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PUBLIC WORKS DEPARTMENT,

HIMACHAL PRADESH (HPPWD)


QUALITY MANAGEMENT SYSTEMS
(ISO 9001: 2008)
(HPPWD Project Reference No.: - PW-SRC/RIDC/Procurement-ISO/2008)

CONSTRUCTION MANUAL
(WORK INSTRUCTIONS)
BRIDGE CONSTRUCTION
HIMACHAL PRADESH ROADS & INFRASTRUCTURE DEVELOPMENT
CORPORATION LTD (HPRIDC)
States Roads Project, Nirman Bhawan
Nigam Vihar, Shimla 171002
Tel No.: 0177-2627602

Issue No: 01
Review & Issue By:

Rev No. 00
Approved By:

Project Director(MR)

MD/ Secretary

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

TABLE OF CONTENTS
Title

Page No.

Chapters
AMENDMENT SHEET .......................................................................................................... i
1.
INTRODUCTION ...................................................................................................1-1
2.
CLASSIFICATION OF BRIDGES..........................................................................2-1
2.1.
Planning and investigation.....................................................................................2-1
2.2.
Designs ..................................................................................................................2-3
2.3.
Detailed Project Report .........................................................................................2-3
2.4.
Tender....................................................................................................................2-4
2.5.
Contract Management ...........................................................................................2-5
3.
PROCESS FLOW FOR BRIDGE CONSTRUCTION ...........................................3-1
4.
QUALITY PLAN FOR BRIDGE / CROSS DRAIN.................................................4-1
4.1.
Background............................................................................................................4-1
4.2.
Scope .....................................................................................................................4-1
4.3.
Abbreviations and Definitions ................................................................................4-1
4.4.
References.............................................................................................................4-2
4.5.
Planning of Bridge / Cross Drain Projects.............................................................4-2
4.6.
Original Construction / Maintenance .....................................................................4-3
5.
QUALITY ASSURANCE REQUIREMENTS FOR BRIDGES ...............................5-1
5.1.
Project Report Preparation ....................................................................................5-1
5.2.
Material Controls....................................................................................................5-1
5.3.
Process Controls ...................................................................................................5-1
6.
QUALITY PROCESS FOR MAINTENANCE OF BRIDGES.................................6-1
6.1.
Annual Maintenance / Ordinary Repairs / Routine Maintenance .........................6-1
6.2.
Periodic Maintenance ............................................................................................6-1
6.3.
Special Repairs......................................................................................................6-1
6.4.
Survey Report ........................................................................................................6-2
7.
NON-CONFORMANCE (NC) AND CORRECTIVE ACTIONS .............................7-1
7.1.
Typical NCs with Product: Concrete / Asphalt work .............................................7-1
8.
TEST PLANS AND CHECKLISTS ........................................................................8-1
8.1.
Test Plan for Cement.............................................................................................8-1
8.2.
Test Plan for Coarse Aggregate............................................................................8-2
8.3.
Test Plan for Fine Aggregate ................................................................................8-3
8.4.
Test Plan for Water for Construction .....................................................................8-4
8.5.
Test Plan for Sheathing .........................................................................................8-5
8.6.
Test Plan for Epoxy Paint ......................................................................................8-6
8.7.
Test Plan for Elastomeric Bearings .......................................................................8-7
8.8.
Test Plan for Pot Bearings.....................................................................................8-8
8.9.
Test Plan for Chemicals for Anti Corrosive - Treatment (CECRI) ........................8-9
8.10. Test Plan for Fusion Bonded Epoxy Coating (FBEC).........................................8-10
8.11. Test Plan for Reinforcement Steel (HYSD).........................................................8-11
8.12. Test Plan for Steel for Pre-Stressing...................................................................8-12
8.13. Test Plan for Steel for MS Liner ..........................................................................8-13
8.14. Test Plan for Elastomeric Expansion Joint (Strip Seal) ......................................8-14
8.15. Checklist for Pile Foundations .............................................................................8-15
8.16. Checklist for Pile Foundations .............................................................................8-18
8.17. Checklist for Pile Cap ..........................................................................................8-19
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8.18. Checklist for Formwork ........................................................................................8-20


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

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

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AMENDMENT SHEET

Sl. No.

Document

Description of Change

Page/
Para.
No.

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1.

INTRODUCTION

This manual intends to provide guidance to the HPPWD engineers in their


functions of investigation, designs, estimation inspection and assurance of quality
of construction and maintenance. It helps in the vendor control and gradation of
contractors and is expected to aid in structured Quality Assurance activities of
HPPWD.
Bridge construction is dependent on several challenges, right from selection of the
terrain, soil conditions, materials, methods, type and design of construction to
supervision and assurance of quality in construction of new approach roads and
maintenance of the same after the area is acquired.
The enclosures would provide typical process flow of road construction, Quality
Assurance requirements, test plans for Quality checks of materials used in
construction and teats and test report Performa for presentation of test results.
The checklists are the Level III documents of an established Quality Management
System (QMS) as per ISO 9001:2008. The Quality Plan drawn up highlights on
the process controls necessary for product realization and improvements. It is
intended to help the internal auditors while carrying out audits of the implemented
QMS of HPPWD.
This document is an important adjunct to the Procedure Manual (Level II)
document and takes into consideration the existing practices and codal needs of
HPPWD. The formats to be used are the same as necessary for the QMS and the
departmental code.
For easy reference to the contents of the manual the following process has been
adopted:
BCM refers to Bridge Construction Manual.
TP refers to Test Plan
CL refers to various Check list for process control.
The test plans are identified as BCM/TP XX refers to the Serial No. of Test plan,
similarly BCM/CL XX refers to the Serial No. of checklist as applicable. The test
plan and checklist should be considered as work instructions necessary for
construction and maintenance of Bridge.
The typical tests and test Performa are given in separate chapters for the purpose
of guidance to the site engineer, quality control staff and also the contractors.

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2.

2.1.

CLASSIFICATION OF BRIDGES

Type of Bridge

Length

Details

Culverts

up to 6m

Bridge structure with a


lineal waterway.

Minor Bridge

6 m- 60 m

On stable rivers and


canals

Major Bridge

more than 60 m

On major river or
tributaries, which are
shifting in nature.

Planning and investigation

2.1.1. Planning
Following factors are taken into consideration:
The need for the structure and its location.
The traffic that will pass over the structure on completion and in future (in
respect of the volume of traffic as well as the axle/wheel load.).
Characteristics of the river / stream / canal.
Subsoil condition.
Construction problems that may arise.
Cost and economics. (including land acquisition).
Alternative sites either by longitudinal shifts of the proposed structure or by
lateral shift of the alignment itself.
2.1.2. Investigation
Techno feasibility study.
Techno economic study.
Detailed survey and project report.
2.1.2.1

Techno Feasibility Study


Selection of Site
o
o
o

Entire reach of the river within the area to be inter-connected are studied
to find out sites which satisfy various conditions for location a bridge
No. of factors each site satisfy are listed and the site which satisfy the
most are selected for further consideration.
Maps are studied to choose sites that appear suitable for locating the
bridge. Choice is narrowed down to three/ four alternative sites. It also
includes gathering information on behaviour of river at sites by studying
available reports.
A detailed assessment of construction problems that can affect its
feasibility, cost and duration of construction.

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2.1.2.2

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

2.1.2.3

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

Traffic surveys and analysis


o
o
o
o
o
o
o

Classified traffic volume survey.


Origin-destination studies.
Speed and delay studies.
Survey for design of Bridge/Cross Drain junctions, Bridge/Cross Drain over
/ under bridges, etc.
Axle load studies.
Accident records.
Traffic projection (for approx. 30 years).

Geographical survey
o
o
o
o

Study of maps and survey sheets.


Study of GIS information.
Detailed ground survey.
Hydrological data collection and survey.

Environmental impact studies


o
o
o

Environmental impact assessment.


Environmental management action plan.
Resettlement and rehabilitation action plan.

Soil surveys
o
o
o
o
o
o

Study of secondary data.


Soil investigation for low embankments.
Special investigation for high embankments.
Soil investigation for cut sections.
Special investigation for land-slide-prone area.
Soil exploration for determining nature of Foundation and carrying out
model/studies.

Drainage studies
o
o
o

Objectives.
High flood level (HFL).
Depth of water table.

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o
o
o

Pounded water level.


Special investigation for cut-sections.
Surface run-off.

Cost benefit
o

Return on investments worked out in more precise terms.


(Benefits by the way of savings or additional earnings)

Investigation for major /Important bridge with waterway of > or=60 m


o
o
o
o
o
o
o

o
o
o

2.2.

Topographical Details.
Catchment area and its characteristics.
Hydrological particulars.
Geo-tech. Details.
Seismology of the area.
Navigational requirements.
Construction Resources:
(i)

Land availability and acquisition.

(ii)

Labour.

(iii)

Material.

(iv)

Habitation and accommodation.

(v)

Water and power.

(vi)

Existing transport and Communication infrastructure.

Important details of nearest bridge across the same river or stream and its
history.
Traffic Present and future trend.
Alternative routes and modes available.

Designs
Detailed pavement design.
Cross Drains design.
Side Drains design.

2.3.

Detailed Project Report

2.3.1. Survey Details


Longitudinal section.
Cross Section.
Earthwork calculations for embankment if any.
2.3.2. Design and Drawing Details
A plan of the proposed structure 1:100 to 1:200.
A Cross Section of the structure also showing the ground profile at the
foundation level both HFL and LFL to the same scale.
A part of elevation and part section along the centerline of the bridge.
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A site plan to the scale 1:1000 or 1:2000.


A cross section to half front elevation along the alignment showing the ground
profile and containing a section through the trial pit at the chain age.
The catchments area map (for major bridge only).
2.3.3. Estimate Details
It is based on Current Schedule of Rates (CSR) applicable for respective Circles.
It includes.
General report detailing about present condition of the road, connectivity,
proposed improvements.
Inspection Certificate by AE and EE.
Abstract detailing name of the work and estimated cost.
Detailed Estimate describing items, units, quantity, rate amount, etc.
Sub-estimates.
Rate Analysis.
Plans.
Index Map.
Bar chart for existing Road condition.
Bar chart for proposed improvements.
Recapitulation sheet.
2.3.4. Other Documents

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

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


Submission of the project report (detailing salient features of bridge, its
estimated cost, and cost benefit ratio, etc.) by EE to EE and subsequent
authorities in accordance with the Delegation of financial powers for
Administrative Approval.
After administrative approval the Project report will be submitted to the
concerned authority for Technical Sanction in accordance with the Delegation
of financial powers.
Upon accord of technical sanction by competent authority, Division initiates the
next activity of tendering.

2.4.

Tender
Notification for Inviting Tenders (NIT)
Preparation of Draft Tender Papers
o
o

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

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Preparation of schedule B.

Tender Documents Shall Contain


o
o

Technical specifications.
Commercial conditions.

Supply of Tender Documents


Clarification of Tender Documents
o
o
o

Scope of Tender.
Eligibility criteria.
Amendment of Tender documents.

Receipt of Tenders and Tender Opening


Tender Evaluation to be in Accordance with Evaluation Criteria
Preparation of Evaluation Report and Award of Contract
Handing Over of Site to the Contractor

2.5.

Contract Management
Supervision
o

Product and process.

