CONCRETE INSPECTION NDE -105

_______________________________________________ Director, QA/QC, Turner Industries Group, L.L.C.

Date_____12/16/2010________

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

Revision Record Revision Rev 0 Date 12/16/2010 DESCRIPITION Initial Release BY RR

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection
1.0 CONCRETE INSPECTION

Procedure: NDE-105 Rev. 0

1.1 Scope This section covers quality control and inspection documentation associated with construction of load bearing concrete structures. Examples of load bearing structures include: pump bases, equipment foundations, tank pads/rings, and paving subject to mobile equipment traffic. This section is not applicable to non-loading bearing concrete such as paving limited to foot traffic only, ladder pads, etc. 1.2 Application This section applies to Craft Supervisors, QC Supervisors, QC Inspectors, and Purchasing Personnel. 1.3 Reference Documents

American Concrete Institute (ACI), 318 (latest revision) Project Specifications Approved Drawings Turner Field QA Plan Turner Industries Group, L.L.C. QA/QC Manual

1.4 General

1.4.1

Concrete construction shall be according to Issued for Construction (IFC) Drawings, and Project Specifications. Concrete suppliers, concrete testing service providers, and soil compaction testing service providers shall be Owner approved.

1.4.2

1.4.3 Prior to the purchase of concrete, the concrete design mix shall be submitted for review and approval to the Project Engineer. 1.4.4 1.4.5 Sub-grade elevations shall be verified for compliance with the design drawings. Upon delivery to the job-site the Inspector shall verify all construction materials meet Owner specifications.

1.5 QC Key Elements 1.5.1 As a minimum, the Craft Supervisor and the QC Supervisor or QC Inspector shall consider the following steps essential to quality control of concrete construction. Construction materials, including concrete, are verified to meet Owner specifications. Proper site storage of construction materials, rebar and other embedment shall be stored away from ground contact.

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

Properly cleaned excavations, soil compaction, and backfill per IFC drawings or specifications. Verification of the location, elevation, and dimensions of forms shall be verified prior to making a pour. Tolerances shall meet the requirements of the Project Specifications unless approved construction drawings specify otherwise. Form work sturdy, tight, wetted/treated. Verification of reinforcing steel installation, anchor bolts, embedment, adhesives. Splicing of reinforcing steel shall meet the requirements of the approved drawings. Appropriate and approved ties shall adequately secure reinforcing steel. Reinforcing steel shall be free of dirt, grease, and other contaminants, prior to pour. Welding to reinforcement steel is not allowed unless approved by Owner Special/abnormal conditions are addressed (ie. hot/cold weather, pour logistics, etc.). Appropriate pre-placement assessment and planning. Proper placement and finishing equipment on hand. Appropriate manpower and experience/qualifications of craft personnel. Communication of the placement plan to all involved. Final inspection of placement preparations, appropriate acceptance signatures or documentation (pre-pour checklist). On site Owner approved concrete testing and documentation. Adherence to placement plan. Finishing to Owner specifications Curing to Owner specifications Form wrecking, visual inspection, blemish repair. Craft Supervisor/Inspector acceptance and documentation for post-pour activities. Owner acceptance/documentation. 1.6 Excavation 1.6.1 1.6.2 1.6.3 1.6.4 Excavations shall be cleared of plant life, root systems, and other debris. The Craft Supervisor prior to excavation shall verify excavation location. Drainage away from foundations shall be maintained both during and after construction. Verification of sub grade soils and structural fill material shall be per IFC drawings.

1.7 Concrete Preparations 1.7.1 The QC Inspector will monitor field concrete placement preparations to ensure compliance to Owner Specifications.

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Turner Industries Group, L.L.C.

