QAP Volume - 1

National Cyclone Risk Mitigation Project (NCRMP) Revenue (DM) Department Government of Andhra Pradesh
Third Party Quality Audit(TPQA)

in Joint venture with
Third Party Quality Audit for Construction of Cyclone Shelters, Roads to Cyclone Shelters & Habitations, Bridges and Culverts under NCRMP
Quality Assurance Plan
INDEX
1 2 3 4 5 6 S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Introduction Quality Control Tests Required/Frequency/Specifications for Roads & Bridges Quality Control Tests Required/Frequency/Specifications for Buildings Methodology for Road construction OK Card Formats Rectification Guidelines LIST OF TABLE'S Original Ground as Embankment Foundation Original Ground as Sub Grade (500 mm Thick ) Embankment up to 3m Height Sub-grade in Cutting or Embankment (500 mm Thick) Embankment Exceeding 3m Height Additional Test on filling with in 600mm of Concrete Structures/ Cement Bound Materials Back Filling to Sub-Surface Drains Aggregate Drains Granular Sub-Base Water Bound Macadam Sub-Base / Base Prime Coat and Tack Coat Open Graded Premix Surfacing Bituminous Macadam Mix seal Surfacing Semi Dense Bituminous Concrete Cement Concrete Pavement Cement for Structural Works Coarse Aggregate for Structures Sand / Fine Aggregate for Structures Reinforcement Steel Water for Concrete and Mortar
1 6 24 28 42 57 Page No 6 6 7 7 8 8 9 9 10 11 13 13 14 15 16 18 20 20 22 23 23
in Joint Venture with
1.0
1.1
INTRODUCTION
Project Background
National Cyclone Risk Mitigation Project (NCRMP) Project Implementation Unit (PIU), Andhra Pradesh, headquartered at Hyderabad has appointed Egis International in JV with Egis India Consulting Engineers (I) Pvt. Ltd for providing the consultancy services for Third Party Quality Audit for 9 coastal districts namely Srikakulam, Visakhapatnam, East Godavari, West Godavari, Krishna, Guntur, Prakasam and Nellore. The project Construction of Multipurpose Cyclone Shelters, Roads to Cyclone Shelters, and Roads to habitations and Roads & Bridges under NCRMP is funded by International Development Association and received through Government of India. This consultancy is envisaged to audit the quality of works being implemented by various line departments working under PIU. As a part of this assignment, the Third Party Quality Auditor (TPQA) will report to PIU on its audit findings. The objectives and description of the services for third party quality audit are: A. Assist the PIU in maintaining the quality standards of the civil works by independent assessment / audit of quality of works at various stages of construction of multipurpose cyclone shelters, roads, bridges and culverts being implemented by PR departments. For bridges and roads, R&B department. B. Report on the compliance with the requirements of Environmental and Social Frame work (ESMF) including the management measures provided in the Environmental Management Plans (EMPs) and the Resettlement Action Plans, when ever required. This QAP is prepared as part of TPQA agreement and the frequency of testing, test report formats, checklists provided in this QAP are for the guidance and implementation by Contactors and Line Departments. The implementation of the same will be monitored by the TPQA during the audit visits. TPQA will also conduct all the required field tests/lab tests for confirmation of the quality requirements 1.2 Third Party Quality Audit
The activity flow of TPQA is as follows. A. The TPQA will guide the implementation engineers with respect to designs as per the contact documents, within the planned time frame, conforming to the guidelines and circulars issued and also based on the objectives of the project.
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B.
The TPQA will review the results of field testing being conducted by the contractor and Line department and when doubts arise in such observations another sample will be taken and will be tested independently to verify whether it is as per the standards or not.
C.
The TPQA will review civil work components of the cyclone shelters and related roads & bridges of these buildings and compliances and non-compliances will be reported regularly to PIU and line department.
D.
The TPQA will visit the construction sites randomly without prior information to the implementing agency, along with the regular site visits. Regular feedback will be given with regards to compliance of suggested corrective measures. Wherever compliances are not happening, a report should be submitted to the PIU and line departments and if necessary Stop Work notice will be issued through the Engineer in-charge.
E.
The TPQA will carry out additional tests, where a prime facie doubt arises related to quality of works and / or compliance of standards using mobile laboratory available with the TPQA team or nearby approved laboratories. The TPQA shall advise few more labs for testing suitably, which after the approval of the PIU / line departments, can be used for testing.
F.
Review the workers safety standards being followed in the construction site to avoid any type of losses / damages, as far as possible.
1.3
1.3.1
QUALITY ASSURANCE PLAN

Introduction
The Quality Assurance Plan (QAP) is the methodology that is selected for ensuring that the project incorporates all elements that are needed for the successful design, construction and maintenance of a project. Since projects vary in scope, the QAP has to be project-specific. The QAP should deal with all aspects of selection and testing of materials, acceptance criteria, guidelines for non-conforming materials and works and documentation. 1.3.2 Quality Control
1.3.2.1 Types of Quality Control One of the most important tasks during the execution of a road contract is technical quality control, i.e. control as to whether the materials and work supplied by the Contractor meet the technical requirements in the contract specifications. There are two types of quality control, which are described below: (a) Control of Methods Method control is usually carried out by the Line Department field staff whose job it is to be on the site and supervise the Contractor during the execution of the works. It is the responsibility of the Line Departments staff to see that the contractor performs the entire required test as per the frequency and all the records
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are maintained. Line department should also see that all the registers, site order books are maintained. All the test reports, registers, site order books etc. will be reviewed and audited by the TPQA during the site visits apart from conducting tests required for confirmation. (b) Control of End-Results End-result control includes field tests e.g. control of the evenness of completed pavement layers and laboratory tests, e.g. Marshall test on bitumen materials. Other tests are a combination of field and laboratory tests. An example of this is the compaction control of earthworks where the achieved density is determined by means of a field test, and where the density with which the result should be compared is found by means of a laboratory test. End results control is carried out by laboratory technicians, and most of the work consists of field and laboratory tests. 1.3.3 Start-up Problems
It is important that start-up problems have been solved before the Contractor starts work. There is often a special need for technical control during the start of the work, because the Contractor has start-up problems. Specifications normally not only state the technical requirements which must be met by materials and works, but also the test methods which must be used for the end-result control. In most cases this is necessary to be able to define the requirements clearly. 1.3.4 Test Specification
Specifications usually describe test methods by referring to standard methods issued by Ministry of Rural Development, and the Bureau of Indian Standards (BIS). 1.3.5 Testing Frequency
The frequency of technical control is usually laid down by the Client at the beginning of a project and is generally related to the specifications. A testing plan giving the testing frequency, standards, acceptance criteria are provided to be followed by the Contractor. 1.3.5.1 NCRMP works of Bridges (9Nos) and roads (2Nos) are being executed by R & B Department and MORT&H specifications and IRC codes are to be followed. 1.3.5.2 NCRMP works of rural roads namely roads to habitation and cyclone shelters and cyclone shelters are being executed by PR Eng. Department and for these works MORD specifications need to be followed.
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1.3.5.3 For cyclone shelters IS: 456 and other relevant IS codes need to be followed The frequency of tests, specifications and requirements are furnished in section 2.0 and 3.0 of this QAP booklet. The frequencies are as per MORT&H and MORD requirements. All the field tests and laboratory tests required are to be done by the contractor. All the field tests are to be done by line Departmental officers and TPQA staff also. Necessary laboratory tests are to be conducted by line departmental officers and conformity laboratory tests are to be done by TPQA officers. This may be modified by the client if necessary. 1.3.6 Method Control
Method control is carried out according to the type of work. Where the work method is of considerable importance and requires constant supervision to achieve the quality, or where in some case, the quality is difficult to improve upon, there should always be a field engineer on the site. Examples are the ramming of piles, the laying of bitumen, embankment construction and concreting etc. Where work methods are of less importance or quality is constantly being achieved by the contractor, a continuous supervision may not be needed, but required confirmatory tests are to be performed as per the frequency. Detailed methodology for all the impartment items are given in section 4.0 of this booklet. TPQA officers will inspect all the works in different stages of works to ensure good quality standards in the work. Methodology of TPQA in ensuring good quality of work: The site engineers will be inspecting the works in progress at regular intervals like once or twice in a week depending on the nature of work. They conduct all the field tests required. They collect and send samples for laboratory testings. The field engineers verify wether the work is going on as per specifications. The site engineers assist the line departmental engineers and the contractor in rectifying the works during construction to the possible extent. The site engineers submit inspection report for every work to the DPM with a copy to PM by E-mail. The DPM will also conduct regular inspections once or twice in a month depending on the nature of work. The Project Manager inspects the works once or twice in a quarter to monitor the quality measures adopted by the contractor, line departmental engineers and TPQA engineers. The materials like bitumen, cement, steel, water and GSB mix etc will be sent to accredited laboratory for testing In case of failure of field density and gradation etc, suitable action will be taken to get it rectified immediately. In case of failure like CBR tests, non-compliance of materials, suitable Non- Compliance report will be issued to the concerned executive Engineer, PIU with copies to the PM, PIU. On receipt of
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compliance it will be verified whether the required remedial measure is carried out or not. The acceptance or otherwise of the Compliance will be intimated to the client. During visits, TPQA will also conduct Quality Assurance prevention to all the Engineers and contractors to enlighten the quality aspects of work As a part of QAP, TPQA has distributed booklets with all the items of work associated with NCRMP phase 1 works to all the Engineers and all the contractors at the QA workshop conducted at Vijayawada on 28-06-2011. The Booklet contains Specifications, Methodology, Dos and donts and Acceptance criteria for all types of works. The subjects incorporated in the booklet are : a) b) c) d) e) f) Rural road construction as per MORD specification and IRC : SP: 20 Road construction as per MORT & H specification Important aspects in construction of structures as per IS : 456 and IRC codes. Quality assurance in reinforcement steel. Good construction practices in reinforcement detailing CC roads as per MORD specifications and as per IRC: SP: 62-2004. The booklet was printed in such a way that all the contractors and Engineers can use it as a reference book at site also. 1.3.7 End-result Control
The frequency of end-result control depends on the quality parameters that are to be checked. Parameters which can vary considerably are continuously controlled. Examples are the composition of bitumen materials and the compaction of bitumen courses. As regards regulating laboratory tests the specification usually determines the number of tests. When the works are started and in cases where difficulties as regards compliance with quality requirements are encountered, laboratory testing will normally be intensified. 1.3.8 Quality Parameters Quality parameters which are usually more or less constant, e.g. the Aggregate Impact Value of stone materials from the same quarry, are only controlled occasionally. The same applies to parameters which can be checked fairly well with the naked eye, e.g. the particle form of crushed stone. As regards the quality of manufactured materials produced by using advanced technology, e.g. steel and bitumen, one usually trusts the manufacturer`s certificates, but when in doubt carry out additional tests. 1.3.9 Reporting of Test Results The test results must be recorded systematically in a format, which must be signed by the testing authority and the representative of the Engineer, if present during the tests.
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2.0 Quality Control Tests Required/Frequency/Specifications for Roads & Bridges

Table 1: Original Ground as Embankment Foundation
Sl. No. 1. 2. Test MDD & OMC (by heavy compaction) Moisture content during field compaction Test Method IS:2720 (Pt 8) IS:2720 (Pt 2) (speedy tester/nuclear meter) IS:2720 (Pt 28) Special Specifications Minimum Frequency 1 test per 3000 Cum Frequently Specified Value MDD not less than 15.2kN/cum OMC+1% to 2% (for expansive clay on wet side of OMC) 95% (90% for expansive clay) Special Specifications
3. 4.
Degree of compaction Tests for high embankment
1 test per 1000 sqm As required
Table 2: Original Ground as Sub-Grade (500mm Thick)

Sl. No. 1. 2. 3. 4. 5.
NOTE:
Test MDD & OMC (by heavy compaction) CBR at 97% MDD Maximum particle size M.C. during field compaction Degree of compaction
Test Method IS:2720 (Pt 8) IS:2720 (Pt 16) IS:2720 (Pt 4) IS:2720 (Pt 2) IS:2720 (Pt 28)
Minimum Frequency 1 test per 3000 Cum 1 test per 3000 Cum Frequently Frequently 1 test per 1000 sqm
Specified Value MDD not less than 17.5kN/cum As in Special Specifications 50mm OMC + 1% to 2% 97%
MDD = Maximum Dry Density; OMC = Optimum Moisture Content; Pt = Part; sqm = square meter; Spl. Spn. = Special Specification; Std. Spn. = Standard Specification; M.C. = Moisture Content; LL = Liquid Limit; Pl = Plasticity Index; Max. = Maximum; Min. = Minimum Heavy Compaction Refers Modified Proctor Tests.
Conversion Factors: 1N = 101.97 g; 1 kN = 101.97 kg; Sl unit of density is kg/cum; For approximate conversion, 1 kN is taken as 100 kg or 1 kg = 10N; 1 g/cc or 1 g/ml = 1000 kg/cum (Example: Soil heaving density 1.52 g/cc will now be written as 1520 kg/cum); unit of force 1 Pa = 1 N/sqm and 1MPa =1 N/sqmm (Example compressive strength of concrete when tested using old machines with dial gauges in Tones or kgs can be converted by the relation, 10kg/sq.cm = 1N/sqmm = 1MPa
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Table 3: Embankment up to 3m Height

Sl. No. 1. 2. 3. 4. Test Gradation/Sand Content Maximum Particle size MDD & OMC (by heavy compaction) M.C. during field compaction Test Method IS:2720 (Pt 4) IS:2720 (Pt 4) IS:2720 (Pt 8) IS:2720 (Pt 2) (Speedy tester/nuclear meter) IS:2720 (Pt 28) By scaling during compaction test 1 2 2 2 Minimum Frequency test per 3000 cum test per 3000 cum test per 3000 cum test per 3000 cum Specified Value As in special specification 75mm MDD not less than 15.2 kN/cum OMC + 1% to 2% (on wet side of OMC for Expansive clay) (95% (for expansive clay 90%) 150mm to 250mm
5. 6.
Degree of compaction Layer thickness (compacted)
1 test per 1000 sqm 1 test per 1000 sqm
Table4: Sub-Grade in Cutting or Embankment (500mm Thick)

Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. Test Gradation/Sand Content Maximum Particle size MDD & OMC (by heavy compaction) CBR at 97% MDD M.C. during field compaction Degree of compaction Layer thickness (compacted) Classification Test Method IS:2720 (Pt 4) IS:2720 (Pt 4) IS:2720 (Pt 8) IS:2720 (Pt 16) IS:2720 (Pt 2) IS:2720 (Pt 28) By Scaling during compaction IS:1498 Minimum Frequency 1-2 test per 3000 cum 1-2 test per 3000 cum 1 test per 3000 cum 1 test per 3000 cum 1 test per 3000 cum 1 test per 500 sqm 1 test per 1000 sqm 1 test per 3000 cum Specified Value As in Special Specifications 50mm MDD not less than 17.5 kN/cum As in special specification OMC + 1% to 2% 97% 100mm to 250mm Expansive clay not allowed*
NOTE: * Where an expansive clay with acceptable free swelling index value is used as a fill material in the embankment or encountered in cutting, the Subgrade and top 500 mm portion of the embankment/ cutting just below the Subgrade shall be removed and filled with CNS soils.
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Table5: Embankment Exceeding 3m Height

Sl. No. 1. 2. 3. 4. 5. 6. 7. Test Gradation/Sand Content Classification LL & PI Maximum Particle size MDD & OMC (by heavy compaction) M.C. during field compaction Degree of compaction Test Method IS:2720 (Pt 4) IS:1498 IS:2720 (Pt 5) IS:2720 (Pt 4) IS:2720 (Pt 8) IS:2720 (Pt 2) (Speedy tester/nuclear meter) IS:2720 (Pt 28) Minimum Frequency 2 test per 3000 cum 1 test per 3000 cum 1 test per 3000 cum Frequently 1 test per 3000 cum 1 test per 1000 Cum 1 test per 1000 Cum( at least one test in every layer) 1 test per 3000 Cum Specified Value As in Special Specifications As in Special Specifications As in Special Specifications 75mm MDD not less than specified value in design OMC + 1% to 2% 95%
8.
Layer thickness (compacted)
By scaling during compaction test
150mm to 250mm
Table6: Additional Test on Filling within 600mm of Concrete Structures/Cement Bound Materials
Sl. No. 1. 2. Test Soluble Sulphate content (expressed as SO3) Total Sulphate content (expressed as SO3) Test Method BS:1377 (Pt 3:1990)/IS:2720(27) BS:1377 (Pt 3:1990) Minimum Frequency As required As required Specified Value Max 1.9 g per litre Max 0.5% by mass
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Table7: Backfilling to Sub-Surface Drains

Sl. No. 1. Test Grading of filter material Test Method IS:2720 (Pt 4) Minimum Frequency Each batch Sieve Size 53mm Specified Value % Passing Class I Class II Class III 100
NOTE: i) Use Class I filter if soil in trench is fine grained (eg. silt, clay or mixture thereof). ii) Use Class II filter if soil in trench is coarse silt to medium sand or sandy type. iii) Use Class III filter if soil in trench is gravelly sand.
2.
Size of holes in perforated pipe
Each batch
45mm 97-100 26.5mm 100 22.4mm 95-100 58-100 11.2mm 100 48-100 20-60 5.6mm 92-100 28-54 4-32 2.8mm 83-100 20-35 0-10 1.4mm 59-96 0-5 710mic 35-80 6-18 355mic 14-40 2-9 180mic 3-15 90mic 0-5 0-4 0-3 Less than D85 size of material surrounding pipe
Table 8: Aggregate Drains

Sl. No. 1. Test Grading of aggregate Test Method IS:2720 (Pt 4) Minimum Frequency Each batch Sieve Size 63mm 37.5mm 19mm 9.5mm
Specified Value % Passing Type A 100 45-100 Type B 100 85-100 0-20 0-5
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3.35mm 600mic 150mic 75mic
25-80 8-45 0-10 0-5
Table 9: Granular Sub-Base

Sl. No. 1. Test Grading for close-graded material Test Method IS:2720 (Pt 4) Minimum Frequency Each batch Specified Value % Passing Grading Grading I Grading III II 100 80-100 100 55-90 70-100 100 35-65 50-80 65-95 25-55 40-65 50-80 20-40 30-50 40-65 10-25 15-25 20-35 3-10 3-10 3-10 Specified Value % Passing Grading Grading I Grading III II 100 100 100 55-75 50-80 10-30 15-35 25-45 < 10 < 10 < 10
NOTE: For required grading, see special specification of concerned project
Sieve Size 75mm 53mm 26.5mm 9.5mm 4.75mm 2.36mm 0.425mm 0.075mm
2.
Grading of coarse graded material
NOTE: For required grading, see special specification of concerned project
IS:2720 (Pt 4)
1 per 200cum Sieve Size 75mm 53mm 26.5mm 9.5mm 4.75mm 2.36mm 0.425mm 0.075mm
NOTE:
DEFINITION OF BATCH APPLICABLE TO AGGREGATES: The quantity of aggregate of same size produced by crushing one type of rock in one continuous operation or a stockpile of aggregate of same size and same type of rock from a single source.
3.
Ten percent fine value (wet)

BS:812 (Pt 111)
1 per 200 cum
Min 50kN
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Sl. No. 4. 5. 6. 7. 8. 9. 10. 11.
Test Water absorption Soundness in Sodium Sulphate (when water absorption > 2%) CBR at 98% compaction MDD & OMC MC for field compaction Degree of compaction LL and PI for material passing 424 micron Deleterious constituents
Test Method IS:2386 (Pt 3) IS:383 IS:2720 (Pt16) IS:2720 (Pt18) Speedy tester/Nuclear meter IS:2720 (Pt 28) IS:2720 (Pt 5) Visual
Minimum Frequency 1 per 200 cum 1 per 200 cum As required As required 1 per 250 sqm 1 per 500 sqm 1 per 200 cum As required
Specified Value Max 2% Max 12 30/25/20 for grading I, II, III 2% to + 1% of OMC Min 98% 25% and 6% Nil
Table 10: Water Bound Macadam Sub-Base/Base

Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 Test Los Angeles Abrasion value Aggregate impact value (alternative of LAA) Combined Flakiness & Elongation Indices Liquid limit of screening material Plasticity index of screening material Fraction passing 75 mic of screening Water absorption for aggregates Soundness in Sodium Sulphate (when water absorption is > 2%) Plasticity index of binding material Grading of coarse aggregates Test Method IS:2386 (Pt 4) IS:2386 (Pt 4) or IS:5640 IS:2386 (Pt 1) IS:2386 (Pt 5) IS:2386 (Pt 5) IS:2386 (Pt 1) IS:2386 (Pt 3) IS:383 IS:2386 (Pt 5) IS:2386 (Pt 1) Minimum Frequency 1 per 200cum 1 per 200cum 1 per 200cum 1 per 100cum 1 per 100cum 1 per 100cum 1 per 200cum 1 per 200cum 1 per 25cum Max 40% Max 30% Max 30% Below 20% Below 6 Max 10% Max 2% Max 12% Less than 6 Grading No. Sieve Range Sieve Size % Passing by weight Specified Value
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Sl. No.
Test In general visual inspection of the aggregates shall be made and not weathered rock samples should be allowed.
Test Method
Minimum Frequency 1.
Specified Value 90-45mm 125mm 90mm 63mm 45mm 22.4mm 2. 63-45mm 90mm 63mm 53mm 45mm 22.4mm 3. 5322.4mm 63mm 53mm 45mm 22.4mm 11.2mm 100 90-100 25-60 0-15 0-5 100 90-100 25-75 0-15 0-5 100 95-100 65-90 0-10 0-5 100 95-100 15-35 0-10 100 90-100 15-35
11.
Grading for screenings
IS:2386 (Pt 1)
1 per 100cum
A.
13.2mm
13.2mm 11.2mm 5.6mm 180mic
B.
11.2mm
11.2mm 5.6mm 180mic
Table 11: Prime Coat and Tack Coat

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Sl. No. 1. 2. 3.
Test Quality of primer Binder temperature for application Rate of spread of binder
Test Method IS:73, IS:217 & IS:8887 Tray Test/Depot Tray Test
Minimum Frequency 2 sample per lot At regular interval One test/500sqm and not less than 2 per day
Specified Value Special Specifications Special Specifications Max variation 2.5%
Table 12: Open Graded Premix Surfacing

Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Test Quality of binder Los Angeles Abrasion Value or Aggregate Impact Value Flakiness Index and Elongation Index (combined) Coating and stripping Soundness in Sodium Sulphate and Magnesium Sulphate Water absorption Stone polishing value Grading of 13.2mm chippings Grading of 11.2mm chippings Binder content for premixing Temperature control: a) Binder at the time of mixing b) Aggregate at the time of mixing c) Discharge temperature of mix Test Method IS:73 IS:2386 (Pt 4) IS:2386 (Pt 1) AASHTO: T182/IS : 6241 IS:2386 (Pt 5) IS:2386 (Pt 3) BS:812 (Pt 114) IS:2386 (Pt 1) IS:2386 (Pt 1) Site check Minimum Frequency 2 per lot 1 per 50cum 1 per 50cum 3 per source 1 per source 1 per 50cum As required 1 per 25cum 1 per 25cum 2 per day Specified Value Special Specifications LAA max 40%, AIV max 30% Max 30% Min retained coating 95% Max 12%/18% Max 1% Min 55 100% passing 22.4mm & retained on 11.2mm 100% passing 13.2mm & retained on 5.6mm 52kg per cum for 13.2mm chippings and 56kg per cum for 11.2mm chippings. 150oC to163oC 155oC to163oC 130oC to160oC
Frequently Frequently Frequently
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Sl. No. 12.
Test Rate of spread of mixed material
Test Method Site check of materials and layer thickness Test Method IS:73 IS:2386 (Pt 4) IS:2386 (Pt 1) AASHTO T:182/IS : 6241
Minimum Frequency Regularly
Specified Value Min 20mm thick
Table 13: Bituminous Macadam

Sl. No. 1. 2. 3. 4. Test Quality of binder Aggregate Impact Value (AIV) or Los Angels Abrasion Value (LAA) Flakiness Index & Elongation Index (combined) Stripping value of aggregate. If the minimum retained coating is <95% Retained Tensile Strength Test shall be carried out specified value is min 80% Soundness in Sodium Sulphate and Magnesium Sulphate Water absorption Grading aggregates Grading I Grading II Nominal aggregate 40mm 19mm size Layer thickness 80-100mm 50-75mm Minimum Frequency 2 per lot 1 per 50cum 1 per 50cum 3 per source Min coating 95% IS:2386 (Pt 5) IS:2386 (Pt 3) IS:2386 (Pt 1) 1 per 50cum 1 per 50cum 2 per day/plant both on individual constituents and mixed aggregates from the dryer Max 12%/18% Max 2% % Passing Grading 1 Grading 2 45mm 100 26.5mm 75-100 100 22.4mm 60-95 75-100 11.2mm 30-55 50-85 5.6mm 15-35 20-40 2.8mm 5-20 5-20 90micron 0-5 0-5 Max 5% passing 75 micron 3.1 to 3.4% for grading I 3.3 to 3.5% for grading II with tolerance 0.3% by weight of total mixture Sieve Size Specified Value Special Specifications AIV - max 30%, LAA max 40% 30% max
5. 6. 7.
8. 9.
Grain size analysis Binder content of mix
Check at plant
2 tests/ day/plant At regular intervals
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10.
Temperature control: a) b) c) d) e) Binder at mixing time Aggregate at mixing time Discharge temperature of mix Laying temperature Temperature at completion of rolling Site check 1 per 250cum Test Method IS:73, 217, 454 Table 24 (Test 2 to 6) Sieve analysis Minimum Frequency 2 per lot 1 per 50cum 1 per 50cum At At At At At frequent frequent frequent frequent frequent intervals intervals intervals intervals intervals
11. 12. Sl. No. 1. 2. 3.
Layer thickness Density of compacted layer Test Quality of binder Quality of aggregate Grading of aggregates
Varies with the type of penetration bitumen 30 - 40 60 - 70 80 -100 160-170 150-165 140-160 160-175 150-170 140-165 Max 170 Max 165 Max 155 Min 130 Min 125 Min 115 Min 100 Min 90 Min 80 Special Specifications Special Specifications Specified Value Special Specification % Passing Sieve Size Type A Type B mix mix 13.2mm 100 11.2mm 100 88-100 5.6mm 52-88 31-52 2.8mm 14-38 5-25 90mic 0-5 0-5 Type A: 22kg; Type B: 19kg 0.27 cum for Type A & B 150oC to163oC 155oC to163oC 130oC to160oC Min 100oC Min 20mm
Table 14: Mix Seal Surfacing
4. 5. 6.
7.
Rate of binder for mix per 10sqm Rate of aggregate per 10sqm Temperature control: a) Binder before mixing b) Aggregate before mixing c) Mix on discharge d) Completion of rolling Thickness after compaction
Site check Site check
2 per day 2 per day Frequently Frequently Frequently Frequently
Table 15: Semi Dense Bituminous Concrete

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Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Quality of 80/100)
Test binder (grade 30/40 to IS:73
Test Method
Minimum Frequency 2 per lot 1 per 50cum 1 per 50cum 1 per 50cum 1 per 50cum As required As required As required 2 per day
Specified Value Special Specifications LAA 35% or AIV 27% max Max 30% Min coating 95% Max 1% (exceptional 2%) Max 12%/18% Not less than 50 Not Less than 55 Sieve Size 19mm 13.2mm 9.5mm 4.75mm 2.36mm 1.18mm 600mic 300mic 75mic % Passing by weight Grading I 100 90-100 70-90 35-51 24-39 15-30 -9-19 3-8 Grading II -100 90-100 35-51 24-39 15-30 -9-19 3-8
Los Angeles Abrasion or Aggregate Impact Value Flakiness and Elongation Index (total) Coating and stripping Water absorption Soundness in Sodium Sulphate/Magnesium Sulphate Sand equivalent value Stone polishing value Grading of mixed aggregate
IS:2386 (Pt 4) IS:2386 (Pt 1) AASHTO T:182/IS 6241 IS:2386 (Pt 3) IS:2386 (Pt 5) IS:2720 (Pt 37) BS:812 (Pt 114) IS:2386 (Pt 1)
10. 11.
Job mix formula Requirements of mix
By mix design ASTM D-1559
Every change of material 2 tests per day or per 400 tone of mix
As per Design S. No. 1. Description Marshall stability Requirement Mn. 8.2 kN @ 60oc
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Sl. No.
Test
Test Method
Minimum Frequency 2. 3. 4.
Specified Value Marshall flow 2-4mm Air voids 3-5% Min VMA (same as Table 27 (test 10 item 6) 5. VFB 65-78% 6. Binder content Min 4.5% for Grading I and Min 5% for Grading II 7. Compaction level No. of blows 75 blows / face See Table 28 (item 11) Same as Table 24 (10)
12. 13.
14. 15. 16.
Permissible variations from JMF Temperature Control: a) Binder b) Aggregate c) Discharge temperature d) Laying temperature e) Completion of rolling Control of binder content and gradation Layer thickness Density of compacted layer
Bitumen extraction and sieving (Appendix 5 of IRC:SP-11) Site check Density of core
2 per day 1 per 250sqm 1 per 250sqm
JMF Special specifications Min 98% of Marshall specimen
Table 16: Cement Concrete

