public works department, himachal pradesh (hppwd) quality ...admis.hp.nic.in/himachal/hpridc/bridge...

PPUUBBLLIICC WWOORRKKSS DDEEPPAARRTTMMEENNTT,, HHIIMMAACCHHAALL PPRRAADDEESSHH ((HHPPPPWWDD))

QQUUAALLIITTYY MMAANNAAGGEEMMEENNTT SSYYSSTTEEMMSS ((IISSOO 99000011:: 22000088))

(HPPWD Project Reference No.: - PW-SRC/RIDC/Procurement-ISO/2008)

CCOONNSSTTRRUUCCTTIIOONN MMAANNUUAALL ((WWOORRKK IINNSSTTRRUUCCTTIIOONNSS))

BBRRIIDDGGEE CCOONNSSTTRRUUCCTTIIOONN

HIMACHAL PRADESH ROADS & INFRASTRUCTURE DEVELOPMENT CORPORATION LTD (HPRIDC)

States Roads Project, Nirman Bhawan Nigam Vihar, Shimla – 171002

Tel No.: 0177-2627602

Issue No: 01 Rev No. 00 Review & Issue By:

Project Director(MR)

Approved By:

MD/ Secretary

Quality Management System Construction Manual (Work Instructions) for

Public Works Department of Himachal Pradesh (HPPWD)

Procedure No.: QMS/WI/BC/Table of Contents Issue 01, Rev 00

Controlled Document Page No.: BC/i

TABLE OF CONTENTS Title Page No. Chapters AMENDMENT SHEET .......................................................................................................... i 1. INTRODUCTION ...................................................................................................1-1 2. CLASSIFICATION OF BRIDGES..........................................................................2-1 2.1. Planning and investigation.....................................................................................2-1 2.2. Designs ..................................................................................................................2-3 2.3. Detailed Project Report .........................................................................................2-3 2.4. Tender....................................................................................................................2-4 2.5. Contract Management ...........................................................................................2-5 3. PROCESS FLOW FOR BRIDGE CONSTRUCTION ...........................................3-1 4. QUALITY PLAN FOR BRIDGE / CROSS DRAIN.................................................4-1 4.1. Background............................................................................................................4-1 4.2. Scope .....................................................................................................................4-1 4.3. Abbreviations and Definitions................................................................................4-1 4.4. References.............................................................................................................4-2 4.5. Planning of Bridge / Cross Drain Projects.............................................................4-2 4.6. Original Construction / Maintenance .....................................................................4-3 5. QUALITY ASSURANCE REQUIREMENTS FOR BRIDGES ...............................5-1 5.1. Project Report Preparation ....................................................................................5-1 5.2. Material Controls....................................................................................................5-1 5.3. Process Controls ...................................................................................................5-1 6. QUALITY PROCESS FOR MAINTENANCE OF BRIDGES.................................6-1 6.1. Annual Maintenance / Ordinary Repairs / Routine Maintenance .........................6-1 6.2. Periodic Maintenance ............................................................................................6-1 6.3. Special Repairs......................................................................................................6-1 6.4. Survey Report ........................................................................................................6-2 7. NON-CONFORMANCE (NC) AND CORRECTIVE ACTIONS.............................7-1 7.1. Typical NCs with Product: Concrete / Asphalt work .............................................7-1 8. TEST PLANS AND CHECKLISTS ........................................................................8-1 8.1. Test Plan for Cement.............................................................................................8-1 8.2. Test Plan for Coarse Aggregate............................................................................8-2 8.3. Test Plan for Fine Aggregate ................................................................................8-3 8.4. Test Plan for Water for Construction.....................................................................8-4 8.5. Test Plan for Sheathing .........................................................................................8-5 8.6. Test Plan for Epoxy Paint ......................................................................................8-6 8.7. Test Plan for Elastomeric Bearings .......................................................................8-7 8.8. Test Plan for Pot Bearings.....................................................................................8-8 8.9. Test Plan for Chemicals for Anti Corrosive - Treatment (CECRI) ........................8-9 8.10. Test Plan for Fusion Bonded Epoxy Coating (FBEC).........................................8-10 8.11. Test Plan for Reinforcement Steel (HYSD).........................................................8-11 8.12. Test Plan for Steel for Pre-Stressing...................................................................8-12 8.13. Test Plan for Steel for MS Liner ..........................................................................8-13 8.14. Test Plan for Elastomeric Expansion Joint (Strip Seal) ......................................8-14 8.15. Checklist for Pile Foundations.............................................................................8-15 8.16. Checklist for Pile Foundations.............................................................................8-18 8.17. Checklist for Pile Cap ..........................................................................................8-19




Controlled Document Page No.: BC/ii

8.18. Checklist for Formwork........................................................................................8-20 8.19. Checklist for Construction of Well Foundation ....................................................8-23 8.20. Checklist for Construction of Well Cap................................................................8-28 8.21. Checklist for Excavation for Open Foundation....................................................8-30 8.22. Checklist for Steel Reinforcement .......................................................................8-33 8.23. Checklist for Structural Concrete.........................................................................8-36 8.24. Preparation of Mix Design of Cement Concrete .................................................8-40 8.25. Checklist for Bearing............................................................................................8-42 8.26. Checklist for Strip Seal Expansion Joints............................................................8-44 8.27. Checklist for Providing and Fixing of Bridge Railing ...........................................8-46 8.28. Construction of Reinforced Concrete for Piers and Abutments..........................8-48 8.29. Construction of Pier Cap and Abutment Cap......................................................8-50 8.30. Providing Reinforced Earth Retaining Wall .........................................................8-53 8.31. Checklist for Application of Epoxy Paint to Exposed Faces of Superstructure ..8-55 8.32. Checklist for Application of Epoxy Pain to Exposed Faces of Superstructure ...8-56 8.33. Checklist for Application of Water Proof Cement Paint to Structure ..................8-57 8.34. Checklist for Tack Coat .......................................................................................8-58 8.35. Checklist for Mastic Asphalt ................................................................................8-60 8.36. Checklist for Dense Bituminous Macadam .........................................................8-62 8.37. Checklist for Asphaltic Concrete .........................................................................8-65 8.38. Providing and Fixing Water Spouts .....................................................................8-68 8.39. Checklist for Application of Aqua Epoxy Paint to Structure ................................8-70 8.40. Checklist for Application of Aqua Epoxy Paint to Structure ................................8-72 9. TESTS AND TEST PROFORMA ..........................................................................9-1 9.1. Tests to be conducted by Construction Division...................................................9-1 9.2. Test report on aggregate characteristics of Grade 2 metal for WBM Work .........9-3 9.3. Test Report on Cement Concrete Cubes..............................................................9-4 9.4. Test Report of Sand Sample .................................................................................9-5 9.5. Test Report of Brick Sample..................................................................................9-6 9.6. Test Report of Coarse Aggregate (40mm and less / 20mm and less) .................9-7 9.7. Test Report of Cement Sample.............................................................................9-8 9.8. Test Report on Aggregate Characteristics of Single Coat Surface Dressing.......9-9 9.9. Test Report on Aggregate Characteristics of 20mm Thick Open Graded Premix Carpet / Seal Coat ...........................................................................................................9-10 9.10. Test Report on Aggregate of Built-up Spray Grout.............................................9-11 9.11. Test Report on Aggregates Characteristic for Semi Dense Bituminous Concrete (SDBC) ........................................................................................................................9-12 9.12. Test Report on Aggregate Characteristics of Bituminous Macadam..................9-13 9.13. Test Report on Coarse Aggregate for Bituminous Concrete ..............................9-14 9.14. Test Report on Aggregates Characteristic for Dense Graded Bituminous Macadam ........................................................................................................................9-15 Annexures Annexure I. : Typical Letter for Public Representation .....................................................I-1 Annexure II. : Typical Covering Letter from Divisionl to Division......................................II-1 Annexure III. : Typical Routine Inspection Proforma for Maintenance of Bridge ............III-1 Annexure IV. : Annual Calendar for QA Checks for Bridge Maintenance...................... IV-1




Controlled Document Page No.: BC/iii

Appendixes Appendix I. : Proforma for Bridge / Cross Drain ................................................................I-1 Appendix II. : Proforma for Bridge.....................................................................................II-1 Appendix III. : Checklist for Proposal Preparation for Bridge/Cross Drain......................III-1



Procedure No.: QMS/WI/BC/Amendment Sheet Issue 01, Rev 00

Controlled Document Page No.: BC/i

AMENDMENT SHEET

Sl. No. Document Description of Change Page/Para. No.

Rev. No.

Date of Issue



Procedure No.: QMS/WI/BC-01/Introduction Issue 01, Rev 00

Controlled Document Page No.: BC/1-1

1. INTRODUCTION This manual intends to provide guidance to the HPPWD engineers in their functions of investigation, designs, estimation inspection and assurance of quality of construction and maintenance. It helps in the vendor control and gradation of contractors and is expected to aid in structured Quality Assurance activities of HPPWD.

Bridge construction is dependent on several challenges, right from selection of the terrain, soil conditions, materials, methods, type and design of construction to supervision and assurance of quality in construction of new approach roads and maintenance of the same after the area is acquired.

The enclosures would provide typical process flow of road construction, Quality Assurance requirements, test plans for Quality checks of materials used in construction and teats and test report Performa for presentation of test results.

The checklists are the Level III documents of an established Quality Management System (QMS) as per ISO 9001:2008. The Quality Plan drawn up highlights on the process controls necessary for product realization and improvements. It is intended to help the internal auditors while carrying out audits of the implemented QMS of HPPWD.

This document is an important adjunct to the Procedure Manual (Level II) document and takes into consideration the existing practices and codal needs of HPPWD. The formats to be used are the same as necessary for the QMS and the departmental code.

For easy reference to the contents of the manual the following process has been adopted:

BCM – refers to Bridge Construction Manual.

TP – refers to Test Plan

CL – refers to various Check list for process control.

The test plans are identified as BCM/TP XX refers to the Serial No. of Test plan, similarly BCM/CL XX refers to the Serial No. of checklist as applicable. The test plan and checklist should be considered as work instructions necessary for construction and maintenance of Bridge.

The typical tests and test Performa are given in separate chapters for the purpose of guidance to the site engineer, quality control staff and also the contractors.



Procedure No.: QMS/WI/BC-02/Classification of Bridges Issue 01, Rev 00


2. CLASSIFICATION OF BRIDGES

Type of Bridge Length Details

Culverts up to 6m Bridge structure with a lineal waterway.

Minor Bridge 6 m- 60 m On stable rivers and canals

Major Bridge more than 60 m On major river or tributaries, which are shifting in nature.

