QAP Volume -1

Third Party Quality Audit(TPQA)

National Cyclone Risk Mitigation Project(NCRMP)

Revenue (DM) DepartmentGovernment of Andhra Pradesh








in Jointventure

with

Third Party Quality Audit for Construction of Cyclone Shelters,Roads to Cyclone Shelters & Habitations, Bridges and Culvertsunder NCRMP

Quality Assurance Plan

inJoint Venture

with

INDEX

1 Introduction 1

2 Quality Control Tests Required/Frequency/Specifications for Roads & Bridges 6

3 Quality Control Tests Required/Frequency/Specifications for Buildings 24

4 Methodology for Road construction 28

5 OK Card Formats 42

6 Rectification Guidelines 57

S.NO LIST OF TABLE'S Page No1 Original Ground as Embankment Foundation 62 Original Ground as Sub Grade (500 mm Thick ) 63 Embankment up to 3m Height 74 Sub-grade in Cutting or Embankment (500 mm Thick) 75 Embankment Exceeding 3m Height 8

6 Additional Test on filling with in 600mm of Concrete Structures/ Cement BoundMaterials 8

7 Back Filling to Sub-Surface Drains 98 Aggregate Drains 99 Granular Sub-Base 1010 Water Bound Macadam Sub-Base / Base 1111 Prime Coat and Tack Coat 1312 Open Graded Premix Surfacing 1313 Bituminous Macadam 1414 Mix seal Surfacing 1515 Semi Dense Bituminous Concrete 1616 Cement Concrete Pavement 1817 Cement for Structural Works 2018 Coarse Aggregate for Structures 2019 Sand / Fine Aggregate for Structures 2220 Reinforcement Steel 2321 Water for Concrete and Mortar 23

Third Party Quality Audit for Construction of Cyclone Shelters,

Roads to Cyclone Shelters & Habitations, Bridges and Culverts

under NCRMPQuality Assurance Plan

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1.0 INTRODUCTION

1.1 Project Background

National Cyclone Risk Mitigation Project (NCRMP) – Project Implementation Unit (PIU), Andhra Pradesh,

headquartered at Hyderabad has appointed Egis International in JV with Egis India Consulting Engineers

(I) Pvt. Ltd for providing the consultancy services for Third Party Quality Audit for 9 coastal districts

namely Srikakulam, Visakhapatnam, East Godavari, West Godavari, Krishna, Guntur, Prakasam and

Nellore. The project “Construction of Multipurpose Cyclone Shelters, Roads to Cyclone Shelters,and Roads to habitations and Roads & Bridges under NCRMP” is funded by International

Development Association and received through Government of India. This consultancy is envisaged to

audit the quality of works being implemented by various line departments working under PIU.

As a part of this assignment, the Third Party Quality Auditor (‘TPQA’) will report to PIU on its audit

findings. The objectives and description of the services for third party quality audit are:

A. Assist the PIU in maintaining the quality standards of the civil works by independent assessment /

audit of quality of works at various stages of construction of multipurpose cyclone shelters, roads,

bridges and culverts being implemented by PR departments. For bridges and roads, R&B

department.

B. Report on the compliance with the requirements of Environmental and Social Frame work (ESMF)

including the management measures provided in the Environmental Management Plans (EMPs) and

the Resettlement Action Plans, when ever required.

This QAP is prepared as part of TPQA agreement and the frequency of testing, test report formats,

checklists provided in this QAP are for the guidance and implementation by Contactors and Line

Departments. The implementation of the same will be monitored by the TPQA during the audit visits.

TPQA will also conduct all the required field tests/lab tests for confirmation of the quality

requirements

1.2 Third Party Quality Audit

The activity flow of TPQA is as follows.

A. The TPQA will guide the implementation engineers with respect to designs as per the contact documents, within

the planned time frame, conforming to the guidelines and circulars issued and also based on the objectives of the

project.




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B. The TPQA will review the results of field testing being conducted by the contractor and Line department and

when doubts arise in such observations another sample will be taken and will be tested independently to verify

whether it is as per the standards or not.

C. The TPQA will review civil work components of the cyclone shelters and related roads & bridges of these

buildings and compliances and non-compliances will be reported regularly to PIU and line department.

D. The TPQA will visit the construction sites randomly without prior information to the implementing agency, along

with the regular site visits. Regular feedback will be given with regards to compliance of suggested corrective

measures. Wherever compliances are not happening, a report should be submitted to the PIU and line

departments and if necessary “Stop Work” notice will be issued through the Engineer in-charge.

E. The TPQA will carry out additional tests, where a prime facie doubt arises related to quality of works and / or

compliance of standards using mobile laboratory available with the TPQA team or nearby approved laboratories.

The TPQA shall advise few more labs for testing suitably, which after the approval of the PIU / line departments,

can be used for testing.

F. Review the workers’ safety standards being followed in the construction site to avoid any type of losses /

damages, as far as possible.

1.3 QUALITY ASSURANCE PLAN

1.3.1 Introduction

The Quality Assurance Plan (QAP) is the methodology that is selected for ensuring that the project

incorporates all elements that are needed for the successful design, construction and maintenance of a

project. Since projects vary in scope, the QAP has to be project-specific. The QAP should deal with all

aspects of selection and testing of materials, acceptance criteria, guidelines for non-conforming materials

and works and documentation.

1.3.2 Quality Control

1.3.2.1 Types of Quality Control

One of the most important tasks during the execution of a road contract is technical quality control, i.e.

control as to whether the materials and work supplied by the Contractor meet the technical requirements

in the contract specifications. There are two types of quality control, which are described below:

(a) Control of Methods

Method control is usually carried out by the Line Department field staff whose job it is to be on the site and

supervise the Contractor during the execution of the works. It is the responsibility of the Line Departments

staff to see that the contractor performs the entire required test as per the frequency and all the records




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are maintained. Line department should also see that all the registers, site order books are maintained. All

the test reports, registers, site order books etc. will be reviewed and audited by the TPQA during the site

visits apart from conducting tests required for confirmation.

(b) Control of End-Results

End-result control includes field tests e.g. control of the evenness of completed pavement layers and

laboratory tests, e.g. Marshall test on bitumen materials. Other tests are a combination of field and

laboratory tests. An example of this is the compaction control of earthworks where the achieved density is

determined by means of a field test, and where the density with which the result should be compared is

found by means of a laboratory test. End results control is carried out by laboratory technicians, and most

of the work consists of field and laboratory tests.

1.3.3 Start-up Problems

It is important that start-up problems have been solved before the Contractor starts work. There is often a

special need for technical control during the start of the work, because the Contractor has start-up

problems. Specifications normally not only state the technical requirements which must be met by

materials and works, but also the test methods which must be used for the end-result control. In most

cases this is necessary to be able to define the requirements clearly.

1.3.4 Test Specification

Specifications usually describe test methods by referring to standard methods issued by Ministry of Rural

Development, and the Bureau of Indian Standards (BIS).

1.3.5 Testing Frequency

The frequency of technical control is usually laid down by the Client at the beginning of a project and is

generally related to the specifications. A testing plan giving the testing frequency, standards, acceptance

criteria are provided to be followed by the Contractor.

1.3.5.1 NCRMP works of Bridges (9Nos) and roads (2Nos) are being executed by R & B Department and

MORT&H specifications and IRC codes are to be followed.

1.3.5.2 NCRMP works of rural roads namely roads to habitation and cyclone shelters and cyclone

shelters are being executed by PR Eng. Department and for these works MORD specifications need to be

followed.




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1.3.5.3 For cyclone shelters IS: 456 and other relevant IS codes need to be followed

The frequency of tests, specifications and requirements are furnished in section 2.0 and 3.0 of

this QAP booklet. The frequencies are as per MORT&H and MORD requirements. All the field tests and

laboratory tests required are to be done by the contractor. All the field tests are to be done by line

Departmental officers and TPQA staff also. Necessary laboratory tests are to be conducted by line

departmental officers and conformity laboratory tests are to be done by TPQA officers. This may be

modified by the client if necessary.

1.3.6 Method Control

Method control is carried out according to the type of work. Where the work method is of considerable

importance and requires constant supervision to achieve the quality, or where in some case, the quality is

difficult to improve upon, there should always be a field engineer on the site. Examples are the ramming

of piles, the laying of bitumen, embankment construction and concreting etc. Where work methods are of

less importance or quality is constantly being achieved by the contractor, a continuous supervision may

not be needed, but required confirmatory tests are to be performed as per the frequency.

Detailed methodology for all the impartment items are given in section 4.0 of this booklet. TPQA officers

will inspect all the works in different stages of works to ensure good quality standards in the work.

Methodology of TPQA in ensuring good quality of work:

The site engineers will be inspecting the works in progress at regular intervals like once or twice in a week

depending on the nature of work. They conduct all the field tests required. They collect and send samples

for laboratory testings. The field engineers verify wether the work is going on as per specifications. The

site engineers assist the line departmental engineers and the contractor in rectifying the works during

construction to the possible extent. The site engineers submit inspection report for every work to the DPM

with a copy to PM by E-mail.

The DPM will also conduct regular inspections once or twice in a month depending on the nature of work.

The Project Manager inspects the works once or twice in a quarter to monitor the quality measures

adopted by the contractor, line departmental engineers and TPQA engineers.

The materials like bitumen, cement, steel, water and GSB mix etc will be sent to accreditedlaboratory for testing

In case of failure of field density and gradation etc, suitable action will be taken to get it rectifiedimmediately.

In case of failure like CBR tests, non-compliance of materials, suitable Non- Compliance reportwill be issued to the concerned executive Engineer, PIU with copies to the PM, PIU. On receipt of




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compliance it will be verified whether the required remedial measure is carried out or not. The acceptanceor otherwise of the Compliance will be intimated to the client.

During visits, TPQA will also conduct Quality Assurance prevention to all the Engineers andcontractors to enlighten the quality aspects of work As a part of QAP, TPQA has distributed booklets withall the items of work associated with NCRMP phase – 1 works to all the Engineers and all the contractorsat the QA workshop conducted at Vijayawada on 28-06-2011.

The Booklet contains Specifications, Methodology, Dos and don’ts and Acceptance criteria for alltypes of works.

The subjects incorporated in the booklet are :

a) Rural road construction as per MORD specification and IRC : SP: 20b) Road construction as per MORT & H specificationc) Important aspects in construction of structures as per IS : 456 and IRC codes.d) Quality assurance in reinforcement steel.e) Good construction practices in reinforcement detailingf) CC roads as per MORD specifications and as per IRC: SP: 62-2004.

The booklet was printed in such a way that all the contractors and Engineers can use it as areference book at site also.

1.3.7 End-result Control

The frequency of end-result control depends on the quality parameters that are to be checked.

Parameters which can vary considerably are continuously controlled. Examples are the composition of

bitumen materials and the compaction of bitumen courses. As regards regulating laboratory tests the

specification usually determines the number of tests. When the works are started and in cases where

difficulties as regards compliance with quality requirements are encountered, laboratory testing will

normally be intensified.

1.3.8 Quality Parameters

Quality parameters which are usually more or less constant, e.g. the Aggregate Impact Value of stone

materials from the same quarry, are only controlled occasionally. The same applies to parameters which

can be checked fairly well with the naked eye, e.g. the particle form of crushed stone. As regards the

quality of manufactured materials produced by using advanced technology, e.g. steel and bitumen, one

usually trusts the manufacturer`s certificates, but when in doubt carry out additional tests.

1.3.9 Reporting of Test Results

The test results must be recorded systematically in a format, which must be signed by the testing authority

and the representative of the Engineer, if present during the tests.




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Third Party Quality Audit for Construction of Cyclone Shelters, Roads to Cyclone

Shelters & Habitations, Bridges and Culverts under NCRMPQuality Assurance Plan

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2.0 Quality Control Tests Required/Frequency/Specifications for Roads & Bridges

Table 1: Original Ground as Embankment Foundation

Sl. No. Test Test Method Minimum Frequency Specified Value1. MDD & OMC (by heavy compaction) IS:2720 (Pt 8) 1 test per 3000 Cum MDD not less than 15.2kN/cum2. Moisture content during field compaction IS:2720 (Pt 2)

(speedy tester/nuclear meter)Frequently OMC+1% to – 2%

(for expansive clay on wet sideof OMC)

3. Degree of compaction IS:2720 (Pt 28) 1 test per 1000 sqm 95% (90% for expansive clay)4. Tests for high embankment Special Specifications As required Special Specifications

Table 2: Original Ground as Sub-Grade (500mm Thick)

Sl. No. Test Test Method Minimum Frequency Specified Value1. MDD & OMC (by heavy compaction) IS:2720 (Pt 8) 1 test per 3000 Cum MDD not less than 17.5kN/cum2. CBR at 97% MDD IS:2720 (Pt 16) 1 test per 3000 Cum As in Special Specifications3. Maximum particle size IS:2720 (Pt 4) Frequently 50mm4. M.C. during field compaction IS:2720 (Pt 2) Frequently OMC + 1% to – 2%5. Degree of compaction IS:2720 (Pt 28) 1 test per 1000 sqm 97%

NOTE: MDD = Maximum Dry Density; OMC = Optimum Moisture Content; Pt = Part; sqm = square meter; Spl. Spn. = Special Specification;Std. Spn. = Standard Specification; M.C. = Moisture Content; LL = Liquid Limit; Pl = Plasticity Index; Max. = Maximum; Min. = MinimumHeavy Compaction Refers Modified Proctor Tests.

Conversion Factors:1N = 101.97 g; 1 kN = 101.97 kg; Sl unit of density is kg/cum; For approximate conversion, 1 kN is taken as 100 kg or 1 kg = 10N; 1 g/cc or 1 g/ml = 1000 kg/cum (Example: Soil heaving density1.52 g/cc will now be written as 1520 kg/cum); unit of force 1 Pa = 1 N/sqm and 1MPa =1 N/sqmm (Example compressive strength of concrete when tested using old machines with dial gauges inTones or kgs can be converted by the relation, 10kg/sq.cm = 1N/sqmm = 1MPa



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Table 3: Embankment up to 3m Height

Sl. No. Test Test Method Minimum Frequency Specified Value1. Gradation/Sand Content IS:2720 (Pt 4) 1 test per 3000 cum As in special specification2. Maximum Particle size IS:2720 (Pt 4) 2 test per 3000 cum 75mm3. MDD & OMC (by heavy compaction) IS:2720 (Pt 8) 2 test per 3000 cum MDD not less than 15.2 kN/cum4. M.C. during field compaction IS:2720 (Pt 2)

(Speedy tester/nuclearmeter)

2 test per 3000 cum OMC + 1% to – 2% (on wet side ofOMC for Expansive clay)

5. Degree of compaction IS:2720 (Pt 28) 1 test per 1000 sqm (95% (for expansive clay 90%)6. Layer thickness (compacted) By scaling during

compaction test1 test per 1000 sqm 150mm to 250mm

Table4: Sub-Grade in Cutting or Embankment (500mm Thick)

Sl. No. Test Test Method Minimum Frequency Specified Value1. Gradation/Sand Content IS:2720 (Pt 4) 1-2 test per 3000 cum As in Special Specifications2. Maximum Particle size IS:2720 (Pt 4) 1-2 test per 3000 cum 50mm3. MDD & OMC (by heavy compaction) IS:2720 (Pt 8) 1 test per 3000 cum MDD not less than 17.5 kN/cum4. CBR at 97% MDD IS:2720 (Pt 16) 1 test per 3000 cum As in special specification5. M.C. during field compaction IS:2720 (Pt 2) 1 test per 3000 cum OMC + 1% to – 2%6. Degree of compaction IS:2720 (Pt 28) 1 test per 500 sqm 97%7. Layer thickness (compacted) By Scaling during

compaction1 test per 1000 sqm 100mm to 250mm

8. Classification IS:1498 1 test per 3000 cum Expansive clay not allowed*

NOTE: * Where an expansive clay with acceptable ‘free swelling index’ value is used as a fill material in the embankment or encountered in cutting, the Subgrade and top 500 mm portion of theembankment/ cutting just below the Subgrade shall be removed and filled with CNS soils.



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Table5: Embankment Exceeding 3m Height

Sl. No. Test Test Method Minimum Frequency Specified Value1. Gradation/Sand Content IS:2720 (Pt 4) 2 test per 3000 cum As in Special Specifications2. Classification IS:1498 1 test per 3000 cum As in Special Specifications3. LL & PI IS:2720 (Pt 5) 1 test per 3000 cum As in Special Specifications4. Maximum Particle size IS:2720 (Pt 4) Frequently 75mm5. MDD & OMC (by heavy compaction) IS:2720 (Pt 8) 1 test per 3000 cum MDD not less than specified value in

design6. M.C. during field compaction IS:2720 (Pt 2)

(Speedy tester/nuclear meter)1 test per 1000 Cum OMC + 1% to – 2%

7. Degree of compaction IS:2720 (Pt 28) 1 test per 1000 Cum( atleast one test in everylayer)

95%

8. Layer thickness (compacted) By scaling during compactiontest

1 test per 3000 Cum 150mm to 250mm

Table6: Additional Test on Filling within 600mm of Concrete Structures/Cement Bound Materials

Sl. No. Test Test Method MinimumFrequency

Specified Value

1. Soluble Sulphate content (expressed asSO3)

BS:1377 (Pt3:1990)/IS:2720(27)

As required Max 1.9 g per litre

2. Total Sulphate content (expressed asSO3)

BS:1377 (Pt 3:1990) As required Max 0.5% by mass



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Table7: Backfilling to Sub-Surface Drains

Sl.No. Test Test Method Minimum Frequency Specified Value

1. Grading of filter materialNOTE:i) Use Class I filter if soil in trench is fine

grained (eg. silt, clay or mixturethereof).

ii) Use Class II filter if soil in trench iscoarse silt to medium sand or sandytype.

iii) Use Class III filter if soil in trench isgravelly sand.

