| Table of Contents |
| | Preface | xv |
| | Author | xvii |
| 1. | Introduction | 1 |
| | References | 5 |
| 2. | Effective Total Quality Management System | 7 |
| 2.1. | Introduction | 7 |
| 2.2. | Quality System | 7 |
| 2.3. | ISO 9000 | 8 |
| 2.4. | Quality Management Requirements | 9 |
| 2.4.1. | Quality Manual | 9 |
| 2.4.2. | Quality Plan | 9 |
| 2.4.3. | Quality Control | 10 |
| 2.4.3.1. | Why Is Quality Control Important? | 10 |
| 2.4.3.2. | Submittal Data | 11 |
| 2.4.3.3. | How to Check Incoming Materials | 12 |
| 2.4.3.4. | Methods of Laying Out and Checking Work | 12 |
| 2.4.3.5. | Material/Equipment Compliance Tests | 14 |
| 2.4.3.6. | When to Inspect Work | 15 |
| 2.4.3.7. | Paperwork and Documentation | 16 |
| 2.4.3.8. | Quality Control Plans | 17 |
| 2.4.4. | Quality Assurance | 18 |
| 2.4.4.1. | Quality Assurance in ISO | 19 |
| 2.4.4.2. | Responsibility of Manufacturer | 19 |
| 2.4.4.3. | Responsibility of Owner | 20 |
| 2.5. | Project Quality Control in Various Stages | 21 |
| 2.5.1. | Feasibility Study Stage | 21 |
| 2.5.2. | Feed (Preliminary) Engineering | 22 |
| 2.5.3. | Detailed Studies | 23 |
| 2.5.3.1. | Design Quality Control | 24 |
| 2.5.4. | Execution Phase | 25 |
| 2.5.4.1. | ISO and Control Work | 26 |
| 2.5.4.2. | Inspection Procedures | 26 |
| 2.5.4.3. | Importance of Contracts in Assuring Project Quality | 27 |
| 2.5.4.4. | Checklists | 27 |
| 2.6. | Operational Phase | 31 |
| 2.7. | Total Building Commissioning System | 32 |
| 2.7.1. | Define Owner's Project Requirements | 34 |
| 2.7.2. | Design Stage | 34 |
| 2.7.2.1. | Review Owner's Project Requirements and Basis of Design | 36 |
| 2.7.2.2. | Issues Log and Role of CxA | 36 |
| 2.7.2.3. | Develop Commissioning Specifications | 38 |
| 2.7.3. | Written Test Procedures | 39 |
| 2.7.4. | Construction Stage | 39 |
| 2.7.5. | Oversee and Document Functional Performance Testing | 40 |
| 2.7.6. | Conduct Owner Training | 41 |
| 2.7.7. | Post-Construction Stage | 42 |
| 2.7.7.1. | Reinspect and Review Performance before End of Warranty Period | 43 |
| 2.7.7.2. | Complete Final Commissioning Report | 44 |
| 2.7.7.3. | Final Satisfaction Review with Customer Agency | 44 |
| | References | 45 |
| 3. | Concrete Materials and Tests | 47 |
| 3.1. | Introduction | 47 |
| 3.2. | Concrete Materials Test | 48 |
| 3.2.1. | Cement | 48 |
| 3.2.1.1. | Cement Test by Sieve No. 170 | 49 |
| 3.2.1.2. | Initial and Final Setting Times of Cement Paste Using Vicat Apparatus | 50 |
| 3.2.1.3. | Density of Cement | 52 |
| 3.2.1.4. | Define Cement Fineness Using Blaine Apparatus | 54 |
| 3.2.1.5. | Compressive Strength of Cement Mortars | 56 |
| 3.2.2. | Aggregate Tests | 58 |
| 3.2.2.1. | Sieve Analysis Test | 58 |
| 3.2.2.2. | Abrasion Resistance of Coarse Aggregates in Los Angeles Test | 60 |
| 3.2.2.3. | Determination of Clay and Other Fine Materials in Aggregates | 61 |