Product Inspection
o

Materials, Equipments, finished product.

Control of Materials
o
o
o

Testing of material for source approval.


Inspection and certification of materials on receipt.
Testing of materials going into construction.

Equipments
o
o

Test frequencies and calibration schedule.


Handling by skilled manpower.

Process Inspection
o

Workmanship, procedures.

Workmanship
o
o

Competent manpower.
Safety.

Procedures
o
o
o

Specifications.
Departmental Codes.
Quality Management Procedures.

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3.

PROCESS FLOW FOR BRIDGE CONSTRUCTION


Requirement from concerned dept

Line Estimation

Scrutiny by CA, TC

Appear in
the budget?

Y
Administrative Approval

Approved?

Y
Preparation of Designs
and detailed estimates

Administrative Approval

Approved?

Y
Tendering and Award of Contract

Execution and Supervision

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4.
4.1.

QUALITY PLAN FOR BRIDGE / CROSS DRAIN

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

4.2.

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

4.3.

Abbreviations and Definitions

4.3.1. Abbreviations
IRC- Indian Roads Congress
DTS-Draft Tender Schedule

No. Number
Divn- Division

Ref. Reference
NC- Non Conformance

4.3.2. Definitions
4.3.2.1

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

4.3.2.2

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

4.3.2.3

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

4.3.2.4

Non-Conformity
Non-fulfillment of specified requirements.

4.3.2.5

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

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by the government in the public works department or by such authorities of the


department to whom the power has been delegated by government. Sanction
accorded to a work by any other department of government is regarded as an
administrative approval of the work.
4.3.2.6

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

4.3.2.7

4.4.

Technical Sanction
For estimate of original work

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

References
ISO 9000:2005 Fundamentals and Vocabulary,
IRC, MOSRTH.

4.5.

Planning of Bridge / Cross Drain Projects


BRIDGE/CROSS DRAIN

Maintenance

Original
Construction

Annual
Maintenance

Periodical
Maintenance

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4.6.

Original Construction / Maintenance

1.

Public Representation.
Typical Letter for Public Representation: From Public / Elected representative
(Annexure I).
Feasibility study by Division
Economic profile and analysis.
Traffic survey.
Preliminary Topographical survey.
Soil survey and Drainage studies.
Initial pavement designs.
Land acquisition estimate.
Traffic analysis and projection.
Line estimate for detail investigation.
Typical Covering Letter from Division to division (Annexure II).
Proposal scrutinized by EE and submission to SE.
Proposal scrutinized by SE and submission to CE.

2.

3.
4.
5.

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


delegated).
6.
7.
8.
9.
10.
11.
12.
13.
14.

EE/SE/CE submits proposal to Govt. for sanctioning the amount towards detail
investigation.
Upon receiving the amount for detail investigation to Division, EE instructs the
Division to carry out the activity.
Based on the investigation results, designs are prepared.
On the basis of designs and by referring to current schedule of rates, applicable to
concerned Circle, detailed estimate is prepared.
Detailed Project Report is submitted by Division to Technical Committee
(TC)/Board of directors.
TC/BOD scrutinizes all the proposals (complete in all aspects) received from
various Divisions.
TC/BOD prioritizes proposals on the basis of need of the project for inclusion in
the budget.
Upon approval from the Govt. (inclusion in the Budget), TC/BOD intimates the
concerned Division accordingly.
The proposals which do not appear in the current budget due to financial
reasons are stored by TC/BOD, for including in the budget of next year by revising
Plans and Estimates.

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5.
5.1.

QUALITY ASSURANCE REQUIREMENTS FOR BRIDGES


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

5.2.

Material Controls
Testing of materials Aggregates coarse, fine, components (base, sub-base,
pavement, shoulders).
Test methods, Acceptance limits.
Sampling and Frequency of testing.
Availability of equipment Monitoring and measurement.
Reports of test results, calibration.

5.3.

Process Controls
Alignment Controls for approach roads Edges, carriageway, horizontal
alignment, vertical profile, pavement thickness.
Road embankment Grade, sub base and fill.
Grain size, Plasticity Index, of materials, moisture content, density.
Sampling and frequency of testing, Test methods, testing equipment,
calibration.
Tests on finished profile.
Granular Base course laying.
o Material testing (Gradation, sizing, aggregate impact values, density).
o Frequency and sampling.
o Test equipment and test methods.
o Tests on surface profile (slope and evenness).
Bituminous Pavement laying.
o Tests on aggregates, bitumen, mix grading.
o Temperature and rate of application of prime and tack coating.
o Temperature for mixing, laying and compaction of bitumen mix.
o Core sampling, assess for density, voids.
o Tests on surface profiles, evenness, slope of the finished pavement.
Cement Concrete (CC) Pavements.
o Tests on aggregates (for the base and paving).
o Tests on cement.
o Tests on Cement Concrete mix, (both in-situ and laboratory).
o Tests on cores.
o Tests on concrete for Cross Drainage.

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6.

QUALITY PROCESS FOR MAINTENANCE OF BRIDGES

The basic objective of a maintenance activity is to ensure safety and meeting


customer requirements. The Quality Assurance activities assure that the
maintenance activities are performed as per plans. Towards this, a calendar is
drawn up at the beginning of the year for both preventive and annual maintenance
of all assets- bridges. A typical maintenance plan is given below:
Maintenance

Annual
Maintenance

6.1.

Periodic (preventive)
Maintenance

Special repairs
(Corrective actions)

Routine
Maintenance

Annual Maintenance / Ordinary Repairs / Routine Maintenance


It includes following nature of works

6.2.

Upkeep of bridges (whitewashing, painting etc).


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

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

6.3.

Special Repairs
It covers damages occurred due to unforeseen / natures calamity.
The process maintenance of Bridge needs a system approach to be followed
involving a series of sequential operations.
Detailed assessment of the present Bridge condition.
Diagnosis of the problem.
Selection of the most appropriate treatment.
This systematic approach enables a clear understanding of determination of
priorities more objectively and allotment of available resources where they are
most needed.
The first step in planning a maintenance operation is to know the existing bridge in
terms of physical condition, structural capacity, surface etc. The following data are
required to be collected. The various inputs are:
Strip map.

Procedure No.: QMS/WI/BC-06/Quality Process for Maintenance of Bridges


Controlled Document

Page No.: BC/6-1

Issue 01, Rev 00

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Surface history.
List of bridges - Major / Minor Bridges.
Condition survey.
Condition surveys at fixed frequency are necessary for determining periodic
renewal requirements and long-term maintenance strategy.

6.4.

Survey Report

Type of
bridge
( Major/Minor)

Routine

Special

Routine

Special

Inspected by:

Routine

Special

Approved by:

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

Procedure No.: QMS/WI/BC-06/Quality Process for Maintenance of Bridges


Controlled Document

Page No.: BC/6-2

Issue 01, Rev 00

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

7.
7.1.

NON-CONFORMANCE (NC) AND CORRECTIVE ACTIONS


Typical NCs with Product: Concrete / Asphalt work

7.1.1. Non-Conformance with Strength Requirements


The specification strength/density for concrete /asphalt recognizes the
statistical possibility of cube failures and thus limits of means, standard
deviation and minimum value of strength are specified. The rejection criteria
are set out in the agreement.
In the event of cube/ density failures outside the provision of the contract then:
(a).

Approval of concreting/asphalting of similar works shall be withheld.

(b).

All aspects of concreting/asphalting shall be reviewed.

(c).

The causes of failure shall be identified and measures taken to remedy


the problem.

7.1.2. Non-Conformance Other than Strength or Finish


Issue of a letter stating the facts and confirming that the works are not
approved.
Approval to carry out concreting/asphalting of a similar nature shall be with
held.
The Contractor shall be asked for his proposals to rectify the non-compliance,
which may involve re-submission of materials, new trial mixes, revised method
statement.
7.1.3. Non-Conformance with Finishing Requirements
Where the required finish is not attained then:
(a).

Approval of similar work shall be withheld.

(b).

All aspects of work shall be reviewed.

(c).

The cause of poor finis shall be identified.

(d).

Revised specifications/instructions to avoid further recurrence of nonconformance shall be issued.

Procedure No.: QMS/WI/BC-07/Non-Conformance (NC) and Corrective Actions


Controlled Document

Page No.: BC/7-1

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Annexure I. : Typical Letter for Public Representation


Date:
To
The Executive Engineer
<Tehsil> Division,
PIN.Sir,
Sub: Submission of proposal (Strike out the non-applicable products)
Ref.:
I am/ We are hereby submitting a proposal in the prescribed format attached
herewith for construction / Improvement / Maintenance of Bridge /Cross Drains /
Buildings / Culverts / Pavedip / causeway / others.
I / We hope this proposal will be considered for necessary approval from
Government and work will be taken up at the earliest.
Thanking you.

Yours truly,

Enclosure:
1. Performa of Bridge/Cross Drain (Appendix I).
2. Bridge (Appendix II).

Procedure No.: QMS/WI/BC/Annexures


Controlled Document

Issue 01, Rev 00


Page No.: BC/AN.I-1

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


No./EE- <Sub-div>/Case worker/ Subject / File No. / Year / Dispatch No. /
Dispatch Date
Date:
To
The Executive Engineer
<>District>
PIN.
Sir,
Sub: Proposal for (Tick mark the applicable)
Bridge/Cross Drain / Bridge under <Head of account>
Ref.: Public Representation dated I am hereby submitting a proposal for construction / Improvement / Maintenance
of Bridge/Cross Drains / Culverts / Pave dip / causeway / others in the prescribed
format attached herewith.
I hope this proposal will be considered for necessary approval from Government
and work will be taken up at the earliest.
Thanking you.
Yours truly,

Executive Engineer
Sub- Division
Enclosure:
1. Checklist for Bridge/Cross Drain (Appendix III).
2. District Map.
3. Tehsil Map.
4. Copy of Representatives Letter, if any.

Procedure No.: QMS/WI/BC/Annexures


Controlled Document

Issue 01, Rev 00


Page No.: BC/AN.II-1

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Annexure III. : Typical Routine Inspection Performa for Maintenance of Bridge


Sl.
No.
1.
2.
3.

4.

5.
6.
7.

Particular action to be
taken
Jungle Clearance
Side drains
Shoulder and Edge
Correct camber
Correct Edges
Pot holes
Erosion cuts
Drain cuts
Carriageway
Fill patches
Fill pot holes
Grit for bleeding
Renewal needed
CD Works
Encroachment details
Road furniture Sign boards
Km and Hectometer
- Stones
Pavement markings
Speed Breaker

8.

Cleaning and repairs of


Bridge/CD proper.

9.

Repair/replacement of
bearings and
expansion joints.
River/Drain training and
Clearing the vents.

10.
11.

Repairs to approaches
/ Embankments.

12.

Repairs to aprons.

13.

White washing/Painting
Parapets /Handrails.

14.

Visual checks for


vegetation, cracks etc.

Chain
age -100

KM 101

KM-102

KM -103

Procedure No.: QMS/WI/BC/Annexure


Controlled Document

KM - 104

Issue 01, Rev 00


Page No.: BC/AN.III-1

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


Sl.
No.
1.
2.
3.
4.

Items
Cleaning and repairs of Bridge/CD
proper.
Repair/replacement of bearings
and expansion joints.
River/Drain training and Clearing
the vents.
Repairs
to
approaches
/
Embankments.