IS:2720 (Pt 4) Each batchSieve Size

% Passing

Class I Class II Class III53mm – – 100

45mm – – 97-10026.5mm – 100 –22.4mm – 95-100 58-10011.2mm 100 48-100 20-605.6mm 92-100 28-54 4-322.8mm 83-100 20-35 0-101.4mm 59-96 – 0-5710mic 35-80 6-18 –355mic 14-40 2-9 –180mic 3-15 – –90mic 0-5 0-4 0-3

2. Size of holes in perforated pipe – Each batch Less than D85 size of material surrounding pipe

Table 8: Aggregate Drains


1. Grading of aggregate IS:2720 (Pt 4) Each batchSieve Size

% PassingType A Type B

63mm – 100

37.5mm 100 85-10019mm – 0-209.5mm 45-100 0-5



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3.35mm 25-80 –600mic 8-45 –150mic 0-10 –75mic 0-5 –

Table 9: Granular Sub-Base

Sl. No. Test Test Method Minimum Frequency Specified Value1. Grading for close-graded material

NOTE: For required grading, see specialspecification of concernedproject

IS:2720 (Pt 4) Each batchSieveSize

% Passing

Grading I GradingII Grading III

75mm 100 – –53mm 80-100 100 –

26.5mm 55-90 70-100 1009.5mm 35-65 50-80 65-954.75mm 25-55 40-65 50-802.36mm 20-40 30-50 40-650.425mm 10-25 15-25 20-350.075mm 3-10 3-10 3-10

2. Grading of coarse graded materialNOTE: For required grading, see special

specification of concernedproject

IS:2720 (Pt 4) 1 per 200cum Specified Value

SieveSize

% Passing

Grading I GradingII Grading III

75mm 100 – –53mm – 100 100

26.5mm 55-75 50-80 –9.5mm – – –4.75mm 10-30 15-35 25-452.36mm – – –0.425mm – – –0.075mm < 10 < 10 < 10

NOTE: DEFINITION OF ‘BATCH’ APPLICABLE TO AGGREGATES:The quantity of aggregate of same size produced by crushing one type of rock in one continuous operation or a stockpile of aggregate of same size and same type of rock from a singlesource.

3. Ten percent fine value (wet) BS:812 (Pt 111) 1 per 200 cum Min 50kN



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Sl. No. Test Test Method Minimum Frequency Specified Value4. Water absorption IS:2386 (Pt 3) 1 per 200 cum Max 2%5. Soundness in Sodium Sulphate

(when water absorption > 2%)IS:383 1 per 200 cum Max 12

6. CBR at 98% compaction IS:2720 (Pt16) As required 30/25/20 for grading I, II, III7. MDD & OMC IS:2720 (Pt18) As required –8. MC for field compaction Speedy tester/Nuclear meter 1 per 250 sqm – 2% to + 1% of OMC9. Degree of compaction IS:2720 (Pt 28) 1 per 500 sqm Min 98%10. LL and PI for material passing 424 micron IS:2720 (Pt 5) 1 per 200 cum 25% and 6%11. Deleterious constituents Visual As required Nil

Table 10: Water Bound Macadam Sub-Base/Base

Sl. No. Test Test Method Minimum Frequency Specified Value

1. Los Angeles Abrasion value IS:2386 (Pt 4) 1 per 200cum Max 40%

2. Aggregate impact value (alternative of LAA) IS:2386 (Pt 4) or IS:5640 1 per 200cum Max 30%

3. Combined Flakiness & Elongation Indices IS:2386 (Pt 1) 1 per 200cum Max 30%

4. Liquid limit of screening material IS:2386 (Pt 5) 1 per 100cum Below 20%

5. Plasticity index of screening material IS:2386 (Pt 5) 1 per 100cum Below 6

6. Fraction passing 75 mic of screening IS:2386 (Pt 1) 1 per 100cum Max 10%

7. Water absorption for aggregates IS:2386 (Pt 3) 1 per 200cum Max 2%

8. Soundness in Sodium Sulphate(when water absorption is > 2%)

IS:383 1 per 200cumMax 12%

9. Plasticity index of binding material IS:2386 (Pt 5) 1 per 25cumLess than 6

10 Grading of coarse aggregates IS:2386 (Pt 1) GradingNo.

SieveRange

SieveSize

% Passingby weight



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In general visual inspection of the aggregatesshall be made and not weathered rock samplesshould be allowed.

1. 90-45mm 125mm

90mm

63mm

45mm

22.4mm

100

90-100

25-60

0-15

0-5

2. 63-45mm 90mm

63mm

53mm

45mm

22.4mm

100

90-100

25-75

0-15

0-5

3. 53-22.4mm

63mm

53mm

45mm

22.4mm

11.2mm

100

95-100

65-90

0-10

0-5

11. Grading for screenings IS:2386 (Pt 1) 1 per 100cum A. 13.2mm 13.2mm

11.2mm

5.6mm

180mic

100

95-100

15-35

0-10

B. 11.2mm 11.2mm

5.6mm

180mic

100

90-100

15-35

Table 11: Prime Coat and Tack Coat



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Sl. No. Test Test Method Minimum Frequency Specified Value1. Quality of primer IS:73, IS:217 & IS:8887 2 sample per lot Special Specifications2. Binder temperature for application – At regular interval Special Specifications3. Rate of spread of binder Tray Test/Depot Tray

TestOne test/500sqm andnot less than 2 per day

Max variation 2.5%

Table 12: Open Graded Premix Surfacing

Sl. No. Test Test Method MinimumFrequency Specified Value

1. Quality of binder IS:73 2 per lot Special Specifications2. Los Angeles Abrasion Value or

Aggregate Impact ValueIS:2386 (Pt 4) 1 per 50cum

LAA max 40%, AIV max 30%

3. Flakiness Index and ElongationIndex (combined)

IS:2386 (Pt 1) 1 per 50cumMax 30%

4. Coating and stripping AASHTO: T182/IS : 6241 3 per source Min retained coating 95%5. Soundness in Sodium Sulphate

and Magnesium SulphateIS:2386 (Pt 5) 1 per source

Max 12%/18%

6. Water absorption IS:2386 (Pt 3) 1 per 50cum Max 1%7. Stone polishing value BS:812 (Pt 114) As required Min 558. Grading of 13.2mm chippings IS:2386 (Pt 1) 1 per 25cum 100% passing 22.4mm & retained on

11.2mm9. Grading of 11.2mm chippings IS:2386 (Pt 1) 1 per 25cum 100% passing 13.2mm & retained on

5.6mm10. Binder content for premixing Site check 2 per day 52kg per cum for 13.2mm chippings and

56kg per cum for 11.2mm chippings.11. Temperature control:

a) Binder at the time of mixingb) Aggregate at the time of

mixingc) Discharge temperature of mix

–––

FrequentlyFrequentlyFrequently

150oC to163oC155oC to163oC130oC to160oC



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Sl. No. Test Test Method MinimumFrequency Specified Value

12. Rate of spread of mixed material Site check of materials and layerthickness

RegularlyMin 20mm thick

Table 13: Bituminous MacadamSl. No. Test Test Method Minimum Frequency Specified Value

1. Quality of binder IS:73 2 per lot Special Specifications2. Aggregate Impact Value (AIV) or

Los Angels Abrasion Value (LAA)IS:2386 (Pt 4) 1 per 50cum AIV - max 30%, LAA – max 40%

3. Flakiness Index & Elongation Index(combined)

IS:2386 (Pt 1) 1 per 50cum 30% max

4. Stripping value of aggregate. If theminimum retained coating is <95% RetainedTensile Strength Test shall be carried outspecified value is min 80%

AASHTO T:182/IS : 6241 3 per source

Min coating 95%

5. Soundness in Sodium Sulphate andMagnesium Sulphate

IS:2386 (Pt 5) 1 per 50cum Max 12%/18%

6. Water absorption IS:2386 (Pt 3) 1 per 50cum Max 2%7. Grading aggregates

Grading I Grading IINominal aggregate 40mm 19mmsizeLayer thickness 80-100mm 50-75mm

IS:2386 (Pt 1) 2 per day/plant both onindividual constituentsand mixed aggregatesfrom the dryer

Sieve Size% Passing

Grading 1 Grading 245mm 100 –

26.5mm 75-100 10022.4mm 60-95 75-10011.2mm 30-55 50-855.6mm 15-35 20-402.8mm 5-20 5-20

90micron 0-5 0-58. Grain size analysis 2 tests/ day/plant Max 5% passing 75 micron9. Binder content of mix Check at plant At regular intervals 3.1 to 3.4% for grading I

3.3 to 3.5% for grading IIwith tolerance 0.3% by weight of totalmixture



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10. Temperature control:

a) Binder at mixing timeb) Aggregate at mixing timec) Discharge temperature of mixd) Laying temperaturee) Temperature at completion of rolling

–––––

At frequent intervalsAt frequent intervalsAt frequent intervalsAt frequent intervalsAt frequent intervals

Varies with the type of penetrationbitumen

30 - 40 60 - 70 80 -100160-170 150-165 140-160160-175 150-170 140-165Max 170 Max 165 Max 155Min 130 Min 125 Min 115Min 100 Min 90 Min 80

11. Layer thickness Site check Special Specifications12. Density of compacted layer 1 per 250cum Special Specifications

Table 14: Mix Seal SurfacingSl. No. Test Test Method Minimum Frequency Specified Value

1. Quality of binder IS:73, 217, 454 2 per lot Special Specification2. Quality of aggregate Table 24 (Test 2 to 6) 1 per 50cum –3. Grading of aggregates Sieve analysis 1 per 50cum

Sieve Size% Passing

Type Amix Type B mix

13.2mm – 10011.2mm 100 88-1005.6mm 52-88 31-522.8mm 14-38 5-2590mic 0-5 0-5

4. Rate of binder for mix per 10sqm Site check 2 per day Type A: 22kg; Type B: 19kg5. Rate of aggregate per 10sqm Site check 2 per day 0.27 cum for Type A & B6. Temperature control:

a) Binder before mixingb) Aggregate before mixingc) Mix on discharged) Completion of rolling

FrequentlyFrequentlyFrequentlyFrequently

150oC to163oC155oC to163oC130oC to160oCMin 100oC

7. Thickness after compaction Min 20mm

Table 15: Semi Dense Bituminous Concrete



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Sl.No.

Test Test Method Minimum Frequency Specified Value

1. Quality of binder (grade 30/40 to80/100)

IS:73 2 per lotSpecial Specifications

2. Los Angeles Abrasion or AggregateImpact Value

IS:2386 (Pt 4) 1 per 50cumLAA 35% or AIV 27% max

3. Flakiness and Elongation Index (total) IS:2386 (Pt 1) 1 per 50cum Max 30%4. Coating and stripping AASHTO T:182/IS 6241 1 per 50cum Min coating 95%5. Water absorption IS:2386 (Pt 3) 1 per 50cum Max 1% (exceptional 2%)6. Soundness in Sodium

Sulphate/Magnesium SulphateIS:2386 (Pt 5) As required

Max 12%/18%

7. Sand equivalent value IS:2720 (Pt 37) As required Not less than 508. Stone polishing value BS:812 (Pt 114) As required Not Less than 559. Grading of mixed aggregate IS:2386 (Pt 1) 2 per day Sieve

Size% Passing by weight

Grading I Grading II19mm 100 --

13.2mm 90-100 1009.5mm 70-90 90-1004.75mm 35-51 35-512.36mm 24-39 24-391.18mm 15-30 15-30600mic -- --300mic 9-19 9-1975mic 3-8 3-8

10. Job mix formula By mix design Every change ofmaterial As per Design

11. Requirements of mix ASTM D-1559 2 tests per day or per400 tone of mix

S. No. Description Requirement1. Marshall stability Mn. 8.2 kN @

60oc



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Sl.No.


2. Marshall flow 2-4mm3. Air voids 3-5%4. Min VMA (same as Table 27 (test 10

item 6)5. VFB 65-78%6. Binder content Min 4.5% for

Grading I andMin 5% forGrading II

7. Compaction levelNo. of blows 75 blows /

face12. Permissible variations from JMF – – See Table 28 (item 11)13. Temperature Control:

a) Binderb) Aggregatec) Discharge temperatured) Laying temperaturee) Completion of rolling

Same as Table 24 (10)

14. Control of binder content and gradation Bitumen extraction andsieving (Appendix 5 ofIRC:SP-11)

2 per day JMF

15. Layer thickness Site check 1 per 250sqm Special specifications16. Density of compacted layer Density of core 1 per 250sqm Min 98% of Marshall specimen

Table 16: Cement Concrete




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Sl. No. Test Test Method Minimum Frequency Specified Value1. Cement (Physical and Chemical tests)

a) Portland Slag Cement IS:4551 per source of supply andoccasionally for long or improperlystored batch. Also manufacturer’scertificate required.

As per relevant IS

2. Los Angeles Abrasion or Aggregate ImpactValue of coarse aggregate

IS:2386 (Pt 3) 1 per source per month Max 35% for LAA and 30% for AIV

3. a) Deleterious constituents in coarseaggregate

b) Deleterious constituents in fine aggregate

IS:2386 (Pt 2)IS:2386 (Pt 2)

1 per source per month1 per source per month IS:383

Clay lumps 4%:Coal and lignite – 1%

4. Total chloride content in aggregate BS:812 (Pt 17) 1 per source Max 0.06%5. Total sulphate content in aggregate BS:812 (Pt 18) 1 per source Max 0.25%6. Soundness in sodium sulphate IS:2386 (Pt 5) 1 per source Max 12%7. Water absorption IS:2386 (Pt 3) Regularly as required Max 2%8. Alkali – aggregate reactivity IS:2386 (Pt 7) 1 per source per month Non-reactive9. Grading of aggregates IS:2386 (Pt 1) 1 per source per month IS:38310. Maximum size of aggregate IS:2386 (Pt 1) 1 per source per month 25mm11. Concrete mix design IS:10262 and

IS:SP231 per source a) Compressive strength/flexural

strength as per Special Specifications

IS: 455 – 1989IS: 10262

1 per source With Portland slag cementconfirming to IS 455 with slag morethan 50%, W/C ratio of 0.45 to0.5%.

12. pH value of water pH Paper 1 per source Min 6 (Acceptable 6 to 9)13. Alkalinity limit by titration IS:3025 1 per source Max 10ml HCL to neutralize 200ml water14. Acidity limit by titration IS:3025 1 per source Max 2ml NaOH to neutralize 200ml water15. Solids in water IS:3025 1 per source Maximum limits per liter:

Organic – 200mg; inorganic – 3000mg;Sulphate – 400mg; chloride – 500mg;Suspended matter 2000mg



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Sl. No. Test Test Method Minimum Frequency Specified Value16. Concrete cube test (7 day & 28 day) IS:516 2 cubes per 150cum or min 6 per

day or batch Special specifications

17. Concrete beam test (7 day & 28 day) IS:516 2 beams per 150cum or min 6 perday or batch Special specifications

18. Core strength of hardened concrete IS:516 Engineer’s discretion Special specifications19. Slump test (for workability) IS:1199 1 per dumper load initially and

1 per alternate dumpersubsequently

As per IS 456

20. Thickness measurement of trial length Core sampling 3 cores per trial Special specifications21. Thickness determination Leveling Grid points of 5 to 6.25m x 3.5m Special specifications22. Verification of level of form Site check 5.0m to 6.25m ± 2mm23. Texture depth Sand patch

method5 measurements in 50m length 1 ± 0.25mm

Note: Definition of ‘Batch’ applicable to cement concrete: The quantity of concrete mixed in one cycle of operation of a batch mixer or the quantity of concrete conveyed ready-mixed ina vehicle or the quantity discharged during one minute from a continuous mix.

Table 17: Cement for Structural Works

Sl. No. Test Test MethodMinimumFrequency

Specified Value

1. General requirement

a) Portland slag cement IS:455

1 per

consignment if

old stock or

improperly

handled

Relevant specifications

2. Total chloride content Test certificate from manufacturer

required

1 per sourceMax 0.05%



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Sl. No. Test Test MethodMinimumFrequency

Specified Value

3. Total sulphur content as SO3 Test certificate from manufacturer

required

1 per source Max 2.5% for tri-calcium aluminate is

upto 5%; 3% for tri-calcium aluminate

>5%

Table 18: Coarse Aggregate for Structures

Sl.No.


1. Los Angeles Abrasion Value IS:2386 (Pt 3) 1 per source/month Max 30% for wearing surface; max 50% for works

2. Soundness in sodium sulphate IS:2386 (Pt 5) 1 per source Max 12%

3. Deleterious constituents:

a) Coal and lignite

b) Clay lumps

c) Soft fragment

d) Total of all deleterious matters

IS:2386 (Pt 2)

IS:2386 (Pt 2)

IS:2386 (Pt 2)

–

1 per source/month

1 per source/month

1 per source/month

1 per source/month

Max 1%

Max 1%

Max 3%

Max 5%

4. Material passing 75 micron IS:2386 (Pt 1) 1 per source/month Max 3%

5. Specific gravity (SSD) IS:2386 (Pt 3) 1 per source/month –

6. Water absorption IS:2386 (Pt 3) 1 per source/month Max 2%

7. Surface moisture content (free

moisture)

IS:2386 (Pt 3) 2 per day–

8. Flakiness index IS:2386 (Pt 1) 1 per source/month Max 35%

9. Grading of coarse aggregate IS:2386 (Pt 1) 1 per source/monthSieve Size

% Passing

40mm 20mm 12.5mm



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Sl.No.