| 3.2.2.4. | On-Site Test | 65 |
| 3.2.2.5. | Aggregate Specific Gravity Test | 68 |
| 3.2.2.6. | Fine Aggregate Test | 68 |
| 3.2.2.7. | Define Specific Gravity for Coarse Aggregate | 69 |
| 3.2.2.8. | Bulk Density or Volumetric Weight Test for Aggregate | 69 |
| 3.2.2.9. | Percentage of Aggregate Absorption | 70 |
| 3.2.2.10. | Recycled Aggregate Concrete | 70 |
| 3.2.3. | Mixing Water Test | 72 |
| 3.3. | Admixtures | 73 |
| 3.3.1. | Samples for Testing | 74 |
| 3.3.2. | Chemical Tests to Verify Requirements | 75 |
| 3.3.2.1. | Chemical Tests | 75 |
| 3.3.2.2. | Ash Content | 76 |
| 3.3.2.3. | Relative Density | 76 |
| 3.3.2.4. | Define Hydrogen Concentration | 77 |
| 3.3.2.5. | Define Chloride Ion | 77 |
| 3.3.3. | Performance Tests | 77 |
| 3.4. | Steel Reinforcement Test | 78 |
| 3.4.1. | Weights and Measurement Test | 78 |
| 3.4.2. | Tension Test | 81 |
| | References | 82 |
| 4. | Concrete Mix Design | 85 |
| 4.1. | Introduction | 85 |
| 4.2. | Essential Statistics Information | 85 |
| 4.2.1. | Arithmetic Mean | 86 |
| 4.2.2. | Standard Deviation | 86 |
| 4.2.3. | Coefficient of Variation | 87 |
| 4.3. | Basics of Concrete Mix Design | 88 |
| 4.3.1. | Normal Distribution | 88 |
| 4.4. | Egyptian Code | 91 |
| 4.5. | British Standard | 94 |
| 4.6. | American Specifications (American Concrete Institute) | 94 |
| 4.6.1. | Acceptance and Refusal for Concrete Mix | 95 |
| 4.6.2. | Concrete Mix Procedure | 96 |
| 4.6.2.1. | Chemical Admixtures | 98 |
| 4.6.2.2. | Selection of Water:Cement Ratio | 100 |
| 4.6.3. | Mix Proportions | 101 |
| 4.6.3.1. | British Standard | 102 |
| 4.7. | Fresh Concrete Test | 102 |
| 4.7.1. | Cylinder and Cube Tests | 102 |
| 4.7.1.1. | Cube Test | 103 |
| 4.7.1.2. | Cylinder Test | 103 |
| 4.7.2. | Predicting Concrete Strength | 105 |
| 4.8. | Define Concrete Density | 106 |
| 4.9. | Defining Settlement for Fresh Concrete | 108 |
| 4.10. | Determining Compacting Factor for Fresh Concrete | 112 |
| 4.11. | High-Performance Concrete Mix | 113 |
| 4.12. | Pumped Concrete Mix | 114 |
| 4.12.1. | Basic Considerations | 114 |
| 4.12.2. | Coarse Aggregate | 115 |
| 4.12.3. | Fine Aggregate | 115 |
| 4.12.4. | Combined Normal Weight Aggregates | 116 |
| 4.12.5. | Water | 116 |
| 4.12.6. | Cementitious Materials | 117 |
| 4.12.7. | Admixtures | 117 |
| 4.12.8. | Field Practice | 118 |
| 4.12.9. | Field Control | 118 |
| 4.13. | Quality Control for Operation | 119 |
| 4.13.1. | Process Control Chart | 119 |
| 4.13.2. | Constructing X-R Chart | 120 |
| | References | 123 |
| 5. | Construction Quality Control | 125 |
| 5.1. | Introduction | 125 |
| 5.2. | Create the Wooden Form | 125 |
| 5.3. | Formwork for High-Rise Buildings | 132 |
| 5.3.1. | Formwork | 132 |
| 5.3.2. | Delivery Systems | 135 |
| 5.3.3. | Allowable Tolerance in Dimensions | 135 |
