quality control manual · web viewfor infrastructure projects of roads & bridges issued by :...

QUALITY CONTROL MANUAL

FOR

INFRASTRUCTURE PROJECTS

OF

ROADS & BRIDGES

Issued By :

PIDB PUNJAB PWD B&R

CONTENTS

CHAPTER NO. SUBJECT PAGES

1 Background and introduction 1-52 Setting up of Field Lab 6-113 Salient Features/ Specifications for road work 12-354 Salient Parameters for concrete works 36-645 Quality control tests and their frequency 65-786(a) Quality Assurance Formats (Worksheet and 79-100

Check list performs)6(b) Check list for various activities 101-1207 Control of Alignment, level and surface regularity 121-1308 Guidelines of the Finalization of scope work 131-1389 Recording of tests results and quality control returns 139-142

1. BACKGROUND & INTRODUCTION

BACKGROUND & INTRODUCTION

Punjab Infrastructure Development Board (PIDB) has prepared an Integrated Infrastructure Development Plan for various roads in Punjab. The plan envisages a capital expenditure exceeding Rs. 2000.00 crore for rehabilitating and widening of existing road network in the state. Such a massive capital expenditure is probably being taken for the first time within the State of Punjab to improve the condition of road network..

PIDB will restrict itself to provide the funds for the construction of road works and will be involved in broad monitoring of the Projects. The works would be taken up by Public works Department, Building and Roads Branch. This would help in capacity building of the PWD. The role of PIDB is similar to a lending agency and in order to have a judicious use of funds PIDB would have a proper supervision and monitoring system during the execution of the projects. Quality control is an important requirement of highway construction for ensuring quality and creating able nation assets. The need for quality control has unchecked in recent times due to a significant increase in traffic intensities, increase in repitition of axle load and level of service expected by road user. Quality control leads to improved quality and uniformity, and ensuring a more economical utilization of materials, also affords a significant reduction in user costs in terms of lower costs of vehicle operation, transportation and maintenance.

Quality management system invokes commitment, procedures, processes and resources essential for achieving the quality norms under broad parameters of specification and contract provisions. It comprises of:

-Quality assurance-Material Testing-Quality Control

Quality assurance programme is achieved through use of suitable materials, specification and execution of work under overall supervision of Technical Committee overseeing the construction activities starting from setting out of alignments and controlling all construction activities with meticulous care upto full completion. The contractor is to prepare, plan and program, make arrangement for plant, machinery, materials and manpower etc. for carrying out different activities within the stipulated time period as per laid down specifications in a most appropriate workmanship and bad engineering practices.

‘Material testing’ refers to laboratory tests conducted on all material right from water, soil to cement and steel which are planned for incorporation in the works to ensure that they satisfy the standards set in IS/ IRC/ MOST ( MORT & H) specifications. Material testing have two operational stages:

I Suitability/Exploratory tests and

II Routine test after proper joint sampling before the use of materials/ mix/ product in permanent work.

‘Quality Control of various activities is done through various field tests including those at plant site, laying/compaction etc.

The volume gives brief outlines of proposed quality control including brief salient features of specification for road and concrete work; frequency of tests, checklist performa for start of different activities, reporting of test results to achieve quality assurance.

1. Provisions for Quality Control in the Contract Agreement of Project:

As per clause 33.2 of the General conditions of Contract agreement, for works, costing more than Rs. 200 Lacs, it is mandatory

(1) To engage a competent and independent Quality Control Consultant by the Contractor to be approved by the CE (IP)

(2) To establish a fully equipped laboratory at Site by the Contractor, which shall be managed by the trained staff by the said Quality Control Consultant.

(3) Contractor shall supply a copy of the agreement entered with the Quality Control Consultant to the CE (IP) and generally the fee for Quality Control consultant should be between 0.5 to 1% of the Contract value.

(4) The payment to the Quality Control Consultant shall be released by the CE (IP) as per agreement and such payments shall be recoverable from the Contractor out of running payments.

(5) Running payments are subject to the production and attachments of Quality Control reports, tests and checks conducted by Quality Control Consultant.

(6) The execution of work by the contractor shall also be subject to surprise, random tests and checks by the Project Engineer / his representative & other higher authorities.

(7) In case of failure of Contractor to ensure Quality assurance on part or whole of the work, the CE (IP) is empowered to select and engage other consultant deemed fit or Quality Control Lab. of PWD (B&R) for such works.

The costs incurred for such alternative shall be recoverable from Contractor and will be chargeable to work.

1.1. Construction materials:

For major construction materials “choice of brands’ have been given to Contractor for use at Site, namely:-

Cement: VIKRAM; Sri or JK Brand (43 Grade Cement)

Reinforcing steel bars: TMT/TOR steel Bars of Rashtriya Ispat Nigam;

TISCO or SAIL

Structural steel: Sail, Rashtriya Ispat Nigam, TISCO or SAIL.

Bitumen of specified grade: From approved Source of Govt. of India.

Emulsions of specified Grade: From approved source of Govt. of India.

Aggregates Only from approved Quarries conforming to grading for various items and meeting other

. requirements laid down in MOST (MORT&H) Specification for Road & Bridge work (up to date)

1.2 SPECIFICATIONS:-

The work shall be carried out as per specifications detailed in “MOST / MORT & H specifications of Road & Bridge works” (up to date) duly supplemented with “IRC Guidelines” and relevant provision of AASHO/ ASTM standards as and where required. Nomelclature of each item has been broadly laid down in Bill of Quantities of work, however in case of any variation/ discrepancy the relevant provision of above specified standards shall have precedent.

1.3 Appointment of Quality Control Consultants

Quality control Consultants shall have a minimum experience of 5 years of conducting and exercising quality control on major road and bridge works; maintains a fully equipped and modem laboratory and must have previous experience of being consultant on major road and bridge projects of MOST/MORT&H and State Govt.

The contractor shall submit complete Bio Data of ‘Quality Control Consultant” with necessary documents and performance certificates from the authority for whom worked previously for approval of the Chief Engineer (IP).

Necessary information on selection of Quality Control Consultant shall be furnished in the following format.

1. Name and style of the Consultant firm.

2. Registration, if any.

3. Approval, if any form the recognized institutions such as MOST(MORT&H), Pb. PWD; B&R; IRC; World Bank; Asian Development Bank/CRRL.

4. Yearly turnover

5. Projects handled in the last 5 years ( with copies of the agreements and performance certificate from authority for such consultances).

6. Address and Details of Laboratory facilities available with consultant firm. ( List to be attached of equipment).

7. Details of staff: including names, their qualifications and experience as employed in Main laboratory of consultant/laboratories established at completed projects.

8. Details of staff proposed to be employed at Project laboratory including their names, experience and qualification.

2. SETTING UP OF FIELD LAB

2.1 14’/16’

w 3 - 6”

20’/25’

W 3’- 6”

A suitable plan of (14’*20’) to (16’*25’) size field lab has been evolved. For accommodating necessary equipments, testing areas and Seating arrangements of Trained Staff. Any suitable size in these Limits be adopted for setting up field lab at site.

AGG/SOIL GARDING AREA

3’ – 0 SHELF

AT2'- 6”LEVEL

MARSHAL STABILITY MACHINE FOR JOB MIX FORMULA

AGG.TESTINGMACHINE

COMP.TETINGMACHINE

WATER TANK

TABLES & CHAIRS

D 3”- 0”

TRAINED STAFF/ITS EXPERIENCE

2.2 Field laboratory shall be manned by following Trained Staff;

Minimum Experience

1. LAB attendants 2 Nos. 2 years

2. LAB Assistant 1 No. 2 years

3. Research Assistants 1 No. 5 years

4. Engineer Incharge Lab. 1 No. Const. Experience of 5 years

List of equipments required in laboratory is appended as Annexure 2.3

2.3 LIST OF EQUIPMENT TO BE PROVIDED IN SITE LABORATORY2.3.1 General

S.No. Description of Equipment No.

i) Oven- Electrically operated, thermostatically controlled, range upto200ºC (sensitivity 1ºC).

1

ii) Platform balance(300 kg capacity) 1iii) Balance (20 kg capacity)- Self indicating type. 1iv) Electronic Balance; 0.6 kg capacity accuracy 0.1 gm; & 5 Kg. With accuracy

0.5gm;1 each

v) Water bath- Electrically operated and thermostatically controlled with adjustable shelves, sensitivity 1ºC.

vi) Thermometers:

Mercury-in –glass thermometer ( range 0ºC to 250ºC).Mercury-in-glass thermometer ( range 0ºC to 40ºC).Mercury in steel thermometer with 30 cm stem ( range upto300ºC

335

vii) Gas Cylinder Burner. 1viii) Glasswares, spatulas, wire gauzes, steel scales, measuring

Tape, casseroles, karahis, enamelled trays of assorted sizes,Pestle-mortar, porcelain dishes, gunny bags, plastic bags,Chemicals, digging tools like pickaxes, shovels, etc.

ix) Set of IS sieves with lid and pan for road worksCoarse Aggregate450 mm diameter sieves125,90,75,63,53,45,37,.5,31,26.5,22.4,19,16.5,13.2,11.2,9.5,6.7,5.6, and 4.75 mm.

2 sets

Fine Aggregate200 mm diameter sieves4.75mm,2.36,2.0,1.18,710u,600u,425u,355u,300u,180u,150u,90u and 75u.For Cement Concrete WorkCoarse Aggregate80mm,63mm,56mm,40mm,25mm,20mm,16mm,12.5mm,10mm and 4.75mm,2.36mm.

2 sets

2 sets

x) Water testing kitxi) First aid boxxii) Physical Balance

2.3.2 For soils and aggregates

S. No. Description of Equipment No.i) Riffle Sample Divider. For Soils & Aggregates 2ii) Atterberg Limits (liquid and plastic limits) determination

Apparatus2

iii) Compaction Test Equipment 4.89 kg rammers ( HeavyCompactive efforts)

6

iv) Density by sand replacement method- Apparatus both Small & Big size. 2

v) Speedy Moisture Meter complete with chemicals 1vi) Core cutter apparatus 10 cm dia, 10/15 cm height, complete

With doly, rammer etc.1

vii) Aggregate Impact Value Test aaaaratus 1viii) Flakiness and Elongation Test Gauges 1ix) Standard measures of 30, 15 and 3 liters capacity along with

Standard tamping rod1

x) CBR Testing machine with accessories and CBR moulds & CBR core cutter. As per IS2720-Part-XVI.

1

xi) Field CBR test equipment as approved by CRRI 1

2.3.3 For bitumen and bituminous mixes

S. No. Description of Equipment No.

i) Penertrometer automatic type adjustable weighing arrangements & needles as per ISI1203-1958.

1

ii) Riffle box-small sizeiii) Centrifuge type bitumen extractor, electric operated,

Complete with petrol/commercial benzene1

iv) Marshall stability test apparatus, complete with all Accessories as per ASTM-1559-62.

1

v) Field density sand replacement apparatus with cutting tray,Chisel, hammer and standard sand.

3

vi) 3 m straight edge Section 4”*13/4” 3

vii) Camber Templates 3viii) Core cutting machine with 10 cm dia diamond cutting edge 1ix) Vacuum pump and 3 specific gravity bottles 1x) Ductility Test apparatus for Bitumen 1xi) Laboratory mixture for Bitumen mixes of 0.02 cum capacity

Electricity operated fitted with heating jacket.1

xii) Test trays for checking Primer/ Tack coats. 5xiii) Hubbard- field stability test apparatus complete

2.3.4 For cement and cement concrete

S.No. Description of Equipment No.i) Vicat Needle apparatus for testing setting times with plungers 1ii) Slump testing apparatus 4iii) Compression and Flexural strength testing machine of 200

Tonne capacity with additional dial for flexural testing1

iv) Table vibrator as per IS2514-1963 1v) Air permeability apparatus 2vi) Vibrating hammer for vibrating dry mix as for Dry Lean

Cement concrete sub-base1

vii) Concrete mixer power driven of 1 cft capacity 1viii) Concrete mould 15*15*15 cm 24ix) Mould for testing compressive strength of cement 10*10*10 cm 12 Nos.x) Specific gravity balance & specific gravity Buckets as per IS-2386

-Part-III.2

xi) Diamond core cutting machine 1

2.3.5 Miscellaneous

i) Roughometer (automatically) 1ii) Profilograph for checking pavement unevenness 1

2.3.6 Laboratory at reach plant site shall be set up as per requirements with appropriate apparatus from above list which may be supplemented as per relevant I.S. code / IRC Guidelines /MOST specification for road and bridge works/ AASHO and ASTM standards.

2.4 TESTING KIT FOR SITE VISITS

1. Mason Thread2. Plumb Bob3. Aluminium heavy weight channel ‘6-0 straight edge4. Vernier caliper5. Spherometer6. Road Market

7. Metallic Tape-30M.8. Steel Tape-3M.9. 25*40 cm internal size steel frame with Angle iron straight edge on inner side.10. Kassi11. Hammer12. Chiesels13. Spatula14. Trowel

3. SALIENT FEATURES/SPECIFICATIONS FOR ROAD

WORK

SALIENT FEATURES / SPECIFICATIONS FOR ROAD WORK

3.0 The road work shall be executed in accordance with MOST / MORT&H. Specifications for Road & Bridge works ( revision upto date) duly supplemented with AASHO/ASTM standards as and where required. The important parameters for the various items of work are briefed here in after. It is mandatory to achieve the laid down parameters duly supported with field tests.

3.1 Parameters of specifications at a Glance

3.1 PARAMETERS OF IMPORTANT SPECIFICATIONS

Sr.No.

BriefSpecification

RelevantMOSTClause

Bitumen ContentRange

NominalSize of Agg.

Grading Range Grade Grade I II

Requirement of job mix formula

Compaction

Thick- TypeNess of of Layer Roller

Min. Density

Remarks

1. GRANULARSUB BASE(Close Graded)

401(Table400-1)

- -I.s. Sieve Passings75mm 100% -53mm 80- 100%26.5mm 100%

OMCVersesMax.DryDensity&CBR

Upto Smooth100mm wheelthick ed Above roller100 (Wt 80

98% of Max. DryDensity

GDI GDIICBR Min Min 30 25

WhenDirectedStr

GSB 70-100%9.5mm 55-90% 50-80%4.75mm 35-65% 40-65%2.3mm 25-55% 30-50%0.425mm 20-40% 15-25%0.075mm 10-25% 3-10% 3-10%

thick to to 100225mm KNMax. Vibratory roller

PI Max Max 6 6

ength shall beVerified byCBR/otherTests inLaboratory

2. WET MIXMACADAMWMM

406(Trade400-10,400-11)

- -53mm 100%45mm 95-100% 26.5mm -22.4mm 60-80%11.2mm 40-60%4.75mm 25-40%2.36mm 15-30%600mm 8-22%75mm 0-8%

OMCVersesMax.DryDensity

Upto Smoo100mm th wheel edRoller

100 to Vibra200mm tory Roller

98% of Max DryDensity

PI= Not more Than 6

Sr.No.

Brief Specifi-cation

RelevantMOSTClause

Bitu-menCont-entRange

NominalSize of Agg.

Grading Range Grade GradeIS 1 11Sieve Passings

Requirement of job mix formula

CompactionThick TypeNess of ofLayer Roller

Min.Frndity

Remarks

3. STRESS ABSORBING MEMBRANE Crack prevention course(a) Hair cracks and maps

522Table500-47

(Single coat)

Modified Binder (SBS)

8-10 Kg per 10m2

area

0.10m3 of 5.6mm chips

N.A N.A N.A N.A N.A N.A N.A

cracks upto 3mm width (b) Map crack ir alligator cracks 3mm to 6mm.© All types of cracks above 6mm width

(Single coat)

Single coat as inter layer

10-12kgper 10m2

area

10-12kgper 10m2

area



N.A N.A N.A

N.A N.A N.A

N.A

N.A

N.A

N.A

N.A

N.A

N.A

N.A

4. BITUMINOUSMACADAM

B.M(50-75MMThick layer)

504

Table500-3,500-4

3.3%to 3.5%by weightof totalmix.

19mmcrushedaggregate

26.5mm 100%

19 90-100%13.2 56-88%4.75 16-36%2.36 4-19%0.3 2-10%0.075 0-8%

OptimumBinderContentVerses Max.Density

Initial rollingWith 80 to 100KN smoothWheeled roller.

IntermediateRolling with Vibrating RollerOrR-15TPneumaticRoller

95% ofMaxDensity as per job mix formula

5. MIXED SEAL SURFACING(TYPE-B)For removal of undulations &ProfileCorrected of Blacktop surface.

512

(Table500-26)

19Kg/10m2

QuantityOf aggregate0.27 cumper 10m2

13.2mm 100%11.2 88-100%5.6 31-52%2.8 5-25%0.090 0-5% mm

Not required, ratio of C.A &F.A are to be fixed for achieving desiredgrading

80-100knsmoothwheeled roller

Minimum2gm/Case Computers( It will covermin 24.44m2

Area)

Note:- For undulations upto 25mm M.SS is to be Adopted.ForCorrection of more than 25mm

Thickness, BM is to be followed.

