qsp - quality and safety plan for railway civil works

7/28/2019 QSP - quality and safety plan for railway civil works

1/41

Construction of Railway bed, Major and Minor Bridges and TrackLinking (Excluding Supply of Rails and Sleepers, Thick Web Switches)S&T and General Electrical Work ICW Doubling Between Abu Railway-Palanpur (50.1 Km) on Ajmer Division of North Western Railway inRajasthan and Gujarat State, India (In two packages) andConstruction of Railway bed, Major and Minor Bridges and TrackLinking (Excluding Supply of Rails and Sleepers, Thick Web Switches)S&T and General Electrical Work ICW Doubling Between Swarupganj-AbuRailway(26.00 Kms) on Ajmer Division of North Western Railway inRajasthan State, India.

QUALITY AND SAFETY PLAN

(QSP)

APRIL 2012VOYANTS SOLUTIONS PVT. LTD.

403, 4th Floor, BPTP Park Centra,

Sector -30, NH-8 Gurgaon - 122002

Phone - 0124-4598200

Telefax - 0124-4019051

E-mail [email protected], www.voyants.in
mailto:[email protected]:[email protected]:[email protected]


2/41

TABLE OF CONTENTS

Chapter 1. INTRODUCTION...........................................................................................................................3

1.1 GENERAL.............................................................................................................................3

1.2 QUALITY AND SAFETY PLAN..........................................................................................31.3 TERMINOLOGY...................................................................................................................3

Quality............................................................................................................................4

Quality And Safety...........................................................................................................5

Quality Control...............................................................................................................5

Quality Audit...................................................................................................................5

Verification Testing .......................................................................................................5

Acceptance.....................................................................................................................5

1.4 DOCUMENTATION AND DATA CONTROL...................................................................6

Contract Documents........................................................................................................6

Quality Control Forms....................................................................................................6Guard Files.....................................................................................................................6

Working Files.................................................................................................................6

Quality Records...............................................................................................................6

1.5 PROCESS CONTROL...........................................................................................................7

Approval Process............................................................................................................7

1.6 REQUEST FOR INSPECTION TO PROCEED AND FOR APPROVAL............................7

1.7 SOURCE APPROVAL..........................................................................................................7

1.8 COMPLETION......................................................................................................................7

1.9 CALIBRATION OF INSTRUMENTS AND EQUIPMENTS...............................................8

1.10 DIAGNOSTIC AND CORRECTIVE ACTION...................................................................81.11 QUALITY AUDIT...............................................................................................................8

Chapter 2. QUALITY CONTROL PROCESS................................................................................................9

2.1 QUALITY CYCLE................................................................................................................9

2.2 TASK RESPONSE MATRIX (FOR PMC)..........................................................................10

2.3 ASSIGNMENT OF PMC.....................................................................................................10

Duties & responsibilities of PM...................................................................................10

Duties and Responsibilities of Experts.........................................................................11

Chapter 3. CONTRACTOR...........................................................................................................................123.1 RESPONSIBILITY OF CONTRACTOR.............................................................................12

Overall Responsibility..................................................................................................12

Chapter 4. QUALITY CONTROL during construction...............................................................................15

4.1 PROCESS CONTROL.........................................................................................................15

4.2 TESTING.............................................................................................................................15

4.3 SITE INSPECTION.............................................................................................................16

Day-to-Day Supervision................................................................................................16

Periodic Site Visits........................................................................................................17

Chapter 5. QUALITY Standards....................................................................................................................185.1 APPLICABLE standards .....................................................................................................18

5.2 SOURCE OF SCREENING PROCESS...............................................................................21

1


3/41

5.3 SOURCE APPROVAL PROCESS......................................................................................21

5.4 MATERIALS APPROVAL.................................................................................................21

5.5 ACCEPTANCE/REJECTION CRITERIA...........................................................................22

5.6 ACCEPTANCE CRITERIA.................................................................................................22

Material........................................................................................................................22

Test Results...................................................................................................................22

Non Conforming Reports (NCR)................................................................................22

5.7 NCR (Explanatory Note)......................................................................................................225.8 CONTROL OF MATERIALs AT SITE...............................................................................23

5.9 TESTING OF MATERIALS AT SITE LABORATORY....................................................24

5.10 CERTIFICATION OF MATERIALS BY MANUFACTURER.........................................24

Chapter 6. QUALITY CONTROL OF WORKS...........................................................................................25

6.1 CONSTRUCTION METHODS...........................................................................................25

6.2 INSPECTION OF PLANT & MACHINERY......................................................................25

6.3 INSPECTION AND TESTING OF WORKS.......................................................................26

6.4 NON CONFIRMING WORKS............................................................................................26

6.5 INSPECTION PROCEDURE..............................................................................................27

Chapter 7. SAFETY PROCEDURES.............................................................................................................28

Contractor Obligations.................................................................................................28

Digging and Excavation works:....................................................................................31

Working near running line :-.........................................................................................32

Safety Fencing...............................................................................................................33

Indemnity by Contractor...............................................................................................35

Damage to Railway Property or Life or Private Property............................................36

Safety of Public.............................................................................................................36

Reporting of Accidents..................................................................................................36

Life-saving Appliances and First aid Equipment...........................................................36

Security Measures.........................................................................................................37

Chapter 8. APPENDIX................................................................................................................................... 38

The contractor shall ensure that all his employees / workmen are covered under

Workmen Compensation Act and shall pay compensation to his workmen as and when

the eventuality tor the same arises................................................................................38

Notwithstanding the above Act/Rules, there is nothing in those to exempt the

contractor from the purview of any other Act or Rule in Republic of India for the safety

of men and materials.....................................................................................................38

If the requirements stated in this document are less stringent than or in conflict with the

country's applicable legislation, the latter shall apply..................................................38

In case ot tailure on the part ot the contractor, the Employer at the cost ot the

contractor shall do the same.........................................................................................40

2


4/41

CHAPTER 1. INTRODUCTION

1.1 GENERAL

All applicable Railways, IRC, BIS, RNVL, RDSO, standards and specifications, all best practices and

document of the project are considered in preparation of this Quality and Safety Plan. The basic conceptof this process is that the contractor ensures that product quality is achieved through adequate

machinery, men, materials, project management, inspection and testing with Project Management

Consultant (PMC). This system requires the Contractor to have Designers, Engineers, Technicians,

Operators, etc, who are competent in execution, inspection and testing of all the Railway Works. The

General idea is that, the Contractor has to perform the necessary execution, inspection and testing to

ensure the likelihood that all his works in Railway bed construction meets the Specifications, instead of

after-the fact execution, to ensure that all the works have met the Specifications. This approach

enables the Contractor much more control over his total operations. He is responsible for his product

from the beginning to the end, construction of all the Project works, till the final acceptance of the

works. The Contractor through its associates ensures execution and testing to make sure that, theactivities are adequate and accurate. Ensuring production of a quality work, its durability and uniform

performance by Contractor is a prominent aspect of the Quality Control Assignment of the Contractor

through PMC.

1.2 QUALITY AND SAFETY PLAN

The intention of this Plan is to provide efficient, high Quality Construction and Safety. Besides it, it is a

crystal clear fact that, adherence to the adopted guidelines does not necessarily guarantee that these

attributes are achieved. All users are to exercise judgment based on good Engineering practice rather

than blind adherence to the adopted guidelines but minimum to ensure that specification requirements

are fully achieved. On the other hand, it is essential to adopt appropriate care regarding engineering

practicing, so that no contradiction may occur with the contract.

This Plan is prepared in compliance of PMC under Para 5.8.1(iii) of the TOR. The QSP explains the

Quality and Safety policy, various duties of the Contractor and PMC with references to Indian Railways

Standards and guidelines, setting up minimum Bench Marks and working out Quality index. The

Quality Assurance Plan of the Contractor will contain the arrangements for Quality Control System, the

internal Quality audit and will be approved by Contractor through PMC.

