Concrete and steel construction : quality control and assurance

Starting with the receipt of materials and continuing all the way through to the final completion of the construction phase, Concrete and Steel Construction: Quality Control and Assurance examines all the quality control and assurance methods involving reinforced concrete and steel structures. This book explores the proper ways to achieve high-quality construction projects, and also provides a strong theoretical and practical background. It introduces information on quality techniques and quality management, and covers the principles of quality control.

The book presents all of the quality control and assurance protocols and non-destructive test methods necessary for concrete and steel construction projects, including steel materials, welding and mixing, and testing. It covers welding terminology and procedures, and discusses welding standards and procedures during the fabrication process, as well as the welding codes. It also considers the total quality management system based on ISO 9001, and utilizes numerous international and industry building standards and codes.

Covers AISC, ACI, BS, and AWS codes Examines methods for concrete quality control in hot and cold weather applications, as well as material properties Illustrates methods for non-destructive testing of concrete and for steel welding--radiographic, ultrasonic, and penetration and other methods. Addresses ISO 9001 standards--designed to provide organizations better quality control systems Includes a checklist to be considered as a QA template

Developed as a handbook for industry professionals, this book also serves as a resource for anyone who is working in construction and on non-destructive inspection testing for concrete and steel structures.

Author Notes

Mohamed A. El-Reedy received his bachelor's degree from Cairo University in 1990, his master's degree in 1995, and his Ph.D from Cairo University in 2000. His main area of research is reliability of concrete and steel structures. Dr. El-Reedy has written numerous publications and presented many papers at local and international conferences. He has published many research papers in international technical journals and has authored four books about total quality management, quality management and quality assurance, economic management for engineering projects, and repair and protection of reinforced concrete structures.

