inspection and testing plan for construction...

Quality inspection & Test Plan – Comprehensive

Dir / Sanjay Sharma,

INSPECTION AND TESTING PLANFOR

CONSTRUCTION MATERIALS

TESTINGThe various tests shall be conducted as per table given below:

Brief Description / Test IS Code

1 Embankment/Structure back fill /RE soil

a) Sp. Gr. Fine, Medium & Coarse grained Soil IS 2720 (Part 3/Sec2)

b) Sp. Gr. Fine, grained Soil IS 2720 (Part 3/Sec1)

c) Sp. Gr. of Soil Specimen and Water Content of Soil. IS 2720 (Part 2)

d) Grain Size Analysis (Wet Sieving) IS 2720 (Part 4)

e) Atterberg limit (LL, PL, & PI) IS 2720 (Part 5)

f) Shrinkage Factors SI, SL IS 2720 (Part 6)

g) OMC, MDD using Heavy Proctor IS 2720 (Part 8)

h) Dry density – moisture content relation by constant weight of soil

method IS 2720 (Part 9)

i) In-Site density by sand replacement method. IS 2720 (Part 28)

j) Consolidation properties IS 2720 (Part 15)

k) Lab CBR soaked and un soaked. IS 2720 (Part 16)

l) Field moisture equipment IS 2720 (Part 18)

m) Direct Shear Test IS 2720 (Part 13)

n) Organic matter IS 2720 (Part 22)

o) Free swell index of soil IS 2720 (Part 40)

p) Soluble Sulphate in soil BS : 1377 (Test 10/9)

2 Sub grade

a) Sp. Gr. Fine, Medium & coarse grained Soil IS: 2720 (Part 3/Sec2)

b) Alterberg Limit LL, PL & PI IS 2720 (Part 5)

c) Total Soluble Solids IS 2720 (Part 21)

d) Organic Matter IS 2720 (Part 22)

e) Calcium Carbonate IS 2720 (Part 23)

f) Cation exchange capacity IS 2720 (Part 24)

g) Silica sesquioxide ratio. IS 2720 (Part 25)

h) PH Value. IS 2720 (Part 26)

I) Total Soluble sulphate IS 2720 (Part 27)

j) Sand equivalent Values of Soil IS 2720 (Part 37)

k) Free Swell index of soils IS 2720 (Part 40)

l) Permeability IS 2720 (Part 17)



m) OMC, MDD using heavy proctor IS 2720 (Part 8)

n) CBR (soaked and unsoaked) IS 2720 (Part 16)

o) Insitu density test by sand replacement method IS 2720 (Part 28)

1. Granular/ Sub-Base & WMM

As per design requirement a sub-base consisting of crushed aggregates, shall be provided. The well-graded

crushed material shall be as per the contract specifications. Ensure that the material is used as per

specification; the following tests shall be conducted as per table given below.

S.No Brief Description of Test IRC/IS/AASHTO/BS CODEIn order of preference given in CA

1. Sieve analysis IS 2386( part 1)

2. Atterberg limits i.e. LL, PL & PI IS 2720 (Part 5)

3. OMC & MDD using heavy proctor. IS 2720 (Part 8)

4. CBR (socked and un-soaked) IS 2720 (Part 16)

5. LAA IS 2386( Part 4)

6. ACV/AIV IS 2386 (Part 4)

7. Soundness Loss test IS 2386 (Part 50

8. Flakiness/Elongation test IS 2386(Part 1)

9. Water absorption IS 2386 (Part 3)

10. 10% fine value BS: 812 (Part 111)

11. Moisture content of loose material BS: 812 (Part 2)

12. Insitu density by Sand Replacement Method IS 2720 (Part 28 )

13. Material finer than 75 micron IS:2386 (Part 1)

14. Determination of specific Gravity IS: 2386 (Part 3)

15. Determination of Organic impurities IS: 2386 (Part 2)

16. Grading

GSB (D/L) Table 400-2 of MORT&H

GSB (U/L) Table 400-1 of MORT&H

WMM Table 400-11 of MORT&H

17. Physical requirements of coarse aggregate for WMM Table 400-10 of MORT&H

2. Coarse and Fine Aggregates (For Concrete)


1. Particle size and shape IS:2386-1963 (Part 1)

2. Estimation of deleterious materials and organic impurities IS:2386-1963 (Part 2)

3. Specific gravity, density, voids, absorption and bulking IS:2386-1963 (Part 3)

4. Mechanical properties IS:2386-1963 (Part 4)

5. Soundness IS:2386-1963 (Part 5)

6. Measuring mortar making properties of fine aggregates IS:2386-1963 (Part 6)

7. Alkali aggregate reactivity IS:2386-1963 (Part 7)



8. Petrographic examination IS:2386-1963 (Part 8)

9.Coarse and fine aggregates from material sources for

concrete (second revision)

IS:383-1970

10. Gradation

Coarse Table 1000-1 of MORT&H

Fine Table 1000-2 of MORT&H

11. Concrete mix design IS:10262-1982 / SP23:1982

12. Code of practice for PCC & RCC IS:456-2000 of BIS

3. DBM/BC





4. Mechanical properties (LAA/AIV) IS:2386-1963 (Part 4)


6. Sand equivalent of fine aggregates IS:2720 (Part 37)

7. Determination of stripping value of aggregates IS:6241-1971

8. Water sensitivity AASHTO T283

9. Gradation

DBM Table 500-10 of MORT&H

BC Table 500-18 of MORT&H

10. Physical requirements for coarse aggregate

DBM Table 500-8 of MORT&H

BC Table 500-17 of MORT&H

11. Sp. Gravity of coarse aggregate AASHTO T85

12. Sp. Gravity of fine aggregate AASHTO T84

13. Sp. Gravity of filler AASHTO T100

14. Stone polishing value of aggregate BS:812 Part 114

4. Water

The water used for general engineering practices shall conform to following tests.

Brief description of Test IRC/IS/AASHTO/BS CodeIn order of preference given in CA

Suitable of water for General Engineering practice. IS: 456

PH value, acidity, alkanets, organic solid should sulphates etc. IS: 3025

5. Bitumen / Bituminous mixes

Bitumen used in bituminous shall be 60-70 and shall conform to following test as tabulated below.



S.No. Brief description of Test IRC/IS/AASHTO/BS CodeIn order of preference given in CA

1 Sp. Gravity at 27ºC IS 1202:1978, AASHTO T100

2 Water percent by mass IS 1211:1978

3 Flash point, closed and open temp, ºC IS 1448(P:691:1969)

4 Softening point ºC IS 1205:1978

5 Penetration at 25ºC, 100g, 5sec, 1/10 min IS 1203:1978

6 Penetration ratio at 4ºC & 25ºC -

7 Ductility test at 27ºC, cm IS 1208:1978

8 Paraffin wax content, % by mass IS 10512:1983

9 Frass breaking point, ºC, min IS 9381:1979

10 Loss on heating, thin film over test IS 1212:1978

11 Retained penetration at 25ºC IS 9382:1979

12 Matter soluble in trichloroethylene IS 1216:1978

13 Viscosity at

a) 60ºC poises IS 1206 (Part 2):1978

b) 135ºC; cost min IS 1206 (Part 3):1978

14 Maximum specific gravity of loose paving mixture ASTM 2041

15Resistance to plastic flow of bituminous mixtures using

Marshall apparatusD-1559 of ASTM

16Resistance to plastic flow of bituminous mixtures using

Marshall apparatusD-5581 of ASTM

17Bulk specific gravity of compressed bitumen mixtures

using ISD specimen

ASTM D-2726 or D-1188 or AASHTO

T-166=00

18 Bituminous mix design MS-2 of Asphalt Institute

19 Bitumen Emulsion IS 8887

6. Cement

Cement used in various grades of concrete mixes in super and substructure (concluding points) shall conform

to the following test.

S.No. BRIEF DESCRIPTION OF TEST IRC/IS/AASHTO/BS CODEIn order of preference given in CA

a) Cement OPC grade 33,43, 53 (Preferably 43 grade) IS: 269, IS:8112, IS:12269

b) Determination of Fineness by dry sieving IS:4031 – (Part 1)

c) Determination of Fineness BAP method. IS:4031 – (Part 2)

d) Soundness – Le – Chatelier IS: 4031 – (Part 3)

e) Determination of Consistency. IS:4031 – (Part 4)

f) Initial & Final setting time. IS:4031 - (Part 5)

1

g) Soundness Auto Clave method IS:4031 – (Part 3)



i) Compressive strength 3,7 & 28 days IS:4031 – (Part 6)

j) Determination of density IS:4031 – (Part 11)

7. Steel

Steel for reinforcement and pre-stressing rebar and high strength steel wire to be used as reinforcement bar

in RCC and pre-tensioning concrete structure shall conform to the following requirements.

S.N Brief description of Test IRC/IS/AASHTO/BS CodesIn order of preference given in CA

1 Steel (Rebar’s)

a) Nominal mass & Cross Section; Tensile Strength and

% elongation

IS:1786,IS:1608

b) Bent Test / re-bend Test IS:1599/1786

c) Chemical Analysis IS:228

d) Pull out test IS:2770(part 1)

2 Steel for Post/Pre tensioning

a) Cold rolled Cold Annealed Sheathing IS:513

b) Nominal & Cross Section, tensile strength and

elongations.