Sl. No. Test Test Method Minimum Frequency Specified Value
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Sl. No. 1.
Test Cement (Physical and Chemical tests) a) Portland Slag Cement Los Angeles Abrasion or Aggregate Impact Value of coarse aggregate a) Deleterious constituents in coarse aggregate b) Deleterious constituents in fine aggregate Total chloride content in aggregate Total sulphate content in aggregate Soundness in sodium sulphate Water absorption Alkali aggregate reactivity Grading of aggregates Maximum size of aggregate Concrete mix design
Test Method IS:455 IS:2386 (Pt 3) IS:2386 (Pt 2) IS:2386 (Pt 2) BS:812 (Pt 17) BS:812 (Pt 18) IS:2386 (Pt 5) IS:2386 (Pt 3) IS:2386 (Pt 7) IS:2386 (Pt 1) IS:2386 (Pt 1) IS:10262 and IS:SP23 IS: 455 1989 IS: 10262
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Minimum Frequency 1 per source of supply and occasionally for long or improperly stored batch. Also manufacturers certificate required. 1 per source per month 1 per source per month 1 per source per month 1 per source 1 per source 1 per source Regularly as required 1 per source per month 1 per source per month 1 per source per month 1 per source 1 per source
Specified Value As per relevant IS Max 35% for LAA and 30% for AIV IS:383 Clay lumps 4%:Coal and lignite 1% Max 0.06% Max 0.25% Max 12% Max 2% Non-reactive IS:383 25mm a) Compressive strength/flexural strength as per Special Specifications With Portland slag cement confirming to IS 455 with slag more than 50%, W/C ratio of 0.45 to 0.5%. Min 6 (Acceptable 6 to 9) Max 10ml HCL to neutralize 200ml water Max 2ml NaOH to neutralize 200ml water Maximum limits per liter: Organic 200mg; inorganic 3000mg; Sulphate 400mg; chloride 500mg; Suspended matter 2000mg
12. 13. 14. 15.
pH value of water Alkalinity limit by titration Acidity limit by titration Solids in water
pH Paper IS:3025 IS:3025 IS:3025
1 1 1 1
per per per per
source source source source
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Sl. No. 16. 17. 18. 19. 20. 21. 22. 23.
Note:
Test Concrete cube test (7 day & 28 day) Concrete beam test (7 day & 28 day) Core strength of hardened concrete Slump test (for workability) Thickness measurement of trial length Thickness determination Verification of level of form Texture depth
Test Method IS:516 IS:516 IS:516 IS:1199 Core sampling Leveling Site check Sand patch method
Minimum Frequency 2 cubes per 150cum or min 6 per day or batch 2 beams per 150cum or min 6 per day or batch Engineers discretion 1 per dumper load initially and 1 per alternate dumper subsequently 3 cores per trial Grid points of 5 to 6.25m x 3.5m 5.0m to 6.25m 5 measurements in 50m length
Specified Value Special specifications Special specifications Special specifications As per IS 456 Special specifications Special specifications 2mm 1 0.25mm
Definition of Batch applicable to cement concrete: The quantity of concrete mixed in one cycle of operation of a batch mixer or the quantity of concrete conveyed ready-mixed in a vehicle or the quantity discharged during one minute from a continuous mix.
Table 17: Cement for Structural Works

Sl. No. 1. Test General requirement a) Portland slag cement IS:455 Test Method Minimum Frequency 1 per consignment if old stock or improperly handled 2. Total chloride content Test certificate from manufacturer required 1 per source Max 0.05% Relevant specifications Specified Value
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Sl. No. 3.
Test Total sulphur content as SO3
Test Method Test certificate from manufacturer required
Minimum Frequency 1 per source
Specified Value Max 2.5% for tri-calcium aluminate is upto 5%; 3% for tri-calcium aluminate >5%
Table 18: Coarse Aggregate for Structures

Sl. No. 1. 2. 3. Test Los Angeles Abrasion Value Soundness in sodium sulphate Deleterious constituents: a) Coal and lignite b) Clay lumps c) Soft fragment d) Total of all deleterious matters 4. 5. 6. 7. 8. 9. Material passing 75 micron Specific gravity (SSD) Water absorption Surface moisture) Flakiness index Grading of coarse aggregate IS:2386 (Pt 1) IS:2386 (Pt 1) 1 per source/month 1 per source/month moisture content (free IS:2386 (Pt 2) IS:2386 (Pt 2) IS:2386 (Pt 2) IS:2386 (Pt 1) IS:2386 (Pt 3) IS:2386 (Pt 3) IS:2386 (Pt 3) 1 per source/month 1 per source/month 1 per source/month 1 per source/month 1 per source/month 1 per source/month 1 per source/month 2 per day Test Method IS:2386 (Pt 3) IS:2386 (Pt 5) Minimum Frequency 1 per source/month 1 per source Specified Value Max 30% for wearing surface; max 50% for works Max 12%
Max 1% Max 1% Max 3% Max 5%

Max 3% Max 2% Max 35% Sieve Size % Passing 40mm 20mm 12.5mm
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Sl. No.
Test
Test Method
Minimum Frequency 63mm 40mm 20mm 12.5mm 10mm 4.75mic
Specified Value 100 95-100 30-70 10-35 0-5 100 95-100 25-55 0-10 100 90-100 40-85 0-10
Table 19: Sand/Fine Aggregate for Structures

Sl. No.
1. 2. 3. 4. 5. General requirement Los Angeles Abrasion of source stone of crushed aggregate Fineness modulus of fine aggregate Soundness in sodium sulphate Deleterious constituents: a) Coal and lignite b) Clay lumps c) Soft fragment d) Total of all deleterious matters Material passing 75 micron Specific gravity (SSD) Water absorption Surface moisture content (free moisture)
Test
Test Method
Visual inspection IS:2386 (Pt 3) IS:2386 (Pt 5) IS:2386 (Pt 2) IS:2386 (Pt 2) IS:2386 (Pt 2) IS:2386 (Pt 1) IS:2386 (Pt 3) IS:2386 (Pt 3) IS:2386 (Pt 3)
Minimum Frequency
Every batch 1 per source/month 1 per source/month 1 per source 1 1 1 1 per per per per source/month source/month source/month source/month
Specified Value
Clean, hard and free from deleterious materials except in traces Max 30% for wearing surfaces Min 2.0 and max 3.5 Max 10% Max Max Max Max 1% 1% 3% 5%
6. 7. 8. 9.
1 per source/month 1 per source/month 1 per source/month 2 per day
Max 3% (15% if crushed aggregate) Max 2%
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Sl. No.
10. 11. 12. 13. Total chloride content
Test
Total sulphate content Alkali aggregate reactivity Grading requirement
Test Method
IS:812 (Pt 17) IS:812 (Pt 18) IS:2386 (Pt 7) IS:2386 (Pt 1)
Minimum Frequency
Every batch Every batch 1 per source per month 1 per day Max 0.06% Max 0.25% Non-reactive Sieve Size 10mm 4.75mm 2.36mm 1.18mm 600mic 300mic 150mic
Specified Value
% Passing Zone I 100 90-100 60-95 30-70 15-34 5-20 0-5 Zone II 100 90-100 75-100 55-90 35-59 8-39 0-10 Zone III 100 90-100 85-100 75-100 60-79 12-40 0-10
Table 20: Reinforcement Steel

Sl. No. 1. 2. 3. Test Characteristic (IS:432) Characteristic (IS:1786) Diameter strength strength of of mild HYSD steel bar Test Method Tests as per relevant IS Codes Tests as per relevant IS Codes Minimum Frequency As per IS 1786 2008 As per IS 1786 2008 As per IS 1786 2008 Specified Value Grade S240 = 240MPa Grade S415 = 415MPa The diameter of steel rods shall be checked frequently on random basis especially for rerolled basis.
Table 21: Water for Concrete and Mortar

Sl. No. 1. Test pH value water
Test Method pH paper
Minimum Frequency 1 per source
Specified Value Minimum 6 (Acceptable range 6 to 9)
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Sl. No. 2. 3. 4.
Test Alkalinity limit by titration Acidity limit by titration Solids in water
Test Method IS:3025 IS:3025 IS:3025
Minimum Frequency 1 per source 1 per source 1 per source
Specified Value Max 10ml HCL to neutralize 200ml water Max 2ml NaOH to neutralize 200ml water Max limits per liter: Organic 200mg; inorganic 3000mg; sulphate 400mg; Chloride 500mg; suspended matter 2000mg
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3.0 Quality Control Tests Required/Frequency/Specifications for Buildings