1.3 TERMINOLOGY

The terms used in the field of quality management have acquired specific meanings and applications,

different from the generic definition found in dictionaries. Internationally accepted definitions and

terminology have been given in ISO: 8402 standard. Further, the following general terminology adopted

is as mentioned below.

Abbreviations Description

ACE Accepted Cost Estimate.

AEROS Assistant Expert Railway Operations and Safety.

BE Bridge Expert

C.A. Construction Contract Agreement.

CBR California Bearing Ratio.


5/41

Abbreviations Description

CD Cross Drainage.

CE Civil Expert

EE Electrical Expert

ENGINEER PMC Consultant

EXE Execution.

FDD TEST Field Dry Density Test.

G.F.C. Good For Construction.

GL Ground Level.ID Identification.

ITP Inspection test Plan.

IVRCL Name of Contracting Agency (The Contractor)

IVRCL The Contractor

M.O.M. Minutes Of Meeting.

MDD Maximum Dry Density.

MTC Manufacturer Test Certificate.

MTN Materials Transit Note.

NCR Non-Conformance Report.

NDT Non Destructive Test.

NMC Natural moisture content.OGL Original Ground Level.

OMC Optimum moisture content.

P&M Plant & Machineries.

PE P Way Expert

PM Project Manager.

PMC Project Management Consultant.

PMP Project Management Plan.

PO Purchase Order.

QSP Quality and Safety Plan

REV Revision.

RVNL Rail Vikas NigamLimited (The Client)

S/C Sub Contractor.

SBC Safe Bearing Capacity.

SD Standard Deviation.

STE Signal and Telecom Expert

TC Test Certificate.

VSPL Voyants Solutions Pvt Ltd (The PMC)

Quality

Quality is defined in the Quality Plan of ISO 9000 as the totality of characteristics of an entity that

bears on its ability to satisfy the stated and implied need.


6/41

Quality And Safety

Quality and Safety of a job is defined as a process which exercises various checks at different stages

of a work right from its inception till its acceptance, to put it in service to ensure that the work has

been properly designed and constructed as per approved designs, drawings and specifications. At

times it is extended to cover the prescribed Defects Liability period. Sometimes its scope is enlarged

to encompass the maintenance aspect over the defect liability period of service life.

Quality Control

Quality Control is defined as the procedure adopted and controls exercised to ensure that the materials

proposed to be used in production, processes adopted for production and workmanship of production

conform to the prescribed standards and laid down acceptance criteria.

The Quality control is exercised by IVRCL, which ensures that the defined objective is achieved

through appropriate tests, checks and inspections by suitable qualified personnel. Furthermore, the

objective evidences of all tests, checks and inspections carried out from time to time aredocumented in prescribed formats for reference and record.

Quality Audit

Quality Audit is a managerial tool used for reviewing the whole or a part of the quality system by

internal or external agencies not connected with the operation of the QA Plan. Quality Audit is

defined to be a systematic study and examination of documents related to quality control corridor

during the construction phase to establish that the inputs during construction process and the

workmanship of work done conform to the prescribed specifications and are of acceptable standards

and if not, to identify whether rejection and / or rectification or any remedial measures are needed.

Verification Testing

Verification testing is defined as the sampling and testing which is carried out independent of quality

control sampling and testing to verify that the contractors results which have been reported are

correct and representative, within statistical parameters of the material being produced / processed.

Acceptance

Acceptance is defined as those operations, inspections, sampling and accepting the tests that areconducted to determine whether the product or service will be accepted for use and payment.

Acceptance is determined using a statistically based acceptance plan in combination with and Safety

that the contractor has fulfilled the quality control obligations. Acceptance is the responsibility of the

Contractor with a rider by PMC / RVNL on dispute.


7/41

1.4 DOCUMENTATION AND DATA CONTROL

Contract Documents

All formally written correspondence between the Client, Contractor, PMC any other official parties

including letters, memorandums, forms, minutes of meetings, site instructions, change orders,

approvals, drawings etc. is collectively known as Contract Documents. These must be carefullyhandled and stored. Any contract documentation could be the subjects of future litigation in case of

any dispute.

Quality Control Forms

The Quality System requirements will specify which Quality control forms or other routine forms

should be completed for which tasks and when they are necessary. It will also show how documents

will be referenced, indexed and stored and retrieved.

Computer Aided Project Management System (CAPMS)

Computer aided Project Management System is the chosen tool for documentation and data control

for this Project. The CAPMS will drive the System. Standard Project Management through MS-

Project is being used. It is intended to retain both soft and hard copy of all contract documents. The

Contractor will furnish such documents to the PMC or to the RVNL, if requisitioned. Project

documents must remain immediately traceable and recoverable at all times. The computer System will

be able to generate any documents, copies, updates etc. as required and will contain all the library of

paper work formed over the life of the Project.

Guard Files

Final copies will be correctly filed in a file System known as Guard files and the relevant copies will

be submitted to PMC on monthly basis for the work done during the month. They will be separately

stored in hard copy and in soft copy on the CAPMS at the office of the Contractor / RVNL / PMC.

Working Files

Other copies or working copies will be filled in a file System known as working files. These are for

project monitoring, field and laboratory use.

Quality Records

Records pertaining to inspections and testing shall include original observations, calculations, derived

data and an identification of personnel involved i.e. inspection and testing. All records shall be

indexed, filed and maintained in a secure location for the entire concession period.


8/41

1.5 PROCESS CONTROL

Approval Process

An approval procedure will be used throughout the Project to have a written record and statement of

due progress. The approval System formalizes requests from the Contractor and clearly agrees stage

approval of the PMC and or RVNL. The Contractor will submit Request For Inspection (RFI) to PMCfor inspection with an unique number at least 24 hours prior to actual execution of work. An advance

statement (RFI Summary) through email with tentative works or activities to be executed against

production of RFIs will be sent to PMC daily. Copy of the RFI Summary and photocopy of RFIs

duly numbered will be sent to the PMC.

The day to day work approval System is based on two main factors.

Request for Inspection to Proceed

Request for Approval on completion.

1.6 REQUEST FOR INSPECTION TO PROCEED AND FOR APPROVAL

In this Project, a comprehensive form has to be developed clubbing Call for inspection and approval on

completion for allowing proceeding with next stage of Execution especially in Railway bed. This form

submitted by the Contractor must be used in every case where a Quality controlled task intends to start.

The form must be duly signed and dated by the Contractors representative and all the experts of the

PMC and the Client have the opportunity to comment at inspection time.

RFIs are submitted in triplicate along with one set of standardized checklist. Formats for checklist for

different elements of work must be carefully prepared covering all the minute details of work as per

standard Engineering practice and approved method statement. The PMC must have to record their

observations against each query in the checklist. Findings of inspection are summarized on the basis of

test as per Construction requirements and recorded in the RFI. The PMC Expert finally signs the form

by either approving or rejecting the work according to the net result of inspection. The works shall

execute once the PMC approves. In turn PMC, as per their matrix of reporting will provide information /

copies to Client. The PMC will return copy of RFI, checklists and approvals along with Running

Account Bills for the quantities and works executed during the period.

1.7 SOURCE APPROVAL

Because of the variability of manufactured, processed and natural items, source approval is required. A

separate form, the details are shown in the QSP, is required for each and every source approval.

1.8 COMPLETION

At the end of project completion a joint inspection along with Client will be done and a snag list shall be

prepared. Upon the completion of these a provisional completion certificate shall be issued by PMC.


9/41

1.9 CALIBRATION OF INSTRUMENTS AND EQUIPMENTS

All measuring instruments and testing equipments (field and laboratory) shall be uniquely numbered,

properly stored, suitably handled in a manner appropriate to its sensitivity. Timely calibration shall be

maintained for all gauges. Every equipment shall be maintained in a known state of calibration. If any

instrument is repaired, steps shall be taken to ensure that recalibration is carried out to restore its

calibration status.

1.10 DIAGNOSTIC AND CORRECTIVE ACTION

An effective System of onsite inspection, method used to identify poor results and procedure to be

followed when poor results or deficiencies occur shall be maintained and documented. This System

shall comprise the followings.