IS:1786 (Part I & II)

c) Structural Steel IS: 2062-1999

d) Welding IS: 816-1969 & IS: 1323-1982

e) Rivets IS: 1148-1982, IS: 1923-1961 & IS: 800-

1984

f) Bolts And Nuts IS: 1363-1967 & 1367-1967

g) HTS wire strands IS: 6006

h) Elastromeric bearings IRC: 83-1987(Part-II), ASTM D-297(Sub

Sec.-10), ASTM D-297 (Appendix X-Z),

ASTM S-3482-78, IS: 3400 (Part-

II,I,X,IV,XIV,XX,III), IS: 226 (lamination)

i) Strip seal expansion joints IRC: 83 (Part-II), IS: 3400 (Part-III), IS: 226,

IS:2062

k) Hume pipes IS: 458 & IS: 3597

Note: All the other component to be used in the project should be as per MORT&H, IS and other

specifications approved by IE.

8. Bricks

Bricks used in substructure shall conform to the following requirements.

S.No Brief description of Test IRC/IS/AASHTO/BS CODEIn order of preference given in CA

Bricks Dimension IS:1077

Determination of Efflorescence IS:3495(Part 3)

1.

Determination of Absorption IS:3495(Part 2)



Determination of Comp. Strength IS:3495(Part 1)

Determination of Warpage. IS:3495(Part 4)

9. Admixtures

Admixture used in concrete work shall confirm to the following requirements.

S.No Brief description of Test IRC/IS/AASHTO/BS CODEIn order of preference given in CA

a. Chloride content IS : 6925

b. Uniformity test IS : 9103

i) Dry material content IS : 9103

ii) Ash content IS : 9103

1.

iii) Relative density IS : 9103

10. Cement Concrete

Cement concrete of various grade used in PCC / RCC / PSC shall confirm to the following requirements.

S. No Brief description of Test IRC/IS/AASHTO/BS CODEIn order of preference given in CA

a. Design mix of various grade of concrete SP : 23 , 1982 / IS : 10262, 1982

b. Consistency of concrete (slump) IS : 516 / IS : 11991

c. Cube compressive strength. IS : 516 / IS : 1199

11. RE Wall Accessories

RE Wall accessories shall confirm to the following requirements.


1 Steel LugsBSEN: 10025:1993 / ISO: 1459:1973 / ISO:1460: 1992 / ISO: 1461: 1973 / BS: 729:1971 and Reinforced Earth Specifications.

2 Lifting Anchors Reinforced Earth Specifications.

3 EPDM Rubber Pads Reinforced Earth Specifications.

4Carbon Steel Reinforcing Strips (Hot Dip

Galvanized)

BSEN: 10025:1993 / ISO: 1459:1973 / ISO:1460: 1992 / ISO: 1461: 1973 / BS: 729:1971 and Reinforced Earth Specifications.

5 Nut & Bolts BS: 3692: 2001 / BS: 729: 2001 &Reinforced Earth Specifications.

6 Foam Reinforced Earth Specifications

7 Geo – textile Reinforced Earth Specifications

12. Back Fill Materials

Backfill material behind RE Wall shall confirm to the following requirements.


1 a. Angle of internal friction IS: 13326, Part-I / Technical Specification ofReinforced Earth



b. GradationIS: 383, 1970 / Technical Specification of Reinforced

Earth

c. Proctor DensityIS: 2720, Part-VIII / Technical Specification of

Reinforced Earth

d. Resistivity Test Technical Specification of Reinforced Earth

e. Field Compaction Test IS: 2720, Part-29 / Technical Specification ofReinforced Earth

13. Elastomeric Bearings:


1. Steel Insert IS: 2262. Raw Elastomer Table 2000-1 of MORT&H, Chloroprene (CR)

Ash Content ASTM D-297 (Sub-section 10)Adhesion Strength (Elastomer to steelplastics) IS: 3400 (part XIV)

Sp. Gr. Test ASTM D-297 (Sub-section 15)Polymer content test ASTM D-297 (Sub-section 10)Identification of polymer ASTM D-297 (Sub-section 15)Shear Modulus MORT&H a) Level 1 acceptance testing Section 2005.3.1 of MORT&H b) Level 2 acceptance testing Section 2005.3.1 of MORT&H c) Any acceptance testing Section 2005.3 of MORT&H

14. Pot PTFE Bearings

Pot PTEF Bearing shall confirm to the following requirements.

Sl. No. Brief description of Test IRC/IS/AASHTO/BS CodeIn order of preference given in CA

a. POT

i) Structural Steel IS: 226 / IS: 2062ii) Caste Steel IS: 1030

iii) Stainless Steel AISI: 304 / AISI: 316 L

b. PTFE BS: 3784

c. Elastomer

i) Hardness IS: 3400 (Part II)ii) Minimum tensile strength IS : 3400 (Part I)

1

iii) Minimum elongation at break IS : 3400 (Part I)

15. Bentonite

Bentonite shall confirm to the following requirements.


a. Density To be confirmed1

b. PH value IS: 3025



c. Silt content IS: 2720 (Part IV)

d. Liquid limit IS: 2720 (Part V)e. Mass con viscosity To be confirmed

16. Retro Reflective Road Marking Paint

Retro Reflective Road Marking shall confirm to the following requirements.


Thermoplastic Materiala) Luminance AASHTO M 249b) Drying Time AASHTO M 250

c) Skid Resistance BS: 6044

d) Yellow ness index AASHTO M 249e) Cracking resistance at low temperature MORT&H

1.

f) Softening Point ASTM D 36

g) Flow resistance AASHTO M 249

Reflection of Glass Beadsa) Gradation BS: 6088

b) Round ness BS: 3262 (Part I)

c) Refractive index MORT&H2.

d) Free Flow MORT&H

9 Thick ness MORT&H

17. Curing Compound

Curing Compound shall confirm to the following requirements.


1 Drying Time ASTM C 150 / ASTM C 156 / ASTM C 309 /BS: 7542

2 Water Retention MORT&H

3 Specific Gravity (At 28ºC) -

4 Water Loss ASTM C 150 / ASTM C 156 / ASTM C 309 /BS 7542

5 Aspect -

18. Mastic Asphalt

Mastic Asphalt shall confirm to the following requirements.







4. Mechanical properties (LAA/AIV) IS:2386-1963 (Part 4)


6. Sand equivalent of fine aggregates IS:2720 (Part 37)

7. Determination of stripping value of aggregates IS:6241-1971

8. Water sensitivity AASHTO T283

Gradation

a. Coarse Aggregate Table 500-30 of MORT&H9.

b. Fine Aggregate Table 500-31 of MORT&H

10. Physical requirements for coarse aggregate Table 500-3 of MORT&H

11. Sp. Gravity of coarse aggregate AASHTO T85

12. Sp. Gravity of fine aggregate AASHTO T84

13. Sp. Gravity of filler AASHTO T100

14. Penetration at 25ºC, 100g, 5sec, 1/10 min IS 1203:1978

15. Softening point ºC IS 1205:1978

16. Loss on heating for 5 hrs. at 163o C IS 1212:1978

17. Solubility in trichloroethylene IS 1216:1978

18. Ash (Mineral Matter) IS 1217:1978

19. Crash Barrier Accessories

Crash Barrier Accessories shall confirm to the following requirements.

S.N Brief description of Test IRC/IS/AASHTO/BS CodesIn order of preference given in CA

G.I. Pipes

a) Dimension’s IS: 1239(part 1), 1990

b) Tensile Strength, % elongation and Bend TestIS: 1239(part 1 & part 2), 1990 & IS: 1608,

1995

1

c) Galvanisation Test IS: 1239(part 1), 1990

M.S. Plate & M 16 U Bolt

a) Tensile Strength, % elongation and Bend Test IS: 2062, 1999 & IS: 1608, 19952

c) Chemical Analysis IS: 2062, 1999 & IS: 1608, 1995

20. Pole sulphide Sea lent and other material for filler type expansion joints

Pole Sulphide Sea lent and other material for filler type expansion joints shall confirm to the following

requirements.


1. Steel Plate Sliding Expansion Joints Section 1900 of MORT&H

2. Filler Joints Section 2605 of MORT&H / IS: 1838

3. Elastomeric Slab Seal Expansion Joint



a) Steel Inserts IS: 226

b) Elastomer IRC: 83(part II)

Strip Seal Expansion Joint

a) Steel (Edge Beam) Steel Grade Rst 37-2 of German

Standard

b) Chloroprene IRC: 83(part II) / Table 2600-1 of

MORT&H

c) Anchorage Steel IS: 2062, 1999

4.

d) Anchorage Loop IS: 2062, 1999

21. Retro Reflective Traffic Sign

Retro Reflective Traffic sign shall confirm to the following requirements.


Traffic Sign Posta) Reinforcing steel IS: 1786, 1985b) Bolts, Nuts & Washers IS: 1364 & IS: 1367c) Plates & Support Sections IS: 226 & IS: 2062

1.

d) Aluminium Sheets IS: 736, Gr. 24345 / Section 1900 ofMORT&H

Traffic Retro-Reflective Sign Sheetinga) High Intensity grade Sheeting ASTM E: 810 / Table 801 of MORT&H

b) Engineering grade Sheeting ASTM E: 810 / Table 802 of MORT&H2.

c) Colour IS: 5 / Section 800 of MORT&H

22. Pile Load Test of Board Piles

Pile Load Test ofBoard Piles shallconfirm to thefollowingrequirements.S.No.