| 5.4. | Detailing, Fabrication, and Installation of Steel Bar | 135 |
| 5.4.1. | Tolerance in Steel Bars in Egyptian Code | 138 |
| 5.4.2. | Allowable Tolerance in ACI 318 | 138 |
| 5.5. | Concrete Cover and Its Specifications | 138 |
| 5.5.1. | British Standard | 139 |
| 5.5.2. | American Code | 143 |
| 5.5.3. | European Code | 143 |
| 5.5.4. | Special Specifications for Structures Exposed to Very Severe Conditions | 145 |
| 5.5.5. | Egyptian Code | 148 |
| 5.5.6. | Placing Concrete Cover | 149 |
| 5.6. | Concrete Pouring | 151 |
| 5.6.1. | Pouring Pumping Concrete | 153 |
| 5.6.1.1. | The Wrong Mix | 156 |
| 5.6.1.2. | Problems with Pipeline | 157 |
| 5.6.1.3. | Operator Error | 158 |
| 5.6.2. | Construction Joint | 158 |
| 5.7. | Compaction Procedure | 159 |
| 5.8. | Curing | 160 |
| 5.8.1. | Curing Process in ACI | 164 |
| 5.8.2. | Curing in British Standard | 165 |
| 5.8.3. | Protecting Special Structures | 167 |
| 5.9. | Hot Weather Concrete | 167 |
| 5.9.1. | Definition of Hot Weather Region | 167 |
| 5.9.2. | Problems of Concretes in Hot Climates | 168 |
| 5.9.2.1. | Fresh Concrete Problem | 168 |
| 5.9.2.2. | Harden Concrete Problem | 168 |
| 5.9.2.3. | Problems Due to Other Factors in Hot Climates | 169 |
| 5.9.3. | Effect of Hot Climate on Concrete Properties | 169 |
| 5.9.3.1. | Control Water Temperature in Mixing | 170 |
| 5.9.3.2. | Control Cement Temperature | 173 |
| 5.9.3.3. | Control Aggregate Temperature | 173 |
| 5.9.3.4. | Control Mixing Ratios | 173 |
| 5.9.3.5. | Control Concrete Mixing Process | 174 |
| 5.9.3.6. | Control Project Management | 175 |
| 5.10. | High-Strength Concrete Quality | 176 |
| 5.10.1. | Cement for High-Strength Concrete | 177 |
| 5.10.2. | Mineral Admixtures | 178 |
| 5.10.2.1. | Silica Fume | 178 |
| 5.10.2.2. | Fly Ash | 181 |
| 5.10.2.3. | Slag | 185 |
| 5.10.2.4. | Comparison of Mineral Additives | 185 |
| 5.11. | Self-Compacting Concrete (SCC) | 186 |
| 5.11.1. | Development of Prototype | 187 |
| 5.12. | Lightweight Aggregate Concrete | 188 |
| 5.12.1. | Lightweight Aggregate | 190 |
| 5.12.2. | Lightweight Coarse Aggregate or Structural Member | 191 |
| | References | 192 |
| 6. | Nondestructive Testing for Concrete | 195 |
| 6.1. | Introduction | 195 |
| 6.2. | Core Test | 195 |
| 6.2.1. | Core Size | 199 |
| 6.2.2. | Sample Preparation | 201 |
| 6.3. | Rebound Hammer | 203 |
| 6.3.1. | Data Analysis | 206 |
| 6.4. | Ultrasonic Pulse Velocity | 206 |
| 6.5. | Load Test for Concrete Members | 211 |
| 6.5.1. | Test Preparation | 212 |
| 6.5.2. | Test Procedure | 213 |
| 6.5.3. | Results Calculations | 214 |
| 6.5.4. | Acceptance and Refusal Limits | 214 |
| 6.6. | Pullout Test | 215 |
| 6.7. | Define Chloride Content in Hardened Concrete | 216 |
| 6.8. | Concrete Cover Measurements | 217 |
| 6.9. | Comparison of Different Tests | 220 |
