Roof Beam & Tie Beam Quality Check

1

Objective

To establish a comprehensive quality control procedure for Plinth, Roof Beams & Tie Beams, ensuring structural stability, durability, and load-bearing capacity through proper inspection and testing methods in accordance with Indian Standards (IS Codes).

2

IS Code References

Inspection Stage	IS Code	Description
Excavation & Foundation	IS 1200:1974, IS 6403:1981	Earthwork Measurement & Soil Bearing Capacity
Formwork & Alignment	IS 14687:1999	Guidelines for Falsework
Reinforcement Check	IS 456:2000, IS 2502:1963	Concrete & Rebar Detailing
Concrete Mix Design	IS 10262:2019, IS 383:2016	Mix Design & Aggregate Quality
Concrete Pouring & Vibrations	IS 1199:1959, IS 4925:2004	Slump Test & Batching
Concrete Strength Testing	IS 516:1959	Cube Test for Strength
Final QA/QC Checks	IS 456:2000	Tolerances & Quality Control

3

Pre-Casting / Pre-Pouring Inspection

A

Formwork & Alignment Check

Ensure formwork dimensions match the structural drawing
Formwork should be properly supported and braced to avoid deformation (IS 14687:1999)
Ensure formwork is clean, oiled, and has no gaps to prevent leakage
Verify that formwork can withstand pouring pressure without displacement
Check formwork joints are tight and properly sealed
Verify proper centering and support system for beam soffit

IS 14687:1999 IS 1200: Part 5-1982

B

Reinforcement (Rebar) Inspection

Check diameter, spacing, and quantity of rebars as per structural drawings (IS 456:2000)
Ensure stirrups (ties) are properly spaced and adequately tied with binding wire
Verify lap length, anchorage, and bends as per IS 2502:1963
Maintain the required concrete cover (25-40mm for beams, depending on design)
Ensure rebars are clean, free from rust, oil, and dirt
Check proper curtailment of bars as per bending schedule
Verify provision of chair bars to maintain top reinforcement position

IS 456:2000 IS 2502:1963 IS 1786:2008

C

Beam Levels & Alignment

Verify that beam levels match approved structural drawings
Ensure beam alignment is correct, and vertical and horizontal position is maintained
Use a spirit level or total station to check beam straightness and level
Check center line of beams with respect to column centerlines
Verify beam-column junction details and connections

IS 456:2000

D

Concrete Mix & Material Approval

Ensure the approved concrete mix is used (IS 10262:2019)
Check that aggregates, cement, and water comply with quality standards (IS 383:2016)
Verify water-cement ratio and ensure no excess water is added to the mix
Check cement storage conditions and expiry dates
Verify aggregate gradation and maximum size compliance

IS 10262:2019 IS 383:2016 IS 456:2000

4

During Pouring Inspection

A

Concrete Placement & Compaction

Ensure slump test is performed to check workability (IS 1199:1959)
Pour concrete in layers (not exceeding 1.5m height) to prevent segregation
Use mechanical vibrators properly to remove air pockets and ensure proper compaction (IS 4925:2004)
Avoid over-vibration as it may lead to segregation of the mix
Maintain consistent pouring rate to avoid cold joints
Check concrete temperature during hot weather concreting

IS 1199:1959 IS 4925:2004

B

Level & Alignment Check

Use plumb bob or total station to ensure beams are aligned and straight
Check beam level matches slab and column levels to avoid misalignment
Monitor formwork for any movement or bulging during pouring
Verify beam soffit levels at multiple points

IS 456:2000

C

Quality Control During Pouring

Take concrete cube samples at regular intervals for strength testing
Monitor concrete consistency and workability throughout pouring
Check for any segregation or bleeding in the concrete
Ensure proper surface finish and leveling of beam top
Document any interruptions or delays during pouring

IS 516:1959 IS 456:2000

5

Post-Pouring Inspection

A

Initial Curing & Protection

Cover freshly poured concrete with wet hessian cloth or polythene sheets to prevent drying
Apply curing compound or keep concrete moist for at least 7 days (IS 7861:1981)
Protect from direct sunlight, rain, and wind that may affect curing
Maintain consistent moisture content during curing period
Monitor concrete temperature during initial setting period

IS 7861:1981 IS 456:2000

B

Surface Finish & Defects Check

Remove formwork only after achieving the required strength (as per IS 456:2000)
Inspect for honeycombing, cracks, or segregation in the beam surface
Ensure proper rectification of minor defects using grout if required
Check for any blow holes or surface irregularities
Verify beam dimensions after formwork removal
Document any surface defects with photographs

IS 456:2000

C

Concrete Strength Testing

Collect cube samples (150mm x 150mm x 150mm) for compressive strength testing (IS 516:1959)
Test cube samples at 7, 14, and 28 days to verify compressive strength
Ensure minimum characteristic strength (e.g., M20, M25) is achieved as per project requirements
Conduct non-destructive tests if required (Rebound hammer, UPV)
Document all test results with proper identification

IS 516:1959 IS 456:2000 IS 13311:2019

D

Final Handover & Documentation

Ensure all Inspection Reports, Cube Test Results, and Material Test Certificates are documented
Close any Non-Conformance Reports (NCRs) before approval
Get final sign-off from consultants/structural engineers
Prepare as-built drawings if any deviations from original design
Submit complete quality dossier for the beam construction

