IRC:SP:47-1998 GUIDELINES ON QUALITY SYSTEMS FOR ROAD BRIDGES (PLAIN, REINFORCED, PRESTRESSED AND COMPOSITE CONCRETE) Published by THE INDIAN ROADS CONGRESS Jamnagar House, Shahjahan Road, New Delhi 110011 1998, Price Rs. 280/- (plus packing & postage)IRC:SP:47- 1998, First Published in June, 1998 Reprinted : October, 2000 Reprinted : June, 2003 (the Rights of Publication and of Translation are Reserved) Printed at Sagar Printers & Publishers, New Delhi 110.003, (1000 copies)10. "1 12, 13, 14, 15, 16, 17. 18. 19, 20. IRC:SP:47-1998, MEMBERS OF THE BRIDGE SPECIFICATIONS AND STANDARDS COMMITTEE AD. Narain* (Convenor) Chief Engineer (8) S&R (Member-Secretary) S.S. Chakraborty Prof. D.N. Trikha RH. Sarma Ninan Koshi S.N. Mane G. Bhatwa AG. Borkar NK. Sinha P.B. Vijay HP. Jamdar GC. Mitra U. Borthakur Surjeet Singh V. Murahari Redd MV.B. Rao Prof. C.S. Surana C.R. Alimchandani N.C. Saxena (As on 2.12,1996) DG(RD) & Addl. Secretary to the Govt. of India, Ministry of ‘Surface Transport (Roads Wing), New Delhi Ministry of Surface Transport (Roads Wing), New Delhi Managing Director, Consulting Engg, Services (I) Pvt. Ltd., 57, Nehru Place, New Delhi-110019 Director, Structural Engg. Res. Centre, Sector-19, Central Govt. Enclave, Kamla Nehru Nagar, PB No. 10, Ghaziabad-201002 Chief Engineer, MOST (Reta), €-7/175, Safdarjung Dev. Area, New Delhi-110016 DG(RD) & Addl. Secy., MOST (Retd.), '56, Nalanda Apartments, Vikaspuri, New Delhi Sr. Vice President Lok Global & National Constn. Lid., Lok Centre, Marol-Maroshi Road, Andheri (E), Mumbai-400059 Chief Engineer (NH), P.W.D., B&R Branch, Patiala ‘A-1, Susnehi Plot No. 22, Arun Kumar Vaidya Nagar, Bandra Reclamation, Mumbai-400050 Chief Engineer (PIC), istry of Surface Transport (Roads Wing), Transport Bhavan, New Dethi-110001 Director General (Works), Central Public Works Department, Nirman Bhavan, Room No.424, New Delhi-110011 Secretary to the Govt. of Gujarat, R&B Department, Block No. 14, Sachivalaya Complex, Gandhinagar-382010 Engineer-in-Chief (Retd.) A-1/59, Saheed Nagar, Bhubaneswar-751007 Secretary, PWD B&R (Ret) Clo Secretary, PWD B&R, Shillong-793001 Seoretary to the Govt. of Machya Pradesh, E-2ICPC, Char Imii, Bhopal-462016 Engineer-in-Chief (R&B), Errum Manzil, Hyderabad-580482 Head, Bridge Division, Central Road Research Institute, P.O. CRRI, Delhi-Mathura Road, New Delhi-1 10020 Civil Engg. Department, Indian Institute of Technology, Hauz Khas, New Delhi-110016 Chairman & Managing Director, STUP Consultants Ltd., 1004-5 & 7, Raheja Chambers, 213, Nariman Point, Mumbal-400021 Director, Intercontinental Consultants & Technocrats (P) Ltd., A-11, Green Park, New Delhi-1 10016 * ADG(®) being notin position. The meeting was presided by Shri A.D. Narain, OG(AID) & Add. Secy.o the Gov. of India MOST woIRC:SP:47-1998, 24 22. 23, 24, 2. 26, 28. 29. 30. 31 22. 33. 34, 36. 37, 39. 40. at 42, 43, M.K. Bhagwagar 8.8. Dhiman S.A. Tambe S.A, Redai Dr. GP. Saha P.Y, Manjure Papa Reddy Vijay Kumar P.C. Bhasin D.T. Grover Dr. V.K. Raina NV. Merani CV. Kand M.K. Mukherjee Mahesh Tandon Dr. T.N. Subba Rao Indu Prakash ‘The Director (V.Chandrasekar) AK Hatit Vinod Kumar President, Indian Roads Congress DG(RD) & Hon, Treasurer indian Roads Congress Secretary, Indian Reads Congress Shitala Sharan Or. M.G. Tamhankar Consutting Engineer, Ben Consultants (P) Lia, F-14/18, Connaught Place, New Delhi-1 410001 Managing Director, S637 Consultants (P) Lia, Flats 3-5, (ond Floor), Local Shopping Genire, J-Block, Saket, New Delhi-i 10017 Secretary (R) to the Govt, of Maharashtra, P.W.D., Mantralaya, Mumbai-400032 Dy. Managing Director, Sammon india Ltd., Gammon House, Veer Savarkar Marg, Prabhadevi, Mumbai-4ooo25 Chiet Engineer, Gecustan Construction Co. Ltd, Hincon House, Lal Bahadur Shastei Marg, Vikhroli (West), Mumbai-éoo0es Principal Executive Director, ge ffeyssinet Prestressed Concrete Co. Ltd, 6/8, 6th Floor, Siatting Centre, Dr. Annie Besant Road, Worl, Maney Managing Director Gysore Structurals Ltd, 12, Palace Road, Bangalore-560052 General Manager Gf State Bridge Corpn. Ltd, 486, Hawa Singh Block, Khel Gaon, New Delhi-t 10049, Broeandakin! Enclave, Greater Kaitashl, New Dethi-t 10019 -1081, New Friends Colony, New Deihi-t 10066 8-43, Sector-14, NOIDA (UP) A:47/1344, Adarsh Nagar, Worl, Mumbaidoo0zs Consultant, E-2/136, Mahavir Nagar, Bhopal4oz016 40/182, Chitranjan Park, New Delhi-110019 Managing Director, Tandon Consultant (P) Ltd, 17, Link Road, dangpura Extn., New Delhi-110014 Ronsttuma Consultancy (P) Lid, 2nd Floor, Pinky Plaza, Sth Road, Khar (W), Mumbai-400052 Chief Engineer (R) SAR Migtaty of Surlace Transport (Roads Wing), New Deth-110001 Highway Research Station, Guindy, Madres.coueae Executive Director (8&8) Deceten Designs & Standards Organisation, Lucknow-226011 Director & Head (Civil Engg ), erat ol ndan Standards, Menak Bhavan, New Delhi 10002 M.S. Guram : Ex-Officio Chief Engineer, B&R Branch, P.W.D., Patiala AD. Narain : Ex-Officio S.C. Sharma - Ex-Officio Corresponding Members Seser Consultant, Consulting Engg. Services (I) Pv. Lid §7, Nehru Place, New Delhi-110019 AY, Director & Head, Bridge Engg. Division, Structural Engg. Research Centre, Ghaziabad (UP) i) oeIRC:SP:47-1998 GUIDELINES ON QUALITY SYSTEMS FOR ROAD BRIDGES (PLAIN, REINFORCED, PRESTRESSED AND COMPOSITE CONCRETE) CONTENTS Page No. SECTION 1 INTRODUCTION 4.4. Background 1 1.2. Need for ‘Guidelines in Quality Systems’ 1 13. Scope 2 1-4. Presentation 2 SECTION 2. GENERAL APPROACH 21. Concept 3 22. Principal Components of Quality System 8 2.3, Requirements of Quality System 4 24. Quality Assurance and Quality Assurance Manual 7 2.5. Classes of Quality Assurance for Bridges 7 28. Guidelines for Selection of QA Class for Bridge Projects 8 2.7. Quality Assurance Manual for Bridges 8 SECTION 3 QUALITY ASSURANCE REQUIREMENTS OF DIFFERENT CLASSES OF QUALITY 3.4. General 15 32. Project-Specific QA Plan 18 3.3. implementation 16 SECTION 4 TYPICAL QUALITY ASSURANCE PLAN FOR CONSTRUCTION AND DESIGN 4.1. Introduction 40 42. Organisation 40 4.3. Controlof Data and Documentation a1 4.4. QA Procedure for Setting Out Works and Temporary Works 43 4.5. Methodology of Working 43 46. Control of Materials 43 47. Control of Workmanship Aspects 4a 48. Protection During Construction Stage “4 4.9. Non-Conforming Products 44 4.10. Quality Audit 4 4.41. Design Aspects 45 4.12, Proformae of Quality Records 45 SECTION 5 TYPICAL PROFORMAE a AB Planning Proformae Proforma A-1 Quality Plan for Coarse and Fine Aggregate 47 Proforma A-2 Quality Plan for Mixing Waterfice (Crushed) 49 Proforma A-3 Quality Plan for Concrete Admixture 50 Proforma A-4 Test Frequency Schedule 52 (iil)IRC:SP:47-1998, B: Inspection Proformae proforma B-1 Data Sheet for Sieve Analysis - Aggregate 53 Proforma B-2 Formwork inspection Check List 54 Eroforma 8-3 Reinforcement inspection Check List 58 Profortna B-4 Inspection Check tist Before Aporoval to Concrete 87 Froforma.B-5 Proforma for Concrete Delivery and Pour Record 59 Proforma B-6 Post Concreting Inspection 60 c ‘Survelilance Proformae proforma C-1 Material Quality Surveillance Form 61 Proforma C-2 Products Quality Sunveillance orn 62 Proforma C-3 Surveillance Form for Pre-Conereting Operations 63 Proforma C-4 Quality Surveillance Form for ‘Workmanship of Concrete 64 D: Proformae for Registers and Records Proforma D-1 Particulars of Work 66 Proforma D-2 Register of Drawings 67 Proforma D-3 Cement Register 68 Proforma.D-4 Consumption of Cement on Different Items of Works (Theoretical and Actual) 69 proforma 0-5 Records of Calibration of Equipment 70 Proforma D-8 Daily Progress Report a Proforma D-7 Register of Inspection Notes 72 Proforma D-8 Register of Observations Memos Issued from the Quality Controt Cel 73 Proforma D-2 Record of Prestressing Work 74 Proforma D-10 Grouting Record 75 Proforma D-11 Proforma for Result Analysis (Comeni) 76 Proforma D-12 Proforma for Result Analysis (Concrete) 7 & Proformas for Procedural Guidelines of QA System proforma E-1 Guidelines for Non-Contorming Works 78 Proforma -2 Quality Audits 80 ANNEXURE Definitions and Terminology 82 BIBLIOGRAPHY 87 wy)IRC:SP:47-1998 SECTION 1 INTRODUCTION 14. Background ‘The Committee for Reinforced, Prestresed and Composite Concrete Bridges (8-6) was constituted by the Indian Roads Congress to look into various aspects including improvements in the existing codes and practices. The composition of the Committee is as under : 4, Shri Ninan Koshi Convenor 2. ShriN.K. Sinha Member-Secretary Members 3. Shti$.G. Joglekar 42. Dr. T.N. Subba Rao 4. ‘Shri D.T. Grover 43. Shri Jayant Basu Roy 5. Shri A.D. Narain 44. Shri P.B. Vijay 6. Shri Shitaia Sharan 15. Shri V. Murahari Reddy 7. Shri M.K, Mukherjee 46. Shri VIM. Madge 8 Dr.M.G. Tamhankar 17. Shri P.D. Gupta 9. Shri Mahesh Tandon 18. Dr.N. Rajagopalan 10. Shri MK. Bhagwagar 19. Rep. of R.0.S.0. 11. Shri S.A” Reddi 20. Rep. of Bureau of Indian Standards Ex-Officio Members 4; President, IRC, (Shri M.S. Guram, Chief Engineer, Punjab PWD B&R, Patiala) 2. Hon. Treasurer, IRC (Shri A.D. Narain, Director General (Road Dev. & Addl. Secy., MOST) 3. Secretary, IRC, (Shri S.C. Sharma, Chief Engineer (Roads), MOST) Corresponding Members 1. Shri Ashok Basa 2. Shri A. Chakrabarti 8. Shri P.S. Tyagi ‘The B-6 Committee decided that a document be prepared on ‘Guidelines on Quality Systems for Road Bridges’ using reinforced, prestressed and composite concrete construction, keeping in view surrent international practice. In July, 1993 the Committee appointed a Group with the following personnel, for preparation of draft guidelines: Shri N.V. Merani Convenor Shri S.G. Joglekar Member-Secretary Shri A.G. Borkar Member Shri S.A. Reddi Member Shri P.Y. Manjure Member Shri Shitala Sharan Member ‘The draft guidelines prepared by the Group were discussed by B-6 Committee and were approved on 14th February 1996. These were further considered and approved by the Bridge Specifications and Standards Committee in their meeting held at New Delhi on 2.12.96. Later on, ‘these guidelines were approved by the Executive Committee during its meeting held at New Delhi on 21.12.96 and by the Council during its meeting held at Nagpur on 13.1.97. 