Quality Control of Concrete

by
Bhupinder Singh, Ph.D.
Associate Professor
Department of Civil Engineering
Indian Institute of Technology Roorkee
Roorkee 247 667
bhupifce@iitr.ernet.in
• What is quality?

‘The totality of features and characteristics of a product or

service that bear on its ability to satisfy stated or implied
needs.’
• What are the stated or implied need in a construction
project?
Workmanship
Quality of constructed work should be as per requirements

Integrity
Work should be executed according to drawings and
specifications

Completion time in the project

According to client’s requirement
• What is quality control?

‘The operational techniques and activities

that are used to fulfill requirements for
quality’
 What are these ‘operational techniques and
activities’ ?
• Evaluation of concrete quality

• In its fresh state, quality of concrete is monitored

using tests for workability like for example the
slump test

• In its hardened state, quality of concrete is

monitored using tests for mechanical properties
like compressive strength, modulus of rupture,
splitting tensile strength etc.
Quality control of concrete in the context of IS
456
Monitoring concrete quality in the fresh state
Rheology is the science of deformation and flow of matter. It describes the
inter-relationship between force, deformation and time.

It is normally applied to more or less fluid materials or materials that exhibit

a time-dependent response to stress.
 Behaviour analogous to a solid in a fluid

Solid Fluid

However, fluids such as blood, foods, cosmetics and concrete shown Non-Newtonian behaviour i.e.,
flow only initiates above some level of stress called as the ‘yield stress’. The best example of yield
stress is the force required to remove tooth-paste from a tube!
Examples of viscosities and shear rates
 Non-ideal Bingham plastic (cement-based materials)

Ideal Bingham plastic (cement-based materials)

Shear thinning with yield response (curd)

Shear thinning with zero yield stress (nail polish)

Shear thickening (suspension of

starch in water, raw mixture for
jalebis)

Yield stress
Newtonian (Water)

Rheological models
 Plastic viscosity

Shear stress
Yield stress

Shear rate
Yield stress

Plastic viscosity

The slump test is an indirect measure of the yield stress

 100 Dia

100
25

13

2mmThick

300

2mm Thick

200 Dia

Slump test apparatus

 How to process the measured slump values at site?
A huge volume of data may be collected at site. How to
process it?
Mean of a data set
Standard deviation of a data set
Coefficient of variation, C.O.V., of a data set
Let for a particular work, the desired initial slump of concrete is 75 mm.

If for similar type of concrete a number of historic records of measured slumps

are available: 76, 74, 70, 66, 78, 80, 86, 75, 70, 68, 79, 80, 75, 69, 70, 74, 70, 68,
68, 70, 76, 75, 80, 70, 75, 68, 70, 75, 78, 74, 68, 70, 75, 78, 80, 85, 85, 75, 70, 70,
and 70 mm. Which of these measured values are acceptable?
Calculate the standard deviation, σ , from the test records +5.09

Range of acceptable values 75

-5.09

σ = 5.09 mm. Let the allowable tolerance in the measured initial slump value be σ.
This implies that the acceptable range of the measured slump values is 75 – 5.09 =
69.91 or say 70 mm and 75 + 5.09 = 80.09 or say 80 mm.

Hence, measured slump values less than 70 mm or more than 80 mm should invite
corrective action!

The Coefficient of Variation, C.o.V. = (5.09/75) x 100 = 6.8% which

corresponds to ‘very good’ level of quality control!!
 Measured physical property and its limiting values

5.
09

75

5.
09

Assumed normal/Gaussian distribution of the physical property. The slump is assumed

to vary as a bell-shaped curve about the mean value
 About 68.2% of the measured slumps
will lie within the acceptable limits.
Here we are being very lenient with our range of This implies acceptance of the possibility
acceptable values
that 31.8% of the results will be out of range

Slump values lower than the Slump values higher than the
minimum acceptable value maximum acceptable value

4σ
About 95% of the measured
slumps will lie within the
acceptable limits.
2σ

Range of acceptable values is large. We are ‘lenient’ with our

quality control as about 68% of all measured values are acceptable!