System for the investigation of non-conformities and for taking actions.

Criteria to determine non conformity in a process or end product

Analysis of process trends to initiate preventive action

Verify that corrective action has actually been implemented effectively.

Procedure to handle client complaint and their resolution.

Records of corrective and preventive actions to demonstrate their effective implementations.

1.11 QUALITY AUDIT

Internal Quality audits shall be carried periodically and a schedule thereof shall be made. The audited

reports shall be discussed with audited group. A corrective action shall be planned on a time bound

basis when deficiencies are found. Follow up measures shall be taken to endure that corrective action

has been effective.


10/41

CHAPTER 2. QUALITY CONTROL PROCESS

The basic concept for production of a quality work is illustrated in the model below:

The main inputs for a Railway project to perform are Men, Materials, Machineries, Money and Time.

The documents specify the materials, their qualities and acceptance criteria for their use. Process control

specifications are usually incorporated in the contract documents. These specify the functional

requirements of the machinery or equipment to be used in the production process. The Contractor

normally establishes the other controls viz., money and time. The PMC usually approves the time input

factor and accordingly recommends the technology of production. The periodic checks during

construction process are carried out as laid down in the various codes and specifications mentioned there

in both by the Construction Contract and the Consultant Contract. The application of these activities

would eventually assure a quality product at the end. A quality control plan for each activity shall be

submitted at least 21 days prior to the start of the activity by IVRCL to PMC which consists of

properties of materials, construction procedure, equipment, inspection plan along with responsibility

matrix, test plan along with reports to be generated, etc

2.1 QUALITY CYCLE

Quality Management of a job is a cyclic process. The following diagram for a Railway work illustrates a

Quality Cycle.

Process Control

Specifications

Quality Inputs Periodic Checks Quality Product

Pre Commencement Activities ofa Construction Contractor

1. Mobilize Men, Materials,

Machineries and Money.

2. Setup Quality Control System.

3. Obtain various approvals.

4. Study and take actions on

remedial measures.

Construction Activities of Contractor

1. Identification of activities.

2. Remedial / Corrective measures.

Suggested by PMC.

3. Carryout periodic checks.4. Review test records.

5. Certify product.

Analysis of a Problem by the PMC

1. Establish causes of defects.

2. Suggest remedial measures.

3. Ensure implementation of remedial

measures.


11/41

2.2 TASK RESPONSE MATRIX (FOR PMC)

S.No. Details of Activities

1 To suggest modifications in the Contractors work program method statements, material sources etc.

including activity scheduling.

2 To ensure that the Construction works are in accordance with technical specifications and other

stipulation of Agreement and the Construction methods proposed by the Contractor are in compliance

with the above stipulations particularly in relation to Contractors Construction equipment and otherresource deployment.

3 To ensure a System of Quality And Safety of works, provisionally approve subject to final approval by

the PMC materials and sources of materials review all bituminous and concrete mix design proposed

by the Contractor, suggest modification in mix design, laying methods, sampling and testing

procedure and Quality control measures to ensure required standard and consistency in Quality at the

commencement of item.

4 Check the setting up of laboratory (including calibration of equipments) and field tests carried out by

the Contractor.

5 Suggest special tests of materials and /or completed works, ask for removal and substitution of

improper materials and / or works as required.

6 To plan, monitor and optimize the use of available resources to expedite construction.

7 To monitor and check day to day Quality control of the Contractor.

8 To evolve a Safety system and ensure Safety during construction including the preparation and

implementation of traffic management plan.

9 To direct the Contractor in all matters concerning Construction Safety and care of the works and if

required, to request the Contractor to provide any necessary lights, guards, fencing and watchman.

10 To direct the Contractor to carry out all such works or to do such things as may be necessary in his

opinion to avoid or to reduce the risk of any emergency affecting the Safety of life or of adjoining

property.

11 To suggest the Contractor to take all necessary steps to protect the environment on and off the site

which arise due to Construction operations.12 To direct the Contractor to take all necessary steps to maintain the rate of progress of works as per the

approved programmed of the Contractor on monthly and quarterly basis.

13 To implement a system for monitoring the progress of work on computer based project management

technique and prepare progress reports on a regular basis.

14 To ensure that high quality construction is achieved and to ensure that all works are carried out in full

compliance with the engineering design, technical specification of concession agreement within

stipulated time period.

15 To extend co-operation and assistance to the Contractors to make possible timely completion of the

Project without diluting the Quality standards.

16 Prepare and issue monthly progress reports along with detailed quality control test statement in a

prescribed format.

18 To review the operation and maintenance Plan prepared by the contractors outlining the routines to be

adopted in each specific location and for the CD works and bridges.

19 Coordinate with different agencies and hold meetings for proper and timely implementation of the

Project.

20 To carry out any other duties relevant to the Project.

21 To obtain support from head office for the team on site.

2.3 ASSIGNMENT OF PMC

Duties & responsibilities of PM

Act as the representative on behalf of the RVNL.


12/41

Review Contractors Construction Program, and Safety Plan.

Interpret the provisions of the Agreement and other related documents

Review the working drawings prepared by the Contractor

Ensuring implementation of Quality and Safety System.

Periodical Supervision of works in accordance with the specification.

Evolve criteria for acceptance of works.

Hold regular meetings with the Contractors and RVNL.

Regular interaction with the Project Managers of the Contractors in all matters relating to progress of

works with particular reference to delays, possible reasons and mitigating measures, Quality and

methodology.

Carryout any other duties relevant to the Project as desired by the RVNL.

Assist the statutory auditors in auditing.

Duties and Responsibilities of Experts

A) Quality And Safety

Assist the Contractor with the setting up of field laboratories.

Review and recommend quarry sites for aggregates, quarry spall, sand, borrow materials etc.

Supervise all the tests to be done in different stages of Construction besides ensuring that specified tests

are done as per stipulated codes and take stage clearance from RVNL.

Check the storing arrangement of Contractors materials and direct if any modification in necessary.

Advise the RVNL in issuing instructions for the approval and rejection of materials at source and at site.

Assist in organizing tests other than the regular tests done by laboratory personnel.

He shall seek approval from RVNL for the designs.

Maintain records of all materials and completed works and ensuring that all materials and completed

works as per technical specifications.

Verify manufacturers certificates.

Check the calibration of testing equipments and Plants.

Assist the PM/RE in the preparation of Project completion reports.

Assist the PM in final inspection of works.


13/41

CHAPTER 3. CONTRACTOR

3.1 RESPONSIBILITY OF CONTRACTOR

The Contractors are responsible for the execution of works in conformance with the requirements of the

contract documents.

Overall Responsibility

The Contractor is responsible for providing

All necessary Plant, labor, equipment and Construction materials to be used in the works.

All Plant equipment, materials and labour for temporary and ancillary works.

Transportation and storage facilities for all materials and equipment Office and accommodation for

staff and labour Sanitation facility at site.

Facility for the Construction team e.g. providing inspection vehicle, messing, Safety jackets,

helmets, Safety shoes & belts etc.

All necessary equipment and laboratory for testing and Quality control.

Labour camps etc.

Control as required in the contract.

The Contractor is responsible for executing and completing the works in accordance with the

specific standards and specifications and within the contractual time allowed to take all clearances

from the regulating authorities and complying statutory requirements.

3.1.1.1 Quality Assurance and Quality Control Duty.

The Contractors QA/QC duties are summarized in table below. Other duties shall be performed as

stipulated in the contract documents or directed by the PMC and RVNL.

List of Contractors QA/QC duties

Activity / Item Contractor s QA/QC Duties

Preparation of

working /shopdrawings.

Prepare and submit working drawings to for review and then with modification as

suggested to submit to PMC for approval.

Design and

Drawings.

Maintain design/ drawing register at site.

Use only approved drawings for Construction.

Replace drawings that have been modified with new ones.

Testing

laboratory and

equipment.

