PUBLIC WORKS DEPARTMENT

Office of the Chief Engineer (Design) Phone : 0471-2325856

Public Works Department Fax :0471-2325856
Thiruvananthapuram- 695033 Email : cedriq .pwd@kerala.gov.in

No. CE/DESIGN/QC/15/2019 Dated: 16/05/2019

TECHNICAL CIRCULAR

The Kerala Public Works Department plays a major role in the construction and
maintenance of NH, SH, MDR, Bridges, Culverts and majority of Government
Buildings. Being spread out across the state, the effective administration of this
requires scientific and authoritative quality checks at every point of the projects
undertaken by the department. The Kerala PWD QC Manual adopted by Government
of Kerala clearly lays down the modus operandi to be followed by the QC wing and
other field officers in this regard. Also, the codal provisions of IS: 456 regarding
acceptance criteria for concrete prescribed in the Quality Manual has been amended.

In this context, it is instructed that the acceptance criteria for concrete is to be

followed as per the latest amendment of IS: 456. Also, clarifications are given below to
follow the Kerala PWD QC Manual meticulously without any lapse or flaws.

1. The quality control system as per clause 7.2 of Kerala PWD QC Manual should
be strictly followed for ensuring quality of projects executed.
2. All specimens shall be labelled with proper identification mark with suitable
paints or plastic stickers, etc.for future reference.
3. The reports of QC tests shall include all the necessary details like type of mix,
location, identification mark, date of sampling, date of testing, concluding
remarks regarding acceptance of concrete, etc. (A typical report sheet for
concrete cub e test is attached.)
4. The Material Engineershall intimate the quality test results to concerned field
officers without any delay preferably through email.
5 . For concrete cube test, following steps shall strictly be adhered to:
i. Sampling from fresh concrete shall be as per IS 1199 and the casting of
concrete cubes for tests shall be made in accordance with IS: 51 6 . (A
detailed procedure is given in Annexure- I for reference.)
 n. The minimum frequency of sampling of concrete of each Grade of concrete
shall be in accordance with Clause 15.2.2 of IS 456-2000.The acceptance of
the concrete shall be considered based on the frequency of samples required
for the quantity of concrete for the each item of work as per tender schedule .
If the quantity of concrete for an item is greater than 30m3, then the
frequency of s a mpling shall be atleast four numbers for second tier quality
test.(Details are given in Annexure- II for reference)
iii. The acceptance criteria for test results for compressive strength of samples
must comply with Table 11 of IS 456:2000 (Amendment No.4) for building
works and clause 18.6 .2 of IRC: 112 for bridge works. (Details are given in
Annexure - II for reference.)
6 . For reinforcing steel, the second tier quality control tests shall be done strictly
according to clause 606.7 of Kerala PWD QC Manual and a s per IS: 1608. The
test results for reinforcing steel shall include i) Tensile strength (Ts), Yield stress
or Proof stress(Ys) , Ts/ Ys Ratio and Elongation (% ) along with the nam e of
manufacturer, Cast/Lot No. and date of test. The acceptance criteria shall be
based on Table 600-10 of PWD QC Manual or Table-3 of IS: 1786 whichever is
latest.(A typical report sheet for testing of reinforcing steel is attached.)
7. For bituminous construction, the density of the finished pavement layer shall
be determined as per clause 2304.6 (d) and (e) of Kerala PWD QC Manual and
IRC 111 -2009 - Design of Bituminous mixes.
Hence, it is instructed that second tier quality tests to be conducted in
the Regional Investigation & Quality Control Labs and District Quality Control
Labs for the concrete, steel and bitumen shall follow the instructions a nd
prepare test results report as stated above without any fail with effect from t h e
date of this circular.