12. Need for Guidelines in Qui In order to achieve the aim of building safe, serviceable, durable and economic concrete bridges, the structural elements should meet Certain requirements. The characteristics that a structure should Systems 1creas 0 ull these requirements have to be spectied. The codes of practice and the contract documents Sue te achieve this by way of defining design criteria, practical res, technical specifications, testing ara SGceelance criteria and workmanship. All these strategies implicitly depend upon human exit for inet: Successful and reliable application which, eventually, determines the quality of the bridge. ‘The basie decra ‘© produce qually work is essential inthe rinds of all those connected with bridge projects, ir 0rdes te achieve the required level of quality ofthe fine produc, as specitied by engineering Seer at osessaty to have a strategy for management oi human skillsby way of Quality System defining Fath pofey, quality assurance pian and quality eueit. Apart rom ths, itis also necessary o expleily dling ey sell, which is expected to be achieved through the Quaity System. These guidelines hove, eselare, Been evolved to facilitate preparation of appropriate Quality System for individual bridge project ees. aney application ofthese guidetines willinculeate, inal those involved in bridge building actviy, an abily eeegae. tne Product or services expected of them consistently, thereby, assuring the users and instiling confidence in the users. in dralting these guidelines, an attempt has been made to achieve compliance with the intemational codes of 1SO £000 series on Quality Sysioms, published by Intemational Steraacs Grganisation, "Compliance with the prosent quidelines will bs a step towards obtaining. ISO Quality Certiication, enabling Indian designers and contractors to compete internationally. 13. Scope Tee guidelines cover quality systems for activities of bridge construction using concrete Clements, These include project preparation, design and drawing, construction and supervision, conte gapagement, quality of materials and equipment used in construction, and workmanship, The guidelines Sho cover the organisational requirement for adoption of quay system by suppliers, purchasers, owrocs approving authorities and consultants. These guidelines will enable : |) compliance with codal requirements of quality control, #) setting up of internal quality systems for each of the organisations dealing with various aspects of bridge construction, ii) setting up of external quality systems by the supplier, to ensure conformance to specitied requirements : ) at final inspection of, ) during production and installation, of ©) during several stages such as design/development, production, installation and ‘maintenance '¥) setting up of long term policies and procedures for quality systems. 14. Presentation ‘These guidelines are presented in the following sections : i) Section 1: Introduction i) Section 2: General Approach lil) Section 3: Requirements of different classes of Quality Assurance: '¥) Section 4: Typical Quality Assurance Plan for Construction and Design ¥) Section 5: Typical Proforma ‘At the end of the guidelines, definitions and terminology are given as an Annexure,IRC:SP:47-1998 SECTION 2 GENERAL APPROACH 21. Concept ‘The term ‘quality’ has been defined as the totality of features and characteristics of a product or Services that bear on its ability to satisty stated or implied needs. In the contractual environments Needs/requirements are specified, whereas in other environments implied needs/requirements should be identified and defined. |The code of practice endeavours to meet the requirements by a three pronged strategy. Firstly, it specifies the acceptable materials of construction outlining the various tests of acceptance; Secondly, it define various design criteria practical rules and sound engineering practices for guiding the designers in arriving at appropriate structural solutions; and thirdly, it deals with the workmanship and other aspects of construction which ensure that the design intents are realised in actual construction. The contract documents and technical specifications define the inter-retation of various parties to the contract as wel as the requirements of quality. All these strategies implicitly depend upon human skill for their successful and reliable application, The total system of policy, management responsibilty, intemal and external control, testing and Quality control, acceptance criteria, corrective action, and documentation is covered in the quality system, It also encompasses the overall organisational structure, responsiblities, procedures and processes for implementing quality management. The aspect of overall management functions that determines the quality Policy and implements it by such means as quality planning, quality control and quality assurance within ite quality system, is referred to as ‘Quality Management’. The terms used in the field of quality management have acquired specific meanings and applications, different from the generic definitions found in dictionaries. Internationally accepted definitions and terminelogy have been included in Annexure, which also gives corresponding usage in relation to bridge projects. The ‘purchaser’ or ‘customer’ is the term used for those who place order for the ‘product’ or service” and the term ‘supplier for those who undertake to procure/produce/supply the same. The quality of the product (oF service) is ensured and maintained by following a documented ‘Quality Plan’ which sets out Specific quality practices, including ‘Quality Control which are operational techniques of controling quail. ‘Quality Assurance’ (QA) includes all those planned actions necessary to provide adequate confidence that the product (or service) will meet the requirements, and is essentially a system of planning, organising and controlling human skills to assure quality. Quality Assurance Plan sets out the planned actions required for Quality assurance. The continuous monitoring and verfication of the status of QA activity to ensure that itis being followed is called ‘Quality Surveillance’. ‘Quality Policy’ is a formally documented statement of ‘management's intentions and directions as regards quality. ‘Quality Audit is a managerial tool used for reviewing the whole or @ part of the quality system by internal or external agencies not connected with the operation of QA plan. “Total Quality Management’ brings to these concepts a long term global management strategy to achieve and improve quality and calls for the participation of all members of the organisation for the benefit of the organisation itself, its members, its customers and society as a whole. 22 Pri ‘cipal Components of Quality System Implementation of quality system involves the following principal components : }) Supplier's Quality Policy ‘Commitment of the management of supplier to achieve and sustain quality of the product or service to meet purchaser's stated or implied needs, whether contractually required or not. ii) Purchaser's Quality Policy Commitment of the management of the purchaser to obtain quality product or service to meet his stated or implied needs.. This includes quality plan of the purchaser to satisty himself about. the quality of end product.IRC:SP:47-1998 iy Internal Quality Systems Internal quality systems of all concerned organisations including quality plan, quatity Sseurance, control of non-conforming products, quality audits and corrective aed |v) Inspection enc Audit inspection and audit of internal quality systema, mutually conducted Guality control tests, or achendently conducted testing by third party and certifcation, ve acs Give confidence to Purchaser or his appointed agent, when required by contract 23. Requirements of Quality System “The requirements of quality system as given below are aimed primarily at achieving owners Satisfaction by preventing non-conformity ) i i) wy » vi) Management Responsibility Zhe cupplior's management shall be responsiblo for quality Policy. This will include resource spebllisation. organisation of personnel defining clearly the responsibility, authority and or aeattation for performance, management and vertication functions nes ot reporting, contro! °f non-conforming product and review and updating, Quality System The supplier shall establish, document and maintain a Quality system including quality plans, Quality manual and procedures. Contract Review Supplier (Designer) shail establish and maintain documented Procedures to control and verity {he design to ensure that specified requiremonts are met, Trees should cover the aspects of Gesign input, design activity, design ouput, design review design verification, design changes, ‘and design validation, Document and Data Control de, SuPlior