6. DENSEBITUMINOUSMACADAMDBM(50-75mmthick layer)

507(table500-8,500-9,500-10,500-10,500-11,500-12)

Min.4.5% bywt. Oftotal Mix

25mm 37.5mm 100%26.5 90-100%19 71-95%13.2 56-80%9.5 ---4.75 38-54%2.36 28-42%1.18 ----0.60 -----0.30 7-21%0.15 ---0.075 2-8%

Optimum Bitumen contents V/sDensity subject to Min stability=9KNFlow=2-4mmVoids=3-6%

Intially with 8-10 T smooth wheeled roller

IntermediateRolling with Vibratory roller

Or

12-15 Tpneumatic tyred roller.

98%of designed density

Filler is to be used 43 grade cement of Vikram, Sri or JK brand.

7. SEMI DENSE BITUMINOUS CONCRETESDBC

For 35-40mmLayer thickness grading-I

For 25-30mmLayer thicknes

508(table500-14,500-15,500-16)

Min4.5%of total mix

Min.5.0% of Total Mix.

13mm

10mm

19mm 100 100%13.2 90-100% 90 9.5 70-90% -4.75 35-51%100% 2.36 24-39% 35-1.18 15-30% 51%0.6 - 24-39%0.3 9-19% 15-30%0.15 - -0.75 3-8% 9-19%

--3-8%

Optimum Bitumen content v/sDensity

Min. stability=8.2 KNFlow=2-4mmVoids=3-5%

Initial with 8-10 T smooth wheeled roller

IntermediateWith vibratoryRoller

Or12-15 Tpneumatictyred roller

98% of DesignedDensity

Filler is to be used 43 grade cement of vikram, sri or JK brand.

s grading-II

i

8 BITUMINOUS CONCRETE

LayerThickness 30-45 min.9(Grading-2)

509

(Table500-17,500-18,500-19)

5% to7% bywt. Oftotal Mix.

13mm 19mm 100%13.2 79-100%9.5 70-88%4.75 53-71% 2.36 42-58%1.18 34-48%0.60 26-38%0.30 18-28%0.15 12-20%0.075 4-10%

Optimum Bitumen content V/s Density Subject to Min. Stability= 9 KN.

Flow=2-4mmAir Voids=3-6%

Initial with 8-10T smooth wheeled roller

Intermediate with vibratory roller

Or12-15 TPneumatic tyred roller

98% of designed density

Filler is to be used 43 gradeCement of Vikram Sri JKBrand.

9. PRIMERCOAT

502( Table 500-1)

7.50Kg.10m2

(M

C/SC)

---- ---- --- - Bitumen emulsion complying with IS-8887---

10. TACK COAT

503

(Table500-2)

2.5KgPer10m 2

(RC)

-- - - -do-

CONCRETE

For culverts & Small bridge.

Pb. PWDSpecification

---20mm

40 10020 59-67%-10 56-44%4.75 32-40%2.36 25-31%1.18 17-24%600u 12-17%

Nominal Mix 1:11/2 is to be used

--------------- Four consecutive samples Av. Strength

Grading curve of aggregate

M-20 concrete

300u 7-11%150u 0-2%

should be 20Mpa +2Mpa whereas IndividualSamples of 3Moulds AV. Strength May be20 Mpa+MPa

should fall between standard grading curve II & III. The designed curve should not cut or Inter mingle with standard curves.

DESIGN MIXCONCRETE

M-25,M30,M35 & M40Concretes

Mixes are to be designed for required slump & to be got approved on the basis of Trial Mixes strength of 7/28Days. Plasticizers, if

required, are to be used of make: FOSROC/ ASIAN /LABS.

3.2 BRIEF GIDELINES FOR CONSTRUCTION

3.2.1 EARTHWORK

(MOST SPECIFICATION CLAUSE 305)

The material to be used in embankments, subgrades, earthen shoulders and miscellaneous backfills shall be soil, moorum, gravel, a mixture of these free from logs, stumps, roots, rubbish, and any other ingredient likely to deteriorate or affect the stability of embankment/subgrade.

The selection material shall be made after conducting necessary soil surveys and laboratory investigation as set out in IRC 36-1970. Only approved materials shall be utilized. Borrow material for subgrade shall have designed CBR and other physical requirement.

To obtain asequate compaction, the embankment shall be constructed in uniform layers. Successive layers of embankment shall not be placed until the layer under construction has been thoroughly compacted to satisfy the specified requirement.

The moisture content of each layer of soil at the time of compaction should be optimum moisture content subject to permitted tolerance. (normally +1 percent to –2 percent).

After the moisture content has been adjusted, the soil shall be processed by means of grades, harrows rotary mixer unless the layer is uniformly met. Clods or hard lumps shall be broken to minimum size but in no case more than 75mm.

Compaction shall be done with vibratory roller of 80-100 KN static weight with plain or pad foot drum or heavy pneumatic tyre roller of 15-30 tonne weight having tyre pressure of at least 7Kg./cm2

The general process of compaction consists of giving two passes without vibration followed by three or four passes with vibration are thereafter one or two static pass to achieve requires compaction. The maximum thickness of layer will be limited to 200mm (compacted). The speed of the roller should be maintained at 60 metre/minute.

When the compaction is complete and surface appears perfectly in order and there are no sign of moving /bulging/springing/yielding under roller wheel and level/line/grade is in order, the quality shall be tested or compaction ( as per table) and moisture content.

Type of work Relative compaction as percentage ofMaximum. Laboratory dry density as per

I.S. 2720 (part 8)(1) Subgrade and earthen Not less than 97. Shoulders

(2) Embankment Not less than 95.

In case of failure under compaction, the bed will be considered for

(i) Further rolling with slight water sprinkling.(ii) Furrowing/ harrowing the top layer and rolling with sprinkling of water.(iii) Removing the soil in soft area and replacing with approved quality and

recomposing the same.

After finally completing the process, the compaction tests shall be done.

After full compaction and when surface is found in perfect order, the surface shall be tested for compaction and surface irregularity to be within below noted limits (MOST clause 903).

(a) Compaction Control Density test by Sand Replacement”(I.S. 2720 ( part 28).

(b) Moisture Content. As per I.S. 2720 ( Part-2)

(c) Tolerance in surface layer (+) 20mm and (-)25mm

Subgrade should be compacted with due attention and care to achieve laboratory CBR values determined on undisturbed samples cut from compacted subgrade in CBR mould fitted with cutting shoe or on remoulded samples, compacted to the field density at the field moisture content.

3.2.2 GRANULAR SUB BASE


Work shall consist of laying & compacting well graded materials on prepared sub grade in accordance with in requirements of MOST clause 401. The material shall be laid in are or more layers as required.

The material shall be spread with the help of a motor grader with hydraulic control to required slope, grade and line.

The sub base material shall consists of natural sand, moorum, gravel, crushed stone or combination thereof, depending upon the grading required free from organic and deleterious material.

The mixing shall be done mechanically.

Moisture content of the loose material shall be checked in accordance with IS:2720 (Part2) and suitably adjusted. The moisture content at the time of compaction shall be within 1 percent above to 2 percent below the optimum moisture content.

Rolling may be done with the help of a smooth wheeled roller of 80 to 100 KN weight if the thickness of compacted layer does not exceed 100mm. For a compacted single layer upto 225mm a vibratory roller of minimum 80 to 100 KN static weight with plain drum or pad foot drum or heavy pneumatic tyred roller of minimum 200 to 300 KN weight having a minimum tyre pressure of 0.7 MN/m2. Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for portions having uni-directional cross fall and super elevation and shall commence at the edges and progress towards the centre for portions having cross fall on both sides.

Each pass of the roller shall uniformly overlap less than one third of the track made in the proceeding pass. The speed of the roller shall not exceed 5 Km per hour.

Rolling shall be continued till the density achieved is at least 98 percent of the maximum dry density determined as per IS:2720 (Part8).

The surface on compaction shall be well closed, free from movement under compaction equipment and from compaction panes ridges, cracks or loose material. All loose, segregated or otherwise defective areas shall be made bad to the full thickness of layer and recompacted.

The finished surface shall be checked for line, level and regularity.

(i) Compaction Specified compaction will One test per 500m2 asbe 98% of maxm. Dry density per IS: 2720 (Part28)determined in lab as per density tests.IS:2720 (Part 8)

(ii) Moisture content As per I.S: 2720(Part2) One test per 200m2

(iii) Tolerance in surface (+)10mm MOST Table 900-1level (-)20mm (Clause 900-3)

3.2.3 WET MIX MACADAM


The work shall consist of laying and compacting clean, crushed, graded aggregate and granular, premixed with water, to a dense mass on a prepared sub granular base in one or more layers to necessary lines, grades and sections. The thickness of single compacted layer shall not be less than 75mm. The thickness to be laid with compacting equipment shall be got approved from the Engineer.

Arrangement shall be made to the lateral confinement of wet mix by laying materials in adjoining shoulders along with that of wet mix macadam layer.

Wet mix macadam shall be prepared in an approval mixing plant having provision for controlled addition of water and forced/positive mixing arrangement like pugmill or type mixer of concrete batching plant.

Water shall be added with due allowance for evaporation losses. The mixed material should be uniformly wet and no segregation should be permitted.

The aggregated mix shall be spread uniformly and evenly by a paver finisher or motor grade with hydraulic control capable of spreading the material uniformly all over the surface. The surface shall be carefully checked with templates.

The rolling shall be done by a smooth wheel roller of 80 to 100 KN weight if the thickness of single compacted layer does not exceed 100mm. For a compacted single layer upto 200mm, the compaction shall be done with the help of vibratory roller of minimum static weight of 80 to 100KN or equivalent capacity roller. The speed of the roller shall not exceed 5 Km./ hour.

Rolling shall commence from the lower edge and progress gradually towards the upper edge in portion having unidirectional cross fall/super elevation.

For portion with camber rolling should begin at the edge with the roller running for ward and backward until the edges have been firmly compacted. The roller shall then progress gradually towards the centre parallel to the centre line of the road.

Rolling should progress parallel to the centre line of the road, uniformly overlapping each proceeding track by at least one third width.

If irregularities develop during rolling which exceed 12mm when tested with a 3m straight edge, the surface would be loosened and premixed material added or removed as required before rolling again.

Rolling should be continued till the density achieved is at least 98 percent of the maximum dry density for the material.

The finished surface shall be well closed, from movement under compaction equipment etc.

After final compaction, the road shall b allowed to dry for 24 hours. No vehicular traffic of any kind should be allowed on the finished wet mix macadam surface till it has dried and the wearing course laid.

The surface finish shall conform to relevant requirements of Chapter-7. Inspection of mix, moisture, segregation will remain regular surveillance and any

suspicious, material will not be allowed to be carried to paver site. Weight of mix of every tipper, time of mix delivery will be maintained and daily to be retained.

The following tests shall be made for acceptance:

(i) Compaction Specified compaction will be One test per 500m2

98% mexm. Dry density as per IS:2720(Part28)determined in lab as per consisting of 10 density

I.S 2720 (Part 8) tests.(ii) Aggregate impact Maximum 30% IS:2386 One test per 200m3

value (Part 4) of aggregateOne test per 1003 of

(iii) Grading As specified aggregateOne test per 1003 of

iv) Flakiness and Maximum 30% aggregate.elongation test IS: 2386 (Part1)

v) Atterberg limit P.I >6 -do-vi) Tolerance (+) 10mm (-) 10mm As per Table 900-1 clause

900.3

3.2.4 PRIME COAT OVER WMM

(MOST SPECIFICATIONS CLAUSE 502)

The work shall consists of application of single coat of low viscosity liquid bituminous material to a porous granular surface preparatory to bituminous treatment.

The primer shall be bitumen Emulsion MC/SC grade complying with I.S. 8887 pf type and Grade as specified or as directed by the Engineer.

The bituminous primer shall not be applied on a wet surface or during dust storm or under the weather is foggy, rainy, windy, or unless the temperature in shade is less than 10C.

The primer distributor shall be pneumatic tyred self-propelled or towed pressure sprayer equipped for spraying the material uniformly at specified rate and temperature.

The surface to be primed shall be swept clean, free from dust and shall be shaped to specified line, grade and section. It shall be free from any irregularities and segregated materials.

The surface shall be allowed to cure for 24 hours following the application of primer and no traffic shall be allowed during curing period.

Test to be carried during application of primer coat includes.

(i) Quality of Binder Two samples per lot subject to approval of Engineer.(ii) Binder temperature At regular closer intervals.

For application.

(iii) Rate of spread of binder Two tests/day.(iv)Tray Test For control of rate of spread of Bitumen with

metal tray of 20cm*20cm.

3.2.5 TACK COAT


It shall consist of application of a single coat of less viscosity liquid bituminous material to an existing bituminous road surface to preparatory to superimposition of a bituminous mix.

The binder shall be Bitumen Emulsion (RC grade) complying I.S. 8887 of type and grade as Specified or directed by Engineer. The rate of application shall be as per contract and normal range of spraying temperature for Bitumen Emulsion shall be 20ºc to 700 C.

The binder distributor shall be pneumatic tyred self-propelled or towed pressure sprayer equipped for spraying the binder uniformly at specified rate and temperature.

The surface shall be cleaned of dust and any extraneous material before application of binder. It shall be left to cure until all the volatiles have evaporated before any subsequent construction is started. No plant or vehicles shall be allowed on the tack coat other than those essential for the construction.

Test to be conducted during application of tack coat shall include.

(i) Quality of Binder Two samples per lot subject to approval of Engineer.(ii) Binder temperature for At regular closer intervals

application. (iii) Rate of spread of Bitumen Two tests/day (iv)Tray Test For control of rate of spread of Bitumen.

3.2.6 BITUMINOUS MACADAM


The work shall consist of construction in a single course having 50mm to 75mm thickness of compacted crushed aggregates premixed with bituminous binder on a previously prepared base.

Proposal for Mix Design of BM will be submitted by Contractor one month before intended date of start along with samples of different size of aggregates, bitumen and fillers. Alternatives proposal with different gradations, without filler and different proportion of bitumen will be made trial mixes till satisfactory results are established and final mix design will be approved. Engineer shall have the right to take for fresh trial with needed modification during the execution of work.

The bituminous macadam construction shall not normally be carried out when the atmospheric temperature in shade is less than 100 C or when the underlying course is damp and wet.

Bituminous macadam shall be prepared in a computerised Hot Mix Plant which shall have essential features as laid down is MORT & H specification /contract specification. All the equipment, like Hot Mix-Plant, Paver, Rollers, tandom roller shall be checked for their work worthiness daily.

Binder and aggregate temperature shall be consistent with proper mixing and laying of the mix. The temperature of mix at the time of laying shall be in range of 1200 C to 1600 C.

Initial rolling shall be done with 80-100 KN static weight Smooth wheel roller followed by intermediate rolling with vibratory roller of 80-100 KN static weight or pneumatic tyred roller

of 150-250 KN weight. Final rolling shall be done with 60-80 KN tandom roller with vibratory system switched off. The rolling shall be continued till entire surface has been rolled to 95 percent of average laboratory density and rolling operation shall be completed in every respect before temperature of mix falls below 1000 C.

Longitudinal joints and edges shall be constructed true to the delineatory line parallel to centre line of road and all joints shall be cut vertical to the full thickness. Longitudinal and transverse joints shall be offset by at least 250mm from those in the lower courses and the joint on the top-most layer shall not be allowed to fall within the wheel path. All transverse joints shall be cut vertically to the full thickness of the previously laid mix with asphalt cutter/ pavement breaker and surface painted with hot bitumen before placing fresh material.

TESTS AT PLANT SITE

The following tests at plant site are to be conducted daily at plant site lab. and results follow the same or next day.

(i) Binder content and One test for 400 ton of Mixgradation test. (Minimum two tests / day / plant)

(ii) Stability of Mix One test for 400 ton mix for Marshal stability, flow, density void.Three specimens to form one test(Minimum two Tests / day / Plant)

(iii) Aggregate Impact value One test per 50m3 of aggregate.

(iv) Flakiness and elongation index One test per 503 of aggregate.

(v) Strippling value of aggregate Initially one set of 3 specimens for each source.

DAILY ROUTINE TESTS

Only approved material shall be used and same shall be checked before being fed in. Temperature of mixed aggregate, bitumen and mix shall be checked at plant site from the first

load. Sample for bitumen extraction and preparation of Marshall mould will be taken from second

tipper for adjustment of plant. If the result of extraction is much beyond limit, repeat test should be taken immediately to affirm the accuracy.

Points to be attached to regularly in day’s work and result of checking duly recorded:- Temperature of Bitumen in tank ( two hourly)- Temperature of aggregate in drier ( four hourly)- Discharge temperature of Mix ( every tipper wise)- Discharge time and dispatch of mix ( every tipper wise)- General appearance of mix specially with regard to coating, segregation and

appearance( every tipper wise)- Check up slip should be given to every tipper. ( Tipper carrying mix dispatched

should not be entertained without check slip)

OTHER PRECAUTIONS

Mix temperature exceeding 1700 C will rejected at Plant site. Mix temperature coming down 300 C at plant site be looked into for immediate correction. Mix having bitumen content more or less than 0.3% from job mix percentage will be reviewed

FIELD QUALITY CONTROL TESTS

(a)(i) stability of mix and flow Minimum 840Kg For each 400 ton one test(average of three mould three specimentsprepared out of one mix) Minimum two test per plant /day

(ii) Flow 2 to 4mm -do-(b) Binder content As per mix design One test for each 400 ton

and gradation per cent. Subject to minimum of two tests/plant/ day.

© Mix grading As per mix design One set of tests on individual and mixed aggregate from drierfor each 400 ton subject to minimum two t-est per plant/ day.