Preface	p. xv
Author	p. xvii
1 Introduction	p. 1
References	p. 5
2 Effective Total Quality Management System	p. 7
2.1 Introduction	p. 7
2.2 Quality System	p. 7
2.3 ISO 9000	p. 8
2.4 Quality Management Requirements	p. 9
2.4.1 Quality Manual	p. 9
2.4.2 Quality Plan	p. 9
2.4.3 Quality Control	p. 10
2.4.3.1 Why Is Quality Control Important?	p. 10
2.4.3.2 Submittal Data	p. 11
2.4.3.3 How to Check Incoming Materials	p. 12
2.4.3.4 Methods of Laying Out and Checking Work	p. 12
2.4.3.5 Material/Equipment Compliance Tests	p. 14
2.4.3.6 When to Inspect Work	p. 15
2.4.3.7 Paperwork and Documentation	p. 16
2.4.3.8 Quality Control Plans	p. 17
2.4.4 Quality Assurance	p. 18
2.4.4.1 Quality Assurance in ISO	p. 19
2.4.4.2 Responsibility of Manufacturer	p. 19
2.4.4.3 Responsibility of Owner	p. 20
2.5 Project Quality Control in Various Stages	p. 21
2.5.1 Feasibility Study Stage	p. 21
2.5.2 Feed (Preliminary) Engineering	p. 22
2.5.3 Detailed Studies	p. 23
2.5.3.1 Design Quality Control	p. 24
2.5.4 Execution Phase	p. 25
2.5.4.1 ISO and Control Work	p. 26
2.5.4.2 Inspection Procedures	p. 26
2.5.4.3 Importance of Contracts in Assuring Project Quality	p. 27
2.5.4.4 Checklists	p. 27
2.6 Operational Phase	p. 31
2.7 Total Building Commissioning System	p. 32
2.7.1 Define Owner's Project Requirements	p. 34
2.7.2 Design Stage	p. 34
2.7.2.1 Review Owner's Project Requirements and Basis of Design	p. 36
2.7.2.2 Issues Log and Role of CxA	p. 36
2.7.2.3 Develop Commissioning Specifications	p. 38
2.7.3 Written Test Procedures	p. 39
2.7.4 Construction Stage	p. 39
2.7.5 Oversee and Document Functional Performance Testing	p. 40
2.7.6 Conduct Owner Training	p. 41
2.7.7 Post-Construction Stage	p. 42
2.7.7.1 Reinspect and Review Performance before End of Warranty Period	p. 43
2.7.7.2 Complete Final Commissioning Report	p. 44
2.7.7.3 Final Satisfaction Review with Customer Agency	p. 44
References	p. 45
3 Concrete Materials and Tests	p. 47
3.1 Introduction	p. 47
3.2 Concrete Materials Test	p. 48
3.2.1 Cement	p. 48
3.2.1.1 Cement Test by Sieve No. 170	p. 49
3.2.1.2 Initial and Final Setting Times of Cement Paste Using Vicat Apparatus	p. 50
3.2.1.3 Density of Cement	p. 52
3.2.1.4 Define Cement Fineness Using Blaine Apparatus	p. 54
3.2.1.5 Compressive Strength of Cement Mortars	p. 56
3.2.2 Aggregate Tests	p. 58
3.2.2.1 Sieve Analysis Test	p. 58
3.2.2.2 Abrasion Resistance of Coarse Aggregates in Los Angeles Test	p. 60
3.2.2.3 Determination of Clay and Other Fine Materials in Aggregates	p. 61
3.2.2.4 On-Site Test	p. 65
3.2.2.5 Aggregate Specific Gravity Test	p. 68
3.2.2.6 Fine Aggregate Test	p. 68
3.2.2.7 Define Specific Gravity for Coarse Aggregate	p. 69
3.2.2.8 Bulk Density or Volumetric Weight Test for Aggregate	p. 69
3.2.2.9 Percentage of Aggregate Absorption	p. 70
3.2.2.10 Recycled Aggregate Concrete	p. 70
3.2.3 Mixing Water Test	p. 72
3.3 Admixtures	p. 73
3.3.1 Samples for Testing	p. 74
3.3.2 Chemical Tests to Verify Requirements	p. 75
3.3.2.1 Chemical Tests	p. 75
3.3.2.2 Ash Content	p. 76
3.3.2.3 Relative Density	p. 76
3.3.2.4 Define Hydrogen Concentration	p. 77
3.3.2.5 Define Chloride Ion	p. 77
3.3.3 Performance Tests	p. 77
3.4 Steel Reinforcement Test	p. 78
3.4.1 Weights and Measurement Test	p. 78
3.4.2 Tension Test	p. 81
References	p. 82
4 Concrete Mix Design	p. 85