Intimate the PMC the details, date of completion with requisite manufacturers and

calibration certificates.

Maintain the equipment in good condition and calibrate as necessary.

Material

Receipt

Enter receipts in material register and maintain manufacturer test certificates for all

materials.


14/41


Material

Testing

Take test samples from the working mix/ material in presence of Engineers or PMCs

Experts.

Perform materials tests as per contract requirement.

Maintain test log.

Collect samples witnessing the PMC, test the same and submit test results to PMC, in

the presence of appointed PMC and submit for PMCs approval and RVNL for review.

Material storing

/ Stock piling.

Make sure that materials are stored properly in the demarked stores or areas.

No contamination should be allowed.

Hazards/ poisonous material should be stored and handled in safe manner.

All corroded / rusted steel material is removed from site.

Steel materials are stored in raised platform and are not directly in contract with

ground.

Strands are stored in water tight and air tight room and are used within 90 days from

the date of manufacture. Rails and Sleepers are stacked as per specified procedures of the Manuals.

The rejected materials shall be removed from the Site.

Rejected

Materials

Enter in material register at site.

Intimate PMC the proposed date of removal from site and confirm after removal.

All necessary and most essential spares for equipment are readily available without

halting the works

All materials whose effectives deteriorate after expiry date are consumed in work

within the said date.

Material

consumption

Enter daily consumption of materials in material register and indicate balance quantity.

Construction

Equipment

Intimate PMC the details, date of mobilization.

Maintain equipment in good working condition.

Construction Intimate PMC when Construction is going to undertaken.

Intimate PMC in advance when critical works such as embankment, pond treatment,

pavement layers, concreting, laying of pipe culverts etc would be undertaken along with

test certificates where necessary. No critical activity shall start unless material certificates

are approved.

Provide necessary QA/ QC of works.

Daily Work

Progress

Maintain daily log

Testing of

works in

progress.

Perform tests as per contract requirements

Submit test reports to PMC.

Maintain test log

Rejected work

items.

Intimate PMC the proposed date of removal from site and confirm after removal or (if so

agreed by the PMC as the case may be) rectify defective work and invite PMC for repeat

inspection.

Safe and proper disposal of rejected and unusable material


15/41


Instructions

from

PMC /

Employer

Enter change orders, site instructions, letters and minutes of meetings in the

instruction log.

Advise compliance

Construction

scheduling and

control

Prepare and update Construction programs and schedules and undertakes work in

accordance with approved schedule.

Submission of revised programs as and when slippage from the Planned program

need to recover to set the works back onto schedule and prepare and submit work

methodologies for approval at least 21days prior to start of activity comprising inspection

plan and responsibility matrix, test plan and responsibility matrix etc. for approval by

PMC / RVNL.

Reporting Prepare and submit daily and monthly progress reports.

Records Signed copies of approved drawings.

Design/ drawing register.

Test reports and test logs.

Materials register.

Site instruction book.

Equipment registers.

Maintain the following records on site.

Labour register.

Permission/ License issued by different authorities.

Other records as specified in the Agreement.


16/41

CHAPTER 4. QUALITY CONTROL DURING CONSTRUCTION

This section of the Plan provides an overview of quality control activities during construction phase,

including process control, testing, site inspection and tracking of instructions. Materials control requirements

are presented in detail in section 5 and work control requirements in section 6.

4.1 PROCESS CONTROL

An approval procedure will be used throughout the project to have a written record and statement of due

progress. The approval system formalizes requests from the Contractor and clearly agrees stage approval

from the PMC subject to review by the RVNL. The approval procedure will form the backup documents

required for CRS inspections. It is to show clear and written communications between Contractor, & PMC,

so there is no doubt or uncertainty. The day-to-day work approval is based on one composite form, termed

as CFI for Call for Inspection and according approval on completion.

Call for Inspection (CFI)

This composite form, submitted by the Contractor, must be used in every case where a quality control task

intends to start. This form must be duly signed and dated by the Contractors representative and all

Engineers associated with that particular activity at specified location have the opportunity to comment

during inspection. The Expert of the PMC will inspect the execution process, test and ensure the task has

been completed to the standard required and write comments to that effect. The form must be duly signed

by the relevant Engineer. If there are negative comments, then the representative of the Contractor will be

informed of the same with the direction to rectify or redo the work and to raise fresh CFI for further

inspection after necessary correction. After successful completion of task the representing engineers of

PMC/RVNL shall sign for its acceptance and return the copy to representing Contractors Engineer. All

copies of clearance and test reports pertaining to a particular Running Accounting Bill shall be submitted

to PMC/RVNL for certification of Bill.

4.2 TESTING

Various tests on materials and works are required to be carried out on site during construction. A well

equipped and properly calibrated site test laboratory is therefore an important element of quality control.

The Contractor is required to set up the site laboratory before commencement of construction activities.

A list of testing equipment provided by the Contractor for the site laboratory is to be submitted to PMC.

As per suggestions of them, testing equipments are to be added or modified including their orientation.

PMC will give final approval to the arranged facilities of the laboratory. Laboratory equipment shall be

properly calibrated and calibration certificates will be kept at the laboratory. Specialized tests at outside

independent laboratories shall be undertaken as per instruction of PMC. The details of input materials

should be recorded in Material Register.

All test results shall be entered into a test logbook as well as in standard formats for respective tests and

conformance/ non-conformance is to be indicated therein. All aspects of materials testing (including test

report formats) and quality control of materials and works are described separately.


17/41

4.3 SITE INSPECTION

Site inspections are to be carried out to ensure that the materials and construction activities conform to the

prescribed standards. Site inspections can be divided into day-to-day supervision and periodic site visits.

Day-to-Day Supervision

On his appointed PMC shall carry out the day-to-day site inspection of all construction activities where

the day to day supervision will be carried out by Contractor. This includes checking of line, level and

layout and inspection of materials and construction activities. The Supervisory team of Contractor shall

see that materials that have been rejected are not in use in works. The PMC as part of inspection would

issue site instructions to the Contractor whether in CFI or in site order book, through letters, as necessary

from time to time. Such observations will also include notes of non conformance for work that has been

found to be not in accordance with the contract requirements, and has to be redone or rectified, as

instructed by PMC. Copy of all CIFs with noting of observations of Experts on works or materials etc.

will be sent to the PMC for review.

Construction activities to be inspected include the following:

Earth work formation construction

Construction of sub grade

Collection of Blanket Materials.

Track Linking

Platform Constructions

Track Electrifications

Signal and Telecom installations.

Laying of cables.

Jointing of Cables.

Operation of plants

Lying of Concrete.

Operation of concrete batching plant

Formwork, staging and steel reinforcement (stage wise before Concrete pouring)

Concrete pouring

Laying and jointing of drainage pipes

Drainage and protection work

Stressing, launching of girder and installation of bearing.

Landscaping

Construction of building and other ancillaries

Kerb casting

Painting

Installation of bearings and expansion joints.

Pre cast and Pre stressing etc.

Supply Materials before placing order and when supplied at site.

Supply Materials and Electrical Items before placing order and when supplied at site. Supply Materials and Permanent Way Items before placing order and when supplied at site.

Supply Materials and Electronic Items before placing order and when supplied at site.


18/41

Supply Materials and Signal and Telecom Items before placing order and when supplied at site.

Other items as mentioned in BOQ.

The Contractor shall give advance notice to the PMC when critical activities are proposed to be

undertaken and when a stage of work has been or is expected to be completed. On completion of a stage

and before proceeding to the next stage, the PMC shall inspect the quality of the works executed. The

final inspection shall encompass tests on completion as specified in the contract documents. The

certification of quality will be based on test reports and site inspection.

Equipment:

Construction equipment is a major component of quality and Safety system. It is necessary that the PMC

check the adequacy of the equipment used by the Contractor for construction as per the standard and

special specification or his appointed Sub Contractors will from time to time, check the calibration of

equipments as necessary. It would be also be necessary to record the equipment used for construction in

the daily logs describing the condition of equipment, no. of hours used for the day for execution of

works including item of work done in brief. PMC will periodically inspect the equipments and advise for

compliance.