5.

Repairs to aprons.

6.

White washing/Painting Parapets


/Handrails.
Visual checks for vegetation,
cracks etc.

7.

AprJun

JulySep

OctDec

JanMar.

X
X

Procedure No.: QMS/WI/BC/Annexures


Controlled Document

Remarks

Issue 01, Rev 00


Page No.: BC/AN.IV-1

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Appendix I. : Performa for Bridge / Cross Drain


1. Name of the Bridge/Cross Drain:
2. Length in Km:
3. Present condition of Bridge/Cross Drain:
4. Improvements required:

Procedure No.: QMS/WI/BC/Appendixes


Controlled Document

Issue 01, Rev 00


Page No.: BC/AP.I-1

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Appendix II. : Performa for Bridge


1. Name of the Bridge:
2. Location of the Bridge:
3. Reason for construction of Bridge:
4. Period of traffic interruption:
5. If proposed for repairs(a).

Present condition of Bridge:

(b).

Cause of damage

(c).

Improvements required:

Procedure No.: QMS/WI/BC/Appendixes


Controlled Document

Issue 01, Rev 00


Page No.: BC/AP.II-1

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


Sl.
No
1.
2.
3.
4.
5.
6.
7.

8.

9.
10.
11.
12.

13.
14.
15.
16.
17.
18.

Particulars

Project 1

Project 2

Project 3

Name of District
Name of Tehsil
Name of constituency
Name of proposed
Bridge/Cross Drain
Category of Bridge/Cross
Drain
Total length of
Bridge/Cross Drain
Length of the Bridge/Cross
Drain proposed for
improvement
Estimated cost Rs. in
Lakhs
Based on the SR for the
year.
Estimated cost for detailed
investigation
Villages benefited
Population benefited
Traffic intensity / census
year
Surface condition of
existing Bridge/Cross
Drain

WBM
From
To

WBM
From
To

WBM
From
To

BT
From
To

BT
From
To

BT
From
To

Proposed improvements
Name of the
representative
Priority level *
Justification
Remarks
Note: Priority Levels *
(a).

Top priority

Bridge/Cross Drains which are badly damaged i.e. traffic


interruption is more than half an hour and having WBM surface.
If the Bridge/Cross Drain is SH and connecting pilgrimage centre.

Procedure No.: QMS/WI/BC/Appendixes


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Page No.: BC/AP.III-1

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

(b).

Medium priority

(c).

Bridge/Cross Drains which are asphalted but badly damaged


traffic interruption is more than half an hour.
If the Bridge/Cross Drain is MDR or motorable and creating
shortcut.

Low priority

Bridge/Cross Drains, which are asphalted but require minimum


improvements.
If it is MDR and traffic intensity is low.

Procedure No.: QMS/WI/BC/Appendixes


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Page No.: BC/AP.III-2

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.
8.1.

TEST PLANS AND CHECKLISTS

Test Plan for Cement


BCM/TP 01

Name of Work :
Agreement No.:

Sanction No. and date:


Estimated Cost :

Sl.No Test/Parameter

Acceptance
Standard

Sampling criteria

Acceptance Criteria

1.

Physical and Chemical Test

IS 4031

As per IS

Conformance to the tests

2.

Ordinary Portland cement 33 Grade

IS 269

Each consignment

Conformance to specification

3.

Portland slag cement

IS 455

Each consignment

Conformance to specification

4.

Portland Pozzolana Cement

IS 1489

Each consignment

Conformance to specification

5.

Rapid Hardening Portland cement

IS 8041

Each consignment

Conformance to specification

6.

Ordinary Portland cement 43 Grade

IS 8112

Each consignment

Conformance to specification

7.

Ordinary Portland cement 53 Grade

IS 12269

Each consignment

Conformance to specification

8.

Sulphate Resistant Portland cement

IS 12330

Each consignment

Conformance to specification

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.2.

Test Plan for Coarse Aggregate


BCM/TP 02

Name of Work :
Agreement No.:
Sl.No Test/ Parameter

Sanction No. and date:


Estimated Cost :

1.

Los Angeles (LA) Abrasion Value

Acceptance
Standard
IS2386 (Pt 4)

Sampling
size
One

Frequency of Test

Acceptance Criteria

monthly

Conformance

2.

Soundness

IS2386 (Pt 5)

One

monthly

Conformance

3.

Alkali-Aggregate Reactivity

IS2386 (Pt 7)

One

monthly

Conformance

4.

Gradation

IS2386 (Pt 1)

One

Daily

Conformance

5.

Deleterious Constitutions

IS2386 (Pt 2)

One

Daily

Conformance

6.

Water Absorption

IS2386 (Pt 3)

One

Daily

Conformance

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

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


Controlled Document

Issue 01, Rev 00


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.3.

Test Plan for Fine Aggregate


BCM/TP 03

Name of Work :
Agreement No.:

Sanction No. and date:


Estimated Cost :

Sl. Test/Parameter
No.
1.
Gradation

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

Frequency of
Test
Daily

Sample size

Acceptance Criteria

One/ lot

Conformance

2.

Deleterious material

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

Daily

One/ lot

Conformance

3.

Water absorption

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

Daily

One/ lot

Conformance

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


Controlled Document

Issue 01, Rev 00


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.4.

Test Plan for Water for Construction


BCM/TP 04

Name of Work :
Agreement No..:
Sl.No Test/Parameter
1.
pH Value
2.

Sanction No. and date:


Acceptance Standard
MOSRTH clause 1010
IRC 21:2000, Clause 302.4

Permissible
solids
(Organic, MOSRTH clause 1010
Inorganic Sulphates, Chlorides)

Sample size

Acceptance Criteria

One

Conformance

One

Conformance

Sample size
One per Source

Acceptance Criteria
Conformance

One per Source

Conformance

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

Sl.No Test/Parameter
1.
pH Value
2.

Acceptance Standard
MOSRTH clause 1010
IRC 21:2000, Clause 302.4

Permissible
solids
(Organic, MOSRTH clause 1010
Inorganic Sulphates, Chlorides)

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Issue 01, Rev 00


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.5.

Test Plan for Sheathing


BCM/TP 05

Name of Work :
Agreement No..:

Sanction No. and date:


Estimated Cost:

Sl.
No.
1.

Test/Parameter

Acceptance Standard

Sample size and Frequency of Test

Acceptance Criteria

Workability

IRC-Appendix 1800/1

One per lot/not exceeding 7000metre

Conformance

2.

Transverse load rating test.

IRC-Appendix Table-1

One per lot/not exceeding 7000 m

Conformance

3.

Tensile load test.

IRC-Appendix Table-2

One per lot/not exceeding 7000 m

Conformance

4.

Water loss test

IRC-Appendix Table-2

One per lot/not exceeding 7000 m

Conformance

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Issue 01, Rev 00


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.6.

Test Plan for Epoxy Paint


BCM/TP 06

Name of Work :
Agreement No.:

Sanction No. and date:


Estimated Cost :

Sl.
No.
1.

Test/Parameter

Acceptance Standard

Acceptance Criteria

As per IS

Sample size and Frequency of


Test
One sample per lot

Salt Spray

2.

Scratch hardness

As per IS

One sample per lot

Conformance to spec

3.

Adhesion

As per IS

One sample per lot

Conformance to spec

4.

Ultra violet Resistance test.

As per IS

One sample per lot

Conformance to spec

5.

Water absorption

As per IS

One sample per lot

Conformance to spec

6.

Pot life

As per IS

One sample per lot

Conformance to spec

7.

Chemical resistance.

As per IS

One sample per lot

Conformance to spec

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


Controlled Document

Conformance to spec

Issue 01, Rev 00


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.7.

Test Plan for Elastomeric Bearings


BCM/TP 07

Name of Work :
Agreement No.:
Sl. Test/Parameter
No.

Acceptance Standard

Sanction No. and date:


Estimated Cost :
Sample size
Acceptance Criteria

1.

Properties of Elastomer

2000.1, IRC 83 (Part 2): 1987,


Appendix 918.4.2

One sample for a lot of 20


bearings

Conformance

2.

Manufacturing Defects

2005.3.3.1

Each

Conformance

3.

Axial load test.

2005.3.3.1

Each

Conformance

4.

Other Characteristics

IRC 83 (Part 2): 1987, Appendix


918.4.2
918 acceptance levels I and II

Each

Conformance

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.8.

Test Plan for Pot Bearings


BCM/TP 08

Name of Work :
Agreement No..:

Sanction No. and date:


Estimated Cost:

Sl.
No.

Test/Parameter

8.8.1. Acceptance Standard

1.

Over all dimensions

Project Specific

2.

Load test

Cl.2006.5.4 MOSRTH

3.

Cl.2006.5.4 MOSRTH

4.

Determination of coefficient of
friction
Permissible rotation

Cl.2006.5.4 MOSRTH

5.

Acceptance Tests

Cl.2008 MOSRTH

Sampling Size

Each
Each
One pair of randomly selected
Sample
One pair of randomly selected
Sample
One pair of randomly selected
Sample

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


Controlled Document

Acceptance Criteria

Conformance of the lot


Conformance of the lot
Conformance of the lot
Conformance of the lot
Conformance of the lot

Issue 01, Rev 00


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.9.

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


BCM/TP 09

Name of Work :
Agreement No..:

Sanction No. and date:


Estimated Cost:

Sl. Test/Parameter
No.

Acceptance Standard

Sampling Size

Acceptance Criteria

1.

De-rusting solution
(Chemical composition)

Indian patent No. 465

One per lot

Conformance

2.

Phosphate jelly
(Chemical composition)

Indian patent No. 109879

One per lot

Conformance

3.

Inhibitor solution
(Chemical composition)

Indian patent No. 109784/67

One per lot

Conformance

4.

Sealing solution
(Chemical composition)

Indian patent No. 112440/67

One per lot

Conformance

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

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


BCM/TP 10
Name of Work :
Agreement No..:

Sanction No. and date:


Estimated Cost:

Sl.
No.

Test/Parameter

Acceptance Standard

Sample size

Acceptance Criteria

1.

Chemical composition

IS

One per lot

Conformance

2.

Thickness

174 + 50 microns

Minimum two bars of each size


from each production shift.

Conformance

3.

Continuity

Visual

Random for coating

Conformance

4.

Adhesion

Bend test

At least one bar of each size


from each production shift.

Conformance

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

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


Controlled Document

Issue 01, Rev 00


Page No.: BC/8-10

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.11. Test Plan for Reinforcement Steel (HYSD)


BCM/TP 11

Name of Work :
Agreement No..:

Sanction No. and date:


Estimated Cost:

Sl.
No.
1.

Test/Parameter

Acceptance Standard

Tensile strength

2.

Elastic modulus

3.

Elongation stress

IS 1786
(415 MPa)
IS 1786
(200 GPa)
IS 1786

4.

Proof stress

IS 1786

5.

Bend Test

IS 1786

Sample Size
One per lot
One per lot
One per lot
One per lot
One per lot

Acceptance Criteria
Conformance
Conformance
Conformance
Conformance
Conformance

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

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Issue 01, Rev 00


Page No.: BC/8-11

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.12. Test Plan for Steel for Pre-Stressing


BCM/TP 12
Name of Work :
Agreement No..:

Sanction No. and date:


Estimated Cost:

Sl. Test/Parameter
No.
1.
Characteristic strength

Acceptance Standard

Sample Size

Acceptance Criteria

IS 14268: 1995

One per lot

Conformance

2.

