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RCC Column/Wall Quality Check Procedure

Comprehensive quality control procedure for RCC column and wall construction ensuring structural integrity, quality, and durability through systematic inspection and testing methods in accordance with Indian Standard codes.

Duration: 14-28 days Team: 5-8 workers Risk Level: Medium Quality Priority: High
1

Objective

To establish a comprehensive quality control procedure for RCC Column/Wall Construction, ensuring structural integrity, load-bearing capacity, and seismic resistance through proper inspection and testing methods in accordance with Indian Standards (IS Codes) including material handling, execution, and documentation.

2

IS Code References

Purpose IS Code Description
RCC Design IS 456:2000 Plain and Reinforced Concrete – Code of Practice
Ductile Detailing IS 13920:2016 Seismic Detailing of RCC Structures
Reinforcement Bars IS 1786:2008 TMT Steel Specifications
Aggregates IS 383:2016 Aggregates for Concrete
Admixtures IS 9103:1999 Concrete Admixtures
Shuttering Plywood IS 4990:2011 Plywood for Concrete Shuttering Work
Calibration IS 17025:2017 Calibration of Lab Equipment
Site Safety IS 3764:1992 Excavation and Site Safety Code
Quality Assurance IS 9000:2015 Quality Management Systems
3

Pre-Construction Quality Check

A
Design Verification & Approval
  • Verify structural drawings are approved by competent authority
  • Check column/wall dimensions, reinforcement details as per drawings
  • Ensure design meets seismic requirements as per IS 13920:2016
  • Verify concrete grade specification (M20/M25/M30)
  • Check foundation adequacy for proposed column loads
IS 456:2000 IS 13920:2016
B
Material Quality Check
  • Cement: Verify test certificates, check manufacturing date (not older than 3 months)
  • Steel bars: Check TMT certification, tensile test reports, size tolerance
  • Aggregates: Verify gradation, specific gravity, water absorption tests
  • Water: Ensure potable water or test for pH, chlorides, sulphates
  • Admixtures: Check manufacturer certification and compatibility
  • Shuttering material: Verify plywood grade, thickness, surface finish
IS 1786:2008 IS 383:2016 IS 4990:2011
C
Site Layout & Setting Out
  • Verify center lines and grid lines from foundation
  • Check column positions with reference to approved drawings
  • Ensure proper benchmarks and reference points are established
  • Verify verticality of column dowel bars from foundation
  • Check adequacy of working space around column areas
IS 962:1989
4

Reinforcement Quality Check

A
Bar Cutting & Bending Check
  • Verify cutting list and bar bending schedule (BBS) accuracy
  • Check bar lengths with tolerance ±25mm
  • Ensure proper bending radius (min 2.5 times bar diameter)
  • Verify hooks and bends as per IS 456:2000 requirements
  • Check bar marking and identification system
  • Ensure bars are free from mud, oil, paint, loose rust
IS 456:2000 IS 2502:1963
B
Reinforcement Placement Check
  • Verify main reinforcement placement as per drawings
  • Check spacing of longitudinal bars (tolerance ±10mm)
  • Ensure minimum reinforcement percentage (0.8% for columns, 0.4% for walls)
  • Verify development length of dowel bars (45 times bar diameter)
  • Check proper lapping arrangements:
    • 40 × dia (in tension zone) – IS 456:2000
    • Lapping in central 1/3rd of column height only – IS 13920
    • No laps in joint or 2d from face of joint
    • Maximum 50% of bars lapped at one section
IS 456:2000 IS 13920:2016
C
Lateral Ties/Stirrups Check
  • Verify stirrup diameter (minimum 8mm for seismic zones)
  • Check spacing requirements:
    • Within beam-column joint: ≤ 100mm
    • Column ends (2 times depth): ≤ 100mm
    • Middle zone: ≤ 300mm or least dimension/4
    • For walls: ≤ 300mm both directions
  • Ensure proper 135° hooks at both ends
  • Check lateral tie extension into core (6 times tie diameter)
  • Verify cross ties for columns with more than 4 main bars
IS 13920:2016 IS 456:2000
D
Cover & Spacers Check
  • Verify concrete cover as per exposure conditions:
    • Mild exposure: 20mm (walls), 25mm (columns)
    • Moderate exposure: 30mm
    • Severe exposure: 45mm
    • Very severe/Extreme: 50mm
  • Check cover block quality (same grade as main concrete)
  • Ensure adequate spacers at 1m intervals
  • Verify cover tolerance (±5mm)
IS 456:2000
5

Formwork Quality Check

A
Formwork Dimensional Check
  • Verify formwork dimensions match structural drawings
  • Check tolerances: ±6mm for cross-section, ±12mm for length
  • Ensure proper verticality using plumb bob (tolerance 1:300)
  • Check alignment with adjacent structural elements
  • Verify opening dimensions for doors, windows, services
IS 456:2000 IS 14687:1999
B
Formwork Material & Support Check
  • Verify plywood grade (BWP/BWR) and thickness (min 12mm)
  • Check formwork joints are tight and leak-proof
  • Ensure adequate props and bracing against lateral loads
  • Verify tie rod spacing and capacity
  • Check release agent application (not oil-based)
  • Ensure formwork is clean and free from debris
IS 4990:2011 IS 14687:1999
6