(d) Aggregate Impact Value >30 One test per 503 of aggregate.(I.S.2386 (Part-4)

(e) Flakiness Index and >30 ---do--Elongation of aggregate. (I.S.2386 (Part-I)

(f) Stripping value Maximum retained Initially one set of 3 specimencoating 95% from each source subsequently

when warranted.

(g) Density of compacted 98% of Lab (i)One test per 250m2

layer density (ii)10% of density test shall bedone on edges.

(h) Surface level and MOST clause 901 Tests shall be done as persurface regularity. Table 900-1 and 900-2.

3.2.6 SEMI DENSE BITUMENOUS CONCRETE


The work shall consist of construction in single layer 25 to 40mm thickness of compacted aggregates premixed with bituminous binder on a previously prepared bituminous surface.

Proposal for Mix design of semi dense bituminous concrete shall be submitted by contractor as detailed in para 3.2.6 with grading of mixed aggregates conforming to “Grading 1” of table 500-15 of MOST specification with minimum bitumen content of 4.5% by mass of total mix of specified grade with additional requirement of “Polished

stone value” of minimum 55” where the aggregates fail to meet the requirement of water sensitivity in Table 500-14 then 2 percent of total weight of aggregate, of cement shall be added without additional cost.

Other details as laid in para 3.2.6 shall be applicable. The newly laid surface shall not be opened to traffic for at least 24 hours after laying and completion of compaction.

Quality control tests shall include:

(a) Stone Polishing Value As required.(b) Rate of spread of mixed material Regular checks on the weight of mixed

material and layer thickness.

© Density of compacted layer One test for 250m2 area.(d) Water sensitivity of mix

3.2.7 DENSE BITUMINOUS MACADAM


The work shall consist of construction in a single or multiple layer with single layer thickness varying from 50 mm to 100mm of combined aggregates and filler premixed with bituminous binder lain in a previously lain in a previously prepared bituminous surface.

Proposal for Mix design of dense bituminous concrete shall be submitted by the contractor as detailed in para 3.3.6 before with grading of combined aggregate confirming to grading 2 of table 500-10 having filler in the form of cement as approved by the Engineer with grading conforming to requirement laid in table 500-9 and minimum bitumen cement of 4.5% by mass of total mix of specified grade as approved by Engineer. The Mix design shall meet the below noted requirement(Table 500-11)

Requirement for Dense Graded Bituminous Macadam.

Minimum Stability at 600 C 9.0KnMinimum flow 2.0mmMaximum flow 4.0mmCompaction level ( No. of blows) 75 blows on each of the two

Faces of the specimen.

Percent air voids 3-6Percent voids in mineral aggregates 10 to 12Percent voids filled with Bitumen 65-75

Other construction details laid down in para 3.2.6 shall be applicable. The newly laid surface shall not be opened to traffic for at least 24 hours after laying and completion of compaction.

Field and Plant site tests as laid in para 3.2.6 and 3.2.7 shall be applicable.

3.2.9 BITUMINOUS CONCRETE


The work comprises of construction in single layer of 25 to 100mm thickness of combined aggregates with bituminous surface content as per job mix formula on previously prepared bituminous surface.

Proposal for mix design of Bituminous concrete shall be submitted by the contractor as detailed in para 3.2.6 herein before with grading of combined aggregate confirming to grading 2 of table 500-13 having filler in the form of cement as approved by the Engineer with grading comprising to requirements laid in table 500-9 and Bitumen content of minimum 5% by mass of total mix of specified grade as approved by the Engineer. The mix design shall meet the below noted requirements.

Minimum Stability at (600 C) 9.0KNFlow 2 to 4 mnCompaction level ( No. of blows) 75 blows on each of the two

Faces of the specimen.

Percent voids in mineral aggregates 10 to 12Percent voids filled with Bitumen 65-75Loss of stability on immersion in water Min.75% retained strengthAt 600 C

Other construction details described in para 3.2.6 shall be complied with. The newly laid surface shall not opened to traffic for at least 24 hours after laying and completion of compaction.

Field and plant site tests as laid in para 3.2.6 and 3.2.7 shall be carried out.

3.2.10 MIX SEAL SURFACING TYPE B


The work shall consist of laying and compaction of close graded premix surfacing material of 20mm thickness composed of close graded aggregates with a bituminous binder on a pervious prepared surface.

Mix proportions shall comprise of 0.27 cum of aggregates per 10 Square metre area with grading conforming to type B of table 500-26 and 19.0 Kg. Of Straight run bitumen of specified grade as approved by the Engineer per 10 Sqm. Of area.

Hot mix plant shall be used for preparation of mix. The Plant shall have separate drier arrangement for heating of aggregates and mixing of aggregate and binder. The temperature of binder at the time of mixing shall be in the range of 150 to 1630 C and that of aggregates in the range of 155 to 1630 C provided that the difference in temperature between the binder and aggregate at no time exceed 140 C. Mixing shall be through to ensure a homogenous mixture in

which all aggregates are uniformly coated and discharge temperature is between 1300 C and 1600

C. The mixed material shall be spread by a Paver and rolling shall commence with 80-100 KN

smooth when tandem roller. Rolling shall begin at the edge and progress towards center longitudinally except that on the Super-elevated and unidirectional portion, it shall progress from the lower to upper edge parallel to centerline of pavement. Rolling operation shall be completed in every respect before the temperature of mix falls below 1000 C. No traffic shall be allowed on the road till the seal coat has been laid.

QUALITY CONTROL TESTS

(a) Quality of Binder Two samples per lot to be subjected to all tests.

(b) Aggregate impact value One test for 50m3 of aggregates

© Flakiness index and elongation -do-index of aggregates

(d) Stripping value Initially one set of 3 representative specimen of each source of supply.

(e) Water absorption of aggregates --do- (f) Grading of aggregates One test for 25m3 aggregates

(g) Stone polishing value As required (h) Temperature of binder at All regulars close intervals

application

(i) Binder content Two tests per day

(j) Rate of spread of mixed Regular control through checks as materialmaterial and layer thickness.

4. SALIENT PARAMETERS FORCONCRETE WORKS

SALIENT PARAMETERS FOR CONCRETE WORKS

4.1 MIX DESIGN

Proposal for concrete mix design shall be submitted by the contractor preferably one month in advance before the intended date of use of concrete in order to complete sampling of coarse and fine aggregates and cement and thereafter to proceed on checking of individual components and gradations and to finalize mix design.

All requirements of IS 456-1978, IS 1313-1980, IS-383-1970 and IS 10262-1982 shall form basis for mix design and proceed in the following manner.

a) Code of practices to be followed:

Gradation of different component of course aggregate as 20 and 10mm should be determined to find out a mixing ration to give gradation as stipulated in table 2 of IS 383-1970.

Grading zone of fine aggregate should be determined and fine aggregate as per IS 383-1970. Specify gravity of Coarse aggregate and fine aggregate as per I.S. 2386 has to determined. Water absorption of Coarse aggregate and fine aggregate to be determined as per I.S. 2386.

free moisture of Coarse and fine aggregate has also to be found out.

b) Selection of water –content Ratio Free water-cement ratio for desired mix grade shall be determined from Figure I in I.S.10262-

1982. The same shall be adjusted for compacting factor and sand zone as per Table 6. The water content shall be determined accordingly.

(c)Cement Content

Cement content will be worked out from required quantity of water and water cement ratio.

d) Fine aggregate & Coarse aggregate contents Finally Coarse and fine aggregate content is found out applying equations from 3.5.1 of I.S.

10262-1982. Due allowance for water absorption by Coarse aggregate and free moisture in sand shall be considered. Trial mixes shall be prepared on the basis of above mix and compressive strength of 150mm cube is determined at 7 days and 28 days cube strength. On observing the quality of mix, workability(to meet required slump) and cube strength, mix design will be finally condidered.

4.2 MATERIALS

4.2.1 STEEL

The steel to be used as reinforcing bars shall be high strength (TMT Rebars) conforming to grade FE-415 of I.S. 1786 of 1985. The steel to be used shall be arranged from original manufactures of steel Billed namely SAIL/Rashtrya Ispat Nigam Limited/TISCO and supplies shall be accompanied by Test Certificates from manufactures. The samples of steel will be sent to any selected laboratory and tests to be conducted shall include:

a) Nominal Diab) Cross-sectional areac) 0.2% proof. Stress.d) Yield stresse) Ultimate tensile strength.f) Elongation test on 1800 bend teste) Rebound test.

4.2.2 Cement

Cement to be used, shall be any of the following with prior approval of the Engineer(with brands limited to Vikram/JK/Sri)

OPC 33 grade confirming IS 269. OPC 43 grade confirming to IS 8112. OPC 53 grade confirming to IS 12269

Each lot of supply of cement shall be accompanied with test certificate from the manufacturer and shall be subject to following tests.

a) Fineness testb) Consistency test.c) Initial and final setting time.d) Compressive Strength test.

4.2.3 Coarse aggregate

Crushed gravel, natural gravel or a combination three of clean, hard, strong, dense, non porous and durable shall constitute coarse aggregate. It shall confirm to IS 383 and tests will be carried as per IS 2386 Part-VIII.

4.2.4 Fine aggregates

Natural sand ( clean and free of deleterious materials) shall conform to I.S. 383 and conformity test shall be carried out as per I.S. 2386 Part I to VIII. Information shall be submitted as per Annexure A of I.S. 383. Fineness modulus shall not be less than 2 nor greater than 3.5 and shall confirm to either of the grading of Zone-I, Zone-II of Table 4 of I.S.383.

4.2.5 Water

It shall confirm to MOST clause 1010 expect that “in para © “ the permissible limit for chloride (CI) shall be read as 250 mg/Itr. For structures having length more than or equal to 30 metre.

4.2.6 Form work All form works for concrete shall be properly designed and planned as per IRC:87” Guide lines

for Designs and Erection of false work for Road Bridges. The contractor shall furnish the detailed information and design of form work for approval with necessary calculations. Design shall confirm to IRC:67, In case of Prestressed concrete Superstructure, careful consideration shall be given to loads on props due to prestressing.

Form work shall be strong and joints shall be leak-proof. Staging shall consist of pipe work of steel with non-tempering joints having adequate cross bracings and diagonal bracings in both directions. Staging shall be provided with appropriately designed base plate resting on firm strata. There shall be no play between any of the members of the staging and it shall be securely fixed.

For distribution of load transfer to the ground through staging, an appropriately designed base plate shall be provided which shall rest on firm sub stratum.

On completion of form work, contractor shall inform for inspection and approval of Project Engineer. Invariably in all concreting, form work shall be examined with respect to stability, workmanship, and dimensional correctness as per drawings and design. All form works shall be thoroughly cleaned immediately before concreting. Precaution as per MOST clause 1506 shall be duly compiled and ensured.

Removal of formwork:- Programme for removal of form work ( i.e. de-shuttering and de-centering) shall be finalized by contractor for scrutiny and approval. Removal shall not be taken without prior approval. Time of removal of form work shall be as under (minimum).

a) Walls, Piers, abutments, columns and vertical faces of : 48 hoursstructural members

b) Soffits of Slabs ( with props left under) 3 daysc) Props (left under slabs) 14 daysd) Soffits of Girders (With Props left under) 7 dayse) Props (left under girders) 28 days

4.2.7 Steel Reinforcement:

Placing of reinforcement shall be done in accordance with specification laid in MOST clause 1605. Reinforcing steel shall confirm to the dimensions, dias, spacing and shapes in the approved bar bending schedules. Placing of reinforcement spacing, overlapping, spacer bars, cover block, stays. Blocks. Chairs, supporting wires shall be property checked. The concreting work shall be taken up only after approval of placing of reinforcement of Project Engineer.

4.3 TEST AND STANDARDS OF ACCEPTANCE

Concrete shall confirm to surface finish and tolerance for respective component as:

COMPONENT TOLERANCEa) Variation in dimension

b) Misplacement from specified position in planc) Surface irregularities measured with 3 metre Straight edge.d) Variation at level at top

a)Variation in C/S dimensionb) Position in planc) Variation of levels at topd) Variation of reduced levels of bearing arease) Variation from plumb overall full height.f) Surface irregularities measured with 3 metre Straight

(+) 50mm(-) 10mn15mm

5mm

+25mm

(+) 10mm(-) 5mm10mm±10mm±5mm±10mm

edgeAll surfaces except bearing areas Bearing areas

a) Upto 2 metre and including 2 metre.Over 2 metre

b) Variation in overall length and overall length between bearingsc)Permissible surface irregularity under measured with 3 metre straight edge or template

a) Variation in thickness of top and bottom slab for box Girder, top and bottom fringe or T-Girders or slabs

(b) Variation in web thickness

© Variation in overall depth or widthd) Variation in overall length and length between bearing

e) Permissible irregularities when measured with 3 metre straight edge or template.

5mm3mm

±5mm

Shall not exceed ±10mm±0.1% of span length whichever is lesser.5mm

-5mm to +10 mm

-5mm to +10mm

±5mm

Shall not exceed ± 10mm ±0.1% of span length whichever is less

5mm

Test samples for 7/28 days compressive strength shall be sampled and tested in following way.

a) Concrete for making test cubes shall be taken from a batch of concrete at point of delivery as per IS 1199 ( Three test specimens shall be for each sample for testing at 28 days. Additional cubes shall be taken to determine strength of concrete at 7 days).

b) A random sampling procedure shall be adopted.c) 150 mm cubes shall be made, cured and tested at the age of 7 and 28 days for

compressive strength as per I.S.516.

4.4 MAJOR ROAD BRIDGES

Contents of IRC:SP:47-1998’ Guidelines on Quality Systems for Road Bridges shall be applicable for major bridge work.

4.5 The following guide lines are given for quality assurance of construction of bridges:

a) For construction of H/L Bridge/ ROB’s minimum quality assurance level Q-3 is to be achieved.

b) For construction of culvert and small bridge minimum quality assurance level Q-2 is to be achieved.

c) In special cases where very large span are involved or high performance concrete and new prestressing system are operative, the quality assurance level will be kept Q-4.

4.6 EXTRACTS OF IRC SP :47 :1998

Sr. no. Item Normal QA Q-2

High QA Q-3

Extra High QA Q-4

1.1.1

MATERIALSGenerala)Material from natural sources

b) Factory manufactured items including cement, steel

Small or medium scale purchases from large and established suppliers/traders.

Source mutually agreed to between contractor and owner’s project terms and documented

May rely on local experience and knowledge of the past performance for coarse and fine aggregates and water.

Manufacture’s tests certificate accepted

As in Q-2. Also bulk purchase form source

Independent testing /acceptance by contractors’& owner’ Q.A teams and documented.

Testing/ acceptance at the start of the project as well as at specified frequency.

Manufactures test certificates with sample checks for initial

As in Q-3, but may also set up own source for supply.

As in Q-3, but with additional (third level) testing/ acceptance by independent agency (such as PMC or Approved Testing Laboratory)

Same as Q-3

Same as Q-3

bearings, expansion joints etc.

c) Records for all materials

d) Testing facilities

with sample check by independent agency for incorporation in structure.

ISO:9000 certificate not essential for manufactured items.

Record of sources and purchase dates for all items.For Manufactured items record of manufacturers’ test certificate.

Testing from nearby established test houses/laboratories.

acceptance only.

Regular testing at specified sampling frequency during construction

Set up mutually agreed QA methods at two levels for inspection/testing to cover the specific purpose order.

In case the manufacturer has ISO:9000 certification, he may be given preference.

As in Q-2. Also record of issue of manufactured materials and location of use.

Physical testing facilities at site. For chemical & Special tests as per Q-2. Use of chemical testing kits for quick checks at site are to be preferred.

As in Q-3, but may also have additional independent QA checks at source (third level check)

As in Q-3, but third level checking by checking by checking appointment of specialized agency for innovative aspects.

As in Q-3

Same as Q-3

As in Q-3, with property equipped testing facilities and laboratory at site under control of QA personnel of

1.2 a) Aggregate coarse aggregates Grading

Other physical tests (crushing value abrasion moisture contents etc.)

Deleterious contents

Aggregate reactivity

b) Fine aggregate (sand)Grading

Other physical tests (crushing value abrasion moisture contents etc.)

Deleterious contents

For control of chlorides etc.

At the beginning for mix design & for every charge of source.

For selection of source if in doubt.

For selection of source if in doubt

Not Applicable

At the beginning for mix design & every change of source

For selection of source if in doubt.

For selection of source if in doubt

Simple but frequent chemical checks at site for effectiveness

At the beginning for mix design and for every change of source/stack and for every major structural element.

At the beginning for mix design and for every change of source

Mandatory for selection of source & whether there is change in source of supply.

Mandatory for selection of source and whether there

At the beginning for mix design and for every change of source.

At the beginning for mix design and for every change of source.

Mandatory for selection of source & whenever there is charge in source of supply.

As in Q-2

External laboratory

contractor & owner (independent of production team).

As in Q-3, but if necessary with increase frequency , (testing at site laboratory).

As in Q-3,(two level checks at site laboratory).

Same as Q-3

Same as Q-3

As in Q-3, but if necessary with increased frequency,(testing at site laboratory)

As in Q-3 (two tier checks at site laboratory)

Same as Q-3

As in Q-2, supported by checking at testing laboratory at site.

1.3

1.4

1.5

Water Suitability Chemical analysis

Cement Normal physical and chemical tests.