Sr No Type of material Chemical Test : Portland Slag cement (IS 455) / Ordinary Portland Cement Physical Test : 1) Standard Consistency 2) Initial Setting Time 3) Final Setting Time 4) Compressive Strength 5) Fineness m/Kg 6) Soundness by Le-Chat 1) Physical Tests : 2) Chemical Test: 1) Specific Gravity 2) Water Absorption 3) Aggregate Impact Value 4) Flakiness Index and Elongation index 5) Sieve Analysis 6) Soundness Test 7) Abrasion Test 1) Sieve analysis & Fineness Modulus 2) Moisture Content 3) Silt Content by volume 4) Water Absorption 5) Specific Gravity Parameter Frequency Once for each lot Code As per IS 4032 Remarks MTC for each lot mandatory
Once for each lot
As per IS 12269, IS 4031 part 1,2,3,4,5,6 & IS 3535
MTC for each lot mandatory
Reinforcement (TMT) Bars
Coarse Aggregate
Fine Aggregate
Supplied by client Supplied by client Once for every source Once in a month / As required Once in a month / As required Once in a month / As required Once per 150 cum Once per Season Once per Season Once per 150 cum As and when required As and when required Once in a month / As required Once for every source
IS 1608 & IS 1786 IS 1786
As per IS 383
As per IS 383
Water
1) pH
Once per source/ As required
As per IS 456 / Tender
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Concrete Admixture
2) 3) 4) 5) 6) 1) 2) 3) 4)
Organic Impurities Inorganic Impurities Sulphates Chloride (%) Suspended Particles pH Specific Gravity Dry Material content Ash Content
Once per each lot
As per IS 9103
5) Chlorides ion Content Mix Design 7 Concrete 1) Slump 2) Compressive Strength test a. 7th days b. 28th days 1) Atterberg's limit, Shear parameter 2) Specific gravity and CBR 3) Grain size Analyses 4) MDD/OMC 5) Field Density/Moisture Content Chemical Test : 1) Dimension 2) Crushing strength 3) Water absorption 4) Efflourescence test 1) Compressive strength of Mortar 1) Compressive strength 2) Setting time 3) Permeability 4) Chloride content For each grade and each brand of cement As Required As per IS 456 As per 10262, IS 456, SP23 and relevant standards As per Mix Design As per IS 456, IS 516 -
Earth work
As per IS 2720
IS 2720
9 10 11
Brick Work Cement/Lime Mortar Water Proofing
Once per 25000 Nos. Once a day As Required
IS 3495, IS 2895 / Tender IS 2250 IS 2645 -
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12 13
Water Proofing ( terrace ) Cement Concrete Floor Tiles Kota Stone / Granite / Green Marble / Sand stone Ceramic / Glazed Tiles /Vitrified Tiles Concrete Flooring Precast Terrazzo Tiles Wooden Door and Window Frame Doors & Windows Fittings & fixtures PVC Shutters & Door Frames Flush Wooden Door Shutter Steel Doors and Windows MS Rolling Shutter Structural steel & steel Tubular sections Aluminum Works
As approved by consultants 1) 2) 3) 1) 2) 3) 1) 2) 3) Water Absorption Transverse Strength Abrasion Test Crushing strength Water absorption Abrasion Test Flexural Strength Water Absorption Dimension
As Required As per R&B / CPWD Specifications One per 1000 sqm As Per R&B / CPWD Specifications IS 1122, 1123, 1124,3622 IS 13630, IS 13711, IS 777, IS 15622
MTC for each lot mandatory -
14
15 16 17 18 19 20 21 22 23 24 25
One per 1000 sqm As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per appendix - C, R&B / CPWD As per appendix - H, R&B / CPWD
Material testing as per concrete Dimensions, Transverse Strength, water absorbtion. Colour, Hardness, Density, Weight, Moisture Content, Porosity, Identification, Rezon, Tissue As per R&B / CPWD Specifications Dimensions & squareness, flexure test, and Impact & indentation test. Dimension, Glue test, Boiling water test etc As per Relevant Standards Material and Dimension 1) Physical Tests 2) Chemical Tests Dimensions and Tolerances, Annodization, Powder Coating
As per IS 1237 IS 4021, IS 287, IS 710 MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory
As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications
IS 10151, 4020 ( 1 to 16 ) IS 2202 (Part 1 & 2) IS 7452, IS 5437, IS 1038, IS 1361 IS 6248 IS 1599, 1608, 2329,2328,2062 IS:733, IS:1948, IS:1949
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26 27
28 29 30 31 32 33 34 35
Anti Termite Treatment Painting for concrete, Masonry and plastered surface Painting and Polishing of wood work Painting of steel work PVC Pipes G.I. Pipes Sanitary ware False Ceiling Gypsum False Ceiling Acoustic Glass work
Chemical Test and Coverage As per Relevant Standards
As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications As per R&B / CPWD Specifications
IS 6313 (Part II & III) IS 428, IS 5410, IS 5411, IS 9862, IS 712, IS 2395 IS 3536, IS 110, IS 337, IS 340, IS 2932 IS 2074, IS 2932, IS 2339, IS 1477 (Part-2) IS 4985 IS : 1239 Part -1 IS 2556, IS 1795, IS 651 IS 2095
MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory MTC for each lot mandatory
As per Relevant Standards As per Relevant Standards As per Relevant Standards As per Relevant Standards As per Relevant Standards Dimensions, Transverse, water absorption and mass of plaster. As approved by Client As per Relevant Standards
As per R&B / CPWD Specifications
IS 5437, 2835,14900
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4.0 Methodology for Road Construction 4.1 Embankment Construction
1. Obtain materials (soil) for embankment from approved sources. Preference should be given to materials that are suitable and become available from nearby road excavation. 2. After clearing the site, mark the limits of embankment by fixing batter pegs and marking toe lines on both sides at regular intervals as guides. The embankment shall be built sufficiently wider (about 300 mm on either side of Roadway) than the specified formation width so that surplus material at the edges may be trimmed to ensure proper compaction of the edges and side slopes. 3. Remove stagnant water, if any, from the foundation of the embankment. 4. Where the available embankment materials (Soil) are not conducive to plant growth, topsoil from areas of cutting and areas to be covered by embankment should be stripped to specified depth not exceeding 150 mm and stored for covering slopes, and other disturbed areas where re-vegetation is required. 5. After removing the top soil/ unsuitable material, foundation for embankment construction shall be prepared as follows: (a) For embankment less than 1.0 m high over natural ground, the ground surface should be loosened up to a minimum depth of 150 mm by ploughing or scarifying and compacted to the specified density. (b) For embankment less than 0.5 m height over an existing black-topped or gravel road, the black-topping shall be removed and the pavement/ gravel road should be scarified to a minimum depth of 150 mm. All particles shall be reduced to a maximum size of 75 mm and compacted. (c) If the granular/ black topped surface lies within 0.50 m - 1 m of the new sub-grade level, the same should be scarified to a depth of at least 50 mm for achieving bond between old and new material. (d) If the existing surface is of cement concrete type and lies within 1 m of the new sub-grade level, the same shall be removed completely. (e) For embankment over ground not capable of supporting equipment, successive loads of embankment materials should be spread in a uniformly distributed layer of adequate thickness to support the equipment and to construct the lower portion of the embankment. (f) For embankment construction on existing slope steeper than 1 Vertical: 4 Horizontal, horizontal benches should be cut in the existing slope to a sufficient width to accommodate placement and compaction equipment. 6. The size of the coarse material in the mixture of earth used for embankment construction should ordinarily not exceed 75 mm. 7. The soil should be spread over the entire width of the embankment in layers not exceeding 150 mm compacted thickness. The clods should be broken to less than 75 mm size. Each layer at moisture content within () 2 % of the optimum moisture content should be thoroughly compacted by roller, to the specified requirements and finished parallel to the final cross-section of the embankment. (Compacted layer thickness can be increased up to 200 mm if heavy vibratory rollers are used).
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8. Compaction of soil should be done at OMC with a tolerance limit of () 2 percent. If the moisture content of soil is outside these limits, it shall be made good by adding water or drying by aeration and exposure to sun till the moisture content is acceptable for compaction. 9. Each layer should be compacted to at least 97 percent of the Standard Proctor Density. The top 300mm of the embankment constituting the sub grade should be compacted to 100 percent Standard Proctor Density. 10. Ensure that longitudinal and cross profiles should be in conformity with the approved drawings. 11. Approval of the Engineer should be obtained for each finished layer. Subsequent layers shall be placed only after the finished layer has been tested and accepted by Engineer. 12. When an existing embankment and/ or sub-grade is to be widened and its slopes are steeper than 1 vertical to 4 horizontal, continuous horizontal benches, each at least 300 mm wide, should be cut into the old slope for ensuring adequate bond with the fresh embankment/ sub-grade material to be added. 13. When the width of the widened portions is insufficient to permit the use of conventional rollers, compaction shall be carried out with the help of small vibratory rollers/ plate compacters/ power rammers or any other equipment approved by the Engineer. 14. The filling around culverts and bridges, for forming approaches up to a distance of twice the height of the road from the back of abutment should be done with granular materials and should not be placed until the concrete or masonry has been in position for 14 days. Approval for the sequence of work and equipment should be obtained from the Engineer before taking up the work. 4.2 Granular sub-base
1. Obtain materials from approved sources. The material should be natural sand, moorum, gravel, crushed stone, crushed slag, brick metal, kankar or a combination thereof and it shall conform to grading and physical requirements. 2. Remove all vegetation and other extraneous material etc. from the sub grade already prepared, lightly sprinkle with water, if necessary, and roll with two passes of 80-100 KN road roller or any other suitable compactor/vibratory roller. 3. The sub-base material should be spread in layers not exceeding 100 mm compacted thicknesses. If suitable vibratory rollers are available, the compacted thickness of layer can be up to a maximum of 225 mm. 4. When the sub-base material consists of a combination of materials, mixing shall be done mechanically by the mix-in-place method, except for small sized jobs. 5. Each layer shall be uniformly spread and thoroughly compacted. Spreading and compaction shall be carried out as per Clause 401.4.2 of the MORD Specifications. 6. Compaction should be carried out at OMC, with a tolerance limit of ( ) two per cent. If the loose material is dry, as compared to OMC, water should be added by sprinkling and thoroughly mixed for uniform wetting. If it has more water than the optimum, it should be left exposed to sun and aeration till the moisture content is acceptable for compaction. Each layer should be compacted to 100 per cent maximum dry density as per standard Proctor Test-IS 2720 (Part 7). 7. Approval of the Engineer should be obtained for each layer. Such an approval would require surface level and compaction control tests.
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8. The earthen shoulders should be constructed simultaneously with the sub-base construction. 4.3 Water Bound Macadam Sub-base/Base/Surfacing
1. The surface to receive the WBM course should be prepared to the lines, grade and cross fall. It should be made free of dust and extraneous material. Large irregularities, where predominant, should be made good by providing profile corrective course. 2. Where the WBM is laid over a fine grained soil sub grade, it is advisable to lay a 100 mm thick intervening layer of screenings or coarse sand. 3. Any existing bituminous surface over which WBM is to be laid shall be completely removed before laying WBM layer. 4. The coarse aggregate should meet the physical and grading requirements laid down in Table 405.1 and Table 405.2. Coarse aggregate can be crushed or broken stone, crushed slag, over burnt brick aggregate, kankar, laterite meeting the prescribed requirements. 5. The spreading of coarse aggregate shall be done from stockpiles along the side of the roadway or directly from vehicles. In no case the aggregate shall be dumped in heaps directly on the surface prepared to receive the aggregates nor shall hauling over uncompacted or partially compacted base be permitted. 6. The coarse aggregate shall be spread uniformly on the prepared subgrade, sub-base or base, as the case may be, to proper profile (by using templates placed across at 6.0 m intervals) in such quantities that would give the required compacted thickness. The thickness of compacted layer should be 100 mm for Grading 1 and 75 mm for Gradings 2 and 3. The appropriate quantity of aggregates is given in Table 405.4. The surface should be checked with templates and all high or low spots remedied. 7. Roll the surface with suitable road rollers till aggregates are partially compacted with sufficient void space left for application of screenings. However, where screenings are not to be applied as in the case of soft aggregates, compaction shall be continued until the aggregates are thoroughly keyed. Rolling shall proceed from inner edge to outer edge at the super-elevated portions and from the edges towards the centre in other portions. The edge should be first compacted with roller running forward and backward. 8. Check the profile transversely and longitudinally with templates/ straight edge. Correct the irregularities by loosening the surface, adding or removing the needed amount of aggregates and re-rolling until the entire surface conforms to the specified camber/ cross fall and grade. 9. Apply screenings to completely fill the interstices maintaining a slow and uniform rate, in three or more applications. The screenings should not be damp at the time of application. 10. Do not apply screenings so fast and thick as to form cakes or ridges on the surface. 11. Continue dry rolling and brooming till no more screenings can be forced into the voids of coarse aggregates. 12. Sprinkle water on the surface taking care that the underlying layer is not damaged. 13. Sprinkling, sweeping and rolling should continue till aggregates are thoroughly keyed, well bonded and firmly set in its full depth and a grout has been formed of screenings. 14. In case the screenings are not of crushable type such as moorum or gravel, it is necessary to add binding material (PI between 4 and 6) after application of screenings. The binding material should be 2 applied in two or more layers at a slow and uniform rate. Generally, the quantity required for 10 m of 75 3 mm thickness of WBM is 0.06 to 0.09 m and for 100 mm thickness, the corresponding quantity would be 3 0.08 to 0.10 m . In case WBM surface is not to be covered with bituminous surfacing, PI of binding material shall be between 4 and 10.
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15. The process of water sprinkling, sweeping and rolling should continue till the resulting slurry forms a wave ahead of roller. 16. The compacted WBM course should be allowed to completely dry and set before the next pavement course is laid or traffic is allowed. 17. The earthen shoulders should be constructed simultaneously with the WBM construction in accordance with Sub-Section 407. 18. The finished surface of WBM should conform to the prescribed tolerances given in Para B. Where the surface irregularity exceeds the tolerances, the WBM layer should be scarified to its full depth over the affected area and corrected by adding or removing and replacing with fresh material. 4.4 WET MIX MACADAM BASE Methodology 1. WMM shall be prepared in an approved mixing plant with mixing arrangements like the pug mill or pan type mixer of concrete batching plant. For small quantities of WMM, the Engineer may permit the use of concrete mixers. 2. Optimum moisture for mixing shall be determined in accordance with IS:2720 (Part 7) after replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size. 3. Lateral confinement for WMM should be provided by laying material in adjoining shoulders along with the wet mix layer. 4. Immediately upon mixing, the aggregates shall be spread uniformly and evenly upon the prepared subbase, in required quantities. In no case should the material be dumped in heaps, directly on the area where it is to be laid. The mix may be spread either by a paver-finisher or motor grader. 5. Thickness of a single compacted WMM layer shall not be less than 75 mm. When vibrating or other approved types of compacting equipment are used, the compacted thickness of up to 200 mm may be adopted. 6. The surface of aggregate shall be carefully checked with templates and all high or low spots should be remedied by removing/ adding aggregate as required. The thickness of layer shall be tested with depth blocks. 7. No segregation of large and fine aggregates shall be allowed. 8. After the mix is laid to proper thickness, grade and cross fall/ camber, the same shall be uniformly compacted with a suitable roller. Rolling shall be continued till the density achieved is at least 100% of the maximum dry density as per IS:2720 (Part 7). 9. If the surface irregularity of WMM course exceeds the permissible tolerances, the full thickness of layer shall be scarified over the affected area, reshaped by adding premixed material or removed and replaced with fresh premixed material as applicable and re-compacted. The area treated in this manner shall not be less than 5 m long and 2 m wide. In no case shall depressions be filled up with unmixed and un-graded materials or fines. 11. After final compaction of WMM, the road shall be allowed to dry for at least 24 hours. 12. Preferably no vehicular traffic should be allowed on the finished WMM surface till it has dried and the wearing course has been laid.
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4.5 PRIME COAT OVER GRANULAR BASE Methodology 1. Bituminous primer should be slow setting bitumen emulsion, use of cutback being restricted to areas having subzero temperature or for emergency operations. 2. The prime coat should be applied only on the top most granular base layer, over which bituminous treatment is to be applied. The granular base surface should be swept clean of dust and loose particles and where required, lightly and uniformly sprinkled with water to moist the surface. 3. The primer should be sprayed uniformly over the dry surface of absorbent granular base, using suitable bitumen pressure distributor or sprayer capable of spraying primer at specified rates and temperature so as to provide a uniformly unbroken spread of primer. Normal temperature range of spraying emulsion should be 20C to 60C. 4. A very thin layer of coarse sand may be applied to the surface of the primer to prevent it from getting picked up under the wheels of vehicles delivering materials for construction of bituminous layer 5. The surface should be allowed to cure preferably for 24 hours. Unabsorbed primer should be blotted with sand using the minimum quantity possible. 4.6 TACK COAT Methodology 1. Use a rapid setting bitumen emulsion for applying a tack coat, the use of cutback being restricted to areas having sub-zero temperature or for emergency applications. 2. The surface on which tack coat is to be applied should be clean, free from dust, dirt and any extraneous materials and dry. 3. The binder should be sprayed uniformly over the surface using suitable bitumen pressure sprayer capable of spraying bitumen and emulsion at specified rates and temperature so as to provide a uniformly unbroken spread of bitumen emulsion. For smaller jobs, a pressure hand sprayer may be used. Normal range of spraying temperature should be 20C-60C in case of emulsion and 50C-80C in case of cutback. 4. The surface should be allowed to cure until all the volatiles have evaporated. 4.7 Bituminous Macadam Methodology 1. Prepare the base on which bituminous macadam course is to be laid and shape to the specified lines, grade and cross-section. 2. Apply tack coat over the base preparatory to laying of the bituminous macadam. 3. Bituminous Macadam should be prepared in a Hot Mix Plant of adequate capacity. 4. Transfer the mixed material quickly to site of work and lay by means of an approved self-propelled mechanical paver. 5. Commence initial rolling with 80-100 kN rollers (three-wheel or tandem type), beginning from the edge and progressing towards the centre longitudinally. On super elevated portions, rolling should progress from lower to upper edge parallel to centre line of pavement. Thereafter, do intermediate rolling with vibratory or pneumatic tyred road rollers. This should be followed by final rolling while the material is still workable.
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6. Any high spots or depressions noticed after the roller has passed over the whole area once should be corrected by removing or adding premixed material. Rolling should recommence thereafter. Each pass should have an overlap of at least one-third of the track made in the preceding pass. Rolling should be continued till all rolIer marks have been eliminated. 7. For single lane roads no longitudinal joint is required, while for double-lane roads longitudinal joints may be required depending on the paver width. 8. For making longitudinal or transverse joint, cut the edges of the bituminous layer laid earlier to their full depth so as to expose fresh surface and apply a thin coat of binder. Lay adjacent new layer and compact flush with the existing layer. 9. Cover the bituminous macadam with the wearing course within a period of 48 hours. If there is any delay in providing wearing course the bituminous macadam surface should be covered with a seal coat before opening to traffic. 4.8 Open graded Premix Surfacing using Bitumen
1. Prepare the base on which premix carpet is to be laid to the specified lines, grade and cross-section. 2. Apply a prime coat followed by tack coat over a granular base preparatory to laying of the carpet. 3. The quantities of material required for 20 mm thick premix carpet should be as indicated in Table 508.1.1. Prepare the mix in a hot mix plant of suitable size with separate dryer arrangement for aggregate. 4. Mixing should be thorough to ensure that a homogenous mixture is obtained. The temperature of 0 0 0 bitumen at the time of mixing should be in the range of 150 C to 160 C and that of aggregates 155 C to 0 163 C, provided that the difference between the temperature of aggregate and the binder should not 0 exceed 14 C. If modified bitumen is used, temperature should be as recommended in Subsection 512. The temperature at the time of discharge of the mixture should be between l30C and 160C. 5. Locate hot mix plant near the work site. The mixed material should be transported quickly to the site of work and laid uniformly by suitable means. 6. The premixed material shall be spread on the road surface with rakes. 7. Commence rolling with 80-100 KN rollers (three-wheel or tandem type), beginning from the edge and progressing towards the centre longitudinally. (On super elevated portions, rolling should progress from lower to upper edge parallel to centre line of pavement). Continue rolling operations till a smooth uniform surface is achieved and all roller marks are eliminated. Each pass should have an overlap of at least onethird of the track made in the preceding pass. 8. Correct any high spots or depressions noticed after the roller has passed over the whole area once by removing or adding premixed material and re-compacting. 9. Provide a seal coat to the surface immediately after laying the carpet. 10. Ordinarily, the road may be opened to traffic after laying the seal coat. 4.9 Seal Coat The seal coat shall be any of the three types mentioned below: Type A: Liquid seal coat comprising of an application of layer of bituminous binder followed by a cover of stone chips. Type B: Premixed seal coat comprising of a thin application of fine aggregate premixed with bituminous binder.
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Type C: Premixed seal coat comprising of an application of 6.7 mm size stone chips premixed with bituminous binder. A. Methodology Apply seal coat immediately after laying the bituminous course. The surface should be clean and free of dust and extraneous material before application of the seal coat. 1. Type A Seal coat with bitumen: (i) Apply heated bitumen with a temperature between 1500C and 1630C uniformly with the help of a bitumen sprayer. (ii) Immediately thereafter, spread stone chips over the bitumen layer at a uniform rate, preferably, with the help of a mechanical grit spreader so as to cover the surface completely. (iii) Commence rolling with 80-100 kN rollers (3-wheel or tandem type), beginning from the edge and progressing towards the centre longitudinally. On super elevated portions, rolling should progress from lower to upper edge parallel to centre line of pavement. If required, spread additional chips by hand to make up irregularities. Continue rolling operations until all aggregate particles are firmly embedded and present a uniform closed surface. 4.10 Pipe Culverts Excavation for pipes 1. Lay the pipes in shallow excavation of natural ground or in open trenches cut in existing embankments taken down to required level. 2. For embankments of height of fill more than 3 m, or three times the external dia of pipe above bed level, construct the embankment to the level above the top of the pipe (equal to external dia of pipe) and width not less than five times the dia of pipe. Lay the pipe in trench after the construction of embankments. 3. If spongy, soft or other unstable material is met with at the location of pipe culvert, remove the material to the required depth, width and length, and back fill with approved granular material properly shaped and compacted to the required level. 4. Where rock or boulder strata is met with, take down excavation to alleast 200 mm below the bottom level of pipe, remove all loose material and fill the space with approved earth. Loading and Unloading of Pipes 1. Make arrangements for lifting, loading and unloading of pipes from factory/yard to site, such that no undue strain or damage occurs due to fall or impact. 2. For manual unloading from trucks, roll down pipes on a pair of skids hooked onto the trucks and control movement with a rope passing round the pipes. Laying of Pipes 1. 2. 3. 4. Preload the areas to induce major portion of settlement before the pipe is installed. Provide a bedding surface of firm foundation of uniform density, throughout the length of culvert with specified bedding material depending on dia of pipe and height of fill above pipe. Lower the pipes in bed either by tripod pulley arrangement or by manual labor using chain pulley blocks in a manner to place them in proper position without damage. When two or more pipes are laid adjacent to each other, place them separated by a distance equal to half the dia of the pipe subject to a minimum space of 450 mm.
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5. 6. 7.
When pipes are laid in two layers, keep the centers of pipes such that when joined shall form equilateral triangles. Lay the pipes as specified in IS:783, for different conditions such as positive projecting condition, trench condition etc. Lay the pipes on the prepared foundation, commencing from outlet and proceed towards the inlet. In case of pipes with bell mouth, keep the belled end facing the upstream. Keep the invert of pipe minimum 150 mm below average bed level. However, if the invert level is more than 300mm, a catch pit of size 1500 x 1000mm upto ground level should be constructed. Install the culvert with a camber, so that the settlement due to the load of the embankment will in time lower the culvert to the desired grade approximately.
8.
Jointing 1. 2. 3. 4. Join the pipes either by collar joint or by flush joint. Place the collar such that its centre coincides with the joints and even annular space is left between the collar and the pipe. Choose either internal flush joint or external flush joint. Fill the jointing space with 1:2 cement mortar, which remains in position when forced with a trowel or rammer. Fill the recess at the end of the pipe with jute braiding dipped in hot bitumen or suitable approved compound, while jointing pipe lines. Keep the width of collars 150-200 mm and caulking space between 13 mm and 20 mm according to dia of pipes.
Back Filling 1. Back fill trenches after the pipes have been laid and after jointing material has hardened. On top of pipe upto 300 mm, thoroughly ram, tamp or vibrate the soil in two layers. Thoroughly consolidate the materials under the haunches of pipes using light mechanical tamping equipment. 2. Carryout filling of the trench simultaneously on both sides of the pipe, such that unequal pressures do not occur. 3. When minimum specified cushion cannot be provided over the pipe, encase the pipe in M 10 concrete of specified thickness. 4.11 Construction of Causeways Under this section quality aspects of different submersible structures viz., Irish/ Flush Causeway, Vented Causeway and Submersible Bridges for rural roads are dealt with: A. Methodology fro Flush Causeway 1. Choose flush causeway (Paved dip) to cross a shallow water course by adopting general guidelines given in clause 1401.0 of MORD Specifications for Rural Roads. 2. Keep top level of floor of causeway same as that of bed of water-course. 3. Build cut-off walls in brick masonry on stone masonry or plain cement concrete with suitable formwork as per provisions given in sections 600, 700, 800 and 900 respectively of this Manual. 4. Excavate for laying of foundation of u/s and d/s cut-off walls. Keep it sufficiently deep to avoid exposure due to scouring. Adopt a PCC footing of 150 mm thickness in M15 grade, laid on a layer of 100 mm thick lean concrete (M10) 5. Adopt a plain cement concrete slab of minimum thickness 200 mm in a minimum grade of M30 as paved dip. Provide construction joints 4-6m apart and seal them with polysulphide.
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6. Provide u/s and d/s protection works, apron, pitching as per requirement. 7. Provide guide posts/stones at required spacing. B Vented Pipe Causeways 1. Choose vented pipe causeway to cater to low flows through circular vents which overtop during monsoon. Usually RCC pipes (NP3 or NP4) are used for providing circular vents. 2. Follow the same methodology as detailed in section 1100 of this Manual for laying of RCC Pipes. 3. Take foundation and head walls sufficiently deep to avoid exposure to scouring in erosive strata. 4. Batter the d/s side headwall on the outside and round the corners. 5. Adopt rectangular or arch on type vents instead of circular pipe as per local practice. 6. Raise end portion of face walls and protect entire top of causeway by well desirable non-erodible wearing coat. Ancillary Items (Wearing coat, Railing, Kerbs, Warning signs, Flood gauges) 1. Provide 75 mm thick C.C. wearing coat in M30 grade with a cross slope of 2.5 per cent towards d/s side of deck slab in submergible bridge. For vented causeways adopt 200 mm thick RCC Slab. 2. Discontinue wearing coat at expansion joint locations. Extend joint fillers upto the top of wearing coat. 3. For CC wearing coat, provide 8 mm dia bars @ 200 mm c/c reducing to 100 mm c/c in both directions over a strip length of 300 mm near expansion joint. 4. Use open type or filler joint with appropriate nose protection. 5. Use metal railing of collapsible or removable or tubular type for submersible bridges. 6. Use discontinuous kerbs 300 mm wide at 1.8 m c/c on both sides, the continuous length of each piece being 1.5 m. 7. Locate advance warning/cautionary signs at about 200 m from the beginning of submerged portion of causeways and submersible bridges, to indicate speed limit, depth of submergence etc. 8. Install flood gauges at 15 m intervals on submerged section of approaches and submersible bridges, regarding depth of flow above road level bridge deck. 4.12 Construction of Slab Culvert 4.12.1 Setting out Survey Setting out survey shall be done as per the Geometric details given in the construction drawing in the following sequences. 1. Setting out the alignment. 2. Working BM established near the work site linked with Reference Bench Mark. 3. Prior approval shall be taken from the Client Engineer. 4. Frequent checking of setting out for formation level shall be carried out at regular intervals. 5. Safeguarding of Survey Monuments shall be done. 6. Following instruments shall be used for setting out. 7. Automatic Levels having a standard deviation of 2mm. per Km. for all double run leveling work. 8. Total Station or one sec. Theodolite shall be used for setting out alignments. 4.12.2 Preparation of Property/Amenities The safeguards shall be provided to roadside trees, plants, pole lines signs, monuments etc. which are not to be disturbed. All adequate precautions against soil erosion, water pollution shall be taken. 4.12.3 Construction methodology 1) Cleaning & removing of sludge from the proposed location.
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2) Construction drawing will be prepared based on the drawing mentioned in above scope separately for each CD work and get it approved from Independent Engineer. 3) Layout will be done by taking original ground level and invert level for the same CD work. 4) BBS shall be sought from the Project Manager. 5) Joint measurement for dismantling of wing wall and other structure will be taken. Height of wing wall & abutment will be decided according to FRL of road. 6) Excavation for the foundation will be done up to founding level & get it approved from the Project Manager. Excavated material will be disposed as per instruction of Engineer. 7) PCC will be done over top of excavated foundation & transfer the layout as per drawing. Record all the necessary survey data in survey register. 8) Reinforcement & shuttering to be assembled for the foundation and approval for the same shall be taken. 9) Construction of abutment on both ends will be done. 10) The wing/dirt wall will be constructed. Pointing of masonry will be done as per drawings. 11) Back filling of abutment with filter material of 150mm thickness will be done simultaneously in layer as per MOST specification mentioned in table no. 300-3 along with embankment filling material and compacted properly. 12) Slab will be cast as per drawing. 13) Proper curing will be done as per instructions. 4.12.4 List of Records 1) Approved Construction Drawings. 2) Necessary Quality Control Records. 3) Cement test report, Cube test report, Concrete register, Fine and course aggregate test report, Reinforcement test report etc. 4) Approved Bar bending Schedule. 5) Survey Register.
4.13 Methodology for Bridge Construction The minor bridges have R.C.C. foundations & Substructure, and R.C.C. superstructures of girder & slab system. 4.13.1 Procedure The longitudinal and transverse centre lines of each foundation are set out on reference pillars at safe distance and the temporary bench mark level is also fixed at site and got approved by the Engineer. These are to be repeatedly checked at every stage/lift. Earthwork excavation is carried out to the required level by machinery and at final stages manually. Water seepage will be controlled by creating a low level sump by the side of the foundation location & pumping out water. The sides of excavation in cutting will be shored up and supported to the satisfaction of the Engineer's representative. If the foundation is resting in rock, pavement breakers or chisels will be used to achieve the final levels required within the specified tolerance. Where the foundation rests on soil, a minimum thickness of 100 mm layer M-15 shall be laid to the level shown on the drawings, after the excavations, lines and levels have been approved by the Engineer. The formwork for the foundations shall be fixed in position on the lean concrete layer or the rock surface, as the case may be, after the reinforcement has been assembled true to the longitudinal and transverse centre lines. The lines, levels, formwork and reinforcement shall be got checked and approved by the Engineer's representative.
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The concrete for the lean mix layer and for the foundation lift will be produced in the batching plant as per design mix approved by the Engineer, and transported to site in transit truck mixer or dumpers, and laid in position with the crane and bucket arrangement. Compaction will be carried out with the needle vibrators, except lean concrete base course, which will be tampled with rammers. Slump tests will be done to assess the workability and the retarders or super plasticizers will be added if required to obtain quality concrete product. Specified number of test cubes will be taken for determining the 7 days & 28 days compressive strength. Vertical shutters will be removed 24 hours after concreting, and the curing will be commenced as per specifications after rectifying the surface deficiency if any. Each lift in foundation and substructure will be laid as stated above. Weep holes will be incorporated in the substructure of abutments and concrete retaining walls as shown in the contract drawings. If found convenient and feasible, reinforcement for any component will be assembled in yard and placed in position in the formwork with the help of crane. The pier cap, abutment cap and pedestals with seat for bearings in minor bridges and the abutment cap in slab culverts will be concreted to the levels and dimensions shown in the contract drawings. After the curing period for the foundations are over, the excavated pit around the foundation will be filled back with earth. In the case of foundations on rock strata, the space around foundation upto the top of rock will be filled with M-15 concrete, and above it soil will be filled up to the natural ground level. The centering for the support of superstructure formwork is proposed to be placed on dry level ground. Therefore each span in turn will be levelled to the required elevation above water level, and the stream will be diverted by suitable arrangement as per site conditions, if necessary. Cribs of 45 cm x 45 cm x 1.5 m will be used to support the superstructure formwork. In minor bridges elastomeric bearings shall be kept in position with Epoxy mortar on top of the pedestals, just before the casting of the superstructure girders. The line and levels have to be approved by the Engineer's representative before concreting starts In minor bridges, the sequence will be as follows: 1. Erect the centering consisting of steel cribs, I-girders & channel purlins. 2. The base plates of girder formwork are placed in position in true line & level 3. Pre-fabricated girders reinforcement is placed on base plates with the help of crane. 4. Cross girders reinforcement in laid in their location. 5. Side shuttering around girders & cross girders are closed, and deck slab shuttering is laid. 6. Line, levels dimensions, formwork, centering and girder & cross girders reinforcement are to be got checked and approved by the Engineer. Concreting will be done up to the bottom of the haunch at the junction of girders and slab. 7. The reinforcement for deck slab, foot path Kerbs and hand rail beams and also the drainage spout will be laid in position in the deck slab formwork and got checked & approved by the Engineer 8. Concreting of deck slab will be done, leaving a pocket of about 40 x 20 cm at top surface at both ends for full width of carriageway to receive expansion joints in due course. 9. Curing will be done as per specifications. When the cube strengths attain the specified value or at the period indicated in the specifications, the formwork will be released and taken for re-use. In minor bridges the sequence of taking up the remaining items will be as under:
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1. Precasting units of concrete handrails. 2. Casting footpath Kerbs and handrail bottom beam. 3. Placing PVC pipe ducts, forming inspection chamber, and filling M-15 concrete in footpaths. 4. Construction of dirt walls and returns walls. When the curing period is over back filling behind abutments with filter media and selected soil, and well compacted. 5. Box cutting for approach slabs, laying lean concrete base layer, placing reinforcement and formwork for approach slabs and concreting to required level. 6. Construction of hand rails by placing the precast railing in cast-in-situ R.C. posts. 7. Fixing the Elastomeric expansion joints in position in deck slab under the supervision of the manufacturer's representative. 8. Laying the A.C. wearing course with a paver using the approved design mix. 9. On embankment slope dry stone pitching over specified filter media and apron will be laid wherever indicated in the contract drawings. Those portions of the structure, which will be backfilled or covered up, shall be measured & recorded before such activity is permitted. 4.14 Plain Cement Concrete Pavement for low volume roads: 4.14.1. Approval of materials, plant, equipment and construction method. (i) A trial length of at least 30 m will be constructed off road to demonstrate the proposed materials, plant, equipment and construction methodology before constructing the concrete pavement. Relevant test data of materials and construction methodology listing all steps, details of personnel and plant, equipment, batching and mixing of materials handling, curing texturing should be furnished by the Contractor. (ii) The trial length will be constructed in 2 days with a minimum 15 m length on each day. (iii) Before taking up the trial length, ensure that the sources with test results of all materials to be used in the concrete work are approved by the Engineer well in advance, (at least 30 days before their use), and the mix design based on laboratory trial mixes using approved materials is submitted for approval of the Engineer at least 30 days prior to the paving of trial length. (iv) The mix design shall be based on the compressive strength of concrete as specified in the contract. The cement content should not be more than 425 kg nor less than 310 kg per cum of concrete unless specified otherwise. If flyash is used to replace a part of cement in the concrete mix, the cement content should not be less than 250 kg/cum. All batching of materials shall be by weight. Volume batching may be allowed for small jobs with the approval of the Engineer. Minimum M 30 grade concrete is recommended. Water cement ratio should not be more than 0.5. Admixtures may be used to achieve the desired workability. (v) Semi-mechanized and labor oriented construction techniques will be permitted. Plant, equipment and tools required for preparation and laying of concrete are listed in Clause 1501.11.2 of MoRD Specifications.
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(vi) Approval of materials, plant, equipment and construction method will be given when the trial length complies with the specifications 2 Prepare the Sub-grade to the specified grades and cross-sections and compact to the design strength specified in the Contract. A day before placing the sub-base, clean the surface and apply a light spray of water on the sub-grade and roll with one or two passes of suitable 80-100 kN roller to stabilize any loose material. 3 Lay granular or WBM grading 3 or lime treated sub-base of the specified type and thickness. Near the bridge or culvert, an additional layer of 200 mm thick non-plastic GSB over the subgrade, should be provided in full panel length and full carriageway width. 4 Provide a separation membrane (125 micron thick plastic sheet) between sub-base and concrete slab. It should be laid without creases. 5 Mark location and type of the joints on either side of the surface of the sub-base, with red paint. (i) Contraction joints shall be mechanically sawn joints spaced 2.5 m to 3.75 m. Length of panel in the direction of traffic shall not be less than the width of the pavement. Joints shall be cut when the pavement is neither too soft nor too hard and is able to bear the weight of the machine and crew. Normally it may vary from 8 to 12 hours depending on weather conditions. (ii) Construction joints shall be butt joints and placed after a days work is over or when work is suspended for more than 30 minutes.
(iii) Expansion joints shall be provided near bridges and slab culverts and consist of a bitumen impregnated joint/ pre moulded synthetic joint filler board, about 20 mm thick, and dowel bars. (iv) Longitudinal joints shall be provided for a two-lane road and shall be saw-cut. 6 All side forms shall be of mild steel channels or fabricated plates with adjustable jacks at the back and of depth equal to the thickness of pavement. Plant, equipment and tools required for preparation and laying of pavement concrete are listed in Clause 1501.11.2 of Specifications for Rural Roads. 7 Pavement concrete shall be produced near the site, using approved concrete mixers of at least 0.2 cum capacity. Readymade concrete conforming to the specified properties of strength and workability may also be used. 8 Check the slump of concrete. It should be in the range of 30 mm 10 mm 9 Concrete shall be placed between the side forms and shall be levelled with rakes and shovels. In concrete panels having acute angles, a bar mat of 10 mm dia ribbed steel bars at 150 mm centre to centre in both directions shall be provided at 50 mm below the top of slab, in the entire panel. 10 Around man-holes or other openings in pavement, place 12 mm thick pre-moulded board as per IS:1838 and bar mats before concreting. 11 Compact concrete by a vibrating screed supplemented by two internal vibrators. 12 As soon as practicable after compaction of concrete, smoothen the surface with a longitudinal float operated from the work bridge. Just before the concrete becomes non-plastic, it shall be textured with a long handled steel or fiber brush. 13 After completion of texturing , before the concrete has taken its initial set, the edges of the slab shall be carefully finished so as to leave the pavement edges smooth and true to line.
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14 After completion of the finalizing operations, the surface of the pavement shall be covered with wet Hessian cloth, burlap or jute mats. They shall be maintained fully wetted and in position for 24 hours. Upon the removal of the wet covering out the end of 24 hours, the slab shall be thoroughly wetted and then cured by ponding or sprinklers. The slab shall be covered with sufficient sandy soil so as to produce a blanket of earth not less than 40 mm thick after wetting. The earth covering shall be thoroughly wetted while it is being placed in the surface and against the sides of the slab and kept thoroughly saturated with water for 14 days. The sand shall not be removed and shall thereafter remain in place till 28 days from date of casting so that the concrete has attained the required strength. 15 After minimum of 28 days after casting the concrete pavement, joint groove at contraction joint shall be widened to 10 mm width and to a depth 18 to 20 mm and shall be sealed.
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5.0
OK CARDS FORMATS
O .K C A R D F O R EM BAN KM EN T C O N S TR U C TIO N
N am e o f co n tracto r P ackage N o .
: :
Em b an km e n t ch ain age
Barro w are a/Q u arry ap p ro ve d Su itab ility o f Mate rial Te m p o rary Be n ch Mark e stab ilish e d A d e q u acy o f w ate rin g arran ge m e n ts A lign m e n t o f Em b an km e n t Botto m Le ve l Gro u n d Im p ro ve m e n t Ex tra w id th p ro vid e d fo r co m p actio n /Ro llin g De n sity Te sts co n d u cte d o n O GL/P re vio u s laye r A d e q u acy o f V ib rato ry ro lle r o r Ro lle r A d e q u acy o f fie ld te st e q u ip m e n t
: : : : : : : : : : :
O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K Re q u ire d /N ot Re q u ire d O K /N ot O K O K /N ot O K O K /N otO K O K /N otO K
A E/A EE/DEE/EE
Contractor
TPQA
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O .K C A R D F O R G r a nula r S ub B a s e
N am e o f co n tracto r P cck age N o . N am e o f W o rk
: : :
Ch ain age
Su itab ility o f Mate rial Mate rial ap p ro v e d Te m p o rary Be n ch Mark e stab lish e d Su rface Le v e l De n sity Te sts co n d u cte d o n Su b b ase
: : : : :
O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o tO K O K /N o tO K O K /N o t O K O K /N o t O K
Sh o u ld e rs C o n stru ctio n w o rk Sim u ltan e o u sly w ith GSB : A d e q u acy o f w ate rin g arran ge m e n ts A d e q u acy o f V ib rato ry ro lle r o r Ro lle r A d e q u acy o f fie ld te st e q u ip m e n t Th ick n e ss o f GSB De n sity Te sts o n GSB : : : : :
A E/A EE/DEE/EE
C ontractor
TP Q A
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O .K C A R D F O R W B M
N am e o f c o n tr a c to r P ack age N o . N am e o f W o rk Ch ain age W BM Grad e Su rface Le v e l o f Su b b ase Su b b ase co m p actio n W id th o f carriage w ay Cam b e r Straigh t Ed ge Ty p e o f scre e n in gs Te m p late s av ailab le Su itab ility o f In p u t Mate rial
: : : : : : : : : : : : : C o arse aggre gate : Scre e n in g : Bin d in g Mate rial : Grad e II / Grad e III O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K
A d e q u acy o f V ib rato ry ro lle r o r Ro lle r A d e q u acy o f fie ld te st e q u ip m e n t Th ick n e ss o f W BM Su rface Le v e ls an d Un d u latio n s
: : : :
A E/A EE/DEE/EE
C o n tracto r
TP Q A
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O .K CAR D FO R O GPC + S EAL CO AT
N am e of the contra ctor Package N o. N am e of Work Chainage Arrange m e nt of te m porary dive rsion Surface Le ve l of base Width of carriage w ay Cam be r board available Straight Edge available Te m plate s available Suitability of Input Mate rial
: : : : : : : : : : : Coarse aggre gate : Bitum e n : Gradation of aggre gate : OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N otOK OK/N otOK OK/N otOK OK/N otOK Type : OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK OK/N ot OK
Prim e coat application Tack coat application Ade quacy of m ixing Plant Te m pe rature of bitum e n at m ixing Te m pe rature of bitum e n at laying Ade quacy of bitum e n distributor Ade quacy of V ibratory rolle r or Rolle r Thickne ss of OGPC Suitability of Aggre gate for se al coat Ade quacy of fie ld te st e quipm e nt
: : : : : : : : : : : : :
Application of bitumen at the rate s pecified

