability values. And at
low viscosity instead of providing a uniform film over aggregates, it will
lubricate the aggregate particles. Orifice type viscometers are used to
indirectly find the viscosity of liquid binders like cutbacks and emulsions.
The viscosity expressed in seconds is the time taken by the 50 ml bitumen
material to pass through the orifice of a cup, under standard test conditions
and specified temperature. Viscosity of a cutback can be measured with
either 4.0 mm orifice at 25o C or 10 mm orifice at 25 or 40o C.
Understanding various highway materials tests (cont’d)

Flash and fire point test

At high temperatures depending upon the grades of bitumen

materials leave out volatiles. And these volatiles catches fire
which is very hazardous and therefore it is essential to qualify this
temperature for each bitumen grade. Bureau of Indian Standards
(BIS) defined the flash point as the temperature at which the
vapour of bitumen momentarily catches fire in the form of flash
under specified test conditions. The fire point is defined as the
lowest temperature under specified test conditions at which the
bituminous material gets ignited and burns.
Flash and fire point test
Understanding various highway materials tests (cont’d)
Float test

Normally the composition of bituminous material can be

measured either by penetration test or viscosity test. But for
certain range of compositions, these tests are not applicable and
Float test is used. The apparatus consists of an aluminium float
and a brass collar filled with bitumen to be tested. The specimen
in the mould is cooled to a temperature of 5oC and screwed in to
float. The total test assembly is floated in the water bath at 50oC
and the time required for water to pass its way through the
specimen plug is noted in seconds and is expressed as the float
value.
Understanding various highway materials tests (cont’d)
Water content test

It is desirable that the bitumen contains minimum water

content to prevent foaming of the bitumen when it is heated
above the boiling point of water. The water in a bitumen is
determined by mixing known weight of specimen in a pure
petroleum distillate free from water, heating and distilling of
the water. The weight of the water condensed and
collected is expressed as percentage by weight of the
original sample. The allowable maximum water content
should not be more than 0.2% by weight.
Understanding various highway materials tests (cont’d)

Loss on heating test

When the bitumen is heated it loses the volatility and gets

hardened. About 50gm of the sample is weighed and
heated to a temperature of 1630C for 5hours in a specified
oven designed for this test. The sample specimen is
weighed again after the heating period and loss in weight is
expressed as percentage by weight of the original sample.
Bitumen used in pavement mixes should not indicate more
than 1% loss in weight, but for bitumen having penetration
FURTHER READING SHOULD INCLUDE
Further reading on this module include:
 Nagaratnam, S.; Carthigesu, T.G.; Rabin, T.; and Kannan,
M. B. 2016. Civil Engineering materials, International
edition. Cengage Learning. Canada.
 Amsterdam, E.V. 2013. Construction materials for civil
engineering second ed. Juta and Company Ltd. South
Africa.
 Bituminous binders for roads- A course on properties use
and applications by South African Road Fund (SARF) and
Asphalt academy,
 The South African Pavement Manual 2014, and
 The internet search.