Form of purchase storage, transportation, and use within acceptable time limit.

Admixtures a)Approval

At the beginning Carried out if in doubt

Manufacturers certificate acceptable & testing in case of doubt or non-availability of certificate.

Trade purchases, intermediate storage in dry and covered place, transportation and use of factory filled, machine stitched bags.

May be permitted under specialist supervision in which case follow Q-3 controls.

checks/control (two level control)

Same as Q-2 Mandatory at the beginning of project and repeated ( for chlorides and sulphates) in between if any change is perceived/ suspected in water quality (including seasonal changes)

As in Q-2 and at frequency of each new consignment & documented. Special tests will be required for special for special cements.

Supply from factory with direct transportation from factory to site godown / silos. Transportation and Transshipment supervised and documented.

Independently carried out acceptance testing after field trails for each sources.

Re-trials with change in Source of Cement.

Routine checking by testing for every batch of admixture.

Same as Q-2 As in Q-3, but at increase frequency during working.

As in Q-3, testing carried out at site laboratory & independently crosschecked at predetermined frequency.

Same as Q-3

As in Q-3, with additional independent tests.

i) Chloride contents.

ii) Spectroscopic signature of accepted product as basis of comparison for production lots.

1.6

b) Dosage dispensing and production controls at site

c) Training of site staff by manufacturer.

Reinforcing Steel Normal Physical tests

Chemical Composition

Dosage to be finalized after field trial mixes, special mechanical devices to be used for dispensing.

Frequent checks for specific gravity.

Continuous monitoring of work ability of concrete.

Visual inspection of concrete after striking forms for local defects (including delayed setting).

Proper training of site staff in use as well as quality control, plus periodic visits by manufacturer’s expert.

Once at beginning and for every change in source in addition to manufacturer’s certificate.

Once at beginning and if in doubt for any source.

Manufacturers’ date/ certificate acceptable as basis of comparison for production lot.

Same as Q-2

Same as Q-2

As in Q-2, and for each consignment

Same as Q-2

Same as Q-2

As in Q-2, but visits b experts at close frequency.

As in Q-3, but further supplemented by random checking by QA team.

Same as Q-2

1.7

Welding

Prestressing Steels/ Anchorage systems & cable anchorage assembly:

a) General ( for all items of prestressing including equipment.)

Storage

Compatibility of various components.

Not ordinarily permissible at site.

In a sealed and moisture proof godown with minimum openings store above ground level on raised supports or in racks.

Such godown will have humidity control

In additional vapour face inhibitors and / or water soluble oils to protect steel.

Suitability of anchorages for use with wires / standards (meeting relevant specifications) to be certified by the

Welding to be done only by qualified and tested welders.

Types of electrodes to be specified for each purpose.

Random testing of welded joints for strength.

Same as Q-2

Same as Q-2

Same as Q-2

As in Q-3, but welders to be periodically tested and also welding to be examined by experts after destructive tests.

Same as Q-2.

Same as Q-2

As in Q-2, but compatibility established at site as required by QA team.

Methods of handling & care taking

b) HT Wires/ stands Mechanical Properties ( Tensile Strength, Proof Stress).

Modules of Elasticity

c) Anchorage System ( Chemical Composition & Heat Treatment, Supplementary Tests).

manufacturer of anchorages. Also compatibility of all other materials and equipment to be thus certified/ cleared.

Also the manufacturer to supply special assistance at site, if required, to train and supervise personnel at work.

Manufacturer’s test Certificate can be accepted. Additional Testing if in doubt.

Insist for manufacturer’s certificate giving stress. Strain curve & modules of elasticity. Sample testing witnessed by independent QA team.

Contact with contaminated surfaces avoided.

Permitted using anchirage or established manufactures of long standing based on certification of suitability & quality by manufacturer.

Same as Q-2

In addition to manufacturer’s certificate, tests done on random samples for a lot of 50 T, or part there of and witnessed by independent QA team of random.

Same as Q-2

As in Q-2, but supported by manufacturers detailed QA plan ( which can be verified by purchaser if necessary).

Same as Q-2

As in Q-3, but every coil, Sample testing witnessed by independent QA team at specified frequency.

Same as Q-2

As in Q-3, but in addition QA plans should be independently checked by QA team and verified at manufacturer’s facilities.

d) Cable Anchorage Assembly

(Acceptance Testing)

Static Tensile test & load transfer test.

Dynamic Test for Cable/anchorage assembly

e) Sheathing cable Dust

Supply

Not normally required.

Not normally

Purchase from, manufacturers with

Manufacturers certificate.

May additionally require testing at site or at independent laboratory as per FIP Guide.

Manufacturers certificate of testing

Also independent laboratory testing as per FIP Code, once for new system of anchorage/ cables.

Same as Q-2

Manufacturers certificate and certificate by testing at independent laboratory as per FIP Guide. Tests may be repeated at the beginning of the proposed materials and witnessed by the representatives of contractor\ owner.

As in Q-3, plus any additional test than a QA team may required

As in Q-3 but preferable to

1.8

1.9

2.2.1

Workability and transverse bending test as per IRC:18

Any other materials (like expansion joints, bearings, railing etc.)

New Materials

WORKMANSHIPGeneral Controls ( Direct & Indirect )a) working & supervision

metallic sheathings coated with water soluble rust-preventive oil.

Test certificate by the Manufacturer for each lot to be furnished.

Manufacturers Certificate supported by sample testing.

Normally not to be used. If used same as Q-3

Skilled and semiskilled workers.

As in Q-2, but additional independent test to be done on random samples.

As in Q-2 with higher frequency of testing andQA plan of manufacturer to be initially approved.

To be accepted by competent technical authority for use thoeity for use after full testing at laboratory/ and field trials.

Special specification for properties testing and acceptance criteria to be evolved and laid down for use at site.

Skilled workers having special training and working under experienced supervisors. ( where trade qualifications are existing should be insisted upon).

fabricate sheathing freshly at site at the required rate.

As in Q-3, but at higher frequency plus any additional test that QA team may require.

As in Q-3 with implementation of QA plan of manufacturer to be audited by QA team of owner to the extent depending on the importance of the team.

As in Q-3 Supplemented by independent checking by QA team of specialist consultants.

Same as Q-2

b) Use of Mock-ups

Periodic vision from owner of his agent.

Periodic check by designer during site visit.

Not ordinarily required.

Full time supervision from contractor as well as from owner or his agent.

As in Q-2, but at predeter mined stages and frequency.

Document inspection and certification of certification of compliance by designers representative.

For-Q-3 quality mock ups are required only for certain elements (typical slice and difficult zones ) which should be specified in tender document. Mock-ups to be carried out in presence of designer and QA team of owner.

Mock-up should use actual proposed methods of construction, including plant and equipment.

Mock-up should use actual proposed methods of construction including plant and equipment.

As in Q-3 but with occasional supervision by expert external agency.

As in Q-3 expect in case of bridges having new technology/ design full time site representative of design agency will be necessary.

Same as Q-3.

As in Q-3, but made mandatory for all difficult and important zones.

Also, mock-ups dealing with new techniques to be carried our under supervision of expert external agency

2.2Concrete mix design.

Notes:Full scale mock-ups of part of structure are made for various purpose as follows:1) Verification of proper detailing and choice of concrete of mix and making modification in either or bot to achieve satisfactory concreting.

2) To establish effective methods of transporting, placing and compacting.

3) Training of workers for operation in (2) above.

4) To demonstration efficacy of the overall construction operations in achieving its aim.

Mix design performed at beginning of work or for new source of materials with subsequent Q.C. as per code and by experienced supervisors.

No work on structure should be permitted before demonstrative mock-up.

As in Q-2 with minimum two level controls.

As in Q-3

As in Q-3.

2.3

2.4

Fabrication and fixing of reinforcement.

Fabrication & fixing of presenting cables.

Relaxation Test

Chemical Composition

Packing

Transportation

Site bending by skilled workers with regular checking by qualified supervisor

Bar bending schedules are made and checked before use.

Correct placement of reinforcement and provision of proper cover checked independently before concreting.

Normally not applicable. If used follow Q-3 practices.

Manufacturers’ certificate

Manufacturer’s Certificate can be accepted with special with special testing, if in doubt.

Packing with two layer for water proofing and mechanical protection.

Transport vehicle check.

Same as Q-2

Same as Q-2

As in Q-2, but checked and documented by QA team.

Modules established initially (acceptance test)

Testing & certification essential for 1000 hours test by independent test house.

As in Q-2, plus testing by independent agency on random sample basis.

Same as Q-2.

Same as Q-2

Same as Q-2

As in Q-2 expect bar bending schedule made by design office only.Same as Q-3.

Modulus established initially and verified by work by work test.

As in Q-3, also tests to be witnessed by contractors/ owners/owners QA team.

Same as Q-3.

Same as Q-2

Same as Q-2

Suitable of coil size/ weight for use at size.

a) Clearing

b) Preparation of steel /cables.

c) Laying & supporting

Protection from environment of physical damage.

Coils handled by mechanical devices prohibiting movement by rolling.

The wire/ strand should and be free of skinks or deformations and straight.

Same as Q-2

Should be free rust Light on wires (not strands) can be removed, wires cleaned and used.

Pre-fabricated and sheathed cable can be permitted.

However, post threaded wires/ strands just before stressing are to be preferred.Cables strictly prepared on raised/ clean benches and kept free from dust at all times.

Cable Layout giving co-ordinates at close intervals as needed by fixing requirements (and not by theoretical curves or equations alone), and supported

Same as Q-2

Only unrusted steel can be used.

Only post threading of wires/ strands permitted (with exceptions if unavoidable).

Same as Q-3

As in Q-3.

2.5FORMWORKa) Materials

b) Design Check

c) Specialist System.

d) Experienced carpenters/fitters.

Any Suitable materials meeting codal requirement s and capable of giving specified form finish.

Spot check.

Specialized formwork systems need not be insisted upon.

Semi- skilled/ Skilled carpenters. Fitters under supervisory staff.

firmly in place, Post threaded cable ducts should be held against floatation during concerting Layout and leak tightness of sheathing to be independently checked and documented by owner’s Q.A. Team of his agent.

Same as Q-2.

Formwork/ design made and approved independently.

Specialised formwork system, to be preferred with properly trained carpenters/ fitters.

Skilled carpenters/ fitters under supervisory staff with the work supervisory

As in Q-3, with additional checking and testing required by QA teams sample checking by expert external agency.

As in Q-2 with regularly and properly maintained shuttering with limited reuses. Shuttering capable of absorbing Air released from concrete and providing goodInsulation t control thermal gradients is to be used. If steel shutter are used, plywood liners or provision of sackrubbing after deshuttering.

Same as Q-3

Same as Q-3.

Same as Q-3.

2.6

e) Tolerances, geometry and leak tightness checks.

f) Deshuttering

g) Formwork for special structure.

Mixing/ Conveyance, placing /Curing of concrete.

Frequent check by carpenters/fitters and checking of important members by supervisory staff.

Under supervisory staff for important members.

Not applicable

Site mixing by mixers or batching plant near site. Occasional two tier control and documented. Transportation by head loads trollies or by mechanized vehicle permitted.

additionally by owners supervisors and agents.

Check for all members by supervisory staff.

As in Q-2. The system should provide should provide for gradualuniform and shockfree deshuttering arrangements.

As per design requirement under control of qualified staff, with additional supervision by owner’s supervisor or agents. Checks by QA team till procedure at site are established.

As in q-2 under two level controls, upto 200m length bridge beyond which batching plant is mandatory.

Use specialized equipment for transportation. The adverse effects of the methods of conveyance(segregation delys stiffening of mix etc.), should be regularly monitored

As in Q-3. Also check for quality of shutter surfaces before reuse & document clearance.Same as Q-3.

Same as Q-3.

Same as Q-3.

Batching plant is mandatory Occasional checks by expert external agency.

As in Q-3

2.7Stressing Cables

Stressing equipment

Check of friction and wobble losses.

Experienced concerting gangs under supervisory staff.

Placing concrete and compacting under supervisory staff.

Normally not applicable if used follow Q-3 practices.

controlled and documented.As in Q-2, with tow level controls. Also regular control by qualified staff. Method of control by pour card recommended.As in Q-2. Also regular control by qualified staff. Surveillance by QA team.

Stressing equipment calibrated tested and certified by manufacturer/supplier.Checking and recalibrated at site at regular predetermined frequency by qualified staff under supervision of owner and his agent.

Only under strict supervision of stressing supervision and site engineer. The manufacturer to supply special assistance at site to train personnel and supervise work

Sample basis check for elongation/pull in of all wires/ strands in the cable assembly (uniformity of stressing).

In-site check on losses by stressing from on side jack using as active and other as a passive

Same as Q-3.

Same as Q-3Efficacy of methods to be regularly checked and demonstrated.

As in Q-3 in presence of independent expert or by QA team.

Same as Q-3 with surveillance by expert agency / or QA team.

Same as Q-3.

As in Q-3 with additional tests as required by QA team.

2.8Grouts & Groutingsa) Grouting of Prestressing Cables.

Composition and Physical properties

Fluidity test bleeding characteristics during working

Equipment

Workers/ Supervisor

Admixtures

b) Grouting with non cementitious special material.

Normally not applicable. If used then follow Q-3 practice.

jack on a sample basis.(For long cables and high total deviation the passive jack may not register pressure within strock length of active jack For such cases special tests or provision of short cables may be required.

At the beginning of work for designing suitable grouts. Physical properties to be verified once in a week or with change of batch of cement of admixture.By visual inspection

Equipment tested & passed for satisfactory performance regularly.

Trained staff under qualifiedSupervision.Surveillance by QA Team.

Where used as per item 5.5Where used as per item 5.5

Normally not required. If used follow q-4.

As in Q-3 which check for every operation.

As in Q-3 but tested and documented for every operation.As in Q-3 with testing witnesses by independent QA team.Same as Q-3.

As per item 5.5

Materials like grease, powder coatings, or other specially formulated mixes

c) Cement Grouting for bolts and fixing apparatus.

Use of special perpacked high strength non-shirnk grouts preferred.

As in Q-2 with regular sample check for efficiency.

should be used only after through testing for suitability including long term effects and by following specially developed suitable methods under expert supervision.As in Q-3 with increased frequency of checking.

iii) Workability of fresh concrete slump test.

IS : 1199 Once test per each dumper load at boyh Batching Plant site and paving site initially when work starts subsequently sampling may be done from alternate dumper.

Iv) Thickness determination.

From the level data of concrete pavement surface and sub-base at grid points of 5/6.25mx3.5m.

v) Thickness measurement for trail length

3 croes per trail length.

vi) Verification of level of string line in the case of slip from paving and steel forms in the case of fixed from paving

String line or steel forms shall be checked for level at an interval of 5.0 m or 6.25 m. The level tolerance allowed shall be +2 mm. These shall be got approved 1-2 hours before the commencement of the concerting activity.

4.7 FREQUENCY OF TESTS FOR CONCRETE WORKS

1. Cement Physical and ChemicalTests.

IS :269IS:455IS:1489IS:8112IS:12269

Once for each source of supply and occasionally when called for in case of long/ improper storage Besides the contractor also will submit daily test data

on cement released by the manufacturer.

2. Coarse and fine aggregates.

i) Gradation IS:2386(Pt.1)

Once test for every day’s work of each fraction of coarse aggregate and fine aggregate initially may be relaxed later at the discretion of the Engineer.

ii) DeleteriousConstituents

IS:2386(Pt.2)

Once test for every day’s work of each fraction of coarse aggregate and fine aggregate initially may be relaxed later at the discretion of the Engineer.

3.CoarseAggregate

i) Los Angles Abrasion value or aggregate Impact test.

ii) Soundness

IS:2386(Pt.4)

IS:2386(Pt.5)

Once for each source of supply and subsequently on monthly basis.Before approving the aggregates and every month subsequently.

iii) Alkali Aggregates reactivity. IS:2386(Pt.5)

--do--

4. Water Chemical Test.. IS:456 Once for approval of source of supply subsequently only in case of doubt.

5. Concrete i) Strength of concrete. I.S.516. 2 cubes and 2 beams per 150m3 or part there of (one for 7 day and other for 28 day strength) or minimum 6 cubes and 6 beams per day’s work whichever is more.

ii) Core strength on hardened concrete.

IS516 As per the requirement of the Engineer only in case of doubt.

iii) Workability of fresh concrete slump test.

IS:1199 Once test per each dumper load at both Batching Plant site and paving site initially when work starts subsequently sampling may be done from alternate dumper.

iv) Thickness determination From the level data of concrete pavement surface and sub-base at grid points of 5/6.25mm*3.5m.

v) Thickness measurement for trail length.

3 croes per trail length.

vi) Verification of level of string line in the case of slip from paving and steel forms in the case of fixed from paving.

String line or steel forms shall be checked for level at an interval of 5.0 m or 6.25m. The level tolerance allowed shall be ±2 mm.These shall be got approved 1-2 hours before the commencement of the concerting activity.