2.1. Planning and investigation

2.1.1. Planning

Following factors are taken into consideration:

• The need for the structure and its location. • The traffic that will pass over the structure on completion and in future (in

respect of the volume of traffic as well as the axle/wheel load.). • Characteristics of the river / stream / canal. • Subsoil condition. • Construction problems that may arise. • Cost and economics. (including land acquisition). • Alternative sites either by longitudinal shifts of the proposed structure or by

lateral shift of the alignment itself.

2.1.2. Investigation

• Techno feasibility study. • Techno economic study. • Detailed survey and project report.

2.1.2.1 Techno Feasibility Study

• Selection of Site o Entire reach of the river within the area to be inter-connected are studied

to find out sites which satisfy various conditions for location a bridge o No. of factors each site satisfy are listed and the site which satisfy the

most are selected for further consideration. o Maps are studied to choose sites that appear suitable for locating the

bridge. Choice is narrowed down to three/ four alternative sites. It also includes gathering information on behaviour of river at sites by studying available reports.

o A detailed assessment of construction problems that can affect its feasibility, cost and duration of construction.





2.1.2.2 Techno-Economic Study

During this investigation technical details are studied in-depth to facilitate estimating the cost of various alternatives. Details obtained for each site are

• Length of bridge. • Length of approaches. • Volume of traffic anticipated. • Distance from important city / town. • Expected duration of construction. • Nature of flow at site. • Construction problems, if any (including land acquisition). • Cost benefit ratio.

2.1.2.3 Detailed Surveys

• Traffic surveys and analysis o Classified traffic volume survey. o Origin-destination studies. o Speed and delay studies. o Survey for design of Bridge/Cross Drain junctions, Bridge/Cross Drain over

/ under bridges, etc. o Axle load studies. o Accident records. o Traffic projection (for approx. 30 years).

• Geographical survey o Study of maps and survey sheets. o Study of GIS information. o Detailed ground survey. o Hydrological data collection and survey.

• Environmental impact studies o Environmental impact assessment. o Environmental management action plan. o Resettlement and rehabilitation action plan.

• Soil surveys o Study of secondary data. o Soil investigation for low embankments. o Special investigation for high embankments. o Soil investigation for cut sections. o Special investigation for land-slide-prone area. o Soil exploration for determining nature of Foundation and carrying out

model/studies.

• Drainage studies o Objectives. o High flood level (HFL). o Depth of water table.





o Pounded water level. o Special investigation for cut-sections. o Surface run-off.

• Cost benefit o Return on investments worked out in more precise terms.

(Benefits by the way of savings or additional earnings)

• Investigation for major /Important bridge with waterway of > or=60 m o Topographical Details. o Catchment area and its characteristics. o Hydrological particulars. o Geo-tech. Details. o Seismology of the area. o Navigational requirements. o Construction Resources:

(i) Land availability and acquisition.

(ii) Labour.

(iii) Material.

(iv) Habitation and accommodation.

(v) Water and power.

(vi) Existing transport and Communication infrastructure.

o Important details of nearest bridge across the same river or stream and its history.

o Traffic – Present and future trend. o Alternative routes and modes available.

2.2. Designs

• Detailed pavement design. • Cross Drains design. • Side Drains design.

2.3. Detailed Project Report

2.3.1. Survey Details

• Longitudinal section. • Cross Section. • Earthwork calculations for embankment if any.

2.3.2. Design and Drawing Details

• A plan of the proposed structure 1:100 to 1:200. • A Cross Section of the structure also showing the ground profile at the

foundation level both HFL and LFL to the same scale. • A part of elevation and part section along the centerline of the bridge.





• A site plan to the scale 1:1000 or 1:2000. • A cross section to half front elevation along the alignment showing the ground

profile and containing a section through the trial pit at the chain age. • The catchments area map (for major bridge only).

2.3.3. Estimate Details

It is based on Current Schedule of Rates (CSR) applicable for respective Circles. It includes.

• General report detailing about present condition of the road, connectivity, proposed improvements.

• Inspection Certificate by AE and EE. • Abstract detailing name of the work and estimated cost. • Detailed Estimate describing items, units, quantity, rate amount, etc. • Sub-estimates. • Rate Analysis. • Plans. • Index Map. • Bar chart for existing Road condition. • Bar chart for proposed improvements. • Recapitulation sheet.

2.3.4. Other Documents

• L sections. • Cross Sections. • Tehsil map. • District map. • Bar chart for existing Bridge/Cross Drain condition. • Bar chart for proposed improvements.

2.3.5. Submission of Project report (Plans and Estimates.)

• Submission of the project report (detailing salient features of bridge, its estimated cost, and cost benefit ratio, etc.) by EE to EE and subsequent authorities in accordance with the Delegation of financial powers for Administrative Approval.

• After administrative approval the Project report will be submitted to the concerned authority for Technical Sanction in accordance with the Delegation of financial powers.

• Upon accord of technical sanction by competent authority, Division initiates the next activity of tendering.

2.4. Tender

• Notification for Inviting Tenders (NIT)

• Preparation of Draft Tender Papers o Pre-qualification of Contractor. o Preparation of Draft Tender Schedules (DTS).





o Preparation of schedule ‘B’.

• Tender Documents Shall Contain o Technical specifications. o Commercial conditions.

• Supply of Tender Documents

• Clarification of Tender Documents o Scope of Tender. o Eligibility criteria. o Amendment of Tender documents.

• Receipt of Tenders and Tender Opening

• Tender Evaluation to be in Accordance with Evaluation Criteria

• Preparation of Evaluation Report and Award of Contract

• Handing Over of Site to the Contractor

2.5. Contract Management

• Supervision o Product and process.

• Product Inspection o Materials, Equipments, finished product.

• Control of Materials o Testing of material for source approval. o Inspection and certification of materials on receipt. o Testing of materials going into construction.

• Equipments o Test frequencies and calibration schedule. o Handling by skilled manpower.

• Process Inspection o Workmanship, procedures.

• Workmanship o Competent manpower. o Safety.

• Procedures o Specifications. o Departmental Codes. o Quality Management Procedures.



Procedure No.: QMS/WI/BC-03/Process Flow for Bridge Construction Issue 01, Rev 00


3. PROCESS FLOW FOR BRIDGE CONSTRUCTION

Requirement from concerned dept

Line Estimation

Scrutiny by CA, TC

Preparation of Designs and detailed estimates

Administrative Approval

Approved?

Tendering and Award of Contract

Execution and Supervision

Appear in the budget?

N

Y

N

Y

Administrative Approval

Approved? N

Y



Procedure No.: QMS/WI/BC-04/Quality Plan for Bridge / Cross Drain Issue 01, Rev 00


4. QUALITY PLAN FOR BRIDGE / CROSS DRAIN 4.1. Background

Bridges are defined as structures, which provide passage over a gap without closing the way beneath. They may be needed for passage of railways, roadways, and footpaths and even for carriage of fluids. A good Bridge/Cross Drain has an important bearing on the economy of a country. In the changing scenario of globalization and economic liberalization, a great deal of emphasis is already laid on development of infrastructure through construction of a dependable Bridge/Cross Drain. Consequently, consistency in the quality of structure, workmanship, reliability etc., have gained paramount importance. In line with this need the document is prepared to provide guidelines for Quality Assurance of Bridge/Cross Drains.

4.2. Scope

These guidelines cover quality system for activities of Bridge/Cross Drain construction. These include steps towards planning and investigation, design and construction, Tendering, Corrective and preventive actions for NCs, etc.

4.3. Abbreviations and Definitions

4.3.1. Abbreviations

IRC- Indian Roads Congress No. – Number Ref. – Reference DTS-Draft Tender Schedule Divn- Division NC- Non Conformance

4.3.2. Definitions

4.3.2.1 Quality

The totality of features and characteristics of a product or service that relies on its ability to satisfy stated or implied need.

4.3.2.2 Quality Assurance

All those systematic and planned actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality.

4.3.2.3 Quality Plan

A document setting out specific practices, resources and sequence of activities relevant to a particular product, service contract or project.

4.3.2.4 Non-Conformity

Non-fulfillment of specified requirements.

4.3.2.5 Technical Sanction

The name is given to the order of the competent authority sanctioning a properly detailed estimate of the cost of a work of construction or repair, to be carried out by the public works department. Ordinarily, such sanction can only be accorded





by the government in the public works department or by such authorities of the department to whom the power has been delegated by government. Sanction accorded to a work by any other department of government is regarded as an administrative approval of the work.

4.3.2.6 Administrative Approval

This term denotes the formal acceptance, by the administrative department concerned, of the proposals for incurring any expenditure in the public works department on a work initiated by or connected with the requirements of such administrative department. It is in effect, an order to the Public Works Department to execute certain specified works at a stated sum to meet the administrative needs of the department requiring the work. .

Administrative Approval Technical Sanction Subject to appearing in the Budget For estimate of original work

4.3.2.7 For Lumpsum Contract – Architectural, Acoustic, Landscaping, electrical etc.

4.4. References

• ISO 9000:2005 – Fundamentals and Vocabulary, • IRC, MOSRTH.

4.5. Planning of Bridge / Cross Drain Projects

Original Construction

Maintenance

Annual Maintenance

Periodical Maintenance

Special Maintenance

BRIDGE/CROSS DRAIN





4.6. Original Construction / Maintenance

1. Public Representation. • Typical Letter for Public Representation: From Public / Elected representative

(Annexure I). 2. Feasibility study by Division

• Economic profile and analysis. • Traffic survey. • Preliminary Topographical survey. • Soil survey and Drainage studies. • Initial pavement designs. • Land acquisition estimate. • Traffic analysis and projection. • Line estimate for detail investigation.

3. Typical Covering Letter from Division to division (Annexure II). 4. Proposal scrutinized by EE and submission to SE. 5. Proposal scrutinized by SE and submission to CE.

(Submission to SE / CE depends upon the amount involved and financial powers delegated).

6. EE/SE/CE submits proposal to Govt. for sanctioning the amount towards detail investigation.

7. Upon receiving the amount for detail investigation to Division, EE instructs the Division to carry out the activity.

8. Based on the investigation results, designs are prepared. 9. On the basis of designs and by referring to current schedule of rates, applicable to

concerned Circle, detailed estimate is prepared. 10. Detailed Project Report is submitted by Division to Technical Committee

(TC)/Board of directors. 11. TC/BOD scrutinizes all the proposals (complete in all aspects) received from

various Divisions. 12. TC/BOD prioritizes proposals on the basis of ‘need of the project’ for inclusion in

the budget. 13. Upon approval from the Govt. (inclusion in the Budget), TC/BOD intimates the

concerned Division accordingly. 14. The proposals which do not appear in the current budget due to financial

reasons are stored by TC/BOD, for including in the budget of next year by revising Plans and Estimates.