shall establish and maintain documented procedures to Control all documents and data which relate to the requirements of these guidelines, This Control shall ensure that obsolete documents are Promptly replaced. The spangesimoditications to documents should be promptly intornon to all concerned and documents re-issued incorporating changes, Purchasing ine cupplier shall establish and maintain documented procedures to ensure that purchased Product conforms to specified requirements. Evaluation of sub-contractors, maintenance of purchasing data and verification of purchased produc, constitns Important components of this requirement,vil) vit) x) x) xi) IRC:SP:47-1998, Control of Customer Supplied Products ‘The supplier shall establish and maintain documented procedures for the control of verifcation, storage and maintenance of customer-supplied products, provided for Incorporation into the supplies of for related activites, Veriication by the supplier does not absolve the customer of the responsibilty to provide acceptable product. Product tdentification and Traceability The supplier should maintain data and documentation, which allow product identification and traceability during all stages of production and delivery. Process Control The supplier shall identify and plan the production, installation and processes that directly affect the quality and shall ensure that these are carried out under centrolled conditions. Documented procedures defining manner of production, use of equipment, compliance with reference to standards/codes, monitoring, control and approval of processes and workmanship Constitute important components of process control, Special situations where the quality of results cannot be fully veritiod by subsequent inspectionvtesting of the processes shall be carried out by qualified operators and/or shall Fequire continuous monitoring and control of process parameters to ensure that the specified requirements are met, Inspection and Testing ‘The supplier shall establish and maintain documented procedures for inspection and testing of activities in order to verity that specified requirements for the products are met. Incoming product should not be used by supplier, prior to inspection and testing. However, in ‘xceptional situations where itis thus used, it shall be positively identified and recorded in order to permit recall and replacement in the event of non-contormance to specified requirements, In-process inspection and testing shall be carried out as required by quality plan and/or documented procedure, ‘The final inspection and testing shall be carried out in accordance with quality plan and/or documented procedures to complete the evidence of conformance of the finished product to specified requirements. No product shall be dispatched until all the activities of the quality plan have been satistactorly completed. Where product shail fail to pass any inspection and/or test, the procedures for control of non-conforming product shall apply. Records shall identify the inspection authority responsible for release of product. Control of Inspection, Measuring and Testing Equipment Documented procedures to control, calibrate and maintain inspection, measuring and testing ‘equipment shall be established and maintained. The equipments should be kept in good operating condition, calibrated at the specified frequency, and used as per instructions. All records about the equipment, including its identification, calibration, malfunction, repair and. certification should be maintained,SRO:8P:47-1098, xii) xiv) x») xvi) xvi) Inspection and Test Status ins insPection and test siatus of products shall be identified by suitable ‘means, which indicate Fecaugane® oF non-conformance of produst with regard to mspection wy tests portormed, Records shail be maintained to identity inspection and test stores, Control of Hon-Conforming Products irre supplier shall establish and maintain procedures to ensure that on-contorming product is Prevented from inadvertent use or installation, Non-conforming product shall be reviewed in accordance with the documented procedures for a) Reworking to meet the specifications, 0) Accepted with or without repair with concession, ©) te-graded for alternative use, or 9) rejacted/scrapped. These activities and their results should be fully documented, Corrective and Preventive Actions Meneling, Storage, Packaging, Preservation and Delivery ree ccuPplier shall establish document and maintain procedures tor handling, storage, Packaging, preservation and delivery of product, rose Wpplisr shall arrange forthe protection ofthe quality of produet after final inspection and sacinstner® contractually specified, this protection shall be entender cy include delivery to destination Contro! of Quality Records ine Supplier shall establish and maintain documented procedures for identification, collection, indexing, access, fling, storage, maintanance and disposition of quality records. Quality sffoctive oranges maintained to demonstraté conformance to the rowued quality and the Siective operation of the quality system. Pertinent sub-contrectere uality records shall element of these data, Retention times of quality records shall be established and recorded Where agreed Pontactually, quality records shall bo made available for avaluaticn by the purchaser or his representative for an agreed period, and maintain documented procedures for planning and inelementing internal quality aucts to verity whether quality actitcg ‘comply with planned Srtaagemonts and to determine the effectiveness of the qualily system {nteral audits shall be scheduled on basis of the status and importance of the activity to be audited. The management personnel responsibie for the area shall take timely corrective action on the deficiencies found by the audit,IRC:SP:47-1998, xvill) Training xix) Servicing winore servicing is specified in the contract, the supplier shall establish and maintain procedures for performing, veritying and reporting that servicing meets the specified requirements, x) Statistical Techniques Where appropriate, the supplier shall establish procedures for identifying need for statistical techniques required for controlling and veritying process capability and product characteristics 24. Quality Assurance and Quality Assurance Manual (Quality Assurance (QA) is defined as allthe planned and systématic activities implemented within {he Quality System and demonstrated as needed, to provide adequate confidence that an entity wil lll the recponclatcs, Soaulty Assurance Manual provides a base document outlining policy, procedures, Da eanties: Compliance, acceptance criteria and decumentation. It should be prepared and accepted by all parties concemed before start of project. !tshould generally cover the following : 2) Identification ofall parties involved in QA and their inter-relationship. b) Internal QA system of each party. ©) Levels of cross-checkingveriication in ease of multiple vertications/controls, including systems of inspection and audit, wherever applicable. ©) Organisation of personnel, responsibilities and lines of reporting for QA purposes. ®) Griteria for acceptance/tejection, including identification of proper authorities for such decisions, §) Inspection at the end of defect liability period. 9) Items to be covered in maintenance manual. h) All formats for documentation. Aoi or @ Product, theultimate responsibilty of compliance with QA Manuel and of achieving roquired quay generaly resis with one party. When process and/or product control is carried out by the suppiier/prviaeey or his agent its termed as intemal control or ‘one level control. For important items of works indepenelont Barallel checks/supervision are carried out by one or more agencies, either on fll scale cr on sampro toca, ‘This is normally cariad out as extemal control or second level control. In some cases, thitd level of conte may also be required such as that by a regulatory body or by insurance agency. These levels of contol Should be clearly defined in the Quality Assurance Manual. The Manual should also ident the responsible Parties, their functions and inter-relation between them, 2.5. Classes of Quality Assurance for Bridges Depending upon the levels of checking/cross-checking and controls, required to provide adequate confidence, four classes of quality assurance are mentioned below : Classes of Quality Assurance Class Nomenclature 4. Nominal QA a 2. Normal QA Qe 3. High QA’ a3 4, Extra High QA, a4IRC:SP:47-1998 Sines the degree of requirement of {Confidence for bridge construction is very high, nominal QA i.e. Class Q-4 hall not be permitted in bridge Construction. Thus there will be only threo classes of QA for ridge construction, namely @-2, O.8 ang 4, JA consistent set of quality assurance aeilies adopted for aitferent operations wi lead to Achievement of one ofthe three classes ctaened above. The detalied description oy the controls falling in {ne above three QA classes for various éctivities are given in Section 3. Ones desired overall quality cla: 's chosen for a bridge project, !) ction Sf 26, Guidelines for Selection of aa Class for Bridge Projects The following guidelines are given for Selection of appropriate QA class for bridges. The word ‘ridges’ includes tlyovers, culverts ang op Such structures carrying road traffie. 2) No bridge should have QA below class Q-2. 