QSP 19-10-12

Construction of Roadbed, Major and Minor Bridges and Track Linking (Excluding Supply of Rails and Sleepers, Thick
Web Switches) S&T and General Electrical Work ICW Doubling Between Abu Railway- Palanpur (50.1 Km) on Ajmer Division of North Western Railway in Rajasthan and Gujarat State, India (In two packages) and Construction of Railway bed, Major and Minor Bridges and Track Linking (Excluding Supply of Rails and Sleepers, Thick Web Switches) S&T and General Electrical Work ICW Doubling Between Swarupganj-AbuRailway(26.00 Kms) on Ajmer Division of North Western Railway in Rajasthan State, India.
QUALITY AND SAFETY PLAN (QSP)
APRIL 2012
VOYANTS SOLUTIONS PVT. LTD.
403, 4 Floor, BPTP Park Centra, Sector -30, NH-8 Gurgaon - 122002 Phone - 0124-4598200 Telefax - 0124-4019051 E-mail info@voyants.in, www.voyants.in
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Construction Of Roadbed, Major And Minor Bridges And Track Linking (Excluding Supply Of Rails And Sleepers, Thick Web Switches) S&T And Genral Electrical Work Icw Doubling Between Aburoad Palanpur (50.1 Km) On Ajmer Division Of North Western Railway In Rajasthan And Gujarat State, India (In Two Packages). Quality and Safety Plan (QSP)
TABLE OF CONTENTS Chapter 1. INTRODUCTION .............................................................................................................. 5 1.1 1.2 1.3 INTRODUCTION ...................................................................................................... 5 GENERAL.................................................................................................................. 5 Objective of Quality AND SAFETY PLAN .............................................................. 6 1.3.1 Documents / Codes / Specification And Applicability .............................. 6 1.3.2 Implementation of QSP ............................................................................. 6 1.3.3 Quality ...................................................................................................... 7 1.3.4 Quality Control ......................................................................................... 7 1.3.5 Quality Audit............................................................................................. 7 1.3.6 Verification Testing .................................................................................. 7 1.3.7 Acceptance ................................................................................................ 7 1.4 DOCUMENTATION AND DATA CONTROL ........................................................ 8 1.4.1 Contract Documents ................................................................................. 8 1.4.2 Quality Control Forms.............................................................................. 8 1.4.3 Computer Aided Project Management System (CAPMS) ......................... 8 1.4.4 Guard Files ............................................................................................... 8 1.4.5 8 1.4.6 Working Files............................................................................................ 9 1.4.7 Quality Records ........................................................................................ 9 1.4.8 Test report of independent laboratory. ..................................................... 9 1.4.9 Test report of all test conducted in contractor laboratory: ...................... 9 1.5 Permanent Record....................................................................................................... 9 1.6 PROCESS CONTROL ............................................................................................. 10 1.6.1 Approval Process .................................................................................... 10 1.7 REQUEST FOR INSPECTION TO PROCEED AND FOR APPROVAL ............. 10 1.8 SOURCE APPROVAL ............................................................................................ 11 1.9 COMPLETION ........................................................................................................ 11 1.10 CALIBRATION OF INSTRUMENTS AND EQUIPMENTS ................................ 11 1.11 DIAGNOSTIC AND CORRECTIVE ACTION ...................................................... 11 1.12 QUALITY AUDIT ................................................................................................... 12 Chapter 2. QUALITY CONTROL PROCESS ................................................................................. 13 2.1 2.2 QUALITY CYCLE .................................................................................................. 13 Duties and responsibilities of PMC .......................................................................... 14 2.2.1 Duties & responsibilities of PM.............................................................. 15 2.2.2 Duties & responsibilities of RE: ............................................................. 15 2.2.3 Duties and Responsibilities of Experts ................................................... 16
Chapter 3.
QUALITY CONTROL during construction ................................................................. 17 3.1 Quality Policy ........................................................................................................... 17 3.1.1 Request for Inspection (RFI)................................................................... 17 Page 1 of 69
3.2 3.3
3.4 3.5
3.1.2 Non Conforming Reports (NCR).......................................................... 17 NCR (Explanatory Note) .......................................................................................... 17 EXECUTION OF WORKS ...................................................................................... 18 3.3.1 Setting up of Field Lab at Construction sites ......................................... 18 3.3.2 The following aspects are to be looked by Field Laboratories ............... 18 TESTING.................................................................................................................. 20 SITE INSPECTION.................................................................................................. 21 3.5.1 Equipment:.............................................................................................. 21
Chapter 4.
QUALITY control procedures ........................................................................................ 22 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 Earth work ................................................................................................................ 22 Blanket Materials ...................................................................................................... 22 Quality Control Checks on Finished Earthwork ....................................................... 22 Execution of Formation Earth Work ........................................................................ 23 Preliminary Works .................................................................................................... 24 Setting out of construction limits .............................................................................. 24 Selection of Borrow Area ......................................................................................... 25 Selection of Fill Material .......................................................................................... 25 General Aspects ........................................................................................................ 25 Compaction of Earth Work....................................................................................... 26 Placement of Back-fills on Bridge Approaches and Similar Locations ................... 26 Drainage Arrangement in Banks .............................................................................. 26 Execution of Work.................................................................................................... 27 LIST OF CODES AND SPECIFICATIONS ........................................................... 28 CERTIFICATION OF MATERIALS BY MANUFACTURER .............................. 32
Chapter 5.
QUALITY CONTROL OF structural concrte .............................................................. 33 5.1 5.2 Objective ................................................................................................................... 33 CONSTRUCTION MATERIAL. ............................................................................. 33 5.2.1 Cement .................................................................................................... 33 5.2.2 Aggregates .............................................................................................. 33 5.2.3 Coarse Aggregate ................................................................................... 33 5.2.4 Fine Aggregate ....................................................................................... 33 5.2.5 Water....................................................................................................... 34 5.2.6 Admixture................................................................................................ 34 5.2.7 Reinforcement Steel ................................................................................ 34 5.2.8 False work and formwork ....................................................................... 34 Concrete Construction .............................................................................................. 34 Concrete Mixing ....................................................................................................... 35 Transporting placing and compacting of concrete. ................................................... 35 Construction of Joint................................................................................................. 35 Curing of Concrete: .................................................................................................. 35 Moist Curing ............................................................................................................. 35 Finishing ................................................................................................................... 36 Page 2 of 69
5.3 5.4 5.5 5.6 5.7 5.8 5.9
5.10 5.11 5.12 5.13 5.14 5.15 Chapter 6.
Quality Control Tests and Standards of Acceptance ................................................ 36 Sampling and testing................................................................................................. 37 Test Specimen and sample strength .......................................................................... 37 Frequency ................................................................................................................. 37 Acceptance Criteria .................................................................................................. 38 Request for Inspection .............................................................................................. 40
quality control for brick works ....................................................................................... 41 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 Objective ................................................................................................................... 41 Quality Control on construction material ................................................................. 41 Bricks Masonry Construction ................................................................................... 41 Measurement of Consistency .................................................................................... 43 Soaking of Bricks: .................................................................................................... 43 Laying of Bricks: ...................................................................................................... 43 Curing ....................................................................................................................... 44 Scaffolding................................................................................................................ 44 Condition of Equipment ........................................................................................... 44 Request For Inspection ............................................................................................. 44 Other Ancillaries Items Of Building Construction ................................................... 45
Chapter 7.
quality control of road works .......................................................................................... 46 ROAD WORK: .................................................................................................................. 46 7.1 Objective ................................................................................................................... 46 7.2 Sub Grade ................................................................................................................. 46 7.3 Sub base & base ........................................................................................................ 46 7.4 Bitumen Work .......................................................................................................... 46 7.5 Quality Control test on finished Road Work: ........................................................... 46 7.6 Bituminous work: ..................................................................................................... 47 7.7 Execution Of Road Work ......................................................................................... 47 Sub grade ............................................................................................................................ 47 i. Geometry: ............................................................................................... 47 ii. Material .................................................................................................. 47 iii. Laying ..................................................................................................... 47 iv. Rolling: ................................................................................................... 47 7.8 Sub base .................................................................................................................... 47 Geometry: .............................................................................................................. 47 7.9 Wet mix Macadom ................................................................................................... 47 i. Material .................................................................................................. 47 ii. Physical Requirement ............................................................................. 48 iii. Grading: I.S. 2386 (Part V) ................................................................... 48 iv. Mixing :................................................................................................... 48 v. Laying : ................................................................................................... 48 vi. Rolling: ................................................................................................... 49 7.10 Water Bound Macadam ............................................................................................ 49 Page 3 of 69
7.11 Tack Coat .................................................................................................................. 51 7.12 Open graded premix carpet using Bitumen .............................................................. 51 Chapter 8. SAFETY PROCEDURES ................................................................................................ 53 8.1 8.2 The Objectives: ......................................................................................................... 53 Contractor Obligations.............................................................................................. 53 8.2.1 Digging and Excavation works: ............................................................. 58 8.2.2 Working near running line:- ................................................................... 59 8.2.3 Safety Fencing ........................................................................................ 60 8.2.4 Indemnity by Contractor ......................................................................... 64 8.2.5 Damage to Railway Property or Life or Private Property ..................... 64 8.2.6 Safety of Public ....................................................................................... 65 8.2.7 Reporting of Accidents ............................................................................ 65 8.2.8 Life-saving Appliances and First aid Equipment.................................... 65 8.2.9 Security Measures ................................................................................... 66
Chapter 9.
APPENDIX ....................................................................................................................... 67 9.1 List of applicable regulations for Safety. .................................................................. 67
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CHAPTER 1.
INTRODUCTION
1.1
INTRODUCTION The Abu Road-Palanpur section is a part of the vital link line connecting the DelhiAhemedabad, and rich in minerals. Apart from Goods traffic, proposed line will be helpful to the development of surrounding regions. Hence Railway has decided to double the Abu Road to Palanpur of Madar-Palanpur Section. The Western dedicated fright corridor is also planned parallel to this section. The section partly lies in Sirohi district of Rajasthan and mostly in Banaskanta district of Gujrat. The work under this project is Construction of Roadbed, Major and Minor Bridges and Track Linking (Excluding Supply of Rails and Sleepers, Thick Web Switches) S&T and General Electrical Work ICW Doubling Between Abu Road- Palanpur (50.1 Km) on Ajmer Division of North Western Railway in Rajasthan and Gujrat State, India (In two packages) and Construction of Roadbed, Major and Minor Bridges and Track Linking (Excluding Supply of Rails and Sleepers, Thick Web Switches) S&T and General Electrical Work ICW Doubling Between Swarupganj-AbuRoad(26.00 Kms) . The Employer and Project owner RVNL have awarded Construction work to M/s IVRCL while the Project Management Consultancy work has been entrusted to M/s Voyants Solutions Private Ltd.
1.2
GENERAL
The Quality And Safety Plan (QSP) has been framed keeping in view the specification of the Contract Agreement, the relevant IRS/ IS codes & sound engineering practices. The document defines the general quality assurance procedures common to various construction activities and also lay down the controls for ensuring quality and system for reporting. This QSP covers the checks, inspections and ensures compliance with the applicable design documents. Inspection checklists and forms to be used for the various construction activities and are enclosed in this Manual as Annexure. This Plan is prepared in compliance of PMC under Para 5.8.1(iii) of the TOR. The QSP explains the Quality and Safety policy, various duties of the Contractor and PMC with references to Indian Railways Standards and guidelines, setting up minimum Bench Marks and working out Quality index. The Quality Assurance Plan of the Contractor will contain the arrangements for Quality Control System, the internal Quality audit and will be approved by Contractor through PMC.
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1.3
Objective of Quality AND SAFETY PLAN While execution of work and its completion as per target is of paramount importance, quality in construction along with safety during execution is equally essential. Quality Assurance in the project ensures high quality inputs in the execution of project using best practices and well defined methodology specified by Indian Railway / EMPLOYER guidelines & test procedure of Bureau of Indian Standard. This is made possible through professional attitudes ethics, well defined working Methodology, proper sequence of work, Quality tests and proper documentation and work environment. It is essential that every person involve in execution, supervision & quality assurance & quality control activities in the organization should have the right approach and attitude, discipline and dedication towards the implementation of maintaining this protocol to achieve high quality output. The Project implementation policy should recognize safety, Quality and Timeliness. The Quality Assurance plan described hereunder reflects these objectives.
1.3.1
Documents / Codes / Specification And Applicability Implementation of specification and codes shall be as per provisions of Section-5, 6, 7 Codes & Technical Specification of Construction Contract. Contractor shall provide all drawings and documents including completion drawings in stipulated number of copies to PMC and also to EMPLOYER.
1.3.2
Implementation of QSP The fundamental objectives for implementing the Quality Assurance Plan are as follows: To ensure good quality materials, conforming to the specification to be utilized in the work with workmanship and better output of the final product. To lay down procedures, well-defined working methodology and sequence of work to guide the engineers of contracting agency supervisions Agency for smooth execution of work. To establish system for checks and cross checks at various levels to ensure the required quality of the work, final product by conducting various test on construction materials and end product time to time as per sequence of construction. To maintain proper documentation / construction and test records. To observe good system of reporting. To deliver products and ensure that the project is completed within the stipulated time frame. To train Engineer engaged in construction activities of the contracting agency and engineers of PMC on quality assurance and various test to be conducted during day to day execution of work. To ensure quality consistent with safety as per the scope of work, specifications and procedures by regular monitoring and checks.
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1.3.3
Quality Quality is defined in the Quality Manual of ISO 9000, as The totality of characteristics of an entity that bears on its ability to satisfy the stated and implied need.
1.3.4
Quality Control
Quality Control is defined as the procedure adopted and controls exercised to ensure that the materials proposed to be used in production, processes adopted for production and workmanship of production conform to the prescribed standards and laid down acceptance criteria. The Quality Control is exercised by construction agency who ensures, that the defined objective is achieved through appropriate tests, checks and inspections by suitable qualified personnel. Furthermore, the objective evidences of all tests, checks and inspections carried out from time to time and documents in prescribed formats for reference and record. 1.3.5 Quality Audit Quality Audit is a managerial tool used for reviewing the whole or a part Quality System by internal or external agencies not connected with the operation of the QA plan. Quality Audit is defined to be a systematic study and examination of document related to Quality control during the construction phase to establish that the inputs during construction process and the workmanship of work done conform to the prescribed specification and are of acceptable standards. If not, to identify whether rejection and / or rectification or any remedial measures are needed. 1.3.6 Verification Testing Verification testing is defined as the sampling and testing which is carried out independent of quality control sampling and testing to verify that the contractors results which have been reported are correct and representative, within statistical parameters of the material being produced / processed. 1.3.7 Acceptance Acceptance is defined as those operations, inspections, sampling and accepting the tests that are conducted to determine whether the product or service will be accepted for use and payment. Acceptance is determined using a statistically based acceptance plan in combination with and Safety that the contractor has fulfilled the quality control obligations. Acceptance is the responsibility of the Contractor with a rider by PMC / RVNL on dispute.
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1.4
DOCUMENTATION AND DATA CONTROL
1.4.1
Contract Documents
All formally written correspondence between the Client, Contractor, PMC any other official parties including letters, memorandums, forms, minutes of meetings, site instructions, change orders, approvals, drawings etc. is collectively known as Contract Documents. These must be carefully handled and stored. Any contract documentation could be the subjects of future litigation in case of any dispute.
1.4.2
Quality Control Forms
The Quality System requirements will specify which Quality control forms or other routine forms should be completed for which tasks and when they are necessary. It will also show how documents will be referenced, indexed and stored and retrieved.
1.4.3
Computer Aided Project Management System (CAPMS)
Computer aided Project Management System is the chosen tool for documentation and data control for this Project. The CAPMS will drive the System. Standard Project Management through MS-Project is being used. It is intended to retain both soft and hard copy of all contract documents. The Contractor will furnish such documents to the PMC or to the RVNL, if requisitioned. Project documents must remain immediately traceable and recoverable at all times. The computer System will be able to generate any documents, copies, updates etc. as required and will contain all the library of paper work formed over the life of the Project.
1.4.4
Guard Files
Final copies will be correctly filed in a file System or may be kept in bonded booklets and the relevant copies will be submitted to PMC on monthly basis for the work done during the month. They will be separately stored in hard copy and in soft copy on the CAPMS at the office of the Contractor / RVNL / PMC.
1.4.5
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1.4.6
Working Files
Other copies or working copies will be filled in a file System known as working files. These are for project monitoring, field and laboratory use.
1.4.7
Quality Records
Records pertaining to inspections and testing shall include original observations, calculations, derived data and an identification of personnel involved i.e. inspection and testing. All records shall be indexed, filed and maintained in a secure location for the entire construction period. 1.4.8 Test report of independent laboratory. All the test results received from the outside laboratory are to kept in a bound Guard file in PMC office as well as in Contractors office and one copy at site of work during construction, to follow the quality Assurance & quality control during construction. 1.4.9 Test report of all test conducted in contractor laboratory: All the test results are to be recorded in the register in the prescribed test formats as enclosed in this manual. Two copy of test report will be prepared. One copy will be kept in PMC office in a Guard file and one copy with contractor office. The entire day-to-day test conducted at working site will be maintained in the test register in the prescribed test formats as per this Q.C. manual. Two copies of test result will be prepared; one copy will be kept in PMC in a Guard file and one copy with contractor office. All these test report of day-to-day work and materials being used in the work will be necessary for verification at later stage about the quality of work executed. Records are also required to be maintained to develop completion drawing and other details, which would becomes permanent records of the work and could be helpful in future to plan developmental activities and remedial measures if need be. 1.5 Permanent Record It would be desirable to prepare completion drawing of Embankments, Minor bridges, station buildings with roads indicating the details construction features like, Cross section of embankments / cutting / type of soil used / blanketing materials / depth of Blanketing material used, geological features, drainage system with minor bridges , site plan showing exact location of all the station buildings, position of minor bridges etc. . These permanent records along with Q.A. and Q.C. record shall be handed over to Employer, at the time of handing over the completion of work.
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1.6
PROCESS CONTROL
1.6.1
Approval Process
An approval procedure will be used throughout the Project to have a written record and statement of process. The approval System formalizes requests from the Contractor and requires stage approval of the PMC and or RVNL. The Contractor will submit Request For Inspection (RFI) to PMC for inspection with an unique number at least 24 hours prior to actual execution of work. An advance statement (RFI Summary) through email with tentative works or activities to be executed against production of RFIs will be sent to PMC daily. Copy of the RFI Summary and photocopy of RFIs duly numbered will be sent to the PMC.
The day to day work approval System is based on two main factors. Request for Inspection to Proceed Request for Approval on completion.
1.7
REQUEST FOR INSPECTION TO PROCEED AND FOR APPROVAL
In this Project, a comprehensive form has to be developed clubbing Call for inspection and approval on completion for allowing proceeding with next stage of Execution especially in Railway bed. This form submitted by the Contractor must be used in every case where a Quality controlled task intends to start. The form must be duly signed and dated by the Contractors representative and all the experts of the PMC and the Client have the opportunity to comment at inspection time.
RFIs are submitted in triplicate along with one set of standardized checklist. Formats for checklist for different elements of work must be carefully prepared covering all the minute details of work as per standard Engineering practice and approved method statement. The PMC must have to record their observations against each query in the checklist. Findings of inspection are summarized on the basis of test as per Construction requirements and recorded in the RFI. The PMC Expert finally signs the form by either approving or rejecting the work according to the net result of inspection. The works shall execute once the PMC approves. In turn PMC, as per their matrix of reporting will provide information / copies to Client. The PMC will return copy of RFI, checklists and approvals to the Contractor and Contractor will attach the same with Running Account Bills for the quantities and works executed claimed in the Running Account Bill.
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1.8
SOURCE APPROVAL
Because of the variability of manufactured, processed and natural items, approval of the material source is required. A separate RFI/CFI is required for each and every source approval.
1.9
COMPLETION
At the end of project completion a joint inspection along with Client will be done and a snag list shall be prepared. Upon the completion of these a provisional completion certificate shall be issued by PMC.
1.10 CALIBRATION OF INSTRUMENTS AND EQUIPMENTS
All measuring instruments and testing equipments (field and laboratory) shall be uniquely numbered, properly stored, suitably handled in a manner appropriate to its sensitivity. Calibration certificates shall be obtained for all stages and fresh calibrations shall be made before end of validity period of calibration certificate. All equipments shall be maintained in a known state of calibration. If any instrument is repaired, steps shall be taken to ensure that recalibration is carried out to restore its calibration status.
1.11 DIAGNOSTIC AND CORRECTIVE ACTION
An effective System of onsite inspection, method used to identify poor results and procedure to be followed when poor results or deficiencies occur shall be maintained and documented. This System shall comprise the followings.
System for the investigation of non-conformities and for taking actions. Criteria to determine non conformity in a process or end product Analysis of process trends to initiate preventive action Verify that corrective action has actually been implemented effectively. Procedure to handle client complaint and their resolution. Records of corrective and preventive actions to demonstrate their effective implementations.
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1.12 QUALITY AUDIT
Internal Quality audits shall be carried periodically and a schedule thereof shall be made. The audited reports shall be discussed with audited group. A corrective action shall be planned on a time bound basis when deficiencies are found. Follow up measures shall be taken to endure that corrective action has been effective.
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CHAPTER 2.
QUALITY CONTROL PROCESS
The basic concept for production of a quality work is illustrated in the model below:
Quality Inputs
Process Control Specifications
Periodic Checks
Quality Product
The main inputs for a Railway project to perform are Men, Materials, Machineries, Money and Time. The documents specify the materials, their qualities and acceptance criteria for their use. Process control specifications are usually incorporated in the contract documents. These specify the functional requirements of the machinery or equipment to be used in the production process. The Contractor normally establishes the other controls viz., money and time. The PMC usually approves the time input factor and accordingly recommends the technology of production. The periodic checks during construction process are carried out as laid down in the various codes and specifications mentioned there in both by the Construction Contract and the Consultant Contract. The application of these activities would eventually assure a quality product at the end. A quality control plan for each activity shall be submitted at least 21 days prior to the start of the activity by IVRCL to PMC which consists of properties of materials, construction procedure, equipment, inspection plan along with responsibility matrix, test plan along with reports to be generated, etc
2.1
QUALITY CYCLE
Quality Management of a job is a cyclic process. The following diagram for a Railway work illustrates a Quality Cycle.
Pre Commencement Activities of a Construction Contractor