Procedure No.: QMS/WI/BC-05/Quality Assurance Requirements for Bridges Issue 01, Rev 00


5. QUALITY ASSURANCE REQUIREMENTS FOR BRIDGES 5.1. Project Report Preparation

• Design and drawings, contracts and contractors, materials, quantity estimation, requirements of human resources, execution, inspection and testing, acceptance / reworking and asset acquisition.

5.2. Material Controls

• Testing of materials – Aggregates – coarse, fine, components (base, sub-base, pavement, shoulders).

• Test methods, Acceptance limits. • Sampling and Frequency of testing. • Availability of equipment – Monitoring and measurement. • Reports of test results, calibration.

5.3. Process Controls

• Alignment Controls for approach roads – Edges, carriageway, horizontal alignment, vertical profile, pavement thickness.

• Road embankment – Grade, sub base and fill. • Grain size, Plasticity Index, of materials, moisture content, density. • Sampling and frequency of testing, Test methods, testing equipment,

calibration. • Tests on finished profile. • Granular Base course laying.

o Material testing (Gradation, sizing, aggregate impact values, density). o Frequency and sampling. o Test equipment and test methods. o Tests on surface profile (slope and evenness).

• Bituminous Pavement laying. o Tests on aggregates, bitumen, mix grading. o Temperature and rate of application of prime and tack coating. o Temperature for mixing, laying and compaction of bitumen mix. o Core sampling, assess for density, voids. o Tests on surface profiles, evenness, slope of the finished pavement.

• Cement Concrete (CC) Pavements. o Tests on aggregates (for the base and paving). o Tests on cement. o Tests on Cement Concrete mix, (both in-situ and laboratory). o Tests on cores. o Tests on concrete for Cross Drainage.



Procedure No.: QMS/WI/BC-06/Quality Process for Maintenance of Bridges Issue 01, Rev 00


6. QUALITY PROCESS FOR MAINTENANCE OF BRIDGES The basic objective of a maintenance activity is to ensure safety and meeting customer requirements. The Quality Assurance activities assure that the maintenance activities are performed as per plans. Towards this, a calendar is drawn up at the beginning of the year for both preventive and annual maintenance of all assets- bridges. A typical maintenance plan is given below:

6.1. Annual Maintenance / Ordinary Repairs / Routine Maintenance It includes following nature of works

• Upkeep of bridges (whitewashing, painting etc). • Upkeep of bridge Drainage system. • Upkeep of earth retaining structures. • Keeping the bridges in good condition (plastering, fittings, electricals).

6.2. Periodic Maintenance Visual examination of the condition of bridges shall be carried out at least once in six months. Regular preventive measures for any damages to approach roads, corrosion and rusting, painting requirements, undesirable vegetation should be carried out. A typical routine inspection Performa for maintenance of bridges is given in (Annexure III).

6.3. Special Repairs It covers damages occurred due to unforeseen / nature’s calamity.

The process maintenance of Bridge needs a system approach to be followed involving a series of sequential operations.

• Detailed assessment of the present Bridge condition. • Diagnosis of the problem. • Selection of the most appropriate treatment.

This systematic approach enables a clear understanding of determination of priorities more objectively and allotment of available resources where they are most needed.

The first step in planning a maintenance operation is to know the existing bridge in terms of physical condition, structural capacity, surface etc. The following data are required to be collected. The various inputs are:

• Strip map.

Maintenance

Annual Maintenance

Periodic (preventive) Maintenance

Special repairs (Corrective actions)

Routine Maintenance



Procedure No.: QMS/WI/BC-06/Quality Process for Maintenance of Bridges Issue 01, Rev 00


• Surface history. • List of bridges - Major / Minor Bridges. • Condition survey.

Condition surveys at fixed frequency are necessary for determining periodic renewal requirements and long-term maintenance strategy.

6.4. Survey Report

Type of bridge ( Major/Minor)

Routine Special Routine Special Routine Special

Inspected by: Approved by: 6.4.1. Method

• Visual inspection

6.4.2. Calendar of QA Planning for Maintenance

The calendar is drawn up for the year, keeping in mind the best time for maintenance activity, such as, pre-monsoon, post monsoon, winter (for hill bridges) etc. A typical calendar is shown for purpose of reference (Annexure IV).



Procedure No.: QMS/WI/BC-07/Non-Conformance (NC) and Corrective Actions Issue 01, Rev 00


7. NON-CONFORMANCE (NC) AND CORRECTIVE ACTIONS 7.1. Typical NCs with Product: Concrete / Asphalt work

7.1.1. Non-Conformance with Strength Requirements

• The specification strength/density for concrete /asphalt recognizes the statistical possibility of cube failures and thus limits of means, standard deviation and minimum value of strength are specified. The rejection criteria are set out in the agreement.

In the event of cube/ density failures outside the provision of the contract then:

(a). Approval of concreting/asphalting of similar works shall be withheld.

(b). All aspects of concreting/asphalting shall be reviewed.

(c). The causes of failure shall be identified and measures taken to remedy the problem.

7.1.2. Non-Conformance Other than Strength or Finish

• Issue of a letter stating the facts and confirming that the works are not approved.

• Approval to carry out concreting/asphalting of a similar nature shall be with held.

• The Contractor shall be asked for his proposals to rectify the non-compliance, which may involve re-submission of materials, new trial mixes, revised method statement.

7.1.3. Non-Conformance with Finishing Requirements

Where the required finish is not attained then:

(a). Approval of similar work shall be withheld.

(b). All aspects of work shall be reviewed.

(c). The cause of poor finis shall be identified.

(d). Revised specifications/instructions to avoid further recurrence of non-conformance shall be issued.



Procedure No.: QMS/WI/BC/Annexures Issue 01, Rev 00

Controlled Document Page No.: BC/AN.I-1

Annexure I. : Typical Letter for Public Representation

Date:

To

The Executive Engineer

<Tehsil> Division,

PIN.-

Sir,

Sub: Submission of proposal (Strike out the non-applicable products)

Ref.:

I am/ We are hereby submitting a proposal in the prescribed format attached herewith for construction / Improvement / Maintenance of Bridge /Cross Drains / Buildings / Culverts / Pavedip / causeway / others.

I / We hope this proposal will be considered for necessary approval from Government and work will be taken up at the earliest.

Thanking you.

Yours truly,

Enclosure:

1. Performa of Bridge/Cross Drain (Appendix I).

2. Bridge (Appendix II).




Controlled Document Page No.: BC/AN.II-1

Annexure II. : Typical Covering Letter from Sub-Division to Division

No./EE- <Sub-div>/Case worker/ Subject / File No. / Year / Dispatch No. / Dispatch Date

Date:

To

The Executive Engineer

<>District>

PIN. –

Sir,

Sub: Proposal for (Tick mark the applicable)

Bridge/Cross Drain / Bridge under <Head of account>

Ref.: Public Representation dated -

I am hereby submitting a proposal for construction / Improvement / Maintenance of Bridge/Cross Drains / Culverts / Pave dip / causeway / others in the prescribed format attached herewith.

I hope this proposal will be considered for necessary approval from Government and work will be taken up at the earliest.

Thanking you.

Yours truly,

Executive Engineer

Sub- Division

Enclosure:

1. Checklist for Bridge/Cross Drain (Appendix III).

2. District Map.

3. Tehsil Map.

4. Copy of Representative’s Letter, if any.



Procedure No.: QMS/WI/BC/Annexure Issue 01, Rev 00

Controlled Document Page No.: BC/AN.III-1

Annexure III. : Typical Routine Inspection Performa for Maintenance of Bridge Sl. No.

Particular action to be taken

Chain age -100

KM -101

KM-102 KM -103 KM - 104

1. Jungle Clearance 2. Side drains 3. Shoulder and Edge

• Correct camber • Correct Edges • Pot holes • Erosion cuts • Drain cuts

4. Carriageway • Fill patches • Fill pot holes • Grit for bleeding • Renewal needed

5. CD Works 6. Encroachment details 7. Road furniture-

• Sign boards • Km and Hectometer

- Stones • Pavement markings • Speed Breaker

8. Cleaning and repairs of Bridge/CD proper.

9. Repair/replacement of bearings and expansion joints.

10. River/Drain training and Clearing the vents.

11. Repairs to approaches / Embankments.

12. Repairs to aprons.

13. White washing/Painting Parapets /Handrails.

14. Visual checks for vegetation, cracks etc.




Controlled Document Page No.: BC/AN.IV-1

Annexure IV. : Annual Calendar for QA Checks for Bridge Maintenance

Sl. No. Items Apr-

Jun July-Sep

Oct-Dec

Jan-Mar. Remarks

1. Cleaning and repairs of Bridge/CD proper. X X X X

2. Repair/replacement of bearings and expansion joints. X X X X

3. River/Drain training and Clearing the vents. X

X

4. Repairs to approaches / Embankments. X X

5. Repairs to aprons. X X 6. White washing/Painting Parapets

/Handrails. X X X

7. Visual checks for vegetation, cracks etc. X X X X



Procedure No.: QMS/WI/BC/Appendixes Issue 01, Rev 00

Controlled Document Page No.: BC/AP.I-1

Appendix I. : Performa for Bridge / Cross Drain

1. Name of the Bridge/Cross Drain:

2. Length in Km:

3. Present condition of Bridge/Cross Drain:

4. Improvements required:




Controlled Document Page No.: BC/AP.II-1

Appendix II. : Performa for Bridge

1. Name of the Bridge:

2. Location of the Bridge:

3. Reason for construction of Bridge:

4. Period of traffic interruption:

5. If proposed for repairs-

(a). Present condition of Bridge:

(b). Cause of damage

(c). Improvements required:




Controlled Document Page No.: BC/AP.III-1

Appendix III. : Checklist for Proposal Preparation for Bridge/Cross Drain

Sl.No

Particulars Project 1 Project 2 Project 3

1. Name of District 2. Name of Tehsil 3. Name of constituency 4. Name of proposed

Bridge/Cross Drain

5. Category of Bridge/Cross Drain

6. Total length of Bridge/Cross Drain

7. Length of the Bridge/Cross Drain proposed for improvement

8. Estimated cost Rs. in Lakhs Based on the SR for the year.

9. Estimated cost for detailed investigation

10. Villages benefited 11. Population benefited 12. Traffic intensity / census

year

WBM From To

BT From To

WBM From To

BT From To

WBM From To

BT From To 13.