Thickne ss of OGPC + Se al Coat Surface Le ve ls and Undulations
AE/AEE/DEE/EE
Contractor
TPQA
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O .K C A R D F O R C U L V R T W O R K
N a m e o f c o n t ra c t o r P ack ag e N o . S t ru c t u re c h a i n a g e C o m p o n e n t o f s t ru c t u re D ra w i n g N o : D e sign S B C SBC A l i n g m e n t V e ri f i e d F o rm w o rk & b a s e i ) F o rm s C l e a n e d i i i ) E e rc t i o n a n d s e a l s a s p e r D ra w i n g F in al C le an -Up : B o t t o m L e v e l V e ri f i e d P h y s i c a l d i m e n s i o n s V e ri f i e d a s p e r d ra w i n g R e i n f o rc e m e n t p l a c e m e n t a s p e r d ra w i n g C o v e r t o re i n f o rc e m e n t a s p e r d ra w i n g P l a c i n g o f f i x t u re s / E m b e d m e n t s a s p e r d ra w i n g S u i t a b i l i t y o f I n p u t M a t e ri a l Cem ent CA FA W a te r A d m i x t u re / S u p e r p l a s t i c i z e r( A s p e r M i x d e sign /A s p e r M TC ) R C C / P C C c o n c re t e g ra d e Q t y o f c o n c re t e t o b e l a i d A v a ila b ility o f W e ig h -b a tch e r A d e q u a c y o f V i b ra t o rs S l u m p o b s e rv e d a s p e r m i x d e s i g n c u b e s c a s t e d a s R e q u i re d A d e q u a c y o f C u ri n g a rra n g e m e n t s T e m p a ra t u re o f c o n c re t e a t P l a c i n g : : : : : : : : : : O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K : : : : : : : : : : : O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K B ra n d : i i ) F o rm s O i l e d : i v ) A l i g n m e n t o f F o rm s : O K /N ot O K O K /N ot O K : : : : : : O K ( M o r e th a n th e d e s i g n e d ) / N o t O K ( Le s s th a n th e d e s i g n e d ) O K /N ot O K
A E/A EE/D EE/EE
C o n t ra c t o r
TP Q A
46 | P a g e
O .K C A R D F O R B R ID G E F O U N D A T IO N
N a m e o f co n tra cto r P a ck a g e N o . N a m e o f W o rk S tru ctu re ch a i n a g e C o m p o n e n t o f s tru ctu re D e sign SBC Ty p e o f So il T e s t m e th o d f o r S B C SBC T y p e o f F o u n d a ti o n B o tto m L e v e l o f F o u n d a ti o n P h y s i ca l d i m e n s i o n s V e ri f i e d a s p e r d ra w i n g R e i n f o rce m e n t p l a ce m e n t a s p e r d ra w i n g C o v e r to re i n f o rce m e n t F o rm w o rk & b a s e
: : : : : : : : : : : : : : O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K B ra n d : F o u n d a ti o n T re a tm e n t : R e q u i re d / N o t R e q u i re d P l a te Lo a d / U n d i s tru b e d / S P T O K ( M o r e th a n th e d e s i g n e d ) / N o t O K ( Le s s th a n th e d e s i g n e d ) D ra w i n g N o :
i ) F o rm s C l e a n e d : i i i ) E e rcti o n a n d s e a l s a s p e r D ra w i n g : Fin al C le an -Up : S u i ta b i l i ty o f In p u t M a te ri a l : Cem ent : CA : FA : W a te r A d m i x tu re / S u p e r p l a s ti ci z e r( A s p e r M i x d e sign /A s p e r M TC ) R C C / P C C co n cre te g ra d e Q ty o f co n cre te to b e l a i d A v a i l a b i l i ty o f W e i g h - b a tch e r A d e q u a cy o f V i b ra to rs S l u m p o b s e rv e d a s p e r m i x d e s i g n cu b e s ca s te d a s R e q u i re d A d e q u a cy o f C u ri n g a rra n g e m e n ts T e m p a ra tu re o f co n cre te a t P l a ci n g : : : : : : : : :
O K /N ot O K O K /N ot O K O K /N ot O K
i i ) F o rm s O i l e d i v ) A l i g n m e n t o f F o rm s
O K /N ot O K : O K /N ot O K
O K /N ot O K O K /N ot O K O K /N ot O K O K /N ot O K
B ra n d
O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K
A E /A E E /D E E /E E
C o n tra c to r
TP Q A
47 | P a g e
O .K C A R D F O R B R ID G E S U B S T R U C T U R E
N a m e o f t h e c o n t ra ct o r P a ck a g e N o . N a m e o f W o rk S t ru c t u re c h a i n a g e C o m p o n e n t o f s t ru ct u re D ra w i n g N o . N o .o f L i f t ( H e i g h t o f L i f t ) F o rm w o rk a n d S e a l s
: : : : : : : : i ) F o rm s C l e a n e d : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K B ra n d : i i ) F o rm s O i l e d i v ) A l i g n m e n t o f F o rm s : : O K/N ot O K O K/N ot O K
i i i ) E e rct i o n a n d s e a l s a s p e r D ra w i n g : Fin al C le an -Up : P h y s i c a l d i m e n s i o n s V e ri f i e d a s p e r d ra w i n g R e i n f o rc e m e n t p l a ce m e n t a s p e r d ra w i n g C o v e r t o re i n f o rc e m e n t a s p e r d ra w i n g P l a c i n g o f f i x t u re s / E m b e d m e n t s a s p e r d ra w i n g ( W e e p H o le s) S u i t a b i l i t y o f In p u t M a t e ri a l : : : : : Cem ent : CA : FA : W ate r : A d m i x t u re / S u p e r p l a s t i ci z e r ( A s p e r M i x d e s i g n / A s p e r M T C ) a d m i x t u re / S u p e r p l a s t i ci z e r A d e q u a c y o f c o n c re t e l a y i n g a rra n g e m e n t s A d e q u a c y o f w o rk s p a ce f o r l a b o u r a n d e q u ip m e n t R C C / P C C c o n c re t e g ra d e Q t y o f c o n c re t e t o b e l a i d A v a i l a b i l i t y o f W e i g h - b a t ch e r A d e q u a c y o f V i b ra t o rs S l u m p o b s e rv e d a s p e r m i x d e s i g n cu b e s c a s t e d a s R e q u i re d A d e q u a c y o f C u ri n g a rra n g e m e n t s T e m p a ra t u re o f c o n cre t e a t P l a ci n g : : : : : : : : : : :
O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K
B ra n d
A E/A EE/D EE/EE
C o n t ra ct o r
TP Q A
48 | P a g e
O .K C A R D F O R B R ID G E S L A B / B E A M
N a m e o f co n tra cto r P a ck a g e N o . N a m e o f W o rk S tru ctu re ch a i n a g e C o m p o n e n t o f s tru ctu re D ra w i n g N o : B e a ri n g s
: : : : : : : i ) B e a ri n g s : i i ) A s p e r M T C ( If n o t T e s te d ) : T e s te d / N o t T e s te d O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K : : : : : Cem ent : CA : FA : W a te r : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K B ra n d : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K B ra n d : i i ) F o rm s O i l e d i v ) A l i g n m e n t o f F o rm s : O K/N ot O K : O K/N ot O K i i i ) P h y s i ca l D i m e n s i o n s : O K / N o t O K
B o tto m Le v e l o f S l a b / B e a m s F o rm w o rk a n d S e a l s
: : i ) F o rm s C l e a n e d :
i i i ) E e rcti o n a n d s e a l s a s p e r D ra w i n g : Fin al C le an -Up P h y s i ca l d i m e n s i o n s V e ri f i e d a s p e r d ra w i n g R e i n f o rce m e n t p l a ce m e n t a s p e r d ra w i n g C o v e r to re i n f o rce m e n t a s p e r d ra w i n g P l a ci n g o f f i x tu re s / E m b e d m e n ts a s p e r d ra w i n g ( D ra i n a g e S p o u ts ) S u i ta b i l i ty o f In p u t M a te ri a l
A d m i x tu re / S u p e r p l a s ti ci z e r( A s p e r M i x d e s i g n / A s p e r M TC ) R C C / P C C co n cre te g ra d e Q ty o f co n cre te to b e l a i d A v a i l a b i l i ty o f W e i g h - b a tch e r A d e q u a cy o f V i b ra to rs S l u m p o b s e rv e d a s p e r m i x d e s i g n cu b e s ca s te d a s R e q u i re d A d e q u a cy o f C u ri n g a rra n g e m e n ts T e m p a ra tu re o f co n cre te a t P l a ci n g
: : : : : : : : :
A E/A EE/D EE/EE
C o n tra cto r
TP Q A
49 | P a g e
O .K C A R D F O R F O U N D A T IO N P C C
N am e o f co n tracto r P ack ag e N o . N am e o f W o rk S tru ctu re ch ain ag e C o m p o n e n t o f s tru ctu re D e s ig n S B C Ty p e o f S o il Te s t m e th o d f o r S B C SBC Ty p e o f F o u n d atio n B o tto m Le v e l o f P C C F o o tin g O u tlin e M ark in g / O rie n tatio n o f co lu m n s P h y s ical d im e n s io n s V e rif ie d as p e r d raw in g F o rm w o rk & b ase i) F o rm s C le an e d
: : : : : : : : : : : : : : : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K iv ) A lig n m e n t o f F o rm s : O K/N ot O K F o u n d atio n Tre atm e n t : R e q u ire d / N o t R e q u ire d P late Lo ad / Un d is tru b e d / S P T O K ( M o r e th a n th e d es i gn ed ) / N o t O K ( Les s th a n th e d es i gn ed ) D raw in g N o :
iii) Ee rctio n an d s e als as p e r D raw in g : F in al C le an - Up : : S u itab ility o f In p u t M ate rial : Cem ent : CA : FA : W ate r : P C C co n cre te g rad e Q ty o f co n cre te to b e laid A v ailab ility o f W e ig h - b atch e r A d e q u acy o f V ib rato rs S lu m p o b s e rv e d as p e r m ix d e s ig n cu b e s cas te d as R e q u ire d A d e q u acy o f C u rin g arran g e m e n ts Te m p aratu re o f co n cre te at P lacin g A E/A EE/D EE/EE C o n tracto r TP Q A : : : : : : : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K
50 | P a g e
O .K C A R D F O R C Y C L O N E S H E L T E R F O O T IN G S
N am e o f co n tracto r P ack ag e N o . N am e o f W o rk S tru ctu re ch ain ag e C o m p o n e n t o f s tru ctu re D e s ig n S B C Ty p e o f F o u n d atio n To p Le v e l o f P C C F o o tin g O u tlin e M ark in g / O rie n tatio n o f co lu m n s P h y s ical d im e n s io n s V e rif ie d as p e r d raw in g R e in f o rce m e n t p lace m e n t as p e r d raw in g C o v e r to re in f o rce m e n t F o rm w o rk & b ase
: : : : : : : : : : : : : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K B ran d D raw in g N o :
i) F o rm s C le an e d : iii) Ee rctio n an d s e als as p e r D raw in g : F in al C le an - Up : S u itab ility o f In p u t M ate rial : Cem ent : CA : FA : W ate r : A d m ix tu re / S u p e r p las ticize r( A s p e r M ix d e s ig n / A s p e r M TC ) R C C / P C C co n cre te g rad e Q ty o f co n cre te to b e laid A v ailab ility o f W e ig h - b atch e r A d e q u acy o f V ib rato rs S lu m p o b s e rv e d as p e r m ix d e s ig n cu b e s cas te d as R e q u ire d A d e q u acy o f C u rin g arran g e m e n ts Te m p aratu re o f co n cre te at P lacin g : : : : : : : : :
O K/N ot O K O K/N ot O K O K/N ot O K
ii) F o rm s O ile d iv ) A lig n m e n t o f F o rm s
: O K/N ot O K : O K/N ot O K
O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K
B ran d :
A E/A EE/D EE/EE
C o n tracto r
TP Q A
51 | P a g e
O .K C A R D F O R C O L U M N S
N a m e o f th e co n tra cto r P a ck a g e N o . N a m e o f W o rk S tru ctu re ch a i n a g e C o m p o n e n t o f s tru ctu re D ra w i n g N o . S ta rte r P ro v i d e d C o l u m n a l i n g m e n t v e ri f i e d Le v e l M a rk e d F o rm w o rk a n d S e a l s
: : : : : : : : : : i ) F o rm s C l e a n e d : P ro v i d e d / N o t p ro v i d e d O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K B ra n d : i i ) F o rm s O i l e d i v ) A l i g n m e n t o f F o rm s : : O K/N ot O K O K/N ot O K
i i i ) E e rcti o n a n d s e a l s a s p e r D ra w i n g : Fin al C le an -Up : P h y s i ca l d i m e n s i o n s V e ri f i e d a s p e r d ra w i n g R e i n f o rce m e n t p l a ce m e n t a s p e r d ra w i n g C o v e r to re i n f o rce m e n t a s p e r d ra w i n g P l a ci n g o f f i x tu re s / E m b e d m e n ts a s p e r d ra w i n g S u i ta b i l i ty o f In p u t M a te ri a l : : : : : Cem ent : CA : FA : W a te r : A d m i x tu re / S u p e r p l a s ti ci z e r ( A s p e r M i x d e s i g n / A s p e r M T C ) a d m i x tu re / S u p e r p l a s ti ci z e r A d e q u a cy o f co n cre te l a y i n g a rra n g e m e n ts A d e q u a cy o f w o rk s p a ce f o r l a b o u r a n d e q u ip m e n t R C C / P C C co n cre te g ra d e Q ty o f co n cre te to b e l a i d A v a i l a b i l i ty o f W e i g h - b a tch e r A d e q u a cy o f V i b ra to rs S l u m p o b s e rv e d a s p e r m i x d e s i g n cu b e s ca s te d a s R e q u i re d A d e q u a cy o f C u ri n g a rra n g e m e n ts T e m p a ra tu re o f co n cre te a t P l a ci n g : : : : : : : : : : :
O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K
B ra n d
A E/A EE/D EE/EE
C o n tra cto r
TP Q A
52 | P a g e
O .K C A R D F O R C Y C L O N E S H EL T ER G R O U N D F L O O R S L A B / B EA M
N a m e o f th e co n tra cto r P a ck a g e N o . N a m e o f th e w o rk S tru ctu re ch a i n a g e C o m p o n e n t o f s tru ctu re D ra w i n g N o . B o tto m Le v e l o f S l a b / B e a m s B a s e o f th e S ca f f o l d i n g B ra ci n g f o r ce n tri n g F o rm w o rk a n d S e a l s
: : : : : : : : : : i ) F o rm s C l e a n e d : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K : : : : : Cem ent : CA : FA : W a te r O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K : : : : : : : : : O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K / N o tO K O K/N ot O K B ra n d : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K B ra n d : i i ) F o rm s O i l e d i v ) A l i g n m e n t o f F o rm s : : O K/N ot O K O K/N ot O K
i i i ) Ee rcti o n a n d s e a l s a s p e r D ra w i n g : Fin al Cle an -Up : P h y s i ca l d i m e n s i o n s V e ri f i e d a s p e r d ra w i n g R e i n f o rce m e n t p l a ce m e n t a s p e r d ra w i n g C o v e r to re i n f o rce m e n t a s p e r d ra w i n g P l a ci n g o f f i x tu re s / Em b e d m e n ts a s p e r d ra w i n g S u i ta b i l i ty o f In p u t M a te ri a l
A d m i x tu re / S u p e r p l a s ti ci z e r ( A s p e r M i x d e s i g n / A s p e r M TC ) R C C / P C C co n cre te g ra d e Q ty o f co n cre te to b e l a i d A v a i l a b i l i ty o f W e i g h - b a tch e r A d e q u a cy o f V i b ra to rs S l u m p o b s e rv e d a s p e r m i x d e s i g n cu b e s ca s te d a s R e q u i re d A d e q u a cy o f C u ri n g a rra n g e m e n ts Te m p a ra tu re o f co n cre te a t P l a ci n g
A E/ A EE/ D EE/ EE
C o n tra cto r
TP Q A
53 | P a g e
O .K C A R D F O R F IR S T F L O O R S L A B / B E A M
N am e o f co n tracto r P ack age N o . N am e o f W o rk S tru ctu re ch ain age C o m p o n e n t o f stru ctu re D raw in g N o : B o tto m Le v e l o f S lab /B e am s F o rm w o rk an d S e als
: : : : : : : : i) F o rm s C le an e d : O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K : : : : : Ce m e nt : CA : FA : W ate r ad m ix tu re /S u p e r p lasticize r : O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K A s p e r M ix d e sign /A s p e r M TC B ran d : O K /N o t O K O K /N o t O K O K /N o t O K O K /N o t O K B ran d : ii) iv ) F o rm s O ile d A lign m e n t o f F o rm s : O K /N o t O K : O K /N o t O K
iii) Ee rctio n an d se als as p e r D raw in g : F in al C le an -Up : P h y sical d im e n sio n s V e rifie d as p e r d raw in g R e in fo rce m e n t p lace m e n t as p e r d raw in g C o v e r to re in fo rce m e n t as p e r d raw in g P lacin g o f fix tu re s/Em b e d m e n ts as p e r d raw in g S u itab ility o f In p u t M ate rial
R C C /P C C co n cre te grad e Q ty o f co n cre te to b e laid A v ailab ility o f W e igh -b atch e r A d e q u acy o f V ib rato rs S lu m p o b se rv e d as p e r m ix d e sign cu b e s caste d as R e q u ire d A d e q u acy o f C u rin g arran ge m e n ts Te m p aratu re o f co n cre te at P lacin g
: : : : : : : : O K /N o tO K O K /N o tO K O K /N o tO K O K /N o tO K O K /N o tO K O K /N o tO K
A E/A EE/D EE/EE
C o n tracto r
TP Q A
54 | P a g e
O .K CAR D F O R BR ICK W O R K
N am e of contractor Package N o. N am e of W ork Type of Brick Physical Dim e nsions of brick as pe r approve d Class W ate r absorption Te ste d Ce m e nt Mortar Mix Hacking for RCC Surface Done Thickne ss of w all as pe r draw ing Le ve l and Plum b Toothing/Ste e ping provide d Thickne ss of Joint Suitability of Input Mate rial
: : : : : : : : : : : : O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K
Ce m e nt : Sand : W ate r : Brick : A de quacy of Curing arrange m e nts :
O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K O K/N ot O K
Brand :
A E/A EE/DEE/EE
Contractor
TPQA
55 | P a g e
Consultancy Services for Third Party Quality Audit (TPQA) for National Cyclone Risk Mitigation Project (NCRMP)
Consultant: EGIS India Consulting Engineers Pvt. Ltd Package No. Contractor: Name of Work: CONSULTANT'S DESCRIPTION OF NONCONFORMANCE:
Non - Conformance ( NCR )

Line Department:
Report
Date:
Ref:
Place of work:
NCR No.
SE DPM's Review and Signed:
Date: Date:
CONTRACTOR'S PROPOSED REMEDIAL ACTION:
Position:
Signed:
Date:
PIU'S RESPONSE: Approval / Rejection of Remedial Action: Accepted Conditionally Accepted Rejected Comments :
AEE/AE Date: CLIENT / CONSULTANT'S CLOSE-OUT: NCR closed NCR not closed, see comments below Comments:
DEE Date:
EE Date:
Closing Inspection:
IRB No.
Date
Name: Reviewed by Client / Consultant:
Position: Date:
Date:
56 | P a g e
6.0 RECTIFICATION GUIDELINES Where the surface regularity of subgrade and the various pavement courses fall outside the specified tolerances, the Contractor shall be liable to rectify these in the manner described below and to the satisfaction of the Engineer. (i) Subgrade; Where the surface is high, it shall be trimmed and suitably compacted. Where the same is low, the deficiency shall he corrected by scarifying the lower layer and adding fresh material and recompacting to the required density. The degree of compaction and the type of material to be used shall conform to the requirements of Clause 303. (ii) Granular Sub-base: Same as at (i) above, except that the degree of compaction and the type of material to be used shall conform to the requirements of Clause 401. (iii) Lime/Cement Stabilized Soil Sub-base: For lime/cement treated materials where the surface is high, the same shall be suitably trimmed while taking care that the material below is not disturbed due to this operation. However, where the surface is low, the same shall be corrected as described herein below. For cement treated material, when the time elapsed between detection of irregularity and the time of mixing of the material is less than 2 hours, the surface shall be scarified to a depth of 50 mm supplemented with freshly mixed materials as necessary and re-compacted to the relevant specification. When this time is more than 2hours, the full depth of the layer shall be removed from the pavement and replaced with fresh material to Specification. This shall also apply to lime treated material except that the time criterion shall be 3 hours instead of 2 hours. (iv) Water Bound Macadam/Wet Mix Macadam Sub-base/Base: Where the surface is high or low, the lop 75 mm shall be scarified, reshaped with added material as necessary and re-compacted to Clause 405. This shall also apply to wet mix macadam to Clause 406. (v) Bituminous Constructions: 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 specifications. Where the surface is high, the full depth of the layer shall be removed and replaced with fresh material and compacted to specifications. For wearing course, where the surface is high or low, the full depth of the layer shall be removed and replaced with fresh material and compacted to specifications, in all cases where the removal and replacement of a bituminous layer is involved, the area treated shall not be less than 5 m in length and not less than 3.5 m in width. (vi) Dry Lean Concrete Sub-base/Rolled Cement Concrete; The defective length of the course shall be removed to full depth and replaced with material conforming to section 1500, as applicable. The area treated shall be at least 3 m long, not less than 1 lane wide and extend to the full depth. Before relaying
57 | P a g e
the course, the disturbed sub grade or layer below shall be corrected by levelling, watering and compacting. (vii) Cement concrete pavement; the defective areas having surface irregularly exceeding the specified limits may be rectified by bump cutting or scrabbling or grinding using approved equipment. When required by the Engineer, areas which have been reduced in level by the above operation(s) shall be retextured in an approved manner either by cutting grooves (5mm deep) or roughening the surface by hacking the surface. If high areas in excess of 6mm or low areas in excess of 3mm occur, exceeding the permitted numbers and if the contractor cannot rectify, the slab shall be demolished and reconstructed at the contractors expense and in no case the area removed shall be less than the full width of the lane in which the irregularity occurs and full length of the slab. If deemed necessary by the Engineer, any section of the slab which deviates from the specified levels and tolerances shall be demolished and reconstructed at the contractors expenses. 6.1. FINISHING FOR BRIDGE COMPONENTS: Immediately after the removal of forms, exposed bars or bolls, if any, shall be cut inside the concrete member to a depth of at least 50 mm below the surface of the concrete and the resulting holes filled with cement mortar. All fins caused by form joints, all cavities produced by the removal of form ties and all other holes and depressions, honeycomb spots, broken edges or corners, and other defects, shall be thoroughly cleaned, saturated with water, and carefully pointed and rendered true with mortar of cement and fine aggregate mixed in the proportions used in the grade of concrete that is being finished and of as dry a consistency as is possible to use. Considerable pressure shall be applied in filling and pointing to ensure thorough tilling in all voids. Surfaces which have been pointed shall be kept moist for a period of twenty four hours. Special pre-packaged proprietary mortars shall be used where appropriate or where specified in the drawing. All construction and expansion joints in the completed work shall be left carefully tooled and free from any mortar and concrete. Expansion joint filler shall be left exposed for its full length with clean and true edges. Immediately on removal of forms, the concrete work shall be examined by the Engineer before any defects arc made good. a) The work that has sagged or contains honeycombing to an extent detrimental to structural safety or architectural appearance shall be rejected. b) Surface defect of a minor nature may/ be accepted. On acceptance, of such work by the Engineer, the same shall be rectified as directed by the Engineer, 6.1.2. Rectification Guidelines for Concrete Structures Though concrete is a relatively durable building material, it may suffer damage or distress during its life period due to a number of reasons. Because of the varying conditions under which it is produced at various locations, the quality of concrete suffers occasionally either during production or during service conditions resulting in distress. The structural causes of distress of concrete may include externally applied and environmental loads exceeding the design stipulations, accidents and subsidence. Sometimes distress in a structure is brought about by poor construction practices, error in design and detailing, construction overloads. The other causes may be drying and shrinkage, thermal stress, weathering, chemical reactions
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and corrosion of reinforcement. In addition to the distress hardened concrete, the plastic concrete may also suffer damage due to plastic shrinkage and settlement cracking. Sometimes on stripping off the forms a number of surface defects such as bulges, ridges, honeycombing, bolt-holes, etc. are noticed on the fresh concrete members. Such defects can be avoided to a large extent by providing a watertight and rigid formwork in such a way that stripping can be done without the use of crowbars or other tools. In addition to these defects, blow-holes develop during concreting operations due to improper design of formwork. These are formed in the surface of concrete by trapped air and water bubbles against the face of formwork. These can be reduced if the form face is slightly absorbent and adequate compaction is provided. In case the blow-holes are exceptionally large, or if a smooth surface is required, they must be filled with 1:1 or 1:2 cement-sand mortars. The sand should be sieved through a 300-m or 600-m sieve, depending upon the smoothness of the finish required. Crushed limestone dust is preferable. The mortar should be rubbed over the affected area with a rubber-faced float, and finally rubbed down with a smooth stone or mortar block for a smooth finish. The honeycombing consisting of groups of interconnected deep voids normally indicate inadequate compaction or loss of grout though joints in formwork or between formwork and previously cast concrete. The affected area is delineated with a saw cut to a depth of 5mm. The unsound material is chipped out to the solid concrete. After the surface has been prepared a bonding coat should be applied to all exposed surfaces and new concrete should be placed against the prepared surface. The bonding coat may consist of a slurry of cement and water, but it is desirable to incorporate a polymer admixture. The repair of bulges and projections can be carried out by chipping of the concrete from the surface and then rubbing the surface with a grinding stone. Scouring of a vertical surface of hardened concrete making it resemble a map of delta of a river is caused by water moving upward against the face of the formwork. This is a sign of excessive wet of harsh concrete. It is a superficial defect so, unless it is unusually deep and the cover to reinforcement is unusually small, the remedial measures consists of early facing up in the same way suggested for filling blowholes. This type of repair (more appropriately called finishing) should be done as soon as possible after the forms are stripped and before the concrete becomes too hard. The repair should preferably be completed within 24hrs of the removal of the forms. This is done to develop a good bond and make the repaired portion as durable and permanent as the original work. If the repairs are not properly done, the newly placed concrete becomes loose and drummy with the passage of time and finally gets detached from the main concrete. The darker color of the repaired patches can be corrected by adding 10-20% white Portland cement to the patching mortar to obtain uniform surface color. The various defects occurring during construction are outlined in the table given below.
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Symptom Cracks in horizontal surface, as concrete stiffens or very soon thereafter Cracks from above ties in reinforcement etc., or at arises, especially in deep lifts Cracks in thick sections, occurring as concrete cools
Cause Plastic shrinkage: rapid range of surface
Prevention Shelter during placing. Cover as early as possible. Use airentrainment
Remedy Seal by brushing in cement or low viscosity polymer
Plastic settlement: concrete continues to settle after starting to stiffen.
Change mix design. Use air-entrainment
Re-compact upper part of concrete while still plastic. Seal cracks after concrete has hardened.
Restrained thermal contraction
Minimize restraint to contraction. Delay cooling until concrete has gained strength.
Seal Cracks
Blowholes in form faces of concrete
Air or water trapped against formwork. Inadequate compaction. Unsuitable mix design. Unsuitable release agent.
Improve vibration change mix design. Use appropriate release agent. Use absorbent formwork
Fill with polymer modified fine mortar
Voids in concrete
Honey combing: Inadequate compaction. Grout loss
Improve compaction. Reduce maximum size of aggregate. Prevent leakage of grout Change mix design, to make more cohesive or reduce water content Ensure uniformity of all relevant factors. Prevent leakage from formwork.
Cut out and make good. Inject resin
Erosion of vertical surfaces, in vertical streaky pattern Colour variations
Scouring: water moving upwards against form face Variations in mix proportions, curing conditions, materials, characteristics of form face, vibration, release agent. Leakage of water from formwork
Rubin polymer modified fine mortar.
Apply surface coating
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Powdery formed surface
Surface retardation, caused by sugars in certain timbers
Change form material. Seal surface of formwork. Apply lime wash to form face before first few uses.
Generally none required
Rust-strains
Pyrites in aggregates. Rain streaking from unprotected steel. Rubbish in formwork. Ends of wire ties turned out.
Avoid contaminated aggregates. Protect exposed steel. Clean forms thoroughly. Turn ends of ties inwards
Clean with dilute acid or sodium citrate / sodium dithionite. Apply surface coating
Plucked surface
Insufficient release agent. Careless removal of formwork.
More care in application of release agent and removal of formwork.
Rub in fin mortar, or patch as for spalled concrete.
Lack of cover to reinforcement
Reinforcement moved during placing of concrete, or badly fixed. Inadequate tolerances in detailing.
Provide better support for reinforcement. More accurate steel fixing. Greater tolerances in detailing
Apply polymer modified cement and sand rendering. Apply protective coating.
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National Cyclone Risk Mitigation Project (NCRMP) Revenue (DM) Department Government of Andhra Pradesh
Third Party Quality Audit(TPQA)