| | References | 221 |
| 7. | Steel Structure Quality Control | 223 |
| 7.1. | Introduction | 223 |
| 7.2. | Steel Properties | 223 |
| 7.2.1. | Strength | 224 |
| 7.2.2. | Stress--Strain Behavior of Structural Steel | 224 |
| 7.2.3. | Steel Properties | 225 |
| 7.2.4. | Variability of Geometry | 225 |
| 7.2.5. | Ductility Requirements | 227 |
| 7.3. | Design Situations | 229 |
| 7.4. | Connection | 230 |
| 7.4.1. | Bolted Connection | 230 |
| 7.4.2. | Welding Connection | 231 |
| 7.4.2.1. | Shielded Metal Arc Welding (SMAW) | 232 |
| 7.4.2.2. | Gas Metal Arc Welding (GMAW) | 234 |
| 7.5. | Welding Types | 234 |
| 7.5.1. | Fillet Weld | 234 |
| 7.5.2. | Butt Weld | 235 |
| 7.5.2.1. | Parts of Butt Weld | 235 |
| 7.5.2.2. | Welding Groove Configurations | 237 |
| 7.5.2.3. | Connection between Steel Plates | 241 |
| 7.5.2.4. | Welding Groove | 244 |
| 7.5.3. | Problems in Welding | 245 |
| 7.5.4. | Welds and Welding Symbols | 248 |
| 7.5.4.1. | Elements of Welding Symbols | 250 |
| 7.5.4.2. | Fillet Weld Dimensions | 257 |
| 7.6. | Stud Weld | 261 |
| 7.7. | Quality Control on Site | 263 |
| 7.7.1. | Quality of Human Resources | 263 |
| 7.7.2. | Handling, Shipping, and Delivery | 264 |
| 7.7.3. | Erection and Shop Drawings | 264 |
| 7.7.4. | Inspection and Testing | 265 |
| | References | 268 |
| 8. | Nondestructive Testing for Steel Structures | 271 |
| 8.1. | Introduction | 271 |
| 8.2. | Visual Test | 271 |
| 8.3. | Radiographic Test | 274 |
| 8.3.1. | Principles | 274 |
| 8.3.2. | Isotope Decay Rate (Half-Life) | 274 |
| 8.3.3. | Radiographic Sensitivity | 276 |
| 8.3.4. | Geometric Unsharpness | 277 |
| 8.3.5. | Scatter Radiation | 279 |
| 8.3.6. | Radio Isotope (Gamma) Sources | 281 |
| 8.3.7. | Radiographic Film | 283 |
| 8.3.7.1. | New Films | 285 |
| 8.3.8. | General Welding Discontinuities | 285 |
| 8.4. | Ultrasonic Test | 289 |
| 8.4.1. | Wave Propagation | 290 |
| 8.4.2. | Attenuation of Sound Waves | 292 |
| 8.4.3. | Reflection in Sound Wave | 293 |
| 8.4.4. | Refraction of Sound Wave and Snell's Law | 295 |
| 8.4.4.1. | Angle Beams | 296 |
| 8.4.5. | Wave Interaction or Interference | 298 |
| 8.4.6. | Transducer Types | 300 |
| 8.4.7. | Calibration Methods | 301 |
| 8.5. | Penetration Test | 302 |
| 8.5.1. | Advantages and Disadvantages of Penetrant Testing | 302 |
| 8.5.2. | Penetrant Testing Materials | 303 |
| 8.5.3. | Penetrants | 306 |
| 8.5.4. | Developers | 306 |
| 8.6. | Magnetic Particle Test | 307 |
| 8.6.1. | Magnetic Field Characteristics | 309 |
| 8.6.2. | Electromagnetic Fields | 310 |
| 8.6.3. | Magnetic Field Orientation and Flaw Detectability | 310 |
| 8.6.4. | Tools for Testing | 312 |
| 8.6.5. | Magnetizing Current | 314 |
| 8.6.6. | Hysteresis Loop and Magnetic Properties | 316 |
| 8.6.7. | Examination Medium | 318 |
| | References | 318 |
| | Index | 319 |