Concrete Quality Check

A
Fresh Concrete Properties
  • Verify concrete mix design approval and implementation
  • Check slump test results (75-150mm for pumped concrete)
  • Ensure concrete temperature (not exceeding 32°C)
  • Verify admixture dosage and mixing time
  • Check workability and cohesiveness
  • Ensure no bleeding or segregation
IS 1199:1959 IS 10262:2019
B
Concrete Pouring & Compaction
  • Pour concrete in layers not exceeding 1.5m height
  • Use needle vibrator (25-40mm diameter)
  • Ensure proper vibration without over-vibration
  • Avoid honeycombing and voids
  • Check for complete filling around reinforcement
  • Verify no displacement of reinforcement during pouring
IS 456:2000
C
Concrete Sampling & Testing
  • Prepare cube samples (minimum 6 cubes per 50m³ or fraction)
  • Ensure proper cube preparation and curing
  • Test cubes at 7 and 28 days
  • Verify strength compliance (minimum 85% of characteristic strength)
  • Conduct non-destructive tests if required:
    • Rebound hammer test
    • Ultrasonic pulse velocity test
    • Core cutting test (if strength deficiency)
IS 516:1959 IS 13311:1992
7

Post-Casting Quality Check

A
Curing & Protection
  • Start curing within 24 hours of casting
  • Maintain continuous moisture for minimum duration:
    • OPC: 7 days minimum
    • PPC: 10 days minimum
    • GGBS/Fly ash: 14 days minimum
  • Use appropriate curing methods (ponding, wet gunny, curing compounds)
  • Protect from direct sunlight and extreme weather
  • Ensure no loading on green concrete
IS 456:2000
B
Formwork Removal & Inspection
  • Remove formwork after minimum strength achievement (16-24 hours for vertical elements)
  • Inspect surface finish and identify defects
  • Check dimensional accuracy post-stripping
  • Verify verticality and alignment
  • Document any surface defects for remedial action
IS 456:2000
C
Surface Finish & Repair
  • Identify and mark surface defects (honeycomb, voids, cracks)
  • Plan remedial measures for defects exceeding tolerance
  • Use approved repair materials and methods
  • Ensure color matching and surface texture
  • Test repaired areas for strength and durability
IS 13620:2018
8

Common Quality Issues & Remedial Measures

Defect Possible Cause Remedial Action
Honeycombing Improper vibration, thick reinforcement, high aggregate content Chipping, cleaning, and patching with polymer-modified mortar
Misalignment Poor formwork installation, inadequate bracing Realignment during early strength gain, additional support
Formwork Leakage Poor joint sealing, inadequate tie rod spacing Repair with suitable sealants, improve joint details
Low Strength Improper mix design, excess water, poor curing Core testing, structural assessment, possible strengthening
Cracks Shrinkage, thermal effects, early loading Epoxy injection, crack routing and sealing
Reinforcement Corrosion Inadequate cover, poor concrete quality Cathodic protection, cover enhancement, surface treatment
Cold Joints Delayed concrete pouring, poor bonding Surface preparation, bonding agent, re-concreting
9

Quality Control Testing Matrix

Test Type Frequency Acceptance Criteria IS Code
Cement Physical Tests Per batch/100 bags As per IS 8112 specifications IS 8112:2013
Steel Tensile Test Per 40 tonnes Yield strength ≥ 500 MPa, UTS ≥ 565 MPa IS 1786:2008
Aggregate Gradation Per 200 tonnes Within specified limits IS 383:2016
Concrete Slump Every batch/truck 75-150mm (as specified) IS 1199:1959
Cube Strength 6 cubes per 50m³ ≥ 85% of characteristic strength IS 516:1959
Cover Meter Test Random 10% locations Within ±5mm tolerance IS 456:2000
Rebound Hammer If strength doubt Correlation with cube strength IS 13311:1992
10

Tolerance Limits as per IS Standards

Parameter Tolerance Limit IS Reference
Verticality ±3mm per meter height IS 456:2000
Cross-section Dimension +10mm / -5mm IS 456:2000
Concrete Cover +10mm / -5mm IS 456:2000
Reinforcement Spacing ±10mm IS 2502:1963
Deviation from Position ±15mm IS 456:2000
Surface Irregularities 6mm in 2m length IS 456:2000
Level Difference ±10mm IS 456:2000
11

Quality Documents to be Maintained & Submitted

Document Type Description Retention Period
Pre-Construction Checklist Material approval, design verification, site readiness Project duration + 2 years
Material Test Certificates Cement, Steel, Aggregates, Water, Admixtures Project duration + 5 years
Mix Design Approval Concrete mix design with trial mix results Project duration + 5 years
Daily Quality Reports Reinforcement, formwork, concreting inspection Project duration + 2 years
Concrete Test Reports Cube test results, slump test, temperature records Structure life + 10 years
Non-Conformance Reports Defect identification, remedial measures, closure Structure life + 10 years
Calibration Certificates Testing equipment, measuring instruments Validity period + 1 year
Progress Photographs Before, during, after construction stages Project duration + 2 years
Final Acceptance Certificate Quality compliance confirmation Structure life
12

Final Acceptance Criteria

  • Concrete strength achieves designed characteristic strength at 28 days
  • All dimensional tolerances are within specified limits
  • Surface finish is smooth and free from major defects
  • Reinforcement placement matches approved drawings
  • Concrete cover is adequate and verified
  • No visible cracks, honeycombing, or structural defects
  • Verticality and alignment within acceptable limits
  • All quality documentation properly maintained
  • Curing completed as per specifications
  • All non-conformances resolved and documented
  • Final inspection report prepared and approved
  • Handover documentation completed
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