1. Mobilize Men, Materials, Machineries and Money. 2. Setup Quality Control System. 3. Obtain various approvals. 4. Study and take actions on remedial measures.
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Construction Activities of Contractor

1. Identification of activities. 2. Remedial / Corrective Suggested by PMC. 3. Carryout periodic checks. 4. Review test records. 5. Certify product.
Analysis of a Problem by the PMC

1. Establish causes of defects.
measures.
2. Suggest remedial measures. 3. Ensure implementation of remedial measures.
2.2
Duties and responsibilities of PMC
The overall responsibility of PMC Consultant specific towards Quality Assurance and Quality Control as shall be exercised through Consultants key personnel and PM will act as Team Leader. The main objectives shall be as under:
The Consultant shall:
a)
Assist the contractor to evolve a system of Quality Assurance for the works, including but not limited to, establishing testing frequencies and acceptance criteria for all materials and construction activities in accordance with the specifications. The system should specify the prescribed quality checks and their frequency to be performed, acceptable limits for each quality check and dos and donts for all important activities, in appropriate format acceptable to the Employer, so that the same can be provided to the concerned field officers responsible for supervision of respective items for ready reference.
b)
Ensure that the procurement of materials and equipment are from the approved sources and are duly inspected by the nominated agencies.
c) d)
Inspect and approve all materials received at site proposed to be incorporated in works; Check concrete mix designs proposed by the contractors and approve/suggest modifications to the mix designs, laying methods, sampling, testing procedures and quality control measures to ensure the required standards and consistency in quality at the commencement of activities;
e)
Inspect
the
quality of
the
works
with
regard
to
workmanship, compliance with the
specifications and all necessary testing required for acceptance of any item of work; f) Assess and check the laboratory and field tests carried out by the contractor, and carry out independent tests in the site laboratory, wherever necessary; g) Maintain records of all testing, including cross referencing to items of work to which each test refers and the location from which any samples were obtained for testing. Page 14 of 69
h)
Ensure that the quality of workmanship and the temporary arrangements/structures made for carrying out the works meet the requirement of specifications and safety standards.
i)
Issue orders to the contractor to remove or make good any work which is found to be:
a) b) c)
2.2.1
Not in accordance with the drawings. Not in accordance with the specifications in terms of either work methods or materials specifications. Covered prior to inspection for acceptance or after rejection as unacceptable.
Duties & responsibilities of PM
Act as the representative on behalf of the RVNL. Review Contractors Construction Program, and Safety Plan. Interpret the provisions of the Agreement and other related documents Review the working drawings prepared by the Contractor Ensuring implementation of Quality and Safety System. Periodical Supervision of works in accordance with the specification. Evolve criteria for acceptance of works. Hold regular meetings with the Contractors and RVNL. Regular interaction with the Project Managers of the Contractors in all matters relating to progress of works with particular reference to delays, possible reasons and mitigating measures, Quality and methodology.
Carryout any other duties relevant to the Project as desired by the RVNL. Assist the statutory auditors in auditing.
2.2.2
Duties & responsibilities of RE:
They shall Assist the Project Manager in charge of all works in their respective jurisdiction. Perform the role and responsibilities envisaged for the consultant in the contract agreement as assigned. Act and represent PM in the absences of PM. Assign duties to Bridge and Civil Experts on day to day basis. Be responsible for regular testing and upkeep of test records for earthwork, foundations, concrete works, structure and bridge works, all other civil works. Monitor the work done by Experts.
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Guide the Experts so as optimum and efficient output is obtained. Observe the provisions in the Contract Agreement. To report and advice PM and daily basis. Take up the instructions from PM on daily basis. Liaison with Contractors staff and RVNL Authorities. Ensure the proper documentation and upkeep the record of documents. Ensure the preparation, Compilation and timely submission of various reports to RVNL. Assist PM/RE/RVNL authorities during Inspections and Meeting as and when needed
2.2.3
Duties and Responsibilities of Experts
A)
Quality And Safety Assist the Contractor with the setting up of field laboratories. Review and recommend quarry sites for aggregates, quarry spall, sand, borrow materials etc. Supervise all the tests to be done in different stages of Construction besides ensuring that specified tests are done as per stipulated codes and take stage clearance from RVNL. Check the storing arrangement of Contractors materials and direct if any modification if necessary. Advise the RVNL in issuing instructions for the approval and rejection of materials at source and at site. Assist in organizing tests other than the regular tests done by laboratory personnel. He shall seek approval from RVNL for the designs. Maintain records of all materials and completed works and ensuring that all materials and completed works as per technical specifications. Verify manufacturers certificates. Check the calibration of testing equipments and Plants. Assist the PM/RE in the preparation of Project completion reports. Assist the PM in final inspection of works.
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CHAPTER 3.
QUALITY CONTROL DURING CONSTRUCTION
3.1
Quality Policy The quality policy of PMC is based on dedicated commitment to implement quality assurance to deliver a product conforming to specifications and standards. The aim is to deliver consistent quality product to the satisfaction of the client.
3.1.1
Request for Inspection (RFI)
This composite form, submitted by the Contractor, must be used in every case where a quality control task intends to start. This form must be duly signed and dated by the Contractors representative and all Engineers associated with that particular activity at specified location have the opportunity to comment during inspection. The Expert of the PMC will inspect the execution process, test and ensure the task has been completed to the standard required and write comments to that effect. The form must be duly signed by the relevant Engineer. If there are negative comments, then the representative of the Contractor will be informed of the same with the direction to rectify or redo the work and to raise fresh RFI for further inspection after necessary correction. After successful completion of task the representing engineers of PMC shall sign for its acceptance and return the copy to representing Contractors Engineer. Non Conforming Reports (NCR)
3.1.2
The purpose of NCR is to establish how to control nonconformity to specific requirements, and to prevent such material from unintended use or installation. If the construction activities carried out by contractor at site are not conforming base on QA/QC Plan and/or construction drawing, the required corrective measure should be instructed to the field engineer at site for corrective action of particular items. If the instruction given by the PMC is overlooked in such incident, Non conformity of such work should be issued to the contractor. The contractor should take immediate action by repaired or reworked, which are taken cause of nonconformity. If necessary, to implement the corrective action to eliminate the cause of nonconformities and to prevent recurrence shall be established.
3.2
NCR (Explanatory Note)
1. Engineers by means of NCR shall report problems, defects or deficiencies identified during construction. 2. NCR shall be raised for problems defects or deficiencies encountered in the following areas: Page 17 of 69
Defective construction materials including rejected materials found at site / stock. Substandard workmanship of construction works at any stage of construction. Failure of materials, finished works or structures to meet specified test requirements. Deviation from approved methodology (method statement) Deviation from Drawing Use of unapproved machineries and equipment. Use of Improper machines and equipments. Breakdown of Plants and Equipments. Insufficient Safety arrangements at Site. Incomplete testing of ingredients. Using any material component which has not been tested. Any other issues, in the opinion of the PMC are not within the accepted bounds of good industry practice.
3. All NCR raised on site shall be issued to the respective construction manager. Alternatively the process owner shall receive the NCR to initiate corrective action (i.e. the purchasing officer in the procurement dept. for rejected material) 4. Where the NCR has a design implication, the corrective action proposed by PMC/RVNL to rectify the non-compliance shall require the approval of the designer prior to its implementation. 5. The originators of the NCR all verify the corrective action for its effectiveness before closing out. 6. The PM shall ensure that the NCR is closed out within the agreed time frame for disposal. 3.3 3.3.1 EXECUTION OF WORKS Setting up of Field Lab at Construction sites To assist the contractor agency to set up a Field Laboratory at least in two places, so that all quality control checks can be performed effectively. The field labs should be manned adequately by trained official & staff capable of carrying out required investigation, soil testing and quality control at site. Testing for physical property of cement, coarse aggregates, fine aggregates, design mix, Railway ballast, road crust materials, testing for compressive strength of cement cubes, conc. cubes, Bricks etc. as are to be done as per the provision of Indian Standard / RDSO guide line / MORTH / IRC specification. 3.3.2 a) The following aspects are to be looked by Field Laboratories For Earthwork: i) To ensure that the quality of supplied soil and blanket material conforms to the accepted limits coarse aggregates, fine aggregates, cement, bricks, physical & chemical properties as per specific I.S. / R.D.S.O. requirements. Page 18 of 69
To evaluate method of compaction by conducting tests in connection with field trials. To exercise moisture and density control as the earth work proceeds in layers rolled with the suitable equipment.
ii) Depending on the requirement, field lab shall be equipped with minimum equipments as specified in respective BIS code to facilitate the following minimum tests. b) For Concrete Work To ensure the concrete making materials like cement, coarse aggregate, fine aggregate satisfied the requirement of Indian standard / R.D.S.O. guide line, test for physical properties of cement. Coarse & fine aggregates can be taken up in the field laboratory of contractor. Test for chemical properties for cement, water, admixture & physical & chemical properties of reinforcement steel can be done in out site laboratory as the equipment for above test will be costly & laboratory at site cannot be help scientific requirement. Depending upon the requirement the filled laboratory shall be equipped with minimum equipments as per the specification of BIS code as to facilitate the following minimum test. 1) Coarse Aggregate i. Sieve analysis ii. Flakiness Index iii. Impact value iv. Specific gravity, water absorption, v. Los Angles Abrasion value Grain size Analysis Sieve and Hydrometer. Atterbergs limits liquid limit & plastic limit. Optimum Moisture Content (O.M.C.), Maximum Dry Density (MDD) and Relative Density Placement moisture content and in-situ Density Free swell index.
2) Fine Aggregate (Sand) i. Organic impurities ii. Silt content iii. Sieve Analysis iv. Specific gravity & water absorption v. Bulking
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c)
Brick Masonry: To ensure that the quality of brick supplied for brick work and sand uniforms to the Indian Standard requirements & Technical specification. Depending on the requirement the filled laboratory shall be equipped with minimum testing equipments as per the specification of BIS Code to conduct the following tests: I. Bricks vi. Water absorption vii. Compressive strength II. Sand viii. As described under conc. Sl. (ii)
d)
Railway Ballast To ensure that the quality of railway ballast conforms to R.D.S.O. guide line. Depending on the requirement the filed laboratory shall be equipped with minimum testing equipments as per the specification of BIS code to conduct the following tests. ix. Water absorption x. Impact value xi. Los Angeles abrasion value
3.4
TESTING
Various tests on materials and works are required to be carried out on site during construction. A well equipped and properly calibrated site test laboratory is therefore an important element of quality control. The Contractor is required to set up the site laboratory before commencement of construction activities.
A list of testing equipment provided by the Contractor for the site laboratory is to be submitted to PMC. As per suggestions of them, testing equipments are to be added or modified including their orientation. PMC will give final approval to the arranged facilities of the laboratory. Laboratory equipment shall be properly calibrated and calibration certificates will be kept at the laboratory. Specialized tests at outside independent laboratories shall be undertaken as per instruction of PMC. The details of input materials should be recorded in Material Register.
All test results shall be entered into a test logbook as well as in standard formats for respective tests and conformance/ non-conformance is to be indicated therein. All aspects of materials testing (including test report formats) and quality control of materials and works are described separately. Page 20 of 69
3.5
SITE INSPECTION
Site inspections are to be carried out to ensure that the materials and construction activities conform to the prescribed standards. Site inspections can be divided into day-to-day supervision and periodic site visits.
The Contractor shall give advance notice to the PMC when critical activities are proposed to be undertaken and when a stage of work has been or is expected to be completed. On completion of a stage and before proceeding to the next stage, the PMC shall inspect the quality of the works executed. The final inspection shall encompass tests on completion as specified in the contract documents. The certification of quality will be based on test reports and site inspection.
3.5.1
Equipment:
Construction equipment is a major component of quality and Safety system. It is necessary that the PMC check the adequacy of the equipment used by the Contractor for construction as per the standard and special specification or his appointed Sub Contractors will from time to time, check the calibration of equipments as necessary. It would be also be necessary to record the equipment used for construction in the daily logs describing the condition of equipment, no. of hours used for the day for execution of works including item of work done in brief. PMC will periodically inspect the equipments and advise for compliance.
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CHAPTER 4.
QUALITY CONTROL PROCEDURES
4.1
Earth work
a)
Frequency of testing at site: At least one test at every change of soil strata material and
subject to lay
to minimum of one test for every 5000 cum to assess suitability of fill down OMC and MDD / Relative Density. b)
Method of test: Fill material shall be tested to ascertain its suitability as per the test procedure format.
c)
Acceptance criteria: Materials conforming to Para 5.0 of RDSO Guidelines for earthwork in Railway Project need only to be used for construction of In addition the soils having classification CH or CI or having gm/cc will not be permitted. embankments.
lower MDD than 1.7
4.2
Blanket Materials a) b) Frequency of Tests at site: Minimum one test per 500 cum or part thereof. Method of Test: Blanket material should be tested as per IS: 2720 (Part4) to plot particle size distribution curve, so as to assess its suitability. It would be necessary to carry out wet analysis to assess actual percentage of fines. To expedite testing work, dry sieve analysis may be carried out if variation between results of dry and wt analysis are not significant and adequate margin exists with respect to acceptance criteria. However, in such cases also, wet analysis has to be carried out at frequent interval to verify the extent of variation. In any situation, acceptance of blanket material would be based on wet analysis only. The sample for wet analysis should be prepared as per Para 4.3 of IS : 2720 (Part4) c) Acceptance Criteria: The material should generally conform to specification as given in RDSOS Guidelines for Earthwork in Railway Projects (Para 4.3.4). However, even if the gradation of the soil is not falling within the enveloping curve but are having MDD minimum 1.9 gm/cc, will be accepted for blanketing.