Elastic modulus

IS 14268: 1995

One per lot

Conformance

3.

Elongation

IS 14268: 1995

One per lot

Conformance

4.

Proof stress

IS 14268: 1995

One per lot

Conformance

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.13. Test Plan for Steel for MS Liner


BCM/TP 13
Name of Work :
Agreement No.:

Sanction No. and date:


Estimated Cost:

Sl.
Test/Parameter
No.
1.
Diameter

Acceptance Standard

Sample Size

As per item of work

One liner/ hundred RMT

Conformance to the specification

2.

Thickness

As per item of work

One liner/ hundred RMT

Conformance to the specification

3.

Tensile strength

IS220

One per lot

Conformance to the Grade specified

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


Controlled Document

Acceptance Criteria

Issue 01, Rev 00


Page No.: BC/8-13

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


BCM/TP 14
Name of Work :
Agreement No.:

Sanction No. and date:


Estimated Cost:

Sl.
No.
1.

Test/Parameter

Acceptance Standard

Sample Size

Acceptance Criteria

Edge beams
a) Weldability.
b) Notch toughness.

Rst37-2 , IS 2062

One per lot

Conformance

2.

Strip seal
a) Tear strength

Clause 915.1 of IRC.83 (Part-II)


Table No. 2600-1. of MOSRTH
specification

One per lot

Conformance

IS 2062

One per lot

Conformance

b) Other properties of
Chloroprene of strip seal.
3.

Anchorages / loop Weldability

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

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


Controlled Document

Issue 01, Rev 00


Page No.: BC/8-14

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.15. Checklist for Pile Foundations


BCM/CL 01
Name of work:
Agreement No.:
Sl.
Particular
No.
1.
2.
3.
4.

5.
6.

7.
8.

Estimated cost :
Sanction No. and date:
Remarks (Y/N/NA Observation if any)

Date
Location /Chainage/ Description of
work.
Execution Check is complete.
If yes, Date and Reference.
MS Liner driven as per conditions of
strata met and the level recorded
The joints of casing are made as tight
as possible to minimise inflow of
water or leakage of slurry during
concreting.
Rock Strata identified and level
recorded.
refer F.B.No. ---Page No. --Adequate socketting in founding
strata obtained and levels recorded.
If Yes, refer F.B.No.--Page No. -Refer PILE F-1
Founding strata approved.
Refer FILE F-2
The shaft is clean of all loose
materials prior to the lowering of the
re-enforcement cage.

/200

/200

/200

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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/200

/200

/200

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of work:
Agreement No.:
Sl.
Particular
No.
9.
10.
11.

12.

13.

14.
15.
16.

Estimated cost :
Sanction No. and date:
Remarks (Y/N/NA Observation if any)

Date
The cover to reinforcing steel is
maintained by suitable spacers.
Concreting under water for cast-insitu piles is done by tremie method.
The finishing of bore, cleaning of
bore, lowering of reinforcement cage
and concreting of pile for full height is
accomplished without any stoppage
in
one
continuous
operation
(MOSRTH Clause 1107).
The first charge of concrete is placed
with sliding plug pushed down the
tube ahead of it to prevent mixing of
water and concrete.
The tremie pipe always penetrates
well into the concrete with adequate
margin of safety against accidental
withdrawal
The Quality Checks exercised during
concreting.;
Additional observation, if any.

/200

/200

/200

/200

/200

/200

Conclusion by inspecting officers


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

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Name of work:
Agreement No.:
Sl.
Particular
No.

17.
18.

Estimated cost :
Sanction No. and date:
Remarks (Y/N/NA Observation if any)

Date
report the corrective action taken and
inform for re-inspection.
Contractor's/ Authorized
Representative Name, Designation
and Signature.
Inspecting Officer Name Designation
and Signature.

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.16. Checklist for Pile Foundations


BCM/CL 02
Name of work:
Agreement No.

Estimated cost :
Sanction no. and date:

8.16.1. PILE F-1


8.16.1.1 Chiseling Record
Date Pile
Top ref. line of
No.
Hard Strata

Weight of
Chisel

Duration of
Chiseling

Height of Fall

Penetration
achieved

Socketing
achieved

SBC of founding
strata

Signature of
Contractor

Signature of
Contractor

Signature of
SO

8.16.2. PILE F-2


8.16.2.1 Foundation Approval
Date Pile
Top Ref. Line
Founding
No.
of Hard Strata Ref. Line

Signature of S.O.

Signature
of EE/ EE

8.16.3. PILE F-3


8.16.3.1 Measurement of Tilt / Shift
Date Pile No.
Tilt in mm.

Shift in mm.

Signature of Contractor

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Signature of S.O.

Remarks

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Page No.: BC/8-18

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.17. Checklist for Pile Cap


BCM/CL 03
Name of work:
Agreement No.
Sl.
No.
1.
2.
3.
4.
5.
6.

7.

8.

Estimated cost :
Sanction No. and date:

Particular

Remarks (Y/N/NA Observation if any)

Date
Location /Chainage/ Description of Item.
Execution activities carried out
Concreting of the pile cap is carried out
in dry conditions.
Quality Checks exercised during
concreting
Additional observation if any
Conclusion by inspecting officerExecution activities are sat6isfactory
/Not satisfactory .If satisfactory, further
bridge further bridge construction
activity to commence by ---- Contractors
to report the corrective action taken and
inform for re-inspection.
Contractor's/ Authorized Representative
Name
Designation and Signature
Inspecting officer
Name
Designation and Signature

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Page No.: BC/8-19

Quality Management System


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8.18. Checklist for Formwork


BCM/CL 04
Name of work:
Agreement No.:
Sl. Particular
No.
1.
2.
3.
4.
5.
6.

7.

8.
9.

Date
Location / Chainage / Description of
Item.
Execution activities carried out
The form work is robust and strong
and the joints are leak-proof
(MOSRTH Clause 1504.1)
Staging has cross bracings and
diagonal bracing's in both directions.
Staging has been provided with an
appropriately designed base plate
resting on firm strata.
The numbers of joint in the formwork
are kept to a minimum by using large
size panel (MOSRTH Clause 1504.2).

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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All joints are leak proof and are


properly sealed with PVC joined
sealing tape, or PVCT sections, foam
rubber, etc. (MOSRTH 1504.2).
Clamps are used to hold the form
together (MOSRTH 1504.3)
Minimum numbers of nails are used,
left projecting and can be withdrawn

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Name of work:
Agreement No.:
Sl. Particular
No.

10.
11.
12.

13.

14.
15.

16.

Date
easily (MOSRTH 1504.3)
The ties are used with HDPE
sheathing (MOSRTH 1504.4)
The chamfers, bevelled edges and
mouldings are made in the formwork
itself (MOSRTH 1504.5)
Shuttering for walls, sloping members
and thin sections of considerable
height is provided with temporary
openings to permit inspection and
cleaning out before
placing of
concrete (MOSRTH 1504.6).
The formwork is coated with the an
approved release agent that will
effectively prevent sticking and will not
stain the concrete surface(MOSRTH
1504.14).
Additional observation if any.

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Conclusion by inspecting officerExecution


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

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Page No.: BC/8-21

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of work:
Agreement No.:
Sl. Particular
No.

17.

Date
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-22

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.19. Checklist for Construction of Well Foundation


BCM/CL 05
Name of work:
Agreement No.:
Sl.
No.
1.
2.
3.

4.

5.

6.

Particular
Date
Location / Chainage /
Description of Item.
Execution inspection carried
out
Necessary reference points
are fixed before well sinking
operations
(MOSRTH
Clause 1203)
A temporary benchmark is
established near the well
foundation and also it
checked
regularly
with
respect to permanent bench
mark.
Sand island is protected
against scour and its height
is sufficient so that it is safe
against wave action.
Floating caissons, wherever
used, are having at least
1.5m free board above water
level.

Estimated cost:
Sanction no. and date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-23

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Public Works Department of Himachal Pradesh (HPPWD)

Name of work:
Agreement No.:
Sl.
No.
7.

8.

9.
10.
11.
12.
13.

14.

Particular
Date
Stability of floating Caissons
is
ensured
against
overturning and capsizing
while being towed and
during sinking.
For floating caissons, a
detailed
statement
of
fabrication,
floating
and
sinking of caissons is
prepared and furnished to
the
Engineer
by
the
Contractor.
Formwork
checked and
found correct.
Reinforcement checked and
found correct.
Mix design for concrete is
approved.
Quality
checks
during
concreting exercised.
During well sinking the tilt
and shift are maintained
within permissible limit.
refer (MOSRTH appendix
1200-I and II).
Safely precautions are taken
while placing Kent ledge on

Estimated cost:
Sanction no. and date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-24

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of work:
Agreement No.:
Sl.
No.

15.

16.
17.

18.

19.

20.

21.

Particular
Date
loading platform such that it
does not interfere with the
dredging process and also
not damage well steining.
The casting of well steining
is done progressively as
sinking proceeds.
The well curb rests on the
hard strata.
Sinking
of
the
well
foundation is done in the
hard strata to the extent
stipulated in drawing.
RLs of all these strata met
with during sinking have
been recorded.
Blasting operation shall be
carried out (Clause 1207.4
of MOSRTH)
Fore walling of Well shall be
approved by SE before
concreting the bottom plug
Holes are drilled/left through
the well steining for inserting
the 32 mm anchor rods duly
socketing in hard rock up to
a depth of 5 meters

Estimated cost:
Sanction no. and date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-25

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Public Works Department of Himachal Pradesh (HPPWD)

Name of work:
Agreement No.:
Sl.
No.
22.

23.
24.

25.

26.

27.

Particular
Date
The anchor rods are grouted
in hard rock by using cement
grout.
Dewatering
register
is
maintained
External faces of well
seining are provided with
protective paint of Coal Tar
Epoxy up to the high tide
level.
Whether the soundness of
bottom plug is tested and if
yes the rise of water level in
the well (It is to be within
permissible
limit
of
10mm/hr.)
If the pneumatic sinking is to
be carried out, medical
supervision,
lighting
arrangement, man locks are
provided, Safety against fire
hazards,
sanitation,
protection against gases and
other safety provisions to be
ensured (MOSRTH 1207.6).
The tilt and shift are within
permissible limit (1:80 and

Estimated cost:
Sanction no. and date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-26

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of work:
Agreement No.:
Sl.
No.

28.
29.

30.

31.

Particular
Date
150mm respectively as per
MOSRTH).
Additional observations if
any.
Conclusion by inspecting
officerThe execution activities are
satisfactory/Not satisfactory.
If satisfactory, further bridge
construction
activity
to
commence by ------If not satisfactory, the
contractors to report the
corrective action taken and
inform for re-inspection.
Contractor's / Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated cost:
Sanction no. and date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-27

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.20.

Checklist for Construction of Well Cap


BCM/CL 06

Name Of Work:
Agreement No.:
Sl.
No.

Particular
Date

1.

Location /Chainage/ Description


of Item.

2.

Execution inspection carried out

3.

Form work, reinforcement of well


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

4.