2) Q-2 class of GA can be adopted for following categories of bridges 8) -8 class of QA can be adopted for following categories of bridges 2). Bridges having spans exceeding 20 m, 5). Bridges having tengins more then eo ', having individual span lengths not exceeding 45 m. ©) Bridges having deck area exceeding 480 sq.m, 9) Construction materials: Plain Concrete, Relnloresd Concrete or Presiressed Concrete For bridges across rivers which are Shitting in nature or which present some Problems of ro nig, andlor tose having special founder Provlems, some of the activities may be raised to higher class, 4) Q-4 class of QA can be adopted for following categories of bridges ®) Bridges buitt with innovative Aesign/conetruction/materais cuch as those using very large ©) Bridges at ocations where no alternative routes are availabo nearby, of Where disruption {0 traffic over tong period is “nscceplable, and whore repaiveplacement ener areIRC:SP:47-1998 27. Quality Assurance Manual for Bridges 2.7.1. The owner, consultant, approving authority, main contractor, material supplier, manufacturers of items to be incorporated in the structures, specialistinominated sub-contractors and equipment manufacturers are the parties involved in the overall QA system for bridge construction. Typical organisational structure for various partes involved in design and construction (owners ‘as well as contractors) are given in Figs. 2.1, 2.2 & 2.3, 2.7.2. Various activities on a bridge project can be classified under three major groups Design Construction Manufacturing 2.7.2.1. In design activity, purchaser is the authority who places the order for design and/or project Preparation. it may be either the owner of the bridge as in the case of preparation of detailed design, or the Contractor, as in the case of ‘design and construct contracts. Supplier is the consultant who undertakes to Prepare the design. The design, drawings and tender documents are the end products, The QA manual Should cover those requirements of Quality System, which primarily concern ‘services’ of ‘expertise’. 2.7.2.2. In construction activity, purchaser is the authority who places the order for construction of bridge. Supplier is the contractor who undertakes to construct the bridge. The bridge itself is the end product. 2.7.2.3, The manufacturing activity fails in the following two categories: The first category consists of factory manufactured items of general use such as cement, reinforcing steel, prestressing steel, admixture and the like. Quality assurance of the manufacturing processes of those items need not be covered under the quality assurance manual for bridges. However the requirements of quality system pertaining to the specifications of quality, testing and acceptance Procedure, procurement, storage, traceability and such other relevant items, which are to be carried out by ‘owner/designer/contractor, should be covered therein. The second category of manufactured items cover prestressing anchorages, bearings, expansion joints, hand rails and the like, which are manufactured by specialist suppliers and are purchased and used 28a finished product in the bridge by the contractor. The quality assurance manual should cover the quality assurance of the manufacturing of such items. 2.7.3, _ Main aspects of activities which affect the quality of a bridge are highlighted below Activity Main Aspects Affecting Quality A Project Preparation (Data collection, 8) Adequacy and accuracy of data, and selection of suitable options, project surveys (including materials survey); document) reliability of data and source; and documentation i) Solutions based on codes and Practices, taking into account for Felevant local and past experience, and documentation, ii) Documentation of all alternatives considered, Review before finalisation,IRO:SP:47-1998 Fig. 2.4 QA. ORGANISATION FOR DESIGN ( ner, Consultant/Contractor) . Levels of Responsibility 1 2 tenegincns Representative ietordessn (0. Qu cep Organisation Imlomexation of Quy Poly & Review 3 Proof Consultant (Needed for) Case : ov ifspited py use) 4° ‘Task Manager (Bridge Engineer) * Including Including Including nctuding Including [Pessons/method —- Analysis, ee GMb earn ee © of internal Design & 7 Gay > Protection - Geologie checking, Detailing ~ Sundari. works & —- Seismologist + approving & > Constructional sation related - Related + independent aspects ~ Computer. specialists Speciaists _Yetification > Tender Docs. gation (rom (from in-house : Interaction Improving in-houge or outside with site Knowledge croutside —souresy . . : turing base sources) : : : consipuction 3 fi ich Meod to be suitably added. The nd special attention is neededIRC:SP:47-1998, Fig. 2.2 Q.A. ORGANISATION FOR CONSTRUCTION (OWNERS) Levels of ee Responsibility DEPARTMENTAL HEAD (ENGINEERING) 1 [ FQM Policy & Overall Responsibility of Proje) 2 Head of QA. in r __.|HO. Regional/Special Implementation of Quality |= + + ¢ + + 6 + 4 +e ee eo! ProjectHead Policy & Review: 1 3 teen eee eens Project Engineer (in-charge of Specific Project) at fea Planning & | [Constrction Contract Engineer Monitoring | | Engineer Management (Site QA Cell Engineer (Supervision) Engineer {Including Including t= Approval of = Checking & construction clearance of QA Manual Intermediate activities = Surveillance ~ Supervision of QA = Checking and Procedures : acceptance of $= Document ei elements of + control 2 strugture Nowet?* seen ceed 1. The Organigram indicates levels of responsibly in four rows. The tines of reporting for execution of work and responsibilty for quality are shown by fll ines and arrow heads. ‘The working level interactions are indicated by dotted lines. Tho decisions concerning relative priorities, and about differences between equal levels are to be taken at higher level of responsibil. 2 For Q-3 and Q-4 QA classes, the responsibillies shown in each box need separate group of personnel with group-head. 3 For GA classes 0-2, some or all activities at one level may be clubbed in one or more groups and the responsibilty of the same entrusted to respective head 4. Instead of Head of GA (Level 4) being a separate wing, itis also possible to make ita part of the office of Regional/Special Project Head. unIRC:SP:47-1908 Fig. 2.3, @.A. ORGANISATION FOR CONSTRUCTION (CONTRACTORS) Responsibility MANAGEMENT 1 [| 0M Policy & Overall Responsibility of Project) — | Levels of = 3) 2 ‘Management Representative (HO. QA Cell) Implementation of Quality Policy & Review see neo . 4 Manager (H.0.) 3 Quality Project Engineer cov] Au prose ee se ee 2 8 2 2 6 94 Gn charge of ProjeeUFunction) 4 5 Jaa. Human Const- Plant & * [Engineer Resources| Planning | | ruction Material} | Equipment = [ite ace | | & safety Engineer | | Engineer | | Engineer | | Engineer . Engineer | of work and responsibility for quality are shown by full ines and arrow heads Tn working level Notes 1 sr aaeaigram indicates levels of responsibilty in four rows, The lines of reporting for execution Uiiforsnne pate iMdicated by dotted lines, The decisions conceming relative protiies, avek any Hiferences between equal levels are tobe taken at higher level of responsibilty, 2. Fath ond O-4 OA classes, the responsibilities shown in each box need separate group of Personnel with group-head. 3 For QA classes Q-2, some of all activities at one level may 'y be clubbed in one or more groups and the responsibility of the same entrusted to respective headle,Design and drawings Preparation of Contract Documents Organisation and Management of ‘Suppliers/Contractors 3 ii) i) » vi) i ii y) » vi) ny ni) wy vy) IRC:SP:47-1998, Detailed Design Basis Report Detailed designs, documentation and ccross-checking Review for constructability and availability of intended construction expertise. Internal review before finalisation, or proof checking, Drawings, bar bending schedules and stressing schedules giving sufficient, unambiguous and clear details specially with regard to assumptions made in the design. Limits of variations in assumptions beyond which reference should be made to the designer, shall also be indicated. Provision of faciltios for carrying out inspection, maintenance and Tepair/strengihening and replacement of certain parts (e.g. bearings, expansion joints etc.) Standardised general conditions of contract including enforceable defect liability clauses, procedures for decision making, in-built mechanism for settlement of disputes, appropriate financial conditions and reasonable Payment schedules. Standardised detailed technical Stipulations of the type and capacity of essential of equipment to be used. Provision and availability of required facilities at site Stipulations with regard to project organisation of contractor as well as the project management organisation of the owner. Stipulation for preparation for QA manual. Stipulations for submission of completion report with all supporting documents and ‘as - built’ drawings, Management's Quality Policy Qualified and experienced technical work force and deployment of trained supervisors/workmen in adequate strength. Preparation of Quality Assurance Manual including provision for quality audit. Mobilisation of adequate resources including suitable plant and ‘equipment and items of falsework. Continuous planning, review and corrective action.IRC:SP:47-1998 Material Procurement Production of items and sub-items of construction (like concrete reinforcement, presiressing cables ete.) Management and Organisation of Owners 4 vi) vi) iy i) ™) ») Adequate financial input including cash-flow and fund management Prequalification of sub-contraciors/ suppliers, Material specifications, inctusing stipulations of Q.C. tests and acceptancelrejection criteria. Quality assurance plan defining documentation with special stross on traceability Adequate stipulations regarding workmanship, Drawings and other documents giving esign intent Ensuring adequate supervision and guality assurance, Inspection and quality surveillance, Deployment of proper and adequate plant and equipment Relevant items covered in (D) & (E) above, Management's quality policy Project specific Q.