4.3
Quality Control Checks on Finished Earthwork Compacted Earth: To assist the contracting agency for routine test for degree of compaction of earth layer of compacted soil at locations selected in specified pattern. Carrying out periodic test checks to ascertain the embankment constructed as per specified compacts efficiency. Page 22 of 69
a)
Method of sampling Various method of selection of sample points for check of in-situ dry density are in vogue. The sampling adopted has to be such that effectiveness of proper compaction having been done for the entire area under consideration can be judged. For this, the Engineer-in-Charge should lay down the method adopted in detail depending on site conditions and accordingly records of checks done are properly maintained. However, in absence of such procedure laid down, following method should be adopted. Suggested Method of Sampling : For each layer, a minimum of one sample at a predetermined interval (In compliance with the requirement stated in next para) along the centerline of the alignment, would be taken in a staggered pattern so as to attain a minimum frequency of tests as given in the RDSOs Guidelines for Railway Project Para 7.2.2.1 (b). For subsequently layer, the stagger should be such that the point of sampling does not fall vertically on the earlier sampling points of the layer immediately below. Additional sampling points can be taken, as considered necessary.
b)
Frequency to Tests: Frequency of test of their acceptance critters has been enclosed as format under Annexure I. Formation Level: Finished top of sub-grade level may have variation from design level by + 50 mm and finished top of blanket layer may also be permitted to have variation from design level by + 50 mm. The ballast should be placed only on level formation without ruts or low pockets. At isolated locations the design level may vary up to + 100 mm Cross Slope: should be 1 in 30 Side Slopes: Side slopes should in no case be steeper than 2 (h): 1(v) bank and 1(h); 1 (v) in cutting. Provision of berm width should not be less than the designed width. Formation Width: Formation width for bank shall normally be 6.85m and 7.15m on curves. For cutting the width excluding side drains shall be 6.25m on straight and 6.55m on curves.
4.4
Execution of Formation Earth Work Earthwork in formation in embankment shall be carried out with suitable soil from outside railway land to be arranged by the contractor at its own cost. No borrow pits for this purpose shall be allowed on the railway land.
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The work shall be executed in conformity to RDSO Guidelines for Earthwork in Railway Projects 2003 (with latest amendments), which forms a part of the contract documents. The contractor, at its own cost identifies the soil suitable for Rly. Formation which he proposes to use in construction of the embankment and obtain the approval of engineer for use of such said soil. The work of execution of earth work embankment shall be carried out and completed by the contractor as per the approved drawings and specifications. Execution of earthwork has to be carried out in systematic manner so as to construct formations of satisfactory quality, which would give trouble free service. The activities and adoption of good practices involved in execution of earthwork are covered under following headings: 4.5 a) Preliminary Works Taking of initial levels and plotting cross sections. General aspects Compaction of earth work Placement of Bank Fill on Bridge Approaches and Similar Locations. Drainage Arrangement in Banks and cuttings Erosion control of slopes on banks and cuttings. Preliminary Works Preparation of Natural Ground : Preparation of Natural ground surface may be carried out as follows : b) Site clearances: Full formation width at ground level plus additional extra width of 1 m on both sides should be cleared of all obstruction viz. vegetation, trees, bushes, building, fences, abandoned structures etc. and thereafter it should be dressed and leveled. Depressions if any, should be filled with suitable soil duly compacted. Finally, leveled surface should be properly compacted by mechanical means to get a level and uniform ground surface. c) When bank is constructed on ground having steep slope then the ground surface should be suitably benched so that mew material of bank gets well bonded with the existing ground surface. 4.6 Setting out of construction limits Centerline of the alignment (@ 200 m c/c or so) and full construction width should be demarcated with reference pegs and dug belling about 90 cm away from proposed toe of the
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bank. Care should be taken not to disturb the pegs during construction. Pegs should be preferably painted for identification. 4.7 Selection of Borrow Area Borrow area should be selected for soil suitable to be used as fill materials for embankment. Tests to assess OMC, MDD/Relative Density need to be conducted. Areas selected for borrow materials need to be earmarked. 4.8 Selection of Fill Material Except for unsuitable soils as mentioned in clause 5.1 of RDSO Guidelines for earthwork in Railway Projects, any type of locally available soil can be used as a construction material. OMC & MDD of the selected fill materials should be tested in the laboratory as per laid down frequency. Use of material should be planned in such a way that soil with higher percentage of coarse grained particle is placed on the upper layers of the embankment. 4.9 General Aspects A field trial for compaction on a test section shall be conducted on fill material to assess the optimum thickness of layer and optimum number of passes for the type of roller planned to be used to arrive at desired density. Procedure for field compaction trials is given in Annexure IV of RDSO Guidelines for Earthwork in Railway Projects for guidance. If the soil has less than required moisture content, necessary amount of water shall be added to it either in borrow pits or after the soil has been spread loosely on the embankment. Addition of water may be done through flooding or irrigating the borrow areas or sprinkling the water on the embankment through a truck mounted water tank sprinkling system. Use of hosepipe for water need to be avoided. If the soil is too wet, it shall be allowed to dry till the moisture content reaches to acceptable level required for the compaction. Placement moisture content of soil should be decided based on the field trial and site conditions. The objective should be to compact near OMC to achieve uniform compaction with specified density in most efficient manner. Clods or hard lumps of soil of borrow area shall be broken to 75 mm or lesser size before placing on embankment. Each layer should be compacted with recommended type of roller up to required level of compaction, commencing from the sides, before putting next upper layer. Page 25 of 69
4.10 Compaction of Earth Work Performance of the embankment would depend to large extent on the quality of compaction done during execution. To ensure proper compaction, precautions / guidelines for this have been given in Para 6.3 of RSDO Guidelines for Earthwork in Railway Projects 2003. This should invariably be followed. 4.11 Placement of Back-fills on Bridge Approaches and Similar Locations The back fills resting on natural ground may settle in spite of heavy compaction and may cause differential settlements, vis--vis, abutments, which rest on comparatively much stiffer base. To avoid such differential settlements, while on one hand it is essential to compact the bank fill in the properly laid layers of soil, on the other hand, the back fill should be designed carefully to keep; Settlements within tolerable limits. Coefficient of sub grade reaction should have gradual change from Approach to the bridge, Back- fills on bridge approaches including boulder filling shall be placed in accordance to para 605 of Indian Railways Bridge Manual 1998. Details are given in design drawings forming part of the Tender. Fill materials being granular and sandy type soil, therefore need to be placed in 150 mm or lesser thick layers and compacted with vibratory plate compactors. While placing backfill material, benching should be made in approach embankment to provide proper bonding. 4.12 Drainage Arrangement in Banks Drainage is the most important factor in the stability of bank/cutting in railway construction. Effective drainage of the rainwater in the monsoon season is very important to safe guard bank/cutting from failure, Railway formation is designed for fully saturated condition of soil. However, flow of water should not be allowed along the track as it not only contaminates ballast but also erodes formation. Stagnation of water for long time on formation is not desirable. Therefore, drainage system should be efficient enough to prevent stagnation and allow quick flow of water. Drainage of Embankment: In bank, cross slope is provided from center towards end to drain out surface water. Therefore normally there is no need of side drains in case of embankment. However, there are situations where height of bank is such that blanket layer Page 26 of 69
goes below normal ground level. In such cases, side drains may require to be constructed along the track at suitable distance so that tack alignment does not become channel for flow of ground surface water. 4.13 Execution of Work The spreading of material in layers of desired thickness over the entire width of embankment should be done by mechanical means and finished by a motor grader. The motor grader blade shall have hydraulic control suitable for initial adjustment and maintain the same so as to achieve the slope and grade. Thickness of layer is decided based on field compaction trials. However, as a good practice thickness of layer should be generally kept as 300 mm for fill materials and 250 mm for blanket material in loose state before compaction. Fill shall be placed and compacted in layers of specified thickness. The rate of progress should be, as for as possible, uniform so that the work is completed to final level almost at the same time. The rolling for compaction of fill material should commence from edges towards center with minimum overlap of 200 mm between each run of the roller.; In final pass, roller should simply move over the surface without vibration so that top surface is properly finished. Extra bank width of 500 mm on either side shall be rolled to ensure proper compaction at the edges. The extra soil would be cut and dressed to avoid any loose earth at the slopes. This should preferably be done with help of grade cutter. At the end of the working day, fill materials should not be left un compacted. Care should be taken during rolling to provide suitable slope on top of the bank to facilitate quick shedding of water and avoid pounding on formation. During construction of formation, there may be rainfall to the extent that rain cuts may develop on the surface of formation due to erosion of soil. Care should be taken that these rain cuts are not allowed to develop wide and deep otherwise these locations will remain weak spots. The contractor must ensure at its own cost, to attend/repair such rain cuts, as a regular measure to the satisfaction of the Engineer. Top of the formation should be finished to a cross slope of 1 in 30 from one end to other towards chess/drain in multiple lines and from center of formation to both sides in single line.
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Once the top surface of the formation has been finished to proper slope and level, movement of either empty or loaded Road vehicle for transportation of ballast, sleepers etc. should not be permitted, as these movements will cause development of unevenness, ruts on the surface, which will accumulate water and weaken the formation. The methodology of transportation of P. Way materials needs to be planned properly avoiding movement on finished formation.
In conversion/doubling/rehabilitation/projects, suitable benching of existing slope shall be done before new earthwork is taken up to provide proper bonding material left on the benched slope. Care needs to be taken to avoid entry of rainwater into the formation from this weak junction; otherwise this would result in development of weak formation, slope failure, maintenance problem due to uneven settlement etc.
At locations where the water table is high and the fill soil is fine-grained, it may be desirable to provide a granular layer of about 30 cm thickness at the base, above subsoil across the full width formation. The contractor shall take this factor into account while designing the formation.
At the places where embankment materials are not conducive to plant growth, top soil obtained from site clearance as well as Top layer of borrow pit which is rich in organic content and suitable for plant growth may be stored for covering. Slopes of embankment & cutting after construction, or other disturbed areas, where re-vegetation is required, as for as practicable.
4.14 LIST OF CODES AND SPECIFICATIONS
Apart from the basic data, specifications etc. all items of works shall be governed by the following Codes, Specifications as revised/corrected/amended up to the time of submission of the tender.
(i) INDIAN RAILWAY STANDARD CODES AND SPECIFICATIONS
1. 2. 3. 4. 5. 6.
Indian Railways Schedule of dimensions for Broad Gauge 2004. Indian Railways Permanent Way Manual. Indian Railways Bridge Manual, 1998 Indian Railways Works Manual. IRS Bridge rules. IRS Welded Bridge Code. Page 28 of 69
7. 8. 9. 10.
IRS Steel Bridge Code. IRS Concrete Bridge Code IRS Sub-structure & Foundation Code. IRS: Specifications for fabrication and Erection of Steel Girder Bridges & Locomotive Turn Tables. (B1-2001)
(ii) INDIAN ROADS CONGRESS CODES AND SPECIFICATIONS Standard Specifications and Code of practice for Road Bridges Section I General features of design. 2. IRC-6: Standard specifications and Code of practice for Road Bridges Section-IILoads & stresses. 3. IRC-21: Standard specifications and Code of practice for Road Bridges Section III Cement concrete (Plain & reinforced) 4. IRC-24: Standard specifications and Code of practice for Road Bridges Section V Steel Road Bridges. 5. 6. 7. 8. IRC-83: Bearings for bridges. IRC-78: Sub-structure for Road Bridges. IRC-87: Design and erection of false work for road bridges. Specifications for Road and Bridge Works issued by Ministry of Road Transport & Highways. (MoRTH)
1.
IRC-5:
(iii) INDIAN STANDARD SPECIFICATIONS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
IS:2062 IS:8500 IS:1786 IS:1148 IS:1149 IS:1363 IS:1929 IS:2004 IS:57 IS:75 IS:77 IS:102
Steel for general structural purposes. Structural steel Micro alloyed (Medium and high strength qualities) High strength deformed steel bars & wires for concrete reinforcement. Hot rolled rivet bars (up to 40mm dia) for structural purpose. High tensile steel rivet bars for structural purposes. (all 3 parts) Hexagon head bolts, screws and nuts of product grade C. Hot forged steel rivets for hot closing (12 to 36 mm dia). Carbon steel forgings for general engineering purposes. Red lead for paints and other purposes. Linseed oil, raw and refined. Linseed oil, boiled for paints Ready mixed paints, brushing, red lead, non-settling priming. Page 29 of 69
13.
IS: 123
Ready mixed paints, brushing, finishing, semi-gloss, for general purposes to Indian Colours etc.
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
IS: 2339 IS: 280 IS: 456 IS: 883 IS: 814 IS: 1182 IS: 2595 IS: 383 IS:2386 IS: 3025 IS: 1791 IS: 4634 IS: 6925
Aluminum paints for general purposes, in dual container. Mild steel wire for general engineering purposes. Plain and reinforced concrete. Design for structural timber in buildings. Covered electrodes for manual metal arc welding. Radiographic examination of butt joints in steel plates. Radiographic testing. Coarse and fine aggregate from natural sources for concrete. (all 8 parts) Tests for aggregates for concrete (all 49 parts) Methods of sampling and test for water and waste water. Batch type concrete mixers. Methods of testing performance of batch type concrete mixers. Methods of test for determination of water soluble chlorides in concrete admixtures.
27. 28. 29. 30. 31. 32. 33. 34.
IS: 9103 IS: 516 IS: 4031 IS: 5513
Admixtures for concrete. Method of test for strength of concrete. (all 15 parts) Physical tests for hydraulic cement. Vicat apparatus.
IS: 10080 Vibration machine for casting standard cement mortar cubes. IS: 10262 Concrete mix designs. IS: 1343 IS: 975 Prestressed concrete. (all 5 parts) Design loads (other than earthquakes) for buildings and structures. (all 41 parts) method of tests for soil. General construction in steel. Conversion factors and conversion tables. Welding in bridges and structures subject to dynamic loading. Seam welding in mild steel. (all 20 parts) Threaded steel fasteners. Hexagonal bolts for steel structures. Ready mixed paint, brushing, zinc chrome, priming. Ready mixed paint, air drying, red oxide-zinc chrome. Rolling and cutting tolerances for hot rolled steel products. Metric steel tape measure. Page 30 of 69
35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.