Checklists
INDEX
Check List No. Title Check list for Clearing and Grubbing Earth Works Check list for Protective works Checklist for Granular Sub base Check list for Wet Mix Macadam Check list for Water Bound Macadam Check list for Laying Prime Coat Check list for Laying Tack Coat Check list for Open Graded Pre Mix Carpet Check list for Bituminous layers using Mechanised Construction (BM, DBM, SDBC, BC) Typical corrective Action Plan for Bituminous layers Placement Check list for Temporary Diversions Checklist for Road Furniture Check list for Pipe Culverts Check list for Slab Culverts and Bridges Check list for Reinforcement Inspection Check list for Formwork Inspection Check list for Inspection Before Approval to Concrete Check list for Batching and Pouring of Concrete Check list for Post Concreting Inspection Check list for Excavation Check list for Anti Termite treatment
Page No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
3 4 8 9 10 11 12 13 14 15 21 23 24 27 29 33 34 35 36 37 38 38
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Checklists
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Check list for Rubber soling Check list for Plain concrete Check list for Shuttering Check list for Reinforcement Check list for Brickwork Check list for Solid block masonry Check list for Plasterwork Check list for Doors/ Windows Check list for Doors/ Windows (Aluminium) Check list for Polished kota stone flooring Check list for Tremix flooring Check list for Oil bound distemper Check list for Oil bound distemper/Water bound distemper/Acrylic bound distemper Check list for White wash Check list for Indian type water proofing terrace Check list for Box type water proofing Check list for fabrication/ Erection Check list for Rolling shutter Check list for Painting of structural steel works
39 39 40 41 42 42 43 43 44 45 46 47 47 48 49 49 50 50 51
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Checklists
CHECK LIST No. 1 Check list for Clearing and Grubbing S.No 1 2 3 4 PRE-CONSTRUCTION STAGE Item Review the plans, special provision, right of way agreements, which may require special staking. Confirm land acquisition is completed and area demarcated is in possession. Confirm encroachments (if any) are removed and tree cutting (if any) is carried out with permission of competent authority. Check whether all the tree roots and stumps are removed in the formation area. Check whether the pits from where trees have been removed are filled with granular material and suitably compacted. Ensure that features and facilities, which are to be preserved, are clearly marked. Attention shall be paid to environmental commitments. Determine the method for disposal of all materials outside the right of way. Identify the location of all public utilities (telephone poles, power lines, water supply lines, sewer lines, UG cables etc.) and ensure proper liaison with concerned authorities for shifting or for carrying out work safely without affecting the utilities during execution of works. CONSTRUCTION STAGE Item 1 2 3 4 5 6 7 8 9 10 Check whether the Executing Agency equipment has required safety devices for the protection of personnel and environment. (In forest areas required spark arresters shall be used in the equipment. Ensure no hazard to public during operations like timber felling, blasting. Ensure a better and coordinated traffic control. Check whether adjacent property and environmentally service-line areas are being affected and prevent such operations. Limits of clearing areas which do not require removal of stumps should be determined, and the height of stumps above natural ground are checked. Determine if dead, dying or otherwise unstable trees, which are in the right of way but outside the clearing limits to constitute a hazard. Any such tree shall be removed. Check whether the cut timber is being handed over to the concerned agencies, in case the contract provides such handing over. When burial of debris is permitted within the right of way that it will not act as a permeable layer, does not block drainage and will not interfere with maintenance. Ensure proper precautions, if burning of debris is permitted. Ensure that the smoke will not interfere with the visibility of public traffic and no air pollution problem is created. Ensure that tree branches overhanging above the roadway are cut off as specified. Checked Checked
5 6 7 8
S.No
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Checklists
CHECKLIST No.2 EARTH WORKS Earthwork includes operation connected with roadway excavation, structure excavation, backfill, ditch/drain excavation, compaction, and embankment construction and borrows area excavation.
S.No
1 2
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
PRE - CONSTRUCTION STAGE Item Confirm required drawings I.e. Longitudinal Section and Cross Section for the proposed stretch are updated and at hand. Confirm centreline of the proposed road has been set out using Total Station. Drive pegs to mark it at every 10 m or less in straight reaches. Erect masonry pillars 23x25 cm at each peg position with two sides plastered. Mark on the pillars proposed level up to which filling is to be done. In the case of road in cutting, two additional pillars are to be constructed on each flank of the road and with the proposed level of formation on the plaster. Check road safety signs such as "Road work under progress"; "Take diversions", etc. are properly positioned. Earmark/detail personnel for traffic control (if any) concerned authorities to be informed in advance and publicize the traffic restriction if any. Make a list of persons deployed at site along with qualification and experience. Confirm reference pillars (Temporary Bench Marks) are erected. Confirm quarries are identified and permission (if any) from appropriate authority has been obtained. Calculate required quantities and assess and satisfy the material is available with quarries. Confirm quarry material has been tested and results are satisfactory. Confirm setting out of curves - Horizontal and vertical have been completed Confirm requisite templates for camber and depth of loose earth spread are available. Check watering arrangements are satisfactory. Check agreed upon plant and machinery including Vibro-hammer for vertical banks is in good working condition. Check fuel, oil, lubricant, urgent spares (if any) are readily available (in the vicinity) nearby. Confirm checking and measuring instruments like levelling instrument / staff of 30 m, tapes etc. is available at site. Check testing equipment for field tests like field density apparatus, rapid moisture meter etc. are available. Confirm registers/site documents for recording the levels and any other activity at site are available. Check whether marking of exact location of CD works have been completed. Check if any vegetation has grown after clearing and grubbing. If yes repeat the operation of clearing and grubbing. Check whether the existing ground has been rolled to meet the Compaction requirement. Whenever Ground improvement has been proposed check if prefabricated drains (band drains), sand for sand blanket, geotextile and free draining material of required quantity are available, before the work is taken up in hand. Please check that the complete design has been approved by the Engineer.
Checked
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Checklists
23
24
Sections where reinforced soil structures are to be provided, check if precast concrete facing units, soil reinforcing elements with accessories / Fitting and back fill material of required quantity are as specification before the work is taken up. Please also check that the design have been approved by the Engineer. Establish contract for coordination with any other agency working/operating in the same area. Preparing Foundation for Embankment:
A 1 2 B 1 2 3 4 C 1
1 2 3 4
6 7 8
Embankment less than 1 m high over natural ground Ensure completely braking-up the cleared ground surface to a minimum depth of 150 mm by ploughing or scarifying. Ensure the ground surface shall than be compacted according to Clause 301.5.5. Embankment less than 0.5 mm high over an existing black- topped or gravel road surface Ensure existing gravel road shall be sacrificed to a minimum depth of 150 mm. Ensure existing black-topped roads, the black-topping shall be removed and the pavement shall be scarified to a depth of 150 mm. Ensure all particles shall be reduced to a maximum size of 50 mm to produce a uniform material. Ensure surface then be compacted according to Clause 301.5.5. Embankment on an existing slope steeper than 1:4 Ensure horizontal benches shall be cut in the existing slope to a sufficient width to accommodate placement and compaction operation. CONSTRUCTION STAGE - In Fill Ensure removal of top 15 to 20 cm of soil when filling is proposed. Ensure ground treatment as per Technical specification in marking areas before earthwork in embankment is taken up. Approved soil for filling to be free from organic or decomposed material. The earth clods more than 75mm in size should be broken to less than 75mm in size and spread over the entire width of the embankment in layers not exceeding 150mm compacted thickness and rolling to be done with rollers (of type and size as specified) . Use templates to ensure uniform thickness of spreading. (Compacted layer thickness can be increased up to 200mm if heavy vibratory rollers are used). Modified (Standard for rural roads) density to be taken at specified intervals and ensure top 500 mm (300mm for rural)of embankment and shoulders to have 97% (100% of standard for rural)modified proctor density and lower layers 95% (97% of standard for rural roads). It Ensure that each layer of earthwork is tested (Density and Moisture content) before starting next layer. Check whether water has been sprinkled over the previous layer top, before lying and next layer. Check the layer thickness of any later lay to compensate the thickness of grades. If it is less than 100 mm, then the previous layer top shall be suitably watered and scarified and then next layer is laid. Ensure proper bonding with old compacted layer and avoid 'peeling off in patches' of the newly laid layer during compaction. Ensure the benching into existing material during hillside construction or where the section changes from embankment to excavation or while widening the existing formation is adequate for proper keying of embankment material to original ground.
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Checklists
10 11
12 13 14 15
16 17 18 B
Ensure that rolling over entire area - completely too outside edges is being carried out. Adequate compaction of earth shall be done in uniform layers of specified thickness duly providing an extra width of 600mm on either side to ensure proper compaction in the slopes also. Trimming to the required width shall be done after the formation is done to full height. Plan cutting operation in such a way to avoid filling the same area later on Ensure camber, super elevation and gradient of road formation after rolling using levels, templates etc. liberally. Special templates to be used for curves No dumping in heaps at the area of work Ensure that the top of the cut section sub-grade is property rolled. If granular sub base is proposed straight on top of the cut formation, the top 500 mm ((300mm for rural) below the cut formation level shall be excavated and re-rolled to have 97% standard modified proctor density compaction. If the soil at the cut formation level is found unsuitable either due to inadequate CBR value or due to sub-standard quality, top 500 mm( 300mm for rural) soil below the cut formation level shall be removed and thrown away. The formation base shall be compacted to 95% of modified proctor density value, and suitable sub-grade material of 500 mm( 300mm for rural) thick shall be placed on top of cut formation and compacted according to the specification, before laying any pavement layers Check the material used for sub-grade, whether it has four days soaked CBR of minimum 10% (or specified in agreement specification) Quality control tests during construction as stipulated in MORT&H Section 900 (MORD section 1800 for rural). Ensure earthwork in Earth retaining Structures as per Technical Specification Rehabilitation of Existing Embankment In case of existing banks, where embankment portion are to be modified, benching of slopes shall be done with a little slope towards the inside of benching so as to give a good grip to the embankment soil with the sub grade. In general the benching shall be 300mm x 600mm (Vertical: Horizontal). Before benching, the slopes shall be cleared of all roots and vegetable matter as per specification. The bank section be brought to design standards by filling layer by layer with suitable material. In case of the old formation to extend horizontally. It shall be cut to a slope not steeper than 1 in 4 and the surface so prepared shall be scarified and made loose for a depth of 150mm. Necessary watering shall be done and the earth surface shall be thus prepared to receive the new embankment. The soil shall be laid in layers and compacted to the required degree of compaction to have a proper bond with the old one. If the old formation is to be raised vertically, vegetation shall be cleared followed by scarifying, watering and placing of the new earth layer as specified above. POST CONSTRUCTION STAGE Item Confirm width of formation is as specified Ensure side slopes are dressed to specified slope. Check camber is achieved. Tolerances in Surface levels as specified. Checked
SNo 1 2 3 4
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Checklists
Typical Sketch showing of Earthwork formation by Benching Method. Here, Embankment height is about 900MM. Depending on the height, Number of steps shall be formed. Extra Width of 600MM in each layer is to be provided to facilitate compaction along the slope also.
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Checklists
CHECKLIST No.3 CHECKLIST FOR PROTECTIVE WORKS S.No PRE-CONSTRUCTION STAGE Item Stone Pitching or Turfing 1 2 3 Confirm slope of embankment is as specified (1Vertical:2Horizontal), duly consolidated. Check the stones collected for size. Large size boulders should be used. Each stone should be over 40 kgs. Smaller size stones should not be used. For turfing, the clods of turf should be at least 50 mm thick and contain roots. Roadside and Catchment Drains 1 2 3 4 Check drains planned for road in cutting. Check whether bed slope is correct. Check whether the slopes of drains are as per designs. Check whether the excavated earth is removed and spread or disposed off. Checked
S.No
CONSTRUCTION STAGE Stone Pitching or Turfing
Checked
1 2
Ensure stone pitching is in accordance with IRC: 89 Clause 5.3.5.1. Ensure Stones and clods of turf are hand packed from bottom on top.
S.No
POST CONSTRUCTION STAGE Item
Checked
1 2
In case of turfing, unless done during the monsoon, daily watering for 30 days should be ensured. In case of drains, ensure excavated earth is removed from site.
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Checklists
CHECKLIST No.4 CHECKLIST FOR GRANULAR SUB BASE S.No 1 PRE-CONSTRUCTION STAGE Item Confirm sub grade is adequately compacted. If there is time gap for execution of GSB layer and the previously finished sub grade, check whether the sub grade test results are valid. Check whether the compaction of the sub grade is still in good condition, if not carryout proof rolling. Clear all loose or external materials before laying GSB from sub grade top Confirm camber, cross slope and side slope of embankment are correct. Check whether the sub grade top surface tolerance levels are within the permissible limits prescribed Confirm grading of GSB materials has been tested and is of correct specifications as per Agreement Specification Check whether the "Ten Percent Fines Value" test (Wet Aggregate Impact Value test for rural) and water absorption value test have been conducted and the results are as per the Specification Check templates available for indicating thickness of loose layer to be spread Check watering arrangements are adequate Confirm rollers are available and in working order CONSTRUCTION STAGE Item Observe the spreading and compacting operations. Ensure the material is being spread without significant segregation. If necessary, obtain samples from the material being spread and conduct sieve analysis test. Check the layer thickness and confirm that it is as per specification requirements Check layer of loose material is as specified in the specification. (For Moisture Content- IS: 2720 Part 2) Check layer of compacted layer is as specified Check density of compacted layer is as specified Density 98% according to IS: 2720 Part 8 ( 100% of Standard Procters laboratory MDD as per IS: 2720 part 7) Observe the compacting operation to determine that the material forms a firm, stable base throughout the spread width. POST CONSTRUCTION STAGE Item Tolerance as specified. Checked
3 4
5 6 7 S.No 1
Checked
2 3 4 5
S.No 1
Checked
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Checklists
CHECKLIST No.5 CHECKLIST FOR WET MIX MACADAM S.No 1 PRE - CONSTRUCTION STAGE Item Check whether the previous true layer GSB or sub grade as the case may be, has been finished properly and is to the required grades and lines and the surface irregularities are within the tolerance levels. Verify whether the sub grade has been prepared to the specifications laid in Cl. 404.3.1 of MOST Check whether GSB/sub grade layer compaction is intact if there is a considerable time delay in execution of WMM and the previous pavement layer (say 10 days). If not, carryout proof rolling Check whether any loose materials or external materials are on the GSB/sub grade top and remove all loose and external materials before laying WMM Confirm mix design is known to supervisor in charge of mixing. The design water content should be known Confirm stone aggregate has been tested and is of acceptable quality and adequate quantity (IS: 2386 Part 5) as per Appendix A Confirm fine aggregate is of correct gradation and adequate quantity Confirm equipment and plant necessary are available and in working order Confirm the sub-base on which wet mix macadam is to be laid is clean Check that the paver is adjusted to give the specified minimum thickness and camber .Do a trial stretch of about 5 to 10 m to confirm this CONSTRUCTION STAGE Item Observe the spreading and compacting operations. Ensure the material is being spread without significant segregation. When WMM is spread by graders/pavers, the layer size particles have a tendency to segregate. Check continuously while spreading that this type of segregation does not take place and take suitable remedial action either manually rectifying or adjusting the blade angles of the paver screed. Ensure no segregation takes place and material is spread without rock pockets Confirm that the gradation of spread materials is as per the job mix, by taking samples from the spread materials and conducting gradation tests Monitor thickness of wet mix macadam layer. (Not less than 75 mm) Monitor whether required camber is achieved Monitor water content. Excess water will/result in separation of coarse and fines (Optimum moisture for mixing IS: 2720 Part 8). Monitor compaction achieved is as required. Observe the compacting operation to determine that the material forms a firm, stable base throughout the spread width. Rolling continued till density achieved is at least 98% of MDD (IS: 2720 Part 8) Control tests and their minimum frequencies as specified in Appendix - A Tolerance shall be within the limits as specified POST CONSTRUCTION STAGE Item Erect barricades or pitchstones to prevent traffic Road shall be allowed to dry for a minimum period of 24 hours. No traffic shall be allowed over the surface before any priming coat is laid Checked
2 3 4 5 6 7 8 9 S.No 1
Checked
2 3 4 5 6
7 8 S.No 1 2
Checked
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Checklists
CHECKLIST No.6 CHECK LIST FOR WATER BOUND MACADAM S.No 1 PRE - CONSTRUCTION STAGE Item Checked
3 4
5 6
7 8 9 10 11 S.No 1
Check whether the existing top layer of base, sub base or sub grade, as the case may be, has been prepared properly as per MORT&H clause 404.3.1 or MORD clause 405.3.1. Whether the previously laid layer compaction is intact in case of considerable time delay in commencement of WBM construction and the previous pavement layer. If not, proof rolling is to be done. Remove any loose materials and external materials present on the previous pavement layer before spreading coarse aggregates Confirm stone Aggregate has been tested for Aggregate Impact Value, Flakiness Index Value Combined FIV and Elongation Index Values in case of MORT&H), Water Absorption and soundness test if water absorption exceeds 2%. Check whether the stone aggregate satisfies the specified gradation as per MORT&H table 400-7 or MORD table 400.8. Check the quality and gradation of screenings as per MORT&H clause 404.2.8 and table 400-8. For rural roads, the relevant MORD clause is 405.2.8 and table is 400.9. Check the quality of binding material as per MORT&H clause 405.2.9 (MORD clause 405.2.9 for rural roads). Check the required templates for indicating the loose thickness of layer to be laid Check watering arrangements are adequate Confirm rollers are available as per requirement in working order confirm availability of camber board, straight edge, spirit level and brooms etc.,
CONSTRUCTION STAGE Item Checked
Observe the spreading, sectioning and dry rolling operations. Ensure the material is spread without significant segregation. If necessary, collect samples from the spread material and check for gradation and verify thickness of layer Observe the application of screenings after dry rolling followed by brooming, uniform water sprinkling and rolling, Check sweeping followed by rolling so that all the voids are filled and dense layer is formed Check the required templates for indicating the loose thickness of layer to be laid.
POST - CONSTRUCTION STAGE Item Checked
S.No
Road shall be allowed to dry for a minimum period of 24 hours. No traffic shall be allowed before laying prime coat
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Checklists
CHECKLIST No.7 CHECK LIST FOR LAYING PRIME COAT PRIME COAT
Prime coat is the application of liquid bitumen/emulsion over an absorbent granular surface preparatory to any superimposed bituminous treatment or construction. Generally prime coat is applied to seal the granular surface
S.No 1 2 3 PRE- CONSTRUCTION STAGE Item Checked
5 6
Check the choice of binder (emulsion or cutback bitumen) and quantity shall be as per relevant specifications. Confirm cut back bitumen or emulsion is known to supervisor in charge of mixing. Confirm binder has been tested and is of acceptable quality. Sampling and Testing of Bituminous primer according to IS: 217 (Cutback bitumen), IS: 454 (Digbol type cutback bitumen), IS: 8887 (Specification for bitumen emulsion for roads of cationic type).Confirm the type of binder, which is going to be used, is as per the particular specification requirements Prime coat shall not be applied on a wet surface or during dust storm or when the weather is rainy, windy or foggy. Ensure that no priming is done when the atmospheric temperature is less than100C Check arrangements for ensuring correct dosing is in place Confirm equipment like binder spreader to be used is available and in working order.
S.No 1
2 3 4 S.No 1 2 3 4
Surface should be swept clean, free from dust and shall be dry. If the surface to be primed is so dry or dusty, a light and uniform sprinkling of water may be done, but no priming shall be undertaken till such time is no surface water is visible Check binder spread per square meter is as specified Check whether the spread of binder is uniform and no uncovered patches are left on the surface Control tests and frequencies shall be as specified
Erect barricades or pitchstones to prevent traffic Surface shall be allowed to cure for a minimum period of 24 hours or any other period as per site conditions If the primed surface is not cured within 24 hours of application, sand may be spread lightly over the primed surface Sand should be spread only thick enough to prevent pickup of bitumen. The need for large amounts of sand to blot up excess liquid bitumen is an indicative of error in selecting the rate of application or type of binder Care shall be taken to remove all loose sand before taking up the next course
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Checklists
CHECKLIST No.8 CHECK LIST FOR LAYING TACK COAT TACK COAT
Tack coat is the application of liquid bitumen/emulsion over an existing road surface preparatory to another bituminous construction over it. Tack coat is applied to ensure better bonding of layers
S.No 1 2 3 4 5
PRE- CONSTRUCTION STAGE Item
Checked
Check the choice of bitumen and quantity shall be as per relevant specifications Confirm cut back mix emulsion is known to supervisor in charge of mixing Confirm bitumen has been tested and is of acceptable quality and confirms to specifications (IS: 217, 454 and 8887) Ensure arrangements for applying liquid bitumen confirm to requirements and all the equipments are available and are in working condition Confirm that surface over which tack coat is to be applied is clean and all loose material or extraneous material is removed either by mechanical brooms or by other approved method
S.No 1 2 3
CONSTRUCTION STAGE Item
Checked
4 5
Check whether the liquid bitumen is heated and the temperature prior to application is within the range Check whether the spread of bitumen is uniform and the entire area is covered uniformly Ensure that no further layer is spread over tacked area before the tack coat is cured (until the water/cutter in case of emulsion/cutback has completely evaporated). In general time gap of 30 minutes will be sufficient Ensure that tack coat is not applied when the atmospheric temperature is less than 100C Check that tack coat is not applied over a freshly laid bituminous course. If due to site condition, traffic is allowed over the finished layer before next layer is laid, a light tack coat as decided based on site conditions shall be applied Normally tack coat is not to be applied over a freshly laid bituminous course. If due to site condition, traffic is allowed over the finished layer before next layer is laid a light tack coat as decided based on site conditions shall be applied
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CHECKLIST No.9 CHECK LIST FOR OPEN GRADED PRE MIX CARPET S.No 1 PRE- CONSTRUCTION STAGE Item Checked
2 3 4
Check the physical requirements of coarse aggregates as specified. Aggregates are to be tested for Aggregate Impact Value, Flakiness Index Value and Water Absorption. Soundness test is necessary if water absorption exceeds 1%. Check Suitable mixing plant, spreading rakes, camber board, templates, bitumen distributors and rollers are available Check thermometer for measuring the temperature and depth gauges etc., are available Check whether the base on which premix carpet is to be laid is prepared to the specified lines, grades and cross-section
S.No 1 2 3
4 5 6
Prime Coat with specified emulsion or cutback bitumen is applied as per the specified rate and cured Tack coat is applied as per the rate specified Mixing should be thorough that a homogeneous mix is obtained. The temperature of bitumen at the time of mixing should be in the range of 150C to 163C and that of aggregates 155C to 163C, provided that the temperature difference between bitumen and aggregates should not exceed 14C Ensure the mix is transported the site quickly Check whether the loose thickness of OGPC mix is ensured to be the required 27mm duly providing longitudinal and cross profile Correct high spots or depressions noticed after the roller has passed over the whole area once by removing or adding premixed material and recomposing. Rolling shall be done with specified type of rollers and upto a stage where no further movement of bituminous carpet ahead of the roller Provide seal coat to the surface immediately after the laying of OGPC carpet.
S.No 1 2 3
Check the edges of the carriageway should be correct within a tolerance limit of of 20mm Check the tolerance of surface level. It should be within 6mm for machine laid and 10mm for manually laid Check for surface regularity. The maximum allowable difference between the pavement course and a 3M straight edger shall not exceed 8mm for both the longitudinal and cross profile Check thickness of compacted layer randomly and check for bitumen content.
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CHECKLIST No.10 CHECKLIST FOR BITUMINOUS LAYERS USING MACHINISED CONSTRUCTION (BM, DBM, SDBC, BC) S.No PRE- CONSTRUCTION STAGE Item GENERAL Confirm mix design is available. Confirm hot mix plant setting and match the mix design. Confirm whether all the materials are as per criteria furnished in agreement Specification Do a trial run for paver settings and for evolving rolling pattern. Ensure freshly laid surface is barricaded or boulder pitched to prevent traffic for 48 hours Check the tolerance in surface levels as specified Check and do not allow any bituminous work when there is a possibility of rain or during rain Check the probable environmental impacts due to functioning of the hot mix plant and ensure proper remedial actions are taken before the actual operation begins. Ensure regular check to monitor the environmental mitigation action plan and its proper implementation PLANT OPERATION Observe the aggregate storage areas and facilities to ensure that storage is as specified. When various sizes are stored separately, required physical separation, either by space between stock piles or some types of wall that will provide separation Determine whether the stock piled aggregate is similar to the material used for the mix design. Confirm their quality Examine the plant whether weighing equipment is as specified See that scales and meters are sealed or tested as required Examine the plant to determine if it has a temperature indicating device or the drier and that it meets requirements set forth in the specification Check method used for including supplemental fine aggregates or bag house dust as per specification Check that the plant is equipped with a functional dust collection system as per specifications Determine if there are safety provisions for sample collection as per specifications Check asphalt storage tanks and determine that they meet specifications. All storage tanks, transfer lines, pumps etc. should have heating oils or should be jacketed and heated to maintain the asphalt at the required temperatures Check batch plants and determine that it meets the requirements of the specifications. a) Check whether there are overflow chutes for the hot aggregate storage, which will prevent overflow between adjacent bins. Examine the chutes to see that they are not clogged. b) Provisions for the binder to be introduced uniformly at the specified location c) A timing device, which will indicate by audible or visual signal the expiration of the mixing period - check to ensure that the system is in working order. Checked
1 2 3 4 5 6 7 8
2 3 4 5 6 7 8 9 10
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S.No 1 2
PRODUCTION STAGE Item Maintain a daily plant record. Use a form approved by the Engineer Ascertain that the production rate for the mix plant does not exceed the specifications. Production rates in continuous mix plants must not exceed those rates established during the preceding aggregate weigh belt and asphalt meter calibration. Monitor plant interlocks. Obtain the required certificates of compliance for all asphalt binder loads Observe aggregate storage and determine that it meets requirement set forth in the specifications Determine that supplemental fine aggregate is kept dry and stored properly. Monitor and record the temperature of the asphalt and aggregate and determine that it meets requirement set forth in the specifications. Any excessive moisture in aggregates may cause slump of flattened loads, accompanied by considerable bubbling or streaming of the mixture Compare aggregate from all bins to determine that it meets specifications. Obtain samples of the aggregate prior to mixing with asphalt, and test for the grading. Gradings used by the laboratory for mix design are based on volume and not weight. When there is a difference of more than 0.2 between the specific gravities of coarse material and fine material, the field sieve analysis must be adjusted to volume for comparison with the design curve Observe the overall plant operation to see that dust or smoke is being controlled as specified Observe plant productions to assume that a homogenous mixture is being produced check the aggregate gradation, mixture consistency, stability and bitumen content. If the mixture appears to be deficient in any of these respects, the condition should be discussed and rectified. For batch mixing, do not approve a mixing time of less than 30 seconds unless the reason for such action is adequately documented and based on tests for uniformity of 'aggregate and asphalt distribution. Mixing time in a continuous' flow mixer is a function of length of the mixing area and the rate of drop in drier drum mixing. The most efficient pug mill mixing is obtained when the level of material is at the top of the paddies, throughout the length of the mixer. Feed must be continuous and uniform for best results. Also it must be noted in the daily report Monitor the temperature of asphalt. In batch plants ensure that the temperature of the asphalt in the line does not drop more than 8 0C (150F). In continuous feed plants ensure that the temperature of the asphalt does not vary more than 28 0C (500F). Check to ensure that all the equipments are functioning properly and within the specifications. When automatic batch mixing is used, check to see that the automatic equipment is functioning within specifications. When any continuous mixing plant (drier drum or drier drum pug mill) is used, check to see that the vibrating unit on the fine bin is in operation. Also ensure that the low-level interlock systems for the aggregate feeder bins and the asphalt storage are functional Observe the operation of all weighing systems. Required scales and meters to be retested whenever there is any indication that there may be in error a) The weight of the material falling from the bin gates to the weighing hopper after the gates are closed must be considered in the batching process. Check that the weigh box containing the total batch does not contact anything, which
Checked
3 4 5 6 7
9 10
11
12
13
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prevents a true indication of the batch weight. b) Periodically check the batching by comparing the total weight of the batches in a truckload with the platform scale weight for the some load (This can be done only when the mixed materials are not kept in silos). c) Check the asphalt scales frequently to make sure that there is no zero error; that the scale levers and knife edges move freely; and that there is no bind or drag on the lever systems. d) The accuracy of meter driven asphalt proportioning devices should be checked by comparing meter totalized readings with asphalt tank stabbings and/or with the combined aggregate totalized readings in conjuction with an onsite vehicle scales. Observe storage of materials in silos to ensure that segregation is prevented, that specified temperatures are maintained, and that minimum silo levels are maintained Examine truck beds prior to loading to ensure that contaminating agents are not used and that parting agents are used sparingly Ensure that the automatic aggregate asphalt proportioning system in continuous mix plants is operating Record all information that will support payment and will assist in determination of causes for out of specification materials.
14 15 16 17
S.No 1 2 3 4 5 6 7 8 9
TRANSPORTATION STAGE Item Check whether truck beds are smooth and free form holes and depression Is there any leakage of gas or oil from trucks? Are trucks equipped with adequate covers? Do truck and paver operate together without interference? Is the method of coating of contact surfaces of truck beds agreed upon? Whether any provision for checking the temperature is made in the trucks. Whether any segregation takes place while loading the trucks from the plant. Check whether there is any spillage of mixed material while loading into the trucks from the plant or at loading the pavers from the trucks. Any spillage shall be removed and discarded. Check the temperature of mix at the time of loading and unloading. If the reduction in temperature is substantial, the mix should be discarded
Checked
S.No 1 2 3 4 5
BITUMEN DISTRIBUTOR Item Are the heaters and the pump in good working condition? Does the distributor have a volume calibration chart? Are spray bars and nozzles unlogged and set at the proper angle for application of tack coat Is a proper thermometer provided to verify temperature? Whether a hand held spray hose with nozzle provided to tack irregular areas.
Checked
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S.No LAYING OPERATIONS 1 2
PRE-LAYING
Checked
4 5 6 7
Item Ensure that the base of previous road surface has been prepared as specified, remove all loose materials and have problems corrected Ensure that the prime coat/tack coat has been applied uniformly and properly. Determine temperature of the asphalt material used for prime coat/tack coat. Check whether all vertical faces are coated Ensure that tack coat material is being applied at the specified rate and at the proper distance in advance of the paving operation. Check distributor spray bar height and nozzle angle Ensure that the tack coat is broken or cured prior to having wherever required Ensure that certificates of compliance have been received for each shipment and that weight and load slips for each liquid asphalt load are accurate Determine the temperature of the air and record Examine the spreading equipment to determine whether it has the specified attributes. Pay particular attention to pavers, which are variable in width, to ensure that spreading and compacting components extend for the full width of the traffic areas lane to be paved Examine rollers to determine whether they have the specified attributes. Ensure that the specified number of rollers is available as decided during the trial compaction. Check frequency of vibratory rollers to assure 30-40 impacts per meter with a tachometer. Whether a rubber tyre roller is used, verify the manufacturers recommended contact pressure Ensure that all equipments required for checking bitumen content/density are available. Check for all hand equipments like, lutes, rakes and shovels Checked
S.No 1
DURING LAYING Item Record measurements of air, surface and asphaltic mix temperatures. Cool air blowing can reduce the temperatures of the mix. A cold surface can suck heat out the mix extremely fast. This will be critical when the lift thickness is thin Observe spreading: a) Check equipment being used to ensure it meets specifications b) Monitor thickness and observe that the road/lane width is being met c) Record number of layers d) Check spread rate against theoretical rate e) Ensure that longitudinal joints are offset as specified f) Check whether the conveyor is exposed to make sure that material is on the hopper conveyor at all times g) Check whether paver hopper is near full at all times. Check flow gates and augurs. Paver wings should not be dumped as large aggregates accumulate in the wings. Waste it at the end of the day Confirm that rolling pattern and compaction effort determined during the trial test are being met. Check breakdown rolling has been accomplished before
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6 7 8 9 10
minimum temperature is reached. Obtain a sample of the completed mixture from the mat behind the paving machine and test it for extraction, moisture, and sieve analysis Identify the samples to indicate both the stationing where they were taken and the approximate area they represent. Analyze the test data at the earliest possible time. It is preferable that samples representing drier - drums or continuous mixing be tested in the field, in order that immediate corrective action can be taken for any deviations. For determining the uniformity of the mixture as placed - consider tests from the mat at longitudinal intervals and not at transverse. For determining mixer efficiency - consider taking samples from the pug mill or discharge gates of batch plant or from the discharge chute of drum-mixer plant. Check the rolling temperature of mix during laying shall be 120 0C - 1600C. It is an extremely important factor in compaction. Rolling should begin in sequences as soon as mat will support the weight of roller without picking up material on the drum or unduly marking of shoving the mat. Check that rolling is done at as high a temperature as possible, because highest initial densities are achieved at high temperature optimal for rolling Check transverse and longitudinal joints are constructed properly. Observe constructions at cold transverse joints to see specifications are being met Observe that the segregation and visual pavement deformities are being avoided or corrected Ensure that smoothness of the surface is as specified record measurements Check the edge alignment of the material being placed. Check is should not be thin or thick compared to lift thickness Ensure that defective areas have not developed. Check pavement for pooling of asphalt, bleeding, ravelling, rock pockets, consistent colour etc
S.No 1
DURING TRAIL COMPACTION Item Use a test trip. The use of a compaction test strip before the start of a project will head off problems before they arise. It will also provide information to the roller operator to establish the: a) Roller pattern and speeds b) Frequency and amplitude settings c) Density specifications for job d) Number of passes, vibratory or static Testing shall be done on a test strip, which is similar in condition and nature to that of the project highway. Preferably a short length of the project road itself is treated as test strip Testing should begin with the roller set at its recommended amplitude. If the unit bounces, or moves sideways, reduce the amplitude setting. If it is obvious that particles are being fractured, reduce the amplitude It should be obvious that maximum amplitude should not be utilized when beginning to roll a thin lift
Checked
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5 6
The use of the test strip is an educated trial and error process to determine the most productive procedure for a particular project Even if density requirements are set by using the marshal or kneading compactor a test strip will still permit the contractor to develop the rolling patterns, type of compactor etc. to meet the specifications DURING ROLLING Item Check the fuel tanks are full and there will be no delay during the day Check the water supply, spray bars and nozzles. Any clogged nozzles need to be cleaned out before work beings Check the engine oil, hydraulic tank Grease the machine and inspect the drums for any dent If the rollers are to be stopped for any length of time, park at an angle on a cool part of the mat. Parking on a warm mat will most likely leave an indentation that will not roll out At the end of a pass, while reversing, turn the roller into a slight curve prior to stopping avoid leaving a transverse ridge across the mat When using a vibratory roller, check whether it is operated at a speed that will provide at least one drum impact or more per 2.5 cm of travel. Ripples may result if this is exceeded Never allow to vibrate when the roller is stationary; use-automatic vibration cut off Check whether deceleration /acceleration is being done smoothly while reversing direction to avoid pushing or shoving the mat Sharp turns shall be avoided otherwise it will cut the mat Checked
S.No 1 2 3 4
5 6
7 8 9
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CHECKLIST No.11 TYPICAL CORRECTIVE ACTION PLAN FOR BITUMINIOUS LAYERS PLACEMENT Test Item Bitumen Content Corrective Action If test results are outside tolerance (0.3% of specified or required) an immediate investigation will be conducted to determine the cause. Corrections will be made and material will be tested immediately to ensure that the correction has been effective. If test results are outside tolerance an immediate investigation will be conducted to determine the cause. Corrections will be made to stockpiles, bins, bells or scales and material will be tested immediately to assure that the correction has been effective. When individual or composite aggregate moisture values differ from those of the plant computer, the plant computer will be adjusted to reflect the most recent aggregate moisture. If the asphalt temperature exceeds the permissible ranges (120C to 160C) the plant operator will immediately take corrective action to raise or lower the temperature as required. Temperature will be closely monitored to verify that the corrections were adequate. If the mix temperature exceeds 160C the plant operator will immediately take corrective action to lower the temperature as needed. Temperature will be closely monitored to verify that the correction was adequate. Asphalt concrete- that exceeds 160C shall not be used in the work and shall be disposed off suitably. If the mix moisture exceeds 1%, the plant operator will note the moisture content and corrective action will be taken to reduce the moisture in the mix. Aggregate piles may be spread to dry, aggregate time in the heater may be increased, etc. If inspection indicates that the sub-grade is not prepared as specified, and as required, immediate action will be taken. Sub grade problems will be corrected-dried, cleaned, compacted, graded, etc. Asphalt concrete will not be placed until the corrections have been made and the Engineer has inspected and approved.
Aggregate Gradation
Aggregate Moisture
Asphalt Temperature
Mix Temperature in the Hot Mix Plant
Mix Moisture
Sub-grade Preparation
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Prime/Tack Coat
If inspection indicates that the prime or tack coat material or application arc not in accordance with the specifications immediately action will be taken,. Prime coat will be re-applied, changed, time for break will be lengthened, etc. Bituminous layer will not be placed until the corrections have been made and the Engineer has inspected and approved. If physical measurements indicate that the ambient temperature is less than specified (13"C), the paving foreman will be notified and placement will cease as soon as safety concerns have been provided for.
Ambient Temperature
Mix Temperature at the Time of Laying
If physical measurements indicate that the mix temperature is below the temperature, which the paving foreman has requested for placement and breakdown, corrective action will be taken immediately. Cool mix will be returned to the plant, the operation will be changed to correct the situation which is causing the problem, and Bituminous mix will be held in covered trucks and not windrowed until necessary.
In-place Density
If field density determination indicates that the bituminous layer is not being placed to a minimum relative density (if specified), immediate action will be taken. Roller operations will be investigated and may be changed, plant will be notified and mix quality will be examined, temperature will be determined, etc. Density will be tested immediately following the corrective action to assure that the action has been effective.
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CHECKLIST No.12 CHECK LIST FOR TEMPORARY DIVERSIONS S.No 1 2 3 4 PRE CONSTRUCTION STAGE Item Checked
FORMATION Check drawings and specifications given in the contract. If site conditions and estimated period of use so dictate, recommend improvement Check alignment for gradients and curves. The alignment should be marked in the same way as formation Carryout checks as given in Check list No. 1 and 2 The general provision laid out in Clause 112 of MOST (111 of MORD for Rural) Specifications may be adhered to
S.No 1 2
3 4
CONSTRUCTION STAGE Item WBM, PIPE CULVERTS AND SURFACE DRESSING Carryout all checks given in Check list No. 1 and 2 For WBM check the following: a) Stone metal laid in correct thickness. b) Adequate compaction is done. c) Blindage spread evenly and adequately watered. d) Surface re-rolled. For CD works carryout checks as per Check list No. 14 and 15 For surface dressing check the following : Surface cleaned and made dust free. Tack coat correctly applied as per specifications, uniformly and without any uncovered gaps. Mixture spread evenly to required thickness and compacted. Test compaction by field density test. Manila ropes or wooden markers laid on edges to improve compaction. Seal coat applied if provided for
Checked
S.No 1 2
POST CONSTRUCTION STAGE Item Check dimensions of completed work Check periodic maintenance earned out
Checked
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CHECKLIST No.13 CHECK LIST FOR ROAD FURNITURE S.No 1 2 3 4 5 6 FENCES Item Review the plans, special provisions and right of way agreements for any special details Compare the planned location with actual conditions in the field to ensure that fences, gates, openings etc will serve the purpose, as intended Fences should not obstruct flow in streams or drainage areas Check that the areas in which fences are to be placed are graded and that high points, which interfere with placing of wire mesh are excavated Examine the fence material so that it satisfies requirements Observe the placing of fence posts and measure the spacing. Observe the placement of corner posts and pull posts to ensure that they are placed at required locations and in accordance with specified details. Also check that the proper type and number of brace posts and diagonal wires are used The barbed wire mesh is placed on the property owners side. For chain link fence, the fabric is generally placed on the highway side Ensure that fencing is snubbed or guyed at all grade depressions as specified Checked
7 8
S.No 1 2
MARKERS AND DELINEATORS
Checked
Item Review the list of markers and delineators shown on the plans Examine the markers and delineators to ensure that they are as specified. Required certificates of compliance shall be obtained from quality control inspectors Observe the installation to ensure that it is performed as specified. Check installation of target plates and ensure washers are used and that the nuts are not tightened to the extent that the enamel is cracked
S.No 1 2
Item RAILINGS AND BARRIERS GENERA Make a careful review of the required details. Review the locations in the field. Review the stakes and layout work. Ascertain the offsets and flares are as per the plans Item
Checked
S.No 1 2 3 4
METAL BEAM GAURD RAILING
Checked
Measure woods posts or concrete posts, they should satisfy the standards Ensure that bolt holes in treated posts are filled with grease when required Observe backfilling of post holes to see that this is performed as specified. Posts should be set to the full depth shown on the plans Measure the spacing of posts and ensure they are as per specifications
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5 6 7 8 9 10 11 12 13 S.No
Ensure that the blocks for metal beam guard railing are toe nailed to timber posts and properly fixed with nuts and bolls on the concrete posts Ensure that rail elements are lapped so that the exposed ends will not face approaching traffic. Check bolts for tightness Measure the height of the railing or barriers above the ground to ensure that it is as shown on the plans Ensure that connections to bridge railings, retaining walls, abutments or other flat surfaces are made as specified Ensure that anchor assemblies are constructed as specified. Cable clips should be installed in the proper directions and tightened to the required torque Where posts are installed in loose soil or near the edge of embankments, it may be necessary to use longer posts Concrete anchors and footings must be built according to the dimensions shown on the plans. Check holes immediately prior to placing concrete Bolts must be long enough so that nuts are threaded completely into the bolt. Be sure that no more than 12mm of bolt is exposed on the traffic side of the rail Ensure that flares are constructed as per the plans CONCRETE BARRIERS Item Check that no concrete barriers or railing is placed on new structures until the false work is released Review the provisions for closing the temporary gaps in barriers during construction Check the forms whether they conform to the guidelines and specifications When extrusion or slip form machineries are used in concrete barrier construction, inspect the grade upon which the machine will ride to determine if it is smooth enough to prevent foreseeable violations of specified tolerances Check the relevant specifications and check lists for producing, placing, finishing and curing cement concrete to be used Equipment and concrete design should be such, in extended or slip form barrier placement, that no hand finishing other than the light brush finish is required. It is desirable to have the traffic face surface of the barrier as smooth as possible PIPE HAND RAILING item Determine that materials and methods used in anchorage and connections are as specified and as shown in the drawings Ensure that cables, chain link fabric and tension wires are connected properly, stretched and tightened as required Check railings for proper alignment, appearance and workmanship Checked Checked
1 2 3 4 5 6
S.No 1 2 3
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S.No 1 2
LANE MARKINGS Item Review the signing and marking plans, any special requirements and other standard details Inspect the equipment for specification compliance. Determine methods for checking spread rates of paint and glass beads, application temperatures of thermo plastic materials and maximum temperature of paint Check pavement temperature prior to application of thermoplastic material. Check atmospheric temperature and conditions prior to applying paint Check condition of the pavement prior to application. The pavement should be dry and clean Check whether the stencils will produce correctly dimensioned pavement markings Check the layout work. Determine whether the pavement markings will be correctly located Ensure that the thermoplastic material is placed within the correct temperature range. Thermoplastic material heated to excessive temperatures can flash and splatter when exposed to air. Temperature gauges mounted on heating equipment should be checked for accuracy Check the lane stripe for correct width and edge definition, lengths of gaps and individual stripes, alignment and correct super imposition of second coats Any drips, over spray, improper markings, and material tracked by traffic shall be removed Check applied thermoplastic material for compliance with thickness requirements Check application rates for glass beads and paint. Check thermoplastic markings for workmanship as they are applied. Bumps resulting from overlaps in extruded materials should not be permitted
Checked
3 4 5 6 7
8 9 10 11 12
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CHECKLIST No.14 CHECK LIST FOR PIPE CULVERTS The works can be of two types, extension or new construction. In the case of pipe culverts the mark out, excavation, bedding and placing of the pipes are most important and any mistake in these activities cannot be corrected except by complete removal and reconstruction. S.No 1 PRE - CONSTRUCTION STAGE Item Test the soil and see if the safe bearing capacity matches design value. Proper bedding shall be provided below the pipes as per section 1100 of MORD specifications for rural roads and as per section 2900 of MORT&H Standard Specifications for MDRs, SHs and NHs. Pipes shall be tested in accordance with IS: 458 (Concrete pipes with and without reinforcement) for the relevant clauses like NP3 and NP4 Check for the identification marks left on the pipes while inspection and testing of pipes were carried out in the manufacturing plant Check for any cracks in the pipes, which might have been caused during transportation or loading and unloading CONSTRUCTION STAGE Item EXCAVATION The excavation should be as per drawings but the following should be checked : The length of excavation caters for the number of pipes plus the spacing of pipes, which should be half the diameter of the pipes but not less than 45cms The depth of excavation should cater for the following : Cushion above pipe of minimum 600mm of half the dia. or the pipe including pavements. If the required cushion is not available due to low embankment embed the pipe in concrete. A minimum of 200mm thick PCC or 150mm RCC all round the pipe shall be provided. The grade of concrete should be as per table 5 of IS-456:2000 Granular/concrete bedding and foundation depending upon the height of embankment as per relevant IRC clauses, if necessary. 1/3 of pipe dia or 300mm will be buried below nala bed to prevent scour. The distances between trenches for foundation of headwalls are such that it suits the proposed pipe lengths. Checked Checked
2 3 4
S.No
1 2
S.No 1 2 3 4
Foundation and Bedding Item Check Check Check Check excavation is correct. mix proportion of PCC is as specified. thickness and material of bedding is as specified. cradles are provided for resting of pipe joints.
Checked
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5 6
Check length of pipe is same as the distance between the outer surfaces of the headwalls. Check proper foundation in case of Black Cotton/Soft soil and concrete bedding in case of rocky strata is provided. Checked Item
S.No Placing of pipes