Periodic Site Visits

Periodic site visits by Senior PMC engineer provide external review of quality of works executed. A

tentative agenda for the site visits is as follows.

Physical inspection of the works under execution and inspection of quality of workmanship.

Review of site documentation and contractor compliance.

Sample verification of test reports and quality certificates.

Review of issues, constraints and lacuna in quality system implementation.

Preparation of action planes for improving the quality.

Inspection of laboratories & plants in operation.

Performance appraisal of the Contractor.


19/41

CHAPTER 5. QUALITY STANDARDS

5.1 APPLICABLE STANDARDS

Quality Control standards for various construction materials and BOQ items shall be as per the Technical

Specifications and testing frequency and procedures shall be but not limited to the following list of

standards:

All goods and materials to be incorporated in the goods be new, unused, and of the most recent or current

models, and that they incorporate all recent improvements in design and materials unless provided for

otherwise in the contract.

a) The specifications mentioned in these specifications shall be prime governing.

b) Where there is conflict between provision in IRS & IS specifications, provisions in IRS

specifications shall prevail.

c) Where there is no provision of specifications in IRS, provisions in IS specifications should be

adopted. Where there are no provisions in IRS and IS Specifications, provisions in IRCSpecifications should be followed.

d) For items not covered in IRS/IS/IRC specifications, BS-5400 Part 1 to 10 may also be

considered.

e) Where applicable CEB/FIP recommendations and codes of practices shall be used if specific

recommendation does not exist in IRS/IRC/BS specifications.

f) The decision of Engineer shall be final and binding in the interpretation of the clause of the

codes of practice and specifications of this tender and no claim whatsoever shall be entertained

on this account from the Contractor.

1.2 LIST OF CODES AND SPECIFICATIONS

Apart from the basic data, specifications etc. all items of works shall be governed by the

following Codes, Specifications as revised/corrected/amended upto the time of submission of the

tender.

(i) INDIAN RAILWAY STANDARD CODES AND SPECIFICATIONS

1. Indian Railways Schedule of dimensions for Broad Gauge 2004.

2. Indian Railways Permanent Way Manual.

3. Indian Railways Bridge Manual, 1998

4. Indian Railways Works Manual.

5. IRS Bridge rules.

6. IRS Welded Bridge Code.

7. IRS Steel Bridge Code.

8. IRS Concrete Bridge Code

9. IRS Sub-structure & Foundation Code.

10. IRS: Specifications for fabrication and Erection of Steel Girder Bridges & Locomotive

Turn Tables. (B1-2001)

11. South Central Railways Standard Schedule of Rates.

12. South Central Railways Specification for Materials and Works

(ii) INDIAN ROADS CONGRESS CODES AND SPECIFICATIONS


20/41

1. IRC-5: Standard Specifications and Code of practice for Road Bridges

Section I General features of design.

2. IRC-6: Standard specifications and Code of practice for Road Bridges

Section-II-Loads & stresses.

3. IRC-21: Standard specifications and Code of practice for Road Bridges Section

III Cement concrete (Plain & reinforced)

4. IRC-24: Standard specifications and Code of practice for Road Bridges Section V Steel Road Bridges.

5. IRC-83: Bearings for bridges.

6. IRC-78: Sub-structure for Road Bridges.

7. IRC-87: Design and erection of false work for road bridges.

8. Specifications for Road and Bridge Works issued by Ministry of Road Transport &

Highways. (MoRTH)

(iii) INDIAN STANDARD SPECIFICATIONS

1. IS : 2062 Steel for general structural purposes.

2. IS : 8500 Structural steel Micro alloyed (Medium and high strength qualities)

3. IS : 1786 High strength deformed steel bars & wires for concrete reinforcement.

4. IS : 1148 Hot rolled rivet bars (up to 40mm dia) for structural purpose.

5. IS : 1149 High tensile steel rivet bars for structural purposes.

6. IS : 1363 (all 3 parts) Hexagon head bolts, screws and nuts of product grade C.

7. IS : 1929 Hot forged steel rivets for hot closing (12 to 36 mm dia).

8. IS : 2004 Carbon steel forgings for general engineering purposes.

9. IS : 57 Red lead for paints and other purposes.

10. IS : 75 Linseed oil, raw and refined.

11. IS : 77 Linseed oil, boiled for paints

12. IS : 102 Ready mixed paints, brushing, red lead, non-settling priming.

13. IS : 123 Ready mixed paints, brushing, finishing, semi-gloss, for general

purposes to Indian Colours etc.

14. IS : 2339 Aluminum paints for general purposes, in dual container.

15. IS : 280 Mild steel wire for general engineering purposes.

16. IS : 456 Plain and reinforced concrete.

17. IS : 883 Design for structural timber in buildings.

18. IS : 814 Covered electrodes for manual metal arc welding.

19. IS : 1182 Radiographic examination of butt joints in steel plates.

20. IS : 2595 Radiographic testing.

21. IS : 383 Coarse and fine aggregate from natural sources for concrete.

22. IS : 2386 (all 8 parts) Tests for aggregates for concrete

23. IS : 3025 (all 49 parts) Methods of sampling and test for water and waste water.

24. IS : 1791 Batch type concrete mixers.

25. IS : 4634 Methods of testing performance of batch type concrete mixers.

26. IS : 6925 Methods of test for determination of water soluble chlorides in concrete

admixtures.

27. IS : 9103 Admixtures for concrete.

28. IS : 516 Method of test for strength of concrete.29. IS : 4031 (all 15 parts) Physical tests for hydraulic cement.

30. IS : 5513 Vicat apparatus.

31. IS : 10080 Vibration machine for casting standard cement mortar cubes.


21/41

32. IS : 10262 Concrete mix design.

33. IS : 1343 Prestressed concrete.

34. IS : 975 (all 5 parts) Design loads (other than earthquakes) for buildings and

structures.

35. IS : 2720 (all 41 parts) method of tests for soil.

36. IS : 800 General construction in steel.

37. IS : 786 Conversion factors and conversion tables.

38. IS : 1024 Welding in bridges and structures subject to dynamic loading.39. IS : 1261 Seam welding in mild steel.

40. IS : 1367 (all 20 parts) Threaded steel fasteners.

41. IS : 6639 Hexagonal bolts for steel structures.

42. IS : 104 Ready mixed paint, brushing, zinc chrome, priming.

43. IS : 2074 Ready mixed paint, air drying, red oxide-zinc chrome.

44. IS : 1852 Rolling and cutting tolerances for hot rolled steel products.

45. IS : 1270 Metric steel tape measure.

46. IS : 9595 Metal Arc Welding.

47. IS : 487 Brush, paint and varnish.

48. IS : 1030 Carbon steel castings for general engineering purposes.

49. IS : 3400 (all 22 parts) Methods of tests for vulcanized rubbers.

50. IS : 1915 Steel bridge code.

51. IS : 1893 Earthquake resident design of structures.

52. IS : 3502 Steel Chequered Plates.

53. IS : 3085 Method of test for permeability of cement mortar and concrete.

54. IS :7320 Concrete slump test apparatus.

55. IS : 5515 Compaction factor apparatus.

56. IS : 6586 Metal spraying for protection of iron steel.

57. IS : 5666 Etch primer.

58. IS : 3955 Design and construction of well foundations.

59. SP 6, 7, 16, 21,22,23,24,34,36, 52,60.

60. IS : 2911 Design and construction of pile foundation

61. IS : 7205 Safety code for erection of structural steel work.

62. IS : 8629 Protection of iron and steel structures form atmospheric corrosion.

63. IS : 5624 Foundation bolts.

64. IS : 7215 Tolerances for fabrication of steel structures

65. IS : 8112 43 Grade OPC.

66. IS : 4326 Earthquake resistant design and construction of buildings.

67. IS : 13920 Ductile detailing of reinforced concrete structures subjected to seismic

forces.