IS: 2720 IS: 800 IS: 786 IS: 1024 IS: 1261 IS: 1367 IS: 6639 IS: 104 IS: 2074 IS: 1852 IS: 1270
46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67.
IS: 9595 IS: 487 IS: 1030 IS: 3400 IS: 1915 IS: 1893 IS: 3502 IS: 3085 IS: 7320 IS: 5515 IS: 6586 IS: 5666 IS: 3955 SP IS:2911 IS: 7205 IS: 8629 IS: 5624 IS:7215 IS: 8112 IS: 4326
Metal Arc Welding. Brush, paint and varnish. Carbon steel castings for general engineering purposes. (all 22 parts) Methods of tests for vulcanized rubbers. Steel bridge code. Earthquake resident design of structures. Steel Chequered Plates. Method of test for permeability of cement mortar and concrete. Concrete slump test apparatus. Compaction factor apparatus. Metal spraying for protection of iron steel. Etch primer. Design and construction of well foundations. 6, 7, 16, 21, 22, 23,24,34,36, 52, 60. Design and construction of pile foundation Safety code for erection of structural steel work. Protection of iron and steel structures form atmospheric corrosion. Foundation bolts. Tolerances for fabrication of steel structures 43 Grade OPC. Earthquake resistant design and construction of buildings.
IS: 13920 Ductile detailing of reinforced concrete structures subjected to seismic forces.
68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79.
IS: 34 IS: 887 IS: 816 IS: 819 IS: 1024 IS: 1261 IS: 1323 IS: 4081 IS: 3764 IS: 7293 IS: 817 IS: 1200
White lead for paints. Animal tallow. Metal arc welding for general construction in mild steel. Resistance spot welding for light assemblies in mild steel. Welding in bridges and structures subject to dynamic loading. Seam welding in mild steel. Oxy-acetylene welding for structural work in mild steel. Safety code for blasting and related drilling operations. Safety code for excavation work. Safety code for working with construction machinery. Training and testing of metal arc welders. (all relevant parts) Method of measurement of building and civil engineering works. Page 31 of 69
80. 81. 82. 83.
IS: 2132 IS: 2131 IS: 1892 IS:14268
Thin walled tube sampling of soils. Standard penetration test for soils. Subsurface investigations. Prestressing Strands
(iv) Miscellaneous: 1. 2. 3. UIC-772R: Bearings of rail bridges BS-5400 (all parts). BS-1449, 3484, 1134, 5296.
NOTE: a) The list given above is by no means exhaustive. All IS, IRC and IRS Codes pertaining to the work shall be applicable. b) Where the drawings and specifications described a portion of the work in only general terms and not in complete detail it shall be understood that only the best general practice is to prevail, materials and workmanship of the best quality are to be employed and the instructions of the Engineer are to be complied with.
4.15 CERTIFICATION OF MATERIALS BY MANUFACTURER
It has been anticipated in the specifications that specialized testing such as water, bearing pads, pot bearing, steel, pre-stress strand, Electrical wires, OFC Cables, Electronic items, Signals, Luminaries, Sleepers, and the like would be carried out utilizing an outside testing agency or the manufacturers as the case may require.
Acceptance of certain manufactured items shall be based on test certificates from the manufacturer conforming to RDSO standards and visual inspection. These items shall bear the IS mark. The PMC shall review the manufacturers certificates for conformance to contract requirements before these items are delivered to site. Upon their delivery and before their installation or incorporation in the works,
The warranty period if any shall be indemnified in favor of RVNL by the Manufacturers.
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CHAPTER 5.
QUALITY CONTROL OF STRUCTURAL CONCRTE
5.1
Objective To assist the contractor to execute all structural concrete work for minor Bridge & Buildings as per the guide line of R.D.S.O. & Technical Specifications. i) ii) iii) To achieve performance of permanent assets created in construction. Adequate quality control. Cheek at all stages of construction i.e. selection of construction materials, adoption of method, use of suitable machinery for execution of work. Following quality control system needs to be adopted.
5.2
CONSTRUCTION MATERIAL.
5.2.1
Cement As per Contract conditions of the client EMPLOYER, the cement to be used shall be Slag Cement, PPC, OPC 43 grade or OPC 53 grade. Regular routine testing such as Normal Consistency, Initial setting Time, Final Setting Time, and compressive strength etc. shall be carried out lot wise to check the quality of the cement prior to the utilization in the project work. In addition samples of cement are to be tested for chemical analysis as well as for physical properties in the outside laboratory also.
5.2.2
Aggregates The physical & chemical properties will be tested in independent laboratory for approving the source. Thereafter routine tests will be conducted in the site laboratory as per the specifications to ensure the consistency of the same.
5.2.3
Coarse Aggregate The aggregates will be tested for Gradation, Flakiness index, Aggregate impact Value, Specific Gravity & water Absorption etc to check the consistency of the quality of the aggregate produced from the crusher.
5.2.4
Fine Aggregate Natural Sand shall be used as fine aggregate as plenty of stocks are available in the area and could be procured easily. The sand collected from source shall be tested for Gradation, Sp. Gravity & Water Absorption and other ,physical & chemical properties such as P H value,
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Chloride content, Alkali aggregate reactivity etc to check its suitability prior to use in the project work. 5.2.5 Water Water is required primarily for hydration of cement and to give fluidity to the plastic mass. The Physical and chemical properties such as PH value, Chloride & Sulphate, Alkalinity, Hardness, Organic Impurities etc of water shall be tested to check the suitability as per IS 3025. The quality of water is to be checked by frequent testing in the site laboratory. 5.2.6 Admixture Admixture shall be tested following IS 9103 and Chloride content shall be tested according to IS 6925. The Manufacturer's Test Certificate shall be produced for every batch of procurement and infrared spectrograph test report shall be produced to ensure the base material. 5.2.7 Reinforcement Steel Steel used in the work shall be high yield strength deformed TMT Steel bars/ corrosion resistance confirming to I.S 1786 1925 manufactured by the Agencies having B.I.S. License.
5.2.8
False work and formwork The formwork shall conform to the shapes, lines and dimensions shown on the drawings such that the relevant tolerance of finished concrete as specified are achieved. Formwork shall be constructed and supported as to remain sufficiently rigid during the placement and compaction of the concrete and shall be sufficiently water-tight to prevent loss of water or mortar from concrete. The formwork and false work must be designed keeping in view all loads and forces. Forces for finished surfaces should be smooth and mortar tight. If wood forms are used, the boards must be uniform in the thickness, tongued and grooved, smoothly finished on the surface next to the concrete, evenly matched and tightly placed, except where the desired surface or appearance requires special treatment. The use of forms of plywood /similar product which can absorb water is recommended. Test procedure for each constituent material has been described in Test procedure of Q.A Manual. Frequency of test for each constituent of concrete has been described in quality Assurance plan.
5.3
Concrete Construction Before starting of concrete construction testing of all the ingredient of Concrete as described above for their physical & chemical properties shall be completed & according to lab test result, Page 34 of 69
approval on construction material is to be obtained from the P.M.C. / EMPLOYER concrete mix design report for all the grade of concrete shall be done in the independent laboratory or contractors laboratory and test report obtained. 5.4 Concrete Mixing Concrete shall be mixed either in a concrete mixer or in batching & mixing plant. The mixer with weight batcher or mixing plan shall be calibrated in the presence of PMC engineer before use of mixer with weigh batcher or Batching plant for concreting work. Mixing shall be continued till materials are uniformly distributed. 5.5 Transporting placing and compacting of concrete. The method of transporting concrete shall be approved by PMC/EMPLOYER Concrete shall be transported and placed as near as practicable to its final position so that no contamination segregation or loss of its constituent materials takes place. Construction shall not be freely dropped into place from a height exceeding 1.50 M. If concrete is mixed in Batching plant & shall have to carried to a distance it shall be carried by transit mixer and should be placed within initial setting time from the time of mixing in the Batching plant. All term form and reinforcement contained in it shall be cleaned and made free from standing water, dust immediately before placing. No concrete shall be placed in any part of the structure until approval of the Engineer of PMC/EMPLOYER. Concrete shall be laid in layer of 450mm maximum and compacted by suitable size of vibrator conforming to I.S 252, I.S 2506, I.S 2514 according to the size of structure & reinforcement mesh in it to obtained dense homogeneous concrete. Care shall be taken during vibration that segregation of concrete near vibrator needle do not occur due to over vibration. 5.6 Construction of Joint Construction joints shall be avoided as far as possible and in no case the location of such joints shall be changed or increased from those provided on the approved drawings. The sequence of centering shall be so organized that cold joint ore totally eliminated. Work shall be carried out continuously up to the construction joints. 5.7 Curing of Concrete: Concreting operation shall not be carried out until adequate arrangements for curing have been made by the contractor at site. Curing and protection of concrete shall start immediately after compaction of concrete to protect it form. 5.8 Moist Curing The concrete should be kept constantly wet for a minimum period of 14 (fourteen) days. Water should apply on unformed surfaces as soon as it can be done without marring the surface and on Page 35 of 69
formed surfaces immediately after the forms are stripped. The concrete shall be kept constantly wet by pounding or covered with a layer of sacking canvas, hessian or a similar absorbent material. When air temperature is expected to drop below 50C during the curing period, additional covering of cotton / gunny bag straw or other suitable blanketing material shall be provided so that concrete temperature at surface does not fall below 100 C. 5.9 Finishing Immediately after removal of forms, exposed bars or bolt, 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 of dry pack consistency. 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. 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. The finished surfaces of concrete after removal of formwork should be such that no touching up is required. All fins caused by form joints, if any, shall be ground using electric surface grinder. Immediately on removal of forms, the concrete work shall be examined by the Engineer before any defects are 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 Engineer.
5.10 Quality Control Tests and Standards of Acceptance Concrete shall confirm to the surface finish and tolerance as prescribed in these specifications for respective and components. Random sampling and lot by lot of acceptance inspection shall be made for the 28 days cube strength of concrete. Concrete under acceptance shall be nationally divided into lots for the purpose of sampling, before commencement of work. The delimitation of lots shall be determined by the following: Page 36 of 69
i) ii)
No individual lot shall be more than 30 cum in volume. At least one cube forming an item of the sample representing the lot shall be taken from concrete of the same grade and mix proportions cast on any day.
iii) iv)
Different grades of mixes of concrete shall be divided into separate lots. Concrete of a lot shall be used in the same identifiable component of the bridge.
5.11 Sampling and testing 1. Concrete for making 3 test cubes shall be taken from a batch of concrete at point of delivery into construction, according to procedure laid down in IS : 1199. 2. A random sampling procedure to ensure that each of the concrete batches forming the lot under acceptance inspection has equal chance of being chosen for taking cubes shall be adopted. 3. 150mm cubes shall be made, cured and tested at the age of 28 days for compressive strength in accordance with IS: 516. The 28 day test strength result for each cube shall form an item of the sample. 5.12 Test Specimen and sample strength Three test specimens shall be made from each sample for testing at 28 day. Additional cubes may be required for various purposes such as to determine the strength of concrete at 7 days for any other purpose. The test strength of the sample shall be the average of the strength of 3 cubes. The individual variation should not be then 15 percent of average. 5.13 Frequency The minimum frequency of sampling of concrete of each grade shall be in accordance with Table below:
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Quantity of concrete in work, m3 1-5 6-5 16-30 31 - 50 51 and above
No. of samples 1 2 3 4 4 plus one additional sample for each additional 50 m3 or part thereof.
At least one sample shall be taken from each shift of work. 5.14 Acceptance Criteria The strength requirement of any particular grade of concrete will be considered satisfactory if the 28 days compressive strengths sets the following requirements: (i) a) For the five sets. The average strength determined from any group of the three consecutive test cubes exceeds the specified characteristic strength (fck) by no less than 0.8 times the current margin. b) Only one individual cube test result in any set may be below the specified characteristic strength (fck) provided that this value is not less than 95% of the specified characteristics strength (fck). (each set consist of 3 cubes) and of individual cubes satisfy
(ii)
Thereafter, provided that the average strength of any fifteen consecutive cubes exceeds the specified characteristics cube strength by at least 0.9 times the current margin all the subsequent test result may be considered acceptable if, c) The average strength as determined from any group of three consecutive test cubes exceeds the specified characteristic cube strength (fck) by not less than 0.6 times the current margin. d) Only one individual cube test result in any set may fall below the specified characteristic strength provided that this value is not less than 90% of the specified characteristics strength. Page 38 of 69
(iii)
Whenever a mix is redesigned due to a change in the quality of aggregate or cement or for any other reason, it shall be considered a new mix and initially subject to the acceptability criteria above.
(iv)
If the concrete produced at site does not satisfy the above strength requirements, the Engineer will reserve the right to require the contractor to improve the methods of batching, the quality of the ingredients and redesign the mix with increased cement content, if necessary. The Contractor shall not be entitled to claim any extra cost for the extra cement used for the modifications stipulated by the Engineer for fulfilling the strength requirement specified.
(v)
It is the complete responsibility of the contractor to redesign the concrete mixes by approved standard methods and to produce the reinforced concrete conforming to the specification and the strength requirements approved by the Engineer. It is expected that the contractor will have competent staff to carry out this work.
(vi)
As frequently as the Engineer may require, testing shall be carried out in the field for: (a) (b) (c) (d) (e) (f) (g) Moisture content and absorption and density of sand and aggregate. Silt content of sand. Grading of sand and aggregates Slump test of concrete Concrete cube test Permeability test for concrete as per DIN 1048 (Part-I) Density and pH value of Plasticizer.
The Contractor shall provide and maintain on site at all times, until the works are completed, equipment and staff required for carrying out these tests. The Contractor shall grant the Engineer or his representative full access to his laboratory at all tests carried out on site. Before concreting commences on any section of the works the Contractor shall obtain approval of the Engineer or his representative as regards the formworks and reinforcements conforming to the drawings. He shall also indicate to the Engineer in writing and obtain his approval for positions of construction joints.
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5.15 Request for Inspection A request for inspection for concrete, with complete information and checklist for reinforcement shall be submitted to the engineer to allow assessment and approval must have been receive prior to commencing rainy follow of activities: a. b. c. d. e. f. g. h. i. Shuttering Checked & Approved Reinforcement checked & approved Staging checked & approved Arrangement of Concreting Construction joint, old concrete surface Quantity and quality of materials / Ingredients Platforms and access for Labors and Safety arrangement Illumination arrangement, standby arrangement Concreting equipment and standby arrangement