1.7.2

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

Formwork shall provide a smooth surface with tight joints. Treatment of forms with oils, wax, or other release agents shall be completed prior to installation of reinforcing bars and other embedment to avoid inadvertent contact with release agents. All foreign material inside forms, such as wood chips, blocks, dried mortar, etc. shall be removed prior to the installation of reinforcement steel and embedment Form ties, spacers, etc shall not leave metal near exposed concrete surfaces. Rebar clearances to exposed concrete surfaces shall be per IFC drawing dimensions and tolerances. Any welding and/or heated bending of reinforcing steel shall have prior approval by the Owner. Reinforcing steel shall be free of excessive corrosion; all embedments shall be generally clean and free of any contaminants that might prevent concrete bonding Reinforcement laps and bar splice lengths shall be determined by the specifications and approved drawings. All reinforcement steel and embeds shall be firmly held in place before and during concrete placement. In the event of movement beyond tolerances, the placement operation shall be halted and the displaced reinforcement or embeds shall be readjusted to original positions. 1.7.8.1 Reinforcement steel shall be tied at sufficient intervals to maintain bar location during concrete placement and consolidation. Tie spacing also depends on handling and traffic on the mat and the position it occupies.

1.7.3

1.7.4

1.7.5

1.7.6

1.7.7

1.7.8

1.7.9

As a final check of locations, dimensions and elevations, the Craft Supervisor may have a surveyor verify the following as applicable:

Plan location Location of anchor bolts. Embed components. Top of concrete. Reinforcement elevations. Form block outs. Other critical dimensions and elevations. Verification may also be done by other qualified personnel.

1.8

Concrete Placement Planning 1.8.1 All concrete pours will involve some level of pre-pour planning. The Craft Supervisor should assess the specific job and determine the appropriate level of pre-pour planning.

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

1.8.1.1 Large and/or complex pours should be well thought through and details addressed and captured in a written pour plan. As a minimum, the following items should be addressed as applicable: Concrete delivery. Concrete testing (batch plant/on-site). Placing sequence/tuning. Equipment needed operability, quantity, and contingencies. Manpower/responsibilities. Conveying of concrete. Addition of High Range Water Reducing Agents (Super Plasticizer) or other additives on-site or at the batch plant. Delay preparations/contingencies Weather conditions, hot (above 90F.) or cold (below 40F) weather concreting techniques. 1.9 Concrete Preparations Acceptance 1.9.1 The Craft Supervisor shall initiate a pre-pour checklist as a final inspection of concrete preparations just prior to the pour. The Craft Supervisor will perform a visual inspection and complete and sign a Pre-Pour Checklist, Exhibit No. 8, as given in this section. Once signed by the Craft Supervisor, the Pre-Pour Checklist is sent to the QC Inspector for verification of accuracy and subsequent filing.

1.9.2

1.9.3 Once both the Craft Supervisor and QC Inspector have signed-off acceptance of the Pre-Pour Checklist, the Owners Inspector shall be contacted for final acceptance. The QC Inspector shall ensure timely delivery of the concrete and check delivery trucks time of departure, and cylinder rotation counter upon the trucks arrival on the site.
1.9.4

Weather conditions should be monitored prior to and during concrete pours, as temperature and moisture play important roles in the strength, workability, curing time, and durability of concrete. The requirements of ACI 305 & ACI 306 shall be met, in addition to any project specifications, which might apply.
1.9.5

The QC Inspector shall not allow the pour if it is raining or if the air temperature is excessively cold, do not pour if the temperature is below 40F.
1.9.6

Surface finishes shall meet the requirements of approved drawings and the project specifications.
1.9.7 1.9.8

Freshly poured concrete shall be protected from detrimental weather conditions.

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

1.9.9 Specific instances where concrete is cured in less than seven (7) days and subjected to loading shall have prior approval of the Project Engineer. 1.10 Concrete Testing 1.10.1 Concrete requiring a compressive strength of 3,000 psi or more shall be tested in accordance with ACI 318 except as follows: 1.10.1.1 One test shall be taken for each day's pour and at least one test be taken for each 50 cubic yards placed. A test shall consist of four cylinders. One such cylinder shall be tested in the laboratory after seven days, one after 14 days and one after 28 days with results submitted to the Owner as soon as-possible. Testing of the remaining cylinder shall be performed as required. 1.10.2 Air content, slump, and temperature tests shall be taken from the concrete samples for each strength test and whenever the consistency of the concrete appears to vary.