The materials are tested in


accordance
with
MOSRTH
specification and are met the
prescribed criteria.

5.

Additional observations if any

6.

Conclusion by inspecting officerExecution


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

Estimated Cost :
Sanction No. And Date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-28

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name Of Work:
Agreement No.:
Sl.
No.

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

7.

Contractor's / Authorized
Representative
Name
Designation and Signature

8.

Inspecting Officer Name


Designation and Signature

Estimated Cost :
Sanction No. And Date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-29

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.21. Checklist for Excavation for Open Foundation


BCM/CL 07
Name Of Work:
Agreement No.:
Sl.
No.

Estimated Cost :
Sanction No. and Date:

Particular

Remarks (Y/N/NA Observation if any)

Date

1.

Location / Chainage / Description of Item.

2.

Pre-execution
checks
have
completed Date and reference.

3.

The plan dimensions of the foundation is


set out at the bottom of original
reference.(As per QA Plan)

4.

A layer of M-15 concrete is provided below


foundation concrete where the bearing
surface is earth.(MOSRTH 2104.3)
(As per QA Plan)

5.

Form work and concrete conform to section


1500 and 1700 respectively of MOSRTH's
Specification 2104.3
Test Plan No-----------If yes ,Date and reference

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been

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Name Of Work:
Agreement No.:
Sl.
No.

Estimated Cost :
Sanction No. and Date:

Particular

Remarks (Y/N/NA Observation if any)

Date

6.

The location of construction joints and its


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

7.

Form work is removed not earlier than 24


hours after placing of concrete.(As per QA.
Plan) MOSRTH 2104.3.

8.

Curing of concrete is done by keeping it


continuously moist for a period of 7 days.
(As per approved QA Plan).
Dewatering, where necessary for laying of
concrete is carried out as per procedure
laid down in clause 2104.3 of MOSRTH.
The annular space is filled with M15
concrete up to top rock in case of
excavation in rock.
(As per approved QA Plan)
The Coal- tar epoxy is painted on the
surface of substructure below ground.
Test Plan No.
If Yes, Date and reference.
Spaces refilled with earth up to surface of
surrounding ground in accordance with
section 300.
Test plan No......

9.

10.

11.

12.

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name Of Work:
Agreement No.:
Sl.
No.

Estimated Cost :
Sanction No. and Date:

Particular

Remarks (Y/N/NA Observation if any)

Date
13.
14.

15.

16.

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If Yes ,Date and reference


Additional observation if any
Conclusion by inspecting officerThe
execution
activities
are
satisfactory/Not satisfactory .If satisfactory,
further bridge construction activity to
commence by ------If not satisfactory, the contractors to report
the corrective action taken and inform for
re-inspection.
Contractor's / Authorized Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Page No.: BC/8-32

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.22. Checklist for Steel Reinforcement


BCM/CL 08
Name of Work :
Agreement No..:
Sl.
No.
1.
2.
3.
4.

5.

6.

7.

Particular
Date
Location/ Chainage / Description of
work
Execution inspection is carried out.
Reinforcement is placed accurately in
position as shown on the drawings.
The bars, crossing one another are
tied together at every intersection with
binding wire, conforming to IS :280
Cover blocks, placed between the
bars and formwork are made of
concrete having the same strength
and specification as those of the
member
Chairs/links/spacer bars to separate
layers of reinforcement approximately
at one meter intervals
Bars coated with Epoxy or any other
approved protective coating is placed,
on supports that do not damage the
coating.

Sanction No. and date:


Estimated Cost:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-33

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No..:
Sl.
No.
8.
9.

Particular
Date
Overlapping of bars, if required is
done as specified in drawings.
Overlapping bars are bound with
annealed steel binding wire, not less
than 1mm diameter and tightly twisted
in such a manner as to maintain
minimum
clear
cover
to
the
reinforcement from the concrete
surface.

10.

Bar is bent cold to the specified shape


and dimension using a proper bar
bending device to obtain the correct
radii of bends and shape.

11.

Bars have not been bent or


straightened in a manner that will
damage the coating.

12.

The method of welding, if permitted in


drawing is conforming to IS2751 and
IS9417.

13.

Additional observation if any.

Sanction No. and date:


Estimated Cost:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-34

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No..:
Sl.
No.
14.

15.

16.

Particular
Date
Conclusion by inspecting officer- The
execution activities are satisfactory/
Not satisfactory.
If satisfactory,
further bridge construction activity to
commence by -If not satisfactory, the contractors to
report the corrective action taken and
inform for re-inspection.
Contractor's / Authorized
Representative
Name
Designation and Signature

Sanction No. and date:


Estimated Cost:
Remarks (Y/N/NA Observation if any)
/

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Inspecting Officer
Name
Designation and Signature

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.23. Checklist for Structural Concrete


BCM/CL 09
Name Of Work::
Agreement No.:
Sl.
No.
1.
2.

3.

4.

5.

6.

Particular
Date
Location/ Chainage / Description of
work
Execution checks have been
completed
Date and reference
The mixer or the ready mix plant at
proper location after considering the
properties of mixes and the
transportation arrangements available
with the contractor, is approved by
the Engineer
(As per approved QA Plan)
The method of transporting and
placing concrete is approved by
Engineer so that no contamination,
segregation or loss of its constituent
materials takes place. (As per
approved QA Plan).
Concrete is not freely being dropped
in to place from height exceeding
1.5 metre (As per approved QA Plan).
No concrete is placed in any part of

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name Of Work::
Agreement No.:
Sl.
No.

7.

8.

9.

10.

11.

12.

Particular
Date
structures until the approval of
Engineer has been obtained.
(As per approved QA Plan).
For
40mm
and
larger
size
aggregates, the cement content is
reduced suitably to a maximum up to
10%
(As per approved QA Plan)
For further water concreting, the
cement content is increased by 10%
(As per approved QA Plan)
The cement content is within the
maximum limit of 540 kg per cubic
metre of concrete.
(As per approved QA Plan)
The design mix of concrete is carried
out as per IS10262.
(As per approved QA Plan)
The mix design is approved by
Engineer well in advance before
actual start of concrete.
(As per approved QA Plan)
The requirement of consistency of
mix is considered in mix design as
indicated in Table 1700-4 of
MOSRTH.
(As per approved QA Plan)

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-37

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name Of Work::
Agreement No.:
Sl.
No.
13.

14.
15.

16.

17.

18.

Particular
Date
The contractor has prepared trial
mixes as per mix design, using
samples of approved material which
are being used in the works, for all
grades to the Engineers satisfaction
prior to commencement of concreting.
(As per approved QA Plan)
The test cubes are tested on 3rd, 7th
and 28th day.
The proportioning for nominal mix
concrete, if required is adopted as
specified in table 1700-6.
(As per approved QA Plan).
The overall limits of deleterious
substances (chloride and sulphate
contents) are as specified in section
1700-4 of MOSRTH.
(As per approved QA Plan)
The use of admixture such as super
plasticizers for concrete are made
with the approval of the Engineer.
(As per approved QA Plan)
The size of coarse aggregates for
concrete to be used in various
components is adopted as specified
in section 1706 of MOSRTH.
(As per approved QA Plan)

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Public Works Department of Himachal Pradesh (HPPWD)

Name Of Work::
Agreement No.:
Sl.
No.
19.

20.
21.

22.

23.

Particular
Date
The
vibrators
proposed
for
compaction of concrete are adopted
as specified in clause 1707-C of
MOSRTH.
(As per approved QA Plan).
Additional observation if any.

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Conclusion by inspecting officer- The


execution activities are satisfactory/
Not satisfactory.
If satisfactory,
further bridge construction activity to
commence by -If not satisfactory, the contractors to
report the corrective action taken and
inform for re-inspection.
Contractor's/Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Page No.: BC/8-39

Quality Management System


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Public Works Department of Himachal Pradesh (HPPWD)

8.24. Preparation of Mix Design of Cement Concrete


BCM/CL 10
Name of work:
Agreement No.:
Sl.
No.
1.
2.
3.

Particular
Date
Location/ Chainage / Description of
Item
Type of mix grade.....

4.

Type of cement......
Grade of cement.....
Maximum nominal size of aggregate

5.

Minimum cement content....

6.

Maximum water/ cement ratio....

7.

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

8.

Type of aggregate ....

9.

Maximum cement content ......

10.

Whether admixture are to be used ?

11.

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

Estimated Cost :
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Public Works Department of Himachal Pradesh (HPPWD)

Name of work:
Agreement No.:
Sl.
No.

Particular

12.

Date
Gradation of coarse aggregate

13.

Gradation of fine aggregate

14.

Following Tests for cement are carried


out Strength, initial setting time, final
setting time.

15.

The Coal-tar epoxy is painted on the


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

16.

Estimated Cost :
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.25. Checklist for Bearing


BCM/CL 11
Name of Work:
Agreement No.:
Sl.
No.
1.
2.
3.

4.
5.
6.
7.

8.

Particular
Date
Location/Chainage/ Description of
Item.
Execution inspection carried out .
Installation of bearing are set
thoroughly level and exact
position as indicated or drawing.
Bearing are handled with care
during installation.
Placing of bearing is carried out in
the presence of Engineer.
Additional observation if any.

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Conclusion by inspecting officerThe execution activities are


satisfactory/
Not satisfactory.
If satisfactory, further bridge
construction activity to commence
by
If not satisfactory, the contractors
to report the corrective action
taken and inform for re-inspection
Contractor's/Authorized

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Page No.: BC/8-42

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work:
Agreement No.:
Sl.
No.

9.

Particular
Date
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated Cost :
Sanction No. and Date:
Remarks (Y/N/NA Observation if any)
/

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.26. Checklist for Strip Seal Expansion Joints


BCM/CL 12
Name of Work:
Agreement No.:
Sl.
No.
1.
2.
3.
4.

5.

6.
7.

Estimated Cost :
Sanction No. and Date:

Particular

Remarks (Y/N/NA Observation if any)

Date
Location/ Chainage/ Description of
Item.
Execution inspection carried out If,
Yes, refer BCM-CL.
Execution inspection carried out If,
Yes, refer BCM-CL
Bolt cavities are cleaned and plugged
with neoprene cavity plugs. Prior to
placing the plugs sufficient sealant is
applied in the cavities.
The top surface of expansion joint truly
merges with the wearing surface on the
deck of the bridge.
Additional observation if any
Conclusion by inspecting officer- The
execution activities are satisfactory/
Not satisfactory. If satisfactory, further
bridge
construction
activity
to
commence by -If not satisfactory, the contractors to
report the corrective action taken and
inform for re-inspection

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work:
Agreement No.:
Sl.
No.
8.

9.

Estimated Cost :
Sanction No. and Date:

Particular

Remarks (Y/N/NA Observation if any)

Date
Contractor's/Authorized Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.27. Checklist for Providing and Fixing of Bridge Railing


BCM/CL 13
Name of Work :
Agreement No.:
Sl.
No.

Estimated Cost:
Sanction No. and date:

Particular

Remarks (Y/N/NA Observation if any)

Date

1.

Location/Chainage/
Item

2.

Execution inspection carried out


If Yes, refer BCM-CL

3.

Special care is taken to watch the


surface of the cast-in-situ portion of
the deck.

4.

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

5.

Additional observation if any

6.

Conclusion by inspection officer. The


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

7.