63mm 100 – –

40mm 95-100 100 –

20mm 30-70 95-100 100

12.5mm – – 90-100

10mm 10-35 25-55 40-85

4.75mic 0-5 0-10 0-10

Table 19: Sand/Fine Aggregate for Structures

Sl. No. Test Test Method Minimum Frequency Specified Value1. General requirement Visual inspection Every batch Clean, hard and free from deleterious materials except in traces

2. Los Angeles Abrasion of source stone of crushedaggregate

IS:2386 (Pt 3) 1 per source/month Max 30% for wearing surfaces

3. Fineness modulus of fine aggregate – 1 per source/month Min 2.0 and max 3.5

4. Soundness in sodium sulphate IS:2386 (Pt 5) 1 per source Max 10%

5. Deleterious constituents:a) Coal and ligniteb) Clay lumpsc) Soft fragmentd) Total of all deleterious matters

IS:2386 (Pt 2)IS:2386 (Pt 2)IS:2386 (Pt 2)–

1 per source/month1 per source/month1 per source/month1 per source/month

Max 1%Max 1%Max 3%Max 5%

6. Material passing 75 micron IS:2386 (Pt 1) 1 per source/month Max 3% (15% if crushed aggregate)

7. Specific gravity (SSD) IS:2386 (Pt 3) 1 per source/month –

8. Water absorption IS:2386 (Pt 3) 1 per source/month Max 2%

9. Surface moisture content (free moisture) IS:2386 (Pt 3) 2 per day –



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Sl. No. Test Test Method Minimum Frequency Specified Value10. Total chloride content IS:812 (Pt 17) Every batch Max 0.06%

11. Total sulphate content IS:812 (Pt 18) Every batch Max 0.25%

12. Alkali – aggregate reactivity IS:2386 (Pt 7) 1 per source per month Non-reactive

13. Grading requirement IS:2386 (Pt 1) 1 per daySieve Size

% PassingZone I Zone II Zone III

10mm 100 100 100

4.75mm 90-100 90-100 90-100

2.36mm 60-95 75-100 85-100

1.18mm 30-70 55-90 75-100

600mic 15-34 35-59 60-79

300mic 5-20 8-39 12-40

150mic 0-5 0-10 0-10

Table 20: Reinforcement Steel

Sl.No.

Test Test MethodMinimumFrequency

Specified Value

1. Characteristic strength of mild steel(IS:432)

Tests as per relevant IS Codes As per IS 1786 -2008

Grade S240 = 240MPa

2. Characteristic strength of HYSD bar(IS:1786)

Tests as per relevant IS Codes As per IS 1786 -2008

Grade S415 = 415MPa

3. Diameter As per IS 1786 -2008

The diameter of steel rods shall be checkedfrequently on random basis especially for re-rolled basis.

Table 21: Water for Concrete and Mortar


1. pH value water pH paper 1 per source Minimum 6 (Acceptable range 6 to 9)



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2. Alkalinity limit by titration IS:3025 1 per source Max 10ml HCL to neutralize 200ml water3. Acidity limit by titration IS:3025 1 per source Max 2ml NaOH to neutralize 200ml water4. Solids in water IS:3025 1 per source Max limits per liter:

Organic – 200mg; inorganic – 3000mg; sulphate – 400mg;Chloride – 500mg; suspended matter – 2000mg



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3.0 Quality Control Tests Required/Frequency/Specifications for Buildings

Sr No Type of material Parameter Frequency Code Remarks

1Portland Slag cement(IS 455) / OrdinaryPortland Cement

Chemical Test : Once for each lot As per IS 4032 MTC for eachlot mandatory

Physical Test :

Once for each lotAs per IS 12269, IS

4031 part 1,2,3,4,5,6 &IS 3535

MTC for eachlot mandatory

1) Standard Consistency2) Initial Setting Time3) Final Setting Time4) Compressive Strength5) Fineness m²/Kg6) Soundness by Le-Chat

2 Reinforcement(TMT) Bars

1) Physical Tests : Supplied by client IS 1608 & IS 1786 MTC for eachlot mandatory2) Chemical Test: Supplied by client IS 1786

3 Coarse Aggregate

1) Specific Gravity Once for every source

As per IS 383 -

2) Water Absorption Once in a month / As required3) Aggregate Impact Value Once in a month / As required4) Flakiness Index and Elongation index Once in a month / As required5) Sieve Analysis Once per 150 cum6) Soundness Test Once per Season7) Abrasion Test Once per Season

4 Fine Aggregate

1) Sieve analysis & Fineness Modulus Once per 150 cum

As per IS 383 -2) Moisture Content As and when required3) Silt Content by volume As and when required4) Water Absorption Once in a month / As required5) Specific Gravity Once for every source

5 Water 1) pH Once per source/ As required As per IS 456 / Tender -



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2) Organic Impurities3) Inorganic Impurities4) Sulphates5) Chloride (%)6) Suspended Particles

6 Concrete Admixture

1) pH

Once per each lot As per IS 9103 MTC for eachlot mandatory

2) Specific Gravity3) Dry Material content4) Ash Content5) Chlorides ion Content

7 Concrete

Mix Design For each grade and eachbrand of cement

As per 10262, IS 456,SP23 and relevant

standards-

1) Slump As Required As per Mix Design -2) Compressive Strength test

As per IS 456 As per IS 456, IS 516 -a. 7th daysb. 28th days

8 Earth work

1) Atterberg's limit, Shear parameter

As per IS 2720 IS 2720 -

2) Specific gravity and CBR3) Grain size Analyses4) MDD/OMC5) Field Density/Moisture ContentChemical Test :

9 Brick Work

1) Dimension

Once per 25000 Nos. IS 3495,IS 2895 / Tender -

2) Crushing strength3) Water absorption4) Efflourescence test

10 Cement/Lime Mortar 1) Compressive strength of Mortar Once a day IS 2250 -

11 Water Proofing

1) Compressive strength

As Required IS 26452) Setting time3) Permeability4) Chloride content



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12 Water Proofing( terrace ) As approved by consultants As Required MTC for each

lot mandatory

13 Cement ConcreteFloor Tiles

1) Water AbsorptionAs per R&B / CPWD

SpecificationsAs Per R&B / CPWD

Specifications -2) Transverse Strength3) Abrasion Test

14Kota Stone / Granite

/ Green Marble /Sand stone

1) Crushing strengthOne per 1000 sqm IS 1122, 1123,

1124,3622 -2) Water absorption3) Abrasion Test

15 Ceramic / GlazedTiles /Vitrified Tiles

1) Flexural StrengthOne per 1000 sqm IS 13630, IS 13711, IS

777, IS 15622MTC for eachlot mandatory2) Water Absorption

3) Dimension

16 Concrete Flooring Material testing as per concrete As per R&B / CPWDSpecifications

17 Precast TerrazzoTiles

Dimensions, Transverse Strength, waterabsorbtion.

As per R&B / CPWDSpecifications As per IS 1237

18 Wooden Door andWindow Frame

Colour, Hardness, Density, Weight, MoistureContent, Porosity, Identification, Rezon,Tissue

As per appendix - C, R&B /CPWD IS 4021, IS 287, IS 710

19 Doors & WindowsFittings & fixtures As per R&B / CPWD Specifications As per appendix - H, R&B /

CPWDMTC for eachlot mandatory

20 PVC Shutters & DoorFrames

Dimensions & squareness, flexure test, andImpact & indentation test.

IS 10151, 4020( 1 to 16 )


21 Flush Wooden DoorShutter Dimension, Glue test, Boiling water test etc As per R&B / CPWD

SpecificationsIS 2202

(Part 1 & 2)MTC for eachlot mandatory

22 Steel Doors andWindows As per Relevant Standards As per R&B / CPWD

SpecificationsIS 7452, IS 5437, IS

1038, IS 1361MTC for eachlot mandatory

23 MS Rolling Shutter Material and Dimension As per R&B / CPWDSpecifications IS 6248 MTC for each

lot mandatory

24Structural steel &

steel Tubularsections

1) Physical Tests As per R&B / CPWDSpecifications

IS 1599, 1608,2329,2328,2062

MTC for eachlot mandatory2) Chemical Tests

25 Aluminum Works Dimensions and Tolerances, Annodization,Powder Coating

As per R&B / CPWDSpecifications

IS:733, IS:1948,IS:1949




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26 Anti TermiteTreatment Chemical Test and Coverage As per R&B / CPWD

SpecificationsIS 6313

(Part II & III)MTC for eachlot mandatory

27

Painting forconcrete, Masonry

and plasteredsurface

As per Relevant Standards As per R&B / CPWDSpecifications

IS 428, IS 5410, IS5411, IS 9862, IS 712,

IS 2395


28Painting and

Polishing of woodwork

As per Relevant Standards As per R&B / CPWDSpecifications

IS 3536, IS 110, IS 337,IS 340, IS 2932


29 Painting of steelwork As per Relevant Standards As per R&B / CPWD

SpecificationsIS 2074, IS 2932, IS

2339, IS 1477 (Part-2)MTC for eachlot mandatory

30 PVC Pipes As per Relevant Standards As per R&B / CPWDSpecifications IS 4985 MTC for each

lot mandatory

31 G.I. Pipes As per Relevant Standards As per R&B / CPWDSpecifications IS : 1239 Part -1 MTC for each

lot mandatory

32 Sanitary ware As per Relevant Standards As per R&B / CPWDSpecifications

IS 2556, IS 1795, IS651


33 False Ceiling Gypsum Dimensions, Transverse, water absorption andmass of plaster.

As per R&B / CPWDSpecifications IS 2095 MTC for each

lot mandatory

34 False CeilingAcoustic As approved by Client MTC for each

lot mandatory

35 Glass work As per Relevant Standards As per R&B / CPWDSpecifications IS 5437, 2835,14900 MTC for each

lot mandatory

Third Party Quality Audit for Construction of Cyclone Shelters, Roads to

Cyclone Shelters & Habitations, Bridges and Culverts under NCRMPQuality Assurance Plan

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4.0 Methodology for Road Construction

4.1 Embankment Construction

1. Obtain materials (soil) for embankment from approved sources. Preference should be given to materialsthat are suitable and become available from nearby road excavation.

2. After clearing the site, mark the limits of embankment by fixing batter pegs and marking toe lines onboth sides at regular intervals as guides. The embankment shall be built sufficiently wider (about 300 mmon either side of Roadway) than the specified formation width so that surplus material at the edges may betrimmed to ensure proper compaction of the edges and side slopes.

3. Remove stagnant water, if any, from the foundation of the embankment.

4. Where the available embankment materials (Soil) are not conducive to plant growth, topsoil from areasof cutting and areas to be covered by embankment should be stripped to specified depth not exceeding150 mm and stored for covering slopes, and other disturbed areas where re-vegetation is required.

5. After removing the top soil/ unsuitable material, foundation for embankment construction shall beprepared as follows:

(a) For embankment less than 1.0 m high over natural ground, the ground surface should be loosened upto a minimum depth of 150 mm by ploughing or scarifying and compacted to the specified density.

(b) For embankment less than 0.5 m height over an existing black-topped or gravel road, the black-toppingshall be removed and the pavement/ gravel road should be scarified to a minimum depth of 150 mm. Allparticles shall be reduced to a maximum size of 75 mm and compacted.

(c) If the granular/ black topped surface lies within 0.50 m - 1 m of the new sub-grade level, the sameshould be scarified to a depth of at least 50 mm for achieving bond between old and new material.

(d) If the existing surface is of cement concrete type and lies within 1 m of the new sub-grade level, thesame shall be removed completely.

(e) For embankment over ground not capable of supporting equipment, successive loads of embankmentmaterials should be spread in a uniformly distributed layer of adequate thickness to support the equipmentand to construct the lower portion of the embankment.

(f) For embankment construction on existing slope steeper than 1 Vertical: 4 Horizontal, horizontalbenches should be cut in the existing slope to a sufficient width to accommodate placement andcompaction equipment.

6. The size of the coarse material in the mixture of earth used for embankment construction shouldordinarily not exceed 75 mm.

7. The soil should be spread over the entire width of the embankment in layers not exceeding 150 mmcompacted thickness. The clods should be broken to less than 75 mm size. Each layer at moisture contentwithin (±) 2 % of the optimum moisture content should be thoroughly compacted by roller, to the specifiedrequirements and finished parallel to the final cross-section of the embankment. (Compacted layerthickness can be increased up to 200 mm if heavy vibratory rollers are used).



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8. Compaction of soil should be done at OMC with a tolerance limit of (±) 2 percent. If the moisture contentof soil is outside these limits, it shall be made good by adding water or drying by aeration and exposure tosun till the moisture content is acceptable for compaction.

9. Each layer should be compacted to at least 97 percent of the Standard Proctor Density. The top300mm of the embankment constituting the sub grade should be compacted to 100 percent StandardProctor Density.

10. Ensure that longitudinal and cross profiles should be in conformity with the approved drawings.

11. Approval of the Engineer should be obtained for each finished layer. Subsequent layers shall beplaced only after the finished layer has been tested and accepted by Engineer.

12. When an existing embankment and/ or sub-grade is to be widened and its slopes are steeper than 1vertical to 4 horizontal, continuous horizontal benches, each at least 300 mm wide, should be cut into theold slope for ensuring adequate bond with the fresh embankment/ sub-grade material to be added.

13. When the width of the widened portions is insufficient to permit the use of conventional rollers,compaction shall be carried out with the help of small vibratory rollers/ plate compacters/ power rammersor any other equipment approved by the Engineer.

14. The filling around culverts and bridges, for forming approaches up to a distance of twice the height ofthe road from the back of abutment should be done with granular materials and should not be placed untilthe concrete or masonry has been in position for 14 days. Approval for the sequence of work andequipment should be obtained from the Engineer before taking up the work.

4.2 Granular sub-base

1. Obtain materials from approved sources. The material should be natural sand, moorum, gravel, crushedstone, crushed slag, brick metal, kankar or a combination thereof and it shall conform to grading andphysical requirements.

2. Remove all vegetation and other extraneous material etc. from the sub grade already prepared, lightlysprinkle with water, if necessary, and roll with two passes of 80-100 KN road roller or any other suitablecompactor/vibratory roller.

3. The sub-base material should be spread in layers not exceeding 100 mm compacted thicknesses. Ifsuitable vibratory rollers are available, the compacted thickness of layer can be up to a maximum of 225mm.

4. When the sub-base material consists of a combination of materials, mixing shall be done mechanicallyby the mix-in-place method, except for small sized jobs.

5. Each layer shall be uniformly spread and thoroughly compacted. Spreading and compaction shall becarried out as per Clause 401.4.2 of the MORD Specifications.

6. Compaction should be carried out at OMC, with a tolerance limit of (± ) two per cent. If the loose materialis dry, as compared to OMC, water should be added by sprinkling and thoroughly mixed for uniformwetting. If it has more water than the optimum, it should be left exposed to sun and aeration till themoisture content is acceptable for compaction. Each layer should be compacted to 100 per cent maximumdry density as per standard Proctor Test-IS 2720 (Part 7).

7. Approval of the Engineer should be obtained for each layer. Such an approval would require surfacelevel and compaction control tests.



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8. The earthen shoulders should be constructed simultaneously with the sub-base construction.

4.3 Water Bound Macadam Sub-base/Base/Surfacing

1. The surface to receive the WBM course should be prepared to the lines, grade and cross fall. It shouldbe made free of dust and extraneous material. Large irregularities, where predominant, should be madegood by providing profile corrective course.

2. Where the WBM is laid over a fine grained soil sub grade, it is advisable to lay a 100 mm thickintervening layer of screenings or coarse sand.

3. Any existing bituminous surface over which WBM is to be laid shall be completely removed before layingWBM layer.

4. The coarse aggregate should meet the physical and grading requirements laid down in Table 405.1 andTable 405.2. Coarse aggregate can be crushed or broken stone, crushed slag, over burnt brick aggregate,kankar, laterite meeting the prescribed requirements.

5. The spreading of coarse aggregate shall be done from stockpiles along the side of the roadway ordirectly from vehicles. In no case the aggregate shall be dumped in heaps directly on the surface preparedto receive the aggregates nor shall hauling over uncompacted or partially compacted base be permitted.

6. The coarse aggregate shall be spread uniformly on the prepared subgrade, sub-base or base, as thecase may be, to proper profile (by using templates placed across at 6.0 m intervals) in such quantities thatwould give the required compacted thickness. The thickness of compacted layer should be 100 mm forGrading 1 and 75 mm for Gradings 2 and 3. The appropriate quantity of aggregates is given in Table405.4. The surface should be checked with templates and all high or low spots remedied.

7. Roll the surface with suitable road rollers till aggregates are partially compacted with sufficient voidspace left for application of screenings. However, where screenings are not to be applied as in the case ofsoft aggregates, compaction shall be continued until the aggregates are thoroughly keyed. Rolling shallproceed from inner edge to outer edge at the super-elevated portions and from the edges towards thecentre in other portions. The edge should be first compacted with roller running forward and backward.