68. IS : 34 White lead for paints.

69. IS : 887 Animal tallow.

70. IS : 816 Metal arc welding for general construction in mild steel.

71. IS : 819 Resistance spot welding for light assemblies in mild steel.

72. IS : 1024 Welding in bridges and structures subject to dynamic loading.

73. IS : 1261 Seam welding in mild steel.

74. IS : 1323 Oxy-acetylene welding for structural work in mild steel.

75. IS : 4081 Safety code for blasting and related drilling operations.

76. IS : 3764 Safety code for excavation work.77. IS : 7293 Safety code for working with construction machinery.

78. IS : 817 Training and testing of metal arc welders.


22/41

79. IS : 1200 (all relevant parts) Method of measurement of building and civil

engineering works.

80. IS : 2132 Thin walled tube sampling of soils.

81. IS :2131 Standard penetration test for soils.

82. IS : 1892 Subsurface investigations.

83. IS : 14268 Prestressing Strands

(iv) Miscellaneous:1. UIC-772R: Bearings of rail bridges

2. BS-5400 (all parts).

3. BS-1449, 3484, 1134, 5296.

NOTE: a) The list given above is by no means exhaustive. All IS, IRC and IRS Codes

pertaining to the work shall be applicable.

b) Where the drawings and specifications described a portion of the work in only general

terms and not in complete detail it shall be understood that only the best general practice

is to prevail, materials and workmanship of the best quality are to be employed and the

instructions of the Engineer are to be complied with.

5.2 SOURCE OF SCREENING PROCESS

The screening process basically refers to the Contractors submittals of their proposed suppliers seeking a

Source approval. The contract specifications stipulate that specific requirements must be met by the

material suppliers. The Contractor shall be required to obtain, from the proposed Supplier , all necessary

information and documentation necessary, will conduct tests as instructed either in their own laboratory or

in the laboratory of the Supplier or in any independent laboratory in presence of and submit to PMC for

approval or rejection of the proposal. The responsibility of the Supplier rests with the Contractor.

5.3 SOURCE APPROVAL PROCESS

The Contractor shall make the Supplier aware of specification requirements to fulfill the delivery of

materials / products as per contract.

A synopsis of the Material Pathway is

Provides source approval the PMC informed of proposed Potential supplies.

Other necessary documentation is to be obtained and provided.

Material arrive On site established procedure implemented by the Contractor.

Materials are Stored or Stacked at site.

Material goes to work site established procedures implemented by the Contractor.

5.4 MATERIALS APPROVAL

The material to be incorporated in work shall be subjected to passing of various tests as brought out in

earlier section. The detailed acceptance criteria for approval of material and finish item of work have been

dealt in this section. To make the acceptance criteria more apprehensive and also to facilitate , a checklist

has also been added as guidance so that Contractor can implement QSP in the most pragmatic manner on


23/41

ground. This checklist would help Contractor in ensuring that work on ground has been executed and

tested as per good engineering practice.

5.5 ACCEPTANCE/REJECTION CRITERIA

Since Quality Control has been exercised on statistical / probability method, hence shall evolve a

mathematical model to satisfy the degree of satisfaction to be achieved. This is most effective and widely

accepted model and yield very satisfactory result to obtain excellent Quality Control and more than 95%satisfaction level.

5.6 ACCEPTANCE CRITERIA

Material

All material brought to site for use in work shall conform to relevant IS/IRC/RVNL/BS code. Materials

do not conform to relevant IS/IRC/RVNL/BS shall be deemed to be rejected and shall be removed from

the work site.

Test Results

The testing result shall be duly combined and submitted to PMC along with Running Account Bill as

per requirement. Only those test results that are not accepted by PMC, contractor shall be resubmitted

after carryout rectification as directed or remove unsuitable item of work from site to spoils and replace

with fresh approved material.

Non Conforming Reports (NCR)

The purpose of NCR is to establish how to control nonconformity to specific requirements, and toprevent such material from unintended use or installation. If the construction activities carried out by

contractor at site are not conforming base on QA/QC Plan and/or construction drawing, the required

corrective measure should be instructed to the field engineer at site for corrective action of particular

items. If the instruction given by the PMC is overlooked in such incident, Non conformity of such work

should be issued to the contractor. The contractor should take immediate action by repaired or reworked,

which are taken cause of nonconformity. If necessary, to implement the corrective action to eliminate the

cause of nonconformities and to prevent recurrence shall be established.

5.7 NCR (EXPLANATORY NOTE)

1. Engineers by means of NCR shall report problems, defects or deficiencies identified during

construction.

2. NCR shall be raised for problems defects or deficiencies encountered in the following areas: -

Defective construction materials including rejected materials found at site / stock.

Substandard workmanship of construction works at any stage of construction.

Failure of materials, finished works or structures to meet specified test requirements.

Deviation from approved methodology (method statement)

Deviation from Drawing

Use of unapproved machineries and equipment.

Use of Improper machines and equipments.

Breakdown of Plants and Equipments.


24/41

Insufficient Safety arrangements at Site.

Incomplete testing of ingredients.

Using any material component which has not been tested.

Any other issues, in the opinion of the PMC are not within the accepted bounds of good

industry practice.

3. All NCR raised on site shall be issued to the respective construction manager. Alternatively the

process owner shall receive the NCR to initiate corrective action (i.e. the purchasing officer in

the procurement dept. for rejected material)

4. Where the NCR has a design implication, the corrective action proposed by PMC/RVNL to

rectify the non-compliance shall require the approval of the designer prior to its implementation.

5. The originators of the NCR all verify the corrective action for its effectiveness before closing out.

6. The PM shall ensure that the NCR is closed out within the agreed time frame for disposal.

5.8 CONTROL OF MATERIALS AT SITE

As materials arrive on site must be properly controlled at the truck, during unloading, during storage,

during transfer to construction site and as they are placed in the structure or on the Railway.

The base steps to proper material management are:

To verify whether materials are approved by PMC and reviewed by RVNL.

Whether consignment carries with it necessary manufacturers certificate regarding quality and

specification.

If the material is judged in conformance, the Contractor may unload the materials to his storage

area.

During unloading, samples will be chosen with respect to mandatory control testing or for audit

testing.

PMC / RVNL may instruct to send samples to independent laboratory

All material must be stored in an approved storage area that affords protection to the material as

required without endangering the Safety of others.

The management of the Contractors storage facility rests with the Contractor.

Each storage area must be suitably marked as Approved, Pending for Approval.

All rejected materials must have to be removed from site or store immediately.

At the work site, the material will be inspected and confirmed that no damage has taken place

during transportation or unloading.

If the material is damaged during construction processes, the material may be declared as

unsuitable by the PMC and it must be removed from site forthwith.

Periodical checking of quality of material other than the actual frequency of testing during the

construction will be made at the laboratory by taking samples from site and conducting tests in

presence of Experts.

Material must be consumed in work before the date of expiry as indicated by the manufacturer or

code of practice.


25/41

5.9 TESTING OF MATERIALS AT SITE LABORATORY

Testing of construction materials is carried out for a variety of reasons and purposes as per the frequencies

prescribed in IRC, IRS, CPWD, RVNL and Technical Specification.

Screening Tests (e.g. Choosing a borrow source, an aggregate supplier, a manufacturer / supplier

etc.

Control Tests (e.g. sampling and testing of materials delivered by supplier).

Routine Tests to verify whether materials conform to the item approved by the PMC.

Audit tests to verify independently the reported properties of materials.

Trial Mixes (Selection of appropriate concrete mix designs, design of bituminous mixtures, and

other non-bituminous base and sub base courses).

Acceptance Tests (e.g. testing of cubes cast of produced concrete to confirm that required strength is

achieved and is consistent).

Special testing as may be deemed necessary and prudent.

The testing to be carried out within the preview of the laboratory includes soil and aggregate

(embankment fill, sub grade, granular sub base, crushed stone, base course, sand, fly ash, cement,

cement concrete, bricks.