Contractor's/ Authorized
Representative

Description

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of

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.

Particular
Date
Name
Designation and Signature

8.

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Inspecting Officer
Name
Designation and Signature

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.28. Construction of Reinforced Concrete for Piers and Abutments


BCM/CL 14
Name of Work :
Agreement No.:
Sl. Particular
No.
Date
1.

Location/Chainage/ Description of
Item

2.

Execution checks are complete. If


yes, Date and reference

3.

The surface of foundation is


scrapped with wire brush and all
loose materials are removed.
(As per approved QA Plan)

4.

In case of solid abutments weep


holes are provided in conformity with
section 2706. (As per approved QA
Plan )

5.

The exposed surface finish is got


smooth and the earth face of
abutment is got rough finished.
(As per approved QA Plan )

6.

Tests are carried out in accordance


with is specifications.
(As per approved QA Plan )

7.

Additional observation if any.

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl. Particular
No.
Date
8.

Conclusion by inspection officer.


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

9.

Contractor's/ Authorized
Representative
Name
Designation and Signature

10.

Inspecting Officer
Name
Designation and Signature

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-49

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.29. Construction of Pier Cap and Abutment Cap


BCM/CL 15
Name of Work :
Agreement No.:
Sl.
No.
1.
2.
3.

4.

5.

6.

7.

Particular
Date
Location/Chainage/ Description of
Item
Execution checks are complete
If yes, Date and reference
For work, reinforcement and
concrete are conformed relevant
sections
of
MOSRTH
specification
(As per approved QA Plan)
The surface of cap is finished
smooth and having a slope for
drawing of water as shown on the
drawings.
(As per approved QA Plan)
The top surface of the pedestal
on which bearings are to be
placed is also be cast horizontal.
(As per approved QA Plan)
The surface on which elastomeric
bearing are to place is wood float
finished.
(As per approved QA Plan)
The surface on which steel

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.

8.

9.
10.

11.

12.

Particular
Date
bearings or pot bearings are to be
placed is cast about 25 mm below
the bottom level of bearings or as
indicated on the drawings (As per
approved QA Plan)
The materials are tested in
accordance
with
MOSRTH
specification and are met the
prescribed criteria.
(As per approved QA Plan)
Additional observation if any.
Conclusion by inspection officer.
Execution
activities
are
satisfactory / Not satisfactory. If
satisfactory,
further
bridge
construction activity to commence
by - - If not satisfactory, the contractors
to report the corrective action
taken and inform for duringexecution re-inspection.
Contractor's/ Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Page No.: BC/8-51

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.

Particular
Date
Designation and Signature

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.30. Providing Reinforced Earth Retaining Wall


BCM/CL 16
Name of Work :
Agreement No.:
Sl.
No.
1.
2.
3.

4.

5.

6.

7.

Estimated Cost:
Sanction No. and date:

Particular

Remarks (Y/N/NA Observation if any)

Date
Location/ Chainage / Description of
Item
Execution checks are complete
If yes, Date and reference.
The Reinforcing element is placed as
per specification. (As per approved QA
Plan).
Laying
and
Compacting:
The
reinforcing element is laid as per
specification.
(As per approved QA. Plan)
Uniform compaction of the fill is
achieved by placing the fill in depth as
specified.
(As per approved QA Plan)
During filling no construction plant runs
directly on the reinforcement.
(As per approved QA Plan)
Compaction of earth fill carried out as
per instruction. Of the Engineer.
(As per approved QA Plan)

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.
8.

9.

10.
11.

12.

13.

Estimated Cost:
Sanction No. and date:

Particular

Remarks (Y/N/NA Observation if any)

Date
During construction of reinforced fill,
the retained material beyond the
reinforcement at rear or the structure is
at the same level as reinforcement fill.
(As per approved QA Plan)
Sealing material for filling joints is
closed cell polyethylene foam or closed
cell polyurethane foam strip.
(As per approved QA Plan)
Additional observation if any.

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Conclusion by inspection officer.


Execution activities are satisfactory /
Not satisfactory. If satisfactory, further
bridge
construction
activity
to
commence by - - If not satisfactory, the contractors to
report the corrective action taken and
inform for re-inspection.
Contractor's/ Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Page No.: BC/8-54

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


BCM/CL 17
Name of Work :
Agreement No.:
Sl. Particular
No.

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)

Date

1.
2.
3.

4.
5.

6.
7.

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Location/Chainage/ Description of Item


Execution checks are completed.
If yes, Date and reference
The epoxy paint is applied in three coats
i) Epoxy polyamide primer coating over
concrete surface.
Thickness 55 micron.
ii) Micaceous iron oxide.
Thickness 110 micron.
iii) Polymide finish paint.
Thickness 110 micron.
( As per approved QA Plan )
Additional observation if any
Conclusion
by
inspection
officer.
Execution activities are satisfactory / Not
satisfactory. If satisfactory, further bridge
construction activity to commence by - - If not satisfactory, the contractors to
report the corrective action taken and
inform for re-inspection.
Contractor's/ Authorized Representative
Name Designation and Signature
Inspecting Officer
Name
Designation and Signature

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Page No.: BC/8-55

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


BCM/CL 18
Name of Work :
Agreement No.:
Sl.
No.
1.
2.
3.

4.
5.

Particular
Date
Location/Chainage/ Description of Item
Execution checks are completed.
If yes, Date and reference.
The epoxy paint is applied in three
coats
i). Zinc based primer coating over
concrete surface.
Thickness 50 micron.
ii). Coal tar epoxy first coat.
Thickness 80 micron.
iii). Coal tar epoxy paint.
Thickness 80 micron.
(As per approved QA Plan )
Additional observation if any
Conclusion by inspection officer. The
execution activities are satisfactory /
Not satisfactory. If satisfactory, further
bridge
construction
activity
to
commence by - - If not satisfactory, the contractors to
report the corrective action taken and
inform for re-inspection.

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


BCM/CL 19
Name of Work:Agreement No.:
Sl.
No.
1.
2.
3.
4.
5.
6.

7.

8.

Particular
Date
Location/Chainage/ Description of
Item.
Execution checks are completed, If
yes, Date and reference...
The water proof cement paint is
applied (As per approved QA Plan).
The surface painted is kept moist for
Seven days for caring.
Additional observation if any.
Conclusion by inspecting officer- The
execution activities are satisfactory/
Not satisfactory.
If satisfactory,
further bridge construction activity to
commence by ---If not satisfactory, the contractors to
report the corrective action taken and
inform for re-inspection.
Contractor's/Authorised
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

/200

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/200

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Page No.: BC/8-57

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.34. Checklist for Tack Coat


BCM/CL 20
Name of Work :
Agreement No.:
Sl.
No.
1.
2.

3.

4.

5.

6.

7.

Particular
Date
Location/Chainage/ Description
of Item.
Execution checks have been
completed Date and Reference
....
The spraying temperature of
bituminous emulsion is in the
range of 20oC to 60oC.
Binder is applied with self
propelled or towed bitumen
pressure sprayer with self
heating arrangements.
The rate of application of
binder is maintained as per
Table 500-2 of MOSRTH or as
specified in the item of tender.
The application of binder
quantity is as specified in
tender (To be ascertained by
using paper and weighing it).
Supervision by the contractor
adequate/ Not adequate.

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.
8.
9.
10.

11.

12.

Particular
Date
safety measures taken
Adequate/ Inadequate
Additional observations if any.

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

/200

/200

/200

/200

/200

/200

Conclusion
by
inspecting
officer- The execution activities
are satisfactory/ unsatisfactory.
If satisfactory, further bridge
construction
activity
to
commence by ---If
not
satisfactory,
the
contractors to report the
corrective action taken and
inform for re-inspection.
Contractor's/Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Page No.: BC/8-59

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.35. Checklist for Mastic Asphalt


BCM/CL 21
Name of Work :
Agreement No.:
Sl.
No.
1.
2.
3.
4.

5.
6.
7.
8.

9.

10.

Particular
Date
Location/Chainage/ Description of
Item.
Execution checks are completed
Date and Reference.....
Tack coat is applied as per clause
503 of MOSRTH.
The procedure for preparation of
mix is adopted as per clause 525.4
of MOSRTH.
Adequate
traffic
safety
arrangements are provided.
The temperature of mix is around
170o C while spreading.
The spreading is carried out as per
the clause 525.4.5 of MOSRTH.
The
construction
joints
are
provided as per clause No.525.46
of MOSRTH.
The final surface finish is in
accordance with clause 525.4.7 of
MOSRTH.
The supervision by contractor is

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.

11.

12.
13.

14.

15.

Particular
Date
adequate/Not adequate
All tests on material are carried out
as per test plan No......................
If yes, Date and reference.
Additional observations if any
Conclusion by inspecting officerThe execution activities are
satisfactory/ Not satisfactory. If
satisfactory,
further
bridge
construction activity to commence
by ---If not satisfactory, the contractors
to report the corrective action taken
and inform for re-inspection.
Contractor's/Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

/200

/200

/200

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Page No.: BC/8-61

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.36. Checklist for Dense Bituminous Macadam


BCM/CL 22
Name of Work :
Agreement No.:
Sl.
No
1.
2.
3.

4.
5.

Particular
Date
Location/Chainage/ Description of
Item.
Execution checks have been
completed.
Date and Reference ....
Tack coat is properly sprayed as
required to the surface where
DBM. is to be laid.
If yes date and reference of
Checklists for tack coat.
Equipments
as
verified
in
Execution check are available in
good working condition .
The mix is prepared in drum mix
plant or any other specified plant

6.

The temperature of binder and


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

7.

The discharge temperature of mix

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No

8.

9.
10.
11.
12.
13.
14.
15.

16.

Particular
Date
is in between 130oC to 160oC
The tipper/ dumper is properly
covered with tarpaulin to avoid fall
in temperature during transport

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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The temperature of mix at the time


of laying is in between 120o C to
160o C
The mix is tested for Bitumen
content Gradation
Proper offsets have been provided
in longitudinal joints of each layer.
The initial or intermediate rolling is
followed by vibratory roller of 80 to
100 KN capacity.
The final rolling is done by 60 to 80
KN tandem roller or by switching
off vibratory system
The rolling is continued till the
entire surface has been rolled to
98% of average laboratory density.
The
surface
finish
of
the
construction
conforms
to
requirements of clause 902 of
MOSRTH-1995. (refer QA Plan)
The rolling is done as per clause
507.4.6 of MOSRTH-1995 edition

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No

17.

18.
19.
20.
21.

22.

23.

Particular
Date
(Refer QA Plan).
The final levels are taken with
reference to GTS.
Field Book No.......
Page No..........
Adequate
traffic
safety
arrangements are provided (refer
QA Plan).
The supervision of sub-contractors
is adequate (refer QA Plan).
Additional observations if any.
Conclusion by inspecting officerThe execution activities are
satisfactory/ Not satisfactory. If
satisfactory,
further
bridge
construction activity to commence
by ---If not satisfactory, the contractors
to report the corrective action
taken and inform for re-inspection.
Contractor's/Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.37. Checklist for Asphaltic Concrete


BCM/CL 23
Name of Work :
Agreement No..:
Sl.
No.
1.
2.
3.

4.
5.
6.

7.
8.