1.10.3

When the construction schedule requires a foundation to be loaded (equipment set) within a few days of the pour, additional strength test cylinders should be taken to allow for strength tests before the foundation is loaded (i.e. 2 day breaks). An approved testing service shall be contracted and arrangements made for concrete testing. Normally test samples are taken upon delivery to the job-site
1.10.4.1

1.10.4

When Super Plasticizer is used, concrete samples for slump tests shall be taken before adding Super Plasticizer to the mix. If Super Plasticizer is added at the batch plant, testing services should be provided at the batch plant. When batch plant testing is performed, arrangements shall be made to communicate test results to the job-site prior to concrete placement. Samples for compressive strength tests and air content tests may be taken before or after the addition of Super Plasticizer to the mix.

1.10.4.2

1.10.4.3

1.10.5

The Craft Supervisor or QC Inspector shall communicate all necessary information needed by the testing service, including the pour description, by fax, email, written memo, etc. The pour description shown on test reports shall be in sufficient detail to link concrete test reports to specific concrete structures.

1.10.6

Slump tests shall be performed after any addition of water to the mix at the job-site. The delivery ticket shall state the max amount of water to be added.

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Turner Industries Group, L.L.C.

1.10.7

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

The QC Inspector or Craft Supervisor shall reject any concrete mix that is tested and determined to be outside of the specification tolerances given on IFC drawings. The Owner's Inspector shall be notified of any rejection of concrete. Concrete Placement and Consolidation 1.11.1 1.11.2 Standing water in excavations shall be removed before concrete placement. Concrete poured against earth shall have the soil pre-wetted or sealed with a vapor barrier to prevent excessive loss of moisture from the fresh concrete. Concrete shall be deposited near its final location. Concrete shall not be allowed to flow laterally unless the whole mix is moving without segregation. Concrete should be placed directly in corners and ends of walls first; flow should be toward the center of formwork. Drop chutes shall be used where concrete free fall is over six feet or to avoid striking reinforcement steel. Consolidation shall be done using properly sized vibrators in accordance with ACI 309. 1.11.7 Vibrators shall be applied systematically at close intervals so that vibrated areas of concrete overlap without omission. Vibration shall continue until concrete is thoroughly consolidated and voids are filled as evidenced by the leveled appearance of concrete at the exposed surface, and the embedment of surface aggregate.

1.11.3

1.11.4

1.11.5

1.11.6

1.12

Finishing and Curing 1.12.1 When given, concrete finishing shall be as specified on IFC drawings/project specifications. 1.12.1.1 Concrete finishing shall not take place while there is excessive wetness or bleed water at the surface of the concrete. 1.12.1.2 Curing compounds shall be approved by the Client prior to their use. 1.12.2 When given, concrete curing shall be according to IFC drawings/project specifications. If no curing method is given one of the following methods should be used: Wet coverings (burlap, sand) Plastic Coverings Ponded water Sprinkling or soaking Membrane-forming curing compounds
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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

Note: Reference ACI 308 Chapter 2 for explanation of techniques.

1.12.3

After form removal and any blemish repair, the Craft Supervisor shall initiate a post-pour checklist as a final inspection of the completed concrete structure. The Craft Supervisor will perform a final visual inspection and complete Exhibit No. 30, Concrete Systems Acceptance Form. Once signed by the Craft Supervisor the Concrete Systems Acceptance Form is sent to the QC Inspector for acceptance and signature. Once both the Craft Supervisor and the Layout Supervisor/Surveyor have signed-off acceptance of Exhibit No. 30, Concrete Systems Acceptance Form, the Owner's Inspector shall be contacted for a final Owner's acceptance.

1.12.4

1.12.5

1.13

Inspection Documentations and Owner Acceptance 1.13.1 The QC Inspector is responsible for retention and compilation of all inspection documentation associated with placement of load bearing concrete. Concrete Placement Acceptance Packages shall consist of the following:

1.13.2

Sign-off of Exhibit No. 8, Pre-Pour Inspection Record Sign-off of Exhibit No. 30, Concrete Systems Acceptance Original inspection/testing reports * (Concrete Test Reports).

*In some cases 28 day compressive strength test results may not be available. In this case the PostPour Checklist should indicate the final test results are not currently available. The Owner's Inspector can accept the final documentation packages. The QC Inspector will forward the final test reports to the Owners Inspector upon receipt.

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

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Turner Industries Group, L.L.C.

Date: 12/16/2010

Concrete Inspection

Procedure: NDE-105 Rev. 0

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