Beside laboratory tests mentioned above a number of field tests such as field density testing, casting

of concrete cubes, slumps, static and dynamic load test of pile, taking cores of concrete are routine

requirements to be followed.

5.10 CERTIFICATION OF MATERIALS BY MANUFACTURER

It has been anticipated in the specifications that specialized testing such as water, bearing pads, pot

bearing, steel, pre-stress strand, Electrical wires, OFC Cables, Electronic items, Signals, Luminaries,

Sleepers, and the like would be carried out utilizing an outside testing agency or the manufacturers as the

case may require.

Acceptance of certain manufactured items shall be based on test certificates from the manufacturer

conforming to RDSO standards and visual inspection. These items shall bear the IS mark. The PMC shall

review the manufacturers certificates for conformance to contract requirements before these items are

delivered to site. Upon their delivery and before their installation or incorporation in the works,

The warranty period if any shall be indemnified in favor of RVNL by the Manufacturers.


26/41

CHAPTER 6. QUALITY CONTROL OF WORKS

This section of the Quality and Safety Plan covers the procedures of checking and reviewing Contractors

method statements, job mix designs, inspection and testing of works leading to final approval or acceptance.

The works include, but not limited to, earthworks, sub base, Electrical Works, Signal and Telecom Works,

and construction of cement concrete structures, fabricated steel items.

6.1 CONSTRUCTION METHODS

It is common practice for the Contractor to submit to suitable method statements to execute a particular task

for checking well before the planned start of operations. Because each contractor has different management

and resources, the methodology for each task is particular. It is for this reason that PMC will check the

methodology and advice and suggest improvement of the same as required. By incorporating the suggestions

of the PMC, the method statement will be revised and submitted to the PMC/RVNL through the PMC for

review and approval. The PMC/RVNL will approve the methodology with or without condition for its

further improvement. The methodology will include what, why, when and how the task will be completed in

accordance with contract conditions.

The General part of the method statement is issued with construction program and includes information on

materials sources, location of facilities, details of facilities and approaches, procedures for minimizing

environmental impact, any other information. The special part is more detailed and applies to a specific task.

This special statement is submitted to PMC at least 21 days prior to the actual commencement of any

activity, in order to review construction method, personnel, equipment, and sequence of construction, testing

and acceptance procedures and any special requirements in comprehensive detail. The responsibility of

Safety while executing any task and its soundness will rest on the Contractor, irrespective of approval by the

PMC.

The PMC will approve in writing the method statement when they are convinced of the feasibility, Safety

and practicality of the method. The method statement is matched to any other relevant quality documents

and forms the modeled task. The task forms part of contract documents and be respectively filed in

accordance with Quality and Safety System.

6.2 INSPECTION OF PLANT & MACHINERY

The PMC must inspect the plant, machinery and laboratory equipment to ensure the items in accordance

with specifications, quality and Safety system, contract and program as agreed. They will be periodically

checked by the PMC. PMC may randomly check equipments. It will be checked by PMC and RVNL

whether calibration of equipments has been made and certified inspection tools complete with accessories

must be ready and in working conditions. This methodology is given below:

The PMC will inspect plant, machinery and laboratory equipments on a routine basis and a written

report will be generated. The Experts of the PMC may inspect them from time to time, if felt

necessary.

The RVNL and PMC will ensure that the plant and machinery or other item is in accordance with

specifications and are capable of achieving the required quality and quantity of the works within the

time schedule and programs.

Laboratory Equipment must be regularly checked and calibrated so that they continuously givecorrect results.


27/41

Because plant, machinery and laboratory equipment suffer with age, it must be ensured that items are

continuously monitored to ensure continued acceptability wherever calibration is necessary/needed, a list of

plants/lab equipment to be calibrated along with frequency of calibration shall be prepared and approval

shall be sought.

The Contractor must be informed in writing the results of occasional, routine or scheduled

inspection with the request to rectify the defects or replace, as necessary.

6.3 INSPECTION AND TESTING OF WORKS

The PMC on request from the Contractor will inspect all works to ensure that each item of work is executed

using approved materials in accordance with contract specifications, approved design and methodology and

quality and Safety plan. The methodology of inspection shall be as follows.

The PMC shall check and inspect on the submission of RFI/CFI and certify on its successful

completion as per Railway specifications and pre-approved work methodologies.

The Contractor will submit CFI to for inspection of work at scheduled date and time. The Contractor

will number the CFIs for convenience of documentation and forward one copy of each to the PMC.

Upon receipt of numbered CFI, PMC will inspect the assigned work. With the help of check list,

specifications, approved work methodology, approved drawings, knowledge and experience, he will

assess and approve the Contractor.

The Contractor will test in accordance with the specifications and the tests will be witnessed by the

Supervisors and Experts of PMC.

The Contractor will set out alignment; take levels etc. with his own surveyor and the PMC will do a

random checking. Before submitting any CFI/RFI for inspection to, the Contractor will record his satisfaction

regarding quality and correctness of work in the check list to be annexed with CFI.

In the event that the work, or part of the work, does not meet the specifications or quality standards

in accordance with the work, PMC may give the contractor an opportunity to rectify the work.

The work must again be inspected/ tested to see whether rectifications are done satisfactorily.

The PMC by selecting CFI at random may inspect work and record his observations either in CFI or

in site order book for information of the / Contractor.

The CFIs will finally be closed by the PM or Resident Engineer or any Expert of PMC with

necessary noting of approval or rejection and shall return the copy to Contractor by keeping hisrequisite copies.

6.4 NON CONFIRMING WORKS

Any work in part or in whole, the PMC has determined to be poor quality or in any way not in accordance

with the contract is called non standard work. On refusal of acceptance of work, the Contractor must be

given opportunity to rectify the work. If this is not possible or the PMC does not approve rectification, the

Contractor must remove the offending item(s). After rectification or reconstruction, the work will again be

re inspected, by the way of submission and approval of RFI/CFI and if found satisfactory, may be accepted.


28/41

6.5 INSPECTION PROCEDURE

For the sake of efficient and effective supervision of works, written procedures and check lists of inspection

and testing have been prepared for the use of supervising staff of the PMC. In order to have a clear cut

concept of construction procedures, flow charts indicating the construction sequence and control points for

the following items of Railway works are prepared .

Bridge work (Other than Steel works)

Bridge work (Steel items Involving Fabrication and Erection)

Bridge work (Supply of Steel items )

Ballast Supply

Poway Supply (Other than steel items)

Poway Supply (Steel Items)

Permanent Way Linking: Installation Works

Permanent Way Linking: Supply and Installation Works

Buildings

Platform, Passenger Amenities and Miscellaneous Works : Other than Steel items

Platform, Passenger Amenities and Miscellaneous Works : Steel items

Supply of Cement

Site Facility

General Electrical items

SOR Items

S&T Works


29/41

CHAPTER 7. SAFETY PROCEDURES

The Objectives:

The main objectives for management control of Safety measures during constructions are:

1. There is no danger to life due to ongoing construction activities.

2. There is no damage to existing track, cables, equipments and machines under operation, due to

ongoing construction activities.3. There are no accidents due to ongoing construction activities.

4. The Safety norms laid down in various Manuals and regulations are observed.

Contractor Obligations

(1) The Contractor shall comply with all the precautions as required for the safety of the workmen

by the I.L.O Convention No.62 as far as they are applicable to the Contract. The Contractor shall

provide all necessary safety appliances; such as safety goggles, helmets, masks, etc to the

workmen and the staff.

(2) Suitable scaffolds shall be provided for workmen for all work that cannot safely be done fromthe ground, or from solid construction except for such short period work as can be done safely

from ladders. When a ladder is used, an extra labourer shall be engaged for holding the ladder

and if the ladder is used for carrying materials as well, suitable foot- holds and hand-holds shall

be provided on the ladder, which shall be given an inclination not steeper than 1/4 to 1 (1/4

horizontal in 1 vertical)

(3) Scaffolding or staging more than 3.25 metres above the ground or floor, swung or suspended

from an overhead support or erected with stationary support, shall have a guard rail properly

attached, bolted, braced and otherwise secured at least 1 metre high above the floor or platform

of such scaffolding or staging and extending along the entire length of the outside and ends

thereof with only such openings as maybe necessary for the delivery of materials. Such

scaffolding or staging shall be so fastened as to prevent it from swaying in from the support or

structure.