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CHAPTER 6.
QUALITY CONTROL FOR BRICK WORKS
BRIK MASONRY: 6.1 Objective To assist the Contractors to execute all brick masonry work for station building and other allied work as per the guide line of R.D.S.O & Technical specification i. ii. iii. To achieve performance & permanent assets created in construction adequate quality control Check at all stages of construction i.e. selection of construction materials, adoption method, use of suitable machinery for execution of work. Following quality control system needs to be adopted. 6.2 Quality Control on construction material Bricks Brick/Fly ash bricks shall be of class 35 having a minimum compressive strength of 3.5 N / mm2 as per Bill of Quantity of contrast Agreement specification. The physical property of this class of brick shall conform to the requirement of Indian standards and will be tested as per I.S. 3495 Part I, Part II, and I.S. 1077 in an independent laboratory in the presence of PMC Engineer by random sampling, from site of work form lot of 10,000 bricks of one brand or part their of. There after routine test will be conducted for each brand exceeding 10,000 bricks in the Contractors Laboratory in the presence of PMC Engineer. Cement Same procedure shall be followed as described in concrete chapter. Sand Same procedure shall be followed as described in Concrete Chapter. Water Water same procedure shall be followed as described in concrete chapter. 6.3 Bricks Masonry Construction Test report of Bricks & other construction materials to be sued in the brick work shall be available at site before starting of the Brick works.
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Preparation of cement mortar Cement and Sand shall be mixed in specified proportions as given in the specification off approved drawing & Bill of Quantity of contract document. Cement shall be weighted and other ingredients in specified proportion shall be measured using boxes of size 40 x35X25 cm .sand shall be measured with a allowance for Bulking .The required amount of water to be added and mortar is produced with working consistency. Mixing of the mortar shall be done in concrete material mixer only at site of work. Concrete and sand with the specified proportions shall be mixed dry thoroughly in mixer, water shall be then added gradually and wet mixing continued at least for 3 minutes. Only the required quantity of water is to be added, for obtaining working consistency. 6.4 Measurement of Consistency A field test for consistency shall be carried out by means of a cone preparation apparatus as given in Appendix B of I.S. 1625. For laying different type of Brick works, the measure of consistency, expressed in cm depth of penetration, given below. i) ii) iii) iv) For laying wall of solid bricks For laying prefer bricks For filling cavities For pointing and plastering 9 to 13 cm 7 to 8 cm 13 to 15 cm 3 to 4 cm
Precautions Mortar shall be mixed only in such a quantity which will be used immediately before it begins to set i.e. within 30 minutes of adding water to the mortar made out of Portland cement. The mortar once sets or cracked shall not be used. 6.5 Soaking of Bricks: Brick shall be soaked in water for a minimum period of one hour before use of water to penetrate whole depth. Alternately, stacks of brick may be profusely sprayed with clean water, at regular interval for a period of less than 6 hours. Bricks after soaking shall be removed form take sufficient in advance so that at the time of laying they must be surface dry. 6.6 Laying of Bricks: Brick shall be laid in English Bond, unless otherwise specified. Half or cut bricks shall not be used except where necessary to complete the bond. The layer of Bricks shall be laid truly in plumb.
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A set of tools comprising of a wooden straight edge, masons spirit level or water level with pipe, one mt. rule, line string and plumb shall be kept at the site of work for proper check during progress. For detail specification on laying the Technical specification are to be followed strictly. 6.7 Curing Green work shall be protected from rain by suitable covering. Masonry work in cement shall be kept constantly moist on all faces for a period of ten days. Initial curing shall be done by sprinkling water carefully so as not to disturb mortar from joints. During hot summer, all the finished or partly done Brick work shall be covered or wetted in such a manner as will prevent rapid drying of brick work. 6.8 Scaffolding Scaffolding shall be strong and sound so as to withstand all loads likely to come upon it. Where plastering, pointing or any other finishing has been indicated for brick work, single scaffolding may be provided unless otherwise specified. Where brick work or tile work is to be exposed and not to be finished with plastering etc. double scaffolding having two independent supports clear for work shall be provided. The holes which provide resting space for horizontal members shall not be left in masonry under one meter in width or immediately near the skew backs of arches. The holes left in the masonry work for supporting scaffolding shall be filled and made good with brick work and finishing as specified well before plastering or pointing work is done. Type and design of scaffolding to be used at works by the contractor shall be got approved by Engineer. However, the contractor shall be responsible for its safety. As far as possible steel tubular scaffolding shall be used. 6.9 Condition of Equipment All equipment used for missing or transporting mortar and bricks shall be clean and free from set mortar, dirt or other injurious foreign substances. 6.10 Request For Inspection A request for inspection for brick work with all necessary information to allow assessment to start work shall be submitted to the Engineer for the following activities and approval must have been receipt prior to commence any follow of action. Availability of test result of Brick Availability of test result of fine aggregate Page 44 of 69
Availability of test result of Cement, water Availability of Mortar making equipment Staging checked & approved Platforms and access for Labors and Safety arrangement Illumination arrangement, standby arrangement Availability assured curing arrangement
6.11 Other Ancillaries Items Of Building Construction All the items such as flooring plastering, doors & windows with fittings, sanitary and water supply items are to be executed as per the approved Technical specification and conditions of contract.
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CHAPTER 7.
QUALITY CONTROL OF ROAD WORKS
ROAD WORK: 7.1 Objective To assist the Contractor to execute all Road Construction work for approach to station Building & platforms as per the guide line of R.D.S.O. & Technical specification for Road Work. (i) (ii) T o achieve performance of permanent assets created in construction. Check all stages of construction i.e. selection of construction materials, adoption of method, use of suitable machinery for execution of work following quality control system needs to be adopted. 7.2 Sub Grade Quality of sub-grade construction shall be controlled through exercise on check on borrow materials. This is required to ascertain the suitability of materials for sub-grade of road and to decide OMC and M.D.D which become the quality input for compaction control quality test shall be carried out for sub-grade material prior to construction work. 7.3 Sub base & base Quality of sub-base construction be controlled through exercise on check on sub-base materials. This is required to ascertain the suitability of materials for sub-base of the road (Crushed stone of required gradation which becomes the quality input. Quality control test for physical properties of materials shall be carried out prior to construction work. 7.4 Bitumen Work Quality of Bituminous work such on tack coat, premix carpet & seal coat shall be controlled through exercise on check on quality of Bituminous materials and coarse aggregate (crushed rock) as per gradation quality control test for physical properties of aggregate & chemical properties of bituminous materials are to carried out prior to construction work. 7.5 Quality Control test on finished Road Work: Sub-grade: To determined the density of compacted layer as per. I.S: 2720 (P-28) Frequency of the test specified in quality assurance plan.
Sub-base and base:
Determination of density of compacted layer as per IS: 2720 (P28).
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7.6
Bituminous work: Tack Coat: (1) (2) Premix Carpet: (1) Temperature of the binder at regular close intervals. Rate of spread of binder, two tests per day. Surface in regulation of checking as per MORT&H clause 902.4
7.7
Execution Of Road Work Sub grade i. Geometry: In case of the New Road and platforms, the sub-grade shall be shaped as per the approved design of road formation to the contour to get a finished surface and consolidated to the depth below to the proposed finished level. The sub grade shall be provided as per the direction of Engineer. ii. Material Granular moorum shall be used as sub grade material. iii. Laying The sub grade material should be laid in layers at top. The camber shall not be less than 1:48. Platform surface shall also be made to suitable slopes as indicated in the drawing. iv. Rolling: Sub grade shall be consolidated by 10 T Power Road roller with required amount of water to achieve O.M.C & maximum dry density. The rolling shall be started from the edge and completed in the center. During rolling surface shall be checked with templates and any irregularity shall be checked with templates and any irregularity shall be corrected.
7.8
Sub base Geometry: The sub-base shall be marked on the well prepared sub grade as per approved drawing. Similarly in platform portion the outer line shall be marked as per approved drawing.
7.9 i.
Wet mix Macadom Material Coarse aggregate of the following physical requirement & grading made out of cross stone shall be used for sub base.
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ii.
Physical Requirement Loss Angeles Abrasion value - (I.S. 2386 Part IV) Aggregate Impact Value Combined flakiness and elongation indices (total) Water absorption ( I.S. 2386 (1-1) - 30 % max - not more than 2 % ( do ) - 40 % max - 30 % max
iii.
Grading: I.S. 2386 (Part V) I.S. Sieve designation 45.00 mm 22.40 mm 11.20 mm 4.75 mm 2.36 mm 0.600 mm 0.075 mm % by weight passing 95 100 60 80 40 60 25 40 15 30 8 22 08
Material finer than 425 micron shall have plasticity index not exceeding 6. Water : Portable water shall be used for mixing of material iv. Mixing : The mix shall be prepared in an approved mixing plant having provision for controlled addition of water, with material satisfying the grading. In case the batching plant for this purpose cannot be installed material can be mixed in the batching plant meant for concrete work. v. Laying : Laying of materials should be done by mechanical means and spreading should be done by mortar grader to the required camber (l in 48). The laying shall be done in one or multiple layer of 75 mm each it rolled with 10 T smooth wheeled Roller. The laying can be made in one layer up to 200 mm if vibratory roller will be used.
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vi.
Rolling: If the thickness of single layer not exceeds 100 mm then smooth wheel roller of 8 to 10 tonne shall be used. For layer up to 200 mm thickness, vibratory roller of 8 to 10 T shall be used. Rolling spread shall not be more than 5 Km per hour. The rolling shall be continued to achieve 98% of the maximum dry density achieved. Care shall be taken to maintain the proper camber (1 in 48). After the compaction is left for 24 hours for drying during this period the road shall be closed for vehicular movement.
7.10 Water Bound Macadam Soling: For Roads over which heavy traffic is expected, a soling layer of hand packed rubble will be laid on the already prepared sub grade. Metal: The Metal shall be of tough, hard, broken stones so as to pass in any direction through a 5 cm. road mesh. Rounded pieces, or flakes or angular chips shall not be used. Each piece shall be square and sharp. Gravel for Roads shall be composed of large, coarse grain free from dirt and impurities. Sand used for blinding road surfaces, shall be sharp, gritty and clean. Moorum shall be good, hard, clean, and free from clay. Stacking All road materials, must, before being stacked, be freed from all earth or other impurity. The material shall be sacked in continuous heaps of such dimensions so that each running meter of the stack will contain the materials required for a running meter of roadway. If site conditions do not permit this other alternate methods as directed by the Engineer may be used. Materials : Unless otherwise specified stone metal of size 50 mm shall be used for metalling of water bound macadam roads. Where the use of brick jelly is specified, the jelly shall preferably be obtained from over burnt bricks only.
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Base In new work, the metal shall be spread over soling completed in accordance with Clause 2. In the case of existing metalled roads, the spreading of any additional metal shall be done after the surface has been scarified as per Clause 4 of RVNL Specifications Part A Chapter 5. Laying The spreading of metal over the prepared based shall be done evenly, with a twisting motion to void segregation, and it shall be to the required profile, with proper allowance kept for consolidation. Usually, loose metal requires an allowance of about 33 1/3% over the consolidated thickness. Compaction (a) The metal shall be consolidated first by dry rolling and then by wet rolling, with a power roller of 8 ton minimum weight. (b) In straight reaches the rolling shall be commenced at the edges and worked gradually towards the centre. In the case of super elevated curves, the rolling shall be commenced at the inside edge and worked towards the outer edge. (c) In dry rolling, after first rolling absolutely dry, light sprinkling of water shall be done to moisten the base and to facilitate interlocking of metal, Dry rolling shall be continued till the metal gets perfectly set and ceases to move when rolled over. During this state, the camber and grade should be checked side by side, and any irregularity found shall be rectified, so that on completion of the dry rolling no surface defect is left. (d) The surface shall then be watered copiously and rolled in the wet condition till the roller ceases to make any visible impression on the surface, and a 25mm piece of metal if placed on it get crushed under the roller without being depressed into the surface. (e) After wet rolling, the surface shall once again be checked and any irregularity exceeding 12 mm shall be rectified by raking out and recompacting with any addition or removal of metal as found necessary. Binding The surface thus made up finally shall then be spread over with the binding material, which may be of soft moorum or selected earth, as specified, the spreading being done in 6 mm layers at a time. It should be copiously watered and rolled so that the layers of binding material are worked well into the voids in the metal, and finally, a wake of surplus slurry is formed before the wheels of the roller.
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Opening The finished work shall be allowed to take its set before being opened to traffic for which it shall be kept protected for a period of at least 24 hours, and preferably 2 or 3 days. In dry weather, the surface should be kept lightly sprinkled with water for about a week. 7.11 Tack Coat Material : The binder used for track coat shall be of bituminous emulsion or cut back. Surface Preparation: The surface on which the tack coat is to be applied shall be cleaned of dust or any extraneous material before application of the binder. Application: The normal range of spraying temperature for bituminous emulsion shall be 20oC 60oC and for a cutback shall be 50oC 80o C if RC 70/ MC 70 grade. The binder shall be applied uniformly with a specified rate and temperature so as to provide as uniformly unbroken spread of bitumen. After application, allow the tack coat to cure without being disturbed. Until the water/ cutter has completely evaporated. The rate of spraying the bituminous material shall be 1.00 kg per 10 square meter of surface area. 7.12 Open graded premix carpet using Bitumen Material : Binder : The binder shall be bitumen of a suitable grade, satisfying the requirement of IS ; 73, 217, 454 or other approved cut back. Aggregate : The coarse aggregate shall conform to clause 504 : 2.2.1 Table 500 (MORT&H) the stone polishing value measured by (BS : 812 P 114) shall not be less than 55. The water Absorption limit shall be limited to a maximum of 1%. The size of Agg. is 20 mm downgraded. Gradation : IS sieve designation (mm) % of Passing by wt.
26.5 19.0 9.5 4.75
100 90 100 56.80 35 - 65
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2.36 0.300 0.075