4.1 Introduction	p. 85
4.2 Essential Statistics Information	p. 85
4.2.1 Arithmetic Mean	p. 86
4.2.2 Standard Deviation	p. 86
4.2.3 Coefficient of Variation	p. 87
4.3 Basics of Concrete Mix Design	p. 88
4.3.1 Normal Distribution	p. 88
4.4 Egyptian Code	p. 91
4.5 British Standard	p. 94
4.6 American Specifications (American Concrete Institute)	p. 94
4.6.1 Acceptance and Refusal for Concrete Mix	p. 95
4.6.2 Concrete Mix Procedure	p. 96
4.6.2.1 Chemical Admixtures	p. 98
4.6.2.2 Selection of Water: Cement Ratio	p. 100
4.6.3 Mix Proportions	p. 101
4.6.3.1 British Standard	p. 102
4.7 Fresh Concrete Test	p. 102
4.7.1 Cylinder and Cube Tests	p. 102
4.7.1.1 Cube Test	p. 103
4.7.1.2 Cylinder Test	p. 103
4.7.2 Predicting Concrete Strength	p. 105
4.8 Define Concrete Density	p. 106
4.9 Defining Settlement for Fresh Concrete	p. 108
4.10 Determining Compacting Factor for Fresh Concrete	p. 112
4.11 High-Performance Concrete Mix	p. 113
4.12 Pumped Concrete Mix	p. 114
4.12.1 Basic Considerations	p. 114
4.12.2 Coarse Aggregate	p. 115
4.12.3 Fine Aggregate	p. 115
4.12.4 Combined Normal Weight Aggregates	p. 116
4.12.5 Water	p. 116
4.12.6 Cementitious Materials	p. 117
4.12.7 Admixtures	p. 117
4.12.8 Field Practice	p. 118
4.12.9 Field Control	p. 118
4.13 Quality Control for Operation	p. 119
4.13.1 Process Control Chart	p. 119
4.13.2 Constructing X-R Chart	p. 120
References	p. 123
5 Construction Quality Control	p. 125
5.1 Introduction	p. 125
5.2 Create the Wooden Form	p. 125
5.3 Formwork for High-Rise Buildings	p. 132
5.3.1 Formwork	p. 132
5.3.2 Delivery Systems	p. 135
5.3.3 Allowable Tolerance in Dimensions	p. 135
5.4 Detailing, Fabrication, and Installation of Steel Bar	p. 135
5.4.1 Tolerance in Steel Bars in Egyptian Code	p. 138
5.4.2 Allowable Tolerance in ACI 318	p. 138
5.5 Concrete Cover and Its Specifications	p. 138
5.5.1 British Standard	p. 139
5.5.2 American Code	p. 143
5.5.3 European Code	p. 143
5.5.4 Special Specifications for Structures Exposed to Very Severe Conditions	p. 145
5.5.5 Egyptian Code	p. 148
5.5.6 Placing Concrete Cover	p. 149
5.6 Concrete Pouring	p. 151
5.6.1 Pouring Pumping Concrete	p. 153
5.6.1.1 The Wrong Mix	p. 156
5.6.1.2 Problems with Pipeline	p. 157
5.6.1.3 Operator Error	p. 158
5.6.2 Construction Joint	p. 158
5.7 Compaction Procedure	p. 159
5.8 Curing	p. 160
5.8.1 Curing Process in ACI	p. 164
5.8.2 Curing in British Standard	p. 165
5.8.3 Protecting Special Structures	p. 167
5.9 Hot Weather Concrete	p. 167
5.9.1 Definition of Hot Weather Region	p. 167
5.9.2 Problems of Concretes in Hot Climates	p. 168
5.9.2.1 Fresh Concrete Problem	p. 168
5.9.2.2 Harden Concrete Problem	p. 168
5.9.2.3 Problems Due to Other Factors in Hot Climates	p. 169
5.9.3 Effect of Hot Climate on Concrete Properties	p. 169
5.9.3.1 Control Water Temperature in Mixing	p. 170
5.9.3.2 Control Cement Temperature	p. 173
5.9.3.3 Control Aggregate Temperature	p. 173
5.9.3.4 Control Mixing Ratios	p. 173
5.9.3.5 Control Concrete Mixing Process	p. 174
5.9.3.6 Control Project Management	p. 175
5.10 High-Strength Concrete Quality	p. 176
5.10.1 Cement for High-Strength Concrete	p. 177
5.10.2 Mineral Admixtures	p. 178
5.10.2.1 Silica Fume	p. 178
5.10.2.2 Fly Ash	p. 181
5.10.2.3 Slag	p. 185
5.10.2.4 Comparison of Mineral Additives	p. 185