5. QUALITY CONTROL TESTS AND THEIR FREQUENCY

QUALITY CONTROL TEST & THEIR FREQUENCY

The Quality control consultant alongwith Project Engineer of Contractor at each site shall be responsible to ensure that materials as used at site and work as executed meets the specification as laid down in the Contract and relevant standards. The activities for compliance shall include:

a) Setting up of laboratories at site including plant site as per requirement and equipment from reputed manufacturer confirming to IS or relevant standards.

b) Determining frequency, location, number and type of tests to be conducted.c) Supervision of sampling and testing carried out at site and their record including to testing carried out

at other approved laboratories.d) Checking regularly the calibration accuracy and operation of testing equipments and plants.e) Checking on Contractor’s proposal for all materials to be incorporated in works and for materials

specified in the contracts, including labeling and recording particulars of samples and sokly storing them in the laboratory until they are no longer required.

f) Checking the sampling, testing and inspection of all materials comply with the norms specified in the Contract.

g) Checking details of all trail mixes and finalization of job mix formula including necessary modifications as a result of variation in source of materials.

h) Asking any special tests that may be required.i) Removal of improper materials, if necessary.

The equipment as required for a typical laboratory has been detailed in chapter-I. The number of each equipment can be varied by the Project Engineer. The frequency for various quality control tests has

been detailed in table appeared herewith for guidelines. The Quality control consultant and Project Engineer of the contractor will carry out 100% checking as per frequency indicated therein. The Project Engineer will carry out at least 5% of the checking. S.E.(QC), Punjab PWD will also carryout checking to his satisfaction and shall have the right to ask for additional tests as may be deemed fit.s

The contractor shall provide necessary co-operation and assistance in obtaining the samples for tests and carrying out the field tests as require by the Project Engineer and SE (QC) including providing labour, attendants, assistance in packing and any other assistance.

For work of embankment, subgrade and pavement construction of subsequent layer of same or other material over the finished layer shall be done after obtaining permission from the Project Engineer. The contractor shall carryout notification in the procedure of work, if found necessary as directed by the Project Engineer / SE (QC) during inspection. Works falling short of quality shall be rectified /redone by the contractor at his own cost, and defective work shall also be removed from site of work by the contractor at his own cost.

5.1 Earthwork

Table 1- Control tests on Borrow Materials : Pre-Construction

Sr.No.

Test Test Methods Minimum Desirable Frequency

a. Gradation IS:2720Part IV-1965

1-2 tests per 8000 cum of soil

b. Plasticity Index IS:2720Part V-1963


c. Modified proctor IS:2720Part VIII-1965


d. CBR (on a set of 3 specimen) IS:2720Part XVI-1965

One test per 3000 cum

e. Deleterious Constituents IS:2720 Part XXVI-1988 AS requiredf. Natural Moisture

ContentIS:2720Part II-1973

One test for 250 cum of soil.

Table 2- Control tests for Compaction of embankment/Fill: During Construction

S.No. Test Test Method Minimum Desirable Frequency

a. Moisture Content before Compaction

IS:2720Part II-1973

2-3 tests per 250 cum of loose soil

b. Compacted Layer Part XXVIII-1966 One test per 1000 cum for embankment construction and one test per 500 cum for subgrade compaction.

Control tests for embankment/ Fill : Post Construction:

Tolerance in Surface Level Max. no. of undulations permitted in any 300m length, exceeding 18 mm Max. permissible variation from specified profile under camber template.

5.2 Granular Sub-Base

Table3-Control tests on Sub-base materials: Pre-Construction


a. Aggregate Impact Value or Los Angles Abrasion value

IS:2386PartIV-1963


b. Plasticity Index of filler Material Gradation

IS:2720Part V-1963

One test per 25 cum

c. Water absorbtion of Aggregates IS:2386Part III-1963


d. Deleterious Constituents IS:2720Part XXXVII-1968

As required

f. CBR test( Soaked) IS:2720 Part XVI-1965

As required

Table4- Control tests on Sub-base Materials : During Construction


a. Moisture Content Before compaction IS:2720Part II-1973


b. Density of Compacted Layer IS:2720Part XXVIII-1966


c. Thickness of Compacted layer As required

Control tests for Granular Sub-Base : Post Construction

Tolerance in Surface Level : ±10mm

Max. permissible undulation ( with 3 m straight edge) 8mn

Max. no. of undulations permitted in any 300 m length, exceeding 30

Max. permissible variation from specified profile under camber template 12

5.3 Wet Mix Macadam

Table5- Control tests On Base Materials: Pre-Construction

S.No. Test Test Methods Minimum Desirable

Frequencya. Los Angles Abrasion value/A.I.V. IS: 2386

Part IV-1963One test per 200 cum

b. Grading of Aggregates and Screening IS:2386Part I-1963


c. Flakiness Index of aggregates IS:2386Part-1983


d. Plasticity of binding Material IS:2720Part V-1970

One test per 25 cum

Table6- Control Tests for Base Course


a. Moisture Content Before Compaction IS:2720Part-1973


b. Density of Compacted Layer IS:2720PartXXVIII-1986


c. Thickness of Compacted Layer As required

Control tests for Wet Mix Macadam: Post Construction:

Tolerance in surface Level ±10mm Max. permissible undulation ( with 3m straight edge) 8mm Max. permissible variation from specified profile under camber template 12mm

5.4 Dense Bituminous Macadam/ Semi Dense Bituminous concrete/ Bituminous concreteTable 7-Control tests On Base Materials : Pre- Construction

S. No. Test Test Methods Minimum Desirable frequency

a. Los Angles Abrasion Value/A.I.V.

IS:2386Part IV-1964


b. Grading of aggregates and Screening

IS:2386Part I-1963


c. Flakiness Index of Aggregates IS:2386Part -1983


d. Quality of binder Is:73-1961 Two Samples per lot to be subjected to all tests

e. Stability of mix. Marshall stability test for stability, flow value, densityAnd void contents.

f. stripping value of Aggregate

IS:6241-1971 One test per 100 cum

Table8- Control tests for DBM/SDBC: During Construction

S. No. Test Test Method Minimum Desirable

Frequencya. Quality of Binder IS:73-1961

IS:215-1961IS:217-1961OR 454 ASAPPLICABLE

As required

b. Los Angles Abrasion IS:2386Part Iv-1963

One test per 50 cum

c. Stripping Value of Aggregate IS:6241-1971 One test per 50 cumd. Flankiness Index of

AggregateIS:2386PartI-1963

One test per 50 cum

e. Water Absorption of Aggregate IS:2386Part III-1963

One test per 50 cum

f. Grading of all in Aggregates IS:2386PartI-1963

One test per 50 cum

g. Temperature of Binder of laying and rolling

Regularly

h. Binder Content Extraction test with Benzene

Two tests per day

I Rate of Spread of Premix Regular Control through Checks on Materials and thickness

j. Density of compacted layer Sand Replacement Method or from cores cut by core Cutting Machine

Two tests per 500 Sq.m

k. Mix grading One set of tests for individual constituents and mixed aggregates from dryer for each 400 tones of mix subject to minimum of two tests/ plant/day.

i. Stability of mix. For each 400 tones of mix produced, a set of 3 Marshall specimens to be prepared and tested for stability, flow value density and void content subject to a minimum if two tests being tested per plant /day.

Control tests for dense Bituminous macadam: Post Construction:

Tolerance in surface Level ±6mm Max. permissible undulation ( with 3 m straight edge) 6mm Max. no. of undulations permitted in any 300m length, exceeding 6mm 20 Max. permissible variation from specified profile under camber template 8mm

5.5 Bituminous Macadam

Table 9- Control Tests On surface Course :Pre-ConstructionS.No. Test Test Mehtods Minimum Desirable

Frequencya. Los Angles Abrasion Value/A.I.V. IS:2386

Part IV-1963One test per 200 cum

b. Grading of Aggregates and Screening IS:2386PartI-1963


C. Flakiness Index of Aggregates IS:2386Part-1983


d. Quality of Binder IS:73-1961 One test per 50 cume. Stripping value of Aggregate IS:6241-1971 One test per 100 cum

Table10- Control Tests for AC: During Construction

S.No. Test Test Mehtod Minimum DesirableFrequency

a. Quality of Binder IS:73-1961IS:215-1961IS:217-1961Or 454 as applicable

As required

b. Los Angles Abrasion Value/A.I.V. IS:2386Part IV-1963

One test per 50 cum

c. Stripping Value of aggregate IS:6241-1971 One test per 50 cumd. Flakiness Index of Aggregate IS:2386

Part I-1963One test per 50 cum


One test per 50 cum

f. Grading of all in Aggregates IS:2386Part –1963

One test per 50 cum

g. Temperature of Binder of Laying and Rolling

Regularly

h. Binder Content Extraction Test with Benzene

Two test per day

I Rate of Spread of Premix. Regular Control through Checks on Materials and Thickness

j. Density of Compacted Layer Sand Replacement Methods or from cores cut by core Cutting Machine

Two tests per 500 Sq.

Control Tests for Bitumen Macadam: Post Construction:

Tolerance in Surface Level ±6mm

Max. Permissible undulation ( with 3 m straight edge) 6mm Max. no. of undulations permitted in any 300m length, exceeding 6 mm 20 Max. permissible variation from specified profile under camber template 8mm

5.6 Bituminous Concrete

Table9- Control Tests On Surface Course: Pre- Construction

S.No. Test Test Methods Minimum Desirable Frequency

a. Los Angles Abrasion Value/A.I.V. IS:2386Part-1963


B. Grading of Aggregates and Screening IS:2386Part I-1963


c. Flakiness Index of Aggregates IS:2386Part-1983


d. Quality of Binder IS:73-1961 One test per 50 cume. Stripping value of Aggregate IS:6241-1971 One test per 100 cum

Table 10-Control Test for B.C. : During Construction


a. Quality of Binder IS:73-1961IS:215-1961IS:217-1961Or 454 asapplicable

As required

b. Los Angles Abrasion Value/ A.I.V. IS:2386Part IV-1963

One test per 50 cum

c. Stripping Value of aggregate IS:6241-1971 One test per 50 cumd. Flakiness Index of Aggregate IS:2386

Part I-1963One test per 50 cum


One test per 50 cum

f. Grading of all in Aggregates IS:2386Part I-1963

One test per 50 cum

g. Temperature of Binder of Laying and Rolling

Regularly

h. Binder Content Extraction test with Benzene

Two tests per day

i. Rate of Spread of Premix Regular Control through Checks on Materials and Thickness

j. Density of Compacted Layer Sand replacement Method or from cores cut by core Cutting

Two tests per 500 Sq.

Machinek. Mix Grading One set of tests on

individual constituents and mixed aggregates from dryer for each 400 tonnes mix subject to is minimum of two tests per plant per day.

l. Stability of mix. For each 400 tonnes of mix produced, a set of 3 Marshall specimens to be prepared and tested for stability, flow value, density and void contents subject to a minimum of two sets being tested per plant per day.

Control Tests for Asphaltic Concrete: Post Construction:

Tolerance in Surface Level Max. permissible undulation ( with 3 m straight edge) Max. no. of undulations permitted in any 300 m length, exceeding 6mm Max. permissible variation from specified profile under camber template The Project engineer, SE (QC), and CE (IP) reserve the right to direct for any additional that

may be required and it shall be binding on the contractor.

5.7 Structural Concrete

Table 11-Control Tests On Structural Concrete: Pre-Construction

S. No. Test Test Methods Minimum Desirable Frequency

a. Physical and Chemical Tests for Cement.

IS:269,IS:455,IS:1489,IS:8112,IS:12269 Once for each source of supply and occasionally when called for in case of long/improper storage. Besides, the Contractor also will submit daily test data on cement released by the Manufacturer.

b. Gradation of Coarse and Fine Aggregates

IS:2386Part I

One test for every day’s work of

each fraction of coarse aggregate and fine aggregate, initially; may be relaxed later at the discretion of the Engineer.

c. Deleterious constituentsOf Coarse and Fine Aggregates

IS:2386Part – II

One test for every day’s work of each fraction of coarse aggregate and fine aggregate, initially; may be relaxed later at the discretion of the Engineer.

d. Water Absorption of Coarse and Fine Aggregates

IS: 2386Part-III

Regularly as required subject to a minimum of one test a day for coarse aggregate and two tests a day for fine aggregate. This data shall be used for correcting the water demand of the mix on daily basis.

e. Los Angles Abrasion Value or Aggregate Impact test for Coarse aggregates

IS:2386Part-IV

Once for each source of supply and subsequently on monthly basis.

f. Soundness for Coarse Aggregates

IS:2386Part V

Before approving the aggregates and every month subsequently.

g. Alkali aggregate reactivity for coarse aggregate.

IS:2386Part –VII

Before approving the aggregates and every month subsequently.

h.Chemical tests for water IS:456 Once for approval

of source of supply, subsequently only in case of doubt.

Table12- Control tests for Structural Concrete – During Construction


a. Strength of Concrete IS:516 Quanity,m3 No. of Samples1-5 16-15 216-30 331-50 451 and 4+additional above for each 50 m3 or part thereof.

b. Workability of fresh concrete-slump test

IS:1199 One test per each dumper load initially and one test per alternate dumper.

c. Chloride and Sulphate content

One test per each dumper load initially and one test per alternate dumper.

d. Density of Fresh Concrete

Four tests per each dumper load.

e. Density of hardened concrete

Four tests per each dumper load.

f. Permeability test Clause 1716.5MOST Specifications-1997

One tests per each dumper load.

5.8 Structural Steel

Table13- Control tests On Structural Steel :Pre-Constructiona. Physical and Chemical Tests

for SteelIS:226,IS:2062,IS:11587, IS:1977,IS:8500,IS:961

Once for each source of supply and occasionally when called for in case of long/improper storage. Besides, the Contractor also will submit test data on steel released by the Manufacturer.

b. Mechanical and Chemical properties of Rivets, bolts, nuts, washers, welding consumables.

Appropriate ISCode.

Once for each source of supply and occasionally when called for.

c. Rolling and Cutting tolerance test

IS:1852 As required

d. Quality of Paint Relevant IS codes. Once for each source of supply and occasionally when called for.

Table 14-Control tests On Structural Steel : Post Construction


Frequencya. Ultrasonic Testing for

Laminations in platesOnce for each source of supply and occasionally when called for.

b. Bolted Connections IS:4000c. Riveted Connections Clause 1905.7.4

MOST Specifications 1997

d. Destructive and Non-destructive tests on Welds

IS:7303 (Part-1), IS: 5334, IS:1182, IS:4853,IS:3658

i)10% of the length of longitudinal and transverse butt welds in tension flanges

ii) 5% of the length of longitudinal and transverse butt welds in compression flanges.

ii) All transverse butt welds in webs adjacent to tension flanges as specified by the Engineer.

5.9 Sheathing Ducts

Table 15- Control tests On Sheathing Ducts

S.No. Test Test Methods Minimum DesirableFrequency

a. Workability Test Appendix-1800/1 of Specifications for Roads and Bridges MOST-1997

Three tests for one lot of supply (not exceeding 7000 m length)

b. Transverse Load Rating Test Appendix-1800/I of Specifications for Roads and Bridges MOST-1997

Three tests for one lot of supply (not exceeding 7000m length)

c. Tension Load test Appendix-1800/I of specifications for roads and Bridges MOST-1997


d. Water Loss Test Appendix-1800/I of Specifications for Roads and Bridges MOST-1997


5.10 Pile Foundation

Table 16- Control Tests On Pile Foundation


Frequencya. Pile Load test IS:2911(Part-IV) Two tests for initial load

tests and 2% of the total number of piles or 2 whichever is more for routine load tests.

5.11 Well foundation

Table 17- control Tests On Well Foundation


a. Tilts and shifts Clause 1207.8 of Specifications for roads and bridges MOST 1997

As required.

5.12 Elastomeric Bearings

Table 18- Control tests On Elastomeric Bearings


a. Physical Properties IS: 3400 (Parts I & II)

Two for each source of supply and occasionally when called for Besides, the Contractor will also submit test data released by the Manufacturer.

b. Maximum Compression Set IS: 3400 (Part 10) Two for each source of supply and occasionally when called for. Besides, the contractor will also submit test data released by the Manufacturer.

c. Accelerated Aging IS: 3400 (Part IV) Two for each source of supply and occasionally when called for. Besides, the Contractor will also submit test data released by the Manufacturer.

5.13 Mortar for Masonry Work

Table 18- Control Tests On Mortar


a. Compressive Strength IS:2250 One sample for every 2 m3

subject to a minimum of 3 samples in a day’s work.

b. Consistency of Mortar IS:2250 One sample for every 2 m3


c. Water Retenivity IS: 2250 One sample for every 2 m3


5.14 Load Test of Super Structure

Table 18

S.No. Test Test Methods Minimum DesirableFrequency

a. Load Test on Super Structure IRC SP:37 One Number

6 (A) QUALITY ASSURANCE FORMATS

(WORKS SHEETS & CHECK LIST PERFORMAS)

6. QUALITY ASSURANCE FORMATS

The quality assurance formats normally used in roard construction are detailed on following pages. Project Engineer of Contractor would have to work out their own formats as per requirement of Project with the approval of Project Engineer and SE (QC).