For proportion of the aggregate follow the table of 500 16 Construction operation:
23 49 59 2-8
Prepare of mix : The temperature of the binder at the time of mix of 150 0c to 1630c and that of aggregate at the range of 1550c to 1630c and that of aggregate at no time exceeds 140C. Mixing shall be through to ensure that a homogeneous mixture is obtained in which all particles of the aggregate are coated uniformly the discharge temperature of mix shall be 1300C to 1600c. Spreading and compacting : The mix shall be spread by senior power Rolling shall be commence with 80 100 KN rollers preferably of smooth wheel tandem type. Rolling shall be begin at the edge and progress towards the center. Roller shall not stand on newly laid materials while there is a risk that it will be deformed thereby rolling operations shall be completed in every respect before the temperature of the mix falls below 1000C. A seal coat conforming to clause 513 shall be applied to the surface immediately after laying the carpet. The surface finish of the construction shall conform to the requirement of the clause 902 (MORT&H). Control of quality of materials and works shall be exercised in accordance with section 900.
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CHAPTER 8. SAFETY PROCEDURES
8.1
The Objectives:
The main objectives for management control of Safety measures during constructions are:
1. There is no danger to life due to ongoing construction activities. 2. There is no damage to existing track, cables, equipments and machines under operation, due to ongoing construction activities. 3. There are no accidents due to ongoing construction activities. 4. The Safety norms laid down in various Manuals and regulations are observed.
8.2
Contractor Obligations
(1)
The Contractor shall comply with all the precautions as required for the safety of the workmen by the I.L.O Convention No.62 as far as they are applicable to the Contract. The Contractor shall provide all necessary safety appliances; such as safety goggles, helmets, masks, etc to the workmen and the staff.
(2)
Suitable scaffolds shall be provided for workmen for all work that cannot be done safely from the ground, or from solid construction except for such short period work as can be done safely from ladders. When a ladder is used, an extra labor shall be engaged for holding the ladder and if the ladder is used for carrying materials as well, suitable footholds and hand-holds shall be provided on the ladder, which shall be given an inclination not steeper than 1/4 to 1 (1/4 horizontal in 1 vertical)
(3)
Scaffolding or staging more than 3.25 meters above the ground or floor, swung or suspended from an overhead support or erected with stationary support, shall have a guard rail properly attached, bolted, braced and otherwise secured at least 1 meter high above the floor or platform of such scaffolding or staging and extending along the entire length of the outside and ends thereof with only such openings as maybe necessary for the delivery of materials. Such scaffolding or staging shall be so fastened as to prevent it from swaying in from the support or structure.
(4)
Working platforms, gangways and stairways shall be so constructed that they do not sag unduly or unequally, and if the height of any platform or gangway or stairway is more Page 53 of 69
than 3.25 metres above ground level or floor level, it shall have closely spaced boards, have adequate width and be suitably provided with guard rails as described in (3) above.
(5)
Every opening in the floor of a structure or in a working platform shall be provided with suitable means to prevent fall of persons or materials by providing suitable fencing or railing with a minimum height of one meter.
(6)
Safe means of access and egress shall be provided to all working platforms and other working places. Every ladder shall be securely fixed. No portable single ladder shall be over 9 metres in length. The width between side rails in a rung ladder shall in no case be less than 30 cm for ladders up to and including 3 metres in length. For longer ladders the width shall be increased at least 6 mm for each additional 30 cm of length. Spacing of steps shall be uniform and shall not exceed 30 cm.
(7)
Adequate precautions shall be taken to prevent danger from electrical equipment. Adequate safety measures shall be taken when any work is undertaken near any live highly charged electric wire. Necessary shutdown may be arranged, where and whenever essential. All rules in force in this connection shall be fully complied with. The Contractor shall ensure all precautions to prevent any accidents due to electrocution or otherwise.
(8)
No materials on any of the sites shall be so stacked or placed as to cause danger or inconvenience to any person or the public. The Contractor shall provide all necessary fencing and lights to protect the public from accidents and shall be bound to bear the expenses of defending every suit, action or other proceedings at law that may be brought by any person for injury sustained owing to neglect of the above precautions and to pay any damages and costs which may be awarded in any such suit, action or proceedings to any such person or which may with the consent of the Contractor be paid to compromise any claim by any such person.
(9)
Excavation and Trenching : All trenches, 1.5 meters or more in depth, shall at all times be supplied with at least one ladder for each 20 meters in length or fraction thereof, Ladders shall be extended from the bottom of the trench to at least 1 meter above the surface of the ground. The sides of a trench, which is 1.5 meters or more in depth shall be stepped back to provide a suitable slope, or be securely held by timber bracing so as to Page 54 of 69
avoid the danger of side collapse. Excavated material shall not be placed within 1.5 meters of the edge of any trench or half the depth of the trench, whichever is more. Excavation shall be made from the top to the bottom. Under no circumstances shall undermining or undercutting be done.
(10)
Demolition : Before any demolition work is commenced and also during the process of the work :
(a)
All roads and open areas adjacent to the work site shall either be closed or suitably protected.
(b)
No electric cable or apparatus, which is liable to be a source of danger other than a cable or apparatus used by operators, shall remain electrically charged:
(c)
All practical steps shall be taken to prevent danger to persons employed by the Employer, from risk of fire or explosion, or flooding. No floor, roof or other part of a building shall be so overloaded with debris or materials as to render it unsafe.
(11)
All necessary personal safety equipment as considered adequate by the Engineer shall be available for use of persons employed on the site and maintained in a condition suitable for immediate use; and the Contractor shall take adequate steps to ensure proper use of such equipment by those concerned.
(a)
Workers employed on mixing asphaltic materials, cement, lime mortars, concrete etc. shall be provided with protective footwear and protective goggles.
(b)
Those engaged in handling any material, which is injurious to the eyes, shall be provided with protective goggles. Those engaged in welding works shall be provided with welders protective eyeshield.
(c)
(d)
Stone breakers shall be provided with protective goggles and protective clothing and seated at sufficiently safe intervals.
(e)
When workers are employed in sewers and manhole, which are in use, the contractor shall ensure that manhole covers are open and manholes are ventilated at least for an hour before workers are allowed to go into them. Manholes so open shall be cordoned off with suitable railing and provide warning signals or boards to prevent accidents to the public.
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(12)
The Contractor shall not employ men below the age of 18 years and women, on the work of painting with products containing lead in any form. Whenever men above the age of 18 years are employed on the work of lead painting, the following precautions shall be taken:
(a)
No paint containing lead or lead products shall be used except in the form of paste or readymade paint.
(b)
Suitable face masks shall be supplied for use by workers when paint is applied in the form of spray or a surface having lead paint dry rubbed and scrapped.
(c)
Overalls shall be supplied by the Contractor to workmen and adequate facilities shall be provided to enable workers to wash during and at the close of any days work.
(13)
When work is performed near any place where there is risk of drowning all necessary equipment shall be provided and kept ready for use and all necessary steps taken for prompt first aid treatment of all injuries likely to be sustained during the course of the work.
(14)
Use of hoisting machines and tackle including their attachments, anchorage and supports shall conform to the following:
(a)
(i) These shall be of good mechanical construction, sound material and adequate strength and free from patent defects and shall be kept in good working order, be regularly inspected and properly maintained.
(ii) Every rope used in hoisting or lowering materials or as a means of suspension shall be of durable quality and adequate strength, and free from defects
(b)
Every crane driver or hoisting appliance operator shall be properly qualified and no person under the age of 21 shall be in charge of any hoisting machine including scaffold equipment. Only trained men over the age of 21 shall be permitted to give signals to such plant and appliance operators.
(c)
For every hoisting machine and every chain hook, shackle, swivel and pulley block used in hoisting, lowering or as means of suspension, safe working load Page 56 of 69
shall be ascertained by adequate means. Every hoisting machine and all gear referred to above shall be plainly marked with safe working load. In case of a hoisting machine or a variable safe working load, each safe working load and conditions under which it is applicable shall be clearly indicated. No part of any machine or any gear referred to in the paragraph above shall be loaded beyond safe working load except for the purpose of testing. In case of the Employers machine, safe working load shall be notified by the Engineer or his Representative. As regards Contractors machines, the Contractor shall notify safe working load of each machine to the Engineer or his Representative, whenever he brings it to the site of work and get it verified by him.
(d)
(15)
Motors, gearing, transmission, electric wiring and other dangerous parts of hoisting appliances shall be provided with efficient safeguards; hoisting appliances shall be provided with such means as will reduce the risk of accident during descent of load to the minimum. Adequate precautions shall be taken to reduce to the minimum risk of any part of a suspended load becoming accidentally displaced. When workers are employed on electrical installations, which are already energized, insulating mats, working apparel such as gloves, sleeves and boots, as may be necessary, shall be provided. Workers shall not wear any rings, watches and carry keys or other materials which are good conductor of electricity.
(16)
All scaffolds, ladders and other safety devices mentioned or described herein shall be maintained in a safe condition and no scaffold, ladder or equipment shall be altered or removed while it is in use. Adequate washing facilities shall be provided at or near places of work.
(17)
These safety provisions shall be brought to the notice of all concerned by displaying on a notice board at a prominent place at the work location. Persons responsible for ensuring compliance with the Safety Code shall be named therein by the Contractor.
(18)
To ensure effective enforcement of the rules and regulations relating to safety precautions, arrangements made by the contractor shall be open to inspection by the Engineer or his Representative.
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(19)
Notwithstanding anything contained in conditions (1) to (17) above, the Contractor shall at its own costs, remain liable to comply with the provisions of all acts, rules, regulations, and bylaws for the time being in force in India and applicable in this matter.
(20)
For work carried out in the vicinity of any wharf or quay, the Contractor shall abide by all the provisions of the Dock Workers (Safety, Health and Welfare) Scheme, 1961.
(21)
The Contractor shall at his own expense provide protective safety Equipment like gloves and footwear for all labour engaged on concrete mixing work and all other types of working involving the use of tar, cement, etc. to the satisfaction of the Engineer or his Representative, and on his failure to do so, the employer shall be entitled to provide the same and recover the cost from the Contractor.
(22)
The Contractor shall be responsible for observance, by the sub-contractors, of the foregoing provisions.
8.2.1
Digging and Excavation works: Joints procedure order for undertaking digging work in the vicinity of underground signaling, electrical and telecommunication cables
A.
A number of Engineering works in connection with gauge conversion/doubling/third line are in progress on various railways, which require extensive digging work near the running track, in close vicinity of the working S&T cables carrying vital Safety circuits as well as electrical cables feeding the power supply to Cabins. ASM room, RRI Cabin, Intermediate blocks Huts (IBH) etc. Similarly, S&T organization under open line or construction units under CAO/C are executing various signaling and telecommunication work requiring digging of earth for laying of cables or casting of foundation for the erection of signal post etc. Rail Tel are also executing the work of laying of quad cables and OFC on various railways as a part of sanctioned works for exclusive use of Railways for carrying voice and data i.e. administrative and control communication, PRS, FOIS etc. or shared by Rail Tel Corporation of India Ltd. On certain sections digging is also required for lying of electrical cables and casting of foundation for the erection of OHE masts by Electrical Deptt. Generally, these works are executed by contractors employed by these organizations.
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B.
However, while carrying out these works in the vicinity of working signaling, telecommunication and electrical cables, at times, cable cuts take place due to JCB machine working along the track or during the digging work being done by Contractors carrying out the Civil Engineering Works. Similarly, such cable cuts are also resulting due to work undertaken by S&T or Electrical Deptt. Such cables faults results in the failure of vital signaling and telecommunication circuits.
i)
The work of excavating the trench and laying of the cable should proceed in quick succession, leaving a minimum time between the two activities.
ii)
Any damage caused to OFC/Quad cable or Electrical cable during execution of the work necessary debit shall be raised on Engineering Department who shall bear the cost of the corrective action.
iii)
All types of bonds i.e. rail bond, cross bond and structure bond shall be restored by the contractor with a view to keep the rail voltage low to ensure safely of personnel.
iv)
Above joint circular shall be applicable for construction as well as open line organization of Engineering, S&T& Electrical.
v)
The S&T cable and Electrical cable route plan should be got approved from the concerned RE(S&T)/RE(Electrical) respectively, before undertaking the work and completion cable route plan should be finalized Block section by Block section as soon as the work is completed.
8.2.2
Working near running line:-
1)
The contractor shall not allow any road vehicle belonging to him or his suppliers etc. to play in railway land next to the running line. If for execution of certain work viz earth work for parallel railway line and supply of ballast for new or existing rail line, gauge conversion etc. road vehicle are necessary to be used in railway land next to the railway line, the contractor shall apply to the Engineer for permission giving the type & no. of individual vehicles, name and license particulars of the drivers, location, duration & timings for such work / movement. The railways/ Employer/Engineer or his authorized representative will personally counsel, examine & certify, the road vehicle drivers, Page 59 of 69
contractor flag men & supervisor and will give written permission giving names of road vehicle drivers, contractors flag men and supervisor to be deployed on the work, location, period and timing of the work. This permission will be subject to the following obligatory conditions
2)
Road vehicles can play along the track after suitable cordoning of track with minimum distance of 6 meters from the centre of the nearest track. For working of machinery close to the running tracks or playing of road vehicles during night hours, the contractor shall apply to the Engineer in writing for permission, duly indicating the site details in a neat sketch and Safety measures proposed to be taken. Subject to the approval of concerned Railway authorities, the Engineer or his authorized representative will communicate permission to the contractor /contractor representative. The contractor and his men shall strictly adhere to the instructions given along with such permissions.