Brief description of Test IRC/IS/AASHTO/BS CodeIn order of preference given in CA

1 Initial Load Test IS: 2911(part IV) & Section 1113 ofMORT&H

2 Routine Load TestIS: 2911(part IV) & Section 1113 of

MORT&H

FREQUENCY OF TESTSThis section describes the types and frequencies of various quality control tests conducted on unbiased

samples collected form field / quarry / source. The EPC Contractor Material Engineer and Supervision

Consultant Material Engineer shall ensure that frequencies of test are maintained as brought out this section

and in subsequent sections. Supervision Consultant Material Engineer shall do test sampling on unbiased

basis. Tests shall be conducted as per relevant code in field Testing Laboratory established by Contractor at

site camp under independent supervision of ‘Supervision Consultant’ Material Engineer. Confirmatory test if

desired by IE shall be carried out at Independent Laboratory like IIT Kharagpur, METARCH. Any sub-



standard material incorporated in work should be identified immediately and Supervision Consultant would

inform the Contractor in writing to carryout removal from site. The frequencies of various tests to be

conducted shall be as per relevant code and MORT&H specification.

23. Borrow Area

Borrow area shall be marked in grid fashion and demarcated & fenced. The borrow area shall be along to the

proposed depth. These pits shall be logged and plotted for proper identification of source of material sampled.

The mathematical model to approve the borrow area the unbiased random samples shall be taken for various

test as per table given below.

Type of Test to be conducted and No. of sample and sample test size.

Gradation, LL, PI, MDD & OMC (Each) 2 Tests 3000 cum soil.

Deleterious content test.Minimum one test on source or change of source or as and when

required.

Moisture content test One test for every 250 cum.

CBR soaked/un soaked small factor One test for every 3000 cum.

Compaction control

Moisture Control (field moisture

equipment)

Six test each for area upto 6000 sq. m of embankment shoulder Ten test each for area upto 500 sqm of subgrade

24. GRANULAR SUB-BASE

Type of Test to be conducted. No. of sample and sample test size.

Gradation. One test per 200 cum.

Atterberg limit One test per 200 cum.

Moisture content prior to compaction 1 test per 250 Sq m per layer

Density of compacted layer 1 test per 500 sq m per layer.

Deleterious matter As required

CBR. As required

25. WET MIX MACADAM

Type of Test to be conducted. Frequencies

Aggregate impact value. One test per 200 cum

Gradation/OMC/Proctor One test per 100 cum

Flakiness elongation index One test per 200 cum

Atterberg limit test (LL/PI) One test per 100 cum

Density of compacted layers One test per 500 cum

26. CEMENT CONCRETE

Type of Test to be Frequencies



conducted.

Job mix design for type of

concrete grade

Prior to commencement of work or as on required basis due to charge in off

gradation

Slump Test One sample on commencement of work or as on required basis.

One sample consist of 3

specimens each for

cube/beam

Sample Quantity1 1-5 cum

2 6-15 cum

3 16-30 cum

4 31-50 cum

4+1 51 and above and one

Additional test for every 50 cum One sample for days work.

Gradation of coarse and fine

aggregate

One per day or on as required basis.

Quality tests on aggregates On required basis or on change of source or at least once in month on

stockpile not less than 3000 cum capacity

27. STEEL


2% proof strength test One test per tot of 10 tonne.

Elongation test -do

Visual Inspection On regular basis on each bar defector bars to be

discarded.

Quality of Geo synthetics material Once on arrival of consign must or as required basis

Determination of angle of pristine between

compote fill and reinforcing element.

IS 13326 (Part I) as required basis.

28. PRIMER COATING AND TACK COATING


Spray rate One test set per 500 sqm and not less than two set tests per

day

Quality of binder This sample per lot or as required basis

Binder temperature for application During spraying or as required basis (At regular closed

intervals)

29. DBM/BC MIX

Type of Test Frequencies

Quality of binder. Initially two sample per lot subsequently on as required basis.

Aggregate Impact Value One test per 50 cum or at least one test for one production day.

Flakiness/ Elongation Index -do-



Stripping value Initially one set of 3 samples from each source and subsequently on requiredbasis or change of source.

Soundness (Magnesiumand Sodium Sulphate)

Initially one determination by each method from each source andsubsequently on required basis or change of source.

Water absorption Initially one set of 3 samples from each source and subsequently on requiredbasis or change of source.

Sand Equivalent Test As on required basis.

Plasticity Index As on required basis.

Mix Gradation One set of tests on individual constituents and mixed aggregates from the

dryer for each 400 tones of mix subject to a minimum of two tests per plant per

day.

Stability of Mix A set of 3 Marshal specimens per 400 tonnes of mix production subject to aminimum of two sets per plant per day.

Water sensitivity of mix As on required basis

Swell test on mix As on required basis for bituminous concrete.

Stone polishing value As on required basis for bituminous concrete or change of source.

Temp control On running of hot mix and laying by paver as on required basis.

Binder Content One test @ 400 tonnes of mix subject to a minimum of two tests per day per

plant.

Rate of spread of mixed

material

Regular control on actual laying.

Density of compacted layer One test @ 250 Sqm area

Percentage of fractured

faces

When gravel is used, one test per 50 cum of aggregate.

30. CEMENT

Type of Test Frequenciesa. Physical Testi) Fineness One test per week no. for each brand of cementii) Soundness by ‘Le-chatelier’ method One test per week no. for each brand of cement

iii) Soundness by ‘Outo-clave test’ method. One test per week no. for each brand of cement

iv) Initial setting time One test per week no. for each brand of cementv) Final setting time One test per week no. for each brand of cementvi) Compressive strength for72±1 hour One test per week no. for each brand of cement

vii) Compressive strengthfor 168±2 hour One test per week no. for each brand of cement

viii) Compressive strengthfor 672±4 hour One test per week no. for each brand of cement

ix) Consistency of standardcement paste. One test per week no. for each brand of cement

b. Chemical Testi. Ratio of percentage oflime to percentages of silica,alumina & iron oxide.

One test for each brand of cement.

ii. Ratio of percentage ofalumina to that of iron oxide.




iii. Insoluble residue, percentby mass


iv. Magnesia, percent bymass


v. Total sulphur content,calculated as sulphuricanhydride (SO3), percent bymass.


vi. Total loss on ignition One test for each brand of cement.

vii. Total chloride content,percent by mass


31. Water for concreting

Type of Test FrequenciesWater for concretingNeutralisation of 200 mlsample of water usingphenolphthalein as anindicator with 0.1 Na-OH.

At approval of source subsequently at every change of source.

Naturalisation of 200 mlsample of works usingmethyl orange as anindicator with 0.1 N Hcl.

At approval of source subsequently at every change of source.

Organic At approval of source subsequently at every change of source.Inorganic solids At approval of source subsequently at every change of source.Sulphates (as SO3) At approval of source subsequently at every change of source.Chlorides (as Cl) At approval of source subsequently at every change of source.Suspended matter At approval of source subsequently at every change of source.

32. Admixture

Type of Test FrequenciesDry material content One test per batchAsh content One test per batchRelative density One test per batchChloride ion content One test per batchPH One test per batch

33. Hume Pipe

Type of Test Frequencies8 tests for lot size up to 5013 tests for lot size 51 to 10020 tests for lot size 101 to 30032 tests for lot size 301 to 500

a. Overall length

b. Internal diameter of pipes

c. Wall thickness

d. Deviation from straight50 tests for lot size 501 & above2 tests for lot size up to 503 tests for lot size 51 to 1005 tests for lot size 101 to 3007 tests for lot size 301 to 500

a. Hydrostatic test

b. Three – Edge bearing test

c. Absorption test10 tests for 101 size 501 and above



34. Bricks

Type of Test FrequenciesDimensions One test for 20 bricks for each source.Compressive strength One test for each source.Water absorption One test for each source.Efflorescence One test for each source.

35. RE Wall Accessories

Type of Test Frequenciesa. Carbon Steel Reinforcing Strips(40X5 mm) (Hot Dip Galvanised)

i) Chemical compositions 5 tests per lot.(Lot of 20 M.T.)

ii) Tensile strength 5 tests per lot.(Lot of 20 M.T.)

iii) Yield strength 5 tests per lot.(Lot of 20 M.T.)

iv) Elongation 5 tests per lot.(Lot of 20 M.T.)

v) Galvanization 5 tests per lot.(Lot of 20 M.T.)

b. Steel Lugsi) Chemical composition 5 tests per lot

(Lot of 10 M.T.)ii) Tensile strength 5 tests per lot

(Lot of 10 M.T.)iii) Yield strength 5 tests per lot

(Lot of 10 M.T.)iv) Elongation 5 tests per lot

(Lot of 10 M.T.)v) Galvanization 5 tests per lot

(Lot of 1000 nos. )

c. Lifting AnchorsMechanical properties 5 tests per lot

(Lot of 10,000 nos.)d. Nuts & Bolts

Chemical analysis 5 tests per 10,000 piecesMechanical properties 5 tests per 10,000 piecesGalvanization 5 tests per 10,000 piecese. EPDM Rubber PadsShort Hardness A tests 5 tests per lot

(Lot of 1000 nos.)f. FOAMDensity 1 test per lot

(Lot of 2000 metre)g. GeotextileMechanical hydraulic properties 1 test per lot

(Lot of 2000 sq. metre)

36. RE Wall Backfill Materials:



Type of Test Frequenciesa. Angle of internal friction‘ ’

At approval of sourceSubsequently at every change of source.

b. GradationAt approval of sourceSubsequently at every change of source.At least one sample per 3000 m3

c. Maximum Dry Density(MDD)

At approval of sourceSubsequently at every change of source.

d. Physio-chemicalrequirement (Resistivity tests)

At approval of sourceSubsequently at every change of source

e. Field Compaction Test For every 500 sq. m of compacted area.Minimum two tests at each level of compacted layer.