Properties of the bell-shaped curve: Approximate distribution of area under normal frequency
distribution curve
Monitoring concrete quality in the hardened state
 For first 50 m3 For second 50 m3

Let the total volume to be concreted at one go = 110 m3

Hence, number of samples required for 28-day strength testing= 4+1+1 = 6

For the remaining

part of 50 m3

Hence, number of cubes to be collected for 28-day strength testing = 6 x 3 = 18

If early age strength testing has to be done, then an additional 18 cubes have to be
collected for 7-day strength testing.

Therefore, total number of cubes required to be collected for strength compliance

= 18 + 18 = 36
What is a random sampling procedure?
First of all, for any project identify what is called as a
‘lot’, a ‘sublot’ and a ‘sample’
 6 km

Project for laying of a concrete road 6 km long

1.5 km 1.5 km 1.5 km 1.5 km

LOT 1 LOT 2 LOT 3 LOT 4

Sublots of length 0.3 km each Casting done in one day for example

SUBLOT SUBLOT SUBLOT SUBLOT SUBLOT

1 2 3 4 5

0.3 km

Test specimen (cylinder for splitting tensile strength or

compressive strength test). Report the average of 3 specimens.
One sample to be collected from each sublot.
Sample
 An example of random sampling
• For example, 50 m3 of concrete has to be deposited in one continuous operation in 10
batches of 5 m3 each. Number of samples required for 28-day strength testing = 4. Let
the 4 samples be collected from 4 different concrete batches.
Lot consisting of a total of 10 trucks/batches, each batch delivering 5 m3

1 2 3 4 5 6 7 8 9 10

Sublot from which one sample (consisting of

three specimens has to be collected)

Cube Cube Cube One sample consisting of 3 specimens

1 2 3

• From which sublots will the four randomly selected samples collected?

• Here, N, population size = 10 ; m, sample size = 4

• Consider the following table of random numbers

• Consider any starting point. Pick up any four numbers whose last two digits are between
1 and 10. Repetitions are not allowed in the selected numbers!
Generate a table of random numbers
 X
X
X : Last three digits are greater than 300 √
√
X
√
√

(random positions in integers)

• Here, N, population size = 10 ; m, sample size = 4

• Consider the following table of random numbers

• Consider any starting point. Pick up any four numbers whose last two digits
are between 1 and 10. Repetitions are not allowed in the selected numbers!
 Starting point

Sample no. 2
Sample no. 3

Sample no. 4

No repetitions
Sample no. 1

Select the first sample

of 3 cubes from truck
no. 1
 Example: Random sampling by time sequence
Random sampling of prestressed concrete railway sleepers manufactured in a precast unit has to be done. The
lot size is a day’s production . Each lot is to be divided into 5 sublots and one sample consisting of 3 sleepers
has to be obtained from each sublot. The plant operates continuously from 7:30 AM to 4:30 PM. At what time
during the production process should the samples be collected?

At what time should

sampling be done
within each sublot?

Sublot time interval = (9 h per lot) x (60 min per hour) / (5 sublots per lot) = 108 min per sublot

One sample consisting of 3 sleepers has to be collected from each sublot.

What is the exact time at which the sample should be collected within each sublot?

These times must be selected ransdomly

 Table of random numbers
Random positions in decimal fractions (four places)
X Y
0.4721 R 0.2091
0.6936 L 0.3182
0.6112 R 0.8908
0.7930 L 0.4818
0.0652 L 0.2091
0.0167 L 0.3727
0.0077 R 0.6181
0.6777 R 0.8636
0.8010 L 0.8362
0.3027 L 0.3454
0.9831 L 0.2364
0.7159 R 0.6181
0.3609 R 0.6454
0.8915 L 0.2636
0.6442 R 0.3182
0.1904 R 0.2562
0.6074 R 0.1818
0.7522 R 0.8908
0.7041 L 0.9181
0.5102 R 0.8362
0.2471 L 0.2364
0.5693 L 0.3182
0.8583 R 0.4545
0.3093 R 0.1818
 From the table of random numbers, choose the first five numbers from Column X. These numbers
are 0.4721, 0.6936, 0.6112, 0.7930 and 0.0652 Randomise the sampling time by multiplying the sublot
time interval with the above numbers. Hence, the randomised sampling intervals for the five sublots
are:

Sublot 1: 0.4721 x 108 = 51 min

Sublot 2: 0.6936 x 108 = 75 min

Sublot 3: 0.6112 x 108 = 66 min

Sublot 4: 0.7930 x 108 = 86 min

Sublot 5: 0.0652 x 108 = 7 min

Hence, the randomised sampling times for each sublot is:

Sublot 1 - 7:30 a.m. + 51 min = 8:21 a.m. (Collect the first sample at this time)

Sublot 2 – 9:18 a.m. + 75 min = 10:33 a.m. (Collect the second sample at this time)

Sublot 3 – 11:06 a.m. + 66 min = 12:12 p.m. (Collect the third sample at this time)

Sublot 4 – 12:54 p.m. + 86 min = 2:20 p.m. (Collect the fourth sample at this time)

Sublot 5 – 2:42 p.m. + 7 min = 2:49 p.m. (Collect the fifth sample at this time)
 Example: Random sampling by material weight
The total tonnage of cement required for a construction project is 15000 bags. The cement will be
delivered at site in lots of 3000 bags each. According to the contract documents, each lot shall be
divided into 5 equal sublots and one cement bag has to be collected for testing from each of the
sublots. Determine the sampling sequence.

600 bags 600 bags 600 bags 600 bags 600 bags

Sublot 1 Sublot 2 Sublot 3 Sublot 4 Sublot 5

One lot of 3000 bags

A random sampling procedure has to be followed. It is required to find which bag number has to be
collected from each of the sublots.
For randomised sample collection, choose any five random numbers from the random number table.
Choose five random numbers from Column Y of the Table starting with S. No. 17. These five random
numbers are: 0.1818, 0.8908, 0.9181, 0.8362 and 0.2364.
To identify the bag number to be sampled, multiply the number of bags in each sublot with the above
random numbers
 In sublot 1, the bag number to be sampled is 0.1818 x 600 = 109 th

In sublot 2, the bag number to be sampled is 0.8908 x 600 = 534 th

In sublot 3, the bag number to be sampled is 0.9181 x 600 = 551 st

In sublot 4, the bag number to be sampled is 0.8362 x 600 = 502 nd

In sublot 5, the bag number to be sampled is 0.2364 x 600 = 142 nd

If a cumulative log of the 3000 bags to be delivered at site in one lot is available, then the bag

numbers to be sampled are:

Sample 1 : 109th bag

Sample 2: 600 + 534 = 1134th bag

Sample 3: 1200 + 551 = 1751st bag

Sample 4: 1800 + 502 = 2302nd bag

Sample 5: 2400 + 142 = 2542nd bag

 Example: Random sampling of depth of concrete pavement
The depth of concrete pavement in a road has to be sampled for acceptance. The total length of the
pavement is 20,000 m and the contract documents identify a total of 4 lots in the pavement each lot having a
length of 5000 m. It has been decided that each lot will be divided into 5 sublots and one depth measurement
has to be made per sublot. Randomise sampling for depth measurement.