(4) Working platforms, gangways and stairways shall be so constructed that they do not sag unduly

or unequally, and if the height of any platform or gangway or stairway is more than 3.25 metres

above ground level or floor level, it shall have closely spaced boards, have adequate width and

be suitably provided with guard rails as described in (3) above.

(5) Every opening in the floor of a structure or in a working platform shall be provided with suitable

means to prevent fall of persons or materials by providing suitable fencing or railing with a

minimum height of one metre.

(6) Safe means of access and egress shall be provided to all working platforms and other working

places. Every ladder shall be securely fixed. No portable single ladder shall be over 9 metres in

length. The width between side rails in a rung ladder shall in no case be less than 30 cm for

ladders up to and including 3 metres in length. For longer ladders the width shall be increased at

least 6 mm for each additional 30 cm of length. Spacing of steps shall be uniform and shall not

exceed 30 cm.


30/41

(7) Adequate precautions shall be taken to prevent danger from electrical equipment. Adequate

safety measures shall be taken when any work is undertaken near any live highly charged

electric wire. Necessary shutdown may be arranged, where and whenever essential. All rules in

force in this connection shall be fully complied with. The Contractor shall ensure all precautions

to prevent any accidents due to electrocution or otherwise.

(8) No materials on any of the sites shall be so stacked or placed as to cause danger or

inconvenience to any person or the public. The Contractor shall provide all necessary fencingand lights to protect the public from accidents and shall be bound to bear the expenses of

defending every suit, action or other proceedings at law that may be brought by any person for

injury sustained owing to neglect of the above precautions and to pay any damages and costs

which may be awarded in any such suit, action or proceedings to any such person or which may

with the consent of the Contractor be paid to compromise any claim by any such person.

(9) Excavation and Trenching : All trenches, 1.5 metres or more in depth, shall at all times be

supplied with at least one ladder for each 20 metres in length or fraction thereof, Ladders shall

be extended from the bottom of the trench to at least 1 metre above the surface of the ground.

The sides of a trench, which is 1.5 metres or more in depth shall be stepped back to provide a

suitable slope, or be securely held by timber bracing so as to avoid the danger of side collapse.

Excavated material shall not be placed within 1.5 metres of the edge of any trench or half the

depth of the trench, whichever is more. Excavation shall be made from the top to the bottom.

Under no circumstances shall undermining or undercutting be done.

(10) Demolition : Before any demolition work is commenced and also during the process of the work :

(a) All roads and open areas adjacent to the work site shall either be closed or suitably

protected.

(b) No electric cable or apparatus, which is liable to be a source of danger other than a cable

or apparatus used by operators, shall remain electrically charged:

(c) All practical steps shall be taken to prevent danger to persons employed by the

Employer, from risk of fire or explosion, or flooding. No floor, roof or other part of a

building shall be so overloaded with debris or materials as to render it unsafe.

(11) All necessary personal safety equipment as considered adequate by the Engineer shall be

available for use of persons employed on the site and maintained in a condition suitable for

immediate use; and the Contractor shall take adequate steps to ensure proper use of such

equipment by those concerned.

(a) Workers employed on mixing asphaltic materials, cement, lime mortars, concrete etc.

shall be provided with protective footwear and protective goggles.

(b) Those engaged in handling any material, which is injurious to the eyes, shall be

provided with protective goggles.

(c) Those engaged in welding works shall be provided with welders protective eye- shield.

(d) Stone breakers shall be provided with protective goggles and protective clothing and

seated at sufficiently safe intervals.

(e) When workers are employed in sewers and manhole, which are in use, the contractor

shall ensure that manhole covers are open and manholes are ventilated at least for anhour before workers are allowed to go into them. Manholes so open shall be cordoned

off with suitable railing and provide warning signals or boards to prevent accidents to

the public.


31/41

(12) The Contractor shall not employ men below the age of 18 years and women, on the work of

painting with products containing lead in any form. Whenever men above the age of 18 years are

employed on the work of lead painting, the following precautions shall be taken:

(a) No paint containing lead or lead products shall be used except in the form of paste or

ready made paint.

(b) Suitable face masks shall be supplied for use by workers when paint is applied in theform of spray or a surface having lead paint dry rubbed and scrapped.

(c) Overalls shall be supplied by the Contractor to workmen and adequate facilities shall be

provided to enable workers to wash during and at the close of any days work.

(13) When work is performed near any place where there is risk of drowning all necessary equipment

shall be provided and kept ready for use and all necessary steps taken for prompt first aid

treatment of all injuries likely to be sustained during the course of the work.

(14) Use of hoisting machines and tackle including their attachments, anchorage and supports shall

conform to the following:

(a) (i) These shall be of good mechanical construction, sound material and adequate strength

and free from patent defects and shall be kept in good working order, be regularly inspected

and properly maintained.

(ii) Every rope used in hoisting or lowering materials or as a means of suspension shall be of

durable quality and adequate strength, and free from defects

(b) Every crane driver or hoisting appliance operator shall be properly qualified and no

person under the age of 21 shall be in charge of any hoisting machine including scaffold

equipment. Only trained men over the age of 21 shall be permitted to give signals to

such plant and appliance operators.

(c) For every hoisting machine and every chain hook, shackle, swivel and pulley block used

in hoisting, lowering or as means of suspension, safe working load shall be ascertained

by adequate means. Every hoisting machine and all gear referred to above shall be

plainly marked with safe working load. In case of a hoisting machine or a variable safe

working load, each safe working load and conditions under which it is applicable shall

be clearly indicated. No part of any machine or any gear referred to in the paragraph

above shall be loaded beyond safe working load except for the purpose of testing.

(d) In case of the Employers machine, safe working load shall be notified by the Engineer

or his Representative. As regards Contractors machines, the Contractor shall notify safe

working load of each machine to the Engineer or his Representative, whenever he brings

it to the site of work and get it verified by him.

(15) Motors, gearing, transmission, electric wiring and other dangerous parts of hoisting appliances

shall be provided with efficient safeguards; hoisting appliances shall be provided with such

means as will reduce the risk of accident during descent of load to the minimum. Adequateprecautions shall be taken to reduce to the minimum risk of any part of a suspended load

becoming accidentally displaced. When workers are employed on electrical installations, which

are already energised, insulating mats, working apparel such as gloves, sleeves and boots, as


32/41

may be necessary, shall be provided. Workers shall not wear any rings, watches and carry keys

or other materials which are good conductor of electricity.

(16) All scaffolds, ladders and other safety devices mentioned or described herein shall be maintained

in a safe condition and no scaffold, ladder or equipment shall be altered or removed while it is in

use. Adequate washing facilities shall be provided at or near places of work.

(17) These safety provisions shall be brought to the notice of all concerned by displaying on a noticeboard at a prominent place at the work location. Persons responsible for ensuring compliance

with the Safety Code shall be named therein by the Contractor.

(18) To ensure effective enforcement of the rules and regulations relating to safety precautions,

arrangements made by the contractor shall be open to inspection by the Engineer or his

Representative.

(19) Notwithstanding anything contained in conditions (1) to (17) above, the Contractor shall at its

own costs, remain liable to comply with the provisions of all acts, rules, regulations, and bylaws

for the time being in force in India and applicable in this matter.

(20) For work carried out in the vicinity of any wharf or quay, the Contractor shall abide by all the

provisions of the Dock Workers (Safety, Health and Welfare) Scheme, 1961.

(21) The Contractor shall at his own expense provide protective safety Equipment like gloves and

footwear for all labour engaged on concrete mixing work and all other types of working

involving the use of tar, cement, etc. to the satisf