PUNAJB PWD B&R(PIDB PROJECTS)

6.1 WORKSHEET FOR BORROW MATERIALS

Name of Work :Material Source :Location :

SN

Loca-Tion

KM in which

Sand Content

Grading%

o.

of Borrow Area

Material is used

% passing through

4.75mm

600mic

200mic

150mic

75mic

P.IValue

Proctor Density

CBR DeLeterious

Natural Miisture

Density

Moisture content

PUNJAB PWD B&R(PIDB PROJECTS)

6.2 WORKSHEET FOR PLASTICITY INDEX TEST(Reference : IS-2720-Part-V-1970)

Name of Work : Date of Sampling :Kind of Material: Sampled by :Material Source : Date of Testing :Location : Tested by :Natural MC : Frequency(As laid down) :

DETAILS OF TESTS

LIQUID LIMIT/TRIAL NO 1 2 3 4 5A. No. of BlowsB. Container No.C. Wt of Tare (gm)D. Wet Wt ofSample + Tare (gm)

E. Dry Wt of Sample +Tare (gm)F. Wt of Water (D-E) (gm)

G. Wt of Dry Soil(E-C) (gm)H. Average % MC (F/Gx100)PLASTIC LIMIT/TRIAL NO 1 2 3 4 5 Avg.I. Container No.J. Wt Wt ofSample + Tare (gm)K. Wet Wt ofSample + Tare (gm)L. Dry Wt of Sample+ Tare (gm)M. Wt of Water (K-L) (gm)N. Wt of Dry Soil (L-J) (gm)O. Average % MC (M/N*100)


6.3 WORKSHEET FOR MOSITURE CONTENT TEST(Reference :IS-2720-Part-II-1973-Second Revision)

Name of Work : Date of Sampling :Material Source : Sampled by :Location : Date of Testing :Kind of material : Tested by :

Frequency( As laid down) :

DETAILS OF TESTS

Test No. 1 2 3 4 5A. Container No.B. Wt of Container (gm)C. Wt of container + Wet Sample (gm)D. Wt of Container + Dry Sample (gm)E. Wt if Water (C-D) (gm)F. Wt of Dry Sample(D-B) (gm)

Average % MC (E/F*100)

PUNAJB PWD B & R(PIDB PROJECTS)

6.4 WORKSHEET FOR WATER ABSORPTION TEST

(Reference : IS-2386-Part-III-1963)

Name of Work :Material Source : Date of Sampling :Location : Sampled by :

Date of testing :Tested by :Frequency (As laid down) :

DETAILS OF TESTS

ITEM 1 2 3 4 5 AverageA. Soaked Surface Dried Weight of Aggregate In Water (gm)B. Wt of Oven Dried Aggregate (gm)C. Weight of Water Absorbed (A-B)(gm)D. Percentage of Absorption[(C/B)*100]Observations:


6.5 WORKSHEET FOR MOISTURE DENSITY TEST(Reference :IS-2720-Part-VII-1965)

Name of Work : Date of Sampling :Material Source : Sampled by :Kind of Material : Date of Testing :Location : Tested by :Chainage : Frequency :

(As laid down)

DETAILS OF TESTS

DRY DENSITY TEST/TRIAL NO. 1 2 3 4 5 AverageA. Wt of Mould (gms)B. Wt of Mould + Wet Soil (gms)C. Wt of Wet Soil (B-A) (gms)D. Volume of Mould (c c)

E. Wet Density of Soil C/D (gms/c c)F. Dry Density of Soil {{C/100+L)} *100]/DMOISTURE CONTENTTEST/CAN NO

1 2 3 4 5 Avg.

G. Wt of CanH. Wt of Wet Soil + Can (gms)I. Wt of Dry Soil + Can (gms)J. Wt of Water (H-I) (gms)K. Wt of Dry Soil (I-G) (gms)L. Average % MC[(J/K)*100]

PUNJAB PWD B& R(PIDB PROJECTS)

6.6 WORKSHEET FOR SIEVE ANALYSIS(Reference :IS-2386-Part-I-1963)

Name of Work : Date of Sampling :Kind of Material : Sampled by :Location : Date of Testing :

Tested by :Weight of Oven Dried Sample: Frequency :

(As laid down) :

DETAILS OF TESTS

IS SieveSize Mm/Micron

WeightRetained(gm)

CummulativeWeightRetained (gm)

WeightPassing (gm)

PercentageRetained

Percentage CumulativeRetained

PercentagePassing

SpecifiedLimits(Laid down)

100 mm90mm80mm63mm50mm40mm25.0 mm25.0 mm16.0 mm12.5 mm10.0 mm4.75 mm2.36 mm1.18mm

600micron425micron300micron150micron75micron

Silt +Clay Content: Weight of dried sample (W1 ) =

Weight of even dried sample retained =On 75micron Sieve (after washing)(W2)Percentage of Silt + Clay Content =(W1-W2) /(W)1)*100

PUNJAB PWD B & R(PIDB PROJECTS)

6.7 WORKSHEET FOR SPECIFIC GRAVITY TEST FOR FINE AGGREGATES

Name of Work : Date of Sampling :Material Source : Sampled by :Location : Date of Testing :

Testing by :Frequency :(As laid down)

FINE AGGREGATES

DETAILS OF TESTS

No. ITEM/TEST NO 1 2 3 AverageA. Weight in air of Saturated Surface Dried

Sample (gm)B. Weight in Air of Oven Dried Sample (gm)C. Weight of Pycnometer Bottle

Filled with Water (gm)D. Pycnometer Water +Sample (gm)E. Percentage Water Absorption=[(A-B)/B]*100F. Bulk Specific Gravity=[(A)/{A-(D-C)}]G. Specific Gravity

=[(B)/{A-(D-C}]H. Apparent Specific

Gravity=[(B)/B-(D-C)}]


6.8 WORKSHEET FOR SPECIFIC GRAVITY TEST FOR COARSE AGGREGATES

Name of Work : Date pf Sampling :Material Source : Sampled by :Location : Date of Testing :

Tested byFrequency :(As laid down)

COARSE AGGREGATES

DETAILS OF TESTS

S.No. ITEM/TEST NO 1 2 3 AverageA. Weight in Air of Saturated Surface

Dried Sample (gm)B. Weight in Air of Oven Dried Sample

(gm)C. Weight of Sample in

Water (gm)D. Percentage Water

Absorption =[(A-B)/B]*100E. Bulk Specific Gravity=[(A)/(A-C)]F. Specific Gravity

=[(B)/(A-C)]G. Apparent Specific Gravity=[(B)/(B-C)]

Observations:

PUNAJB PWD B& R(PIDB PROJECTS)

6.9 WORKSHEET FOR SAND CONTENT TEST(IS:2730 Part-IV-1965)

Name of Work : Date of Sampling :Kind of material : Sampled by :Source of Material : Date of Testing :Location : Tested by :

Frequency :(As laid down)

DETAILS OF TESTS

S.No. ITEM/TEST NO 1 2 3 AverageA. Original Weight (gm)B. Oven Dried Weight

(gm)C. Oven Dried Weight Retained on 75

Micron IS Sieve(After Washing) (gm)

D. Percentage of Sand Content =[(C/B)*100]

Observations:


6.10 WORKSHEET FOR FIELD COMPACTION TEST BY CORE CUTTER METHOD

(Reference :IS-2720-Part-XXIX)

Name of Work : Date of Testing :Source of material : Tested byLayer No. : Frequency :Location : (As laid down) :

Station of Test :

DETAILS PF TESTS

MAXIMUM DRY DENSITY/TEST NO. 1 2 3 AverageA. Wt of Wet Soil + Core CutterB. Wt of CoreC. Wt of Wet Soil (A-B)D. Volume of Core Cutter- 1000C.C.E. Wet Density of Soil (C/D)F. Dry Density of Soil [E/(100+M)]*100G. M.D.D…………..OMC……….Relative Compaction =[(F/G)*100]=MOISTURE CONTAINER NO. 1 2 3 AverageH. Wt of Wet Soil +ContainerI. Wt of Dry Soil +Container

j. Moisture Container (H-I)K. Wt. Of ContainerL. Wt of Dry Soil (I-K)M. % of Moisture (J/L)*100


6.11 OBSERVATION SHEET FOR STRIPPING VALUE TEST

(Reference : IS: 6241-1971)

Name of Work : Date of Sampling :Aggregate Source :Location : Sampled by :

Type of Aggrgate : Date pf Obsn :

Type of Binder : Observed by :

Percentage Binder Used: Frequency(As laid down) :

Total Wt of Aggregate:Total Wt of Binder :Temp of Water Bath :

DETAILS OF OBSERVATIONS

DETAILS/OBSERVATION NO 1 2 3 AverageStripping Percentage as Observed from the Aggregates on Visual InspectionLimits Value not to be

greater than 25%

Observations:


6.12 WORKSHEET FOR AGGREGATE IMPACT VALUE(IS:2386 Part-IV-1963)

Name of Work : Date of Sampling :

Kind of Material : Sampled by :Location : Date of Testing :

Tested by :Frequency (As laid down)

DETAILS OF TESTS

Sr. No.

TRIAL NO 1 2 3 Average

A. Initial Weight(gms)B. Weight Retained After test

On Sieve No. 2.36mm (gms)

C. Percentage weight Loss =[(A-B)/(A)*100][Aggregate Impact Value (A/V)]

Average % Loss (A/V)=Specification % Loss (A/V)=Observations:


6.13 WORK SHEET FOR FLANINESS INDEX TEST

(Reference :IS:2368-Part I-1965)

DETAILS OF TESTS

S.No. PassingThroughIS : Sieve

Retained on Is Sieve

Wt of Sample (Gms)

Wt Passed through Thickness gauge (Gms)

Percentage of Flaky Particles (Flakiness Index)

1 63mm 50mm X1 Y1 (Y1/X1)*1002 50mm 40mm X2 Y2 (Y2/X2)*1003 40mm 31.5 X3 Y3 (Y3/X3)*1004 31.5mm 25mm X4 Y4 (Y4/X4)*1005 25mm 20mm X5 Y5 (Y5/X5)*1006 20mm 16mm X6 Y6 (Y6/X6)*1007 16mm 12.5mm X7 Y7 (Y7/X7)*100

8 12.5mm 10mm X8 Y8 (Y8/X8)*1009 10mm 6.3mm X9 Y9 (Y9/X9)*100

Results: x(x1+…..+x9)≠ Y1+….Y9) ≠ (Y/X)*100=(Flakiness Index)

Observations:


6.14 WORKSHEET FOR FIELD COMPACTION TEST BY REPLACEMENT METHOD.

(IS-2720-Part-XXVIII-1966)

Name of Work : Date of Testing :Source of Material : Tested by :Chainage :Layer No. : Frequency

(As laid down) :

Station of test : Type of Test : Proctor/Mod

ProctorLimits : 95/98/100% of MDD

DRY DENSITY/TEST NO 1 2 3 AverageA. Wt of Soil (gm)B. Wt of Sand Taken (gm)C. Wt. Of Sand Left in Cylinder (gm)D. Wt of Sand in Cone (gm)E. Wt of Sand in Pit [B-(C+D)] (gm)F. Volume of Pit (E/Density of Sand)(c c)G. Wet Density of Soil (A/F) (gm/c c)H. Dry Density of Soil [{G/(100+p)}*100](gm/c c)I. MDD……….. OMC………….J. Relative CompactionMOISTURE CONTENT/CONTAINER NO. 1 2 3 AverageK. Wt of Wet Soil +ContainerL. Wt of Dry Soil +ContainerM. Moisture Content in Sample (K-L)N. Wt of ContainerO. Wt of Dry Soil (L-N)P. % of Moisture [(M/O)*100]


6.15 CALIFORNIA BEARING RATIO TEST(IS-2720-Part-XVI-1965)

Name of Work : Date of Sampling :Kind of Material : Sampled by Location : Soaked/Unsoaked :Condition of Specimen: Providing Ring :Date Moulded :Date of Testing :Calibration Factor :Period of Soaking : Tested byDry Density (gm/ c c) : Frequency(Before Soaking) (As laid down)Dry Density (gm/ c c) :

(After Soaking)PercentageMoisture Content

DETAILS OF TESTS

S.No DialGaugeReading

Penetration (0.01 mm)

Load Dial Gauge Reading

Load on Plunger(L) kg

Unit LoadKg/sg.cm (L/19.635)

Corrected Unit Load From Curve kg/sq.cm

1 02 503 1004 1505 2006 250 (X)7 3008 4009 500 (Y)10 60011 70012 800


6.16 WORK SHEET FOR BINDER CONTENT

DETERMINATION

Name of Work : Date of Sampling :Kind of Material: Sampled by :Material Source :Location : Date of Testing :

Tested by :Frequency :(As laid down)

ITEM 1 2 3 AverageA. Weight of Mix (gm)B. Initial Weight of Filter Paper (gm)C. Weight pf Mix after Extraction (gm)D. Weight of Filter Paper after Extraction with Fine Materials (gm)E. Weight of Fine Materials (D-B)(gm)F. Percentage of Binder Content =[(A)-(C+E)](gm)G. Percentage of Binder Content =[(F/A)*100]

Observation : (Allowable Value from job Mix Formula=±0.3%/±0.5%)


6.17 WORKSHEET FOR MARSHAL STABILITYOBSERVATIONS

Name of Work : Date of Sampling :

Chainage : Sampled by :

Kind of Material:

Date of Testing : Tested by(As laid down)

STABILITY AND FLOW VALUE DETERMINATION

Mixing temperature, c : Grade of Bitumen (80-100)/(60-70):Pen, grade

Number of Blows on Either Side: Compacting temperature, Cº :

Flow Value Dial 1 Division : Providing Ring Calibration Factor :

DETAILS OF TESTS

Sample No. Bitumen Content Percent

Maximum Providing Ring Reading

Stability Value (Kg)

Measured Corrected

Flow Dial Reading

Flow Value 0.01 mmunits

123Average%123Average%123Average%


6.18 WORKSHEET FPR MARSHAL STABILITY TEST CALCULATIONS AND RESULTS

Name of Work :Locations : Date of Testing :Job Mix Formula :No. of Blows :

DETAILS /SPECIMEN NO. 1 2 3 4 5 6A. Bitumen by Wt of Aggregate %B. Bitumen by Wt of Mix (%)C. Aggregate by Wt of Mix (%)D. Dry Wt of Specimen in Air Igm)E. Dry Wt of Specimen in Water (gm)F. Saturated Surface Dry Wt (1 min in water)(gm)G. Volume of Specimen (F-E) (c c)H. Bulk Density of Mix (D/G) (gm/c c)I. Volume of Bitumen {(H*B)/SG of Bitumen)*100(%) j. Volume of Aggregates [{(H*C)/SG of Mix aggregate)*100](%)

K. Air Voids in Mix. [100-(I+J)](%)L. Total voids in Mineral Aggregates (VMA)(100-J) (%)M. Voids Filled with Bitumen [(I/L)*100] (%)N. Corrected Stability (kg)O. Flow (mm)


6.19 WORKSHEET FOR COMPRESSIVE STRENGHT TEST(Reference IS-516-1959)

Name of Work : Date of :

Construction Site : Casting

Location : Sampled by :

Slump : Date of Testing

Sample Received At Lab by : (As laid

Down) :

DETAILS OF TESTS

S.No. Area of Mould Sq. cm

Weight

Gm

Density

Gm/c c

Load

Kg

Strength

Kg/sq.Cm

Required Strength

Kg/sq.cm123456789101112Observations:


6.20 WORKSHEET FOR BRICKS TEST(Reference : IS-3495-Part-I to V-1973 – First Revision)

Name of :WorkMaterial Date of Sampling :Source :Location : Sampled by :Chainage Date of Testing :Quality at : Tested by :Site :Brand of : Frequency Bricks : (as laid down) :

6.21 WATER ABSORPTION TEST

Brick No 1 2 3 4 5 AverageA. Original Dry Wt (gm)B. Wt of Brick After Absorption for 24 hrs(gm)C. Wt of Water Absorbed (A-b)(gm))D. Average % Absorption (C/A*100)

6.22 COMPRESSIVE STRENGTH TEST

Date of flushing bed Faces Date of Testing :With Cement-Sand Mortar(1:1) Tested by :

Brick No 1 2 3 4 5 AverageE. Bed Face Area of

Brick (sq cm)F. Maximum Load at FailureIn (kg)G. Compressive Strength (F/E)(kg/Sq cm)

Observations : (Limits : AVG. not less than 105 kg/sq. cm).

6 (B) CHECK LIST FOR VARIOUSACTIVITIES

CHECKLIST FOR VARIOUS ACTIVITIES

The contractor is to plan and program, make arrangements for materials, labour, plant and machinery etc. for carrying out various activities in respect of work to plan for completion of work with in stipulated time period. The contractor is required to plan for daily output of various activities and items of work in most desirable workmanship manner including meeting of specifications under the overall Supervision and to entire satisfaction of Project Engineer-cum-Executive Engineer.

The contractor is required to make various arrangements and tests of materials, including job mix formula before starting of work everyday including proceeding with next activity on the completion of first activity. Before any work is taken up ( i.e earthwork, GSB, WMM, Prime/tack coat, bituminous layers and cement concrete) the Project Engineer or his representative or would check lists referred hereinafter and shall allow for starting of the activity for that day.

Material daily report and Laboratory daily report shall be submitted by Quality control Engineer. Basically all the test whether in field or in laboratory are to be conducted by the contractor either in the presence of Supervisory personnel or Quality Control Engineer and the test results shall to be submitted in the appropriate formats to the Project Engineer-cum-Executive Engineer. The Quality Control Consultant shall conduct the tests independently to confirm the test results done by the contractor.

FORM F-1

PUNJAB PWD B & R (PIDB PROJECTS)

Name of Contractor :Name of Work :Code No. :

CHECK LIST FOR EARTH WORK

Location _______________________Date __________ Time ___________RFI No. _______________________

SLNO.