Particular
Date
Location/Chainage/ Description of
Item.
Execution checks have been
completed. Date and Reference ....
Tack coat is properly sprayed as
required to the surface where DBM
is to be laid.
If yes, date and reference of
checklist for tack coat.
Equipments
as
verified
in
Execution check are available in
good working condition.
The mix is prepared in drum mix
plant or any other specified plant.
The temperature of binder and
aggregate is maintained in the
range between 150oC to 163oC and
155oC to 163oC respectively at the
time of mixing.
The discharge temperature of mix
is in between 130oC to 160oC
The tipper/ dumper is properly

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No..:
Sl.
No.

9.

10.

11.
12.

13.
14.

15.

16.

Particular
Date
covered with tarpaulin to avoid fall
in temperature during transport.
The temperature of mix at the time
of laying is in between 120oC to
160o C.
The mix is tested for
Bitumen content
Gradation
Proper offsets have been provided
in longitudinal joints of each layer.
The initial or intermediate rolling is
followed by vibratory roller of 80 to
100 KN capacity.
The final rolling is done by 60 to 80
KN tandem roller or by switching off
vibratory system.
The rolling is continued till the
entire surface has been rolled to
98% of average laboratory density.
The
surface
finish
of
the
construction
conforms
to
requirements of clause 902 of
MOSRTH-1995.(refer QA Plan).
The rolling is done as per clause
507.4.6 of MOSRTH-1995 edition
(Refer QA Plan).

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No..:
Sl.
No.
17.

18.
19.
20.
21.

22.
23.

Particular
Date
The final levels are taken with
reference to GTS.
Field Book No.......
Page No..........
Adequate
traffic
safety
arrangements are provided (refer
QA Plan).
The supervision of sub-contractors
is adequate (refer QA Plan).
Additional observations if any.
Conclusion by inspecting officerThe
execution
activities
are
satisfactory / Not satisfactory. If
satisfactory,
further
bridge
construction activity to commence
by ---If not satisfactory, the contractors
to report the corrective action taken
and inform for re-inspection
Contractor's/Authorized
Representative Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.38. Providing and Fixing Water Spouts


BCM/CL 24
Name of Work :
Agreement No.:
Sl.
No.
1.
2.
3.
4.

5.
6.

Particular
Date
Location/Chainage/ Description of
Item.
Execution
inspection
activity
carried out.
The pipe is given protective coats
before placement.
The whole assembly is placed in
true position lines and levels as
shown in the drawings with
necessary cut-out in the shuttering
for deck slab and held in place
firmly.
Additional observations if any.

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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/200

/200

/200

/200

Conclusion by inspecting officerThe execution activities are


satisfactory/
Not satisfactory. If
satisfactory,
further
bridge
construction activity to commence
by ---If not satisfactory, the contractors
to report the corrective action

Procedure No.: QMS/WI/BC-08/Test Plans and Checklists


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Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.

7.

8.

Particular
Date
taken and inform for re-inspection.
Contractor's/Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

Estimated Cost:
Sanction No. and date:
Remarks (Y/N/NA Observation if any)
/

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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.39. Checklist for Application of Aqua Epoxy Paint to Structure


BCM/CL 25
Name of Work :
Agreement No.:
Sl.
No.
1.
2.
3.

4.
5.

Estimated Cost:
Sanction No. and date:

Particular
Remarks (Y/N/NA Observation if any)
Date
Location/Chainage/ Description of
Item.
Execution checks are completed.
If, yes, Date and reference.
The epoxy paint is applied in two
coats.
Aqua
Epoxy
coating
over
concrete surface. Thickness 150
micron.
Aqua Epoxy second coat.
Thickness 250 micron
(As per approved QA plan).
Additional observations if any.
Conclusion by inspecting officerThe execution activities are
satisfactory/
Not satisfactory.
If satisfactory, further bridge
construction activity to commence
by ---If not satisfactory, the contractors
to report the corrective action
taken and inform for reinspection.

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Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.
6.

7.

Estimated Cost:
Sanction No. and date:

Particular
Remarks (Y/N/NA Observation if any)
Date
Contractor's/Authorized
Representative
Name
Designation and Signature
Inspecting Officer Name
Designation and Signature

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Page No.: BC/8-71

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

8.40. Checklist for Application of Aqua Epoxy Paint to Structure


BCM/CL 26
Name of Work :
Agreement No.:
Sl.
No.
1.
2.
3.
4.
5.
6.
7.

8.

Estimated Cost:
Sanction No. and date:

Particular
Remarks (Y/N/NA Observation if any)
Date
Location/Chainage/ Description of
Item.
Approved drawing of the structure
is available.
Design calculations and the
drawings of the formwork and
centering are available.
The centering and formwork design
is approved by competent authority.
The erection of formwork and
centering is done conforming to
approved drawings.
The design of the formwork
facilitates proper and access to all
parts of formwork for inspection.
In case of pre-stressed concrete
super
structure,
careful
consideration is given to loads on
props due to pre-stressing (if
applicable only).
Care has been taken to ensure that
the form work does not retrain the
shortening of beam during pre-

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Public Works Department of Himachal Pradesh (HPPWD)

Name of Work :
Agreement No.:
Sl.
No.

9.
10.
11.
12.
13.
14.

15.

16.

Estimated Cost:
Sanction No. and date:

Particular
Remarks (Y/N/NA Observation if any)
Date
stressing
Proper lubrication is provided to
shuttering panels.
Formwork is adequately supported
so that plate will not bulge due to
pressure of green concrete
All supports are strong and all nut
bolds are properly tightened
The formwork conforms to the
approved drawing.
Additional observations if any
Conclusion by inspecting officerThe
execution
activities
are
satisfactory/
Not satisfactory. If
satisfactory,
further
bridge
construction activity to commence
by ---If not satisfactory, the contractors to
report the corrective action taken
and inform for re-inspection
Contractor's/Authorized
Representative
Name
Designation and Signature
Inspecting Officer
Name
Designation and Signature

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Page No.: BC/8-73

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.
9.1.

TESTS AND TEST PROFORMA

Tests to be conducted by Construction Division

9.1.1. Field Tests


Sl.
No.
1.
2.
3.
4.

5.
6.
7.
8.
9.

Item

Tests to be conducted

Embankment

Density, Atterberg limits, Moisture Content


(Suitability before and Execution).
GSB
Gradation / Atterberg Limits / Moisture Content /
Density.
WBM
Impact Value, Gradation, Flakiness and Elongation.
Bituminous Works
Temperature (Binder / Mix), Rate of Spread of
Bitumen.
Gradation, Impact, Flakiness and Elongation for
Aggregates.
Binder Content.
Sand
Gradation
Silt / Clay / Deleterious Materials.
Bricks
Size and Shape
Coarse Aggregate
Gradation, Water Absorption, Impact, Flakiness
and Elongation.
Concrete
Slump
Any other possible test at field

Frequency for field test: 100%. Other tests are conducted by QC staff at
laboratory. Tests to be conducted by Quality Control Division
9.1.2. Laboratory Tests
Sl.
No.
1.

Item
Embankment

2.

GSB

3.

WBM

4.

Bituminous Works

5.

Sand

6.

Bricks

7.

Coarse Aggregate

8.

Concrete

Test to be conducted
Density, Atterberg limits, Moisture Content
(Suitability before and Execution).
Gradation / Atterberg Limits / Moisture Content /
Density, CBR*.
Impact Value, Gradation, Flakiness & Elongation,
Abrasion Test*.
Temperature (Binder / Mix) Rate of Spread of
Bitumen.
Gradation, Impact, Flakiness and Elongation for
Aggregates.
Binder Content, Stripping value, Marshall Stability
Analysis (Mixture Design) Penetration value,
Softening Point, Viscosity, Density, Ductility*.
Gradation
Silt / Clay / Deleterious Materials.
Size and Shape, Compressive strength, water
Absorption*.
Gradation, Water Absorption, Impact, Flakiness
and Elongation, Abrasion Test*.
Slump, Compressive strength, Mix Design of
Concrete*.

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Issue 01, Rev 00

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

Sl.
No.
9.

Item
Soil

10.

Cement

11.

Tiles

Test to be conducted
SBC Test, Grain size analysis, Classification of
Soils, Density, Moisture Content, Atterberg limits,
Direct Shear Test, Triaxial shear test CBR*.
Normal Consistency, Initial and Final setting time,
Fineness, Strength of Cement (3 days, 7 days, 28
days)*.
Water Absorption, Size and shape, Transverse
Flexural Strength*.

Notes:
* Test to be conducted at QC Lab only (100 %).
Other tests are conducted by both construction staff and QC staff
(10 % Frequency for QC). Frequency to be decided..

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Page No.: BC/9-2

Issue 01, Rev 00

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.2.

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

Name of work :
Reference : Executive Engineer PWD Division
Letter No.
Dated :
Date of Testing :
Requirement as per MOSRTH Specification Section 400 clause 404 and test conducted as per IS 2386:1963

Test
No.

1.

1.
2.
3.

Details
of
Sample

Impact value 30% max

Los Angles Abrasion


Value 40% max

2.

3.

Water
absorption
value 2%
(max
4.

Flakiness
Index Max
20%

5.

Percentage passing by weight through I.S. Sieve


Designation (Table 400-7)
Remarks
90mm
100%
6.

63mm
90-100 %
7.

53mm
25-75%
8.

45mm
0-15%
9.

22.40
mm 0-5%
10.

11.

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

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.3.

Test Report on Cement Concrete Cubes

Name of work :
Reference : Executive Engineer PWD Division
Date of Testing :

Letter No.

Dated :

Tested as per IS : 516-1959

Test
No.

1.

1.
2.
3.

Details
of
Casting

2.

Date of
Testing

3.

Age of
Cube in
days

4.

Location of
Concreting

5.

Grade /
Proportion
of mix

6.

Wt. of
Specimen
in gm

7.

Compressive
strength of CC
cubes in kg/cm2

8.

9.

Requirement
as per IS 456:
2000

Remarks

10. 11.

12.

13.
Compressive
strength of CC
cubes is computed
for 28 days curing
vide
MOSRTH
table 900-5 Section
900

The test results relate to the sample tested and shall not be reproduced in part.
Materials need to be tested as per frequency of MOSRTH Section 900 and IS Specification.
Test samples collected by the QC Division/supplied by the Concerned EE through field staff.

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.4.

Test Report of Sand Sample

Name of work :
Reference : Executive Engineer PWD Division
Letter No.
Dated :
Date of Testing :
Indian standard specification for coarse aggregate IS : 383-1970 Table -1 & 4 and test carried out as per IS 2386:1963
Sample
No.

1.

1.
2.
3.

Description of
sand sample
tested
Grading limit
for
fine
aggregate as
per IS 3831970 Table 1
&
4
for
concrete work
2.

Deleterious material % by Wt
Passing
Clay Coal &
75
Others
lumps Lignite
Micron
IS Sieve

Max
3.00%

3.

Max
Max
1.00% 1.00%

4.

5.

Max
1.00%

6.

% by weight passing the IS Sieve


Total

10
mm

100%
Max
100%
5.00%
100%
7.

8.

4.75
mm

2.36
mm

90-100% 60-95%
90-100% 75-100%
90-100% 85-100%
9.

1.18 mm

600 mm

300
micron

150
micron

Grading
zone of
sand
sample

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

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

5-20%
8-30%
12-40%

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

Gr - I
Gr - II
Gr - III

12.