Surface condition of existing Bridge/Cross Drain

14. Proposed improvements 15. Name of the

representative

16. Priority level * 17. Justification 18. Remarks

Note: Priority Levels *

(a). Top priority

Bridge/Cross Drains which are badly damaged i.e. traffic interruption is more than half an hour and having WBM surface.

If the Bridge/Cross Drain is SH and connecting pilgrimage centre.




Controlled Document Page No.: BC/AP.III-2

(b). Medium priority

Bridge/Cross Drains which are asphalted but badly damaged traffic interruption is more than half an hour.

If the Bridge/Cross Drain is MDR or motorable and creating shortcut.

(c). Low priority

Bridge/Cross Drains, which are asphalted but require minimum improvements.

If it is MDR and traffic intensity is low.



Procedure No.: QMS/WI/BC-08/Test Plans and Checklists Issue 01, Rev 00


8. TEST PLANS AND CHECKLISTS

8.1. Test Plan for Cement

BCM/TP 01

Name of Work : Sanction No. and date: Agreement No.: Estimated Cost : Sl.No Test/Parameter Acceptance

Standard Sampling criteria Acceptance Criteria

1. Physical and Chemical Test IS 4031

As per IS Conformance to the tests

2. Ordinary Portland cement 33 Grade IS 269 Each consignment Conformance to specification

3. Portland slag cement IS 455 Each consignment Conformance to specification

4. Portland Pozzolana Cement IS 1489 Each consignment Conformance to specification

5. Rapid Hardening Portland cement IS 8041 Each consignment Conformance to specification



8. Sulphate Resistant Portland cement IS 12330 Each consignment Conformance to specification





8.2. Test Plan for Coarse Aggregate

BCM/TP 02

Note: Samples will be drawn for testing whenever there is a change of source of supply.

Name of Work : Sanction No. and date: Agreement No.: Estimated Cost : Sl.No Test/ Parameter Acceptance

Standard Sampling size

Frequency of Test Acceptance Criteria

1. Los Angeles (LA) Abrasion Value IS2386 (Pt 4) One monthly Conformance

2. Soundness IS2386 (Pt 5) One monthly Conformance

3. Alkali-Aggregate Reactivity IS2386 (Pt 7) One monthly Conformance

4. Gradation IS2386 (Pt 1) One Daily Conformance

5. Deleterious Constitutions IS2386 (Pt 2) One Daily Conformance

6. Water Absorption IS2386 (Pt 3) One Daily Conformance





8.3. Test Plan for Fine Aggregate

BCM/TP 03

Name of Work : Sanction No. and date: Agreement No.: Estimated Cost : Sl. No.

Test/Parameter Acceptance Standard

Frequency of Test

Sample size Acceptance Criteria

1. Gradation IS2386 (Pt.1) IRC 21:2000, Clause 302

Daily One/ lot Conformance

2. Deleterious material IS2386 (Pt.2) IRC 21:2000, Clause 302


3. Water absorption IS2386 (Pt.3) IRC 21:2000, Clause 302






8.4. Test Plan for Water for Construction

BCM/TP 04

8.4.1. Test Plan for Water for Construction from Drains / River

Sl.No Test/Parameter Acceptance Standard Sample size Acceptance Criteria 1. pH Value MOSRTH clause 1010

IRC 21:2000, Clause 302.4

One per Source

Conformance

2. Permissible solids (Organic, Inorganic Sulphates, Chlorides)

MOSRTH clause 1010

One per Source

Conformance

Name of Work : Sanction No. and date: Agreement No..: Sl.No Test/Parameter Acceptance Standard Sample size Acceptance Criteria 1. pH Value MOSRTH clause 1010

IRC 21:2000, Clause 302.4 One Conformance

2. Permissible solids (Organic, Inorganic Sulphates, Chlorides)

MOSRTH clause 1010 One Conformance





8.5. Test Plan for Sheathing

BCM/TP 05 Name of Work : Sanction No. and date: Agreement No..: Estimated Cost:

Sl. No.

Test/Parameter Acceptance Standard Sample size and Frequency of Test Acceptance Criteria

1. Workability IRC-Appendix 1800/1

One per lot/not exceeding 7000metre

Conformance

2. Transverse load rating test. IRC-Appendix Table-1

One per lot/not exceeding 7000 m

Conformance

3. Tensile load test. IRC-Appendix Table-2


Conformance

4. Water loss test IRC-Appendix Table-2


Conformance





8.6. Test Plan for Epoxy Paint

BCM/TP 06

Name of Work : Sanction No. and date: Agreement No.: Estimated Cost :

Sl. No.

Test/Parameter Acceptance Standard Sample size and Frequency of Test

Acceptance Criteria

1. Salt Spray As per IS One sample per lot

Conformance to spec

2. Scratch hardness As per IS One sample per lot

Conformance to spec

3. Adhesion As per IS One sample per lot

Conformance to spec

4. Ultra violet Resistance test. As per IS One sample per lot

Conformance to spec

5. Water absorption As per IS One sample per lot

Conformance to spec

6. Pot life As per IS One sample per lot

Conformance to spec

7. Chemical resistance. As per IS One sample per lot

Conformance to spec





8.7. Test Plan for Elastomeric Bearings

BCM/TP 07

Name of Work : Sanction No. and date: Agreement No.: Estimated Cost : Sl. No.

Test/Parameter Acceptance Standard Sample size Acceptance Criteria

1. Properties of Elastomer 2000.1, IRC 83 (Part 2): 1987, Appendix 918.4.2

One sample for a lot of 20 bearings

Conformance

2. Manufacturing Defects 2005.3.3.1 Each Conformance

3. Axial load test. 2005.3.3.1 Each Conformance

4. Other Characteristics IRC 83 (Part 2): 1987, Appendix 918.4.2 918 – acceptance levels I and II

Each Conformance





8.8. Test Plan for Pot Bearings


Sl. No.

Test/Parameter 8.8.1. Acceptance Standard Sampling Size Acceptance Criteria

1. Over all dimensions Project Specific Each Conformance of the lot

2. Load test Cl.2006.5.4 MOSRTH Each Conformance of the lot

3. Determination of coefficient of friction

Cl.2006.5.4 MOSRTH One pair of randomly selected Sample

Conformance of the lot

4. Permissible rotation Cl.2006.5.4 MOSRTH One pair of randomly selected Sample


5. Acceptance Tests Cl.2008 MOSRTH One pair of randomly selected Sample






8.9. Test Plan for Chemicals for Anti Corrosive - Treatment (CECRI)

BCM/TP 09

Note: Samples will be tested on a quarterly basis in a year.

Name of Work : Sanction No. and date: Agreement No..: Estimated Cost: Sl. No.

Test/Parameter Acceptance Standard Sampling Size Acceptance Criteria

1. De-rusting solution (Chemical composition)

Indian patent No. 465 One per lot Conformance

2. Phosphate jelly (Chemical composition)

Indian patent No. 109879 One per lot Conformance

3. Inhibitor solution (Chemical composition)

Indian patent No. 109784/67 One per lot Conformance

4. Sealing solution (Chemical composition)

Indian patent No. 112440/67 One per lot Conformance





8.10. Test Plan for Fusion Bonded Epoxy Coating (FBEC)


Sl. No.

Test/Parameter Acceptance Standard Sample size Acceptance Criteria

1. Chemical composition

IS One per lot Conformance

2. Thickness 174 + 50 microns Minimum two bars of each size from each production shift.

Conformance

3. Continuity Visual Random for coating

Conformance

4. Adhesion Bend test At least one bar of each size from each production shift.

Conformance

Note: Samples will be tested every quarter in a year.





8.11. Test Plan for Reinforcement Steel (HYSD)

BCM/TP 11

Note: Samples will be drawn whenever there is change of source of supply.

Name of Work : Sanction No. and date: Agreement No..: Estimated Cost: Sl. No.

Test/Parameter Acceptance Standard Sample Size Acceptance Criteria

1. Tensile strength IS 1786 (415 MPa) One per lot Conformance

2. Elastic modulus IS 1786 (200 GPa) One per lot Conformance

3. Elongation stress IS 1786 One per lot Conformance

4. Proof stress IS 1786 One per lot Conformance

5. Bend Test IS 1786 One per lot Conformance





8.12. Test Plan for Steel for Pre-Stressing

BCM/TP 12

Name of Work : Sanction No. and date: Agreement No..: Estimated Cost:

Sl. No.


1. Characteristic strength

IS 14268: 1995 One per lot Conformance

2. Elastic modulus IS 14268: 1995

One per lot Conformance

3. Elongation IS 14268: 1995


4. Proof stress IS 14268: 1995






8.13. Test Plan for Steel for MS Liner

BCM/TP 13

Name of Work : Sanction No. and date: Agreement No.: Estimated Cost:

Sl. No.


1. Diameter

As per item of work One liner/ hundred RMT Conformance to the specification

2. Thickness As per item of work

One liner/ hundred RMT Conformance to the specification

3. Tensile strength IS220 One per lot Conformance to the Grade specified





8.14. Test Plan for Elastomeric Expansion Joint (Strip Seal)

BCM/TP 14

Name of Work : Sanction No. and date: Agreement No.: Estimated Cost:

Sl. No.


1. Edge beams a) Weldability. b) Notch toughness.

Rst37-2 , IS 2062 One per lot Conformance

2. Strip seal a) Tear strength b) Other properties of

Chloroprene of strip seal.

Clause 915.1 of IRC.83 (Part-II) Table No. 2600-1. of MOSRTH specification

One per lot

Conformance

3. Anchorages / loop Weldability IS 2062 One per lot

Conformance

Note: Samples will be drawn for conformity testing if there is any change in source of supply.





8.15. Checklist for Pile Foundations

BCM/CL 01 Name of work: Estimated cost : Agreement No.: Sanction No. and date: Sl. No.

Particular Remarks (Y/N/NA Observation if any)

Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location /Chainage/ Description of

work.

2. Execution Check is complete. If yes, Date and Reference.

3. MS Liner driven as per conditions of strata met and the level recorded

4. The joints of casing are made as tight as possible to minimise inflow of water or leakage of slurry during concreting.

5. Rock Strata identified and level recorded. refer F.B.No. ---- Page No. ---

6. Adequate socketting in founding strata obtained and levels recorded. If Yes, refer F.B.No.--- Page No. --- Refer PILE F-1

7. Founding strata approved. Refer FILE F-2

8. The shaft is clean of all loose materials prior to the lowering of the re-enforcement cage.





Name of work: Estimated cost : Agreement No.: Sanction No. and date: Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 9. The cover to reinforcing steel is

maintained by suitable spacers.