37. H. T. Strand:

Type of Test Frequenciesa. Physical Tests: At approval of source

Subsequently at every change of source.Nominal diameter For each reel.Breaking strength, 0.2%proof load, %ageelongation, relaxation loss.

One test for each batch for every 5 nos. of coil / reel.

b. Chemical test At approval of sourceSubsequently at every change of source

38. Sheathing Ducts:

Type of Test FrequenciesWorkability Test At least 3 samples for one lot of supply (not exceeding 7000 metre length).Transverse Load RatingTest At least 3 samples for one lot of supply (not exceeding 7000 metre length).

Tension Load Test At least 3 samples for one lot of supply (not exceeding 7000 metre length).Water Loss Test At least 3 samples for one lot of supply (not exceeding 7000 metre length).

39. Elastomeric Bearings:

Type of Test FrequenciesSteel Insert: Two tests per lot/ Change of sourceRaw Elastomer Content Two tests per lot/ Change of sourceAsh Content Two tests per lot/ Change of sourceAdhesion Strength (Elastomer to steelplastics) Two tests per lot/ Change of source

Sp. Gr. Test Two tests per lot/ Change of sourcePolymer content test Two tests per lot/ Change of sourceIdentification of polymer Two tests per lot/ Change of sourceShear Modulus a) Level 1 acceptance testing Two tests per lot/ Change of source b) Level 2 acceptance testing One tests per lot/ Change of source c) Any acceptance testing

40. Pot Bearing:Type of Test Frequencies

a. POT



i) Structural Steel Two tests per lot/ Change of sourceii) Caste Steel Two tests per lot/ Change of sourceiii) Stainless Steel Two tests per lot/ Change of sourceb. PTFE Two tests per lot/ Change of sourcec. Elastomer

i) Hardness Two tests per lot/ Change of source

ii) Minimum tensile strength Two tests per lot/ Change of sourceiii) Minimum elongation at break Two tests per lot/ Change of source

41. Expansion Joint (Elastomeric):

Type of Test Frequencies1. Steel Plate Sliding Expansion Joints

2. Filler Joints

3. Elastomeric Slab Seal Expansion Joint

a) Steel Inserts

b) Elastomer

4. Strip Seal Expansion Joint

a) Steel (Edge Beam)

b) Chloroprene

c) Anchorage Steel

d) Anchorage Loop

4. Steel Plate Sliding Expansion Joints

42. Bentonite:

Type of Test Frequenciesa) Liquid Limit (IS 2720 Part V 1965) One test for each lotb) Sand Content One test for each lotc) Relative Density One test for each lot & each activityd) Free Swell Index One test for each lotf) Density One test for each lot & each activityg) Marsh Cone Viscosity One test for each lot & each activityh) PH value One test for each loti) Silt content One test for each lot

43. Road Marking Paint:

Type of Test FrequenciesI ) Daylight Luminatce Ktisk s Once for each lot

II) Daylight luminanu yellow Once for each lot

III) Drying Time Once for each lot

IV) Skid Ratid Once for each lotV) Yellowness Index Once for each lot



VI) Cracking resistance at low temperature Once for each lot

VII) Softening Point Once for each lot

VIII) Plow Resistance Once for each lot

IX) Reflection of Glass Bedsa) Gradationb) Rouednessc) Refractive Indexd) Free Flow

Once for each lot

X) Thickness Once for each lot

44. Curing Compound

Type of Test Frequenciesa) Density at 30oC One test per batchb) Flow time in B-4 FordCup

One test per batch

c) Flash point [Approx.] One test per batchd) Drying time [ ASTM C156]

One test per batch

45. Mastic Asphalt

Type of Test Frequencies

Quality of binder No. of samples per lot and tests as per IS : 73 & IS : 8887 as applicable.

Aggregate Impact Value One test per 50 cum or at least one test for one production day.

Flakiness/ Elongation Index -do-

Stripping value Initially one set of 3 samples from each source and subsequently on requiredbasis or change of source.

Water absorption -do-

Grading of aggregates Two tests per day per plant both on the individual constituent and mixedaggregates from the dryer.

Water sensitivity of mix Initially one set of 3 samples from each source and subsequently on requiredbasis or change of source.

Soundness (Magnesiumand Sodium Sulphate)

Initially one determination by each method from each source andsubsequently on required basis or change of source.

Percentage of fractured

faces

When gravel is used, one test per 50 cum of aggregate.

Binder content andaggregate grading

Periodic, subject to minimum of two tests per day per plant.

Control of temperature ofbinder and aggregate formixing and of the mix at thetime of laying and rolling

At regular close intervals.

Rate of spread of mixedmaterial

Regular control through checks of layer thickness.

Hardness number One tests for each 400 tonnes of mix subject to a minimum of two tests per

day.

46. Crash Barrier handrail accessoriesType Of Tests Frequencies



G.I. Pipes

a) Dimension’s IS: 1239(part 1), 1990

b) Tensile Strength, % elongation and Bend Test IS: 1239(part 1 & part 2), 1990 & IS: 1608, 1995

c) Galvanisation Test IS: 1239(part 1), 1990

M.S. Plate & M 16 U Bolt

a) Tensile Strength, % elongation and Bend Test IS: 2062, 1999 & IS: 1608, 1995

c) Chemical Analysis IS: 2062, 1999 & IS: 1608, 1995

47. Pole sulphide Sea lent and other material for filler type expansion jointsType Of Tests Frequencies

Steel Plate Sliding Expansion Joints Section 1900 of MORT&H

Filler Joints Section 2605 of MORT&H / IS: 1838

Elastomeric Slab Seal Expansion Joint

a) Steel Inserts IS: 226

b) Elastomer IRC: 83(part II)

Strip Seal Expansion Joint

a) Steel (Edge Beam) Steel Grade Rst 37-2 of German Standard

b) Chloroprene IRC: 83(part II) / Table 2600-1 of MORT&H

c) Anchorage Steel IS: 2062, 1999

d) Anchorage Loop IS: 2062, 1999

48. Retro Reflective Traffic SignType Of Tests Frequencies

Traffic Sign Posta) Reinforcing steel IS: 1786, 1985b) Bolts, Nuts & Washers IS: 1364 & IS: 1367c) Plates & Support Sections IS: 226 & IS: 2062d) Aluminium Sheets IS: 736, Gr. 24345 / Section 1900 of MORT&HTraffic Retro-Reflective Sign Sheetinga) High Intensity grade Sheeting ASTM E: 810 / Table 801 of MORT&H

b) Engineering grade Sheeting ASTM E: 810 / Table 802 of MORT&H

c) Colour IS: 5 / Section 800 of MORT&H



Parameters of Important Specifications

Grading Range Compaction

Grade

Sl.No.

BriefSpecification

RelevantMOSTClause

BitumenContentRange

Nominalsize ofAgg.

I II

Require-ment ofjob mixformula

Thick-ness ofLayer

Type ofRoller

Min. Density Remarks

I.S. Sieve PassingsUpto100mmthick

As per contractrequirement &Job Mix Formula(JMF)

SmoothwheeledRoller(Wt. 80to 100KN)

1. GRANULARSUB BASE(CloseGraded GSB)

401(Table400-1)

--- ---

75mm53mm26.5mm9.5mm4.75mm2.36mm0.425mm0.075mm

100%80-100%55-90%35-65%25-55%20-40%10-25%3-10%

---100%70-100%50-80%40-65%30-50%15-25%3-10%

OMCversesMax. DryDensity& CBR Above

100 to225mmthickMax.

VibratoryRoller CBR

PI

LL

GD I

Min30

Max6

Max25

GD II

Min30

Max6

Max25

1. Whendirected,the strengthshall beverified byCBR/othertests inlaboratory.

2. L.L. & PI ofmaterialpassing425(0.425mm)sieve

2. WET MIXMACADAMWMM

406(Table400-10,400-11)

--- --- 53mm45mm26.5mm22.4mm11.2mm4.75mm2.36mm60075

100%95-100%---60-80%40-60%25-40%15-30%8-22%0-8%

OMCVersusMax.DryDensity

Upto75mm.morethan75 to200mm

SmoothwheeledRoller

VibratoryRoller

As per contractrequirement &Job Mix Formula(JMF)

PI = Not morethan 6

Materialpassing0.425mmsieve



Grading Range

Grade Grade

I I

Requirementof job mixformula

CompactionThick Type ofRoller

Min. Density

RemarksSl.No.