1 2 3 4 5 Check spacing between pipes is not less than 1/2 dia. of pipe or 50 cms, whichever is more. Check pipes do not protrude beyond the headwalls. Check cross slope of pipes is as per design. Check joints of pipes properly done using collars or other methods as per specifications. Joints shall be sealed with mortar, rubber gaskets or other sealing materials. Check pipe joints properly cradled. Joints shall be kept covered and damp for at least 4 days. Head walls
S.No 1 2 3
Item
Checked
4 S.No 1 2 3 4
Check headwall foundation is as per drawing. Check headwall constructed as per design. If the same is of un-course rubble ensures headers are used. UCR masonry cannot be constructed properly to have a watertight joint at outer surface of pipe at headwalls. In that case the pipes should be encased in M20 grade Concrete as per Table 5 of IS 456:200 near the headwalls to prevent floodwater from entering around the pipes. Ensure curing for 7 days. Filling earth over Pipes Checked
Item
Ensure the culvert is filled with approved earth in layers not more than 30cms, watered and compacted. Ensure filling material free of boulders and black cotton or other unsuitable soils. Initial compaction should be done manually. Rolling to be done only after 30cm of earth has been laid over the pipes.
General In general embankment is formed to the full height as required in the profile and plan drawings. Then the pipe culverts are marked and excavated for pipe laying. The formed embankment is cut to slope, preferably not steeper than 3(Horizontal):1(Vertical) on the either side of the embankment to the proposed pipe foundation ensuring base width of 750mm on either side of pipe at the foundation level and, there after, to cut serrations/benches in the slope duly moistened and then earth fill be placed in layers and compacted. This will ensure better compacted embankment on either side of the pipes. In case pipes are laid before embankment is constructed, the portion between the pipe rows and for a width of 0.6 to 0.75m on either side of the pipe shall be backfilled with coarse granular materials and rolled along with earthwork.
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CHECKLIST No.15 CHECKLIST FOR SLAB CULVERTS AND BRIDGES S.No PRE CONSTRUCTION STAGE Item FOUNDATION 1 2 Confirm line out and position of abutments Confirm sub-soil investigation has been carried out up to 3m below design foundation depth and design assumptions match actual site conditions a. Soil Investigation for foundation: IS: 1498, IS: 1888, IS: 1892, IS: 2131, IS: 2720, IS: 4434, IS: 1968 and IRC: 75 b. Foundations resting on Rock: IS: 5313, IS: 4464, IS: 7292, IS: 7317 and IS: 7746 for in-situ tests Check drawings are available at site Check materials like aggregate, sand, cement, HYSD bars have been tested as per Agreement specifications and test results are satisfactory Check adequate numbers of moulds are available for taking CC cubes for testing Check curing arrangements are adequate. In case, moist curing with water is to be done, ensure availability of water, water gun, availability of sacks/ hessian cloth rolls for covering the exposed surfaces of concrete and spraying water to keep these continuously wet for 14 days. In case, curing is to be done with membrane forming curing compound, ensure availability of approved quality curing compound conforming to ASTM-C-309-81 Type-II with test certificates and availability of mixing drum and power spray nozzle. Check the required compressive strength of concrete for various items and mix designs are available Check equipment and plant like weigh-batching machines, concrete mixers, water measuring arrangements, Vibrators etc. are available Check quality control equipment like slump cones are available Check whether the area to be concreted is free from standing water. The area shall be properly dewatered and kept clean before concreting If underwater concreting is to be done, ensure that the same is done through termite pipes, or drop bottom buckets or any other approved methods Before concreting check the weather. If extreme weather concreting is to be done, ensure necessary precautionary methods as stipulated in the specifications. No concreting shall be done if the atmospheric temperature is above 35C or below 5C. The temperature of wet concrete should be less than 40C and all necessary steps to control the concrete temperature particularly during hot weather concreting. Ensure that proper platforms or pathways are laid for movement of people in and around the concreting area and they are sound and safe Checked
3 4 5 6
7 8 9 10 11 12
13
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S.No 1
CONSTRUCTION STAGE Item Check and strictly ensure production of design mix concrete with the proportioning of cement, sand, and coarse aggregate in the concrete mixer by weight, measured addition of water by volume / weight, and addition of admixture, if specified, by volume / weight, duly adhering to the specified watercement (W/C) ratio; mixing in mechanical mixer / batching plant to obtain cohesive mix of uniform colour & consistency; and the measurement as well as recording of slump of concrete mix corresponding to W/C ratio. Check the load tickets if concrete is delivered through transit mixers or agitators.
Checked
Check and record slump of concrete at the production and delivery point. The loss of slump should not be more than 25 mm.
Check that no additional water added during hauling or at delivery point without prior instructions. If additional quantity of water in the mix has to be added to
4 5
overcome the difficulties of placement and compaction, the cement content should also be proportionally increased so that the water-cement (W/C) ratio as specified is not exceeded
Check that the transported concrete is not segregated and contains no cement balls Ensure that concrete is placed while fresh and before it has taken an initial set. Ensure that stiffening of concrete has not taken place in case of transported concrete Observe the method of placing of concrete and ensure concrete to place without any segregation and it is being compacted by specified vibrators Check that no over vibration takes place. Concrete shall be vibrated to the point where mortar and water flush to the surface. Under vibration will leave rock pockets contact between the vibrator and any reinforcement should be minimum, if possible avoid such contacts If concreting is done through chutes, ensure that segregation of mortar and aggregate does not take place. In case the drop height is more, a remixing of concrete shall be done before placing Ensure that the drop of concrete shall not be more than 1.5 meters (as per section 1709). In case of underwater concreting, ensure that extra 10% cement is added in the mix over and above the required cement quantity as decided in the mix design. If any use of admixtures is allowed, check whether they are being mixed as per the specifications or approvals. If concrete is pumped, ensure that approved type of pump is being used. Ensure that no segregation takes place in pipes. Ensure that a continuous pumping is done. In case of frequent stoppages, the pumps are to be cleaned properly otherwise, the pumped material will remain in the pipelines. In that case cleaning will be very tedious concreting operation may have to be stopped till the pump and pipelines are cleaned Ensure adequate CC cubes collected for testing, as per Cl.1716.2.
6 7
9 10 11 12
13
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S.No 1 2
POST CONSTRUCTION STAGE Item Ensure curing earned out for 14 days Ensure CC cubes tested for 7 days and 28 days strength. In case of M: 35 concrete 56 and 90 days strengths must also be determined and found satisfactory. PRE CONSTRUCTION STAGE Item ABUTMENTS, PIERS AND SLABS In addition to the pre-construction checks for foundation, the following additional checks will be carried out: Formwork is of desired quality and rigidly fixed. Special care is required to be taken for second and subsequent lifts to avoid bulging and honeycombing at junction of lifts
Checked
S.No
Checked
3 S.No 1 2 3 4 5 6 7 8 9 10
Confirm reinforcement is correctly tied as per drawings ensuring specified cover for reinforcement is strictly maintained through provision of adequate number of cover blocks / spacers / concrete chairs / supporting bars etc.
Approved type of vibrators are available and in working condition CONSTRUCTION STAGE Item Check slab thickness, wall thickness and the area to be concreted is clean from foreign materials Ensure mix design is followed. Carry out workability tests such as slump test to ensure correct water cement ratio Ensure approved type of vibrators is used. In case of abutments and wing walls ensure weep holes are provided at specific horizontal and vertical spacing Check the surface, in case of slab with straight edge. Remove any depressions and irregularities Ensure adequate CC cubes (as per Table 1700.8) collected for testing Ensure that water is not used as a finishing aid. If approved, use approved chemical finishing aids or evaporation retardants During placing of concrete, check for any movement or deformation of forms have the permissible tolerance limits. Ensure that required cover for reinforcement is maintained and not disturbed while placing concrete. Checked
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S.No 1 2 3 4 S.No 1 2 3
POST CONSTRUCTION STAGE Item Ensure date of casting painted on surface as soon as side forms are removed Ensure curing carried out for not less than 14 days. Ensure that the formwork/false work is removed after stipulated time. Ensure CC cubes tested as per laid down norms and the results are satisfactory. APPROACHES TO CULVERT/ BRIDGE Item Ensure soil used for back filling is of approved material Ensure embankment built, up in layers of 30 cm compacted to 20cms. Test compaction of each layer by field density test. 98% compaction is necessary. Ensure invert filters are provided at weep holes.
Checked
Checked
PROTECTIVE WORKS: All checks as listed at Check list 2 will be carried out. If additional protective works like aprons or flood protection bunds have been provided for in the designs, it will be verified that these are constructed as per drawings and specifications.
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CHECKLIST No.16 CHECKLIST FOR REINFORCEMENT INSPECTION
S.NO 1 2 3 4 5 6 7
Latest revision being used
ITEM
Working drawing checked and approved Bar bending schedules approved Reinforcement steel material approved Bar bending and cutting satisfactory Formwork member spacing correct Corrosion treatment of bars is done by giving a coating of cement - water slurry (cement wash). This is necessary to protect the reinforcement from exposure to highly saline atmosphere during storage, fabrication, and use.
YES
CHECKED NO
NA
8 9 10 11 12 13 14 15 16
Bar sizes correct Bar lap lengths correct Bar laps at correct locations Bar tied as specified (check proper quality binding wires are used) Bar assemblyrigid and adequately supported (Including spacers/chair supports) Cover to bottom bars correct Cover to side bars correct Cover to top bars correct Cover blocks approved including fixing
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CHECKLIST No.17 CHECKLIST FOR FORMWORK INSPECTION
S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
ITEM
Formwork design/drawing/sketch approved including de-shuttering arrangements Trial panel approved (if required) Formwork alignment correct Formwork levels correct, including screeds Formwork dimensions correct Formwork member spacing correct Formwork member material quality acceptable False work member sizes correct False work member spacing correct False work member material quality acceptable Gaps between primary and secondary members closed/wedged. Face boarding/plywood/metal thickness correct Joints between panels closed (no gaps) Joints between panels flush (no steps/lips) Panel flatness acceptable Gaps between secondary members and face panels closed Tie rod material and sizes correct Tie rod spacing correct19. Tie rods tight, face cones flush Spacers between shutter surface tightly fitting Box outs, cast-in-items, ducts fixed correct, securely Pre-stressing sheathing and vents, alignments and spacing of supports acceptable Empty sheathing secured against floatation Pre-stressing anchorage positions and fixing acceptable Chamfers/fillets sizes, straightness, fixing acceptable Formwork clean Formwork release oil material approved Form work release oil [Material applied correctly Construction joint preparation satisfactory Safe access constructed Adequate workspace provided for labour, equipment Shutter vibrator (if required) location and fixing arrangements approved
YES
CHECKED NO
NA
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CHECKLIST No.18 CHECKLIST FOR INSPECTION BEFORE APPROVAL TO CONCRETE
S.NO 1 2
ITEM
Method statement approved Batching plant mixers in working order (Separate dispenser for admixture, if required, available)
YES
CHECKED NO
NA
3 4 5 6
Standby batcher in working order Water, sand, coarse aggregate, cement, and admixture approved Water, sand, coarse aggregate, admixture, cement Stock sufficient Concrete conveying arrangement (including transit mixers) available in working condition and of sufficient capacity
7 8 9 10 11 12 13 14 15 16 17 18 19 20
Formwork/scaffolding approved Reinforcement approved Pre-stressing sheathing approved Concreting equipment in working order Standby crane, vibrators present Tremie in working order (for under water work) Concrete gang present, including carpenter, steel fixer, mechanics and electricians Access like walkways are provided Safety arrangements adequate Lighting provided Communication between various points provided Arrangements for arranging suspension/stoppage of concrete provided Curing arrangements made Laboratory notified
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CHECKLIST No.19 CHECKLIST FOR BATCHING AND POURING OF CONCRETE S.No 1 2 3 4 5 S.No 1 2 3 4 CONCRETE MIXING Item Check the concrete grade and the respective mix Design already approved. Check Check Check Check the condition of aggregates to be used the weighing and water dispensing methods adopted during the mixing whether the mixer machine has been cleaned properly whether required mixing time is allowed. Checked Checked
TRANSPORTATION/CONVEYANCE OF CONCRETE Item Check whether the equipment is in proper working order. Check whether specified methods are being followed. Check whether the stipulated time limits are observed. Check whether non-conforming wet concrete is being rejected and disposed off. PLACING OF CONCRETE Item Check whether the concrete is not segregated during pour. The height of dropping is controlled. It should not exceed 1.5m. Check whether the concrete is poured in layers of about 300 mm Check that the vibrator is applied systematically to compact uniformly and adequately. Avoid over vibration. Concrete shall not be pulled or pushed. Pouring should be done close to the final position Cold joints are not allowed to be developed Under water concrete shall be poured only by termites or pipeline. The forms are not displaced or deformed during the concrete pour and vibration No slurry loss. Suitable no. of carpenters should be present and watch formwork during the pour The concrete is poured within the allowable time limits from the time of batching Concrete cubes are taken as required as per table 1700.8 of MORT&H(table 800.10 of MORD for rural) Check the curing arrangements whether they are satisfactory
S.No 1 2 3 4 5 6 7 8 9 10 11
Checked
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CHECKLIST No.20 Check list for Post Concreting Inspection LOCATION: Date of: Date of pour: Curing: Start Date: Date of side shutter stripped: Method Class of finish specified: Finish Date:
Curing: Whether properly done as specified and curing register maintained. 1. 2. (Honeycombing/sand Streaks/air bubbles/cold defects joints) Non Conformance Report No . 3. Cracks: Class of Finish: Surface Defects : No defects Minor Major effects Date: No cracks: Cracks: Nature of Cracks: 4. 5. 6. Any Other Defects: If Cracking Noticed: Position/Dimensions: Alignment Levels Dimension NS = Not Satisfactory, * S = Satisfactory Inspected by (for Executing Agency) Approved by Signed Date Signed Date S or S or S or NS NS NS
Non Conformance report No :
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CHECKLISTS FOR CONSTRUCTION OF CYCLONE SHELTERS CHECKLIST No.21 S.No 1 2 3 4 5 6 7 8 9 10 11 Check list for Excavation Item After closing of the traverse, survey lines shall be plotted 2 m away from the main building line for reference work. Theodolite shall be fixed on the survey point available on the grid of the building. Opposite point of the peg shall be bisected. One point shall be fixed at distance given in the drawings for footing. The same process shall be done for the other side of the footing. Lay out, alignment & size of the excavation pit shall be marked on the ground as per drawing by considering 300 mm working space. Diagonal of the footing shall be verified before starting of excavation. Excavation shall be started after finalizing disposition place. Excavation shall be done mechanically. Depth of excavation shall be checked frequently by using level machine as given in the drawing. Side slope of the excavation pit shall be checked for safety point of view. After getting sufficient depth, the same shall be verified & surface shall be dressed by employing labours. Checked
CHECKLIST No.22 S.No 1 2 3 4 5 6 7 Anti termite treatment Item Proper dressing of the excavation pit shall be done. It shall be free from loose earth. The bottom surface of the footing shall be rodded or channelling as given in the drawing. Product for the anti termite treatment shall be approved in advance. Check concentration of chemical emulsion before using. Preparation of solution shall be done as per manufacturers specification & based on the area to be treated at required rate of application. Check that spraying equipments are in working condition. The bottom surface and the sides (up to height of 300 mm) of the excavation made for foundation shall be treated with chemical at the rate of 5litre per square meter surface area. 8 Check for rate of application of the chemical emulsion.
Checked
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CHECKLIST No.23 S.No 1 2 3 4 5 6 Rubber soling Item The rubber should be hard, durable and free from other defects. The rubber should be of suitable size and shape to give the required compacted thickness. The rubber is laid in vertical position of the sub-grade but closely packed by arranging the stones. The filling of the interstices shall be done with quarry spawls / metal simultaneously with the placing of the rubber. Ramming near the walls and column shall be done properly to the required level / slope, camber etc. Compaction must be carried out with 3 tonne static roller. The finishing of the surface shall be done by trimming to required level / slope as per requirement. Checked
CHECKLIST No.24 S.No 1 2 3 4 5 6 7 8 9 Plain Concrete. Item Carry out the study of the grade of concrete for PCC. It shall be verified before starting PCC for sufficient availability of material, manpower & machines Formwork & dimension for Plain concrete work shall be checked as per drawings. Mix proportion shall be displayed on the weight batcher & the same shall be implemented. Mix for the PCC shall be laid on the surface at required thickness. Compaction of the concrete shall be done by using Rammer till expulsion of the air is from the concrete is stopped. Carry out finishing at required thickness. After 24 hours formwork of the concrete shall be removed. Curing shall be done sufficient period. Checked
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CHECKLIST No.25 S.No 1 2 3 4 5 Shuttering: Item Use formwork, which is rigid and closely fitted, with sufficient strength to support wet concrete. Ensure that centring plates, plants, planks or plywood are properly cleaned. Take care to apply suitable form release agent after proper cleaning of formwork, before placing reinforcement. Ensure proper check for line, level and plumb before starting concreting activity. Shuttering to be checked in stage wise. i.e. as per the approved shuttering scheme
nd
Checked
st
beam bottom alignment and level and rigidity of staging to take the load. 2 Beam sides. 3 slab shuttering and levels. IV th Fixing of side supports, bhida, etc. for rigidity. 6 7 Special care should be taken to check column caps supports at junction of beams. Pockets, insert to be carefully placed and check before placing concrete. Fixing of pockets and inserts should be rigid to avoid displacement during concreting. 8 9 10 11 12 Use of Magic tape for gap filling. Provide extra supports at joints of wall plates beam bottom. Proper care must be taken to prevent building if centring. Leave slab formwork undisturbed till concrete gains 70 % of required strength. Take care not to damage the concrete while striking the centring off. time period for removal of shuttering should be as detailed below: a) c) Walls, columns and vertical side of beams Beam soffits (props left under) Spanning up to 4.5 m - Spanning more than 4.5 m e) Removal of Props under beams and arches -Spanning under 6 m - Spanning over 6 m repetition. 14 days 21 days 16 to 24 hours 3 Days 7 days b) Slab d) Removal of props under the slab
rd
After deshuttering all the materials should be properly stacked and cleaned for next
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CHECKLIST No.26 S.No 1 2 3 4 5 6 7 8 9 10 11 12 Reinforcement: Item Ensure that reinforcement bars are clean free from grease. Oil, paint, rust, dust or any other objectionable foreign material. Ensure that all the reinforcement rods are thoroughly cleaned before fabrication, pitted and defective rods are rejected. Ensure that straightening of bars is done without damaging the configuration, cutting, bending should be as per Bar bending schedule (B.B.S) Ensure that the vertical distance between the successive layer of bars in beams or other members are maintained by providing mild steel spacer sat required interval. Check reinforcement for size, spacing, location, numbers, overlaps, welding joints, hooks, bent ups, rusting, greasing and ties as per drawings and bar bending schedule. Ensure staged overlaps, cold bending and anchorage, wherever necessary. Ensure that the reinforcement is kept in position by ghodies, chairs etc. during placing and compaction of concrete. Ensure proper placement of cover blocks, embedded inserts and cut outs if any. Ensure that car ladders are provided on the reinforcement to avoid displacement of reinforcement. ensure that before placing the concrete, the reinforcement is checked for bent up bars, lap length, hooks, rings and distribution bars etc. Ensure proper binding of reinforcement. Ensure that the lap joints of bars are staged in about 40 % to 50 % in column, walls, etc. or as specified. Checked
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CHECKLIST No.27 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Brick work : Item Ensure to have information regarding specification of cement mortar. Soak the bricks before starting the brick work. Mixing of mortar must be done properly and thoroughly with specified proportion of ingredients on an impervious platform. Keep the frog up, while placing the brick. Fill the joints between the bricks properly. Ensure to carry out RADO at every 4 layer. Supervise line, level and plumb from time to time during the days progress The joints must be raked to an average depth of 10 mm when mortar is green. If plaster or pointing is not to be done, the joints should be struck flush. Proper hacking of RCC surface in contact with brick masonry must be done for proper bond. Courses must be truly horizontal with suitable bond pattern to break the vertical joints. Suitable toothing or grooves or stepping to be provided for continuation of brick work Thickness of joint must be uniform and not more than 13mm min Disallow vertical joint filling by spreading mortar Masonry may raised up to 150 cm in a day. Raising with all connected brick work be carried out at one level For 230 mm thick wall, maintain one face in line. This face can be pre planned to take all kinds of single coat plasters. For higher thickness walls both faces should be in line First mark up layer of brick work needs to be laid in direct supervision for door / window / any other opening to be kept accurately as per the drawings or layout Curing must be done for at least seven days or as laid down in specification CHECKLIST No.28 S.No 1 2 3 4 5 6 Solid Block Masonry: Item All block shall be soaked in advance prier to starting the work All block work shall be plumb, square and properly bonded. The sides of block shall not be broken The thickness of courses shall be uniform with courses horizontal All connected work shall be carried out at nearly one level and no portion of the work shall be left more than one course lower than the adjacent work Blocks shall be so laid that all joints are well filled with mortar as specified in specification. The thickness of joints shall as per specifications The face joints shall be raked to a minimum depth of 10 mm by raking tools daily during the progress of work when the mortar is still green, so as to provide a proper key for the plaster or pointing. When plastering or pointing is not required, the joints shall be struck flush.
th
Checked
Checked
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CHECKLIST No.29 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Plasterwork: Item The type of plaster, number of coats, thickness required and cement mortar proportion shall be as per specifications Ensure to water the brick wall properly start of plastering Ensure that the measurement box is ready for usage prier to start of work shall be done Deep and close hacking of the R.S.C surface for purpose of plastering must be done Chicken mesh at brick wall and R.C.C member must be provided Select suitable sand for different type of plasters Ensure that proper dry mixing of cement and sand is done on impervious platform Holes provided for scaffolding while executing brick work must be plugged or double scaffolding must be used Level marking must be done in advance (Plaster thiya). Supervise line, level and plumb from time before plaster starts setting. All the necessary tools required for execution of work available with the mason Watch the plaster line, level and plumb. Chip off concrete surface before starting plaster and provide suitable groove Gaps around door and window frames must be filled properly Check the best coat of plaster prier to application of finishing coat of neeru, sagol or cement While executing final coat of sand faced plaster or aggregate plaster due care must be taken as to while the joints are to be provided at the end of days work CHECKLIST No.30 S.No 1 2 3 4 5 6 7 8 9 10 Doors / Windows: Item Ensure that wood used for the works is as per quality specified BOQ of wood sizes should give adequate allowance for cutting and smoothening. BOQ needs to be double checked with carpenters before ordering Only approved fixtures to be used Check whether verticals of door frames are minimum 50 mm below finished floor level With bottom spacer patti fixed, surface of window / door frame coming contract with brick work / concrete needs to be painted with the material specified before fixing of the frame The frame hold fast must be grouted with cement mortar rigidly Ensure that the glass is free from waves, bubbles and other defects. Check the thickness of glass before fixing Check that doors / windows frames are erected in plumb, line, level and diagonals Ensure that the work of painting / oiling is started after approval of completed wood work Glazing must be fixed with out play with suitable wooden beading Checked Checked
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CHECKLIST No.31 S.No 1 Doors / Windows (Aluminium) Item Aluminium section shall be as per the sectional drawings provide or as specified in the items. Each member of the D/W shall be well defined for its size, shape, and weight per metre, profile and finished surface 2 3 4 Fabricator shall be get fabrication drawings before starting the work Aluminium sections shall be defined for manufacturers like, Indal, Jindal, Hindalco or equivalent Aluminium sections to be used for fabrication shall be well defined for anodizing (Matt finish or Glossy finish), natural or color anodizing, section with powder coating in different color etc 5 6 7 Aluminium doors and windows shall be specified for panel material like Glass / Laminated boards/ Box type aluminium lamination etc Only approved hardware fixtures shall be used as per specified and tender items Finished opening sizes should match perfectly with prefabricated D/W sizes. To ensure about the exact dimensions, make up sample or templates (either from wood material or M.S. material) shall be used 8 9 10 11 In case, a dimension doesnt match with the material supplied, openings shall be rectified Arrangement for all approved hardware fitting as per the drawing shall be ensured before fixing of the material Glazing shall be fixed to the extruded sections by means of extruded aluminium beading, Glass panes shall be provided with rubber lining before fixing The aluminium frames shall be fixed to the masonry by means of aluminium lugs fixed to the frame (by counter sunk galvanized machines screws) and the hole / pocket will be grouted with M 15 grade concrete as per drawing. In case of concrete wall, the frames shall be fixed by 96 mm long, 12 mm dia metallic fasteners. Any steel material coming in contact with aluminium shall be galvanized 12 13 The windows / ventilators / doors shall be checked ensure smooth operation, perfect level and plumb All aluminium D/W section should have protective film or coating. This film or coating can be removed only at the time of handing over (on completion of all civil works including painting). Checked
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CHECKLIST No.32 S.No 1 2 3 4 5 Polished Kota Stone flooring: Item Polished Kota stone shall be selected from quarry (source) where stone available is uniform in shade, hard and homogenous in texture, lamination, stone shall be machine polished at cource and of required size and thickness FARMA shall be in true size and right angle (with zero tolerance)and should be approved by the engineer Average out the sizes, from the supply and make suitable FARMA Hand dressing OR machine cutting of the edges shall be channel with fine sand as per the requirement. Hand dressed stones shall be grinded in suitable with fine sand for obtaining sharp, straight edges Initial check shall be done for with color shade by washing the surface in yard itself, it be followed by stack the finished stone with at least 3 different marks I/II/III. While laying due care should be taken to use assorted stones in different rooms. By this way color variation shall be adjusted room / Area wise All broken edges /corner stones to be suitably used Area shall be scrapped/cleaned/washed before starting the mortar bedding, after finalizing flooring pattern Preparation of mortar to the required proportion is essential. The thiayas shall be made to required level and slope well in advance. Laying of mortar to suitable thickness keeping reference thiayas line dori shall be supervised form time to time Neat cement paste shall be spread over mortar bedding and around the edges of the stone. Then the stone shall be fixed close to the previous stone and shall have a hairline joint. Stone surface shall be pressed / tapped gently with the wooden mallets till the stone is in true line and level. Cement paste at the edges at the will try to come out from joints, which should be scrapped off. Again joints shall be filled up with neat cement paste to fill up the gaps and surplus mortar removed. Suitable color pigment to be used for joint sealing to match with the stone color Flooring shall continue at least 10 mm inside the wall plaster line Any irregularities (othas) due to natural bends in stones should be restricted to 2 mm at joints Curing of flooring shall be carried out for 7 days by sprinkling water or by wetting Polishing activity to follow only after adequate curing the sequence of polishing will be as under st a) 1 cut with rough emery stone 80 No. to polishing m/c (heavy) which should even out all irregularities (othas) plus OR minus. Normal cut of 2 mm is achieved with this emery. Floor shall be washed and ragada is removed to check the joints. All joints shall be regrouted with cement paste. Setting shall be allowed for at least 2 days. nd rd b) 2 and 3 cut with finer emery stone. 120/220 no. Joint grouting shall be attended for every cut of polishing; Normally 1 mm cut is achieved. Surface is fairy in level and without any scratch or chakkar lines of the mat chining. c) Final light coat of polishing shall be done with masala (Oxalic Acid) to achieve the scratch less finished surface. Light polishing coat shall continue till the acceptable result is achieved. Checked
6 7 8 9
10 11 12 13
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CHECKLIST No.33 S.No 1 2 3 4 5 6 7 8 9 Tremix Flooring: Item Initial suitable layout of construction joints and isolation joints shall be decided prier to start Tremix flooring The surface of the guide channels (on which the surface vibrator is supported) shall be cleaned from concrete. Align the guide channels to true required level, panel casting layout shall be strictly followed as per step 1 Concrete shall be placed and distributed evenly and as near the final level as possible Concrete shall be placed and vibrated with an immersion vibrator in front of screed vibrator. Heaping of concrete in front of screed vibrator will be avoided Ensure that the areas close to channels and stop ends are carefully vibrated. Ensure not distribute the concrete with the poker vibrator as it would create a risk of over vibration and segregation Surface vibration should start as soon as there is enough concrete in front of the screed vibrator. Screed vibrator is to be pulled from both ends The filler pads as soon as the sufficient concrete surface is vibrated. Vacuum watering process must start within 30 minutes from the time of start of concrete pouring The filter pads are placed in such a way that there is at least 100 mm (4) fresh concrete visible around the filter pads on all four sides. Filter pads should be overlapped with each other at least 250 mm (10) Suction pad must be rolled open over the filter pads and dewatering must then start. Extent of dewatering is related to thickness of floor concrete i.e. Average 4 min. per inch thickness OR physical check of dewatering surface which should not give foot print while walking to be seen. Excess /less dewatering not advisable While repeating dewatering process subsequently, suction pad must be rolled out at least 300 mm over the vacuum dewatered area. Before spreading the suction pad on dewatered area, it is essential to give one pass of skim floater (with the disc) along the edge of the dewatered concrete The central pipe of the suction pad shall the suction hose, which in turn shall be connected to the vacuum pump. When the pump is started, vacuum will be created between the top cover and filters pads. Excess water from the concrete will be taken into the vacuum pump tank and discharged through p pipe away from fresh panel Checked
10
11
12 13 14 15 16 17 18
After Vacuum dewatering, scrapping operation shall be made diagonally in two direction over the concrete surface
The concrete, which is collected during scrapping, shall be used for adjusting small surface irregularities of the vacuum treated surface The first finishing operation shall be done by floating with the skim floater attached with a disc The second finishing operation shall be trowelling with skim floater attached with the trowelling blades. Normally, trowelling is to be continued till the smooth surface finish is achieved without floater marks Curing can be done by ponding, covering with plastic sheets or gunny bags. Curing must be done for at least 7 days Groove cutting for construction joints or isolation joints shall follow the sequence of tremix flooring without much time lapse Groove filling can be done with any elastomeric material subsequently, Groove cleaning and drying needs to be ensured
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CHECKLIST No.34 S.No Oil bound distemper: Preparation of surface: 1 2 3 4 5 6 7 Item Checked
The plastered surface shall be thoroughly cleaned with a brush to remove dust, dirt, grease, mortar dropping and other foreign matter and sand subsequently smooth with sand paper New plaster surface shall be allowed to dry for at least four months before applications of distemper or one coat of while wash with white cement shall be done prier to painting All unnecessary nails, hooks etc. shall be removed. Pitting in plaster shall be made good with plaster again and papered with a fine grade sand paper and made smooth A coat of paint shall be applied over the patches. The surface shall be allowed to dry thoroughly before the regular paint is applied. The surface affected by moulds, moss, fungi, algae lichens, efflorescence etc. shall be treated A primer coat of cement primer of approved manufacturer shall be applied over the plaster surface in case of new work The primer shall be applied with a brush on the clean, dry and smooth surface. Horizontal strokes shall be given first and vertical strokes shall be applied immediately afterwards. This entire operation will constitute one coat A Coat of putty (lapi) shall be applied to the entire surface. Putty shall be prepared by mixing whiting chalk, primer/paint in required proportion as directed by the Engineer-inCharge and Architect. The second coat of primer and putty shall then be applied an it shall thereinafter be allowed to dry for at least 48 hours. Fine sand papering is required for both lapi coats Any moisture in plaster will create problem of pealing off or swelling. Due cautioning to be given to clients/consultant it they insist on painting to start during initial four months of drying. Fine sand papering is required for both lapi coats . CHECKLIST No.35 Checked
S.No 1
Oil bound distemper/Water bound distemper/Acrylic bound distemper: Item The distemper shall be diluted with mineral turpentine oil or any other prescribed thinner in a manner recommended by the manufacturer only, sufficient quantity of distemper for a days work shall be prepared On any surfaces, after the primer coat has dried for at least 48 hours, the surface shall be lightly sand papered to make it smooth for receiving the distemper, taking care not to rub out the priming coat Sufficient quantity of distemper shall be mixed to finish one room at time. The application of a coat in each room shall be finished in one operation and no work shall be started in any room, which cannot be completed on the same day 15-cm. double bristled distemper brush shall be used. After a days work, brushes shall be thoroughly washed in hot water soap solution and hung down to dry. Old brushes, which are dirty and caked with distemper, shall not be used on the work Protective measure: The surface of doors, windows, ventilators of furniture and machines etc. and such other part of the buildings, which are not to be distempered, shall be protected from being splashed upon. On completion, surfaces shall be cleaned of distemper splashes, if any
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CHECKLIST No.36 S.No 1 2 3 4 5 White wash: Item The wall to be painted must be thoroughly scrapped with sand paper The first coat of white wash is to be done within 7 days of plaster The slaked lime must be screened through coarse cloth and the adhesive must be added as specified. Lime must be soaked for 24 hours in advance application by spray, brush, coil brush to be decide in advance Lime coat must be applied with a brush and the desired sequence must be as under: One stroke of brush from downward and another from bottom upwards over the first. Similarly one stroke from right and other from the left over the first before the first dries 6 7 8 9 10 11 S.No 1 2 3 4 5 6 Brush application needs criss cross painting to avoid brush marks Machines, Doors, windows, floors etc. shall be covered from being splashed upon The cracks and holes are required to be filled with proper adhesive after the first coat Small quantity of ultra marine is o be added in last two coats of white wash There coats are to be applied over the plastered surface Subsequent white is to be applied only after preceding coat has become sufficiently dry Colour Washing: Item Follow up steps 1 to 11 as white wash The wash shall be prepared by adding required quantity of colour pigment to the lime wash prepared under the head white wash The mineral colours not affected by lime shall be added to white wash The colour wash shall be done after preparation of sample of colour wash The surface to be colour washed shall be first treated with a priming coat of white wash Minimum two to three coats of colour shall be applied to attain uniform shade over the whole surface Checked Checked
S.No 1 2 3
Cement Paint: Item Get the cement paint and shade approved The surface should be thoroughly cleaned all loose materials be removed The surface should be watered thoroughly and should be allowed to drain off before starting the cement painting application is b criss cross direction till uniform color shade is obtained
Checked
4 5 6
The second coat shall be started after 2 hours of the first coat The entire surface shall be moist cured for seven days
A grey and Blue pigment tends to fade off, so discuss with customer and clarity
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Checklists
CHECKLIST No.37 S.No 1 2 3 4 5 6 7 8 9 10 11 12 Indian type water proofing terrace: Item Ensure that the item and specifications of the work are studied before carrying out of the work Water proofing material must be of make as specified /directed Check that the recommended waterproofing compound is mixed with mortar, which is used for Roda fixing as well as final top finishing layer. (IPS) The parapets, walls, must be plastered before application of water proofing material. Suitable vata and nose to be made as part of treatment Ensure surface scrapping and cleaning before start of activity. (Thorough cleaning of terrace) Before staring this activity, ensure that the proper slop and level is checked for drainage. Ridge and valleys to be marked properly and rain water down take points to be finished with waterproof mortar The finished top surface must be smooth with Dori mark in both direction to give 1X1 pattern The openings, needs inverted kerbs to end IWP with Vata Av. recommended thickness for IWP is 150 mm-any extra thickness required for longer slopes to be planned in advance. Water proofing shall be carried out in two layers During final layer, provide & lay minimum 40 mm thick IPS layer in cement concrete (1:2:4) with maximum size of aggregate 3 to 6 mm. Simultaneously with polishing trowel, using CM (1:2)shall be applied IWP thickness at lowest vally point (i.e. at the RWP mouth) should be 2 . IWP shall be cured for 21 days by flooding the water to 25 mm depth in panel of 1mX1m formed by weak mortar bonding CHECKLIST No.38 S.No 1 2 3 Box type Water proofing: Item For providing and laying Box type waterproofing treatment to floors and external surfaces of underground structures. Will comprise of waterproofing layer, layer, average 50/100 mm thick for floors, using layers of kotah stones placed diagonally with staggered joints Rough kotah stone shall confirm specification waterproofing consist of the following layers: a) 20 mm thick cement sand mortar bedding with approved waterproofing compound @ 4 % by Wright of cement shall be laid on PCC & 20 mm graded aggregate free from impurities shall be spread on the floor. b) 15 mm thick rough kotah stone to be laid diagonally with staged joints. Joints shall be sealed by 1:1 cement mortar with approved waterproofing chemical. This shall project 300 mm all around RCC raft. c) Well cured walls shall be treated in the vertical direction by fixing a layer of kota stones. Treatment shall be carried out 300 mm above the finished GL. Treatment to floor and wall shall be scaled such that it is continues. Correct chamfers, correct slopes etc. shall be maintained by providing PCC in the ratio of 1:4:8 in required locations Corner laps in vertical and horizontal plane needs proper overlapping of the stone On final completion of stone fixing smooth waterproof cement plaster is done over the rough stone Proper watering for 7 days shall be required
Checked
Checked
4 5 6 7
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Checklists
CHECKLIST No.39 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Fabrication / Erection: Item Estimate the power requirement for peak quantum of work Ensure availability of sufficient space for fabrication yard adequate lighting arrangement for night work The platform for fabrication is to be prepared before starting the work The approach road for unloading of the materials carrying the fabricated materials to the site has to be proper and prepared and prepared in advance The site office and store space for fabricator must be completed in advance. Suitable distribution board for power supply above to be provided Estimation of quantity of the structural steel must be carried out from approved shop drawings. Carry out the analysis for cutting lengths to reduce the wastage Skilled qualified welders, fitters, gas cutter and technicians must be recruited for the job The welding, gas cutting, grinding etc. procedure must be approved before the start of work The welding rods must be of approved make and quality, suitable for type of fabrication. Adequate stocks to for all consumables to be maintained The layouts are to be checked and the zig is to be approved after assembling The centrelines are to be checked before erection and the erection sequence and procedure is to be approved before start The members are to be properly aligned with proper tightening of bolts bracing sag rods, ties etc to be erected simultaneously before alignment Grouting of the base is to be carried out after erection alignment. Grouting holes to be provided in base plates Samples must be collected for establishing rolling margins weights difference and is required to be recorded. Average 3 samples form every incoming lot of steel must be collected Dimensional differences in rolled sections to be pointed out and recorded, (if more than tolerance level are found in material supplied.) BOQ for nut bolts for connections to be prepared. CHECKLIST No.40 S.No Rolling Shutter: Item Check that the dimensions and gauge of the material used for the shutter are as per drawings. Normally shutter gauge, guide rails gauge, hood gauge needs to be specified. Only approved vendor to supply for maintenance of free service Check whether the welding done is perfect and junctions are properly grooved Ensure that inserts, bolts, fixtures, fastening fittings are fixed in their position accurately and in alignment Painting must be done by quality paint and number of coats should be specified Before placing and indent for procurement check the following. a) Brick work opening size. b) Minimum 9 brick columns on both sides. c) Rolling shutter is to be fixed from inside or outside. 2 d) Gear operation system for more than 10m size. e) Top shaft fittings e.g. springs, bearings, brush, gear warm. f) Adequate clearance above lintel for fixing top shaft and hood cover.
Checked
Checked
1 2 3 4 5
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Checklists
CHECKLIST No.41 S.No Painting of structural steel works Item Checked
Surface treatment:
1 All the surfaces of steel work to be painted shall be thoroughly cleaned of all loose mill scale, rust, grease, dirt and other foreign matter. All welding, blurs, drilled holes, Gas cut edges need proper surface cleaning Oil and grease removal shall be carried out either by solvent cleaning or by using alkali type degreasing agents. To remove grease material the surface shall be cleaned with solvents containing emulsifier De rusting and de scaling of steel shall be carried out manually, mechanically, or chemically
Primer paint:
Primer and finish paints shall be compatible with each other to avoid cracking and wrinkling. 1 2 3 Painting: Painting shall be carried out only on thoroughly dry surfaces. (Procure only approved paint product and also the approved colour shade). No painting shall be done in frosty/foggy weather or when the humidity is high enough to cause condensation on the surface to be painted The application of paint film shall serve the twin purpose of protecting the steel from corrosion and giving the decorative appearance. A paint, which gives the steel adequate protection over a long period together with good appearance, shall therefore be adopted. Procure only approved paint product and also the approved colour shade Structural steel surfaces shall be given the first coat of primer at shop and the second coat after it is erected in position. Further, any abraded surfaces of the first coat during transport from shop to site and during erection needs to be attended with primer coats Application of finishing paints shall be carried out within the shortest possible time interval after primer since the primer coats are too thin to give adequate corrosion protection of the steel surface over a long duration Painting shall be carried out by brushing or spraying At least 24 hours shall elapse between the applications of successive coats. Each coat shall vary slightly in shade and this shall be got approved by the engineer Minimum dry film thickness of each coat of finish paint of synthetic enamel shall be as specified in the respective item of work (average 40 microns). Surfaces inaccessible after assembly shall receive two coats of primer prior to assembly Surfaces inaccessible after erection, including top surface of purlins supporting sheeting or top surfaces of floor beams supporting grating or chequered plate shall receive one additional coat of finish paint over and above the number of coats specified prior to erection Suitable covering shall be as necessary to prevent paint from splashing on equipment, floors, walls, doors, windows, and fittings etc
6 7 8 9 10
11
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TEST RESULTS REPORTING FORMATS Sl.No. I 1. 2. 3 4 5 6. 7 8. II 1. 2. 3. III 1. 2. 3. 4. 5. 6. 7. 8. 9 IV 1. 2. 3. 4. 5. V 1 2 3 VI 1 2 3 4 5 6 7 Atterberg Limits Moisture Content Moisture Content with Rapid moisture meter Dry Density and Moisture Content Relationship Modified Procter California Bearing Ratio & Expansion Ratio Free Swelling Index SWELL PRESSURE TEST by CONSOLIDOMETER METHOD Gradation of Aggregate GRANULAR SUB BASE Gradation for Coarse Graded Granular Sub Base Gradation for Close Graded Granular Sub Base Ten Percent Fines AGGREGATES Specific Gravity & Water Absorption of Aggregates Aggregates Impact Value Los Angeles Abrasion Value Test Soundness of Aggregates Worksheet for Soundness Flakiness Index and Elongation Index Stripping Value of Road Aggregates Tests on Fine Aggregates/Sand Mortar Jar Test BITUMINOUS WORKS Penetration Value of Bitumen Ductility Test Specific Gravity of Bitumen Transverse Distribution of Primer/Tack Coat / Binder Binder Content CONCRETE Cement Test Record Concrete Cube Record Determination of Compressive Strength of Concrete Cores Field Testing Formats Silt content of Fine aggregate Gradation of Fine Aggregate Moisture content in Aggregate Gradation of WBM Field density by Sand Replacement method Field Density by Core cutter Method Rebound hammer test results QC-29 QC-30 QC-31 QC-32 QC-33 QC-34 QC-35 QC-26 QC-27 QC-28 QC-21 QC-22 QC-23 QC-24 QC-25 QC-12 QC-13 QC-14 QC-15 QC-16 QC-17 QC-18 QC-19 QC-20 QC-9 QC-10 QC-11 Description EARTH WORK AND BORROW AREAS QC-1 QC-2 QC-3 QC-4 QC-5 QC-6 QC-7 QC-8 Form No.
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ATTERBERGS LIMITS TEST METHOD: IS: 2720 (PART-V) Client Consultant Contractor Location/ Chainage : : : : Date of Sampling : Date of Testing Sampled by OBSERVATIONS LIQUID LIMIT 1 2 3 4 : :
QC-1
Description of Material : Source of the Material : Sample No. SL. NO. 1 2 3 4 5 6 :
DESCRIPTION No. of Blows (n) Container No. Mass of Container +Wet Soil, W2 (gm) Mass of Container +Oven dried soil, W3 (gm) Mass Container W1 (gm) Water Content W2 W 3 % w = --------x100 W3 W 1
PLASTIC LIMIT 2 3 4
REMARKS:
% MOISTURE CONTENT
NO. OF BLOWS (LOG SCALE) LIQUID LIMIT (%) FROM GRAPH