10. Concreting under water for cast-in-situ piles is done by tremie method.

11. The finishing of bore, cleaning of bore, lowering of reinforcement cage and concreting of pile for full height is accomplished without any stoppage in one continuous operation (MOSRTH Clause 1107).

12. The first charge of concrete is placed with sliding plug pushed down the tube ahead of it to prevent mixing of water and concrete.

13. The tremie pipe always penetrates well into the concrete with adequate margin of safety against accidental withdrawal

14. The Quality Checks exercised during concreting.;

15. Additional observation, if any.

16. Conclusion by inspecting officers Execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by --- If not satisfactory, the contractors to





Name of work: Estimated cost : Agreement No.: Sanction No. and date: Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 report the corrective action taken and inform for re-inspection.

17. Contractor's/ Authorized Representative Name, Designation and Signature.

18. Inspecting Officer Name Designation and Signature.





8.16. Checklist for Pile Foundations

BCM/CL 02

Name of work: Estimated cost : Agreement No. Sanction no. and date:

8.16.1. PILE F-1

8.16.1.1 Chiseling Record Date Pile

No. Top ref. line of Hard Strata

Weight of Chisel

Duration of Chiseling

Height of Fall Penetration achieved

Signature of Contractor

Signature of SO

8.16.2. PILE F-2

8.16.2.1 Foundation Approval Date Pile

No. Top Ref. Line of Hard Strata

Founding Ref. Line

Socketing achieved

SBC of founding strata

Signature of Contractor

Signature of S.O. Signature of EE/ EE

8.16.3. PILE F-3

8.16.3.1 Measurement of Tilt / Shift Date Pile No. Tilt in mm. Shift in mm. Signature of Contractor Signature of S.O. Remarks





8.17. Checklist for Pile Cap

BCM/CL 03

Name of work: Estimated cost : Agreement No. Sanction No. and date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location /Chainage/ Description of Item. 2. Execution activities carried out 3. Concreting of the pile cap is carried out

in dry conditions.

4. Quality Checks exercised during concreting

5. Additional observation if any 6. Conclusion by inspecting officer-

Execution activities are sat6isfactory /Not satisfactory .If satisfactory, further bridge further bridge construction activity to commence by ---- Contractors to report the corrective action taken and inform for re-inspection.

7. Contractor's/ Authorized Representative Name Designation and Signature

8. Inspecting officer Name Designation and Signature





8.18. Checklist for Formwork

BCM/CL 04

Name of work: Estimated Cost : Agreement No.: Sanction No. and Date: Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location / Chainage / Description of

Item.

2. Execution activities carried out 3. The form work is robust and strong

and the joints are leak-proof (MOSRTH Clause 1504.1)

4. Staging has cross bracings’ and diagonal bracing's in both directions.

5. Staging has been provided with an appropriately designed base plate resting on firm strata.

6. The numbers of joint in the formwork are kept to a minimum by using large size panel (MOSRTH Clause 1504.2).

7. All joints are leak proof and are properly sealed with PVC joined sealing tape, or PVCT sections, foam rubber, etc. (MOSRTH 1504.2).

8. Clamps are used to hold the form together (MOSRTH 1504.3)

9. Minimum numbers of nails are used, left projecting and can be withdrawn







Date / /200 / /200 / /200 / /200 / /200 / /200 easily (MOSRTH 1504.3)

10. The ties are used with HDPE sheathing (MOSRTH 1504.4)

11. The chamfers, bevelled edges and mouldings are made in the formwork itself (MOSRTH 1504.5)

12. Shuttering for walls, sloping members and thin sections of considerable height is provided with temporary openings to permit inspection and cleaning out before placing of concrete (MOSRTH 1504.6).

13. The formwork is coated with the an approved release agent that will effectively prevent sticking and will not stain the concrete surface(MOSRTH 1504.14).

14. Additional observation if any.

15. Conclusion by inspecting officer- Execution activities are satisfactory/Not satisfactory .If satisfactory, further bridge construction activity to commence by ----- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.

16. Contractor's / Authorized







Date / /200 / /200 / /200 / /200 / /200 / /200 Representative Name Designation and Signature

17. Inspecting Officer Name Designation and Signature





8.19. Checklist for Construction of Well Foundation

BCM/CL 05 Name of work: Estimated cost: Agreement No.: Sanction no. and date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location / Chainage /

Description of Item.

2. Execution inspection carried out

3. Necessary reference points are fixed before well sinking operations (MOSRTH Clause 1203)

4. A temporary benchmark is established near the well foundation and also it checked regularly with respect to permanent bench mark.

5. Sand island is protected against scour and its height is sufficient so that it is safe against wave action.

6. Floating caissons, wherever used, are having at least 1.5m free board above water level.





Name of work: Estimated cost: Agreement No.: Sanction no. and date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 7. Stability of floating Caissons

is ensured against overturning and capsizing while being towed and during sinking.

8. For floating caissons, a detailed statement of fabrication, floating and sinking of caissons is prepared and furnished to the Engineer by the Contractor.

9. Formwork checked and found correct.

10. Reinforcement checked and found correct.

11. Mix design for concrete is approved.

12. Quality checks during concreting exercised.

13. During well sinking the tilt and shift are maintained within permissible limit. refer (MOSRTH appendix 1200-I and II).

14. Safely precautions are taken while placing Kent ledge on






Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 loading platform such that it does not interfere with the dredging process and also not damage well steining.

15. The casting of well steining is done progressively as sinking proceeds.

16. The well curb rests on the hard strata.

17. Sinking of the well foundation is done in the hard strata to the extent stipulated in drawing.

18. RL’s of all these strata met with during sinking have been recorded.

19. Blasting operation shall be carried out (Clause 1207.4 of MOSRTH)

20. Fore walling of Well shall be approved by SE before concreting the bottom plug

21. Holes are drilled/left through the well steining for inserting the 32 mm anchor rods duly socketing in hard rock up to a depth of 5 meters






Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 22. The anchor rods are grouted

in hard rock by using cement grout.

23. Dewatering register is maintained

24. External faces of well seining are provided with protective paint of Coal Tar Epoxy up to the high tide level.

25. Whether the soundness of bottom plug is tested and if yes the rise of water level in the well (It is to be within permissible limit of 10mm/hr.)

26. If the pneumatic sinking is to be carried out, medical supervision, lighting arrangement, man locks are provided, Safety against fire hazards, sanitation, protection against gases and other safety provisions to be ensured (MOSRTH 1207.6).

27. The tilt and shift are within permissible limit (1:80 and






Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 150mm respectively as per MOSRTH).

28. Additional observations if any.

29. Conclusion by inspecting officer- The execution activities are satisfactory/Not satisfactory. If satisfactory, further bridge construction activity to commence by ------- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.

30. Contractor's / Authorized Representative Name Designation and Signature






8.20. Checklist for Construction of Well Cap

BCM/CL 06 Name Of Work: Estimated Cost : Agreement No.: Sanction No. And Date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location /Chainage/ Description

of Item.

2. Execution inspection carried out 3. Form work, reinforcement of well

cap and reinforcement of Sub-structure (Abutment / PIER) anchored into the well cap and the concrete conform to relevant sections of MOSRTH Specification

4. The materials are tested in accordance with MOSRTH specification and are met the prescribed criteria.

5. Additional observations if any 6. Conclusion by inspecting officer-

Execution activities are satisfactory/Not satisfactory .If satisfactory, further bridge construction activity to commence





Name Of Work: Estimated Cost : Agreement No.: Sanction No. And Date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 by ------- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.21. Checklist for Excavation for Open Foundation

BCM/CL 07 Name Of Work: Estimated Cost : Agreement No.: Sanction No. and Date:

Sl. No.


Date / /200 / /200 / /200 / / 200 / /200 / /200 1. Location / Chainage / Description of Item.

2. Pre-execution checks have been completed Date and reference.

3. The plan dimensions of the foundation is set out at the bottom of original reference.(As per QA Plan)

4. A layer of M-15 concrete is provided below foundation concrete where the bearing surface is earth.(MOSRTH 2104.3) (As per QA Plan)

5. Form work and concrete conform to section 1500 and 1700 respectively of MOSRTH's Specification 2104.3 Test Plan No------------ If yes ,Date and reference





Name Of Work: Estimated Cost : Agreement No.: Sanction No. and Date:

Sl. No.


Date / /200 / /200 / /200 / / 200 / /200 / /200 6. The location of construction joints and its

treatment is done as per requirements of section 1700. (As per QA Plan).

7. Form work is removed not earlier than 24 hours after placing of concrete.(As per QA. Plan) MOSRTH 2104.3.

8. Curing of concrete is done by keeping it continuously moist for a period of 7 days. (As per approved QA Plan).

9. Dewatering, where necessary for laying of concrete is carried out as per procedure laid down in clause 2104.3 of MOSRTH.

10. The annular space is filled with M15 concrete up to top rock in case of excavation in rock. (As per approved QA Plan)

11. The Coal- tar epoxy is painted on the surface of substructure below ground. Test Plan No………. If Yes, Date and reference.

12. Spaces refilled with earth up to surface of surrounding ground in accordance with section 300. Test plan No......





Name Of Work: Estimated Cost : Agreement No.: Sanction No. and Date:

Sl. No.


Date / /200 / /200 / /200 / / 200 / /200 / /200 If Yes ,Date and reference

13. Additional observation if any 14. Conclusion by inspecting officer-

The execution activities are satisfactory/Not satisfactory .If satisfactory, further bridge construction activity to commence by ------- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.22. Checklist for Steel Reinforcement

BCM/CL 08 Name of Work : Sanction No. and date: Agreement No..: Estimated Cost: Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location/ Chainage / Description of

work

2. Execution inspection is carried out. 3. Reinforcement is placed accurately in

position as shown on the drawings.

4. The bars, crossing one another are tied together at every intersection with binding wire, conforming to IS :280

5. Cover blocks, placed between the bars and formwork are made of concrete having the same strength and specification as those of the member

6. Chairs/links/spacer bars to separate layers of reinforcement approximately at one meter intervals

7. Bars coated with Epoxy or any other approved protective coating is placed, on supports that do not damage the coating.





Name of Work : Sanction No. and date: Agreement No..: Estimated Cost: Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 8. Overlapping of bars, if required is

done as specified in drawings.

9. Overlapping bars are bound with annealed steel binding wire, not less than 1mm diameter and tightly twisted in such a manner as to maintain minimum clear cover to the reinforcement from the concrete surface.

10. Bar is bent cold to the specified shape and dimension using a proper bar bending device to obtain the correct radii of bends and shape.