BriefSpecification

RelevantMOSTClause

BitumenContentRange

Nominal sizeof Agg.

I.S. Sieve Passing

3. PRIMERCOAT

502 (Table500-1)

7.50 Kg. per10m2

(MC/SC)

--- --- --- Bitumenemulsioncomplying with IS-8887

4. TACK COAT 503 (Table500-2)

2.50 Kg.per 10m2

(RC)

--- --- --- --- - do -

5. STRESSABSORBING-INTER LAYERMEMBRANECrackpreventioncourse (torestrain cracksto reproduce)

(a) Hair cracks& mapscracks upto3mm width

(b) Map crack oralligatorcracks 3mmto 6mm

(c) All types ofcracks above6mm width

522 Table500-47

(Singlecoat)

(Singlecoat)

Singlecoat asinter layer

ModifiedBinder(SBS)Table500-44

8-10 Kgper 10m2

area

10-12 Kgper 10m2

area

10-12 Kgper 10m2

area

0.10m3 of5.6mmnominal sizechips

0.11 m3 of5.6mmnominal sizechips

0.10 m3 of11.2mmnominal sizechips

11.2mm

2.8mm

11.2mm

2.8mm

13.2mm

5.6mm

100%

0%

100%

0%

100%

0%

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.



Grading Range

Grade Grade

I I



Min. Density

RemarksSl.No.

BriefSpecification

RelevantMOSTClause

BitumenContentRange

Nominal sizeof Agg.

I.S. Sieve Passing

6. BITUMINOUSMACADAMB.M

(50-75mmthick layer)

504

(table 500-3, 500-4

3.3% to3.5% bywt. oftotal Mix

19mmcrushedaggregate

26.51913.24.752.360.30.075

100%90-100%

OptimumBindercontentverses Max.Density

Initial rollingwith 80 to 100KN smoothwheeled roller.

IntermediateRolling withVibratingRoller or R-15T pneumaticRoller andfinish rollingwith 6-8Tonnessmoothwheeledtandem rollers.

As percontractrequirement& Job MixFormula(JMF)

7. DENSEBITUMINOUSMACADAMDBM(50-75mmthick layer)

507 (table500-8,500-9,500-10,500-11,500-12)

Min.4.5% bywt. oftotal Mix

25mm 37.5mm26.51913.29.54.752.361.180.600.300.150.075

100%90-100%71-95%56-80%--38-54%28-42%----7-21%--2-8%

OptimumBitumencontents v/sDensitysubject toMin stability =9 kN at 600CFlow = 2-4mm AirVoids = 3-6%

Initially with 8-10 T smoothwheeled roller.

IntermediateRolling withvibratory rollerOr 12-15 Tpneumatictyred roller andfinish rollingwith 6-8Tonnessmoothwheeledtandem rollers.


Filler is to beused 43 gradecement ofVikram, Sri orJK Brand.



Grading Range

Grade Grade

I I

I.S. Sieve Passing

Sl.No.

BriefSpecification

RelevantMOSTClause

BitumenContentRange

Nominalsize ofAgg.



Min. Density

Remarks

GD-I GD-II8. SEMI DENSE

BITUMINOUSCONCRETESDBCFor 35-40mmlayer thicknessGrading-I

For 25-30mmlayer thicknessgrading-II

508(Table500-14,500-15,500-16)

Min4.5% oftotal Mix.

Min5.0% oftotal Mix.

13mm

10mm

19mm13.29.54.752.361.180.600.300.150.075

100%90-100%70-90%35-51%24-39%15-30%---9.19%--3-8%

--100%90-100%35-51%24-39%15-30%---9.19%--3-8%

OptimumBitumencontents v/sDensity

Min stability =8.2 kN at600C Flow =2-4mm AirVoids = 3-6%


Intermediatewith vibratoryroller Or 12-15T pneumatictyred roller andfinish rollingwith 6-8Tonnessmoothwheeledtandem rollers.



9. BITUMINOUSCONCRETE

Layerthickness 30-45 min. 9(Grading –2)

509(Table500-17,500-18,500-19)

5% to7% bywt. oftotal Mix.

13mm 19mm13.29.54.752.361.180.600.300.150.075

100%79-100%70-88%53-71%42-58%34-48%26-38%18-28%12-20%4-10%

OptimumBitumencontents v/sDensitysubject toMin stability =9 kN

Flow = 2-4mm AirVoids = 3-6%


Intermediatewith vibratoryroller Or 12-15 Tpneumatictyred roller.





Grading Range

Grade Grade

I I

I.S. Sieve Passing

Sl.No.

BriefSpecification

RelevantMOSTClause

BitumenContentRange

Nominalsize ofAgg.



Min. Density

Remarks

10. MIXED SEALSURFACING(TYPE-B)For removal ofundulations &profilecorrected ofBlacktopsurface.

512

(Table500-26)

19Kg/10m2

Quantityofaggregate1.27 cumper 10m2

13.211.25.62.80.090mm

100%88-100%31-52%5-25%0-5%

Not requiredratio of C.A &F.A are to befixed forachievingdesiredgrading

Wheeled roller

As perSpecification

Note: -Forundulationsupto 25mmM.SS is to beadopted.

For correctionof more than25mmthickness BMis to beprovided.

Quality Control tests and their Frequencies

CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR SUB-BASES AND BASES (EXCLUDING BITUMEN BOUND BASES)Sl.No.

Type ofConstruction

Test Frequency (Min.)

1 Granular (i) Gradation(ii) Atterberg limits(iii)Moisture content prior to compaction(iv)Density of compacted layer(v) Deleterious constituents(vi) C.B.R.

One test per 200 cumOne test per 200 cumOne test per 250 cumOne test per 500 cumAs requiredAs required

2 Wet MixMacadam

(i) Aggregate Impact Value(ii) Grading(iii) Flankiness and Elongation Index(iv) Atterberg limits of portion of aggregate passing 425 micron sieved(v) Density of compacted layer

One test per 200 Cum of aggregate.One test per 100 Cum of aggregate.One test per 200 Cum of aggregate.One test per 100 cum of aggregate.One test per 500 Cum of aggregate.



CONTROL TESTS AND THEIR BITUMINOUS FREQUENCY FOR BITUMINOUS WORK TEST ON BITUMINOUS CONSTRUCTIONS:

The tests and their minimum frequencies for the different types of bituminous works shall be as under:

Acceptance criteria

The acceptance criteria for tests on density and Marshall stability shall be subject to the condition that the mean value is not less thanspecified value plus:

[1.65 - _________1.65__________] times the standard deviation (No. of samples)0.5

Sl.No.

Type ofConstruction


3 Prime Coat /Tack coat

(i) Quality of binder Number of samples per coat and tests as per IS:73, IS:217 and IS8887 as applicable.

(ii) Binder temperature for application. At regular close intervals.(iii) Rate of spread of Binder. One test per 500 m3 and not less than two tests per day.

4 Seat Coat /surfaceDressing

(i) Quality of Binder Same as mentioned under Serial No. 1

(ii) Aggregate Impact Value / Los AnglesAbrasion value

One test per 50m3 of aggregate.

(iii) Flakiness Index and Elongation Index One test per 50m3 of aggregate.(iv) Stripping value of aggregates. (Immersion

Tray Test)Initially one set of 3 representatives’ specimens for each source ofsupply. Subsequently, when warranted by changes in the equalityof aggregates.

(v) Water absorption of aggregates. Initially one set of 3 representatives’ specimens for each source ofsupply. Subsequently, when warranted by changes in the equalityof aggregates.

(vi) Water sensitivity of mix. Initially one set of 3 representatives’ specimens for each source ofsupply. Subsequently, when warranted by changes in the equalityof aggregates. (if required).



Sl.No.

Type ofConstruction


(vii) Grading of aggregates. One test per 25m3 of aggregate.(viii) Soundness (Magnesium and Sodium

Sulphate)Initially, one determination by each method for each source ofsupply, then as warranted by change in the quality of theaggregates.

(ix) Polished stone value. As required.(x) Temperature of binder at application. At regular close intervals.(xi) Rate of spread of materials. One test per 500m2 of work, and not less than two tests per day.(xii) Percentage of fractured faces. When gravel is used, one test per 50m3 of aggregates.

5 BituminousMacadam

(i) Quality of Binder Same as mentioned under Serial No. 1

(ii) Aggregate Impact Value / Los AnglesAbrasion value.

Same as mentioned under Serial No. 1

(iii) Flakiness Index and Elongation Index. Same as mentioned under Serial No. 2(iv) Stripping Value Same as mentioned under Serial No. 2(v) Water sensitivity of mix. Same as mentioned under Serial No. 2(vi) Grading of aggregates. Two tests per day per plant both on the individual constituents

and mixed aggregates from the dryer.(vii) Water absorption of aggregates. Same as in Serial No. 2(viii) Soundness (Magnesium and Sodium

Sulphate)Same as mentioned under Serial No. 2

(ix) Percentage of fractured faces. Same as mentioned under Serial No. 2(xi) Control of temperature of binder and

aggregate for mixing at the time of layingand rolling.

As regular close intervals.