3)
Nominated vehicles and drivers shall be utilized for work in the presence of at least one flag man and one supervisor certified for such work. In order to monitor the activities during night hours, additional staff may have to e posted based on the need of the individual site.
4)
The contractor machinery, equipment and vehicle shall normally operate 6 m clear of track. Any movement/work at less than 6m and up to a minimum of 3.5m clear of track centre, shall be carried out only in the presence of a person the Engineer. No part of the road vehicle shall be allowed at less than 3.5m from track centre.
5)
The contractors machinery and equipment like Cranes, Flash Butt Welders, Ballasting machinery Compactor. Track Laying Systems etc. are required to operate close to the existing line carrying traffic. Contractor is fully responsible for operating these machinery without endangering the Safety of the running line and traffic.
8.2.3
Safety Fencing
i)
Before commencing any work close to the running track, the contractor shall provide Safety fencing and obtain the specific permission of Engineer to commence the work in that stretch. Page 60 of 69
ii)
The fencing shall be for a height of 1.5 meters with wooden/Casurina balli posts of length 2.1m at 3 m centre to centre spacing as per relevant BOQ item.
iii)
The contractor shall maintain the Safety fencing in good working condition through out the period till the work in a given stretch is completed. He can remove the fencing after getting the approval of Engineer. The fencing material will be the property of the contractor. Serviceable material obtained from the released fencing can be re used for providing fencing in subsequent stretches.
iv)
The contractor will be paid for providing Safety fencing along the track as per the relevant item in the BOQ. The contractors special attention is drawn to Para 826 of Indian Railways Permanent Way Manual introduced under advanced Correction Slip no. 69 dated 23/5/2001, reproduced below which should invariably be complied with. 826 Safe working of ContractorsA large number of men and machinery are deployed by the contractor for track renewals, gauge conversions, doublings, bridges rebuilding etc. It is therefore essential that adequate Safety measures are taken for Safety of the trains as well as the work force. The following measures should invariably be adopted:-
1)
i)
The contractor shall not start any work without the presence of Railway/PMC supervisor at site.
ii)
Wherever the road vehicle and/ or machinery are required to work in the close vicinity of railway line, he work shall be so carried out that there is no infringement to the railways schedule of dimensions. For this purpose the area where road vehicle s and/or Machinery are required to play, shall be demarcated and acknowledged by the contractor. Special care shall be taken for turning / reversal road vehicle / machinery without infringing the running track. Barricading shall be provided wherever justified and feasible as per site conditions. The look out and whistle caution orders shall be issued to the trains and speed restrictions imposed where considered necessary. Suitable flag men / detonators shall be provided where necessary for protection of trains.
iii)
iv)
The supervisor / workmen should be counseled about Safety measures. A competency certificate to the contractors supervisor as per Performa annexed Page 61 of 69
shall be issued by Expert which will be valid only for the work for which it has been issued. v) The unloaded ballast / rail/sleepers/other P.Way materials after unloading along track should be kept clear off moving dimensions and stacked as per the specified heights and distance from the running track. vi) Supplementary site specific instructions, wherever considered necessary, shall be issued by the PMC.
COMPETENCY CERTIFICATE
Certified
that
Shri______________________________P.Way
supervisor
of
M/S________________________________________has been examined regarding P. Way working on _____________________work. His knowledge has been found satisfactory and he is capable of supervising the work safely.
______________________________________________________ PM/RE
2)
The work of formation in bank and cuttings throughout the length of doubling is adjacent to track under running traffic. Many of the bridges on the proposed double line are to be constructed either as extensions or just adjacent to the existing bridges under running traffic. The work of installation of track throughout the length of doubling is adjacent to track under running traffic. The work of installation of track and Signals in the Station yards including alternations to the existing Track & Signals has to be done adjacent to or in replacement of the existing Track and Signals which are under running traffic. The contractor shall ensure that the Safety of the running lines and running traffic is not endangered, because of his work.
3)
Any traffic /traction blocks, temporary speed restrictions and caution orders, required in this connection shall also be got sanctioned from the Railway authorities well in advance, through the Engineer. The Railway may sanction the same for specific sites within the overall recovery time available in the Railways time tables. The contractor shall have to schedule his programme according to the convenience of the Railways. No claim from the contractor for any delay/ inconvenience/ loss on this account shall be entertained by the Employer.
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4)
The contractor shall provide at site at his own cost, all protection measures including exhibition and lighting of all Temporary Engineering Signals as per Railway rules, instructions and norms. All lights provided by the contractor shall be screened so as not to interfere with any signals light on the Railways or with any traffic or signal lights of any local or other authority.
5)
Ancillary and Temporary works The contractors proposals for erection of all ancillary and temporary works shall be in conformity with the proposals submitted along with the tender and modifications there to as approved by the Engineer. ii) The Contractor shall submit drawings, supporting design calculations where called for by the Engineer and other- relevant details of all such works to the Engineer for approval at least one month before he desires to commence such works. Approval by the Engineer of any such proposal shall not relieve the contractor of his responsibility for the sufficiency of such works. iii) The contractor shall, at his own cost, design and provide any temporary arrangements including relieving/service girders required in connection with the above said works and remove the same; when no longer required. These arrangements shall conform to railway norms. The contractor shall obtain all necessary approvals and sanctions .of the concerned Railway authorities including Commissioner of Railway Safety through the Engineer in advance and well in time. iv) The contractor shall ensure and be entirely responsible for proper design,
i)
fabrication, provision and upkeep of all temporary arrangements and all associated activities so as not to endanger Safety of any assets, running track, traffic and traveling public and for following all extent instructions, norms, practice and procedures laid down by Railway authorities in this respect, which may be ascertained from the Railways through the Engineer v) If required, Railways may, in order to ensure the Safety of the running track, post at site Regular Railway staff to watch the efficacy and Safety of temporary arrangements and protection measures round the clock for the period the same exist in the running line and till the running line is restored back to normal. Railways may also supervise the insertion, maintenance and removal of the temporary arrangements. The cost of such staff shall be borne by the Employer. vi) Notwithstanding the above, the contractor shall not, however, be relieved of his Page 63 of 69
responsibility and obligation as aforesaid. vii) Save as provided in Para 7 (e) above, the Contractor shall bear the cost of complying with all Safety requirements. No extra payment will be made for complying with the Safety provisions under this chapter and the cost of all such elements to meet the Safety requirements shall be deemed to be included in the Bill of Quantities.
6)
The contractor remains fully responsible for ensuring Safety. In case of any accident, the Contractor shall bear cost of all damages to his equipment and men and also damages to Railway and its passengers.
7)
Suitable barricading to forewarn road vehicle driver shall be provided by the contractor. The luminous tape, strung on bamboo or steel poles can be considered for such barricading. Barricading arrangement should be got approved by the Engineer.
8.2.4
Indemnity by Contractor
The Contractor shall indemnify and save harmless the Railway I Employer I Engineer from and against all actions, suit proceedings, losses, costs, damages, claims, and demands of every nature and description brought or recovered against the Railways I Employer I Engineer by reason of any act or omission of the contractor, his agents or employees, in the execution of the works or in his guarding the same. All sums payable by way of compensation under any of these conditions shall be considered as reasonable compensation to be applied to the actual loss or damage sustained, and whether or not any damage shall have been sustained.
8.2.5
Damage to Railway Property or Life or Private Property
The contractor shall be responsible for all risks to the works and for the trespass and, shall make good this own expense all loss or damage whether to the works themselves or to any other property of the Railway or the lives of persons or property of others from whatsoever cause in connection with the works until they are taken over by the Employer and this although all reasonable and proper precautions may have been taken by the Contractor, and in case the Railway/Employer/Engineer -shall be called upon to make good any costs, loss or damages or to pay, any compensation; including that payable under the provisions of Workmens compensation act or any statutory amendments thereof to any person or persons sustaining damages as aforesaid, by reason of any act, or any negligence or any omissions on the part of the contractor, Page 64 of 69
he amount of any costs or charges including costs and charges in connection with legal proceedings, which the Railway/ Employer/ Engineer may incur in reference thereto, shall be charged to the contractor. The Railway/Employer /Engineer shall have the power and right to pay or\to defend or compromise any claim of threatened legal proceedings or in anticipation of legal proceedings being instituted consequent on the action or default of the contractor, to take such steps as may be considered necessary or desirable to ward off or mitigate the effect of such proceedings, charging to Contractor, as aforesaid, any sum or sums of money which may be paid and any expenses whether for reinstatement or otherwise which may be incurred and the propriety of any such payment, defend or compromise, and the incurring of any such expanse shall not be called in question by the Contractor.
8.2.6
Safety of Public
(i)
The Contractor shall be responsible to take all precautions to ensure the Safety of the Public whether on Public or Railway property and shall post such look out men as may in the opinion of the Engineer be required to comply with regulations pertaining to the work.
(ii)
The Contractor shall provide effective barricading using G.I. corrugated sheets around foundation pits, trenches, erection sites, demolition sites etc., to prevent accidents and injuries to the public. He shall erect barricading duly leaving safe passage for the movement of the public as per the directions of Engineer.
(iii) No payment will be made for providing such barricading and the rates quoted by the Contractor shall be inclusive of such Safety measures.
8.2.7
Reporting of Accidents
The Contractor shall report to the Engineer details of any accidents as soon as possible after its occurrence. In the case of any fatality or serious accident, the Contractor shall, in addition, notify the Engineer and the Employer immediately by the quickest available means.
8.2.8
Life-saving Appliances and First aid Equipment
The Contractor shall provide and maintain upon- the Works sufficient, proper and efficient lifesaving appliances and first-aid equipment to the approval of the Engineer and in accordance with the requirements of ILO Convention No. 62. The appliances and equipment shall be available for use at all time
Page 65 of 69
8.2.9
Security Measures
(a)
Security arrangements for the work shall be in accordance with general requirements and the contractor shall conform to such requirements and shall be held responsible for the action or inaction on the part of his staff, employees and the staff and employees of his subcontractors.
(b)
Contractor's as well as Sub Contractor's employees and representatives shall wear identification Badges (cards), uniforms, helmets, gum boots and other Safety / protection gadgets / accessories provided by the Contractor. Badges shall identify the Contractor and show the employee's name and number and shall be worn at all times while at site.
(c)
All vehicles used by the contractor shall be clearly marked with the Contractor's name or identification mark
(d)
The contractor shall be responsible for security of works for the duration of the contract and shall provide and maintain continuously adequate security personnel to fulfill these obligations.. The requirements of security measures shall include but not be limited to, maintenance of Law and Order at site, provisions of all lighting guard, flagmen, and all other measures necessary for protection of works within the colonies, camps and elsewhere at site, all materials delivered to the site and all persons employed in connection with the works continuously throughout working and non-working periods including nights, Sundays and holidays, for the duration of the contract. However, at work sites in close proximity of traffic corridors where public and traffic are likely to come close to the work area, suitable barricading as proposed by contractor and approved by Engineer shall be provided.
(e)
No separate payment will be made for providing security measures and will be deemed to be included in the rates quoted by the contractor.
Contractor will have to comply the instructions circulated for Safety on Worksites Specially Doubling and Third line Works being implemented by RVNL, circulated vide RVNL's letter No. 2009/RVNUR/CC/Circular Dt. 10.02.2009 and letter of even No. Dt.12.03.10 and any subsequent instructions on this issue.
Page 66 of 69
CHAPTER 9.
APPENDIX
9.1
List of applicable regulations for Safety.
In addition, the construction works shall be undertaken in accordance with all applicable legislation and Indian statutory requirements listed below but not limiting to:
i) ii) iii) iv) v)
Indian Electricity Act 2003 and Rules 1956 National Building Code, 2005 Factories Act, 1948, Factories Rules. Motor Vehicles Act as amended in 1994 and The Central Motor Vehicles Rules, 1989. Indian Road Congress Code IRC: SP: 55-2001 Guidelines on Safety In Road Construction Zones.
vi) vii) viii)
The Petroleum Act, 1934 and Rules 1976 Gas Cylinder Rules, 2003 Indian Explosives Act. 1884, along with the Explosives substance Act 1908 and the Explosives Rules 1983
ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) xix) xx) xxi) xxii) xxiii) xxiv) xxv)
The (Indian) Boilers Act, 1923 The Public Liability Insurance Act 1991 and Rules 1991 Minimum Wages Act, 1948 and Rules 1950 Contract Labour Act, 1970 and Rules 1971 Child Labour (Prohibitions & Regulations) Act, 1986 and Rules 1950 Environment Protection Act, 1986 and Rules 1986 Air (Prevention and control of Pollution) Act, 1981 Water (Prevention and Control of Pollution) Act, 1974 The Noise Pollution (Regulation & Control) Rules, 2000 Notification on Control of Noise from Diesel Generator (DG) sets, 2002 Recycled Plastic Usage Rules, 1998 Notification, Central Ground Water Board, Act January 1997 Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989 The Hazardous Waste (Management & Handling) Rules, 1989 Hazardous Waste Management Rules 1989 (as amended in 1999) Fly ash utilization notification, Sept 1999 as amended in August 2003 Workman Compensation Act, 1923 along with allied Rules
The contractor shall ensure that all his employees / workmen are covered under Workmen Page 67 of 69
Compensation Act and shall pay compensation to his workmen as and when the eventuality tor the same arises.
Notwithstanding the above Act/Rules, there is nothing in those to exempt the contractor from the purview of any other Act or Rule in Republic of India for the safety of men and materials.
If the requirements stated in this document are less stringent than or in conflict with the country's applicable legislation, the latter shall apply.
9.2
Laboratory Testing Procedures. The standard procedures for conducting laboratory tests are provided separately in Appendix 2 with this Quality and Safety Plan.
9.3
Laboratory Test Result Formats. The standard laboratory test result formats are provided separately in Appendix 3 with this Quality and Safety Plan.
Page 68 of 69

