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GOVERNMENT OF TAMIL NADU

HIGHWAYS DEPARTMENT

HIGHWAYS RESEARCH STATION

Training program for newly recruited


Assistant Engineers
Quality control and Assurance of
Highway Projects

From 17.05.2016 to 20.05.2016


QUALITY
 Totality of features and characteristics of a product for service
that bears on its ability to satisfy the projects functional
requirements.
 The quality of output is always agreed upon between the
contractor and the employer
 The quality objective is to achieve zero defects with best
quality of the project works.
 Possible only by ensuring quality control at every stages
during progress of construction.
 Quality is conformity to standards and requirements to
achieve excellence and economy.
QUALITY CONTROL
The operational techniques or a system of
maintaining standards by reviewing, checking,
inspecting and testing
Product oriented and focuses on defect
identification
Set of activities to ensure quality in the work.
The activities focus on identifying defects in the
actual work done.
QUALITY ASSURANCE
All actions taken to ensure that standards and procedures
are followed to and that delivered products or services meet
performance requirements.
Process oriented and focuses on defect prevention
Set of activities to ensure quality in the process by which
works are done.
The goal of QA improve and develop test processes so that
defects do not arise when the work is being done.
The well designed quality assurance system will provide
confidence that the project outputs will fulfil all the
requirements for which it is being planned.
Quality assurance system basic parameters.

Site documents
Mandatory and optional testing
Availability of field and departmental laboratories
Manufacturing test certificates
Departmental team inspections Checklist guide for
works
Site inspections
Post quality testing of finished works Quality
certification
Monthly reporting and review meetings
Benefits of QC/QA
Improved quality
Uniformity
Economic utilization of materials
Reduction in user cost
Additional cost – Fraction of resulting benefits
0.5 to 1% of construction cost
Requirements for good QC practices
Well prepared estimates based on field tests
and established test procedures
Provision for quality control in estimates
Staff with adequate training and knowledge
Adequate QC equipments and lab facilities
Periodical review and appraisal of QC data
Updating of knowledge
Causes of non-conforming works
Lack of training
Lack of resources
Poor communication / incomplete instructions
Inadequately defined work practices
Inadequate supervision
Inadequate planning and
Non maintenance of records
Lack of involvement
Quality control methodology
Control of Materials
Test Procedure
Frequency
Acceptance Criteria
Corrective actions
Equipments and calibration
Documenting the results
Estimate stage considerations

Get required test results and data (CBR, BBD &


Traffic census)
Avoid manipulation and errors
Make uniform provisions along and across the
road
Adequate provisions for shoulder and drain
Include geometric components and corrections
QC requirements

Testing of materials

Manufacturing/mixing process

Tests during laying/finishing


QC requirements

Material to be used

Methodology to be adopted

Works to be performed

Shall be as per specifications


MORTH Section 900 (QC) Highlights
Field laboratory manned by qualified Civil Engineer shall be provided
by the contractor

Contractor shall carry out QC tests on the materials and work to the
stipulated frequency

The contractor shall provide necessary cooperation and assistance in


obtaining samples for tests and carrying out field tests including lab
equipments, transportation, consumables and personnel.

Works found falling short of quality shall be rectified by the contractor


at his own cost

The cost of the above provisions and services shall be deemed to be


incidental to work
Control of Alignment, Level and Surface Regularity

Works shall conform to the lines, grades and cross sections shown in
the drawings

The edges of the carriageway shall be correct within a tolerance of ±10


mm, for lower layers of pavement it is ±25 mm

The levels of subgrade and other pavement layers shall not vary from
those calculated with reference to the LS & CS of the road swhon on the
drawings

For subgrade permitted tolerance in surface levels is ±20 mm, for


flexible pavement sub base it is ±10 mm, for manually laid base course it
is ±15 (machine laid ±10 mm) and for bituminous base/binder
course/wearing course it is ± 6 mm

For BC surface the permissible value of roughness is 2000 mm/km.


Typical flow chart for quality control in road works
Source: Quality Assurance Handbook for Rural Roads
Typical flow chart for quality control in road works
Source: Quality Assurance Handbook for Rural Roads
(contd...)