8. Check the profile transversely and longitudinally with templates/ straight edge. Correct the irregularitiesby loosening the surface, adding or removing the needed amount of aggregates and re-rolling until theentire surface conforms to the specified camber/ cross fall and grade.

9. Apply screenings to completely fill the interstices maintaining a slow and uniform rate, in three or moreapplications. The screenings should not be damp at the time of application.

10. Do not apply screenings so fast and thick as to form cakes or ridges on the surface.

11. Continue dry rolling and brooming till no more screenings can be forced into the voids of coarseaggregates.

12. Sprinkle water on the surface taking care that the underlying layer is not damaged.

13. Sprinkling, sweeping and rolling should continue till aggregates are thoroughly keyed, well bonded andfirmly set in its full depth and a grout has been formed of screenings.

14. In case the screenings are not of crushable type such as moorum or gravel, it is necessary to addbinding material (PI between 4 and 6) after application of screenings. The binding material should beapplied in two or more layers at a slow and uniform rate. Generally, the quantity required for 10 m2 of 75mm thickness of WBM is 0.06 to 0.09 m3 and for 100 mm thickness, the corresponding quantity would be0.08 to 0.10 m3. In case WBM surface is not to be covered with bituminous surfacing, PI of binding materialshall be between 4 and 10.



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15. The process of water sprinkling, sweeping and rolling should continue till the resulting slurry forms awave ahead of roller.

16. The compacted WBM course should be allowed to completely dry and set before the next pavementcourse is laid or traffic is allowed.

17. The earthen shoulders should be constructed simultaneously with the WBM construction in accordancewith Sub-Section 407.

18. The finished surface of WBM should conform to the prescribed tolerances given in Para B. Where thesurface irregularity exceeds the tolerances, the WBM layer should be scarified to its full depth over theaffected area and corrected by adding or removing and replacing with fresh material.

4.4 WET MIX MACADAM BASE

Methodology

1. WMM shall be prepared in an approved mixing plant with mixing arrangements like the pug mill or pantype mixer of concrete batching plant. For small quantities of WMM, the Engineer may permit the use ofconcrete mixers.

2. Optimum moisture for mixing shall be determined in accordance with IS:2720 (Part 7) after replacing theaggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size.

3. Lateral confinement for WMM should be provided by laying material in adjoining shoulders along withthe wet mix layer.

4. Immediately upon mixing, the aggregates shall be spread uniformly and evenly upon the prepared sub-base, in required quantities. In no case should the material be dumped in heaps, directly on the areawhere it is to be laid. The mix may be spread either by a paver-finisher or motor grader.

5. Thickness of a single compacted WMM layer shall not be less than 75 mm. When vibrating or otherapproved types of compacting equipment are used, the compacted thickness of up to 200 mm may beadopted.

6. The surface of aggregate shall be carefully checked with templates and all high or low spots should beremedied by removing/ adding aggregate as required. The thickness of layer shall be tested with depthblocks.

7. No segregation of large and fine aggregates shall be allowed.

8. After the mix is laid to proper thickness, grade and cross fall/ camber, the same shall be uniformlycompacted with a suitable roller. Rolling shall be continued till the density achieved is at least 100% of themaximum dry density as per IS:2720 (Part 7).

9. If the surface irregularity of WMM course exceeds the permissible tolerances, the full thickness of layershall be scarified over the affected area, reshaped by adding premixed material or removed and replacedwith fresh premixed material as applicable and re-compacted. The area treated in this manner shall not beless than 5 m long and 2 m wide. In no case shall depressions be filled up with unmixed and un-gradedmaterials or fines.

11. After final compaction of WMM, the road shall be allowed to dry for at least 24 hours.

12. Preferably no vehicular traffic should be allowed on the finished WMM surface till it has dried and thewearing course has been laid.



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4.5 PRIME COAT OVER GRANULAR BASE

Methodology

1. Bituminous primer should be slow setting bitumen emulsion, use of cutback being restricted to areashaving subzero temperature or for emergency operations.

2. The prime coat should be applied only on the top most granular base layer, over which bituminoustreatment is to be applied. The granular base surface should be swept clean of dust and loose particlesand where required, lightly and uniformly sprinkled with water to moist the surface.

3. The primer should be sprayed uniformly over the dry surface of absorbent granular base, using suitablebitumen pressure distributor or sprayer capable of spraying primer at specified rates and temperature soas to provide a uniformly unbroken spread of primer. Normal temperature range of spraying emulsionshould be 20°C to 60°C.

4. A very thin layer of coarse sand may be applied to the surface of the primer to prevent it from gettingpicked up under the wheels of vehicles delivering materials for construction of bituminous layer

5. The surface should be allowed to cure preferably for 24 hours. Unabsorbed primer should be blottedwith sand using the minimum quantity possible.

4.6 TACK COAT

Methodology

1. Use a rapid setting bitumen emulsion for applying a tack coat, the use of cutback being restricted toareas having sub-zero temperature or for emergency applications.

2. The surface on which tack coat is to be applied should be clean, free from dust, dirt and any extraneousmaterials and dry.

3. The binder should be sprayed uniformly over the surface using suitable bitumen pressure sprayercapable of spraying bitumen and emulsion at specified rates and temperature so as to provide a uniformlyunbroken spread of bitumen emulsion. For smaller jobs, a pressure hand sprayer may be used. Normalrange of spraying temperature should be 20°C-60°C in case of emulsion and 50°C-80°C in case ofcutback.

4. The surface should be allowed to cure until all the volatiles have evaporated.

4.7 Bituminous Macadam

Methodology

1. Prepare the base on which bituminous macadam course is to be laid and shape to the specified lines,grade and cross-section.

2. Apply tack coat over the base preparatory to laying of the bituminous macadam.

3. Bituminous Macadam should be prepared in a Hot Mix Plant of adequate capacity.

4. Transfer the mixed material quickly to site of work and lay by means of an approved self-propelledmechanical paver.

5. Commence initial rolling with 80-100 kN rollers (three-wheel or tandem type), beginning from the edgeand progressing towards the centre longitudinally. On super elevated portions, rolling should progress fromlower to upper edge parallel to centre line of pavement. Thereafter, do intermediate rolling with vibratory orpneumatic tyred road rollers. This should be followed by final rolling while the material is still workable.



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6. Any high spots or depressions noticed after the roller has passed over the whole area once should becorrected by removing or adding premixed material. Rolling should recommence thereafter. Each passshould have an overlap of at least one-third of the track made in the preceding pass. Rolling should becontinued till all rolIer marks have been eliminated.

7. For single lane roads no longitudinal joint is required, while for double-lane roads longitudinal joints maybe required depending on the paver width.

8. For making longitudinal or transverse joint, cut the edges of the bituminous layer laid earlier to their fulldepth so as to expose fresh surface and apply a thin coat of binder. Lay adjacent new layer and compactflush with the existing layer.

9. Cover the bituminous macadam with the wearing course within a period of 48 hours. If there is any delayin providing wearing course the bituminous macadam surface should be covered with a seal coat beforeopening to traffic.

4.8 Open graded Premix Surfacing using Bitumen

1. Prepare the base on which premix carpet is to be laid to the specified lines, grade and cross-section.

2. Apply a prime coat followed by tack coat over a granular base preparatory to laying of the carpet.

3. The quantities of material required for 20 mm thick premix carpet should be as indicated in Table

508.1.1. Prepare the mix in a hot mix plant of suitable size with separate dryer arrangement for aggregate.

4. Mixing should be thorough to ensure that a homogenous mixture is obtained. The temperature ofbitumen at the time of mixing should be in the range of 1500 C to 1600 C and that of aggregates 1550C to1630C, provided that the difference between the temperature of aggregate and the binder should notexceed 140C. If modified bitumen is used, temperature should be as recommended in Subsection 512. Thetemperature at the time of discharge of the mixture should be between l30°C and 160°C.

5. Locate hot mix plant near the work site. The mixed material should be transported quickly to the site ofwork and laid uniformly by suitable means.

6. The premixed material shall be spread on the road surface with rakes.

7. Commence rolling with 80-100 KN rollers (three-wheel or tandem type), beginning from the edge andprogressing towards the centre longitudinally. (On super elevated portions, rolling should progress fromlower to upper edge parallel to centre line of pavement). Continue rolling operations till a smooth uniformsurface is achieved and all roller marks are eliminated. Each pass should have an overlap of at least one-third of the track made in the preceding pass.

8. Correct any high spots or depressions noticed after the roller has passed over the whole area once byremoving or adding premixed material and re-compacting.

9. Provide a seal coat to the surface immediately after laying the carpet.

10. Ordinarily, the road may be opened to traffic after laying the seal coat.

4.9 Seal Coat

The seal coat shall be any of the three types mentioned below:

Type A: Liquid seal coat comprising of an application of layer of bituminous binder followed by a cover ofstone chips.

Type B: Premixed seal coat comprising of a thin application of fine aggregate premixed with bituminousbinder.



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Type C: Premixed seal coat comprising of an application of 6.7 mm size stone chips premixed withbituminous binder.

A. Methodology

Apply seal coat immediately after laying the bituminous course. The surface should be clean and free ofdust and extraneous material before application of the seal coat.

1. Type A Seal coat with bitumen:

(i) Apply heated bitumen with a temperature between 1500C and 1630C uniformly with the help of abitumen sprayer.

(ii) Immediately thereafter, spread stone chips over the bitumen layer at a uniform rate, preferably, with thehelp of a mechanical grit spreader so as to cover the surface completely.

(iii) Commence rolling with 80-100 kN rollers (3-wheel or tandem type), beginning from the edge andprogressing towards the centre longitudinally. On super elevated portions, rolling should progress fromlower to upper edge parallel to centre line of pavement. If required, spread additional chips by hand tomake up irregularities. Continue rolling operations until all aggregate particles are firmly embedded andpresent a uniform closed surface.

4.10 Pipe Culverts

Excavation for pipes

1. Lay the pipes in shallow excavation of natural ground or in open trenches cut in existing embankmentstaken down to required level.

2. For embankments of height of fill more than 3 m, or three times the external dia of pipe above bed level,construct the embankment to the level above the top of the pipe (equal to external dia of pipe) and widthnot less than five times the dia of pipe. Lay the pipe in trench after the construction of embankments.

3. If spongy, soft or other unstable material is met with at the location of pipe culvert, remove the materialto the required depth, width and length, and back fill with approved granular material properly shaped andcompacted to the required level.

4. Where rock or boulder strata is met with, take down excavation to alleast 200 mm below the bottomlevel of pipe, remove all loose material and fill the space with approved earth.

Loading and Unloading of Pipes

1. Make arrangements for lifting, loading and unloading of pipes from factory/yard to site, such that noundue strain or damage occurs due to fall or impact.

2. For manual unloading from trucks, roll down pipes on a pair of skids hooked onto the trucks and controlmovement with a rope passing round the pipes.

Laying of Pipes

1. Preload the areas to induce major portion of settlement before the pipe is installed.

2. Provide a bedding surface of firm foundation of uniform density, throughout the length of culvertwith specified bedding material depending on dia of pipe and height of fill above pipe.

3. Lower the pipes in bed either by tripod pulley arrangement or by manual labor using chain pulleyblocks in a manner to place them in proper position without damage.

4. When two or more pipes are laid adjacent to each other, place them separated by a distance equalto half the dia of the pipe subject to a minimum space of 450 mm.



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5. When pipes are laid in two layers, keep the centers of pipes such that when joined shall formequilateral triangles.

6. Lay the pipes as specified in IS:783, for different conditions such as positive projecting condition,trench condition etc.

7. Lay the pipes on the prepared foundation, commencing from outlet and proceed towards the inlet.In case of pipes with bell mouth, keep the belled end facing the upstream. Keep the invert of pipeminimum 150 mm below average bed level. However, if the invert level is more than 300mm, acatch pit of size 1500 x 1000mm upto ground level should be constructed.

8. Install the culvert with a camber, so that the settlement due to the load of the embankment will intime lower the culvert to the desired grade approximately.

Jointing

1. Join the pipes either by collar joint or by flush joint. Place the collar such that its centre coincideswith the joints and even annular space is left between the collar and the pipe.

2. Choose either internal flush joint or external flush joint. Fill the jointing space with 1:2 cementmortar, which remains in position when forced with a trowel or rammer.

3. Fill the recess at the end of the pipe with jute braiding dipped in hot bitumen or suitable approvedcompound, while jointing pipe lines.

4. Keep the width of collars 150-200 mm and caulking space between 13 mm and 20 mm accordingto dia of pipes.

Back Filling

1. Back fill trenches after the pipes have been laid and after jointing material has hardened. On top ofpipe upto 300 mm, thoroughly ram, tamp or vibrate the soil in two layers. Thoroughly consolidatethe materials under the ‘haunches’ of pipes using light mechanical tamping equipment.

2. Carryout filling of the trench simultaneously on both sides of the pipe, such that unequal pressuresdo not occur.

3. When minimum specified cushion cannot be provided over the pipe, encase the pipe in M 10concrete of specified thickness.

4.11 Construction of Causeways

Under this section quality aspects of different submersible structures viz., Irish/ Flush Causeway, VentedCauseway and Submersible Bridges for rural roads are dealt with:

A. Methodology fro Flush Causeway

1. Choose flush causeway (Paved dip) to cross a shallow water course by adopting generalguidelines given in clause 1401.0 of MORD Specifications for Rural Roads.

2. Keep top level of floor of causeway same as that of bed of water-course.

3. Build cut-off walls in brick masonry on stone masonry or plain cement concrete with suitableformwork as per provisions given in sections 600, 700, 800 and 900 respectively of this Manual.

4. Excavate for laying of foundation of u/s and d/s cut-off walls. Keep it sufficiently deep to avoidexposure due to scouring. Adopt a PCC footing of 150 mm thickness in M15 grade, laid on a layerof 100 mm thick lean concrete (M10)

5. Adopt a plain cement concrete slab of minimum thickness 200 mm in a minimum grade of M30 aspaved dip. Provide construction joints 4-6m apart and seal them with polysulphide.



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6. Provide u/s and d/s protection works, apron, pitching as per requirement.

7. Provide guide posts/stones at required spacing.

B Vented Pipe Causeways

1. Choose vented pipe causeway to cater to low flows through circular vents which overtop duringmonsoon. Usually RCC pipes (NP3 or NP4) are used for providing circular vents.

2. Follow the same methodology as detailed in section 1100 of this Manual for laying of RCC Pipes.

3. Take foundation and head walls sufficiently deep to avoid exposure to scouring in erosive strata.

4. Batter the d/s side headwall on the outside and round the corners.

5. Adopt rectangular or arch on type vents instead of circular pipe as per local practice.

6. Raise end portion of face walls and protect entire top of causeway by well desirable non-erodiblewearing coat.

Ancillary Items (Wearing coat, Railing, Kerbs, Warning signs, Flood gauges)

1. Provide 75 mm thick C.C. wearing coat in M30 grade with a cross slope of 2.5 per cent towards d/sside of deck slab in submergible bridge. For vented causeways adopt 200 mm thick RCC Slab.

2. Discontinue wearing coat at expansion joint locations. Extend joint fillers upto the top of wearingcoat.

3. For CC wearing coat, provide 8 mm dia bars @ 200 mm c/c reducing to 100 mm c/c in bothdirections over a strip length of 300 mm near expansion joint.

4. Use open type or filler joint with appropriate nose protection.

5. Use metal railing of collapsible or removable or tubular type for submersible bridges.

6. Use discontinuous kerbs 300 mm wide at 1.8 m c/c on both sides, the continuous length of eachpiece being 1.5 m.

7. Locate advance warning/cautionary signs at about 200 m from the beginning of submerged portionof causeways and submersible bridges, to indicate speed limit, depth of submergence etc.

8. Install flood gauges at 15 m intervals on submerged section of approaches and submersiblebridges, regarding depth of flow above road level bridge deck.

4.12 Construction of Slab Culvert

4.12.1 Setting out Survey

Setting out survey shall be done as per the Geometric details given in the construction drawing in thefollowing sequences.

1. Setting out the alignment.2. Working BM established near the work site linked with Reference Bench Mark.3. Prior approval shall be taken from the Client Engineer.4. Frequent checking of setting out for formation level shall be carried out at regular intervals.5. Safeguarding of Survey Monuments shall be done.6. Following instruments shall be used for setting out.7. Automatic Levels having a standard deviation of ± 2mm. per Km. for all double run leveling work.8. Total Station or one sec. Theodolite shall be used for setting out alignments.

4.12.2 Preparation of Property/AmenitiesThe safeguards shall be provided to roadside trees, plants, pole lines signs, monuments etc. whichare not to be disturbed. All adequate precautions against soil erosion, water pollution shall be taken.

4.12.3 Construction methodology1) Cleaning & removing of sludge from the proposed location.



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2) Construction drawing will be prepared based on the drawing mentioned in above scope separately foreach CD work and get it approved from Independent Engineer.

3) Layout will be done by taking original ground level and invert level for the same CD work.4) BBS shall be sought from the Project Manager.5) Joint measurement for dismantling of wing wall and other structure will be taken. Height of wing wall &

abutment will be decided according to FRL of road.6) Excavation for the foundation will be done up to founding level & get it approved from the Project

Manager. Excavated material will be disposed as per instruction of Engineer.7) PCC will be done over top of excavated foundation & transfer the layout as per drawing. Record all the

necessary survey data in survey register.8) Reinforcement & shuttering to be assembled for the foundation and approval for the same shall be

taken.9) Construction of abutment on both ends will be done.10) The wing/dirt wall will be constructed. Pointing of masonry will be done as per drawings.11) Back filling of abutment with filter material of 150mm thickness will be done simultaneously in layer as

per MOST specification mentioned in table no. 300-3 along with embankment filling material andcompacted properly.