# plan Froject organisation including deployment of competent personnel Ensuring adequate supervision and quality surveillance. Provision for quality audit.IRC:SP:47-1998 SECTION 3 QUALITY ASSURANCE REQUIREMENTS OF DIFFERENT CLASSES OF QUALITY 31 General ‘This section contains detailed guidelines indicating requirements of different classes of quality for bridge projects. The seloction ofa class for projecs is discussed in Section 2, The requirements of quality control and level (degree) of control are given in Table 3.1 under six sub-heads, as follows: 1) Project Preparation 2) Design and Drawings 3) Contractual Aspects 4) Construction Organisations 5) Materials ©) Workmanship Aspects of project preparation as well as designs and drawings have been covered briefly, and are indicative of the general approach, However, the aspects of construction affecting quality are covered in greater detail 3.2 Project-Specific QA Plan ‘The contents of the table provide broad check list of various activities for atypical bridge project. Based on this table and QA class chosen in accordance with Section 2 a detailed ‘project-specific’ qualily assurance plan shall be prepared in each case. All relevant factors must be considered in detal before finally choosing the overall quality assurance class for a particular project or even for particular activities within the project itself, taking into account the consistency of the QA requirements for all critical components of the bridge. Such QA plan is normally prepared by the owner, or by construction agency, and when prepared by the latter, itis scrutinized and approved by the owners or the consultants to the project. The QA plan shall be documented in the form of QA Manual. The QA plan/manual so prepared should form part of the contract agreement. A typical QA plan for construction activities is illustrated in Section 4, 3.3 Implementation Implementation of quality assurance plan may be carried out by the following methods : 1) Internal control by the construction agency 2)” Extemal control either by the owners or by the third party inspection agency. The choice of agency for enforcement of quality assurance plan should preferably be spelt out in the tender documents. 15IRG:SP:47-1998, TABLE 4 QUALITY ASSURANCE REQUIREMENTS Sr. item ‘Normal QA High GA Extra High QA No. Q2 a3 a4 1. |PROJECT PREPARATION 41] Adequacy ang + Data collection Data collection |. As in a-9, but reliability of deta 12] Q.A. systems a Documentation 2. |DESIGN & DRAWINGS 2.1 [Organisation 2.2 Ja) Drawings from primary local sources gither in-house or through other agencies, Verification and certification at local level within the organisation. Project prepared and approved following’ QA principles and in-house checking and verification Owner's in-house/ ‘consuitants/eontr actors design Offices with established internal QA Procedures, Can be based on type design with Necessary notes to cover variation. 16 from primary local sources and cross checking by other methods either in-house or through Specialised sur- vey and investi- gation agencie: Verification and certification at senior or central level within the or- ganisation, Asin Q-2, butin. dependent checking and review through 8 separate in- house unit, or through exter- nal organisa. tion Asw2Q-2, butine dependent checking and review through an in-house unit or through ox- temal organisa. tion, Project specific drawings made at pre-execution stage indicating limits of validity of details given on the drawing, supplemented by verification and checks through other expert agencies ang use of more sophisticated methods, As in Q-3 but independent checking and review by an external organisation is essential. As in Q-3, but checking | and review by an external organisation is essential Same as 0.3Sr. Item No. Normal Qa, High On a3 IRC:SP:47-1998 Extra High OA Oa b) Bar Bending Schedules, Cable layout & stressing schedule 2.3/Design Review & Proof Checking 2.4|Design Modifi- cations due to site variations or | substitute materials and other reasons 2.5 | As built drawings 2.6|Maintonance of As-built Drawing, design, specitication & construction information, Drawings giving full details issued after internal checking, Bar Bending Schedules, full details of cable layout & stressing schedule to be given by designer, and verified at site by constructor. Designs may be submitted for checking by n-house but independent design unit. Design notes should clearly state the limits of validity of drawings, Reference should be made to design office for changes. As built drawings essential. To be maintained by owner, and maintenance agency. "1 Same as 0-2, Asin Q-2, butin- dependent de- sign checking and review through an in- house unit or through exter- nai organisa- tion. As in Q-2, but all ‘changes incor- porated in re- vised drawings & re-issued within roason- able period, As in Q-2, but all changes incor- Porated in re- vised drawings & re-issued within reason able period. As in Q-2, but full record to be maintained in addition at cen- tral office for govt. depart. ments, Same as 0-2 As in Q-3, but checking and reviow by organisation is ‘essential Same as Q-3 Same as Q-3, As in Q-3, but additionally records to be maintained also by microfilming digital storage methods,IRO:SP:47-1993 sr tem | Normal QA High aa, | Extra High an a2 as | a6 No. | & oe 27| ode restsPreto. | | Opeten | ee oe Same as 0 neous should be? fineness cosy b) Structurar model > Not ordinarily oe Necessary ~ AsinQ-3, butare tee necessary shouldbe care |” A5/%0-2 utara isd cu before | S880ntal fr iinetiation of | Specie spec design, | developments) in eaaiten | ton Prati ite [+ Not orainaniy |. no testing on sings, butno tearing ate Pesos sampivtecby | 5400-3. nano sonic? (wre: ounerappoined | $88R0 on larger aren, te agency tor | Soule 10 ba cheering | 2neeurages achiever mont | She iatiat | of quality is to mobilised if Botrecurgo” | Mobili 2. | conmaacruat aspects | (Contact socumsas 3.1] 2) Prequatitication cromieeerett —|- Prateranie to | preqaitcane (wai Consaion ot eon proavaity cor, |” Praguat | tractor 33 basis of PQ ap. canned’ |- approve airing |e peegvereas | same 08 0 Gonracets course ot woneny |” Rrequalities appronriats | §X Ror toon shore soni | contacraes, Su eee red Wants | specited neIRC:SP:47-1998 Sr. No. tem Normal QA az High QA a3 Extra High QA a4 8.2/2) Specifications and 3.3 34 Contract Docu- ments 'b) Prebid meeting QA Manual Defect liability period. (Respon- sibilities of owner & contractor should be defined in the tender document). Following stand- ‘ard general items of work and specifications. If special specifi- cations are needed for any item of work follow Q-3 level for the same. Complete contract document should be easily accessible. Not applicable. Requirements can be covered in tender document, Minimum 1 year. For manufactured items appropriate defect liability Period to be specified. 19 Complete con- tract documents with full specifi- cations includ- ing all relevant codes should be available at site at all. times Specifications for non-stan- dard items to be detailed, finalised and cleared at ap- Propriate level of resporisibil- ity. Preferable. Asin Q-2, in ad- dition contractor to submit and get approved the QA manual defining all activities with minimum two levels of con- trols. Each of the controlling authority to have their own QA manual cov- ering their re- sponsibilities. ‘One yearin gon- eral and longer as appropriate tor special items, of work, Same as Q-2. Same as Q-3, Essential. As in Q-3, but with minimum three level of controls, for specialised/inn ovative items, Samo as @-3, Same as Q-2.IRC:SP:47-19¢8, 1 = & orn Normal Qa High oA Extra High OA No a2 ag ae coxstaucrion | ORGANISATIONS | 4.1 Organisation of [- Sontractor's | > As in Q-2, but As in 0-3, with contractor | execution staff with separately | additional exter- responsible for setupGagroup | nel “quent, | both supsrviaion for operation of | surveitante 4% and aurvalence of ually plan. aut quality, with | j external | Agencyioviner for auait of quailty j Plan and ite | Sporation, t 1 42|Organisation of Ovmer may have | - As in 0-2, but As in 0-3, with Owner! Project his own execution with spociatly |” adatonal “enter Management Consuitant (Pic) | | 43) Planning of construction activities staff responsible supervision/surve lance of quality, It not, appoint outside agency as PMc, Board planning made by constructor and got approved from ownen/PMC. Deployment of skilled labour. Execution of work only after prior intimation "to owners super. visory represen- tative, Use of Bar Charts recommenced, 20 set-up QA group tor operation of quality plan. As in Q-2, but with consteuc- tion activities planned in de- {ails including material plan ning, sequenc- ing of work, identitying re: quirement of skilled labour, supervisory staff and meth. ods of quality control, Use of bar chart or PERT) CPM techni- ques and regular re- view as part of monitoring and Feplanning ac- tivity, nal quality surveillance and audi, As in Q.3, with involvement of designer/special Ist consultant for work planning of innovative aspects. As in Q-3, with monitosing by special’ cell set up by owner.IRC:SP:47-1998 sr. Hom Normal QA High A Extra High QA No. a2 as ad 4.4 | Supervision Full time super- As in Q-2, with As in Q-3, with visors for all additional full additional speci- construction acti- time. supervi- alist’ level vities, sion by second supervision for independent innovative asp- agency (owner ects, ‘oF consultant) Periodic visits by designeriowner. 