(xii) Rate of spread of mixed material. Regular control through checks of layer thickness.(xiii) Density of compacted layer. One test per 250m2 area.(x) Binder content and aggregate grading. Periodic, subject to minimum of two tests per day per plant.

6 DenseBituminousMacadam/Semi DenseBituminousConcrete/

(i) Quality of Binder. Same as mentioned under Serial No. 1



Sl.No.

Type ofConstruction


BituminousConcrete.

(ii) Aggregate Impact Value / Los AnglesAbrasion value.


(iii) Flakiness Index and Elongation Index. Same as mentioned under Serial No. 2(iv) Stripping value(v) Soundness (magnesium and Sodium


(vi) Water absorption of aggregates. As in Serial No. 2(vii) Sand equivalent test Water sensitivity of

mix.As required.

(viii) Plastic Index. As required.(ix) Polished stone value. As required for Semi Dense Bituminous Concrete / Bituminous

Concrete.(x) Percentage of fractured faces. Same as mentioned under Serial No. 2(xi) Mix grading One set of tests on individual constituents and mixed aggregate

from the dryer for each 400 tonnes of mix subject to a minimum oftwo tests per plant per day.

(xii) Stability of Mix For each 400 tonnes of mix produced, a set of 3 Marshalspecimens to be prepared and tested for stability, flow value,density and void content subject to a minimum of two sets beingtested per plant per day.

(xiii) Water sensitivity of mix (Retained TensileStrength)


(xiv) Swell test on the mix. As required for the Bituminous concrete.(xv)Control of temperature of binder in boiler,

aggregate in the dryer and mix at the timeof laying and rolling.


(xvi) Control of binder content and grading of themix.

One test for each 400 tonnes of mix subject minimum of two testper day per plant.

(xvii) Density of compacted layer. One test per 250m2 area.7 Mastic

Asphalt(i) Quality of binder. Same as mentioned under Serial No. 1

(ii) Aggregate Impact Value / Los Angles Same as mentioned under Serial No. 2



Sl.No.

Type ofConstruction


Abrasion value.(iii) Flakiness Index and Elongation Index. Same as mentioned under Serial No. 2(iv) Stripping value Same as mentioned under Serial No. 2(v) Water sensitivity of mix. Same as mentioned under Serial No. 2(vi) Grading of aggregates. Two tests per day per plant both on the individual constituents

and mixed aggregates from the dryer.(vii) Water absorption of aggregates. Same as in Serial No. 2(viii) Soundness (Magnesium and Sodium


(ix) Percentage of fractured faces. Same as mentioned under Serial No. 2(x) Binder content and aggregate grading. Periodic, subject to minimum of two tests per day, per plant.(xi) Control of temperature of binder and

aggregate for mixing and of the mix at thetime of laying and rolling.


(xii) Rate of spread of mixed material. Regular control through checks of layer thickness.(xiii) Hardness number One test for each 400 tonnes of mix subject to a minimum of two

tests per day.8 Modified

Binder(i) Softening Point. Initially on submission thereafter daily if site blended, weekly if

pre-blended.(ii) Penetration at 250C and 40C Initially on submission thereafter daily if site blended, weekly if

pre-blended.(iii) Elastic Recovery. Initially on submission thereafter daily if site blended, weekly if

pre-blended.(iv) Ductility Initially on submission thereafter daily if site blended, weekly if

pre-blended.(v) Flush Point. Initially on submission thereafter daily if site blended, weekly if

pre-blended.(vi) Fraass Breaking Initially on submission.(vii) Viscosity at 1500C Initially on submission.(viii) Thin film oven test, penetration, softening

point, elastic recover of residue, loss onbeating.



Sl.No.

Type ofConstruction


FREQUENCY OF QUALITY CONTROL TESTS FOR PAVING QUALITY CONCRETE:

9 Cement Physical and chemical testsIS:269IS:455IS:1489IS:8112IS:12269

Once test each tests source of supply and occasionally whencalled for in case of long / improper storage. Besides theContractor also will submit daily test data on cement released bythe manufacturer.

10 Coarse andFineAggregates

GradationIS: 2386(Pt. 1)

One test for every day’s work of each fraction of coarse aggregateand fine aggregate, initially may be relaxed later at the discretionof the Engineers.

Deleterious ConstituentsIS: 2386(Pt. 2)

One test for every day’s work of each fraction of coarse aggregateand fine aggregate, initially may be relaxed later at the discretionof the Engineers.

Water Absorption IS: 2386(Pt. 3)

Regularly as required subject to a minimum one of test a day forcoarse aggregate and two tests a day for fine aggregate. Thisdata shall be used for correcting the water demand of the mix ondaily basis.

11 CoarseAggregate

i) Los Angles Abrasion value or aggregateimpact test IS:2386 (Pt. 4 )

Once for each source of supply and subsequently on monthbasis.

ii) Soundness IS:2386 (Pt. 5)

Before approving the aggregates and every month subsequently.

iii) Alkali aggregate reactivity. IS:2386 (Pt. 7) Before approving the aggregates and every month subsequently.12 Water Chemical Tests IS:456 Once for approval of source of supply, subsequently only in case

of doubt.13 Concrete i) Strength of Concrete

IS: 5162 cubes and 2 beams per 150m3 or part thereof (one for 7 daysand other 428 days strength) or minimum 6 cubes and 6 beamsper days work whichever is more.

ii) Core strength on hardened concreteIS:516

As per the requirement of the Engineer, only in case of doubt.

iii) Workability of fresh concrete-Slump TestIS:1199

One test per each dumper load at both batching plant site andpaving site initially when work starts. Subsequently sampling maybe done from alternate dumper.



Sl.No.

Type ofConstruction


iv) Thickness Determination From the level data of concrete pavement surface and sub-baseat grid point of 5/6.25 m x 3.5 m

v) Thickness measurement for trial length. 3 Cores per trial length.vi) Verification of level of string line in the case

of slip form paving and steel form in the caseof fixed form paving.

String line or steel forms shall be checked for level at interval of5.0 m or 6.25 m. The level tolerance allowed shall be +- 2mm.These shall be got approved 1-2 hours before thecommencement of the concreting activity.

Quality Assurance Standards

Quality Assurance

Road Work

1.0 Earth work

S.No.

Item Nominal QA(Q-1)

Normal QA(Q-2)

High QA(Q-3)

Extra High QA (Q-4)

a) Tests for density As per MOST As per MOST As per MOSTSpec., each compact layer

Same as Q-3.

b) Geometry Check Final Layer Final Layer All Layer Same as Q-3.c) Equipment Static rollers required Vibratory rollers preferred Vibratory rollers mandatory. Vibratory rollers mandatory.

2.0 Non-Bituminous WorkGranular Sub-Bases:

S.No.


Normal QA(Q-2)

High QA(Q-3)

Extra High QA (Q-4)

a) Material -- Premix preferred Premix to suitable grading asper mixed design required.

Same as Q-3.

b) Laboratory Tests -- Random sampling andtesting

Each layer to be sampled fromlocation and tested all as perMOST

Same as Q-3.

c) Geometry -- Top Layer All Layers As per Q-3.



S.No.


Normal QA(Q-2)

High QA(Q-3)

Extra High QA (Q-4)

Checks

3.0 Bituminous Work

Granular Bases / Binder Course Bases:

S.No.


Normal QA(Q-2)

High QA(Q-3)

Extra High (QA Q-4)

MATERIALa) Aggregate Hand broken

acceptableCrushed preferred Crushed and screamed

mandatory.Same as Q-3

b) Binder Quality Accept manufacturerTC, conduct routinetests.

Same as Q-1 Quality source-test everyconsignment at arrival.

Quality source; test everyconsignment, employ third party ifreqd.

WORKMANSHIPa) Paving Manual procedure

acceptableMechanical paverpreferred

Sensor paver mandatory. Same as Q-3.

b) Compaction Static equipmentacceptable

Vibratory Equipmentpreferred

Vibratory Equipmentpreferred

Same as Q-3.

c) Geometry Checks Top layer All layers All layers All layers

Wearing Course – Asphalt / Concrete:

S.No.


Normal QA(Q-2)

High QA(Q-3)

Extra High QA (Q-4)

a) Material /Aggregates

Hand brokenaggregate acceptable

Crushed aggregatepreferred

Crushed / screenedaggregate mandatory

Same as Q-3.

b) Mixing Site mixingacceptable

Plant mixingpreferred

Plant mixing mandatory Same as Q-3.

c) Paving Manual Acceptable Paver Preferred Paver Mandatory Paver Mandatoryd) Compaction Static equipment

acceptableVibratory Equipmentpreferred

Vibratory EquipmentMandatory

Same as Q-3.

e) Geometry Checks Top Layer Top Layer All Layers All Layers usingSophisticated



S.No.


Normal QA(Q-2)

High QA(Q-3)

Extra High QA (Q-4)

Equipment.

4.0 Concrete Work

The following guidelines are given for quality assurance of construction of bridges:

a) For construction of H/L Bridge / ROB’s minimum quality assurance level Q-3 is to be achieved.

b) For construction of culvert and small bridge minimum quality assurance level Q-2 is to be achieved.

c) In special cases where very large span are involved or high performance concrete and new prestressing system are operative, thequality assurance level will be kept Q-4.