12) Slab will be cast as per drawing.13) Proper curing will be done as per instructions.

4.12.4 List of Records1) Approved Construction Drawings.2) Necessary Quality Control Records.3) Cement test report, Cube test report, Concrete register, Fine and course aggregate test report,

Reinforcement test report etc.4) Approved Bar bending Schedule.5) Survey Register.

4.13 Methodology for Bridge Construction

The minor bridges have R.C.C. foundations & Substructure, and R.C.C. superstructures of girder &slab system.

4.13.1 ProcedureThe longitudinal and transverse centre lines of each foundation are set out on reference pillars at safedistance and the temporary bench mark level is also fixed at site and got approved by the Engineer.These are to be repeatedly checked at every stage/lift.

Earthwork excavation is carried out to the required level by machinery and at final stages manually.Water seepage will be controlled by creating a low level sump by the side of the foundation location &pumping out water. The sides of excavation in cutting will be shored up and supported to thesatisfaction of the Engineer's representative. If the foundation is resting in rock, pavement breakers orchisels will be used to achieve the final levels required within the specified tolerance.

Where the foundation rests on soil, a minimum thickness of 100 mm layer M-15 shall be laid to thelevel shown on the drawings, after the excavations, lines and levels have been approved by theEngineer.The formwork for the foundations shall be fixed in position on the lean concrete layer or the rocksurface, as the case may be, after the reinforcement has been assembled true to the longitudinal andtransverse centre lines. The lines, levels, formwork and reinforcement shall be got checked andapproved by the Engineer's representative.



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The concrete for the lean mix layer and for the foundation lift will be produced in the batching plant asper design mix approved by the Engineer, and transported to site in transit truck mixer or dumpers,and laid in position with the crane and bucket arrangement. Compaction will be carried out with theneedle vibrators, except lean concrete base course, which will be tampled with rammers. Slump testswill be done to assess the workability and the retarders or super plasticizers will be added if requiredto obtain quality concrete product. Specified number of test cubes will be taken for determining the 7days & 28 days compressive strength. Vertical shutters will be removed 24 hours after concreting, andthe curing will be commenced as per specifications after rectifying the surface deficiency if any.

Each lift in foundation and substructure will be laid as stated above. Weep holes will be incorporatedin the substructure of abutments and concrete retaining walls as shown in the contract drawings. Iffound convenient and feasible, reinforcement for any component will be assembled in yard and placedin position in the formwork with the help of crane. The pier cap, abutment cap and pedestals with seatfor bearings in minor bridges and the abutment cap in slab culverts will be concreted to the levels anddimensions shown in the contract drawings.

After the curing period for the foundations are over, the excavated pit around the foundation will befilled back with earth. In the case of foundations on rock strata, the space around foundation upto thetop of rock will be filled with M-15 concrete, and above it soil will be filled up to the natural groundlevel.

The centering for the support of superstructure formwork is proposed to be placed on dry levelground. Therefore each span in turn will be levelled to the required elevation above water level, andthe stream will be diverted by suitable arrangement as per site conditions, if necessary. Cribs of 45cm x 45 cm x 1.5 m will be used to support the superstructure formwork.

In minor bridges elastomeric bearings shall be kept in position with Epoxy mortar on top of thepedestals, just before the casting of the superstructure girders. The line and levels have to beapproved by the Engineer's representative before concreting startsIn minor bridges, the sequence will be as follows:

1. Erect the centering consisting of steel cribs, I-girders & channel purlins.

2. The base plates of girder formwork are placed in position in true line & level

3. Pre-fabricated girders reinforcement is placed on base plates with the help of crane.

4. Cross girders reinforcement in laid in their location.

5. Side shuttering around girders & cross girders are closed, and deck slab shuttering is laid.

6. Line, levels dimensions, formwork, centering and girder & cross girders reinforcement are to be gotchecked and approved by the Engineer. Concreting will be done up to the bottom of the haunch atthe junction of girders and slab.

7. The reinforcement for deck slab, foot path Kerbs and hand rail beams and also the drainage spoutwill be laid in position in the deck slab formwork and got checked & approved by the Engineer

8. Concreting of deck slab will be done, leaving a pocket of about 40 x 20 cm at top surface at bothends for full width of carriageway to receive expansion joints in due course.

9. Curing will be done as per specifications. When the cube strengths attain the specified value or atthe period indicated in the specifications, the formwork will be released and taken for re-use.

In minor bridges the sequence of taking up the remaining items will be as under:



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1. Precasting units of concrete handrails.

2. Casting footpath Kerbs and handrail bottom beam.

3. Placing PVC pipe ducts, forming inspection chamber, and filling M-15 concrete in footpaths.

4. Construction of dirt walls and returns walls. When the curing period is over back filling behindabutments with filter media and selected soil, and well compacted.

5. Box cutting for approach slabs, laying lean concrete base layer, placing reinforcement andformwork for approach slabs and concreting to required level.

6. Construction of hand rails by placing the precast railing in cast-in-situ R.C. posts.

7. Fixing the Elastomeric expansion joints in position in deck slab under the supervision of themanufacturer's representative.

8. Laying the A.C. wearing course with a paver using the approved design mix.

9. On embankment slope dry stone pitching over specified filter media and apron will be laidwherever indicated in the contract drawings.

Those portions of the structure, which will be backfilled or covered up, shall be measured &recorded before such activity is permitted.

4.14 Plain Cement Concrete Pavement for low volume roads:

4.14.1. Approval of materials, plant, equipment and construction method.

(i) A trial length of at least 30 m will be constructed off road to demonstrate the proposed materials, plant,equipment and construction methodology before constructing the concrete pavement. Relevant test data ofmaterials and construction methodology listing all steps, details of personnel and plant, equipment,batching and mixing of materials handling, curing texturing should be furnished by the Contractor.

(ii) The trial length will be constructed in 2 days with a minimum 15 m length on each day.

(iii) Before taking up the trial length, ensure that the sources with test results of all materials to be used inthe concrete work are approved by the Engineer well in advance, (at least 30 days before their use), andthe mix design based on laboratory trial mixes using approved materials is submitted for approval of theEngineer at least 30 days prior to the paving of trial length.

(iv) The mix design shall be based on the compressive strength of concrete as specified in the contract.The cement content should not be more than 425 kg nor less than 310 kg per cum of concrete unlessspecified otherwise. If flyash is used to replace a part of cement in the concrete mix, the cement contentshould not be less than 250 kg/cum. All batching of materials shall be by weight. Volume batching may beallowed for small jobs with the approval of the Engineer. Minimum M 30 grade concrete is recommended.Water cement ratio should not be more than 0.5. Admixtures may be used to achieve the desiredworkability.

(v) Semi-mechanized and labor oriented construction techniques will be permitted. Plant, equipment andtools required for preparation and laying of concrete are listed in Clause 1501.11.2 of MoRDSpecifications.



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(vi) Approval of materials, plant, equipment and construction method will be given when the trial lengthcomplies with the specifications

2 Prepare the Sub-grade to the specified grades and cross-sections and compact to the design strengthspecified in the Contract. A day before placing the sub-base, clean the surface and apply a light spray ofwater on the sub-grade and roll with one or two passes of suitable 80-100 kN roller to stabilize any loosematerial.

3 Lay granular or WBM grading 3 or lime treated sub-base of the specified type and thickness. Near thebridge or culvert, an additional layer of 200 mm thick non-plastic GSB over the subgrade, should beprovided in full panel length and full carriageway width.

4 Provide a separation membrane (125 micron thick plastic sheet) between sub-base and concrete slab. Itshould be laid without creases.

5 Mark location and type of the joints on either side of the surface of the sub-base, with red paint.

(i) Contraction joints shall be mechanically sawn joints spaced 2.5 m to 3.75 m. Length of panel in thedirection of traffic shall not be less than the width of the pavement. Joints shall be cut when the pavementis neither too soft nor too hard and is able to bear the weight of the machine and crew. Normally it mayvary from 8 to 12 hours depending on weather conditions.

(ii) Construction joints shall be butt joints and placed after a day’s work is over or when work is suspendedfor more than 30 minutes.

(iii) Expansion joints shall be provided near bridges and slab culverts and consist of a bitumenimpregnated joint/ pre moulded synthetic joint filler board, about 20 mm thick, and dowel bars.

(iv) Longitudinal joints shall be provided for a two-lane road and shall be saw-cut.

6 All side forms shall be of mild steel channels or fabricated plates with adjustable jacks at the back and ofdepth equal to the thickness of pavement. Plant, equipment and tools required for preparation and layingof pavement concrete are listed in Clause 1501.11.2 of Specifications for Rural Roads.

7 Pavement concrete shall be produced near the site, using approved concrete mixers of at least 0.2 cumcapacity. Readymade concrete conforming to the specified properties of strength and workability may alsobe used.

8 Check the slump of concrete. It should be in the range of 30 mm ±10 mm

9 Concrete shall be placed between the side forms and shall be levelled with rakes and shovels. Inconcrete panels having acute angles, a bar mat of 10 mm dia ribbed steel bars at 150 mm centre to centrein both directions shall be provided at 50 mm below the top of slab, in the entire panel.

10 Around man-holes or other openings in pavement, place 12 mm thick pre-moulded board as perIS:1838 and bar mats before concreting.

11 Compact concrete by a vibrating screed supplemented by two internal vibrators.

12 As soon as practicable after compaction of concrete, smoothen the surface with a longitudinal floatoperated from the work bridge. Just before the concrete becomes non-plastic, it shall be textured with along handled steel or fiber brush.

13 After completion of texturing , before the concrete has taken its initial set, the edges of the slab shall becarefully finished so as to leave the pavement edges smooth and true to line.



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14 After completion of the finalizing operations, the surface of the pavement shall be covered with wetHessian cloth, burlap or jute mats. They shall be maintained fully wetted and in position for 24 hours. Uponthe removal of the wet covering out the end of 24 hours, the slab shall be thoroughly wetted and thencured by ponding or sprinklers. The slab shall be covered with sufficient sandy soil so as to produce ablanket of earth not less than 40 mm thick after wetting. The earth covering shall be thoroughly wettedwhile it is being placed in the surface and against the sides of the slab and kept thoroughly saturated withwater for 14 days. The sand shall not be removed and shall thereafter remain in place till 28 days fromdate of casting so that the concrete has attained the required strength.

15 After minimum of 28 days after casting the concrete pavement, joint groove at contraction joint shall bewidened to 10 mm width and to a depth 18 to 20 mm and shall be sealed.



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5.0 OK CARDS FORMATS

N am e of contractor :

Package N o. :

Em bankm e nt chainage :

Barrow are a/Quarry approve d : O K/N ot O K

Suitabil ity of Mate rial : O K/N ot O K

Te m porary Be nch Mark e stabil ishe d : O K/N ot O K

A de quacy of w ate ring arrange m e nts : O K/N ot O K

A lignm e nt of Em bankm e nt : O K/N ot O K

Bottom Le ve l : O K/N ot O K

Ground Im prove m e nt : Re quire d/N ot Re quire d

Ex tra w idth provide d for com paction/Roll ing : O K/N ot O K

De nsity Te sts conducte d on O GL/Pre vious laye r : O K/N ot O K

A de quacy of V ibratory ro l le r or Rolle r : O K/N otO K

A de quacy of f ie ld te st e quipm e nt : O K/N otO K

AE/AEE/DEE/EE Contractor TPQA

O .K CARD FO R EMBAN KMEN T CO N S TRUCTIO N



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P cckage N o. :

N am e of W ork :

Chainage :

Suitab i l ity of Mate rial : O K /N ot O K

Mate rial approve d : O K /N ot O K

Te m porary Be nch Mark e stab lishe d : O K /N ot O K

Surface Le ve l : O K /N ot O K

De nsity Te sts conducte d on Sub base : O K /N ot O K

Shoulde rs Construction w ork S im ultane ously w ith GSB : O K /N ot O K

A de quacy of w ate ring arrange m e nts : O K /N ot O K

A de quacy of V ibratory ro l le r or Ro lle r : O K /N otO K

A de quacy of f ie ld te st e quipm e nt : O K /N otO K

Thickne ss of GSB : O K /N ot O K

De nsity Te sts on GSB : O K /N ot O K

AE/AEE/DEE/EE Contractor TPQA

O .K CARD FO R Granular S ub Base



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N am e of c on tra c tor :

P ackage N o. :

N am e of W ork :

Chainage :

W BM Grade : Grade II / Grade III

Surface Le ve l of Sub base : O K /N ot O K

Sub base com paction : O K /N ot O K

W idth of carriage w ay : O K /N ot O K

Cam be r : O K /N ot O K

Straight Edge : O K /N ot O K

Type of scre e nings : O K /N ot O K

Te m plate s avai lab le : O K /N ot O K

Suitab i l ity of Input Mate rial : O K /N ot O K

Coarse aggre gate : O K /N ot O K

Scre e ning : O K /N ot O K

Bind ing Mate rial : O K /N ot O K

A de quacy of V ibratory ro l le r or Ro lle r : O K /N ot O K

A de quacy of f ie ld te st e quipm e nt : O K /N ot O K

Thickne ss of W BM : O K /N ot O K

Surface Le ve ls and Undulations : O K /N ot O K

A E/A EE/DEE/EE Contractor TP Q A

O .K CARD FO R W BM



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Name of the contra ctor :

Package No. :

Name of Work :

Chainage :

Arrangement of temporary diversion : OK/Not OK

Surface Level of base : OK/Not OK

Width of carriage way : OK/Not OK

Camber board available : OK/Not OK

Straight Edge available : OK/Not OK

Templates available : OK/Not OK

Suitability of Input Material :

Coarse aggregate : OK/Not OK

Bitumen : OK/Not OK Type :

Gradation of aggregate : OK/Not OK

Prime coat application : OK/Not OK

Tack coat application : OK/Not OK

Adequacy of mixing Plant : OK/Not OK

Temperature of bitumen at mixing : OK/Not OK

Temperature of bitumen at laying : OK/Not OK

Adequacy of bitumen distributor : OK/Not OK

Adequacy of V ibratory roller or Roller : OK/Not OK

Thickness of OGPC : OK/Not OK

Suitability of Aggregate for seal coat : OK/Not OK

Adequacy of fie ld test equipment : OK/NotOK

Application of bitumen at the rate specified : OK/NotOK

Thickness of OGPC + Seal Coat : OK/NotOK

Surface Levels and Undulations : OK/NotOK

AE/AEE/DEE/EE Contractor

O.K CARD FOR OGPC + SEAL COAT

TPQA



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N a m e o f co n tra cto r

P a ck a g e N o .

S t ru ctu re ch a i n a g e :

C o m p o n e n t o f s t ru ctu re:

D ra w i n g N o : :

D e s i g n S B C :

S B C : O K ( M o r e th a n th e d e s i g n e d ) / N o t O K ( Le s s th a n th e d e s i g n e d )

A l i n g m e n t V e r i f i e d : O K / N o t O K

F o rm w o rk & b a s e

i ) F o rm s C l e a n e d : O K / N o t O K O K / N o t O K

i i i ) E e rc t i o n a n d s e a l s a s p e r D ra w i n g : O K / N o t O K O K / N o t O K

F i n a l C l e a n - U p : : O K / N o t O K

B o tto m L e v e l V e r i f i e d : O K / N o t O K

P h y s i ca l d i m e n s i o n s V e r i f i e d a s p e r d ra w i n g : O K / N o t O K

R e i n f o rce m e n t p l a ce m e n t a s p e r d ra w i n g : O K / N o t O K B ra n d :

C o v e r to re i n f o rce m e n t a s p e r d ra w i n g : O K / N o t O K

P l a c i n g o f f i x tu re s / E m b e d m e n ts a s p e rd ra w i n g

: O K / N o t O K

S u i ta b i l i ty o f In p u t M a te r i a l : O K / N o t O K

C e m e n t : O K / N o t O K

C A : O K / N o t O K

F A O K / N o t O K

W a te r : O K / N o t O K

A d m i x tu re / S u p e r p l a s t i c i z e r( A s p e r M i xd e s i g n / A s p e r M T C )

: O K / N o t O K

R C C / P C C co n cre te g ra d e :

Q ty o f co n cre te to b e l a i d :

A v a i l a b i l i ty o f W e i g h - b a tch e r : O K / N o tO K

A d e q u a cy o f V i b ra to rs : O K / N o tO K

S l u m p o b s e rv e d a s p e r m i x d e s i g n : O K / N o tO K

cu b e s ca s te d a s R e q u i re d : O K / N o tO K

A d e q u a cy o f C u r i n g a rra n g e m e n ts : O K / N o tO K

T e m p a ra tu re o f co n cre te a t P l a c i n g : O K / N o tO K

A E / A E E / D E E / E E C o n tra cto r T P Q A

i i ) F o rm s O i l e d :

i v ) A l i g n m e n t o f F o rm s :

O .K C A R D F O R C U L V R T W O R K



47 | P a g ein

Joint Venturewith

N a m e o f co n tra cto r :P a ck a g e N o . :N a m e o f W o rk :

S tru ctu re ch a i n a g e :

C o m p o n e n t o f s tru ctu re :

D e s i g n S B C : D ra w i n g N o :

T y p e o f S o i l :