4.5 | Quality Surveillance Quality sure As in Q-2, but by As in Q-3 with ‘and Audit veillance by separate QA special audit for constructors’ cells of con- efficacy of qualitied structor and innovative engineers, and owner/PMC. aspects. | owners’ super- {two level QA) visory represen- following format tative, and docu- mented quality i plan, ‘ Regular surv | lance and audit | are essential. 5. |MATERIALS 5.1 | General a) Materials from ‘Small or medium As inQ-2. Also | - As in Q-3, but natural sources scale purchases bulk purchase may also set up from large and from source. own source for established suppliers/ traders, Sources mutually agreed to betwoon contractor and owners’ project toams and documented. May rely on local experience and knowledge of the past performance for coarse and fine aggregates and water. 2 Independent testing/accept- ance by contractors’ & owners’ Q.A. teams and doc: umented, Testing/accept- ance at the start of the project as well as at speci- fied frequency. ‘supply. As in Q-3, but with additional (third level) testing/accept- ance by independent agency (such as PMc or Approved Tost: ing Laboratory) Same as 0-3.iRC:SP:47-1888 Sr. Item No. b) Factory manu- factured items including cement, steal bearings, expansion Joints ete, ©) Records for all materials ) Testing faclities + Manufacturer's tests certificate accepied with sample check by independent agency tor incorporation in structure, 1$0:9000 certi- ficate not essential for manufactured items, Record of sources and purchase dates for all items, For manufactured items record of manufacturers’ test cortticaie, ting trom hearby estab- lished test houses laboratories, 2 Manufacturer's test certificates with sample checks for initial acceptance only. Regular testing at specified sampling fre quency during construction. Set up mutuaity agreed QA methods at two levels for ine spectionvtesting to cover the Specific pur- chase order. Incasethe man- ufacturor has 1S0:9000 certifi- cation, he may be given prefer- ence. As in Q-2, Also record of issue of manufactured materials and location of use, Physical testing faciltios at site, For chemical & Special tests as per Q-2. Use of Chemical testing kits for quick checks at site are to be pre- ferred, Extra High oa a4 Same as Q-3. As in Q-3, but may also have additional inde- Pendent Qa checks at source (third “lever check). As in 0-3, but third “level checking — by appointment of Specialised agency tor innovative asp- ects, As in O-a, Same as 0-3, As in G-3, with Properly equi- Pped testing facilities & laboratory at site under control of QA personnel of contractor & owner (inde. Pendent — of Production team),IRC:SP:47-1998 Sr. Item Normal QA High QA Extra High A No. ae a3 a4 52/a) Aggregates Coarse Aggre- gates Grading Other physical tests (crushing value abrasion moisture contents etc.) Deleterious contents Aggregate reactivity Fine Aggregate (sand) Grading Other physical tests (crushing value, abrasion, moisture contents ete.) At the beginning formix design & for every change of source, For selection of source If in doubt. For selection of source if in doubt. Not applicable. At the beginning for mix design & every change of source. For selection of source if in doubt. 23 Atthe beginning for mix design and for every change of, source/stack and for every ‘major structural element, Atthe beginning for mix design and for every change of, source, Mandatory for selection of source and whenever there is change in source of supply. Mandatory tor selection. of source and whenever there is change in source of supply. At the beginning for mix design and for every stack, change of source/tor every ‘major structural ‘element mix. Atthe beginning for mix design and for every change of, source. As in Q-3, but if necessary with increased fre- quency, (testing at site labo- ratory). As in Q-3 (two level checks at site laboratory), Same as 0-3, Same as 0-3. As in Q-3, but if necessary with increased frequency, (testing at site laboratory). As in Q-3 (two tier checks at site laboratory).IRC:8P:47-1988, Item Normal QA High aa, Extra High OA a2 a3 a4 + Deleterious soureyation of | = Mandatory se |. same asa.a, Contents source if in doubt. lection of source and whenever thore is change in source of sup- ply. + For contro! of Simple but | - Asinae - Asin Q-2, chlorides ete. frequent chemical Supported by i checks at site for checking at ttectiveness, Testing laboratory at site, External labo- ratory checks/ control (two level control), 5.3 | Water + Suitabitity At the beginning. + Same as a.2. + Same as a2 Chemical analysis 5.4/ Cement Normal Physical and chemical tests, Carried out it in doubt. Manufacturers certificate accept. able & testing in case of doubt or Ron-availabillty of certificate u Mandatory at the beginning of Project and re- Peated (for chlorides and sulphates) in between if any change is per- ceivedisuspec ted in water quality (inelud- ing seasonal changes), As in Q-2 and at frequency of each new con- signmont and documented Special tests will be required for special ce- ments, + Asin Q-3, but at increased frequency during working, As in a3. Testing carried ; out at site laboratory and indendently cross-checked at predetermined frequency.IRC:SP:47-1998 Sr. Item 5S + Form of purchase, storage, trans- portation, and use within acceptable time limit Admixtures a) Approval b) Dosage —dis- pensing and production con- trols at sito Normal QA High QA, Extra High QA a2 a3 aa Trade Purchases, Supply tromfac- | - Sameas a3. intermediate storage invdry and, covered place, transportation and use of factory filled, machine stitched bags. May be permitted under specialist supervision in which case follow Q-3 controls. Dosage to be finalised atter field trial mixes, special mechanical dovices to be used tor dispensing, Frequent checks for specific gravity. Continuous moni- toring of work- ability of concrete. 25 tory with direct transportation from factory to site godown/ silos. Transpor- tation and trans- shipment supervised and documented Independently carried out ac ceptance test- ing after field trials for each Re-trials with change in Source of, Cement Routine check- ing by testing for every batch of admixture. Manufacturers’ data/certificate acceptable as basis of com- parison for pro- duction lot. Same as Q-2. ii) As in Q-3, with additional inde- pendent tests, Chloride con- tents Spectroscopic signature of accepted pro- duct as basis of comparison for production lots. Same as Q-2.| Sr | No, IRG:SP:47-1998, stem Normal QA a2 High OA a3 Extra High QA a4 °) Training of site staff by manufacturer 5.6 | Reinforcing Stee! Normal Physical Tests Chemical Composition Welding Visual inspection of concrete after striking forms for local defects (including delayed setting). Proper training of site staff in use as well as ‘quality control, plus Periodic visits by manufacturer's expert. Once at beginning and for every change in source in addition to manufacturer's certificate. Once at beginning, and if in doubt for any source, Not ordinarily Permissible at 26 Same as 0-2, As in Q.2, and for each con signment, Same as Q-2 Welding to be done only by qualified and tested welders, Types of elec- trodes to be specified for each purpose, Random testing of welded joints for strength, As in Q-2, but visits by experts at close frequency, As in Q3, but further suppli- mented by random checking by QA team, Same as 0-2, As in Q-3, but welders to be periodically tested and also welding to be examined by experts after destructive tests.IRC:SP:47-1998 sr. Item Normal QA High OA | Extra High QA No. 2 as | a4 5.7 | Prestressing Steols/ ‘Anchorage Systems and Cable-anchor- age assembly a) General (for all In a sealed and Same as 0-2. - Same as Q-2, items of pre- moisture proof stressing including godown with equipment) ‘minimum openings store above ground level on raised supports or in racks. = Storage ‘Such godown will Same as Q-2. + Same as 0-2 have humidity control. In addition, vapour face inhibitors and/or water soluble oils to protect steel = Compatibility of of Same as 0-2. + As in Q-2, but various compo- nents Methods of handl- ing & caretaking anchorages for use with wires/ strands (meeting relevant speci- fications) to be certified by the manufacturer of anchorages. Also compatibility of all other materials and equipment to be thus certified/ cleared Also the manu- facturer to supply special assistance at site, if required, to. train’ and supervise _per- sonnel at work. an Same as Q-2. compatibility established at site as required by QA team. + Sameas 0-2,IRO:SP:47-1998 sr. | No. | 4 tem Normal Qa, a2 High OA as - Extra High QA a4 b) HT Wires/ Strands Mechanical Pro- Perties (Tensile Strength, Proof Stress) Modulus of Elasticity Relaxation Test Chemical Com- Position Packing Transportation Manufacturer's Test Certificate can bo accepted. Additional Testing iin doubt, Insist for manu- facturer's certi- ficate