5.0 Extracts of IRC SP: 47: 1998Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

11.1

MATERIALSGenerala) Material from natural

sources

Small or medium scale purchasesfrom large and establishedsuppliers/traders.

As in Q-2. Also bulk purchasefrom source.

As in Q-3, but may also set up ownsource for supply.

Source mutually agreed to betweencontractor and owner’s project termsand documented.

Independent testing/acceptanceby contractor & owner Q.A.teams and documented.

As in Q-3, but with additional (thirdlevel) testing / acceptance byindependent agency (such as PMCor Approved Testing Laboratory

May rely on local experience andknowledge of the past performancefor coarse and fine aggregates andwater.

Testing / acceptance at the startof the project as well as atspecified frequency.

Same as Q-3.

b) Factory manufactureditems including

Manufacturer’s tests certificateaccepted with sample check by

Manufacturers test certificateswith sample checks for initial

Same as Q-3.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

cement, steelbearings, expansionjoints, etc.

independent agency for incorporationin structure.

acceptance only.

Regular testing at specifiedsampling frequency duringconstruction.

As in Q-3, but may also haveadditional QA checks at source(third level check)

Set up mutually agreed QAmethods at two levels forinspection / testing to cover thespecific purpose order.

As in Q-3, but third level checkingby appointment of specializedagency for innovative aspects.

ISO : 9000 certificate not essential formanufactured items.

In case the manufacturer hasISO : 9000 certification, he maybe given preference.

As in Q-3.

c) Records for allmaterials.

Record of sources and purchasedates for all items. For manufactureditems record of manufacturers’ testcertificates

As in Q-2. Also record of issueof manufactured materials andlocation of use.

Same as Q-3

d) Testing facilities Testing from nearby established testhouses / laboratories

Physical testing facilities at site.For chemical & special tests asper Q-2. Use of chemical testingkits for quick checks at site areto be preferred.

As in Q-3, with property equippedtesting facilities and laboratory atsite under control of QA personnelof contractor & owner (independentof production team.

1.2 Aggregate coarseaggregates At the beginning for mix design & for

every charge of source.At the beginning for mix designand for every change of source /

As in Q-3, but it necessary withincrease frequency, (testing at site



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

Grading

Other physical tests(crushing value abrasionmoisture contents etc.)

Deleterious contents

Aggregate reactivity

b) Fine aggregate (sand)

Grading

Other physical tests(crushing value abrasionmoisture contents etc.)

Deleterious contents

For control of chloridesetc.

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



Simple but frequent chemical checksat site for effectiveness

stack and for every majorstructural element.

At the beginning for mix designand for every change of source.

Mandatory for selection ofsource & whether there ischange in source of supply.

Mandatory for selection ofsource and whether there



Mandatory for selection ofsource & whenever there ischarge in source of supply.

As in Q-2

External laboratory checks /control (two level control)

laboratory).

As in Q-3 (two level checks at sitelaboratory)

Same as Q-3

Same as Q-3

As in Q-3, but if necessary withincreased frequency, (testing at sitelaboratory).

As in Q-3 (Two tier checks at sitelaboratory)

Same as Q-3

As in Q-2, supported by checking attesting laboratory at site.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

1.3 Water SuitabilityChemical analysis

At the beginning Carried out if indoubt

Same as Q-2. Mandatory at thebeginning of project andrepeated (for chlorides andsulphates) in between if anychange is perceived / suspectedin water quality (includingseasonal changes)

Same as Q-2. As in Q-3, but atincrease frequency during working.

1.4 Cement Normal physicaland chemical tests.

Form of purchasestorage, transportation,and use withinacceptable time limit.

Manufacturer’s certificates acceptable& testing in case of doubt or non-availability of certificate.

Trade purchases, intermediatestorage in dry and covered place,transportation and use of factory filled,machine stitched bags.

As in Q-2 and at frequency ofeach new consignment &documented special tests will berequired for special for specialcements.

Supply from factory with directtransportation from factory tosite godown / silos.Transportation andtransshipment supervised anddocumented.

As in Q-3, testing carried out at sitelaboratory & independently cross-checked at predeterminedfrequently.

Same a Q-3

1.5 Admixturesa) Approval May be permitted under specialist

supervision in which case follow Q-3controls.

Independently carried outacceptance testing after fieldtrails for each sources.

Re-trials with change in sourceof Cement.

Routine checking by testing forevery batch of admixture.

Manufacturers’ date / certificateacceptable as basis ofcomparison for production lot.

As in Q-3, with additionalindependent tests.

i) Chloride contents.

ii)Spectroscopic signature ofaccepted product as basis ofcomparison for production lots.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

b) Dosage dispensingand productioncontrols at site

c) Training of site staff bymanufacturer

Dosage to be finalized after field trialmixes, special mechanical devices tobe used for dispensing.

Frequent checks for specific gravity

Continuous monitoring of work abilityof concrete

Visual inspection of concrete afterstriking forms for local defects(including delayed setting).

Proper training of site staff in use aswell as quality control, plus periodicvisits by manufacturer’s certificate

Same as Q-2

Same as Q-2

Same as Q-2

As in Q-2, but visits b experts atclose frequency.

1.6 Reinforcing Steel NormalPhysical tests

Once at beginning and for everychange in source in addition tomanufacturer’s certificate.

As in Q-2, and for eachconsignment

As in Q-3, but further supplementedby random checking by QA team.

Chemical composition

Welding

Once at beginning and if in doubt forany source.

Not ordinarily permissible at site.

Same as Q-2

Welding to be done only byqualified and tested welders.

Types of electrodes to bespecified for each purpose.

Random testing of welded jointsfor strength.

Same as Q-2

As in Q-3, but welders t beperiodically tested and also weldingto be examined by experts afterdestructive tests.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

1.7 Prestressing Steel /Anchorage systems &cable anchorageassembly

a) General (for all itemsof prestressingincluding equipment).

Storage

Compatibility of variouscomponents.

Methods of handling &care taking

b) HT Wires / stands

In a sealed and moisture proofgodown with minimum openings storeabove ground level on raised supportsor in racks.Such godown will havehumidity control

In Additional vapour face inhibitorsand / or water soluble oils to protectsteel

Suitability of anchorages for use withwire / standards (meeting relevantspecifications) to be certified by themanufacturer of anchorages. Alsocompatibility of all other materials andequipment to be thus certified /cleared.

Also the manufacturer to supplyspecial assistance at site. If required,to train and supervise personnel atwork.

Same as Q-2

Same as Q-2

Same as Q-2

Same as Q-2

Same as Q-2

Same as Q-2

As in Q-2, but compatibilityestablished at site as required byQA team.

Same as Q-2



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

Mechanical properties(Tensile Strength, proofStress).

Modules of Elasticity

Manufacturer’s Test Certificate can beaccepted. Additional Testing if indoubt.

Insist for manufacturer’s certificategiving stress. Strain curve & modulesof elasticity. Sample testing witnessedby independent QA team.

Contact with contaminated surfacesavoided.

In addition to manufacturer’scertificate, tests done on randomsamples for a lot of 50 T, or partthereof and witnessed byindependent QA team ofrandom.

Same as Q-2

As in Q-3, but every coil. Sampletesting witnessed by independentQA team at specified frequency.

Same as Q-2

c) Anchorage System(ChemicalComposition & HeatTreatmentSupplementary Tests)

d) Cable AnchorageAssembly (AcceptanceTesting)

Static Tensile test & loadtransfer test

Permitted using anchorage orestablished manufactures of longstanding based on certification ofsuitability & quality by manufacturer.

Not normally required.

As in Q-2, but supported bymanufacturers detailed QA plan(which can be verified bypurchaser if necessary).

Manufacturers certificate

May additionally require testingat site or at independentlaboratory as per FIP Guide.

As in Q-3, but in addition QA plansshould be independently checked byQA team and verified atmanufacturer’s facilities.

Manufacturer’s certificate andcertificate by testing at independentlaboratory as per FIP Guide. Testsmay be repeated at the beginning ofthe proposed materials andwitnessed by the representatives ofcontractor / owner.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

Dynamic Test for Cable /anchorage assembly

e) Sheathing Cable Dust

Supply

Workability andTransverse bending testas per IRC : 18

Not normally

Purchase from manufacturers withmetallic sheathings metallicsheathings coated with water solublerust –preventive oil.

Test certificate by the Manufacturerfor each lot to be furnished.

Manufacturers certificate oftesting

Also independent laboratorytesting as per FIP Code, oncefor new system of anchorage /cables.

Same as Q-2

As in Q-2, but additionalindependent test to be done onrandom samples.

As in Q-3, plus any additional) testthan a QA team may required.

As in Q-3, but preferable to fabricatesheathing freshly at site at therequired rate.

As in Q-3, but at higher frequencyplus any additional test that QAteam may require.

1.8 Any other materials (likeexpansion joints,bearings, railing etc.)

Manufacturers Certificate supportedby sample testing.

As in Q-2 with higher frequencyof testing and

As in Q-3 with implementation of QAplan of manufacturer to be auditedby QA team of owner to the extentdepending on the importance of theteam.

1.9 New Materials Normally not to be used. If used sameas Q-3

QA plan of manufacturer to beinitially approved. To beaccepted by competenttechnical authority for usethoeity for use after full testing atlaboratory / and field trials.Special specification forproperties testing and

As in Q-3. Supplemented byindependent checking by QA teamof specialist consultants.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

acceptance criteria to beevolved and laid down for use atsite.