11. Bars have not been bent or straightened in a manner that will damage the coating.

12. The method of welding, if permitted in drawing is conforming to IS2751 and IS9417.






Name of Work : Sanction No. and date: Agreement No..: Estimated Cost: Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 14. Conclusion by inspecting officer- The

execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by -- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.23. Checklist for Structural Concrete

BCM/CL 09 Name Of Work:: Estimated Cost : Agreement No.: Sanction No. and Date:

Sl.No.



work

2. Execution checks have been completed Date and reference

3. The mixer or the ready mix plant at proper location after considering the properties of mixes and the transportation arrangements available with the contractor, is approved by the Engineer (As per approved QA Plan)

4. The method of transporting and placing concrete is approved by Engineer so that no contamination, segregation or loss of its constituent materials takes place. (As per approved QA Plan).

5. Concrete is not freely being dropped in to place from height exceeding 1.5 metre (As per approved QA Plan).

6. No concrete is placed in any part of





Name Of Work:: Estimated Cost : Agreement No.: Sanction No. and Date:

Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 structures until the approval of Engineer has been obtained. (As per approved QA Plan).

7. For 40mm and larger size aggregates, the cement content is reduced suitably to a maximum up to 10% (As per approved QA Plan)

8. For further water concreting, the cement content is increased by 10% (As per approved QA Plan)

9. The cement content is within the maximum limit of 540 kg per cubic metre of concrete. (As per approved QA Plan)

10. The design mix of concrete is carried out as per IS10262. (As per approved QA Plan)

11. The mix design is approved by Engineer well in advance before actual start of concrete. (As per approved QA Plan)

12. The requirement of consistency of mix is considered in mix design as indicated in Table 1700-4 of MOSRTH. (As per approved QA Plan)






Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 13. The contractor has prepared trial

mixes as per mix design, using samples of approved material which are being used in the works, for all grades to the Engineers’ satisfaction prior to commencement of concreting.(As per approved QA Plan)

14. The test cubes are tested on 3rd, 7th and 28th day.

15. The proportioning for nominal mix concrete, if required is adopted as specified in table 1700-6. (As per approved QA Plan).

16. The overall limits of deleterious substances (chloride and sulphate contents) are as specified in section 1700-4 of MOSRTH. (As per approved QA Plan)

17. The use of admixture such as super plasticizers for concrete are made with the approval of the Engineer. (As per approved QA Plan)

18. The size of coarse aggregates for concrete to be used in various components is adopted as specified in section 1706 of MOSRTH. (As per approved QA Plan)






Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 19. The vibrators proposed for

compaction of concrete are adopted as specified in clause 1707-C of MOSRTH. (As per approved QA Plan).


21. Conclusion by inspecting officer- The execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by -- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.

22. Contractor's/Authorized Representative Name Designation and Signature






8.24. Preparation of Mix Design of Cement Concrete

BCM/CL 10 Name of work: Estimated Cost : Agreement No.: Sanction No. and date:

Sl. No.



Item

2. Type of mix grade.....

3. Type of cement...... Grade of cement.....

4. Maximum nominal size of aggregate

5. Minimum cement content....

6. Maximum water/ cement ratio....

7. Workability in terms of slump.......

8. Type of aggregate ....

9. Maximum cement content ......

10. Whether admixture are to be used ?

11. Type of admixture.... Condition of usage....





Name of work: Estimated Cost : Agreement No.: Sanction No. and date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 12. Gradation of coarse aggregate

13. Gradation of fine aggregate

14. Following Tests for cement are carried out Strength, initial setting time, final setting time.

15. The Coal-tar epoxy is painted on the surface of concrete below ground. Test Plan No................ If Yes, Date and reference.

16. Spaces refilled with earth upto surface of surrounding ground in accordance with Section 300. Test Plan No................ If Yes, Date and reference.





8.25. Checklist for Bearing

BCM/CL 11

Name of Work: Estimated Cost : Agreement No.: Sanction No. and Date:

Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location/Chainage/ Description of

Item.

2. Execution inspection carried out . 3. Installation of bearing are set

thoroughly level and exact position as indicated or drawing.

4. Bearing are handled with care during installation.

5. Placing of bearing is carried out in the presence of Engineer.


7. Conclusion by inspecting officer- The execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by – If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection

8. Contractor's/Authorized






Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 Representative Name Designation and Signature






8.26. Checklist for Strip Seal Expansion Joints

BCM/CL 12 Name of Work: Estimated Cost : Agreement No.: Sanction No. and Date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location/ Chainage/ Description of

Item.

2. Execution inspection carried out If, Yes, refer BCM-CL.

3. Execution inspection carried out If, Yes, refer BCM-CL

4. Bolt cavities are cleaned and plugged with neoprene cavity plugs. Prior to placing the plugs sufficient sealant is applied in the cavities.

5. The top surface of expansion joint truly merges with the wearing surface on the deck of the bridge.

6. Additional observation if any 7. Conclusion by inspecting officer- The

execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by -- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection






Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 8. Contractor's/Authorized Representative

Name Designation and Signature






8.27. Checklist for Providing and Fixing of Bridge Railing

BCM/CL 13 Name of Work : Estimated Cost: Agreement No.: Sanction No. and date:

Sl. No.



Item

2. Execution inspection carried out If Yes, refer BCM-CL

3. Special care is taken to watch the surface of the cast-in-situ portion of the deck.

4. Railing is not followed any irregularity in the alignment of the deck.

5. Additional observation if any 6. Conclusion by inspection officer. The

execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by - - - If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.

7. Contractor's/ Authorized Representative





Name of Work : Estimated Cost: Agreement No.: Sanction No. and date:

Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 Name Designation and Signature






8.28. Construction of Reinforced Concrete for Piers and Abutments

BCM/CL 14 Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl. No.



Item

2. Execution checks are complete. If yes, Date and reference

3. The surface of foundation is scrapped with wire brush and all loose materials are removed. (As per approved QA Plan)

4. In case of solid abutments weep holes are provided in conformity with section 2706. (As per approved QA Plan )

5. The exposed surface finish is got smooth and the earth face of abutment is got rough finished. (As per approved QA Plan )

6. Tests are carried out in accordance with is specifications. (As per approved QA Plan )






Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200

8. Conclusion by inspection officer. Execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by - - - If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.29. Construction of Pier Cap and Abutment Cap


Sl.No.



Item

2. Execution checks are complete If yes, Date and reference

3. For work, reinforcement and concrete are conformed relevant sections of MOSRTH specification (As per approved QA Plan)

4. The surface of cap is finished smooth and having a slope for drawing of water as shown on the drawings. (As per approved QA Plan)

5. The top surface of the pedestal on which bearings are to be placed is also be cast horizontal. (As per approved QA Plan)

6. The surface on which elastomeric bearing are to place is wood float finished. (As per approved QA Plan)

7. The surface on which steel






Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 bearings or pot bearings are to be placed is cast about 25 mm below the bottom level of bearings or as indicated on the drawings (As per approved QA Plan)

8. The materials are tested in accordance with MOSRTH specification and are met the prescribed criteria. (As per approved QA Plan)

9. Additional observation if any. 10. Conclusion by inspection officer.

Execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by - - - If not satisfactory, the contractors to report the corrective action taken and inform for during-execution re-inspection.


12. Inspecting Officer Name






Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 Designation and Signature





8.30. Providing Reinforced Earth Retaining Wall




Item

2. Execution checks are complete If yes, Date and reference.

3. The Reinforcing element is placed as per specification. (As per approved QA Plan).

4. Laying and Compacting: The reinforcing element is laid as per specification. (As per approved QA. Plan)

5. Uniform compaction of the fill is achieved by placing the fill in depth as specified. (As per approved QA Plan)

6. During filling no construction plant runs directly on the reinforcement. (As per approved QA Plan)

7. Compaction of earth fill carried out as per instruction. Of the Engineer. (As per approved QA Plan)







Date / /200 / /200 / /200 / /200 / /200 / /200 8. During construction of reinforced fill,

the retained material beyond the reinforcement at rear or the structure is at the same level as reinforcement fill. (As per approved QA Plan)

9. Sealing material for filling joints is closed cell polyethylene foam or closed cell polyurethane foam strip. (As per approved QA Plan)


11. Conclusion by inspection officer. Execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by - - - If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.31. Checklist for Application of Epoxy Paint to Exposed Faces of Superstructure

BCM/CL 17 Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location/Chainage/ Description of Item 2. Execution checks are completed.

If yes, Date and reference

3. The epoxy paint is applied in three coats i) Epoxy polyamide primer coating over concrete surface. Thickness 55 micron. ii) Micaceous iron oxide. Thickness 110 micron. iii) Polymide finish paint. Thickness 110 micron. ( As per approved QA Plan )

4. Additional observation if any 5. Conclusion by inspection officer.

Execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by - - -If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.32. Checklist for Application of Epoxy Pain to Exposed Faces of Superstructure


Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location/Chainage/ Description of Item 2. Execution checks are completed.

If yes, Date and reference.

3. The epoxy paint is applied in three coats i). Zinc based primer coating over

concrete surface. Thickness 50 micron.

ii). Coal tar epoxy first coat. Thickness 80 micron.

iii). Coal tar epoxy paint. Thickness 80 micron.

(As per approved QA Plan )

4. Additional observation if any 5. Conclusion by inspection officer. The

execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by - - - If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.





8.33. Checklist for Application of Water Proof Cement Paint to Structure

BCM/CL 19 Name of Work:- Estimated Cost: Agreement No.: Sanction No. and date:

Sl.No.



Item.

2. Execution checks are completed, If yes, Date and reference...

3. The water proof cement paint is applied (As per approved QA Plan).

4. The surface painted is kept moist for Seven days for caring.

5. Additional observation if any. 6. Conclusion by inspecting officer- The

execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by ---- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.

7. Contractor's/Authorised Representative Name Designation and Signature






8.34. Checklist for Tack Coat

BCM/CL 20



Date / /200 / /200 / /200 / /200 / /200 / /200 1. Location/Chainage/ Description

of Item.

2. Execution checks have been completed Date and Reference ....

3. The spraying temperature of bituminous emulsion is in the range of 20oC to 60oC.

4. Binder is applied with self propelled or towed bitumen pressure sprayer with self heating arrangements.

5. The rate of application of binder is maintained as per Table 500-2 of MOSRTH or as specified in the item of tender.

6. The application of binder quantity is as specified in tender (To be ascertained by using paper and weighing it).

7. Supervision by the contractor adequate/ Not adequate.







Date / /200 / /200 / /200 / /200 / /200 / /200 8. safety measures taken

Adequate/ Inadequate


10. Conclusion by inspecting officer- The execution activities are satisfactory/ unsatisfactory. If satisfactory, further bridge construction activity to commence by ---- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.35. Checklist for Mastic Asphalt

BCM/CL 21 Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl.No.