5.11 Self-Compacting Concrete (SCC)	p. 186
5.11.1 Development of Prototype	p. 187
5.12 Lightweight Aggregate Concrete	p. 188
5.12.1 Lightweight Aggregate	p. 190
5.12.2 Lightweight Coarse Aggregate or Structural Member	p. 191
References	p. 192
6 Nondestructive Testing for Concrete	p. 195
6.1 Introduction	p. 195
6.2 Core Test	p. 195
6.2.1 Core Size	p. 199
6.2.2 Sample Preparation	p. 201
6.3 Rebound Hammer	p. 203
6.3.1 Data Analysis	p. 206
6.4 Ultrasonic Pulse Velocity	p. 206
6.5 Load Test for Concrete Members	p. 211
6.5.1 Test Preparation	p. 212
6.5.2 Test Procedure	p. 213
6.5.3 Results Calculations	p. 214
6.5.4 Acceptance and Refusal Limits	p. 214
6.6 Pullout Test	p. 215
6.7 Define Chloride Content in Hardened Concrete	p. 216
6.8 Concrete Cover Measurements	p. 217
6.9 Comparison of Different Tests	p. 220
References	p. 221
7 Steel Structure Quality Control	p. 223
7.1 Introduction	p. 223
7.2 Steel Properties	p. 223
7.2.1 Strength	p. 224
7.2.2 Stress-Strain Behavior of Structural Steel	p. 224
7.2.3 Steel Properties	p. 225
7.2.4 Variability- of Geometry	p. 225
7.2.5 Ductility Requirements	p. 227
7.3 Design Situations	p. 229
7.4 Connection	p. 230
7.4.1 Bolted Connection	p. 230
7.4.2 Welding Connection	p. 231
7.4.2.1 Shielded Metal Arc Welding (SMAW)	p. 232
7.4.2.2 Gas Metal Arc Welding (GMAW)	p. 234
7.5 Welding Types	p. 234
7.5.1 Fillet Weld	p. 234
7.5.2 Butt Weld	p. 235
7.5.2.1 Farts of Butt Weld	p. 235
7.5.2.2 Welding Groove Configurations	p. 237
7.5.2.3 Connection between Steel Plates	p. 241
7.5.2.4 Welding Groove	p. 244
7.5.3 Problems in Welding	p. 245
7.5.4 Welds and Welding Symbols	p. 248
7.5.4.1 Elements of Welding Symbols	p. 250
7.5.4.2 Fillet Weld Dimensions	p. 257
7.6 Stud Weld	p. 261
7.7 Quality Control on Site	p. 263
7.7.1 Quality of Human Resources	p. 263
7.7.2 Handling, Shipping, and Delivery	p. 264
7.7.3 Erection and Shop Drawings	p. 264
7.7.4 Inspection and Testing	p. 265
References	p. 268
8 Nondestructive Testing for Steel Structures	p. 271
8.1 Introduction	p. 271
8.2 Visual Test	p. 271
8.3 Radiographic Test	p. 274
8.3.1 Principles	p. 274
8.3.2 Isotope Decay Rate (Half-Life)	p. 274
8.3.3 Radiographic Sensitivity	p. 276
8.3.4 Geometric Unsharpness	p. 277
8.3.5 Scatter Radiation	p. 279
8.3.6 Radio Isotope (Gamma) Sources	p. 281
8.3.7 Radiographic Film	p. 283
8.3.7.1 New Films	p. 285
8.3.8 General Welding Discontinuities	p. 285
8.4 Ultrasonic Test	p. 289
8.4.1 Wave Propagation	p. 290
8.4.2 Attenuation of Sound Waves	p. 292
8.4.3 Reflection in Sound Wave	p. 293
8.4.4 Refraction of Sound Wave and Snell's Law	p. 295
8.4.4.1 Angle Beams	p. 296
8.4.5 Wave Interaction or Interference	p. 298
8.4.6 Transducer Types	p. 300
8.4.7 Calibration Methods	p. 301
8.5 Penetration Test	p. 302
8.5.1 Advantages and Disadvantages of Penetrant Testing	p. 302
8.5.2 Penetrant Testing Materials	p. 303
8.5.3 Penetrants	p. 306
8.5.4 Developers	p. 306
8.6 Magnetic Particle Test	p. 307
8.6.1 Magnetic Field Characteristics	p. 309
8.6.2 Electromagnetic Fields	p. 310
8.6.3 Magnetic Field Orientation and Flaw Detectability	p. 310
8.6.4 Tools for Testing	p. 312
8.6.5 Magnetizing Current	p. 314
8.6.6 Hysteresis Loop and Magnetic Properties	p. 316
8.6.7 Examination Medium	p. 318
References	p. 318
Index	p. 319

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