5
PLASTIC LIMIT (%)
PLASTICITY INDEX (%)
For the Contractor
For the Engineer
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MOISTURE CONTENT TEST METHOD: IS: 2720 (PART-II) Client Consultant Contractor : : :
QC-2
Location / Chainage Description of Material Source of Material Sample No.
: : : : Date of Sampling : Date of Testing Sampled By : :
OBSERVATIONS Sl. No. 1 2 DISH NO. WEIGHT OF DISH, W1 GMS DESCRIPTION SAMPLE 1 SAMPLE 2 SAMPLE 3
WEIGHT OF DISH + WET SOIL, W2 GMS
WEIGHT OF DISH + DRY SOIL, W3 GMS
5 6
WEIGHT OF MOISTURE, (W2-W3) GMS WEIGHT OF DRY SOIL, (W3-W1) GMS
MOISTURE CONTENT, w = [(W2-W3) / (W3-W1)] x 100 %
AVERAGE MOISTURE CONTENT:
For the Contractor
For the Engineer
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QC-3 MOISTURE CONTENT TEST METHOD : IS : 2720 (PART - II) : : : Speedy Moisture : meter No. :: Date of Sampling : Date of Testing Sampled By : :
Client Consultant Contractor
: : : : OBSERVATIONS
Sl. No. 1 2
DESCRIPTION Moisture Meter Reading Corrected Moisture Content (W)
SAMPLE 1
SAMPLE 2
SAMPLE 3
AVERAGE MOISTURE CONTENT:
For the Contractor
For the Engineer
B4 | P a g e
DRY DENSITY AND MOISTURE CONTENT RELATIONSHIP MODIFIED PROCTOR IS: 2720 PART VIII Client/Engineer : Consultant : Contractor : SAMPLE NO. SAMPLE DESCRIPTION Mould Wt. Mould + Wet Soil Wt. Mould Wt. Wet Soil Volume of Mould Wet Density Container Wt. Container + Wet Soil Wt. Container + Dry Soil Wt. Water Wt. Container Wt. Dry soil : : No. g. g. g. cc g/cc N g. g. g. g. DATE: LOCATION:
QC-4
Moisture Content cc. Dry Density g/cc DESCRIPTION OF THE SAMPLE MOISTURE CONTENT (%)
Max. Dry Density (Max. d): For the Contractor
g/cc
Optimum Moisture Content=%
DRY DENSITY
For the Engineer
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QC-5 CALIFORNIA BEARING RATIO & EXPANSION RATIO TEST METHOD: IS : 2720 (PART - XVI) Client / Engineer Consultant Contractor : : :
: : : :
Date of Sampling : Date of Testing : Sampled by :
Volume of Mould V = 2250 cm3