P
a
1000 m
ve
m
Sublot 1 Sublot 2 Sublot 3 Sublot 4 Sublot 5 e
nt
w
id
th
=
One lot of total length = 5000 m 4
m
1000 m
P
a
Randomly selected sampling point for
ve x depth measurement
m
e
nt
w y
id Coordinate system for the random sampling point
th
=
 Coordinates of the sampling points
Sublot No. Longitudinal random number Sublot length Sampling point location Sampling point location
(from the X column of the (m) from start of sublot from start of lot
random number table) (m) (m)
Local X coordinate Global X coordinate
1 0.5651 1000 565.1 565.1

2 0.4742 1000 474.2 1474.2

3 0.9483 1000 948.3 2948.3

4 0.2951 1000 295.1 3295.1

5 0.0441 1000 44.1 4044.1

Sublot No. Transverse random number
(from the Y column of the
random number table)
1 0.1545
Sublot width Sampling point location Sampling point location
(m) from start of sublot from start of lot
(m) (m)
Local Y coordinate Global Y coordinate
4 0.618 0.618

2 0.06727 4 0.27 0.27

3 0.4000 4 1.6 1.6

4 0.06451 4 0.26 0.26

5 0.1273 4 0.51 0.51

‘Improper compaction can lead to significant strength reduction’
Approximate check on degree of compaction of cubes at site
Higher weight Better strength

Lower weight Lower strength

Higher weight Better strength

Higher weight Better strength

Effect of curing conditions on concrete strength
Compression strength = Measured Peak Load
Cross-sectional area

σ= P/A (N/mm2 or MPa)

Cube or cylinder strength? Which is a more accurate measure of
concrete compressive strength?
µP P

µP
P
Cracks extend throughout the specimen height
 De
hc

sce
an
br

nd
g

ing
in
nd

br
ce

an
As

ch
Decreasing platen restraint
increasing brittleness

The descending branch is a function of the degree of platen restraint

Measured stress-strain relationships of concrete in uniaxial compression for
different types of anti-friction media
For the same concrete mixture, due to the effect of
platen restraint, cube strength will always be larger
than cylinder strength. Cylinder strength = 0.80 times
the cube crushing strength
 Gauge length

Measuring the uniaxial stress-strain behaviour of concrete

Stress-strain curves of concrete in uniaxial compression
 Ultimate load

Initial elastic phase

Such cracking may

exist even prior to
load application

Stress-strain curves of concrete in uniaxial compression and stages of micro-cracking

 Continuous crack

Voi
Bond crack d

Aggregate particle

Fluorescent microscope image of a concrete specimen

 Beyond this stress concrete
ε1 begins to dilate because of
ε2 internal cracking

Longitudinal strain
 Failure criteria
for concrete in
uniaxial comp.

Elastic modulus (initial tangent modulus)

Hognestad’s idealised stress-strain curve for concrete in uniaxial

compression
 This is a boundary condition
and CANNOT be found out
experimentally. Find by operating
(dσ / dε) at ε = 0 on the stress-strain
relationship.
Ec

IS 456:2000
To exercise
control on
‘within-test’
variation’
 Individual test result shall be > this strength
Mean of a group of 4 test results shall be > this strength
Mix design is carried out for this strength
Concrete grade

Graphical representation of the IS 456:2000 concrete compressive strength

acceptability criteria
Four non-overlapping
consecutive samples
fck

SAMPLE NUMBER
 Overall probability becomes 75% pass
and 25% fail

Probability of acceptance when resampling

At a bridge construction site, the specified grade of concrete is M30 and a
standard deviation of 3 MPa has been established at site. The following cube
test results each representing a days production of concrete (average strength
of 3 specimens tested at 28 days) are available. Apply IS 456:2000 acceptance
criteria to the test results
Note that
only those
samples are
selected which
satisfy the +/-
15% criteria

1 2 3

4 5 6
How to apply the acceptability criteria if the number of samples is less than 4?
Amendment No. 4 to IS 456:2000
 No. of samples required
to be collected = 4+1 = 5

Av. = 52.88 MPa

0.85 Av.=44.95
fck - 4 = 41 MPa
MPa
Mean = 52.73 MPa
1.15Av.= 60.81
➢45 + 4 = 49 MPa
MPa
➢Hence, OK.
 No. of samples required
to be collected = 4+1 = 5

Batch-to-batch variation

Additional cubes
fck - 4 = 46 MPa
for 7-day strength Mean = 56.58 MPa
test (0.66 x 28-day ➢50 + 4 = 54 MPa
strength = 33 MPa) ➢Hence, OK.