Item.

2. Execution checks are completed Date and Reference.....

3. Tack coat is applied as per clause 503 of MOSRTH.

4. The procedure for preparation of mix is adopted as per clause 525.4 of MOSRTH.

5. Adequate traffic safety arrangements are provided.

6. The temperature of mix is around 170o C while spreading.

7. The spreading is carried out as per the clause 525.4.5 of MOSRTH.

8. The construction joints are provided as per clause No.525.46 of MOSRTH.

9. The final surface finish is in accordance with clause 525.4.7 of MOSRTH.

10. The supervision by contractor is





Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl.No.


Date / /200 / /200 / /200 / /200 / /200 / /200 adequate/Not adequate

11. All tests on material are carried out as per test plan No...................... If yes, Date and reference.


The execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by ---- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection.







8.36. Checklist for Dense Bituminous Macadam

BCM/CL 22 Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl.No



Item.

2. Execution checks have been completed. Date and Reference ....

3. Tack coat is properly sprayed as required to the surface where DBM. is to be laid. If yes date and reference of Checklists for tack coat.

4. Equipments as verified in Execution check are available in good working condition .

5. The mix is prepared in drum mix plant or any other specified plant

6. The temperature of binder and aggregate is maintained in the range between 150oC to 163oC and 155oC to 163oC respectively at the time of mixing.

7. The discharge temperature of mix





Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl.No


Date / /200 / /200 / /200 / /200 / /200 / /200 is in between 130oC to 160oC

8. The tipper/ dumper is properly covered with tarpaulin to avoid fall in temperature during transport

9. The temperature of mix at the time of laying is in between 120o C to 160o C

10. The mix is tested for Bitumen content Gradation

11. Proper offsets have been provided in longitudinal joints of each layer.

12. The initial or intermediate rolling is followed by vibratory roller of 80 to 100 KN capacity.

13. The final rolling is done by 60 to 80 KN tandem roller or by switching off vibratory system

14. The rolling is continued till the entire surface has been rolled to 98% of average laboratory density.

15. The surface finish of the construction conforms to requirements of clause 902 of MOSRTH-1995. (refer QA Plan)

16. The rolling is done as per clause 507.4.6 of MOSRTH-1995 edition





Name of Work : Estimated Cost: Agreement No.: Sanction No. and date: Sl.No


Date / /200 / /200 / /200 / /200 / /200 / /200 (Refer QA Plan).

17. The final levels are taken with reference to GTS. Field Book No....... Page No..........

18. Adequate traffic safety arrangements are provided (refer QA Plan).

19. The supervision of sub-contractors is adequate (refer QA Plan).

20. Additional observations if any. 21. Conclusion by inspecting officer-








8.37. Checklist for Asphaltic Concrete

BCM/CL 23

Name of Work : Estimated Cost: Agreement No..: Sanction No. and date: Sl.No.



Item.

2. Execution checks have been completed. Date and Reference ....

3. Tack coat is properly sprayed as required to the surface where DBM is to be laid. If yes, date and reference of checklist for tack coat.

4. Equipments as verified in Execution check are available in good working condition.

5. The mix is prepared in drum mix plant or any other specified plant.

6. The temperature of binder and aggregate is maintained in the range between 150oC to 163oC and 155oC to 163oC respectively at the time of mixing.

7. The discharge temperature of mix is in between 130oC to 160oC

8. The tipper/ dumper is properly







Date / /200 / /200 / /200 / /200 / /200 / /200 covered with tarpaulin to avoid fall in temperature during transport.

9. The temperature of mix at the time of laying is in between 120oC to 160o C.

10. The mix is tested for • Bitumen content • Gradation

11. Proper offsets have been provided in longitudinal joints of each layer.

12. The initial or intermediate rolling is followed by vibratory roller of 80 to 100 KN capacity.

13. The final rolling is done by 60 to 80 KN tandem roller or by switching off vibratory system.

14. The rolling is continued till the entire surface has been rolled to 98% of average laboratory density.

15. The surface finish of the construction conforms to requirements of clause 902 of MOSRTH-1995.(refer QA Plan).

16. The rolling is done as per clause 507.4.6 of MOSRTH-1995 edition (Refer QA Plan).







Date / /200 / /200 / /200 / /200 / /200 / /200 17. The final levels are taken with

reference to GTS. Field Book No....... Page No..........

18. Adequate traffic safety arrangements are provided (refer QA Plan).

19. The supervision of sub-contractors is adequate (refer QA Plan).


The execution activities are satisfactory / Not satisfactory. If satisfactory, further bridge construction activity to commence by ---- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection







8.38. Providing and Fixing Water Spouts




Item.

2. Execution inspection activity carried out.

3. The pipe is given protective coats before placement.

4. The whole assembly is placed in true position lines and levels as shown in the drawings with necessary cut-out in the shuttering for deck slab and held in place firmly.


6. Conclusion by inspecting officer- The execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by ---- If not satisfactory, the contractors to report the corrective action







Date / /200 / /200 / /200 / /200 / /200 / /200 taken and inform for re-inspection.







8.39. Checklist for Application of Aqua Epoxy Paint to Structure


Sl. No.



Item.

2. Execution checks are completed. If, yes, Date and reference.

3. The epoxy paint is applied in two coats. Aqua Epoxy coating over concrete surface. Thickness 150 micron. Aqua Epoxy second coat. Thickness 250 micron (As per approved QA plan).








Sl. No.


Date / /200 / /200 / /200 / /200 / /200 / /200 6. Contractor's/Authorized

Representative Name Designation and Signature






8.40. Checklist for Application of Aqua Epoxy Paint to Structure




Item.

2. Approved drawing of the structure is available.

3. Design calculations and the drawings of the formwork and centering are available.

4. The centering and formwork design is approved by competent authority.

5. The erection of formwork and centering is done conforming to approved drawings.

6. The design of the formwork facilitates proper and access to all parts of formwork for inspection.

7. In case of pre-stressed concrete super structure, careful consideration is given to loads on props due to pre-stressing (if applicable only).

8. Care has been taken to ensure that the form work does not retrain the shortening of beam during pre-







Date / /200 / /200 / /200 / /200 / /200 / /200 stressing

9. Proper lubrication is provided to shuttering panels.

10. Formwork is adequately supported so that plate will not bulge due to pressure of green concrete

11. All supports are strong and all nut bolds are properly tightened

12. The formwork conforms to the approved drawing.


The execution activities are satisfactory/ Not satisfactory. If satisfactory, further bridge construction activity to commence by ---- If not satisfactory, the contractors to report the corrective action taken and inform for re-inspection





Procedure No.: QMS/WI/BC-09/Tests and Test Performa Issue 01, Rev 00


9. TESTS AND TEST PROFORMA 9.1. Tests to be conducted by Construction Division

9.1.1. Field Tests

Sl. No.

Item Tests to be conducted

1. Embankment Density, Atterberg limits, Moisture Content (Suitability before and Execution).

2. GSB Gradation / Atterberg Limits / Moisture Content / Density.

3. WBM Impact Value, Gradation, Flakiness and Elongation. 4. Bituminous Works Temperature (Binder / Mix), Rate of Spread of

Bitumen. Gradation, Impact, Flakiness and Elongation for Aggregates. Binder Content.

5. Sand Gradation Silt / Clay / Deleterious Materials.

6. Bricks Size and Shape 7. Coarse Aggregate Gradation, Water Absorption, Impact, Flakiness

and Elongation. 8. Concrete Slump 9. Any other possible test at field

Frequency for field test: 100%. Other tests are conducted by QC staff at laboratory. Tests to be conducted by Quality Control Division

9.1.2. Laboratory Tests

Sl. No.

Item Test to be conducted

1. Embankment Density, Atterberg limits, Moisture Content (Suitability before and Execution).

2. GSB Gradation / Atterberg Limits / Moisture Content / Density, CBR*.

3. WBM Impact Value, Gradation, Flakiness & Elongation, Abrasion Test*.

4. Bituminous Works Temperature (Binder / Mix) Rate of Spread of Bitumen. Gradation, Impact, Flakiness and Elongation for Aggregates. Binder Content, Stripping value, Marshall Stability Analysis (Mixture Design) Penetration value, Softening Point, Viscosity, Density, Ductility*.

5. Sand Gradation Silt / Clay / Deleterious Materials.

6. Bricks Size and Shape, Compressive strength, water Absorption*.

7. Coarse Aggregate Gradation, Water Absorption, Impact, Flakiness and Elongation, Abrasion Test*.

8. Concrete Slump, Compressive strength, Mix Design of Concrete*.





Sl. No.

Item Test to be conducted

9. Soil SBC Test, Grain size analysis, Classification of Soils, Density, Moisture Content, Atterberg limits, Direct Shear Test, Triaxial shear test CBR*.

10. Cement Normal Consistency, Initial and Final setting time, Fineness, Strength of Cement (3 days, 7 days, 28 days)*.

11. Tiles Water Absorption, Size and shape, Transverse Flexural Strength*.

Notes: * Test to be conducted at QC Lab only (100 %). • Other tests are conducted by both construction staff and QC staff

(10 % Frequency for QC). Frequency to be decided..





9.2. Test report on aggregate characteristics of Grade 2 metal for WBM Work

Name of work : Reference : Executive Engineer PWD Division Letter No. Dated : Date of Testing :

Requirement as per MOSRTH Specification Section 400 clause 404 and test conducted as per IS 2386:1963

Impact value 30% max Percentage passing by weight through I.S. Sieve Designation (Table 400-7)

Test No.

Details of

Sample Los Angles Abrasion

Value 40% max

Water absorption value 2%

(max

Flakiness Index Max

20% 90mm 100%

63mm 90-100 %

53mm 25-75%

45mm 0-15%

22.40 mm 0-5%

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

1. The test results relate to the sample tested & shall not be reproduced in part. 2. Materials need to be tested as per frequency of MOSRTH Section 900. 3. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC. Division)





9.3. Test Report on Cement Concrete Cubes


Tested as per IS : 516-1959

Compressive strength of CC

cubes in kg/cm2 Test No.