2.

2.1

WORKMANSHIP

General Controls (Direct& indirect)a) Working & supervision

Skilled and semiskilled workers.

Periodic vision from owner of hisagent.

Periodic check by designer during sitevisit.

Skilled workers having specialtraining and working underexperienced supervisors.(Where trade qualifications ateexisting should be insistedupon).

Full time supervision fromcontractor as well as from owneror his agent.

As in Q-2, but at predeter minedstages and frequency.

Same as Q-3

As in Q-3, but with occasionalsupervision by expert externalagency.

As in Q-3 expect in case of bridgeshaving new technology / design fulltime site representative of designagency will be necessary.

b) Use of Mock-ups Not ordinarily required.

Document inspection andcertification of certification ofcompliance by designersrepresentative.

For Q-3 quality mock ups arerequired only for certainelements (typical slice anddifficult zones) which should be

Same as Q-3.

As in Q-3, but made mandatory forall difficult and important zones.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

specified in tender document.Mock-ups to be carried out inpresence of designer and QAteam of owner.

Mock-up should use actualproposed methods ofconstruction, including plant andequipment.

Mock-up should use actualproposed methods ofconstruction including plant andequipment.

No work on structure should bepermitted before demonstrativemock-up.

Also, mock-ups dealing with newtechniques to be carried out undersupervision of expert externalagency.

As in Q-3.

2.2 Concrete Mix design Mix design performed at beginning ofwork or for new source of materialswith subsequent Q.C. as per code andby experienced supervisors.

As in Q-2 with minimum twolevel controls.

As in Q-3.

Notes:

Full scale mock-ups of part of structure are made for various purpose as follows:

1) Verification of proper detailing and choice of concrete of mix and making modification in either or both to achieve satisfactory concreting.2) To establish effective methods of transporting, placing and compacting.3) Training of workers for operation in (2) above.4) To demonstration efficacy of the overall construction operations in achieving its aim.

Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

2.3 Fabrication andfixing ofreinforcement.

Site bending by skilled workers withregular checking by qualifiedsupervisor

Bar bending schedules are made andchecked before use.

Correct placement or reinforcementand provision of proper cover checkedindependently before concreting.

Same as Q-2

Same as Q-2

As in Q-2, but checked anddocumented by QA team.

Same as Q-2

As in Q-2 expect bar bendingschedule made by design officeonly.Same as Q-3

2.4 Fabrication & fixingof presenting cables.

Relaxation Test

ChemicalComposition

Packing

Transportation

Normally not applicable. If used followQ-3 practices.

Manufacturer’ certificate

Manufacturer’s Certificate can beaccepted with special testing, if indoubt.

Packing with two layers for waterproofing and mechanical protection.

Transport vehicles check.

Protection from environment ofphysical damage.

Coils handled by mechanical devicesprohibiting movement by rolling.

Modules established initially(acceptance test)

Testing & certification essential for1000 hours test by independent testhouse.

As in Q-2, plus testing by independentagency on random sample basis.

Same as Q-2.

Same as Q-2.

Modulus established initially andverified by work test.

As in Q-3, also tests to be witnessedby contractors / owners / owners QAteam.

Same as Q-3.

Same as Q-2.

Same as Q-2.

Same as Q-2.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

Suitable of coilsize/weight for use atsize.

a) Cleaning

The wire / strand should be free ofskinks or deformations and straight.

Same as Q-2.

Should be free rust Light on wires (notstrands) can be removed, wirescleaned and used.

Only unrusted steel can be used.

b) Preparation ofsteel / cables.

c) Laying &supporting

Pre-fabricated and sheathed cablecan be permitted.

However, post threaded wires/strands just before stressing are to bepreferred.

Cables strictly prepared on raised /clean benches and kept free from dustat all times.

Cable Layout giving co-ordinates atclose intervals as needed by fixingrequirements (and not by theoreticalcurves or equations alone), andsupported firmly in place. PostThreaded cable ducts should be heldagainst floatation during concreting.

Layout and leak tightness ofsheathing to be independentlychecked and documented by owner’sQ.A. Team of his agent.

Only post threading of wires/strandspermitted (with exceptions ifunavoidable).

Same as Q-3.

As in Q-3.

As in Q-3, with additional checkingand testing required by QA teamssample checking by expert externalagency.

2.5 FORMWORK



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

a) Materials

b) Design Check

c) Specialist System.

d) Experiencedcarpenters /fitters.

e) Tolerances,geometry and leaktightness checks.

f) De-shuttering

Any Suitable materials meeting codalrequirements and capable of givingspecified form finish.

Spot check.

Specialized formwork systems neednot be insisted upon.

Semi-skilled / Skilled carpenters,fitters under supervisory staff.

Frequent check by carpenters/ fittersand checking of important membersby supervisory staff.

Under supervisory staff for importantmembers.

Same as Q-2.

Formwork / design made andapproved independently.

Specialised formwork system, to bepreferred with properly trainedcarpenters / fitters.

Skilled carpenters / fitters undersupervisory staff with the worksupervised additionally by ownerssupervisors and agents.

Check for all members by supervisorystaff.

As in Q-2. The system should providefor gradual uniform and shock-free de-shuttering arrangements.

As in Q-2 with regularly and properlymaintained shuttering with limitedreuses. Shuttering capable ofabsorbing Air released fromconcrete and providing goodinsulation control thermal gradientsis to be used. If steel shutter areused, plywood liners or provision ofsack rubbing after de-shuttering.

Same as in Q-3.

Same as Q-3.

Same as Q-3.

As in Q-3. Also check for quality ofshutter surfaces before reuse &document clearance.

Same as Q-3

g) Formwork forspecial structure

Not applicable As per design requirement undercontrol of qualified staff, with

Same as Q-3



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

additional supervision by owner’ssupervisor or agents. Checks by QAteam till procedure at site areestablished.

2.6 Mixing / Conveyanceplacing / Curing ofconcrete

Site mixing by mixers or batchingplant near site. Occasional two tiercontrol and documented.

Transportation by head leads trolliesor by mechanized vehicle permitted.

Experienced concreting gangs undersupervisory staff.

Placing concrete and compactingunder supervisory staff.

As in Q-2 under two level controls,upto 200m length bridge beyondwhich batching plant is mandatory.

Use specialized equipment fortransportation. The adverse effects ofthe methods of conveyance(segregation delays stiffening of mixetc.), should be regularly monitoredcontrolled and documented.

As in Q2, with two level controls. Alsoregular control by qualified staff.Method of control by pour cardrecommended.

As in Q-2. Also regular control byqualified staff. Surveillance by QAteam.

Batching plant is mandatory.Occasional checks by expertexternal agency.

As in Q-3.

Same as Q-3.

Same as Q-3. Efficacy of methodsto be regularly checked anddemonstrated.

2.7 Stressing Cables

Stressing equipment

Stressing Operations

Normally not applicable if used followQ-3 practices.

Stressing equipment calibrated testedand certified by manufacturer/supplier.

Checking and recalibrated at site atregular predetermined frequency byqualified staff under supervision ofowner and his agent.

Only under strict supervision ofstressing supervision of stressing

As in Q-3 in presence ofindependent expert or by QA team.



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

Check of friction andwobble losses.

supervision and site engineer. Themanufacturer to supply specialassistance at site to train personneland supervise work.

Sample basis check for elongation /pull in of all wires / strands in thecable assembly (uniformity ofstressing).

In-site check on losses by stressingfrom on side jack using as active andother as a passive jack on a samplebasis.(For long cables and high totaldeviation the passive jack may notregister pressure within strock lengthof active jack. For such cases specialtests or provision of short cables maybe required).

Same as Q-3 with surveillance byexpert agency / or QA team.

Same as Q-3.

As in Q-3 with additional tests asrequired by QA team.

2.8 Grouts & Groutings.a) Grouting of

PrestressingCables.

Composition andPhysical properties.

Fluidity test bleedingcharacteristicsduring workingEquipment

Normally not applicable. If used thenfollow Q-3 practice.

At the beginning of work for designingsuitable grouts. Physical properties tobe verified once a week or withchange of batch of cement ofadmixture.

By visual inspection

Equipment tested & passed forsatisfactory performance regularly.

Trained staff under qualifiedsupervision. Surveillance by QA team.

As in Q-3 which check for everyoperation.

As in Q-3 but tested anddocumented for every operation.

As in Q-3 with testing witnesses byindependent QA team.

Same as Q-3



Sr.No.

Item Normal QA(Q-2)

High QA(Q-3)

Extra High QA(Q-4)

Workers / Supervisor

Admixtures

b) Grouting with non-cementitiousspecial material.

c) Cement Groutingfor bolts and fixingapparatus

Use of special per-packed highstrength non-shrink grouts preferred.

Where used as per item 5.5. Whereused, as per item 5.5.

Normally not required, if used followQ-4. As per item 5.5

Materials like grease, powdercoatings, or other speciallyformulated mixes should be usedonly after through testing forsuitability including long term effectsand by following specially developedsuitable methods under expertsupervision.

As in Q-3 with increased frequencyof checking.

inspection and testing plan for construction...

Documents