giving stressistrain curve and modulus of elasticity. Samplo testing witnessed by independent QA team, Manufacturers contificate. Manufacturer's Contficate can be accepted with special testing, if in doutr, Packing with two layer for water- Proofing and mechanical pro tection, Transport vehicle check. Protection from environmental or Physical damage, 28 In addition to manufacturer's certificate, tests done on random samples fora lot of 50 T, or part thereof and wit. essed by inde- Pendent QA team at random, - Same as -2, + Modulus estab- lished initially (acceptance test) + Testing & Corti. fication essen- tial for 1000 hours test by dependent test house. + As in 2-2, plus testing by inde. pendent agency on random sam ple basis, + Same as a-2, + Same as Q-2 As in Q-3, but for every | coil. Sample testing witnessed by independent QA team at specifiod frequency. Same as Q-2. Modulus estab- lished initially and verified by works test, As in Qs. Also tests to be witnessed by contractors/ owners QA team, Samo as 0-3, Same as 0-2, Same as Q-2.IRC:SP:47-1998 Sr. tem Normal QA High QA, Extra High OA No. a2 as a4 + Suitability of coil + Coils handled | - Sameasa-2 Same as Q-2, sizefweight for use by mechanical at site dovices prohibiting movement by rolling. - The wire/strand | should be free of kinks or defor- mations and straight. - Contact with contaminated surfaces avoided. ©) Anchorage Sys- + Permitted using | - As in Q2 but As in Q3, but in tem (Chemical anchorage of supported by addition QA Composition Geo- established manufacturers plans should be metry & Hoat manufacturers of detailed QA independently Treatments, Supp- long. standing plan (which can checked by QA lementary Tests) based on be verified by teamand verified certification of | purchaser if at manutac- suitability & quality | necessary). turer's facilities. by manufacturer. 4) Cable Anchorage Assembly (Accept- ance Testing) + Static Tensile test + Not normally | - Manufacturers Manufacturers & load transfer required. certificate. certificate and test. certificate by testing at independent laboratory as per FIP Guide. Tests may be repeated at the beginning of the project with the Proposed materials & witnessed by the representatives: of contractor! + May addition- 29 ally require test- ing at site or at independent laboratory as per FIP Guide.IRC:SP:47-1998, os aaa ee — = Sr Item Normal QA High aa, Extra High QA No. a2 as as + Dynamic Test for eed MANY | - Manutacturers | As in ag, plus 58 59 Cable/Anchorage assembly ©) Sheathing/Cable Duct > Supply + Workability and Transverse bend- ing test as per IRC:18 Any othor materials (like expansion joints, bearings, | tailing etc.) New Materials required Purchase from manufacturers with” metalic sheathings coated with water soluble tust-preventive oil, Test certificate by the Manufacturer for each lot to be furnished, Manufacturers’ Cerificate supp- orted by sample testing, Normally not to be used. “If used, same as Q.3, 30 certificate of testing, Also indepen. dent laboratory testing ae per FIP Code, once for new system of anchor. ages/cables. Same as 0-2, As in Q-2, but additional inde- pendent test to be done on ran- dom samples. As in Q-2 with higher — fre- quency of test- ing and QA plan of man- ufacturer to be initially ap- Proved, To be accepted by competent technical au- thority for use after full testing ateegiabores toryland field tei- als. any additional tests that a QA team may require, As in Q-3, but Preferable to fabricate shea. thing freshly at site at the Fequired rate. As in Q-3, but at higher frequency plus any additional test that Q4 team may require. As in Q-3 with implementation of QA plan of manufacturer to be audited by QA team of owner to the extent depending on the importance of the item. As in a3 ‘supplimented by independent checking by QA. team of special- ist consultants. eIRC:SP:47-1998 Sr. tem Normal QA High QA, Extra High QA No. az as a4 Special speciti~ ‘ations for prop- erties, testing and acceptance criteria to be evolved and laid down for use at site, 6. | WORKMANSHIP 6.1 |General Controls : (Direct & indirect) a) Working & Skilled and Skilled workers Same as 0-3, Supervision semi-skilled having special workers. Periodic super- vision from owner or his agent. Periodic check by designer during site visit. 31 training and working under experienced su- pervisors (Where trade qualifications are’ existing should be in- sisted upon), Full time super- vision from con- tractor as well as from owner or his agent. ‘As in Q-2, but at Predeter-'mined stages and fre- quency. Documented in- spection and certification of compliance by dosigners’ rep- resentative As in Q-3 but with occasional supervision by expert external agency. Asin Qs In case of bridges having new technology/ design full-time site represent- ative of design agency will be necessary, Same as Q-3,IRC:SP:47-1998 = peat sx | item | Normal QA High aa ExtraHigh aa No. | ae a3 a4 ») Use of Mock- upet 7 aurea ety | For as quaity |- As in aa, but required. mock-ups are mado mandatory | required only for for all difficult certain lo. and important ments (typical zones. slice and diffi- | cult zones), which should be Specified in ten- der document, Mock-ups to be carried out in Presence of de- | signer and QA team of owner, | ~ Mock-up shoud | Also, mockupe use actual pro- |” eating oak tes Posed methods techniques to be Sf construction, caried out under including plant | Supervisicn et and equipmont expert external agency No work on |. Asinas structure should bopermitie be- | fore demonsia: tive mockup, 6.2 | Concrete mix design Me emoctsion [- Asmazwin |. semoa pertormed at |” minima wt Beginning of work Tovel controls | or for new source of materials with subsequent Q.c, {as per code and by exporienced supervisors achieve satisfactory G) _Te.establish effective methods of traneporting, Placing and compacting, ) Training of workers for operation in (2) abowe #) To demonstrate efficacy of the overall construction ‘operations in achieving its aim. p sshve sete ella and choise of conte mix and making medicaionn either or both to concreting. 32IRC:SP:47-1998 sx tem Normal OA | ign oa Extra High OA No. o2 a8 oe 63 |Fabrication and Site bending by |. Sameas@-2. |- Same as a2 fixing of skilled workers | reinforcement with “regular | checking by | qualified super- visor. | | Bar bending Sameasa-2. | Asin 2 except Schedules are bar" bending made and checked | schedule made before use. | by design office only Correct placement As in a-2, but | eame as a, of reinforcement checked and and provision of documented by Proper cover QA team. Checked indepen: dently “before conereting, 6.4 Fabrication & Fixing «|= Normally not of Prestressing Cables a) Cleaning b) Preparation of steol/cables applicable. if used, follow Q-3 practices. 3 Should be free of rust. Light rust on wires (not strands) can be re moved, wires cleaned and used. Pre-fabricated and sheathed cable can be permitted, However, post- threaded’ wires/ strands just be- fore stressing are to be pro- ferred Cables strictly Prepared on raised/clean benches and kept free from dust at all times. - Only unrusted steel, can be used, - Only post threading of wires/strands permitted (with exceptions if unavoidable), = Same as 3,IRC:SP:47-1998, sr. No. Item Normal QA az High a, as Extra High OA aa 65 ©) Laying & Suppor ing Formwork, a) Materials Any — suitable material meeting codal require- ments and capable of giving specified form finish, 34 Cable layout Prepared giving co-ordinates at close intervals as needed by fixing require. ments (and not by theoretical curves or equa- tions atone), and supported firmly in place. Post threaded cable ducts should be held against floata- tion during con- creting, Layout and leak tightness of sheathing to be independently checked and documented by owner's Q.A, Team of his agent. Same as Q-2, Asin Q-3, As in Q-3, with additional checking and testing required by QA teams. ‘Sample checking by expert external agency, As in Q-2 with regularly and Properly maintained shuttering with limited re-uses. Shuttering capable of absorbing air released from concrete and Providing good insulation to control thermal gradients is to be Used. If steel shutters are used, plywood: liners or provi- sion of sack- Tubbing after deshuttering,IRC:SP:47-1998, Sr. tem Normal QA High QA Extra High QA No. a2 a3 a4 b) Design Check Spot checks. + Formwork/des- Same as Q-3, ign made and approved inde- pendently. /c) Specialist Specialised form- | - Specialised Samo as Q-3, Systems work systems formwork sys- need not be tem, to be pre- insisted upon. ferred with properly trained carpentersifitte 1s. 4) Experienced ‘Semi-skilled/skill + Skilled carpen- Same as 0-3 9) f carpentersiftters Tolerances, geo- metry and leak- tightness checks Deshuttering Formwork for Special Structures ed carpenters! fitters under supervisory staff Frequent checks by carpenters/ fitters and checking of important mem- bers by super- Visory statt Under supervisory staff for important members. Not Applicable. 