DESCRIPTION REMARKSYES NO

1. Are sufficient number of dozers, graders and rollers available at site.

2. Are there are pipes, conduits, wires, cables below ground.

3. Is the site clean.4. Clearing/ grubbing done properly?5. Is natural ground compacted?6. Is a draining layer required & has the area been

delineated?

7. Is the draining layer in place?8. Are toe points as per cross section?9. Is the cut material suitable for benching?10. Is the layer properly watered?11. Is the compacted layer ready to field testing?12. Is the compaction of placed layer satisfactory and

ready for next layer?13. Have the deficiency been to the contractor for

rectifications?General Remarks:-

______ ______ ___________Quality Project Project Control Engineer Engineer Engineer (Contractor).

Form : F-2PUNJAB PWD B &R(PIDB PROJECTS)


CHECK LIST FOR GRANULAR SUB BASE


SL. NO.


1. Are sufficient number of graders, dozers and rollers for spreading and compaction available.

2. Are the results of laboratory tests for the borrow material within the project specification?

3. Is the material watered properly?4. Is the material within the tolerances for size?5. Is additional moisture required?6. Are the number of passes of rollers, speed and

procedures correct?7. Are the layers adequately placed and compacted?8. Are there any crack on the surface due to excessive

fines or due to over rolling?9. Is the compacted layer ready for field testing?10. Is the compaction of the placed layer satisfactory and

ready for next layer11. Has the layer been proof rolled?12. ADDITIONAL CHECK ON SHOULDERS

Are the shoulders to correct slopes?

13. Are shoulders trimmed to correct width?14. Has adjacent AWC been cleaned at shoulders edges?15. Have the deficiencies been reported to the Contractor

for rectification?General Remarks:-

____________________________________Quality Project ProjectControl Engineer EngineerEngineer (Contractor)



CHECK LIST FOR THE WET MIX MACADAM


SL. NO.


1. Is there sufficient equipment for placing and compacting the WMM?

2. Is the GSB approved for density and level?3. Do the WMM grading confirm to MOST Specification.4. Is the sub-base slightly moist prior to placing WMM

base?5. Have the steel level pins plus wire been checked for

level before paver commences work?6. Is there any segregation during laying of the WMM?7. Is the loose lift thickness adequate to give the

specification final thickness?8. Do the WMM base appear to have uniform moisture

content?9. Are there cracks on the surface e due to the excessive

rolling?10. Have the loose and segregated portions been rectified?11. Is the WMM base ready for field testing?12. Are the density test results satisfactory and is the WMM

base ready for prime coat?13. Has the finished layer been proof rolled?14. Have the deficiencies been reported to the Contractor for

rectification?General Remarks:-

____________________________________Quality Project ProjectControl Engineer EngineerEngineer (Contractor)



CHECK LIST FOR PRIME COAT/TACK COAT


SL. NO.


1. Is the weather & temperature suitable for Priming?2. Was compaction tested?3. Is surface clean?4. Has surface been lightly dampened?5. Are any pool of water?6. Are spray jets and pumps ok?7. Any leakages?8. Sufficient Trays available?9. Is the thermometer on the sprayer ok?10. Has the temperature of prime been checked?

(Recommended temperature 330 to 550)11. Speed clock working?12. Is the distributor traveling at recommended speed?13. Pressure pump ok?14. Have the deficiencies been reported to the Contractor for

rectification?General Remarks:-

____________________________________

Quality Project ProjectControl Engineer EngineerEngineer (Contractor)



CHECK LIST FOR DENSE BITUMINOUS MACADAM /BITIMINIOUS MACADAM

WORKS


SL. NO.


1. Is the whether & temperature suitable for asphalting?2. Is the paver in good working condition?3. Is the stand by equipment available?4. Is a prime or tract coat required prior to proceeding

with the DBM?5. Is the WMM base course approved and primed and

cleaned to allow the laying of bituminous base course to proceed?

6. Are the survey stacks and wire setup property to control the width and level if asphalt?

7. Is the departure time, weight and temperature mentioned in the delivery slip?

8. Are the placement and compaction temperature with in the specified range?

9. Is the rolling operation, i.e number of passes, speed, weight contact pressure etc. correct?

10. Is there any segregation in the pavment?11. Is there thermometer in site?12. Is the loose lift thickness adequate to ensure the correct

layer thickness after compaction?13. Have the cold construction joints been primed/ coated?14. Have the DBM samples been collected for laboratory

testing?15. Are the finished levels of DBM within the tolerance?16. Have the deficiencies been reported to the Contractor


____________________________________Quality Project Project

Control Engineer EngineerEngineer (Contractor)



CHECK LIST FOR BITUMINOUS CONCRETE /SEMI DENSE BITIMINIOUS CONCRETE


SL. NO.


1. Is the paver in good working condition?2. Is the stand by equipment available?3. Is the underlying base course approved and cleaned to

allow the wearing course to proceed?4. Is tact coat required prior to proceeding with the BC?5. Is the whether satisfactory for lying the?6. Are the survey stacks and wire setup property to control

the width and level if asphalt?7. Is the departure time, weight and temperature

mentioned in the delivery slip?8. Are the placement and compaction temperature with in

the specified range?9. Is the rolling operation, i. e. number of passes, speed,

weight contact pressure etc. correct?10. Is there any segregation in the payment?11. Is there thermometer in site?12. Is the loose lift thickness adequate to ensure the correct

the correct layer thickness after compaction?13. Have the cold construction joints been primed/ coated?14. Have the BC samples been collected for laboratory

testing? 15. Are the finished levels of asphalt within the tolerance?16. Have the deficiencies been reported to the Contractor


____________________________________Quality Project ProjectControl Engineer Engineer

Engineer (Contractor)

Form : F-6

PUNJAB PWD B &R(PIDB PROJECTS)


CHECK LIST FOR BITUMINOUS MIX DELIVEY & LAYING

Truck/ Tipper No. : Type of Mix. : Date / Time of : Leaving plant : Temperature : Delivery Slip Issued : Yes/NO

Time of reporting at site :Temperature of mix. :KM/Lane of laying :Time of discharge :Temperature at the time of :Discharge :Time at departure :

______________ _______________ __________________

Representative of Representative of Representative ofCONTRACTOR Q.C ENGINEER PROJECT ENGINEER




CHECK LIST FOR FORM WORK

SL. NO.


1. Form Work design/ drawings approved including de- sheuttering

2. Trial panel approved ( if required)3. Form work alignment correct.4. Form work levels correct.5. Form work dimensions correct.6. Form work member spacing correct.7. Form work member material quality acceptable8. False work members spacing, sizes & quality

acceptable.9. Gaps between primary and secondary members

wedged.10. Joints between panels closed and flushed.11. Panel flatness acceptable.12. Tie rods spacing correct and properly tight13. Spaces between shutter surface tightly fitted.14. Box outs, cast-in-items, ducts, fixed correct, securely.15. Pre-stressing shuttering and vents, alignment and

spacing of supports acceptable.16. Empty sheating secured against floatation.17. Pre- stressing anchorage position and fixing acceptable.18. Chamfers (fillet sizes, straightness, fixing acceptable.)19. Formwork clean20. Formwork release oil material approved and applied.21. Construction joint preparation satisfactory.22. Contraction / Expansion joint preparation satisfactory.23. Safe access constructed.24. Adequate work space provided for labour, equipment.25. Shutter Vibrators (if required), location and fixing

arrangements approved.

General Remarks

______________ ________________ _______________QUALITY CONTROL PROJECT ENGINEER PROJECT ENGINEER (CONTRACTOR) ENGINEER




CHECK LIST FOR REINFORCEMENT

SL. NO.


1. Working drawings with latest revision approved.2. Bar schedules approval.3. Reinforcing steel material approved.4. Bar bending and cutting satisfactory.5. Corrosion treatment of bars, if required, satisfactory.6. Bar sizes correct.7. Bar spacing correct.8. Bar lap lengths correct.9. Bar laps at correct location.10. Bars ties as specified.11. Bar assembly rigid and adequately supported.12. Cover to bottom bars correct.13. Cover to side bars correct.14. Cover to top bars correct.15. Cover blocks approved including fixing.

General Remarks





CHECK LIST FOR CONCRETE WORK

SL. NO.


1. Mix design Approved.2. Batching Plant/ concrete weight batcher in working

order.3. Stand by mixer in working order.4. Water, sand, coarse aggregate, cement and admixture

approved.5. Water, sand, coarse aggregate, cement, admixture stock

sufficient.6. Concrete conveying arrangement, (Transit Mixer) in

working condition and adequate capacity.7. Form work approved.8. Reinforcement approved.9. Pre stressing sheathing approved.10. Sufficient vibrator available in working condition. 11. Tremie in working order ( for under water work.)12. Concrete gang present, including carpenter, steel fixer.13. Access as provided adequate.14. Safety arrangements provided.15. Lighting arrangements provided.16. Communication between various points provided.17. Arrangement for stoppage of concrete provided.18. Curing arrangements made.19. Laboratory notified for sampling.

General Remarks




CHECK LIST FOR CONCRETE DELIVERY & POUR

1) CONCRETE DELIVERY AT BATCHING PLANT Concrete grade : M Tipper/ Transit Mixer No. : W/c ratio : Time : Cement content : Location : Maxm Aggregate Size : mm Admixture : Design slump : mm

2) POUR AT SITE

Member of structure : Slump : MM Discharge Started : hours Placement completed : hours No. of cubes taken : Placement Temperature : 0C Ambient temperature : 0C Weather condition

______________ _______________ __________________

Representative of Representative of Representative ofCONTRACTOR Q.C ENGINEER PROJECT ENGINEER




CHECK FOR POST CONCRETEING INSPECTION

SL. NO.

DESCRIPTION REMARKSSatisfactory Not

Satisfactory 1. STRIPPING OF SIDE SHUTTERING.a) Position / dimension of member.b) Surface defects: honey combing / Air Bubbles/ cold

joints.c) Cracks :Number and natured) Class of finish.e) Any other defect.2. EACH STAGE OF PRESTRESSING.a) Position / dimension of member.b) Surface defects: honey combing / Air Bubbles/ cold

joints.c) Cracks :Number and natured) Class of finish.e) Any other defect.3. DE- CENTRINGa) Position / dimension of member.b) Surface defects: honey combing / Air Bubbles/ cold

joints.c) Cracks :Number and natured) Class of finish.e) Any other defect.



CALIBRATION CHART OF BATCHING PLANT FOR AGGREGATE GAUGE CALIBRATED DATE :

LoadApplied(KG)

DIAL GAUGE READING

TRIAL-1 TROA;-11 TROA;-111 AVERAGELoading Un-

LoadingLoading Un-

LoadingLoading Un-

Loading0

501001502002503003504004505005506006507007508008509009501000105011001150REMARKS :PROJECT ENGINEER CONTRACTORS REPRESENTATIVE


CALIBRATION CHART OF BATCHING PLANT FOR WATER METER CALIBRATED DATE :

SL.NO TRIAL-1 TRIAL-11 TRIAL-111 AverageMETREReading(LTRS)

WATERMeasured(LTRS)

METREReading(LTRS)

WATERMeasured(LTRS)

METREReading(LTRS)

WATERMeasured(LTRS)

1. 10 10 102. 20 20 203. 30 30 304. 40 40 405. 50 50 506. 60 60 607. 70 70 708. 80 80 809. 90 90 9010. 100 100 10011. 110 110 11012. 120 120 12013. 130 130 13014. 140 140 14015. 150 150 150REMARKS:PROJECT ENGINEER: CONTRACTORS REPRESENTATIVE


CALIBRATION CHART OF BATCHING PLANT FOR CEMENT GAUGE CALIBRATED DATE :

LoadApplied(KG)

DIAL GAUGE READING

TRIAL-1 TROA;-11 TROA;-111 AVERAGELoading Un-

LoadingLoading Un-

LoadingLoading Un-

Loading0501001502002503003504004505005506006507007508008509009501000105011001150REMARKS :PROJECT ENGINEER CONTRACTORS REPRESENTATIVE

Form : F-17PUNJAB PWD B &R

(PIDB PROJECTS)

CALIBRATION REPORT (Cube Testing Machine)

DATE OF CALIBRATION TEMP.GAUGE NO. CAPACITYEQUIPMENT MODELFORCE MEASURING DEVICE SL. NO.CERITFIED BY PLACE

REF.

SL.NO.

1.2.3.4.5.6.7.8.9.

10.

DEFLECTIONIN DIAL GAUGE

INPROVING RING

ACTUALLOAD

APPLIED

AVERAGEOF THREEREADINGS

INDICATEDLOAD ONGAUGEERROR

NOTE : to obtain correct result positive (+) error to be subtracted, negative (-) error to be added to the indicated load readings on machine gauges.

PROJECT ENGINEER CONTRACTORS REPRESENTATIVE


RECORDS OF CALIBRATION OF EQUIPMENT

Name of Work :Name of Contractor :

ITEM Date Calibrated & person certifying

(for vendor of contractor)

Date ofNext

Calibration

Date ofInspection &

Person approving

(for department

Result ofInspection

Result ofInspection

* Frequency of Calibration for different equipment to be specified in advance.

PROJECT AUTHORISED REPRESENTATIVE ENGINEER OF CONTRACTOR

7. CONTROL OF ALIGNMENT , LEVELAND

SURFACE REGULARITY

7. CONTROL OF ALIGNMENT , LEVEL AND SURFACE REGULARITY

7.1 GENERAL

All works shall be constructed to the specified lines, grades, cross-sections and dimensions. The objective is to achieve a well built pavement conforming to the required horizontal and vertical profile, design thickness of different payment courses and stipulated standards of riding quality.

Given here are the producers for checking and permissible tolerances in different cases.

7.2 HORIZONAL ALIGNMENT

The checking of horizontal alignment shall be done with respect to the centre line to the road as shown on the plans. It involves checking the geometrics of the road way as well as edges or the various pavement layers vis-à-vis the design centre line. Horizontal alignment can be controlled properly only if the centre line of the road has been marked in the field by means of reference pillars on both sides of the centre line located as frequent intervals along the straight and at all changes of horizontal curvature. Manner of doing so is explained in IRC : 36-1970. To ensure compliance with plans, edges or each pavement layer should be delineated with respect to the centre line before placement, with the help of pegs, strings of other tools.

Allowable tolerances in respect in respect of horizontal alignment are recommended to be as follows:

(i) Carriageway edges + 10mm

(ii) Edges of the road + 40mmway and lower layer ofpavement

7.3 SURFACE LEVELS OF PAVEMENT COURSES.

Surface levels of pavement courses calculated with respect to the longitudinal and cross profiles shown on the drawing shall be checked through grid leveling / spot leveling etc. from the sub grade upwards for each successive layer. Actual levels of the different courses shall not vary from the design levels beyond the tolerances indicated below :

Subgrade (+) 20mm(-) 25mm

Sub- baseFlexible pavement (+) 10mm

(-) 20mm

Base course for flexible pavement(a) Bituminous course (+) 6mm

(-) 6mm

(b) Other than bituminous Machine laid (+) 10mm

(-) 10mm

Wearing course for flexible pavement

(a) Machine laid (+) 6mm(-) 6mm

(b) Manually laid (+) 10MM(-) 10mm

Care shall be taken that the negative tolerance for wearing course indicated above is not permitted in conjunction with the positive tolerance for base course if the thickness of the former is reduced by more than 6mm for flexible pavements.

For checking compliance with the above requirement for subgrade, sub-base and base course, measurements of the surface levels shall be taken on a grid of points placed at 6-25 metre longitudinally and 3.5 metre transversely. For any 10 consecutive measurements taken longitudinally or transversely not more than one measurements shall be permitted to exceed the tolerance as above, this one measurement being not is excess of 5mm above the permitted tolerance.

For checking the compliance with the above requirement of bituminous wearing courses, measurements of the surface levels shall be taken on a grid of points spaced at 6.25 metre along the length and 0.5 metre from the edges and at the centre of the pavement. In any length of pavement, compliance shall be deemed to be met for the final road surface, only if the tolerance given above is satisfied for any point on the surface.

7.4 CONTROL ON LAYER THICKNESS

Even though checks on surface level of pavement courses provide an indirect control on the layer thickness, additional measures may be necessary to establish that the thickness of constructed course is in accordance with specifications. These measures could be in the form of thickness blocks or cross as may be applicable. Control on the spread of material also provides an indirect check on the layer thickness. Whereas small deviations in thickness may be unavoidable, larger deviations would unduly vitiate the pavement design.

In general, the average thickness, should not be less than the specified thickness. In addition the spot reduction thickness should not exceed 15mm in the case of bituminous macadam and 6mm in the case of bituminous concrete.

7.5 STANDS OF SURFACE REGULARITY

The criteria for surface evenness, both for longitudinal and transverseProfile have been reviewed and the latest recommendations approved by the Indian Road Congress in August 1976 (Published in IRC: Special Publication 16 : 1977 “Surface Evenness of Highway Pavements”) are indicated in table 7.1. During construction, the surface evenness should be controlled as explained in paras 7.6 and 7.7.

Table 7.1

RECOMMENDED STRANDARDS FOR SURFACEEVENNESS FOR PAVEMENT CONSTRUCTION

Sr. Type of Construction Longitudinal Profile with 3 meter CrossNo. straight Edge1.