Results of 15
cubes
• Although 56.58 MPa is greater than 54 MPa, this result
gives us no idea about the degree of quality control at site.

• For example, at one site, the mean strength is 54.2 MPa (>
54 MPa) and at the other site the mean strength is 57.2
MPa (> 54 MPa). As per IS 456:2000, both the results are
satisfactory but these results tell NOTHING about the
degree of quality control at the two sites
 The IS 456:2000 recommendations do not make any
attempt to analyse the variability of measured strengths.
Except for control on within-test variations by way of the
+/- 15% criteria no evaluation of the batch-to-batch
variation of concrete strengths is specified.
Variability of measured strengths
The test results are said to follow a normal distribution if they are more or less
equally spaced about the mean value !

The normal distribution curve is characterised by its mean and standard

deviation
 Normal distribution curve as an ‘envelope’
to the histogram

Histogram of the measured strengths

Individual test result

Equation for the normal distribution curve,

Measured cube strengths at a construction site
Histogram of the measured cube strengths

Envelope curve to the histogram

 Average strength = 29.54 MPa
Standard deviation = 3.24 MPa
C.o.V. = 11%

Average strength

Normal distribution curve fitted to the cube strengths

 f

ơ ơ
15.9% of 15.9% of
results are results are
less than more than
f-ơ f-ơ
2.3% of 2.3% of
results are results are
less than more than
f - 2ơ f - 2ơ

Typical frequency distribution of strength data and corresponding normal

distribution
 σσ

σ
σ

Characteristic strength, fck, as

per IS 456:2000

Areas under various segments of the normal distribution curve for deviations of
1.64 and 2 standard deviations from the mean
Areas under various segments of the normal distribution curve as a function of
standard deviation
Normal distribution curves for three different cases with the same mean but
different variability. For which case is the quality control the best?
Quantitative Assessment of Variability
Determination of standard deviation
Example: At a construction site, concreting has been completed in three stages and the results of
standard 28 days cube tests are given in Table below. Determine the standard deviation for the grade
of concrete:
STAGE 1 STAGE 2 STAGE 3
Sample No. Cube strength, Sample No Cube strength Sample No Cube strength
(MPa) (MPa) (MPa)
Sample no. Cube strength (MPa) Sample No Cube strength(MPa)
 1 2
3 4
5 6

1 2 3 4 5 6
͌
<
 Analysis of trends in measured concrete
strengths – How to detect intervention points?
 Individual test results and their average (of two test results)

High degree of noise and scatter associated with the average results

Typical individual test result

Average of individual test results

Average of 1 and 2
A plot of the ‘Moving Average Strength’ is a useful tool for
identifying trends in concrete strength and particularly for
identifying when intervention is required!
 Moving average of three results
The first data point in this plot is obtained only after 3 test results
are available

The moving average of three results reduces the noise and

scatter associated with the average of two results

Control Zone

3
1

Reject zone Caution Zone

 Moving average of five results

Moving average of five results. Lesser noise.

2
5
1 3

The first data point in this plot is obtained only after 5 test results
are available
 Moving average of ten results
The first data point in this plot is obtained only after 10 test results
are available

Moving average of ten results. Noise is least.

7
8
2
6
1 3 5
9
4 10
 Detection of intervention points using CUSUM

CUMulative SUM control chart or CUSUM chart can be used to help detect
relatively small changes or shifts in average concrete strength for example,
quickly.
 (37+34.7+32.8)/3 = 34.8

Average of 19 test
results

(34.7+32.8+37.8)/3 = 35.1
No obvious indication of a Trend detection is improved by using
change in data is seen in this the moving average chart because
plot scatter and noise in the data is reduced

CUSUM chart clearly indicates that a shift

in average compressive strength has occurred
from the 10th strength test onwards
THANK YOU