T e s t m e th o d f o r S B C : P l a te Lo a d / U n d i s tru b e d / S P T

S B C : O K ( M o r e th a n th e d es i g n ed ) / N o t O K ( Les s th a n th e d es i g n ed )

T y p e o f F o u n d a t i o n :

B o tto m Le v e l o f F o u n d a t i o n : O K / N o t O K R e q u i re d / N o t R e q u i re d

P h y s i ca l d i m e n s i o n s V e ri f i e d a s p e rd ra w i n g

: O K / N o t O K


C o v e r to re i n f o rce m e n t : O K / N o t O K

F o rm w o rk & b a s e


i i i ) E e rct i o n a n d s e a l s a s p e r D ra w i n g : O K / N o t O K O K / N o t O K

F i n a l C l e a n - U p : O K / N o t O K

S u i ta b i l i ty o f In p u t M a te ri a l :

C e m e n t : O K / N o t O K B ra n d :


F A : O K / N o t O K

W a te r O K / N o t O K

A d m i x tu re / S u p e r p l a s t i c i z e r( A s p e r M i xd e s i g n / A s p e r M T C )

:







A d e q u a cy o f C u ri n g a rra n g e m e n ts : O K / N o tO K


A E /A E E /D E E /E E C o n tra cto r TP Q A

F o u n d a t i o n T re a tm e n t :



O .K C A R D F O R B R ID G E F O U N D A T IO N



48 | P a g ein

Joint Venturewith

N a m e o f th e co n tra cto r :

P a ck a g e N o . :N a m e o f W o rk :

S tru ctu re ch a i n a g e :


D ra w i n g N o . :

N o .o f L i f t ( H e i g h t o f L i f t ) :

F o rm w o rk a n d S e a l s : O K / N o t O K


i i i ) E e rct i o n a n d s e a l s a s p e r D ra w i n g : O K / N o t O K O K / N o t O K

F i n a l C l e a n - U p : O K / N o t O K

P h y s i ca l d i m e n s i o n s V e ri f i e d a s p e r d ra w i n g : O K / N o t O K


C o v e r to re i n f o rce m e n t a s p e r d ra w i n g : O K / N o t O K

P l a c i n g o f f i x tu re s / E m b e d m e n ts a s p e r d ra w i n g( W e e p H o l e s )

: O K / N o t O K

S u i ta b i l i ty o f In p u t M a te ri a l :

C e m e n t : O K / N o t O K B ra n d :



W a te r : O K / N o t O K

A d m i x tu re / S u p e r p l a s t i c i z e r ( A s p e r M i xd e s i g n / A s p e r M T C ) a d m i x tu re / S u p e r p l a s t i c i z e r

: O K / N o t O K

A d e q u a cy o f co n cre te l a y i n g a rra n g e m e n ts : O K / N o t O K

A d e q u a cy o f w o rk s p a ce f o r l a b o u r a n de q u i p m e n t

: O K / N o t O K







A d e q u a cy o f C u ri n g a rra n g e m e n ts : O K / N o tO K


A E / A E E / D E E / E E C o n tra cto r

O .K C A R D F O R B R ID G E S U B S T R U C T U R E



T P Q A



49 | P a g ein

Joint Venturewith

N am e o f co n tracto r :

P ack ag e N o . :

N am e o f W o rk :

S tru ctu re ch a in ag e :


D raw in g N o : :

B e arin g s :

i ) B e arin g s : Te s te d / N o t Te s te d

i i ) A s p e r M TC ( If n o t Te s te d ) : O K / N o t O K O K / N o t O K

B o tto m Le v e l o f S lab / B e am s : O K / N o t O K

F o rm w o rk an d S e a ls : O K / N o t O K

i ) F o rm s C le an e d : O K / N o t O K O K / N o t O K

i i i ) Ee rctio n an d s e a ls as p e r D raw in g : O K / N o t O K O K / N o t O K

F in a l C le an - U p O K / N o t O K

P h y s ica l d im e n s io n s V e ri f ie d as p e r d raw in g : O K / N o t O K

R e in f o rce m e n t p lace m e n t as p e r d raw in g : O K / N o t O K B ran d :

C o v e r to re in f o rce m e n t as p e r d raw in g : O K / N o t O K

P lacin g o f f i x tu re s / Em b e d m e n ts as p e rd raw in g ( D ra in ag e S p o u ts )

: O K / N o t O K

S u i tab i l i ty o f In p u t M ate ria l :

C e m e n t : O K / N o t O K B ran d :



W ate r : O K / N o t O K

A d m ix tu re / S u p e r p las ti ci ze r( A s p e r M ix d e s ig n / A sp e r M TC )

: O K / N o t O K

R C C / P C C co n cre te g rad e :

Q ty o f co n cre te to b e la id :

A v a i lab i l i ty o f W e ig h - b atch e r : O K / N o tO K

A d e q u acy o f V ib rato rs : O K / N o tO K

S lu m p o b s e rv e d as p e r m ix d e s ig n : O K / N o tO K

cu b e s cas te d as R e q u i re d : O K / N o tO K

A d e q u acy o f C u rin g arran g e m e n ts : O K / N o tO K

Te m p aratu re o f co n cre te at P lacin g : O K / N o tO K

A E/ A EE/ D EE/ EE C o n tracto r

O .K C A R D F O R B R ID G E S L A B / B EA M

i i ) F o rm s O i le d :

i v ) A l ig n m e n t o f F o rm s :

TP Q A

i i i ) P h y s ica l D im e n s io n s :



50 | P a g ein

Joint Venturewith

N am e o f co n tracto r :P ack age N o . :N am e o f W o rk :

S tru ctu re ch ain age :

C o m p o n e n t o f stru ctu re :

D e sign S BC : D raw in g N o :

Ty p e o f S o i l :

Te st m e th o d fo r S BC : P late Lo ad /Un d istru b e d /S P T

S BC : O K ( M o r e th a n th e d es i gn ed ) /N o t O K ( Les s th a n th e d es i gn ed )

Ty p e o f F o u n d atio n :

Bo tto m Le v e l o f P C C : O K /N o t O K Re q u ire d /N o t Re q u ire d

F o o tin g O u tl in e : O K /N o t O K

M ark in g/O rie n tatio n o f co lu m n s : O K /N o t O K

P h y s ical d im e n sio n s V e ri f ie d as p e rd raw in g

: O K /N o t O K

F o rm w o rk & b ase : O K /N o t O K O K /N o t O K

i) F o rm s C le an e d O K /N o t O K

i i i ) Ee rctio n an d se als as p e r D raw in g :

F in al C le an -Up : : O K /N o t O K

S u itab i l i ty o f In p u t M ate ria l : O K /N o t O K

C e m e n t : O K /N o t O K

C A : O K /N o t O K

F A : O K /N o t O K

W ate r : O K /N o t O K

P C C co n cre te grad e : O K /N o tO K

Q ty o f co n cre te to b e la id : O K /N o tO K

A v ai lab i l i ty o f W e igh -b atch e r : O K /N o tO K

A d e q u acy o f V ib rato rs : O K /N o tO K

S lu m p o b se rv e d as p e r m ix d e s ign : O K /N o tO K

cu b e s caste d as Re q u ire d : O K /N o tO K

A d e q u acy o f C u rin g arran ge m e n ts : O K /N o tO K

Te m p aratu re o f co n cre te at P lacin g

A E/A EE/DEE/EE C o n tracto r TP Q A

O .K C AR D F O R F O U N DATIO N P C C

F o u n d atio n Tre atm e n t :

iv ) A l ign m e n t o f F o rm s :



51 | P a g ein

Joint Venturewith

N am e o f co n tracto r :P ack age N o . :N am e o f W o rk :


C o m p o n e n t o f stru ctu re :

D e sign S BC : D raw in g N o :

Ty p e o f F o u n d atio n :

To p Le v e l o f P C C : O K /N o t O K

F o o tin g O u tl in e : O K /N o t O K

M ark in g/O rie n tatio n o f co lu m n s : O K /N o t O K

P h y sical d im e n sio n s V e ri f ie d as p e rd raw in g

: O K /N o t O K

Re in fo rce m e n t p lace m e n t as p e r d raw in g : O K /N o t O K Bran d

C o v e r to re in fo rce m e n t : O K /N o t O K

F o rm w o rk & b ase

i ) F o rm s C le an e d : O K /N o t O K O K /N o t O K

i i i ) Ee rctio n an d se als as p e r D raw in g : O K /N o t O K O K /N o t O K

F in al C le an -Up : O K /N o t O K

S u itab i l i ty o f In p u t M ate rial :

C e m e n t : O K /N o t O K Bran d :



W ate r : O K /N o t O K

A d m ix tu re /S u p e r p lasticize r(A s p e r M ixd e sign /A s p e r M TC )

: O K /N o t O K

RC C /P C C co n cre te grad e :







Te m p aratu re o f co n cre te at P lacin g : O K /N o tO K


i i )F o rm s O i le d :

iv ) A l ign m e n t o f F o rm s :

O .K C AR D F O R C Y C L O N E S HEL TER F O O TIN G S



52 | P a g ein

Joint Venturewith

N am e o f th e co n tracto r :

P ack ag e N o . :N am e o f W o rk :

S tru ctu re ch a in ag e :


D raw in g N o . :

S tarte r P ro v id e d : P ro v id e d / N o t p ro v id e d

C o lu m n a l in g m e n t v e ri f ie d : O K / N o t O K

Le v e l M ark e d : O K / N o t O K

F o rm w o rk an d S e a ls : O K / N o t O K

i ) F o rm s C le an e d : O K / N o t O K O K / N o t O K

i i i ) Ee rctio n an d s e a ls as p e r D raw in g : O K / N o t O K O K / N o t O K

F in a l C le an - U p : O K / N o t O K

P h y s ica l d im e n s io n s V e ri f ie d as p e r d raw in g : O K / N o t O K

R e in f o rce m e n t p lace m e n t as p e r d raw in g : O K / N o t O K B ran d :

C o v e r to re in f o rce m e n t as p e r d raw in g : O K / N o t O K

P lacin g o f f i x tu re s / Em b e d m e n ts as p e r d raw in g : O K / N o t O K

S u i tab i l i ty o f In p u t M ate ria l :

C e m e n t : O K / N o t O K B ran d :



W ate r : O K / N o t O K

A d m ix tu re / S u p e r p las ti ci ze r ( A s p e r M ixd e s ig n / A s p e r M TC ) ad m ix tu re / S u p e r p las ti ci ze r

: O K / N o t O K

A d e q u acy o f co n cre te lay in g arran g e m e n ts : O K / N o t O K

A d e q u acy o f w o rk s p ace f o r lab o u r an de q u ip m e n t

: O K / N o t O K

R C C / P C C co n cre te g rad e :


A v a i lab i l i ty o f W e ig h - b atch e r : O K / N o tO K

A d e q u acy o f V ib rato rs : O K / N o tO K

S lu m p o b s e rv e d as p e r m ix d e s ig n : O K / N o tO K

cu b e s cas te d as R e q u i re d : O K / N o tO K

A d e q u acy o f C u rin g arran g e m e n ts : O K / N o tO K

Te m p aratu re o f co n cre te a t P lacin g : O K / N o tO K

A E/ A EE/ D EE/ EE C o n tracto r

O .K C A R D F O R C O L U M N S


i v ) A l ig n m e n t o f F o rm s :

TP Q A



53 | P a g ein

Joint Venturewith

N am e o f th e co n tracto r :

P ack age N o . :N am e o f th e w o rk :



D raw in g N o . :

B o tto m Le v e l o f S lab /B e am s : O K /N o t O K

B ase o f th e S caf fo ld in g : O K /N o t O K

B racin g fo r ce n trin g : O K /N o t O K

F o rm w o rk an d S e als : O K /N o t O K

i ) F o rm s C le an e d : O K /N o t O K O K /N o t O K

i i i ) Ee rctio n an d se als as p e r D raw in g : O K /N o t O K O K /N o t O K


P h y s ica l d im e n s io n s V e ri f ie d as p e r d raw in g : O K /N o t O K

R e in fo rce m e n t p lace m e n t as p e r d raw in g : O K /N o t O K B ran d :

C o v e r to re in fo rce m e n t as p e r d raw in g : O K /N o t O K

P lacin g o f f ix tu re s/Em b e d m e n ts as p e r d raw in g : O K /N o t O K

S u itab i l i ty o f In p u t M ate ria l :

C e m e n t : O K /N o t O K B ran d :



W ate r O K /N o t O K

A d m ix tu re /S u p e r p lasticize r (A s p e r M ix d e s ign /A sp e r M TC )

: O K /N o t O K

R C C /P C C co n cre te grad e :





cu b e s caste d as R e q u ire d : O K /N o tO K



A E/A EE/D EE/EE C o n tracto r

O .K C AR D F O R C Y C L O N E S H EL TER G R O U N D F L O O R S L AB/ BEAM


iv )A l ign m e n t o f F o rm s :

TP Q A



54 | P a g ein

Joint Venturewith

N am e o f co n tracto r :

P ackage N o . :N am e o f W o rk :

Stru ctu re ch ain age :

C o m p o n e n t o f stru ctu re:

Draw in g N o : :

Bo tto m Le v e l o f S lab /Be am s : O K /N o t O K

Fo rm w o rk an d Se als : O K /N o t O K

i) Fo rm s C le an e d : O K /N o t O K O K /N o t O K

i i i ) Ee rctio n an d se als as p e r Draw in g : O K /N o t O K O K /N o t O K


P h ysical d im e n sio n s V e ri f ie d as p e r d raw in g : O K /N o t O K

Re in fo rce m e n t p lace m e n t as p e r d raw in g : O K /N o t O K Bran d :

C o v e r to re in fo rce m e n t as p e r d raw in g : O K /N o t O K

P lacin g o f f ix tu re s/Em b e d m e n ts as p e r d raw in g : O K /N o t O K

Su itab i l i ty o f In p u t M ate rial :

C e m e n t : O K /N o t O K Bran d :


FA : O K /N o t O K

W ate r O K /N o t O K

ad m ix tu re /Su p e r p lasticize r : A s p e r M ix d e sign /A s p e r M TC

RC C /P C C co n cre te grad e :

Q ty o f co n cre te to b e laid :



Slu m p o b se rv e d as p e r m ix d e sign : O K /N o tO K





O .K CAR D F O R F IR S T F L O O R S L AB/ BEAM

i i ) Fo rm s O i le d :

iv ) A l ign m e n t o f Fo rm s :



55 | P a g ein

Joint Venturewith


Package N o. :

N am e of Work :

Type of Brick :

Physical Dim ensions of brick as per approved Class : OK/N ot OK

Water absorption Tested : OK/N ot OK

Cem ent Mortar Mix : OK/N ot OK

Hacking for RCC Surface Done : OK/N ot OK

Thickness of w all as per draw ing : OK/N ot OK

Leve l and Plum b : OK/N ot OK

Toothing/Steeping provided : OK/N ot OK

Thickness of Joint : OK/N ot OK

Suitability of Input Material

Cem ent : OK/N ot OK Brand :

Sand : OK/N ot OK

Water : OK/N ot OK

Brick : OK/N ot OK

Adequacy of Curing arrangem ents : OK/N ot OK

AE/AEE/DEE/EE

O.K CARD FOR BRICK WORK

Contractor TPQA



56 | P a g ein

Joint Venturewith

CONSULTANT'S DESCRIPTION OF NONCONFORMANCE:

SE Date:

DPM's Review and Signed: Date:

CONTRACTOR'S PROPOSED REMEDIAL ACTION:

Position: Signed: Date:

PIU'S RESPONSE:

Approval / Rejection of Remedial Action:

Accepted

Conditionally Accepted Rejected

Comments :

AEE/AE DEE EE

Date: Date: Date:

CLIENT / CONSULTANT'S CLOSE-OUT:

NCR closed NCR not closed, see comments below

Comments:

Name: Position: Date:

Reviewed by Client / Consultant: Date:

Consultancy Services for Third Party Quality Audit (TPQA) for National Cyclone Risk Mitigation Project (NCRMP)

Consultant: EGIS India Consulting Engineers Pvt.Ltd Non - Conformance Report

( NCR )Date:

Package No. Ref: NCR No.Contractor: Line Department: Place of work:

Name of Work:

Closing Inspection:IRB No. Date



57 | P a g ein

Joint Venturewith

6.0 RECTIFICATION GUIDELINES

Where the surface regularity of subgrade and the various pavement courses fall outside the specified

tolerances, the Contractor shall be liable to rectify these in the manner described below and to the

satisfaction of the Engineer.

(i) Subgrade; Where the surface is high, it shall be trimmed and suitably compacted. Where the same is

low, the deficiency shall he corrected by scarifying the lower layer and adding fresh material and

recompacting to the required density. The degree of compaction and the type of material to be used shall

conform to the requirements of Clause 303.

(ii) Granular Sub-base: Same as at (i) above, except that the degree of compaction and the type of

material to be used shall conform to the requirements of Clause 401.

(iii) Lime/Cement Stabilized Soil Sub-base: For lime/cement treated materials where the surface is high,

the same shall be suitably trimmed while taking care that the material below is not disturbed due to this

operation. However, where the surface is low, the same shall be corrected as described herein below. For

cement treated material, when the time elapsed between detection of irregularity and the time of mixing of

the material is less than 2 hours, the surface shall be scarified to a depth of 50 mm supplemented with

freshly mixed materials as necessary and re-compacted to the relevant specification. When this time is

more than 2hours, the full depth of the layer shall be removed from the pavement and replaced with fresh

material to Specification. This shall also apply to lime treated material except that the time criterion shall be

3 hours instead of 2 hours.