13.

14.

15.

10.

11.

Remarks

16.

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

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.5.

Test Report of Brick Sample

Name of work :
Reference : Executive Engineer PWD Division
Date of Testing :

Sl.
No.

Date of
Testing

Class
designation and
Identification
mark on the top
of the brick

1.

2.

3.

1.
2.
3.

Water
absorption
Value in
%

Crushing
strength of
brick
in
kg/cm2

4.

5.

Letter No.

Dated :

Average Value of bricks

Requirement as per IS 1077:1992

Water
absorption
in %
6.

Water
Crushing
absorption
strength of
Value in %
brick
in
20.00%
2
kg/cm
(Max)
7.
8.

Minimum Crushing
strength
brick Remarks
35/50/75
kg/cm2
(based on class of
Bricks)
9.
10.

The test results relate to the sample tested & shall not be reproduced in part.
Materials need to be tested as per frequency of IS Specification.
Test samples collected by the QC Division/supplied by the Concerned EE through field staff.

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.6.

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

Name of work :
Reference : Executive Engineer
Letter No.
Dated :
Date of Testing :
Indian standard specification for coarse aggregate IS 383:1970 Table -1 & 2 and test carried out as per IS 2386:1963
Size of coarse
Percentage by weight passing the IS Sieve
aggregate
Details of
Test
Aggregate
80mm
40mm
20mm
10mm
4.75mm
Sample
No.
Impact
40mm and down
100%
95-100%
30-70%
10-35%
0-5%
Collected
Remarks
Value Max
20mm and down
100%
95-100%
25-55%
0-10%
30%
1.
2.
3.
4.
5.
6.
7.
8.
9.

1.
2.
3.

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

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.7.

Test Report of Cement Sample

Name of work :
Reference : Executive Engineer/ PWD Division
Date of Testing :

Letter No.

Dated :

Tested as per IS 4031:1988


Setting time in Minutes
Sl.
No.

Details of sample collected Brand Grade


Invoice Receipt No. & dt.

Standard
consistency of
cement in %

IS Specification as per IS 8112:1976


(Reaffirmed 1989) for OPC 43 grade
IS Specification as per IS 12269-1987
(Reaffirmed 1999) for OPC 53 grade
IS Specification as per IS 1489(Pt 1) 1991
(Reaffirmed 1999) for PPC (Fly Ash based)
IS Specification as per IS 455:1989
(Reaffirmed 1995) for PSC (Slag)

1.

1.
2.
3.

2.

3.

Minimum Compressive strength


of cement at the age, MPa
Remarks

Initial setting
time, min

Final setting
time, max

3 days

7 day

28 days

30 minutes

600 minutes

23

33

43

30 minutes

600 minutes

27

37

53

30 minutes

600 minutes

16

22

33

30 minutes

600 minutes

16

22

33

4.

5.

6.

7.

8.

9.

The test results relate to the sample tested & shall not be reproduced in part.
Materials need to be tested as per frequency of MOSRTH Section 900 and IS Specification.
Test samples collected by the QC Divisionl/supplied by the Concerned EE through field staff.

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.8.

Test Report on Aggregate Characteristics of Single Coat Surface Dressing

Name of work :
Reference : Executive Engineer PWD Division
Date of Testing :

No. of
Tests

1.

1.
2.
3.

Letter No.

Dated :

Requirement as per MOSRTH Specification Section 400 clause 404 and test conducted as per IS 2386;1963
Nominal
Grading Requirements for chips for surface dressing
size
Percentage by wt
Details
Impact
Water
Passing
of
value
Absorption 1%
19
13.2
9.5
6.3 2.36 0.075
13.2 mm Remarks
Sample
30%
(Max)
13 MM
mm
mm
mm mm mm
mm
retained on
Tested
(max)
9.5 mm
100 85-100 0-40 0-7
0-2
0-1.5
65% min
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

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

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


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Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.9.

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

Name of work :
Reference : Executive Engineer PWD Division
Letter No.
Dated :
Date of Testing :
Requirement as per MOSRTH Section 500 clause 511 & 513 and test conducted as per IS 2386:1963
Grading for 20mm Open
Grading for Seal Coat
Graded Premix Carpet
Aggregate
(Table 500-23)
% passing by weight
% passing by weight through
through I.S. Sieve
Required
Required
I.S. Sieve designation
Water
Details Impact
designation
Bitumen
Bitumen
value Absorption
of
Test
Content in
Content in
Type A
Type B
value 1%
No. Sample 30%
13.20 mm
11.20mm
% for
% for seal
(clause
(clause
(max)
Tested (max)
metal
metal
carpet mix
coat mix
513.2.2)
513.2.3)
22.40 11.20 13.20 5.60
11.2 2.36 2.36
180
mm
mm
mm mm
mm mm mm
mic
100
100%
0% 100% 0%
0% 100% 0%
%
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

1.
2.
3.

Remarks

14

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

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


Controlled Document

Issue 01, Rev 00


Page No.: BC/9-10

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

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


Name of work :
Reference : Executive Engineer PWD Division
Letter No.
Dated :
Date of Testing :
Requirement as per MOSRTH Specification (4th revision) Section 500 clause 506 and test conducted as per IS 2386:1963
Percentage passing by weight (Table 500-7)
Test No.

1.

1.
2.
3.

Details
of
Sample
Tested

Impact
value
30%
Max

2.

3.

Aggregate
Water
Absorption
value 2%
Coarse
Max

4.

IS Sieve Designation
53 mm

26.5mm

22.4mm

13.2mm

5.6mm

2.8mm

100

40-75

0-20

0-5

Key

100

100

100

40-75

0-20

0-5

5.

6.

7.

8.

9.

10.

11.

Remarks

12.

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

Asst./ Junior Engineer

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


Controlled Document

Issue 01, Rev 00


Page No.: BC/9-11

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.11. Test Report on Aggregates Characteristic for Semi Dense Bituminous Concrete (SDBC)
Name of work :
Reference : Executive Engineer PWD Division
Letter No.
Dated :
Date of Testing :
Requirement as per MOSRTH Specification (4th revision 2001) Section 500 clause 508 and test conducted as per IS 2386:1963
Details
of
sample
collected

Impact
value
27%
(max)

Water
Absorption
value 2%
(max)

Percentage by weight passing IS Sieve (Table 500-15)


13.20
9.5
4.75
2.36
1.18
0.300
19mm
mm
mm
mm
mm
mm
mm
100
90-100 70-90
35-51
24-39
15-30
9-19
-100
90-100 35-51
24-39
15-30
9-19

0.075
mm
3-8
3-8

Sl.
No.

Test
No.

1.

Apart from conformity with the grading and quality requirement for individual ingredients the mixure shall meet the requirements
set out in Table 500-16 (For Mixture Design).
The test results relate to the sample tested & shall not be reproduced in part.
Materials need to be tested as per frequency of MOSRTH Section 900.
Test samples collected by the QC Division/supplied by the Concerned EE through field staff.

2.
3.
4.

Grading I
Grading II

Asst./ Junior Engineer

Remarks

Executive Engineer/In-charge
PWD (QC Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


Controlled Document

Issue 01, Rev 00


Page No.: BC/9-12

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.12. Test Report on Aggregate Characteristics of Bituminous Macadam


Name of work :
Reference: Executive Engineer PWD Division
Letter No.
Dated :
Date of Testing :
Requirement as per MOSRTH Specification (4th revision) Section 500 clause 504 and test conducted as per IS : 2386-1963
Impact
value
Test
No.

1.

1.
2.
3.

Details
of
sample
Tested

2.

Water
Absorption
value

30%
Max

3.

2% Max

4.

Percentage passing by weight (Table 500-4)


IS Sieve Designation

Grading
I (80-100
mm)
II (50-75
mm)

5.

45
mm
100
%

37.5
mm
90100

26.5
mm
75100

19
mm

13.2
mm

35-61

100

90100

56-88

6.

7.

8.

9.

10.

4.75
mm
1322
1636

11.

Bitumen
Content %
by weight
of total mix

2.36
mm

0.300
mm.

0.075
mm

4-19

2-10

0-8

3.1 - 3.4

4-19

2-10

0-8

3.3 - 3.5

12.

13.

14.

15.

Remarks

16.

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

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


Controlled Document

Issue 01, Rev 00


Page No.: BC/9-13

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.13. Test Report on Coarse Aggregate for Bituminous Concrete


Name of work :
Reference : Executive Engineer PWD Division
Letter No.
Dated :
Date of Testing :
Requirement as per MOSRTH Specification (4th revision) Section 500 clause 509
Percentage by weight passing I.S. Sieve (Table 500-18)
26.5 19 13.2 9.5 4.75 2.36 1.18 0.6 0.3 0.15 0.075 Remarks
Grading
Impact Water
Details
Sl. Test
mm mm mm mm mm mm mm mm mm mm
mm
value Absorption
of
No. No.
I
7959523528221510524% value 2%
sample
100
2-8
50-65 mm
100 79
72
55
44
34
27
20
13
(max)
collected (max)
II
79- 70- 534234- 26- 18- 12100
4-10
30-45 mm
100 88
71
58
48
38
28
20

1.
2.
3.
4.

Apart from conformity with the grading and quality requirement for individual ingredients the mixture shall meet the requirements
set out in Table 500-19 (For Mixture Design).
The test results relate to the sample tested and shall not be reproduced in part.
Materials need to be tested as per frequency of MOSRTH Section 900.
Test samples collected by the QC Division/supplied by the Concerned EE through field staff.

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


Controlled Document

Issue 01, Rev 00


Page No.: BC/9-14

Quality Management System


Construction Manual (Work Instructions) for
Public Works Department of Himachal Pradesh (HPPWD)

9.14. Test Report on Aggregates Characteristic for Dense Graded Bituminous Macadam
Name of work :
Reference :
Letter No.
Dated :
Date of Testing :
Requirement as per MOSRTH Specification Section-500 clause 507 Table 500-10 and test conducted as per IS 2386:1963

Test
No.

1.
2.
3.
4.

Details
of
Sample
Tested

Flakiness
AggreWater
absorp
Elongation
gate
Index
Impact
-tion
(Combined
value
Max
) Max 30% Max 27%
2%

Nominal
aggregate Grading 45
size
mm
Grade
40 mm
100
I
Grade
20 mm
II

Percentage by weight passing I.S. Sieve


37-5 26.5
19
13.2 4.75 2.36
0.3 0.075
mm
mm mm mm
mm
mm
mm mm
95655538287-21 2-8%
100
93
75
54
42
100
90- 715638287-21 2-8%
%
100 95
80
54
42

Remarks

Apart from conformity with the grading and quality requirement for individual ingredients the mixture shall meet the requirements
set out in Table 500-16 (For Mixture Design).
Materials to be tested as per frequency of MOSRTH Section 900.
Test samples of aggregates were collected/ supplied by the QC Division/supplied by the Concerned EE through field staff.
The Gradation of DBM in the proportion of the aggregate as mentioned above shall be adopted and gradation shall be got
confirmed in the filed by carrying filed gradation test

Asst./ Junior Engineer

Executive Engineer/In-charge
PWD (QC. Division)

Procedure No.: QMS/WI/BC-09/Tests and Test Performa


Controlled Document

Issue 01, Rev 00


Page No.: BC/9-15