Maximum Maximum MaximumPermissible number of Permissible

Undulation mm. Undulations Variation formPermitted in any Specified 300 metre length profileexceeding mm. Under camber18 16 12 10 6 template mm.

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

1. Earthen sub-grade 24 30 - - - - 152. Stone soling/brick soling 20 - 30 - - - 123. Stablised soil 15 - - 30 - - 12

4. Water bound macadam with Over size metal(40 to 90mm size) 15 - - 30 - - 12

5. Water bound macadam with 12 - - - 30 -Normal size metal (20 to 50mm and 40 to 63 mm size) Penetration macadam or BUSG

6. Surface dressing (two coats) 12 - - - 20 - 8over WBM (20-50 mm or 40-63mm size metal)Penetration macadam or BUSG

7. Open graded premix carpet 10 - - - - 30 620-25 mm thick

8. Bituminous macadam 10 - - - - 30@@ 6

9. Bituminous Concrete 8 - - - - 20@@ 4

10. Cement Concrete 8 - - - - 10@@ 4

Note:i. For surface dressing in all cases, the standard of surface evenness will be the same as for the surface receiving the surface dressing.

ii. @@ These are four machines laid surfaces. If laid manually due to unavoidable reasons, tolerance up to 50% above the values in this column may be permitted at the discretion of the Engineer in charge. However, this relaxation does not apply to the value of maximum undulation for longitudinal profile mentioned in column 3 of the table.

iii. Surface evenness requirements in respect of both longitudinal and cross profile should be simultaneously satisfied.

7.6 Control of Transverse profile

The checking of transverse profile should commence right from the sub grade level and continued for each successive layer up to the top. Checking is done with the help of camber boards/ templates a few typical designs of which are shown are Fig. 1,2 and 3.

The template in fig. 1 has adjustable reference pods so that the template can be pre-set for any desired profile Fig. 2 shown a template in which the bottom piece for checking is replaceable to correspond to the specified profile. These designs are meant usually for checking the profile over a single-lane width. For two lane or multi-lane roads, generally the checking operations will required to be carried out individually for each lane.

For obtaining correct transverse profile on the finished surface of layer, it is necessary that the spread material (before compacting/finishing) should conform to the desired profile as far as possible. Therefore, the profile of the spread material should be continuously regulated with templates/ camber boards (placed perpendicular to the road centre line). Normally, set of three temples should be used in series at an interval of about 10 metres. Checking of the finished surface subsequently should be on the same lines. Additional checks may be made where visual appearance suggests an excessive variation.

7.7 Control of Longitudinal Profile

The longitudinal evenness is specified in terms of the maximum permissible irregularity under a straightedge. Typical designs for a metallic straight-edge and measuring wedge are given in Fig.4. The sub-grade level.

The procedure to be followed for marking surface unevenness measurements with a straight-edge is given at Appendix.I

Straight-edge measurements are slow and rather tedious. Travelling and rolling type of straight-edge as well as other improved devices have been developed in some other countries for facilitating the work on control of surface evenness. A device available in India for this purpose is the Unevenness Indicator developed at the Central Road Research Institute. This is a traveling straight-edge type of device which pre-set according to the specification for the surface under check, performs the following functions on being run by two workmen along the lines of measurement at a walking speed of about 5 Km per hour.

i. Instantaneously indicates the size of irregularity through a pointer moving on a graduate dial, to enlarged scale.

ii. Sounds a buzzer at locations where the irregularity is in excess of the maximum permissible (as pre-set)

iii. Automatically marks, through colour spray, locations where the irregularity is in excess of the permissible maximum (as pre-set).

The unit is simple to operate and is now readily available in the market. This should be used wherever possible.

The criteria in column 4 to 8 ….. of Table 7.1 are meant to ensure that there are not too many irregularities of a size one lower than the permissible maximum. This check is exercised by counting the related irregularities as they occur and then seeing whether there is excessive occurrence over any 300 mm length. Each depression/hump is to be counted only once. Both straight-edge and Unevenness Indicator methods are amenable to exercising of this control.

The maximum permitted number of surface irregularities shall be as per table7.2

Table 7.2

MAXIMUM PERMITTED NUMBER OF SURFACE IRREGULARITY

Surfaces of carriageway Surface of lay-bays, areas and aAnd paved shoulders -ll bituminous base

Irregularity 4mm 7mm 4mm 700Length (m) 300 75 300 75 300 75 300

75

NationalHighwaysExpressways 20 9 2 1 40 18 4 2

Roads of LowerCategory 40 18 4 2 60 27 63

(Category of each section of road as described in Contract)

The maximum allowable difference between the road surface and underside of a 3m straight-edge when placed parallel with, or at right angle to the centre line of the road at points decided by the Engineer shall be:

For pavement surface (Bituminous and cement concrete) 3mmFor base course Bituminous 6mmFor granular sub-base/base courses 8mmFor sub-base concrete pavements 10mm

Rectification

Where the surface regularity of subgrade and the various pavement courses fall outside the specified tolerances, it shall be rectified in the following manners.

(i) Subgrade : Where the surface is high, it shall be trimmed and suitably compacted. Where the same is low, the deficiency shall be corrected by scarifying the lower layer and adding fresh material and re compacting to the required density.

(ii) Granular subgrade: Same as at (i) above.

(iii) Wet mix macadam sub base/ base : Where the surface is high or low, the top 75mm sgall be scarified, reshaped with added material and recompacted.

(iii) Bituminous construction : For bituminous construction other than wearing course, where the surface is low, the deficiency shall be corrected by adding fresh material over a suitable tack coat if needed and recompacting to specification. Where the surface is high the full depth of the layer shall be removed and replaced with fresh material and compacted to specification.

For wearing course, where the surface is high or low the full depth or the layer shall be removed and replaced with fresh material and compacted to specification. In all cases, where the removal and replacement of a bituminous layer is involved, the area treated shall not be less than 5 metre length and not less than 3.5 metre in width.

8. SURVEYS STUDIES ANDPREPARATION OF DETAILED

PROPOSALS

From :

The Chief Engineer (IP),Punjab PWD B&R Branch,Chandigarh.

To

1. The Project Engineer cum EE,Central Works Division,SAS Nagar.

2. The Project –Engineer cum EE,Provisional Division,SAS Nagar,

3. The Project-Engineer cum EE,Central Works Division,ROPAR.

4. The Project-Engineer cum EE,C/W Division No.3LUDHIANA.

5. The Project-Engineer cum EE,Provisional Division,AMRITSAR, NAWANSHAHAR.

6. The Project-Engineer cum EE,R & D Division No.3,

LUDHIANA

7. The Project- Engineer cum EE,Provisional Division,JALANDHAR.

Memo No. : IP/ CH/362-368 Dated :9.7.2000

Sub: Execution of Road Project :Preparation of Detailed Proposal for Approval of Technical Committee of PIDB.

Although Item Rate DNIT’s from the execution of road Projects are based upon physical scope of work and engineering design as approved by the Technical Committee including specification, however quantities of various items as included in the DNIT are tentative and are liable to undergo some variation on account of specified site conditions. Similarly on account of recent amendments in MOST/ Specifications for Road and Bridge works and IRC guidelines, some additional items may be involved or completion of works.

Now, therefore it has been decided that before actual execution of work detailed designs and proposal are prepared based on detailed surrey along the complete reach for the approval of the Engineer as provided under the agreement. There surveys shall be conducted an completed preferably during the Mobilization period of 21 days through the Contractual agencies for finalization of scope of earth work. Drainage profile corrections. Road geometrics, provising of M.S. Railing in built areas etc.

Guidelines appended herewith are to be followed for the finalization of quantities of various items and additional item, if any; so that the revises scope of on the basis of site conditions as per detailed measurements at site be got approved from Technical Committee at the earliest and preferably before actual in various reaches.

The detailed proposal duly signed by the SDE incharge, Contractor or his authorized representative and certified by the Project Engineer be submitted for each work. Efforts are to be made to start the work at the earliest ; therefore full cooperation is to be executed to Contractor for the finalization of the scope of work and to check for any variations.

Sd/-DA/Guidelines Chief Engineer (IP)

8. GUIDELINES OF THE FINALIZATION OF SCOPE OF WORK

8.1 Earth work:

The Quantities of the E/W in the DNIT’s are tentative and are to be finalized subject to following studies and measurements.

1. Recording of existing levels of the centre line of the road at an interval of 15m and or proposed portions of raising at an interval of 10 meter.

2. Recording of existing of levels of the cross section corresponding to the longitudinal section at center, edges of the metalled portions, at edges of existing berms, and NSL on both sides and existing side slopes positions.

3. Bench mark should be a permanent feature and in no case it should be culvert top or level Road junction. Reduced B.M. should be a transferred at suitable intervals but not beyond more than 1 Km. Strech.

4. Earth as and where typing in mounds/heaps on berms is to be shown in cutting & is to be properly assessed with levels/ contours.

5. The existing longitudinal and cross section along with surplus earth available on berms is to be recorded in MB, which should be duly signed by the Contractor, SDE, incharge and be verified by the Project Engineer.

6. The proposal levels of finished road surface including widening /4 lanning and Raising portions & berms etc. should be super imposed on the existing levels on separate graph sheets and the Proposal is to be got approved before actual execution.

7. E/W in embankments is to be worked out, after giving credit of surplus earth available in cutting from berms, if any excavation on account of widening portions.

8. On the approval of the proposal, the actual levels achieved at site are again to be entered in M/B for actual quantities payable for excavation, cutting an embankments.

9. The sources of the earth for embankments purposes are to be identified & intimated by the contractor in writing. The soil samples are to be tested at field lab for soil analysis. i.e. sand contents , liquid limit an plastic limits, OMC & Proctor density with heavy compaction and soaked of sources soil. The actual earth filling is to be started only after the approval source.

8.2 PROFILE CORRECTIONS

Whenever the profile corrections are required on the existing roads, the proposal should be supported with following studies.

1. Were ever the road surface is having Map creaks or alligator cracks, such areas should be preserved. The provision of crack prevention course (Stress Absorbing Membrane to inhibit the propagation of cracks is to be made.

2. The camber corrections of the existing road surface, as per the site are to supported with correction of involved is more than 25 mm thick, the same be rectified by B.M… if less than 25 mm & it is to be corrected with Mixed Seal surfacing type B.

3. In case the road surface is undulatory & needs profile corrections, before strengthening, the proposal should be supported with existing surface levels at an interval of 5’-10” in lateral direction and at interval of 10 ft in longitudinal direction for working out average thickness of corrective layers.

8.3 DRAINAGE

Drainage of the road surface especially in the built up areas on the roads passing through villages and in the urban areas is to be given top importance. By all means, no portion of the road should be left without proper drainage, the absence of which is likely to damage the road. For this purpose the following studies are required for final assessment:

1. All the built up in areas on the road passing through the road passing through urban areas be identified, Its existing level along with plinth levels of construction on both side be marked. The maximum inundation of road during people season and time for natural drainage be checked up from the local people and recorded.

2. No raising in such areas be proposed more than the existing plinth levels of construction on both sides.

3. The section of suitable drain as per MOST standards for the drainage of the discharge of rainwater be proposed on both sides.

4. In case of built up areas of villages along the road, the drainage of the storm water through proposed drain is to be made on roadside ditches beyond such areas.

5. For Urban areas, the stretches are long, thus it has to be studied that the discharge of drains through side roads is not blocked. In such wherever culverts under side roads are required be proposed. The disposal of rainwater as per natural gradients is to be ensured side.

6. Length of drain for all such reaches be clearly marked on plan including final disposal.

7. Wherever necessary, provision of catch pits and chutes be also made for draining the storm water in to the parallel drains etc. be also made.

8.4 PROVISION OF LAY BYES

1. preferably near sales tax Barriers and Octoroi posts, provision of lay byes (150ft*12ft) size of both sides of the road at suitable interval is to be kept, in open reaches.

2. The lay byes are to be finished with kerb and channels on outer edges.3. Draining of such Lay byes shall be made away from the road.4. Provision of all such lay byes should be marked on the plan, and the additional quantities of various

items involved be worked separately.

8.5 EXTENSION OF EXISTING CULVERTS AND SMALL BRIDGES

The proposal for widening of existing Culverts/bridges and that for new Culverts, if any, shall include.

1. Where ever the widening of the roads is form 17ft to 22ft, existing culverts/small bridges are to be widened up to 33ft.

2. For widening a from 22ft to 33 ft existing culverts and bridges are to be widened up to 44ft.3. New culverts, if required and are justified to be provided for cross drainage are to be identified

and to be include in the proposal.4. For storm water drainage of the roads, through proposed surface drains, if culvert is required

under side in the same must be identified and be included in the proposal.5. The foundation sub structure and super structure of the existing culverts/small bridges is to be

kept same as provided in case of existing culverts. In case the original drawings of culverts/small bridges are not traceable, the existing sizes be checked at site and are to be adopted after verification by Project Engineer.

6. For Super Structure such culverts /small bridge Nominal Concrete Mix (1:11/2 :3)is to be use, with Fe 415 TMT/TOR steel reinforcement bars.

7. Construction of any H/L bridge covered in the Road Project shall be subject to the approval of GAD and structural drawings by the CE(IP).

8. Longitudinal plan of the road showing all such extension of existing culverts/small Bridges and construction of H/L bridges is to be prepared and submitted with proposal.

8.6 ROAD SIGNAGE & OVERHEAD SIGNAGE

The proposal for road signage and over head signage shall include:

1. Regulatory Mandatory signboards to be provided at suitable places as per IRC Guide lines their location and approx. numbers.

2. Warning and cautionary Signs as per IRC Guidelines, their location and approx. numbers.3. Guide or Informatory signs as per IRC Guidelines, their location and approx. numbers.4. Overhead gantry signboards are only to be provided in the important towns, where the state

highways bifurcate for information and guidance of traffic.

8.7 TRAFFIC MARKINGS

The proposal for traffic marking in thermoplastic paint shall include:

1. Providing of zebra crossing near schools, which is mandatory as per the orders of Hon’ble High Court.

2. Center line; Lay bye lines including non overtaking zones, if any.

3. Traffic marking at Traffic Signals/ Junction/Intersection.

9. RECORDING OF TEST RESULTS &QUALITY CONTROL RETURNS

9.1 VALIDITY OF TESTS RESULTS/CERTIFICATES

Checks & tests on quality Controls of Materials ; pre and post construction activities, involved in the execution of works, as per required frequency and procedure shall be carried out regularly at site and their record shall be maintained properly. Those tests which are beyond the scope of field lab. or for the purpose of verification/confirmations of field tests, if required, such testings shall be got done through following labs.

i) Verification/confirmation of field test - Pb. PWD (B&R Research Results Lab. Nabha Road, Patiala.

ii) Job Mix formula for Bitumen Mixes, - I) Consultant Lab.GSB and WMM ii) Any other reputed laboratory

With the permission of Project Engineer.

iii) Concrete Mix Design - As above and reputediv) CBR, C & Ǿ values of Earth work - Laboratory with the permission

and CBR of Granular Sub base sources of Project Engineer.

v) Important materials of bridges such as :a) Bearings - At manufacturer’s Lab . in the

presence of representative of Project Engineer.

b) Prestressing strands (must accompany - At Supplier’s Laboratorywith test certificates)

c) Prestressing accessories, sheathing,- At supplier’s laboratory (with end anchorages, cones all accessories accompanied

with test certificate.

d) Expansion joints - At supplier’s laboratory(From empanelled manufacturers of MOST)

9.2 DUTIES OF QUALITY CONTROL CONSULTANT

Record of all tests along with the supporting documents such as work sheets, check list proformas etc. shall be properly maintained by the Quality Control Consultant at site in the field lab.

It will be the joint responsibility of the agency, Quality Control Consultant and Project engineer to ensure that:

(A) Prior approvals are obtained, well in time for:

Source of earth for embankment on the basis of suitability determined by grain size analysis, OMC verses MDD, unconfined undrained compression values of C& Ǿ and their possible trial testings in field lab.

Granular Sub base material on the basis of OMC verses MDD & CBR. For Wet Mix macadam on the basis of OMC v/s Max Dry Density. Optimum Binder content verses Max. Density for Bituminous Macadam. Optimum Bitumen Content verses Density subject to desired parameters of stability flow &

voids for DBM, SDBC and Bituminous soncrete. Mix Designs.

(B) Checking the Quality of materials as per required frequency and keeping its record.

(C) Testing/ checking of Post Construction works as per desired frequency.

(D) Keeping record of consignment of important materials and the manufacturer’s Test certificates.

(E) Occasional verification of test results of cement & steel from the independent reputed lab.

(F) Occasional checking of calibration of Machinery /Testing Equipments and keeping its record.

(G) Filling and keeping record of check list proformas before the start of activities.

(H) Preparing of Quality Control returns and sending to the concerned authorities.

9.3 MAINTENANCE OF QUALITY CONTROL RECORD

Following register shall be maintained for recording results:-

(i) Record of consignment of Cement, Steel, Bitumen and Emulsion with manufacturer’s Test Certificates details.

ii) Approval of source of materials.

iii) Approval of Job Mix Formula of Bituminous specifications and non bituminous specifications.

iv) Approval of concrete mix design.

v) Checking earth work in embankment.

vi) Post construction test of Non Bituminous specifications.

vii) Post construction test of bituminous specifications.

viii) Compressive strength of cubes.

ix) Slump at the time of pouring concrete.

(x) Control of alignments and surface regularity.

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