QSP 19-10-12

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Construction of Roadbed, Major and Minor Bridges and Track Linking (Excluding Supply of Rails and Sleepers, Thick

QUALITY AND SAFETY PLAN (QSP)

5.3 5.4 5.5 5.6 5.7 5.8 5.9

5.10 5.11 5.12 5.13 5.14 5.15 Chapter 6.

APPENDIX ....................................................................................................................... 67 9.1 List of applicable regulations for Safety. .................................................................. 67

DOCUMENTATION AND DATA CONTROL

Quality Control Forms

Computer Aided Project Management System (CAPMS)

REQUEST FOR INSPECTION TO PROCEED AND FOR APPROVAL

1.10 CALIBRATION OF INSTRUMENTS AND EQUIPMENTS

1.11 DIAGNOSTIC AND CORRECTIVE ACTION

1.12 QUALITY AUDIT

QUALITY CONTROL PROCESS

Process Control Specifications

Pre Commencement Activities of a Construction Contractor

Construction Activities of Contractor

Analysis of a Problem by the PMC

2. Suggest remedial measures. 3. Ensure implementation of remedial measures.

Duties and responsibilities of PMC

The Consultant shall:

workmanship, compliance with the

Duties & responsibilities of PM

Duties & responsibilities of RE:

Duties and Responsibilities of Experts

QUALITY CONTROL DURING CONSTRUCTION

Request for Inspection (RFI)

NCR (Explanatory Note)

QUALITY CONTROL PROCEDURES

lower MDD than 1.7

4.14 LIST OF CODES AND SPECIFICATIONS

(i) INDIAN RAILWAY STANDARD CODES AND SPECIFICATIONS

(iii) INDIAN STANDARD SPECIFICATIONS

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

27. 28. 29. 30. 31. 32. 33. 34.

IS: 9103 IS: 516 IS: 4031 IS: 5513

80. 81. 82. 83.

IS: 2132 IS: 2131 IS: 1892 IS:14268

4.15 CERTIFICATION OF MATERIALS BY MANUFACTURER

QUALITY CONTROL OF STRUCTURAL CONCRTE

Quantity of concrete in work, m3 1-5 6-5 16-30 31 - 50 51 and above

QUALITY CONTROL FOR BRICK WORKS

QUALITY CONTROL OF ROAD WORKS

Sub-base and base:

Determination of density of compacted layer as per IS: 2720 (P28).

26.5 19.0 9.5 4.75

100 90 100 56.80 35 - 65

2.36 0.300 0.075

CHAPTER 8. SAFETY PROCEDURES

Working near running line:-

Damage to Railway Property or Life or Private Property

Life-saving Appliances and First aid Equipment

List of applicable regulations for Safety.

i) ii) iii) iv) v)

vi) vii) viii)

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