IS 456:2000

6

Column Interface Quality Check

A

Column-Beam Junction Details

Verify proper development length of beam reinforcement into column
Check column stirrup spacing in beam-column joint zone (IS 13920:2016)
Ensure proper confinement reinforcement in joint area
Verify beam top bars are properly anchored into column
Check for proper concrete consolidation in joint region
Ensure column vertical bars are not displaced during beam casting

IS 456:2000 IS 13920:2016

B

Construction Joint Treatment

Clean construction joints thoroughly before casting subsequent lifts
Apply bonding agent at construction joints if required
Ensure surface roughness at joints for better bond
Remove laitance and loose concrete from joint surfaces
Wet the surface before casting fresh concrete

IS 456:2000

C

Column Reinforcement Continuity

Verify column main bars are continuous through beam level
Check for proper spacing between column bars and beam reinforcement
Ensure adequate cover to column reinforcement
Verify column bar splices are as per approved drawings
Check column bar projection for subsequent floor construction

IS 456:2000 IS 2502:1963

7

Common Defects & Remedial Measures

Defect	Possible Cause	Remedial Measure
Honeycombing	Inadequate compaction, high water-cement ratio	Chipping and patching with polymer modified mortar
Cracks in Beam	Early formwork removal, shrinkage	Epoxy injection for structural cracks, monitoring
Cold Joints	Delay between concrete pours	Surface preparation and epoxy bonding agent
Improper Alignment	Formwork movement during pouring	Assessment by structural engineer, possible strengthening
Low Strength Concrete	Improper mix design, poor curing	Non-destructive testing, reinforcement if required
Cover Deficiency	Improper spacer placement, formwork issues	Local repair with protective coating
Joint Leakage	Poor formwork joint sealing	Grout injection and surface treatment
Reinforcement Corrosion	Inadequate cover, poor concrete quality	Cathodic protection, concrete repair

8

Quality Inspection Equipment

Measuring tape and steel scale for dimensional checks
Spirit level for checking horizontal and vertical alignment
Slump cone for concrete workability testing
Thermometer for concrete temperature monitoring
Cube molds for strength test samples
Magnifying glass for surface defect inspection
Rebound hammer for non-destructive strength testing
Camera for documentation and evidence
Cover meter for checking concrete cover
Ultrasonic pulse velocity equipment
Weighing scale for material proportioning
Total station for precise level and alignment checks

9

Testing Procedures for Beam Quality

Test Type	Purpose	IS Code	Frequency
Slump Test	Workability assessment	IS 1199:1959	Every batch or 30m³
Compressive Strength	Concrete strength verification	IS 516:1959	6 cubes per 25m³ or per day
Rebound Hammer	Surface hardness check	IS 13311:Part 2	As required for NDT
UPV Test	Homogeneity and crack detection	IS 13311:Part 1	Representative sampling
Core Test	In-situ strength assessment	IS 516:1959	When cube strength is low
Cover Measurement	Reinforcement cover check	IS 456:2000	5% of reinforcement
Load Test	Structural adequacy	IS 456:2000	If required by engineer

10

Comprehensive Inspection Checklist - Beam Quality

Inspection Item	Acceptance Criteria	Reference
Formwork Dimensions	± 5mm of plan dimensions	IS 14687:1999
Reinforcement Spacing	Stirrups: ± 10mm, Main bars: ± 5mm	IS 2502:1963
Concrete Cover	25mm for beams + 5mm tolerance	IS 456:2000
Concrete Slump	100-150mm for beams	IS 1199:1959
Concrete Strength	Min characteristic strength + 1.65 × standard deviation	IS 516:1959
Beam Alignment	± 6mm from true position	IS 456:2000
Surface Finish	No honeycombing, voids < 10mm	IS 456:2000
Column-Beam Joint	Proper confinement and development length	IS 13920:2016
Formwork Removal	Min 7 days or 70% strength achieved	IS 456:2000
Curing Duration	Minimum 7 days continuous curing	IS 456:2000

11

Quality Assurance Final Checklist

All material test certificates are available and reviewed
Formwork inspection completed and approved
Reinforcement inspection completed as per drawings
Concrete mix design approved and implemented
Slump tests conducted and results within limits
Cube samples collected and tested
Proper compaction and vibration completed
Curing process implemented correctly
Formwork removed at appropriate time
Surface defects identified and rectified
Dimensional checks completed and within tolerance
Column-beam junction properly executed
NDT tests conducted if required
All NCRs closed with proper remedial action
Final approval from structural consultant
Quality dossier prepared and documented
As-built drawings updated with any changes
Handover certificate issued

12

Important Safety & Quality Notes

Always check and ensure conformance to project-specific requirements and drawings.
Maintain proper curing for minimum 7 days to achieve optimum strength.
Ensure all tests and inspections are documented and traceable.
Obtain proper approvals before proceeding to subsequent construction stages.
For higher seismic zones, additional reinforcement detailing may be required.
Hot weather concreting requires special precautions for temperature control.
Cold weather concreting may require protection from freezing.
Monitor concrete strength development before applying loads.
Ensure proper safety measures during formwork and reinforcement work.
Regular calibration of testing equipment is essential for accurate results.