(iv) Water Bound Macadam/Wet Mix Macadam Sub-base/Base: Where the surface is high or low, the lop

75 mm shall be scarified, reshaped with added material as necessary and re-compacted to Clause 405.

This shall also apply to wet mix macadam to Clause 406.

(v) Bituminous Constructions: For bituminous construction other than wearing course, where the surface is

low, the deficiency shall be corrected by adding fresh material over a suitable tack coat if needed and re-

compacting to specifications. Where the surface is high, the full depth of the layer shall be removed and

replaced with fresh material and compacted to specifications. For wearing course, where the surface is

high or low, the full depth of the layer shall be removed and replaced with fresh material and compacted to

specifications, in all cases where the removal and replacement of a bituminous layer is involved, the area

treated shall not be less than 5 m in length and not less than 3.5 m in width.

(vi) Dry Lean Concrete Sub-base/Rolled Cement Concrete; The defective length of the course shall be

removed to full depth and replaced with material conforming to section 1500, as applicable. The area

treated shall be at least 3 m long, not less than 1 lane wide and extend to the full depth. Before relaying



58 | P a g ein

Joint Venturewith

the course, the disturbed sub grade or layer below shall be corrected by levelling, watering and

compacting.

(vii) Cement concrete pavement; the defective areas having surface irregularly exceeding the specified

limits may be rectified by bump cutting or scrabbling or grinding using approved equipment. When required

by the Engineer, areas which have been reduced in level by the above operation(s) shall be retextured in

an approved manner either by cutting grooves (5mm deep) or roughening the surface by hacking the

surface. If high areas in excess of 6mm or low areas in excess of 3mm occur, exceeding the permitted

numbers and if the contractor cannot rectify, the slab shall be demolished and reconstructed at the

contractors expense and in no case the area removed shall be less than the full width of the lane in which

the irregularity occurs and full length of the slab.

If deemed necessary by the Engineer, any section of the slab which deviates from the specified levels and

tolerances shall be demolished and reconstructed at the contractor’s expenses.

6.1. FINISHING FOR BRIDGE COMPONENTS:

Immediately after the removal of forms, exposed bars or bolls, if any, shall be cut inside the concretemember to a depth of at least 50 mm below the surface of the concrete and the resulting holes filled withcement mortar. All fins caused by form joints, all cavities produced by the removal of form ties and all otherholes and depressions, honeycomb spots, broken edges or corners, and other defects, shall be thoroughlycleaned, saturated with water, and carefully pointed and rendered true with mortar of cement and fineaggregate mixed in the proportions used in the grade of concrete that is being finished and of as dry aconsistency as is possible to use. Considerable pressure shall be applied in filling and pointing to ensurethorough tilling in all voids. Surfaces which have been pointed shall be kept moist for a period of twentyfour hours. Special pre-packaged proprietary mortars shall be used where appropriate or where specifiedin the drawing. All construction and expansion joints in the completed work shall be left carefully tooled andfree from any mortar and concrete.

Expansion joint filler shall be left exposed for its full length with clean and true edges. Immediately onremoval of forms, the concrete work shall be examined by the Engineer before any defects arc madegood.

a) The work that has sagged or contains honeycombing to an extent detrimental to structural safety orarchitectural appearance shall be rejected.

b) Surface defect of a minor nature may/ be accepted. On acceptance, of such work by the Engineer, thesame shall be rectified as directed by the Engineer,

6.1.2. Rectification Guidelines for Concrete Structures

Though concrete is a relatively durable building material, it may suffer damage or distress duringits life period due to a number of reasons. Because of the varying conditions under which it is produced atvarious locations, the quality of concrete suffers occasionally either during production or during serviceconditions resulting in distress. The structural causes of distress of concrete may include externally appliedand environmental loads exceeding the design stipulations, accidents and subsidence. Sometimes distressin a structure is brought about by poor construction practices, error in design and detailing, constructionoverloads. The other causes may be drying and shrinkage, thermal stress, weathering, chemical reactions



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and corrosion of reinforcement. In addition to the distress hardened concrete, the plastic concrete mayalso suffer damage due to plastic shrinkage and settlement cracking. Sometimes on stripping off the formsa number of surface defects such as bulges, ridges, honeycombing, bolt-holes, etc. are noticed on thefresh concrete members. Such defects can be avoided to a large extent by providing a watertight and rigidformwork in such a way that stripping can be done without the use of crowbars or other tools. In addition tothese defects, blow-holes develop during concreting operations due to improper design of formwork.These are formed in the surface of concrete by trapped air and water bubbles against the face offormwork. These can be reduced if the form face is slightly absorbent and adequate compaction isprovided. In case the blow-holes are exceptionally large, or if a smooth surface is required, they must befilled with 1:1 or 1:2 cement-sand mortars. The sand should be sieved through a 300-µm or 600-µm sieve,depending upon the smoothness of the finish required. Crushed limestone dust is preferable. The mortarshould be rubbed over the affected area with a rubber-faced float, and finally rubbed down with a smoothstone or mortar block for a smooth finish.

The honeycombing consisting of groups of interconnected deep voids normally indicateinadequate compaction or loss of grout though joints in formwork or between formwork and previously castconcrete. The affected area is delineated with a saw cut to a depth of 5mm. The unsound material ischipped out to the solid concrete. After the surface has been prepared a bonding coat should be applied toall exposed surfaces and new concrete should be placed against the prepared surface. The bonding coatmay consist of a slurry of cement and water, but it is desirable to incorporate a polymer admixture.

The repair of bulges and projections can be carried out by chipping of the concrete from thesurface and then rubbing the surface with a grinding stone. Scouring of a vertical surface of hardenedconcrete making it resemble a map of delta of a river is caused by water moving upward against the faceof the formwork. This is a sign of excessive wet of harsh concrete. It is a superficial defect so, unless it isunusually deep and the cover to reinforcement is unusually small, the remedial measures consists of earlyfacing up in the same way suggested for filling blowholes.

This type of repair (more appropriately called finishing) should be done as soon as possible afterthe forms are stripped and before the concrete becomes too hard. The repair should preferably becompleted within 24hrs of the removal of the forms. This is done to develop a good bond and make therepaired portion as durable and permanent as the original work.

If the repairs are not properly done, the newly placed concrete becomes loose and drummy withthe passage of time and finally gets detached from the main concrete. The darker color of the repairedpatches can be corrected by adding 10-20% white Portland cement to the patching mortar to obtainuniform surface color. The various defects occurring during construction are outlined in the table givenbelow.



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Symptom Cause Prevention Remedy

Cracks in horizontalsurface, as concretestiffens or very soonthereafter

Plastic shrinkage:rapid range of

surface

Shelter during placing.Cover as early aspossible. Use air-entrainment

Seal by brushing in cementor low viscosity polymer

Cracks from aboveties in reinforcementetc., or at arises,especially in deeplifts

Plastic settlement:concrete continuesto settle after startingto stiffen.

Change mix design.Use air-entrainment

Re-compact upper part ofconcrete while still plastic.Seal cracks after concretehas hardened.

Cracks in thicksections, occurringas concrete cools

Restrained thermalcontraction

Minimize restraint tocontraction. Delaycooling until concretehas gained strength.

Seal Cracks

Blowholes in formfaces of concrete

Air or water trappedagainst formwork.Inadequatecompaction.Unsuitable mixdesign. Unsuitablerelease agent.

Improve vibrationchange mix design. Useappropriate releaseagent. Use absorbentformwork

Fill with polymer –modifiedfine mortar

Voids in concrete Honey combing:Inadequatecompaction. Groutloss

Improve compaction.Reduce maximum sizeof aggregate. Preventleakage of grout

Cut out and make good.Inject resin

Erosion of verticalsurfaces, in verticalstreaky pattern

Scouring: watermoving upwardsagainst form face

Change mix design, tomake more cohesive orreduce water content

Rubin polymer – modifiedfine mortar.

Colour variations Variations in mixproportions, curingconditions,materials,characteristics ofform face, vibration,release agent.Leakage of waterfrom formwork

Ensure uniformity of allrelevant factors. Preventleakage from formwork.

Apply surface coating



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Powdery formedsurface

Surface retardation,caused by sugars incertain timbers

Change form material.Seal surface offormwork. Apply limewash to form facebefore first few uses.

Generally none required

Rust-strains Pyrites inaggregates. Rainstreaking fromunprotected steel.Rubbish informwork. Ends ofwire ties turned out.

Avoid contaminatedaggregates. Protectexposed steel. Cleanforms thoroughly. Turnends of ties inwards

Clean with dilute acid orsodium citrate / sodiumdithionite. Apply surfacecoating

Plucked surface Insufficient releaseagent. Carelessremoval of formwork.

More care inapplication of releaseagent and removal offormwork.

Rub in fin mortar, or patchas for spalled concrete.

Lack of cover toreinforcement

Reinforcementmoved duringplacing of concrete,or badly fixed.Inadequatetolerances indetailing.

Provide better supportfor reinforcement. Moreaccurate steel fixing.Greater tolerances indetailing

Apply polymer modifiedcement and sand rendering.Apply protective coating.






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Third Party Quality Audit for Construction of Cyclone Shelters, Roads toCyclone Shelters & Habitations, Bridges and Culverts under NCRMP Checklists

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INDEX

Check List No. Title Page No.

1 Check list for Clearing and Grubbing 3

2 Earth Works 4

3 Check list for Protective works 8

4 Checklist for Granular Sub base 9

5 Check list for Wet Mix Macadam 10

6 Check list for Water Bound Macadam 11

7 Check list for Laying Prime Coat 12

8 Check list for Laying Tack Coat 13

9 Check list for Open Graded Pre – Mix Carpet 14

10Check list for Bituminous layers using Mechanised Construction

15(BM, DBM, SDBC, BC)

11 Typical corrective Action Plan for Bituminous layers Placement 21

12 Check list for Temporary Diversions 23

13 Checklist for Road Furniture 24

14 Check list for Pipe Culverts 27

15 Check list for Slab Culverts and Bridges 29

16 Check list for Reinforcement Inspection 33

17 Check list for Formwork Inspection 34

18 Check list for Inspection Before Approval to Concrete 35

19 Check list for Batching and Pouring of Concrete 36

20 Check list for Post Concreting Inspection 37

21 Check list for Excavation 38

22 Check list for Anti Termite treatment 38

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23 Check list for Rubber soling 39

24 Check list for Plain concrete 39

25 Check list for Shuttering 40

26 Check list for Reinforcement 41

27 Check list for Brickwork 42

28 Check list for Solid block masonry 42

29 Check list for Plasterwork 43

30 Check list for Doors/ Windows 43

31 Check list for Doors/ Windows (Aluminium) 44

32 Check list for Polished kota stone flooring 45

33 Check list for Tremix flooring 46

34 Check list for Oil bound distemper 47

35 Check list for Oil bound distemper/Water bound distemper/Acrylicbound distemper

47

36 Check list for White wash 48

37 Check list for Indian type water proofing terrace 49

38 Check list for Box type water proofing 49

39 Check list for fabrication/ Erection 50

40 Check list for Rolling shutter 50

41 Check list for Painting of structural steel works 51

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CHECK LIST No. 1

Check list for Clearing and Grubbing

S.No PRE-CONSTRUCTION STAGE Checked

Item1 Review the plans, special provision, right of way agreements, which may require

special staking.2 Confirm land acquisition is completed and area demarcated is in possession.3 Confirm encroachments (if any) are removed and tree cutting (if any) is carried out

with permission of competent authority.4 Check whether all the tree roots and stumps are removed in the formation area. Check

whether the pits from where trees have been removed are filled with granular materialand suitably compacted.

5 Ensure that features and facilities, which are to be preserved, are clearly marked.6 Attention shall be paid to environmental commitments.7 Determine the method for disposal of all materials outside the right of way.8 Identify the location of all public utilities (telephone poles, power lines, water supply

lines, sewer lines, UG cables etc.) and ensure proper liaison with concerned authoritiesfor shifting or for carrying out work safely without affecting the utilities duringexecution of works.

S.No CONSTRUCTION STAGE Checked

Item1 Check whether the Executing Agency equipment has required safety devices for the

protection of personnel and environment. (In forest areas required spark arrestersshall be used in the equipment.

2 Ensure no hazard to public during operations like timber felling, blasting.3 Ensure a better and coordinated traffic control.4 Check whether adjacent property and environmentally service-line areas are being

affected and prevent such operations.5 Limits of clearing areas which do not require removal of stumps should be determined,

and the height of stumps above natural ground are checked.6 Determine if dead, dying or otherwise unstable trees, which are in the right of way but

outside the clearing limits to constitute a hazard. Any such tree shall be removed.7 Check whether the cut timber is being handed over to the concerned agencies, in case

the contract provides such handing over.8 When burial of debris is permitted within the right of way that it will not act as a

permeable layer, does not block drainage and will not interfere with maintenance.9 Ensure proper precautions, if burning of debris is permitted. Ensure that the smoke will

not interfere with the visibility of public traffic and no air pollution problem is created.10 Ensure that tree branches overhanging above the roadway are cut off as specified.

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CHECKLIST No.2

EARTH WORKS

Earthwork includes operation connected with roadway excavation, structure excavation, backfill,ditch/drain excavation, compaction, and embankment construction and borrows area excavation.

S.No PRE - CONSTRUCTION STAGE CheckedItem

1 Confirm required drawings I.e. Longitudinal Section and Cross Section for theproposed stretch are updated and at hand.

2 Confirm centreline of the proposed road has been set out using Total Station. Drivepegs to mark it at every 10 m or less in straight reaches. Erect masonry pillars23x25 cm at each peg position with two sides plastered. Mark on the pillarsproposed level up to which filling is to be done.

3 In the case of road in cutting, two additional pillars are to be constructed on eachflank of the road and with the proposed level of formation on the plaster.

4 Check road safety signs such as "Road work under progress"; "Take diversions",etc. are properly positioned.

5 Earmark/detail personnel for traffic control (if any) concerned authorities to beinformed in advance and publicize the traffic restriction if any.

6 Make a list of persons deployed at site along with qualification and experience.7 Confirm reference pillars (Temporary Bench Marks) are erected.8 Confirm quarries are identified and permission (if any) from appropriate authority

has been obtained.9

Calculate required quantities and assess and satisfy the material is available withquarries.

10 Confirm quarry material has been tested and results are satisfactory.11 Confirm setting out of curves - Horizontal and vertical have been completed12 Confirm requisite templates for camber and depth of loose earth spread are

available.13 Check watering arrangements are satisfactory.14 Check agreed upon plant and machinery including Vibro-hammer for vertical

banks is in good working condition.15 Check fuel, oil, lubricant, urgent spares (if any) are readily available (in the

vicinity) nearby.16 Confirm checking and measuring instruments like levelling instrument / staff of 30

m, tapes etc. is available at site.17 Check testing equipment for field tests like field density apparatus, rapid moisture

meter etc. are available.18 Confirm registers/site documents for recording the levels and any other activity at

site are available.19 Check whether marking of exact location of CD works have been completed.20 Check if any vegetation has grown after clearing and grubbing. If yes repeat the

operation of clearing and grubbing.21

Check whether the existing ground has been rolled to meet the Compactionrequirement.

22Whenever Ground improvement has been proposed check if prefabricated drains(band drains), sand for sand blanket, geotextile and free draining material ofrequired quantity are available, before the work is taken up in hand. Please checkthat the complete design has been approved by the Engineer.

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23Sections where reinforced soil structures are to be provided, check if precastconcrete facing units, soil reinforcing elements with accessories / Fitting and backfill material of required quantity are as specification before the work is taken up.Please also check that the design have been approved by the Engineer.

24Establish contract for coordination with any other agency working/operating in thesame area.

Preparing Foundation for Embankment:A Embankment less than 1 m high over natural ground1 Ensure completely braking-up the cleared ground surface to a minimum depth of

150 mm by ploughing or scarifying.2 Ensure the ground surface shall than be compacted according to Clause 301.5.5.B Embankment less than 0.5 mm high over an existing black- topped or

gravel road surface1 Ensure existing gravel road shall be sacrificed to a minimum depth of 150 mm.2 Ensure existing black-topped roads, the black-topping shall be removed and the

pavement shall be scarified to a depth of 150 mm.3 Ensure all particles shall be reduced to a maximum size of 50 mm to produce a

uniform material.4 Ensure surface then be compacted according to Clause 301.5.5.C Embankment on an existing slope steeper than 1:41 Ensure horizontal benches shall be cut in the existing slope to a sufficient width to

accommodate placement and compaction operation.CONSTRUCTION STAGE - In Fill

1 Ensure removal of top 15 to 20 cm of soil when filling is proposed.2 Ensure ground treatment as per Technical specification in marking areas before

earthwork in embankment is taken up.3 Approved soil for filling to be free from organic or decomposed material.4 The earth clods more than 75mm in size should be broken to less than 75mm in

size and spread over the entire width of the embankment in layers not exceeding150mm compacted thickness and rolling to be done with rollers (of type and sizeas specified) . Use templates to ensure uniform thickness of spreading.(Compacted layer thickness can be increased up to 200mm if heavy vibratoryrollers are used).

5 Modified (Standard for rural roads) density to be taken at specified intervals andensure top 500 mm (300mm for rural)of embankment and shoulders to have 97%(100% of standard for rural)modified proctor density and lower layers 95% (97%of standard for rural roads).