SL NO.
OBSERVATIONS
MOULD NO. __ BEFORE SOAKING AFTER SOAKING MOULD NO. __ BEFORE SOAKING AFTER SOAKING MOULD NO. __ BEFORE SOAKING AFTER SOAKING
DESCRIPTION
1 Mass of Mould W1 (gm.) 2 Mass of Mould + Wet soil W2 (gm.) 3 Mass of Wet Soil W2-W1 (gm.) 4 Bulk Density b = (W2 - W1)/V (gm./cm3)
5 Container No. 6 Mass of Container W5 (gm.) 7 8 9 10 Mass of Container + Wet Soil Sample W3 (gm.) Mass of Container + Oven Dried Soil Sample W4 (gm.) Water Content % w = [(W3-W4)/(W4-W5)]x100 Dry Density (100b)/(100+w) (gm./cm3)
Mould No. Initial Dial gauge reading, ds (mm) Proving, Ring Capacity
Final Dial gauge reading, dt (mm) Height of specimen, h (mm) Expansion ratio [(dt-ds)/h] x 100 Proving Ring Factor
B6 | P a g e
In Joint Venture with
PENETRATION SL. NO. MOULD NO. (mm) Dial gauge reading (divs) Unit Load (Kg/cm2)
PROVING RING DIAL READINGS MOULD NO. Dial gauge reading (divs) Unit Load (Kg/cm2) MOULD NO. Dial gauge reading (divs) Unit Load (Kg/cm2)
1 2 3 4 5 6 7 8 9 10 Mould No.
0.5 1 1.5 2 2.5 4 5 7.5 10 12.5 C.B.R at 2.5 mm in % C.B.R at 5.0 mm in % Remarks
Note: Standard Load
Penetration, mm 2.5 5
Unit Standard Load, kgf/cm2 70 105
Total Standard Load, kgf 1370 2055
For the Contractor
For the Engineer
B7 | P a g e
FREE SWELLING INDEX TEST METHOD: IS:2720 (PART XXXX) QC-6 Client: Consultant: Contractor:
Location/Chainage Description of Material : Source of the Material : Sample No. : : Date of Sampling: Date of Testing Sampled by : : FREE SWELLING INDEX F.S.I. = (H2-H1)X 100 H1
Carriageway: L/R Carriageway: L/R
OBSERVATIONS
SL. NO. LOCATION/ CHAINAGE HEIGHT OF THE SOIL SPECIMEN IN KEROSENE, H1, MM HEIGHT OF THE SOIL SPECIMEN IN WATER, H2, MM
DEPTH
REMARKS
1 2 3 4 5 6 7 8 9 10 Free Swell Index (percent) Less than 50 50 to 100 100 to 200 More than 200 Degree Of Expansion Low Medium High Very high Degree Of Severity Non-Critical Marginal Critical severe
For the Contractor
For the Engineer
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SWELL PRESSURE TEST by CONSOLIDOMETER METHOD Client: Consultant: Contractor: Date of Sampling: Date of Testing Sample No. : : Sampled by
QC-7
: : : :
1. Details of soils sample : i) Location : ii) Boring No. : iii) Depth : iv) Visual description of soil : v) Liquid limit : Plasticity index : vi) Percentage of soil fraction below 0002 mm NATURAL DENSITY Description Test-1 Test-2 Weight of container- ring + weight specimen Weight of container Diameter of container Initial thickness of soil sample Wet density in g/ml Dry density in g/ml Time of starting Elapsed time in hours 0 0.5 1 2 4 8 12 16 20 24 36 48 60 72 96 For the Contractor
2.Details of soil specimen i) Undisturbed or remoulded ii) Specific gravity of the soil
MOISTURE CONTENT Description Before Test Weight of container + wet soil Weight of container
+Dry Soil
After Test
Weight of container Weight of water Weight of Dry soil Moisture content in percent Date Swelling dial Reading
For the Engineer B9 | P a g e

GRADATION OF AGGREGATES
TEST METHOD: IS:2720 (PART IV) QC-8 Client : Consultant : Contractor : Location/Chainage Description of Material Source of the Material Sample No.
MASS OF SOIL RETAINED in gms.
: : : : Date of Sampling : Date of Testing Sampled by : :
OBSERVATIONS
IS SIEVE DESIGNATION CUMULATIVE MASS RETAINED in gms. CUMULATIVE PERCENTAGE RETAINED PERCENTAGE PASSING REMARKS
45 mm 37.5 mm 26.5 mm 22.4 mm 19.00 mm 13.2 mm 11.2 mm 9.5 mm 5.6 mm 4.75 mm 1.80 mm 2.36 mm 300 mic 90 mic 75 mic Pan Total For the Contractor For the Engineer
B10 | P a g e
GRADATION FOR COARSE GRANULAR SUB-BASE

TEST METHOD: IS:2720 (PART IV) QC-9 Client: Consultant: Contractor: Location/Chainage Description of Material Source of the Material Sample No. : : : :
CUMULATIV E MASS RETAINED (gm.)
Date of Sampling: Date of Testing : Sampled by :
OBSERVATIONS
IS SIEVE DESIGNATION MASS OF SOIL RETAINE D (gm.) CUMULATIVE PERCENTAGE RETAINED PERCENTAGE PASSING LIMITS PERCENTAGE PASSING IS SIEVE FOR GRADING I GRADING II GRADING III
75.0 mm 53.0 mm 26.5 mm 4.75 mm 0.075 mm PAN
100 55-75 10-30 < 10
100 50-80 15-35 < 10
1 100 25-45 <10
GRADATION CURVE
100 90
70 60 50 40 30 20 10 00
SIEVE DESIGNATION (LOG-SCALE)
For the Contractor

PERCENTAGE PASSING
80
GRADATION FOR CLOSE GRADED GRANULAR SUB-BASE

TEST METHOD: IS:2720 (PART IV) QC-10 Client: Consultant: Contractor: Location/Chainage Description of Material Source of the Material Sample No. : : : :
CUMULATIVE MASS RETAINED (gm.)
OBSERVATIONS
IS SIEVE DESIGNATION MASS OF SOIL RETAINED (gm.) CUMULATIVE PERCENTAGE RETAINED PERCENTAGE PASSING LIMITS PERCENTAGE PASSING IS SIEVE FOR GRADING I GRADING II GRADING III
75.00 mm 53.00 mm 26.50 mm 9.50 mm 4.75 mm 2.36 mm 0.425 mm 0.075 mm PAN
100 80-100 55-90 35-65 25-55 20-40 10-25 3-10
100 70-100 50-80 40-65 30-50 15-25 3-10
100 65-95 50-80 40-65 20-35 3-10
GRADATION CURVE
100 90 80 60 50 40 30 20 10 00 SIEVE DESIGNATION (LOG-SCALE) 70
For the Contractor

PERCENTAGE PASSING
TEN PERCENT FINES

TEST METHOD: BS:812 (PART III) QC-11 Client: Consultant: Contractor: Location/Chainage Description of Material Source of the Material Sample No. : : : : Date of Sampling: Date of Testing Sampled by : : Carriageway: L/R Carriageway: L/R
OBSERVATIONS
S. NO. ITEM DESCRIPTION SAMPLE NO.1 SAMPLE NO.2 SAMPLE NO.3 SAMPLE NO.4 SAMPLE NO.5
REMARKS
1 2 3 4 5 6
TOTAL SAMPLE TAKEN, M1 (gm.) PASSING 2.36 MM SIEVE, M2 (gm.) LOSS M1-M2 = M3 (gm.) % FINES M = (M3/M1) X 100 TOTAL FORCE APPLIED, F (KN) FORCE REQUIRED = [14F/(M=4)] KN
FORCE REQUIRED FOR 10% FINES VALUE =
KN.
For the Contractor

SPECIFIC GRAVITY & WATER ABSORPTION OF AGGREGATES

TEST METHOD : IS: 2386 (PART III) QC-12 Client : Consultant : Contractor : Location/Chainage Description of Material Source of the Material Sample No. : : : :
Date of Sampling : Date of Testing : Sampled by :
OBSERVATIONS
SL. NO. DETAILS TEST NUMBER 1 2 3 MEAN VALUE
Weight of saturated aggregates and basket in Water, W1 (gm) Weight of basket in Water, W2 (gm) Weight of saturated surface dry Aggregates in air, W3 (gm) Weight of oven dried aggregates in air, W4 (gm)
Specific Gravity
W4 W3 (W1 W2)
Apparent Specific Gravity
W4
W4 (W1 W2) Water Absorption (W3 W4) x100 W4
For the Contractor

AGGREGATES IMPACT VALUE

TEST METHOD : IS: 2386 (PART IV) QC-13 Client: Consultant: Contractor: Location/Chainage Description of Material Source of the Material Sample No. : : : : Date of Sampling: Date of Testing Sampled by : :
OBSERVATIONS
Sl. No. 1 Description Total Weight of the Aggregate taken W1 (gm) Weight of Aggregate retained on 2.36 mm I.S. Sieve, W2(gm) Weight of Aggregates passing 3 through 2.36 mm I.S. Sieve W3=W1-W2(gm) Aggregate Impact Value (W3/W1) x 100% 1 2 3 Average Value
For the Contractor
For the Engineer
B15 | P a g e
LOS ANGELES ABRASION VALUE TEST

TEST METHOD: IS:2386 (PART IV) QC-14 Client: Consultant: Contractor: Sample Description : Location : Source : Sample No.: Date : Carriageway: L/R Carriageway: L/R
Cycle (33 R.P.N)
500
No.
Initial Weight
..gm
Weight Retained after Test on No. 12 Sieve
..gm
A B x 100 A
% By Weight Passing No. 12 Sieve ..%
Remarks:
_______________________________________________________________ _______________________________________________________________
For the Contractor
For the Engineer
B16 | P a g e
SOUNDNESS OF AGGREGATES
(No. of Cycles 5) TEST METHOD : IS: 2386 (PART V) QC-15 Client: Consultant: Contractor: Location: Source: Sample Description: Sample No.: Date: Kind of Solution: Recording Test Data Grading of Weight of Percentage Original Test Passing Sample Fractions Designated Percent Before Test After Test (Retained) (gms) Soundness of Fine Aggregates 150 mic 300 mic 600 mic 1.18 mic 2.36 mic 4.75 mic 10 mm Totals Soundness of Coarse Aggregates 63 mm 50 mm 40 mm 25 mm 20 mm 12 mm 10 mm Totals For the Contractor For the Engineer B17 | P a g e
Sieve Size Passing Retained
Weight Percentage Loss
Remarks
150 mic 300 mic 600 mic 1.18 mic 2.36 mic 4.75 mic
50 mm 40 mm 25 mm 20 mm 12 mm 10 mm 4.75 mm
WORKSHEET FOR SOUNDNESS TEST

(No. of Cycles 5) Client: Consultant: Contractor: Location : Source : Sample Description: Reagent Used:
Wt. Of Sample before Immersion (gm) Cycle No. Temp. of Na2SO4/ MgSO4 Solution (C) Immersion in Na2SO4/MgSO4 In Out Date Time Date Time Date In
QC-16
Sample No.: Date : Size of Aggregate: ______ mm to ______ mm

Oven Drying Time Date Out Qualitative Examination of Fractions of Sample Coarser than 20 mm size Time
Cycle -1
Cycle -2
Cycle -3
Cycle -4
Cycle -5
For the Contractor

FLAKINESS INDEX AND ELONGATION INDEX

TEST METHOD : IS: 2386 (PART I) QC-17 Client: Consultant: Contractor: Location/Chainage Description of Material Source of the Material Sample No. : : : :
OBSERVATIONS
Flakiness Index Weight of Passing through Sl. No. I.S. Sieve in size (mm) Retained on I.S. Sieve size (mm) the aggregate taken in each fraction (gm.) Weight of aggregate in each fraction passing Thickness gauge (gm.) 1 2 3 4 5 6 7 8 9 63 50 40 31.5 25 20 16 12.5 10 50 40 25 25 20 16 12.5 10 6.3 W: (w/W) x100: COMBINED F.I.+E.I.+________________% For the Contractor For the Engineer B19 | P a g e
Elongation Index Weight of Non-Flaky aggregate taken in each fraction (gm.)
Weight of aggregate in each fraction not passing the Length gauge (gm.)
w: % (w1/W1) x100:
W1: %
w1:
STRIPPING VALUE OF ROAD AGGREGATES

TEST METHOD: IS: 6241 QC-18 Client Consultant Contractor : : :
Quarry Identification No. Description of Material Type of Binder Percentage of Binder
: : : :
Sample No.
Date of Sampling: Date of Testing Sampled by : :
OBSERVATIONS
SL. No. Stripping Percentage Remarks
AVERAGE VALUE: Remarks :
For the Contractor
For the Engineer
B20 | P a g e
TESTS ON FINE AGGREGATES / SAND

QC-19 Client : Consultant : Contractor : Carriageway: L/R Carriageway: L/R
SPECIFIC GRAVITY OF FINE AGGREGATES / SAND
DESCRIPTION Wt. of empty pycnometer (gms) A1 Wt. of empty pycnometer + dry sand (gms) A2 Wt. of empty pycnometer + dry sand + water (gms) A3 Wt. of dry sand (gms) A2-A1=A Wt. of Pycnometer + Water (gms) A4 Wt. of wet sand (gms) A3-A4=B Specific Gravity of Sand = A/(A-B) Bulking of Sand DESCRIPTION Initial volume of sand in measuring cylinder (V1) Volume of Sand after submergence in water (V2) Percentage Bulking = ((V1-V2)/-1)*100 SIEVE ANALYSIS OF FINE AGGREGATES / SAND I.S. Sieve Mass of Sand Retained (gm) %age Mass Retained Cumulative %age Retained
AVERAGE
AVERAGE
%age Passing
I.S. Zone I
I.S. Zone II
I.S. Zone III
10 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron Total Weight FINENESS MODULUS: For the Contractor
100 90 - 100 60 - 95 30 - 70 15 - 34 5 -20 0 - 10
100 90 - 100 75 - 100 55 - 90 35 - 59 8 - 30 0 - 10
100 90 100 85 100 75 100 60 - 79 12 40 0 10
For the Engineer
B21 | P a g e
MORTAR TEST QC-20 Client Consultant Contractor Supplier Sample No. Description of Material : : : : : : Date of Sampling : Date of Testing Sampled by : :
Description Weight of Mortar taken in Sprit Jar1 Dry Weight of Mortar in Sprit jar1 % of Water Content in Mortar Wet weight of mortar in sprit jar2 Wet weight of mortar after sieving Dry weight of mortar after sieving % of cement in mortar Weight of Sand taken Wet weight of sand after sieving Dry weight of sand after sieving % of fines in Sand Actual Cement content in mortar W1 W2 W W3 W4 W5 C W6 W7 W8 F ((w6-w8)/w6))x100 C-F [(w3-w5/w3)x100]-w (w1-w2/w1) x100
Trail-I (grams)
Trail-II (Grams)
For the Contractor
For the Engineer
B22 | P a g e
PENETRATION VALUE OF BITUMEN

TEST METHOD: IS: 1203 QC-21 Client Consultant Contractor Supplier Sample No. Description of Material : : : : : : Date of Sampling : Date of Testing Sampled by : :
OBSERVATIONS
INITIAL SL. NO. TYPE OF MATERIAL TEMP IN (C) READING 1/10 MM (R1) INITIAL READIN G 1/10 MM (R2) PENETRA TION IN 1/10 MM (R2-R1) PENETRATIO N IN 1/10 MM (AVERAGE) REMARKS
For the Contractor
DUCTILITY TEST
QC-22 Client: Consultant: Contractor: Selection / Control Sample: Date of Sampling: Sampled by: Sampled at: To be used: Date of Test: Tested by: Tested at: Carriageway: L/R Carriageway: L/R
GRADE OF BITUMEN =
Trial 1 Cm
Trial 2 Cm
Determination of ductility expressed as the distance in centimeter to which a standard briquette of bitumen under standard conditions can be stretched before the thread breaks.
Average Result : Ductility Value = IS: 1208 (1979) Clients/Consultants Representative Representative
For the Contractor
For the Engineer
B24 | P a g e
SPECIFIC GRAVITY OF BITUMEN

TEST METHOD: IS: 1202 QC-23 Client: Consultant: Contractor:
Location/Chainage Description of Material Source of the Material Sample No.
: : : : Date of Sampling: Date of Testing Sampled by : :
OBSERVATIONS
SL. NO. 1 2 3 4 5 6 DESCRIPTION Weight of Pycnometer (W1 ) Weight of Pycnometer + Sample (W2 ) Weight of Pycnometer + Sample + Water (W 3) Weight of Pycnometer + Full of Water (W 4) Weight of Sample (W2 - W1) (W2 - W1) Specific Gravity of Sample (W4 - W1 ) (W3 - W2 ) SAMPLE SAMPLE NO.1 NO.2 SAMPLE NO.3 AVERAGE
For the Contractor
For the Engineer
B25 | P a g e
RATE OF SPREAD PRIMER/TACK COAT/BINDER

TEST METHOD: IS: 1707 QC-24 Client: Consultant: Contractor: Location/Chainage Description of Material Source of the Material Spreading Temperature : : : : OBSERVATIONS Offset Wt. of Wt. of Area of Wt. of Rate of % Variation Overall from Empty Pad + Pad Material Spread from Mean C/L Pad Material (m2) (Kg) (Kg/m2) Specification (Kg/m2) (m) (Kg) (Kg) 4 5 6 7 8=7-6 9=8/5 10 11 Date of Testing Spray Pressure (PSI) Vehicle Speed (m/min) Specified Rate of Spread : : : :
Sl. No. 1
Pad No. 2
Chainage (Km) 3
Remarks:
For the Contractor

BINDER CONTENT
TEST METHOD: IRC: SP - 11 QC-25 Client: Consultant: Contractor: Carriageway: L/R Carriageway: L/R
Location/Chainage
: Date of Sampling : Date of Testing Sampled by : :
Description of Material : Source of the Material : Sample No. :
OBSERVATIONS Sl. No. 1. 2. 3. 4. 5. 6. Description Weight of mix, W (gm.) Weight of sample (Bowl + Mix) before extraction, W1 (gm.) Weight of sample (Bowl + Mix) after extraction, W2 (gm.) Weight of filter paper before extraction, W3 (gm.) Weight of filter paper after extraction, W4(gm.) Bitumen content by wt. Of mix % = [(W1 W2) (W4 W3)]/Wx100 Sample 1 Sample 2 Sample 3 Remarks
For the Contractor
For the Engineer
B27 | P a g e
CEMENT TEST RECORD

QC-26 Client: Consultant: Contractor: Carriageway: L/R Carriageway: L/R
Brand : Type :
Manufacturing Week Date of Receipt at Site Date of Sampling/Testing Testing at Temperature
: : : : 27C 2C
Grade : Lot No.: CONSISTENCY PROPERTIES
1 Normal Consistency (%) Initial Setting Time (Minutes) Final Setting Time (Minutes)
Average
MORTAR CUBE COMPRESSIVE STRENGTH 1 Compressive Strength 3 days Compressive Strength 7 days Compressive Strength 14 days Compressive Strength 28 days 2 3 Average
For the Contractor
For the Engineer
B28 | P a g e
CONCRETE CUBE RECORD QC-27 Client: Consultant: Contractor: Structure No Location Element Lift R.L. Date of Casting Grade of Concrete Required Strength at 28 days Quantity of Concrete Slump of Concrete : : : : : : : : : Carriageway: L/R Service Road: L/R Brand of Cement Grade of Cement Water Cement Ratio Proportion of Mix Cement per Batch F.A. per Batch C.A. per Batch Water per Batch Sampled by : : : : : : : : :
CUBE COMPRESSIVE STRENGTH TEST I.D. No. Area of Cube (cm2) S.S.D. Wt., (gm) Density, (gm/cm3) 7-days comp. Strength (__/__/__) Load (kg) Strength (MPa) 28-Days Comp. Strength (__/__/__) Load (kg) Strength (MPa)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Remarks: For the Contractor For the Engineer
B29 | P a g e
Q -2 C 5
C M R S IV S R N T O C N R T C R S O P ES E T E GH F O C EE OE ( IS: 5 6an 1 9 ) 1 d 19 N e of w = am ork Agreem num ent ber= PACK E N M = AG U BER Location: G of concrete: M rade Age of Core: C reD e sio s o im n n C m re o p ssive Eu n q ivale t C m re o p ssive S n tho C rre n tre g f o ctio Cb ue avg C re o H U ate /D ltim S n tho tre g f A rag ve e C re o S n th tre g th e ickn ss F r acto W ig t g H ig t D e r R e h m e h iam te atio Lo ad C n te o cre S n th tre g ( C) o ccC re f o (F ) (N m) /m 2 (K ) N (C F) * (H ) (D ) N m /m 2 (C F 1 5 * * .2 ) D of T ate esting : D of Sam : ate pling Sam by : pled
S C ain e/ I. h ag N. o O t ffse
th e ickn ss
1 2 3 4 5
A p n C riaa p r IS 5 -2 0 : cce ta ce rite s e :4 6 0 0 1) C oncreteinthem ber representedbyacoretest shall beconsideredacceptableif theaverageequivalent cubestrengthof the em cores is equal toat least 85percent of thecubestrengthof thegradeof concretespecifiedfor thecorrespondingageandnoindividual corehas astrengthless than75percent. 2) E quivalent cubecom pressivestrength=1.25x correctedcylinder com pressivestrength as per IS5161956(R eaffirm ed 1999)
C onsultant S ignature N eandD am esignation C ontractor S ignature N eandD am esignation D ngineer ept.E S ignature N eandD am esignation
B30 | P a g e
QC-29
Client:
Consultancy Services for Third Party Quality Audit (TPQA) for National Cyclone Risk Mitigation Project (NCRMP)
NCRMP
Place of work: Agreement No. Name of work
SILT CONTENT IN SAND

Sample No: Source/Location: Tested By: Trial No. Total Volume of Sand Taken Volume of Sand after Submerging Volume of Silt after Submerging Silt Content, % Average Silt Content, % Silt Content = (Volume of Silt After Submerging) X 100 (Volume of Sand After Submerging) Acceptance Criteria Specified : _____________________________________ 1 2 3 Sampling Date: Testing Date:
Remarks:
Consultant Signature
Contractor Signature
Dept. Engineer Signature Name and Designation B31 | P a g e
Name and Designation
QC-30
Client:
NCRMP
SIEVE ANALYSIS FOR FINE AGGREGATE

(IS 383) Document No: Sample Location: Source of Material: Sample Taken: Sieve Size (mm) 10.000 4.750 2.360 Material Retained (gm) Cumulative Weight retained (gm) Material retained (%) Fines passing (%) Specified Limits Zone I 100 90 - 100 60 - 95 Zone II 100 90 - 100 75 - 100 Zone III 100 90 - 100 85 - 100 Zone IV 100 95 - 100 95 - 100 Date Sampled: Date Tested:
1.180 0.600 0.300 0.150 Pan Consultan t Signature Contract or Signature
30 - 70 15 - 34 5 - 20 0 - 10
55 - 90 35 - 59 8 - 30 0 - 10
75 - 100 60 - 79 12 - 40 0 - 10
90 - 100 80 - 100 15 - 50 0 - 15
Dept.Engineer Signature
B32 | P a g e
QC-31
M O ISTU R E C O N TEN T (FIN E A G G R EG A TE & C O A R SE A G G R EG A TE)

Packag e N o S o u rc e L o c a t io n F in e A g g r e g a t e D e s c r ip t io n W t. o f W e t A g g re g a te W t. o f D ry a g g re g a te M o is t u r e C o n t e n t C o a rse A g g re g a te - 2 0 m m D e s c r ip t io n W t. o f W e t A g g re g a te W t. o f D ry A g g re g a te M o is t u r e C o n t e n t C o a rse A g g re g a te - 1 0 m m D e s c r ip t io n W t. o f W e t A g g re g a te W t. o f D ry A g g re g a te M o is t u r e C o n t e n t W 1(g m ) W 2(g m ) (W 1-W 2)/W
2
: : :
D a t e o f s a m p lin g D a t e o f t e s t in g
: :
Aver age
W 1(g m s) W 2(g m s) (W 1-W 2)/W

2
*100 (% )
Aver age
W 1(g m ) W 2(g m ) (W 1-W 2)/W

2
*100 (% )
Aver age
*100 (% )
F o r th e C o n tra cto r
F o r t h e E n g in e e r
B33 | P a g e
QC-32
Client:
NCRMP
GRADATION FOR WBM

Document No: Sample Location: Source of Material: Sample Taken: Cumulative Weight retained (gm) Specified Limits for grading Material retained (%) Materials passing (%) Date Sampled: Date Tested:
Sieve Size (mm)
Material Retained (gm)
I 100 90-100 25-60 0-15 0-5 -
II 100 90-100 25-75 0-15 0-5 -
III 100 95-100 65-90 0-10 0-5
125.0 90.0 63.0 53.0 45.0 22.4 11.2 Pan
Consultant Signature
Contractor Signature
Dept.Engineer Signature
B34 | P a g e
QC-33
Client
FIELD DENSITY TEST BY SAND REPLACEMENT METHOD

(IS 2720, Part - 28)
RFI No. Date:
SECTION Chainage Representing Test Chainage Offset from Center line Layer No. of Level. Source of Material (Name & Chainage) FIELD DENSITY Pouring cylinder No Weight of wet material from hole (W w) Weight of sand + cylinder before pouring (W 1) Weight of sand + cylinder after pouring (W 2) Weight of sand in cone (W 3) Weight of sand in hole (W 4=W 1-w2-W 3) Bulk Density of Sand (Ya) Bulk Density of Material (Yb=(W w/W 4)xYa) MOISTURE CONTENT (By Rapid Moisture Method) Speedy Moisture meter No. Moisture Meter Reading Corrected moisture content (W) RESULTS Field MDDYd = 100 xYb/(100+W) Lab max dry density Optimum moisture content Compaction obtained Compaction required g/cc g/cc % % % % % g g g g g g/cc g/cc (m)
Consultant Engineer
Contractor
Pass/Fail Dept. Engineer
B35 | P a g e
QC-34
Client
NCRMP
FIELD DENSITY TEST BY CORE CUTTER METHOD

(IS 2720, Part - 29)
Date:
SECTION Chainage Representing Test Chainage Offset from Center line Layer No. of Level. Source of Material (Name & Chainage) FIELD DENSITY Core cutter No. Internal diameter Internal height Weight of empty Core cutter (W1) Weight of Core cutter with soil (W2) Weight of wet soil (W2- W1) Volume of cutter (V) Bulk density (Yb) = W2-W1 / V Moisture Content (By Rapid Moisture Meter) Speedy Moisture meter No. Moisture Meter Reading Corrected moisture content (W) Field MDDYd = 100 xYb/(100+W) Lab max dry density Optimum moisture content Compaction obtained Compaction required Remarks: Consultant Engineer % % g/cc g/cc % % % cm cm g g g cm3 g/cc (m)
Contractor
Dept. Engineer B36 | P a g e
QC-35
Consultancy Services for Third Party Quality Audit (TPQA) for National Cyclone Risk Mitigation Project (NCRMP) Client : Name of work : Package No. REBOUND HAMMER TEST ( Non Destructive Test for Concrete) IS : 13311 (Part 2) 1992 Site Name : Date of Testing : Chainage: Grade of Concrete : Position of Number of Readings Taken Hammer : S Location Description 1 2 3 4 5 6 7 8 9 10 11 12 13 No 1
14
15
16
Rebound No. Comp. Strength 2 (N/mm ) Rebound No. 2 Comp. Strength 2 (N/mm ) Rebound No. 3 Comp. Strength 2 (N/mm ) Rebound No. 4 Comp. Strength 2 (N/mm ) Rebound No. 5 Comp. Strength (N/mm2) The estimation of strength of concrete by rebound hammer method cannot be held to be very accurate and probable accuracy of prediction of concrete strength in a structure is Remarks : Consultant Signature Name and Designation 25 percent. Contractor Signature Name and Designation Dept.Engineer Signature Name and Designation
Avg. Comp. Strength 2 (N/mm )
B37 | P a g e

QAP Volume - 1

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National Cyclone Risk Mitigation Project (NCRMP) Revenue (DM) Department Government of Andhra Pradesh

Third Party Quality Audit(TPQA)

Quality Assurance Plan

in Joint Venture with

Quality Assurance Plan

in Joint Venture with

Quality Assurance Plan

QUALITY ASSURANCE PLAN

in Joint Venture with

Quality Assurance Plan

in Joint Venture with

Quality Assurance Plan

Quality Assurance Plan

in Joint Venture with

Quality Assurance Plan

in Joint Venture with

Quality Assurance Plan

2.0 Quality Control Tests Required/Frequency/Specifications for Roads & Bridges

Degree of compaction Tests for high embankment

1 test per 1000 sqm As required

Table 2: Original Ground as Sub-Grade (500mm Thick)

in Joint Venture with

Quality Assurance Plan

Table 3: Embankment up to 3m Height

Degree of compaction Layer thickness (compacted)

1 test per 1000 sqm 1 test per 1000 sqm

Table4: Sub-Grade in Cutting or Embankment (500mm Thick)

in Joint Venture with

Quality Assurance Plan

Table5: Embankment Exceeding 3m Height

Layer thickness (compacted)

By scaling during compaction test

in Joint Venture with

Quality Assurance Plan

Table7: Backfilling to Sub-Surface Drains

Size of holes in perforated pipe

Table 8: Aggregate Drains

Quality Assurance Plan

3.35mm 600mic 150mic 75mic

25-80 8-45 0-10 0-5

Table 9: Granular Sub-Base

NOTE: For required grading, see special specification of concerned project

Grading of coarse graded material

NOTE: For required grading, see special specification of concerned project

Ten percent fine value (wet)

BS:812 (Pt 111)

1 per 200 cum

Quality Assurance Plan

Sl. No. 4. 5. 6. 7. 8. 9. 10. 11.

Table 10: Water Bound Macadam Sub-Base/Base

in Joint Venture with

Quality Assurance Plan

Grading for screenings

13.2mm 11.2mm 5.6mm 180mic

11.2mm 5.6mm 180mic

Table 11: Prime Coat and Tack Coat

Quality Assurance Plan

Specified Value Special Specifications Special Specifications Max variation 2.5%

Table 12: Open Graded Premix Surfacing

Frequently Frequently Frequently

in Joint Venture with

Quality Assurance Plan

Sl. No. 12.