Details of

Casting

Date of Testing

Age of Cube in

days

Location of Concreting

Grade / Proportion

of mix

Wt. of Specimen

in gm 1 2 3 4

Requirement as per IS 456: 2000

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Compressive strength of CC cubes is computed for 28 days curing vide MOSRTH table 900-5 Section 900

1. The test results relate to the sample tested and shall not be reproduced in part. 2. Materials need to be tested as per frequency of MOSRTH Section 900 and IS Specification. 3. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC. Division)





9.4. Test Report of Sand Sample


Indian standard specification for coarse aggregate IS : 383-1970 Table -1 & 4 and test carried out as per IS 2386:1963 Deleterious material % by Wt % by weight passing the IS Sieve

Sample No.

Description of sand sample tested

Passing 75

Micron IS Sieve

Clay lumps

Coal & Lignite Others Total 10

mm 4.75 mm

2.36 mm 1.18 mm 600 mm 300

micron 150

micron

Grading zone of sand

sample

Remarks

Grading limit for fine aggregate as per IS 383-1970 Table 1 & 4 for concrete work

Max 3.00%

Max 1.00%

Max 1.00%

Max 1.00%

Max 5.00%

100% 100% 100%

90-100%90-100%90-100%

60-95%75-100%85-100%

30-70% 55-90% 75-100%

15-34% 35-59% 60-79%

5-20% 8-30%

12-40%

0-10% 0-10% 0-10%

Gr - I Gr - II Gr - III

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

1. The test results relate to the sample tested & shall not be reproduced in part. 2. Materials need to be tested as per frequency of MOSRTH Section 900 and IS Specification. 3. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC. Division)





9.5. Test Report of Brick Sample


Average Value of bricks Requirement as per IS 1077:1992

Sl. No.

Date of Testing

Class designation and

Identification mark on the top

of the brick

Water absorption Value in

%

Crushing strength of brick in kg/cm2

Water absorption

in %

Crushing strength of brick in kg/cm2

Water absorption Value in % 20.00% (Max)

Minimum Crushing strength brick 35/50/75 kg/cm2 (based on class of Bricks)

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

1. The test results relate to the sample tested & shall not be reproduced in part. 2. Materials need to be tested as per frequency of IS Specification. 3. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC. –Division)





9.6. Test Report of Coarse Aggregate (40mm and less / 20mm and less)

Name of work : Reference : Executive Engineer Letter No. Dated : Date of Testing :

Indian standard specification for coarse aggregate IS 383:1970 Table -1 & 2 and test carried out as per IS 2386:1963 Size of coarse

aggregate Percentage by weight passing the IS Sieve

80mm 40mm 20mm 10mm 4.75mm 40mm and down 100% 95-100% 30-70% 10-35% 0-5%

Test No.

Details of Sample

Collected 20mm and down

Aggregate Impact

Value Max 30% - 100% 95-100% 25-55% 0-10%

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9.

1. The test results relate to the sample tested & shall not be reproduced in part. 2. Materials need to be tested as per frequency of MOSRTH Section 900 and IS Specification. 3. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC. Division)





9.7. Test Report of Cement Sample

Name of work : Reference : Executive Engineer/ PWD Division Letter No. Dated : Date of Testing :

Tested as per IS 4031:1988

Setting time in Minutes Minimum Compressive strength of cement at the age, MPa

Sl. No.

Details of sample collected Brand Grade Invoice Receipt No. & dt.

Standard consistency of cement in %

Initial setting time, min

Final setting time, max 3 days 7 day 28 days

Remarks

IS Specification as per IS 8112:1976 (Reaffirmed 1989) for OPC 43 grade

30 minutes 600 minutes 23 33 43

IS Specification as per IS 12269-1987 (Reaffirmed 1999) for OPC 53 grade


IS Specification as per IS 1489(Pt 1) – 1991 (Reaffirmed 1999) for PPC (Fly Ash based)


IS Specification as per IS 455:1989 (Reaffirmed 1995) for PSC (Slag)


1. 2. 3. 4. 5. 6. 7. 8. 9.

1. The test results relate to the sample tested & shall not be reproduced in part. 2. Materials need to be tested as per frequency of MOSRTH Section 900 and IS Specification. 3. Test samples collected by the QC Divisionl/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC. Division)





9.8. Test Report on Aggregate Characteristics of Single Coat Surface Dressing


Requirement as per MOSRTH Specification Section 400 clause 404 and test conducted as per IS 2386;1963

Nominal size

Grading Requirements for chips for surface dressing Percentage by wt

19 mm

13.2 mm

9.5 mm

6.3 mm

2.36 mm

0.075 mm

Passing 13.2 mm

retained on 9.5 mm

No. of Tests

Details of

Sample Tested

Impact value 30% (max)

Water Absorption 1%

(Max) 13 MM

100 85-100 0-40 0-7 0-2 0-1.5 65% min

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.






9.9. Test Report on Aggregate Characteristics of 20mm Thick Open Graded Premix Carpet / Seal Coat


Requirement as per MOSRTH Section 500 clause 511 & 513 and test conducted as per IS 2386:1963 Grading for 20mm Open Graded Premix Carpet

(Table 500-23)

Grading for Seal Coat Aggregate

% passing by weight through I.S. Sieve designation

% passing by weight through I.S. Sieve

designation

13.20 mm metal

11.20mm metal

Type A (clause 513.2.2)

Type B (clause 513.2.3)

22.40 mm

11.20 mm

13.20 mm

5.60 mm

11.2 mm

2.36 mm

2.36 mm

180 mic

Test No.

Details of

Sample Tested


Water Absorption value 1%

(max)

100% 0% 100% 0%

Required Bitumen

Content in % for

carpet mix

100% 0% 100% 0%

Required Bitumen

Content in % for seal coat mix

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 14






9.10. Test Report on Aggregate of Built-up Spray Grout


Requirement as per MOSRTH Specification (4th revision) Section 500 clause 506 and test conducted as per IS 2386:1963 Percentage passing by weight (Table 500-7)

IS Sieve Designation Aggregate

53 mm 26.5mm 22.4mm 13.2mm 5.6mm 2.8mm

Coarse 100 40-75 - 0-20 - 0-5

Test No.

Details of

Sample Tested

Impact value 30% Max


Max Key 100 100 100 40-75 0-20 0-5

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

1. The test results relate to the sample tested & shall not be reproduced in part. 2. Materials need to be tested as per frequency of MOSRTH Section 900. 3. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer





9.11. Test Report on Aggregates Characteristic for Semi Dense Bituminous Concrete (SDBC)


Requirement as per MOSRTH Specification (4th revision 2001) Section 500 clause 508 and test conducted as per IS 2386:1963 Percentage by weight passing IS Sieve (Table 500-15)

19mm 13.20 mm

9.5 mm

4.75 mm

2.36 mm

1.18 mm

0.300 mm

0.075 mm

Grading I 100 90-100 70-90 35-51 24-39 15-30 9-19 3-8

Sl. No.

Test No.

Details of

sample collected

Impact value 27%

(max)


(max) Grading II -- 100 90-100 35-51 24-39 15-30 9-19 3-8

Remarks

1. Apart from conformity with the grading and quality requirement for individual ingredients the mixure shall meet the requirements

set out in Table 500-16 (For Mixture Design). 2. The test results relate to the sample tested & shall not be reproduced in part. 3. Materials need to be tested as per frequency of MOSRTH Section 900. 4. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC Division)





9.12. Test Report on Aggregate Characteristics of Bituminous Macadam

Name of work : Reference: Executive Engineer PWD Division Letter No. Dated : Date of Testing :

Requirement as per MOSRTH Specification (4th revision) Section 500 clause 504 and test conducted as per IS : 2386-1963 Percentage passing by weight (Table 500-4) Impact

value

Water Absorption

value IS Sieve Designation Grading 45 mm

37.5 mm

26.5 mm

19 mm

13.2mm

4.75mm

2.36 mm

0.300 mm.

0.075 mm

Bitumen Content % by weight

of total mix

I (80-100 mm)

100%

90-100

75-100 - 35-61 13-

22 4-19 2-10 0-8 3.1 - 3.4

Test No.

Details of

sample Tested 30%

Max 2% Max

II (50-75 mm) - - 100 90-

100 56-88 16-36 4-19 2-10 0-8 3.3 - 3.5

Remarks

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.






9.13. Test Report on Coarse Aggregate for Bituminous Concrete


Requirement as per MOSRTH Specification (4th revision) Section 500 clause 509 Percentage by weight passing I.S. Sieve (Table 500-18)

Grading 26.5 mm

19 mm

13.2 mm

9.5 mm

4.75 mm

2.36 mm

1.18 mm

0.6 mm

0.3 mm

0.15 mm

0.075 mm

Remarks

I 50-65 mm 100 79-

10059-79

52-72

35-55

28-44

22-34

15-27

10-20

5-13 2-8

Sl. No.

Test No.

Details of

sample collected



(max) II

30-45 mm - 100 79-100

70-88

53-71

42-58

34-48

26-38

18-28

12-20 4-10

1. Apart from conformity with the grading and quality requirement for individual ingredients the mixture shall meet the requirements

set out in Table 500-19 (For Mixture Design). 2. The test results relate to the sample tested and shall not be reproduced in part. 3. Materials need to be tested as per frequency of MOSRTH Section 900. 4. Test samples collected by the QC Division/supplied by the Concerned EE through field staff. Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC Division)





9.14. Test Report on Aggregates Characteristic for Dense Graded Bituminous Macadam

Name of work : Reference : Letter No. Dated : Date of Testing : Requirement as per MOSRTH Specification Section-500 clause 507 Table 500-10 and test conducted as per IS 2386:1963

Percentage by weight passing I.S. Sieve Nominal aggregate

size Grading 45

mm 37-5 mm

26.5 mm

19 mm

13.2 mm

4.75 mm

2.36 mm

0.3 mm

0.075 mm

40 mm Grade I 100 95-

100 65-93 - 55-

75 38-54

28-42 7-21 2-8%

Test No.

Details of

Sample Tested

Flakiness Elongation

Index (Combined) Max 30%

Aggre-gate

Impact value

Max 27%

Water absorp

-tion Max 2%

20 mm Grade II - 100

% 90-100

71-95

56-80

38-54

28-42 7-21 2-8%

Remarks

1. Apart from conformity with the grading and quality requirement for individual ingredients the mixture shall meet the requirements

set out in Table 500-16 (For Mixture Design). 2. Materials to be tested as per frequency of MOSRTH Section 900. 3. Test samples of aggregates were collected/ supplied by the QC Division/supplied by the Concerned EE through field staff. 4. The Gradation of DBM in the proportion of the aggregate as mentioned above shall be adopted and gradation shall be got

confirmed in the filed by carrying filed gradation test Asst./ Junior Engineer Executive Engineer/In-charge PWD (QC. Division)