Ace: Annexures I & II and copy of typical test report sheets (2Nos.)
Copy to: 1. Director (I&QC)
2. All Executive Engineers, RI&QC Labs, & all Assistant Executive Engineers, District labs
of Quality Control wing PWD.
3.1T Cell.
 Annexure -1

RECORDING OF SAMPLES

The following information regarding the concrete cube samples shall be recorded :
a) Date and time of sampling
b) Mix proportions (proportion of ingredients including water, admixtures, etc.)
c) Whether it is collected from Mixers or place of deposition
d) The location of the sampled batch after placing
e) Temperature and weather conditions.

SAMPLING OF FRESH CONCRETE IN THE FIELD AS PER IS: 1199

This method specifies the procedure to be followed in the field for obtaining
representative samples of fresh concrete directly from the mixer or from concrete at
the time and place of deposition.

Sample: The composite sample shall be truly representative of the batch and shall be
not less than 0.02 m3 in volume. It shall be composed of a mixture of portions taken
from different points in the batch. When continuous mixers are used, a batch shall be
regarded as the discharge from the mixture during one minute.

Procedure to collect samples from Mixers: At least three a p proxima tely equal
sample increments totaling 0.02 m3 shall be taken from a batch during its discharge
and each sample increment shall be collected by passing a clean and dry container
a cross the stream of concrete. This container shall be constructed of non-absorbent
m a teria l, prefera b ly of m et al a nd shall be such that the s ample retained is not
segrega t ed . A fla t surface with reta ining sides will fulfil this pur p ose. Where th ree
sample increments are taken they shall be taken at about the time when one-quarter,
one-half and three-quarters of the concrete have been discharged from the mixer and
if more than three are taken they shall be at correspondingly shorter, but equally
spaced, interva ls.

Procedure to collect samples from concrete at the time and place of Deposition:
The sample shall be taken while a batch of concrete is being, or immediately after it
has been, discharged on the site. The sample shall be collected from not less than five
well-distributed positions, avoiding the edge of the m a ss where segregation m ay have
occurred.
Mixing the Composite Sample: The composite sample obtained by either of the
methods described above, shall be mixed on a non-absorbent base either with a shovel
or by other suitable tool in such a manner as to ensure uniformity. The sample thus
obtained shall be used immediately for the purpose of carrying out the tests. Care
shall be taken to protect the sample from the weather.

MOULDING OF CONCRETE CUBES OF SIZE 150X150X1SOMM AS PER IS: 516

The test specimens shall be made as soon as practicable after mixing, and in such a
way as to produce full compaction of the concrete with neither segregation nor
excessive laitance. The concrete shall be filled into the mould in layers approximately
5 em deep . In placing each scoopful of concrete, the scoop shall be moved around the
top edge of the mould as the concrete slides from it, in order to ensure a symmetrical
distribution of the concrete within the mould. Each layer shall be compacted either by
hand or by vibration as described below. After the top layer bas been compacted, the
surface of the concrete shall be finished level with the top of the mould, using a trowel,
and covered with a glass or metal plate to prevent evaporation.

Compacting by Hand: When compacting by hand, the standard tamping bar (a steel
ba r 16 mm in diameter, 600mm long and bullet pointed at the lower end) shall be
used and the strokes of the bar shall be distributed in a uniform manner over the
cross-section of the mould. The number of strokes per layer required to produce
specified, conditions will vary according to the type of concrete. In no case shall the
concrete be subjected to less than 35 strokes per layer for 150 mm cubes. The strokes
shall penetrate into the underlying layer and the bottom layer shall be rodded
throughout its depth. Where voids are left by the tamping bar, the sides of the mould
shall be tapped to close the voids.

Compacting by Vibration: When compacting by vibration, each layer shall be

vibrated by means of an electric or pneumatic hammer or vibrator or by means of a
suitable vibrating table until the specified condition is attained.