35 tors/titters under super- visory staff with the work super- vised addition. ally by owners’ supervisors or agents, Checks for all ‘members by su- pervisory staff As in Q-2. The system should provide for grad- wal, uniform and shock-free deshuttering ar- range- ments. As per design requirement under control of qualified staff, with additional supervision by ‘owners’ supor- visors or agents. Checks by QA team till procedures at site are estab- lished As in Q-3. Also check for quality of shutter surfaces before re-use & docu- ment clear ance. Same as 0-3, Same as 0-3,IRC:SP:47-1998 Sr. Item Normal A High Qa Extra High QA No. a2 a3 a4 6.6 | Mixing/Conveyan/ Site mixing by As in Q-2 unde Batching plant is Placing/Curing of Conerste mixers or batching plant near site Occasional two tier control and documented, Transportation by head ioads/tolies or by mechanised vehicle permitted Experionced con- creting gangs under supervisory staff, Placing concrete and compacting under supervisory statt Proper curing under frequent checks 36 two level con- trols, upto 200 m length of bridge beyond which batching plant is manda- tory Use specialised equipment for transportation, ‘The adverse of focts of the methods of con- veyance (segre- gation delays slitfening of mix etc.), should be regularly moni- tored controlled and docu: mented, As in Q2, with two level’ con- trols. Also regu: lar control by qualified staff. Method of con: trol by pour card recommended, As in Q-2, Also regular control by qualified staff, Surveil- lance by QA team. As in Q-2, but checked by in- dependent su- pervisors and documented. mandatory Occasional checks by expert external agency. As inQ-3, Same as Q-3, Sameas Q-3, but occasional check by expert external agoncy. Same as Q-3, efficacy of methods to be regularly checked and domonstrated,IRC:SP:47-1998 Sr. tem Normal QA, High OA, Extra High QA No. a2 as a4 6.7 |Siressing of Cables + Normally not Stressing equi- pment Stressing Oper- ations Check of friction and wobble losses applicable if used, follow a3 practices. Ey Stressing equip- ment calibrated, tested and corti- fied by manu- facturer/ supplier. Checking and re-calibration at site at regular pre-determined frequency by qualified staff under supervi- sion of owner and his agent. Only under strict super- vision of stressing super- visor and site engineer. The manu- facturer to supply spe- cial assistance at site to. train personnel and supervise work. Sample basis check for olon- gation/pull in of all wires/strands in the cable as- sembly (unifor- mity of stressing). In-situ check on losses by stressing from one side jack using as active jack and other as a passive jack on a sam- ple basis. As in Q-3, in presence " of independent expert or by QA, team. Same as Q-3, with surveillanes by expert or QA team, Same as 0-3, As in Q-3 with additional tests as required by QA team,IRC:SP:47-1998 sr No. Normal QA, a2 High OA as Extra High OA a4 68 Grouts & Grouting a) Grouting of Prestressing Cables = Composition and Physical properties + Fluidity test bleeding characteristics during working, = Equipment | = Normally not applicable. if used then follow 0-3 practice. 38 (For long cables and high total deviation the passive jack may not register pressures wit in stroke length of active jack. For such cases ‘special tests oF provision of short cables may be re quired.) At the beginning of work for designing suit- able grouts. Physical proper- tios to be veri- fied once ina week or with change of batch ‘of cement or ad- mixture. By visual in- spection Testing at fre- quency of once a week or with change of batch of cement/ad- mixture, Equipment tested & passed for satisfactory performance regularly. = As in Q-3 which check for. every operation, + As in Q-3 but tested and documented for every oparation. + As in Q-3 with testing wit nessed by independent QA team.IRC:SP:47-1998 Sr. tem Normal QA High QA Extra High QA No. az as | Workers/Super- Trained staff |- Sameasas visors under qualified supervision. Surveillance by QA team, + Adinixtures Where used, as |- As peritem 5.5. b) Grouting with non-cementitious/ special materials, Jc) Coment Grouting for bolts & fixing apparatus Use of special pre-packaged high strength non- shrink — grouts preferred. Methods to be established on mock-up. por item 5.5. Normally not re- quired. If used follow Q-4, As in Q-2 with regular sample checks for effi cacy. Materials like grease, powder coatings, or other specially formulated mixes should be used only after thorough testing for suitability including tong term effects and by _ following specially deve~ loped suitable methods under expert super- vision, As in Q-3 with increased fre- quency of, checking. 39,IRC:SP:47-1998 SECTION 4 TYPICAL QUALITY ASSURANCE PLAN FOR CONSTRUCTION AND DESIGN a4 Introduction Quality Planning to assure quality of product has been adopted over the last few decades for special and complex projects. However, in case of bridge engineering and construction, some efforts in this regard are visible oniy in the recent few years. As a result of continuing efforts, it has become possible to evolve appropriate methods and level of documentation for Quality Assurance Plan for bridge projects. Surveillance of project implementation if well organised into a quality assurance plan, contributes towards the quality. For this. step by step procedures, which would help in achieving consistent and ‘comprehensive methods of checking and approval of works at every stage, need to be established and documented. These procedures should be reviewed periodically, amended as found necessary, and revised documents prepared. All parties involved in the QA pian should have their internal QA systems clearly defined in form of a specific Quality Assurance Manual (QAN) for the respective purposes, such as, QAM for Design (by the Design Organisation), QAM for construction (by the contractor), QAM for manufactured products (by the manufactures or suppliers). Itis also necessary for owneripurchaser to have his own internal QA plan. QAM {for bridge projects as a whole integrating all these plans shall be prepared/or approved by the owner and/or approving authority, if any. Each vendor (i. supplier, designer, contractor, manufacturer) will thus have its ‘own internal QA procedures which are required to be agreed upon, in advance, with the purchaser of the respective activity. As bridge building in india is mostly undertaken by Govt. agencies, itis necessary that the contractor/designer obtains concurrence of their QAM from the concemed Government Department (Department). The Guidelines provided in Sections 2 and 3 should be used by the respective parties in evolving their internal QA Systems. As an illustrative example, this Section 4 deals with the structure and contents of the operational QAM to be agreed between the contractor and the Department for adoption at site (Quality assurance plan fora bridge construction project, documented in quality assurance manual, ‘would essentially comprise the following aspects : — Organisation — Contro! of data and documentation, both product (bridge) rolated documents, and quality related records together with control documents — QA. procedure for setting out of works and temporary works — Methodology of working — Control of materials — Control of workmanship aspects Protection during construction stage Non-conforming products = Quality augit 42 Organisation In most of the cases, the management of the constructor shall be responsible for jointly reviewing “ne requirements of the project with the owner, and structuring the appropriate organisation for the same. this project specific organisation is headed by Project Engineer. The duties, among the staff below him could be generally on the following functional ines : a) Planning Engineer Covering all aspects of work planning, resource requirements of both materials and labour, progress review and internal interface activities. 40») ° ¢ e) f) 9) IRC:SP:47-1998 Materials Engineer In-charge of material management including procurement and quality control aspects viz. inspection, field sampling and testing. Construction Engineers (No. as per requirement) In-charge of various construction activities and responsible for following approved working methods, drawings and specifications. Plant, Equipment and Instrumentation Engineer In-charge of deployment, operation, maintenance of various mechanical and electrical plant ‘and equipment, as well as instrumentation needed at site for construction. Other Aspects as required This includes responsibilities for safety, human resources ete, Quality Assurance Engineer Responsible for all aspects of preparation, review, acceptance of quality plan and operation of the same at site. He is also in-charge of quality related records and documents. Quality Audit Independent team reportingtto management, The duties of assisting engineers and supervisory staff at various levels should be clearly specified as are relevant to the quality assurance systems. Depending on the specific project requirements and size, the number of staff doing various functions listed above can be increased/decreased. (Note: The organisational designations of persons performing above tasks depend upon the constructors’ organisations). 43. Control of Data and Documentation 4.3.1. Bridge Related Documents Drawings, specifications, work instructions and other bridge related documents shall be maintained as described below to ensure that only the latest approved documents ate used for the construction of each part of the work, which covers both the temporary and the permanent works : a) b) ° a) e) ‘The issuing authority should maintain the registers of drawings/documents giving information about reference number, revision reference, title, date of issue, to whom issued, number of copies issued, status of issue, date of approval, purpose of issue etc. (Superseded

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