Curing: The test specimen shall be stored in a place, free from vibration, in moist air
of at least 90 percent relative humidity and at a temperature of 27° ± 2 oe for 24 hours
± l hour from the time of addition of water to the dry ingredients, After this period, the
specimens shall be m a rked and removed from the moulds a nd, unless required for test
within 24 hours, immediately submerged in clean, fresh water or saturated lime
solution and kept there until taken out just prior to test. The water or solution in
which the specimens are submerged shall be renewed every seven days and shall be
maintained at a temperature of 27° ± 2 °C. The specimens shall not be allowed to
become dry at any time until they have been tested.
 Annexure -II
CONCRETE CUBE SAMPLING PROCEDURE AS PER IS: 456 AND IRC: 112

A random sampling procedure shall be adopted to ensure that each concrete

batch shall have a reasonable chance of being tested that is, the sampling should be
spread over the entire period of concreting and cover all mixing units. The minimum
frequency of sampling of concrete of each grade shall be in accordance with the
following:

Quantity of concrete Number of samples

for the work (m3)
1 to 5 1
6 to 15 2
16 to 30 3
-·--
31 to 50 4
5 1 and above 4 plus one additional sample for each
additional 50m3 or part thereof

Note: Atleast one sample shall be taken from each shift.

Test specimen and test sample: Three test specimens shall be made for each sample
for testing at 28 days. The test results of the sample shall be the average of the
strength of three specimens. The individual variation should not be more than + 15
percent of the average. If more, the test results of the sample are invalid.

Acceptance Criteria for compressive strength: The concrete sha ll be deemed to

comply with the strength requirements when both the following conditions are to meet
irrespective of the grade of concrete:

i) When quantity of concrete for each item of the work is more than 30m3
a) The m ean strength determined from any group of four consecutive non-overla pping
test results of samples shall exceed specified characteristic compressive strength (fck)
plus 3MPa.
b) Strength of any individual sample shall not be less than specified characteristic
compressive strength (fck) minus 3MPa.
ii) When quantity of concrete for each item of the work is between
6m3 and 30m3
a) The mean strength determined from two or three (as per frequency of sampling)
samples shall exceed specified characteristic compressive strength (fck) plus 4MPa.
b) Strength of any individual sample shall not be less than specified chara cteristic
compressive strength (fck) minus 2MPa.

iii) When quantity of concrete for each item of the work is less than 6m3
The compressive strength determined from one sample shall exceed specified
ch a racteristic compressive strength (fck) plus 4MPa.
 . ----~~~·~~~l·:~..... KERALA PUBLIC WORKS DEPARTMENT Form No. QC-Cl(R)/2019
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~'~~{i'l~ CONCRETE CUBE TEST AND ACCEPTANCE Report No. 1 Date :
REGIONAL LABORATORY: DISTRICT LABORATORY:
DIVISION: SUBDIVISION: SECTION :
Name of Work: Grade of concrete:
Type and Brand Name of ce m ent : OPC/PPC/
Grade of cement
Ite m No. of Tender Shedule : Qty. in Tender Shedule{m\ a) Cement kg
ME
Type of Structure: Building/Bridge/Culvert/Pavement/Others .... b) Fine Aggregate kg
Component of Ia) Superstructure: I ~
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Result
Conclusion:

Tested: Tech nician/Oversser (QC) Verified: Asst. M aterial Engineer/A E Approved: M at er ial Engineer/AEE
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--~~- TESTING OF REINFORCEMENT STEEL BARS Dat e:
REGIONAL LABORATORY: IDISTRICT LABORATORY:
DIVISION : lsUBDIVISION: SECTION :
Name of Work: Grade of steel:
Nominal diamet er of bar mm
1 Brand name
Item No. ofTender Shedule: low. in Tender Shedule(kg): Place of manufacture
Type of Structure : Building/Bridge/Culvert/Others BIS Certification Ma rking
Cast/Lot number

A. GENERAL DATA B. ORIGINAL DATA C. TEST DATA D. ANALYSIS OF RESULTS

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Tested : Technician/Oversser (QC) Verif ied: Asst. Material EngineerI AE Approved: Material Engineer/AEE