6 It Ensure that each layer of earthwork is tested (Density and Moisture content)before starting next layer.

7 Check whether water has been sprinkled over the previous layer top, before lyingand next layer.

8 Check the layer thickness of any later lay to compensate the thickness of grades.If it is less than 100 mm, then the previous layer top shall be suitably watered andscarified and then next layer is laid. Ensure proper bonding with old compactedlayer and avoid 'peeling off in patches' of the newly laid layer during compaction.

9 Ensure the benching into existing material during hillside construction or wherethe section changes from embankment to excavation or while widening theexisting formation is adequate for proper keying of embankment material tooriginal ground.

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10 Ensure that rolling over entire area - completely too outside edges is being carriedout.

11 Adequate compaction of earth shall be done in uniform layers of specifiedthickness duly providing an extra width of 600mm on either side to ensure propercompaction in the slopes also. Trimming to the required width shall be done afterthe formation is done to full height.

12 Plan cutting operation in such a way to avoid filling the same area later on13 Ensure camber, super elevation and gradient of road formation after rolling using

levels, templates etc. liberally. Special templates to be used for curves14 No dumping in heaps at the area of work15 Ensure that the top of the cut section sub-grade is property rolled. If granular sub

base is proposed straight on top of the cut formation, the top 500 mm((300mm for rural) below the cut formation level shall be excavated and re-rolledto have 97% standard modified proctor density compaction. If the soil at the cutformation level is found unsuitable either due to inadequate CBR value or due tosub-standard quality, top 500 mm( 300mm for rural) soil below the cut formationlevel shall be removed and thrown away. The formation base shall be compactedto 95% of modified proctor density value, and suitable sub-grade material of 500mm( 300mm for rural) thick shall be placed on top of cut formation andcompacted according to the specification, before laying any pavement layers

16 Check the material used for sub-grade, whether it has four days soaked CBR ofminimum 10% (or specified in agreement specification)

17 Quality control tests during construction as stipulated in MORT&H Section 900(MORD section 1800 for rural).

18 Ensure earthwork in Earth retaining Structures as per Technical SpecificationB Rehabilitation of Existing Embankment

In case of existing banks, where embankment portion are to be modified,benching of slopes shall be done with a little slope towards the inside of benchingso as to give a good grip to the embankment soil with the sub grade. In generalthe benching shall be 300mm x 600mm (Vertical: Horizontal). Before benching,the slopes shall be cleared of all roots and vegetable matter as per specification.The bank section be brought to design standards by filling layer by layer withsuitable material.In case of the old formation to extend horizontally. It shall be cut to a slope notsteeper than 1 in 4 and the surface so prepared shall be scarified and made loosefor a depth of 150mm. Necessary watering shall be done and the earth surfaceshall be thus prepared to receive the new embankment. The soil shall be laid inlayers and compacted to the required degree of compaction to have a properbond with the old one.If the old formation is to be raised vertically, vegetation shall be cleared followedby scarifying, watering and placing of the new earth layer as specified above.

SNo POST CONSTRUCTION STAGE Checked

Item1 Confirm width of formation is as specified2 Ensure side slopes are dressed to specified slope.3 Check camber is achieved.4 Tolerances in Surface levels as specified.


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Typical Sketch showing of Earthwork formation by Benching Method. Here,Embankment height is about 900MM. Depending on the height, Number of stepsshall be formed. Extra Width of 600MM in each layer is to be provided to facilitate

compaction along the slope also.



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CHECKLIST No.3

CHECKLIST FOR PROTECTIVE WORKS

S.No PRE-CONSTRUCTION STAGE Checked

Item

Stone Pitching or Turfing

1 Confirm slope of embankment is as specified (1Vertical:2Horizontal), dulyconsolidated.

2 Check the stones collected for size. Large size boulders should be used. Each stoneshould be over 40 kgs. Smaller size stones should not be used.

3 For turfing, the clods of turf should be at least 50 mm thick and contain roots.

Roadside and Catchment Drains

1 Check drains planned for road in cutting.

2 Check whether bed slope is correct.

3 Check whether the slopes of drains are as per designs.

4 Check whether the excavated earth is removed and spread or disposed off.


Stone Pitching or Turfing

1 Ensure stone pitching is in accordance with IRC: 89 Clause 5.3.5.1.

2 Ensure Stones and clods of turf are hand packed from bottom on top.

S.NoPOST CONSTRUCTION STAGE Checked

Item

1 In case of turfing, unless done during the monsoon, daily watering for 30 daysshould be ensured.

2 In case of drains, ensure excavated earth is removed from site.



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CHECKLIST No.4

CHECKLIST FOR GRANULAR SUB BASE

S.No PRE-CONSTRUCTION STAGE CheckedItem

1 Confirm sub grade is adequately compacted. If there is time gap for execution ofGSB layer and the previously finished sub grade, check whether the sub gradetest results are valid. Check whether the compaction of the sub grade is still ingood condition, if not carryout proof rolling. Clear all loose or external materialsbefore laying GSB from sub grade top

2 Confirm camber, cross slope and side slope of embankment are correct. Checkwhether the sub grade top surface tolerance levels are within the permissiblelimits prescribed

3 Confirm grading of GSB materials has been tested and is of correct specificationsas per Agreement Specification

4 Check whether the "Ten Percent Fines Value" test (Wet Aggregate Impact Valuetest for rural) and water absorption value test have been conducted and theresults are as per the Specification

5 Check templates available for indicating thickness of loose layer to be spread6 Check watering arrangements are adequate7 Confirm rollers are available and in working order

S.No CONSTRUCTION STAGE CheckedItem

1 Observe the spreading and compacting operations. Ensure the material is beingspread without significant segregation. If necessary, obtain samples from thematerial being spread and conduct sieve analysis test. Check the layer thicknessand confirm that it is as per specification requirements

2 Check layer of loose material is as specified in the specification. (For MoistureContent- IS: 2720 Part 2)

3 Check layer of compacted layer is as specified4 Check density of compacted layer is as specified Density 98% according to IS:

2720 Part 8 ( 100% of Standard Procter’s laboratory MDD as per IS: 2720 part 7)5 Observe the compacting operation to determine that the material forms a firm,

stable base throughout the spread width.

S.No POST CONSTRUCTION STAGE Checked

Item1 Tolerance as specified.



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CHECKLIST No.5

CHECKLIST FOR WET MIX MACADAM


1 Check whether the previous true layer GSB or sub grade as the case may be, hasbeen finished properly and is to the required grades and lines and the surfaceirregularities are within the tolerance levels. Verify whether the sub grade hasbeen prepared to the specifications laid in Cl. 404.3.1 of MOST

2 Check whether GSB/sub grade layer compaction is intact if there is aconsiderable time delay in execution of WMM and the previous pavement layer(say 10 days). If not, carryout proof rolling

3 Check whether any loose materials or external materials are on the GSB/subgrade top and remove all loose and external materials before laying WMM

4 Confirm mix design is known to supervisor in charge of mixing. The design watercontent should be known

5 Confirm stone aggregate has been tested and is of acceptable quality andadequate quantity (IS: 2386 Part 5) as per Appendix A

6 Confirm fine aggregate is of correct gradation and adequate quantity7 Confirm equipment and plant necessary are available and in working order8 Confirm the sub-base on which wet mix macadam is to be laid is clean9 Check that the paver is adjusted to give the specified minimum thickness and

camber .Do a trial stretch of about 5 to 10 m to confirm this


1 Observe the spreading and compacting operations. Ensure the material is beingspread without significant segregation. When WMM is spread by graders/pavers,the layer size particles have a tendency to segregate. Check continuously whilespreading that this type of segregation does not take place and take suitableremedial action either manually rectifying or adjusting the blade angles of thepaver screed. Ensure no segregation takes place and material is spread withoutrock pockets

2 Confirm that the gradation of spread materials is as per the job mix, by takingsamples from the spread materials and conducting gradation tests

3 Monitor thickness of wet mix macadam layer. (Not less than 75 mm)4 Monitor whether required camber is achieved5 Monitor water content. Excess water will/result in separation of coarse and fines

(Optimum moisture for mixing IS: 2720 Part 8).6 Monitor compaction achieved is as required. Observe the compacting operation

to determine that the material forms a firm, stable base throughout the spreadwidth. Rolling continued till density achieved is at least 98% of MDD (IS: 2720Part 8)

7 Control tests and their minimum frequencies as specified in Appendix - A8 Tolerance shall be within the limits as specified

S.No POST CONSTRUCTION STAGE CheckedItem

1 Erect barricades or pitchstones to prevent traffic2 Road shall be allowed to dry for a minimum period of 24 hours. No traffic shall be

allowed over the surface before any priming coat is laid



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CHECKLIST No.6

CHECK LIST FOR WATER BOUND MACADAM

S.No PRE - CONSTRUCTION STAGE Checked

Item

1 Check whether the existing top layer of base, sub base or sub grade, as the casemay be, has been prepared properly as per MORT&H clause 404.3.1 or MORDclause 405.3.1.

2 Whether the previously laid layer compaction is intact in case of considerabletime delay in commencement of WBM construction and the previous pavementlayer. If not, proof rolling is to be done.

3 Remove any loose materials and external materials present on the previouspavement layer before spreading coarse aggregates

4 Confirm stone Aggregate has been tested for Aggregate Impact Value, FlakinessIndex Value Combined FIV and Elongation Index Values in case of MORT&H),Water Absorption and soundness test if water absorption exceeds 2%.

5 Check whether the stone aggregate satisfies the specified gradation as perMORT&H table 400-7 or MORD table 400.8.

6 Check the quality and gradation of screenings as per MORT&H clause 404.2.8 andtable 400-8. For rural roads, the relevant MORD clause is 405.2.8 and table is400.9.

7 Check the quality of binding material as per MORT&H clause 405.2.9 (MORDclause 405.2.9 for rural roads).

8 Check the required templates for indicating the loose thickness of layer to be laid9 Check watering arrangements are adequate10 Confirm rollers are available as per requirement in working order11 confirm availability of camber board, straight edge, spirit level and brooms etc.,


Item

1 Observe the spreading, sectioning and dry rolling operations. Ensure thematerial is spread without significant segregation. If necessary, collect samplesfrom the spread material and check for gradation and verify thickness of layer

2 Observe the application of screenings after dry rolling followed by brooming,uniform water sprinkling and rolling, Check sweeping followed by rolling so thatall the voids are filled and dense layer is formed

3 Check the required templates for indicating the loose thickness of layer to belaid.

S.No POST - CONSTRUCTION STAGE Checked

Item

1 Road shall be allowed to dry for a minimum period of 24 hours. No traffic shallbe allowed before laying prime coat



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CHECKLIST No.7

CHECK LIST FOR LAYING PRIME COAT

PRIME COATPrime coat is the application of liquid bitumen/emulsion over an absorbent granular surfacepreparatory to any superimposed bituminous treatment or construction. Generally prime coat isapplied to seal the granular surface

S.No PRE- CONSTRUCTION STAGE CheckedItem

1 Check the choice of binder (emulsion or cutback bitumen) and quantity shall beas per relevant specifications.

2 Confirm cut back bitumen or emulsion is known to supervisor in charge ofmixing.

3 Confirm binder has been tested and is of acceptable quality. Sampling andTesting of Bituminous primer according to IS: 217 (Cutback bitumen), IS: 454(Digbol type cutback bitumen), IS: 8887 (Specification for bitumen emulsion forroads of cationic type).Confirm the type of binder, which is going to be used, isas per the particular specification requirements

4 Prime coat shall not be applied on a wet surface or during dust storm or whenthe weather is rainy, windy or foggy. Ensure that no priming is done when theatmospheric temperature is less than100C

5 Check arrangements for ensuring correct dosing is in place6 Confirm equipment like binder spreader to be used is available and in working

order.


1 Surface should be swept clean, free from dust and shall be dry. If the surface tobe primed is so dry or dusty, a light and uniform sprinkling of water may be done,but no priming shall be undertaken till such time is no surface water is visible

2 Check binder spread per square meter is as specified3 Check whether the spread of binder is uniform and no uncovered patches are left

on the surface4 Control tests and frequencies shall be as specified


Item1 Erect barricades or pitchstones to prevent traffic2 Surface shall be allowed to cure for a minimum period of 24 hours or any other

period as per site conditions3 If the primed surface is not cured within 24 hours of application, sand may be

spread lightly over the primed surface4 Sand should be spread only thick enough to prevent pickup of bitumen. The need

for large amounts of sand to blot up excess liquid bitumen is an indicative of errorin selecting the rate of application or type of binder

5 Care shall be taken to remove all loose sand before taking up the next course



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CHECKLIST No.8

CHECK LIST FOR LAYING TACK COAT

TACK COAT

Tack coat is the application of liquid bitumen/emulsion over an existing road surface preparatory to

another bituminous construction over it. Tack coat is applied to ensure better bonding of layers

S.No PRE- CONSTRUCTION STAGE Checked

Item1 Check the choice of bitumen and quantity shall be as per relevant specifications2 Confirm cut back mix emulsion is known to supervisor in charge of mixing3 Confirm bitumen has been tested and is of acceptable quality and confirms to

specifications (IS: 217, 454 and 8887)4 Ensure arrangements for applying liquid bitumen confirm to requirements and all

the equipments are available and are in working condition5 Confirm that surface over which tack coat is to be applied is clean and all loose

material or extraneous material is removed either by mechanical brooms or byother approved method


Item1 Check whether the liquid bitumen is heated and the temperature prior to

application is within the range2 Check whether the spread of bitumen is uniform and the entire area is covered

uniformly3 Ensure that no further layer is spread over tacked area before the tack coat is

cured (until the water/cutter in case of emulsion/cutback has completelyevaporated). In general time gap of 30 minutes will be sufficient

4 Ensure that tack coat is not applied when the atmospheric temperature is lessthan 100C

5 Check that tack coat is not applied over a freshly laid bituminous course. If due tosite condition, traffic is allowed over the finished layer before next layer is laid, alight tack coat as decided based on site conditions shall be applied

6 Normally tack coat is not to be applied over a freshly laid bituminous course. Ifdue to site condition, traffic is allowed over the finished layer before next layer islaid a light tack coat as decided based on site conditions shall be applied



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CHECKLIST No.9

CHECK LIST FOR OPEN GRADED PRE –MIX CARPET

S.No PRE- CONSTRUCTION STAGE Checked

Item1 Check the physical requirements of coarse aggregates as specified. Aggregates are

to be tested for Aggregate Impact Value, Flakiness Index Value and WaterAbsorption. Soundness test is necessary if water absorption exceeds 1%.

2 Check Suitable mixing plant, spreading rakes, camber board, templates, bitumendistributors and rollers are available

3 Check thermometer for measuring the temperature and depth gauges etc., areavailable

4 Check whether the base on which premix carpet is to be laid is prepared to thespecified lines, grades and cross-section


Item1 Prime Coat with specified emulsion or cutback bitumen is applied as per the

specified rate and cured2 Tack coat is applied as per the rate specified3 Mixing should be thorough that a homogeneous mix is obtained. The

temperature of bitumen at the time of mixing should be in the range of 150°C to163°C and that of aggregates 155°C to 163°C, provided that the temperaturedifference between bitumen and aggregates should not exceed 14°C

4 Ensure the mix is transported the site quickly5 Check whether the loose thickness of OGPC mix is ensured to be the required

27mm duly providing longitudinal and cross profile6 Correct high spots or depressions noticed after the roller has passed over the

whole area once by removing or adding premixed material and recomposing.Rolling shall be done with specified type of rollers and upto a stage where nofurther movement of bituminous carpet ahead of the roller

7 Provide seal coat to the surface immediately after the laying of OGPC carpet.


Item1 Check the edges of the carriageway should be correct within a tolerance limit of

of ± 20mm2 Check the tolerance of surface level. It should be within ± 6mm for machine laid

and ± 10mm for manually laid3 Check for surface regularity. The maximum allowable difference between the

pavement course and a 3M straight edger shall not exceed 8mm for both thelongitudinal and cross profile

4 Check thickness of compacted layer randomly and check for bitumen content.



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CHECKLIST No.10

CHECKLIST FOR BITUMINOUS LAYERS USINGMACHINISED CONSTRUCTION (BM, DBM, SDBC, BC)

S.No PRE- CONSTRUCTION STAGE CheckedItem

GENERAL1 Confirm mix design is available.2 Confirm hot mix plant setting and match the mix design.3 Confirm whether all the materials are as per criteria furnished in agreement

Specification4 Do a trial run for paver settings and for evolving rolling pattern.5 Ensure freshly laid surface is barricaded or boulder pitched to prevent traffic for

48 hours6 Check the tolerance in surface levels as specified7 Check and do not allow any bituminous work when there is a possibility of rain

or during rain8 Check the probable environmental impacts due to functioning of the hot mix

plant and ensure proper remedial actions are taken before the actual operationbegins. Ensure regular check to monitor the environmental mitigation action planand its proper implementation

PLANT OPERATION1 Observe the aggregate storage areas and facilities to ensure that storage is as

specified. When various sizes are stored separately, required physicalseparation, either by space between stock piles or some types of wall that willprovide separation

2 Determine whether the stock piled aggregate is similar to the material used forthe mix design. Confirm their quality

3 Examine the plant whether weighing equipment is as specified4 See that scales and meters are sealed or tested as required5 Examine the plant to determine if it has a temperature indicating device or the

drier and that it meets requirements set forth in the specification6 Check method used for including supplemental fine aggregates or bag house

dust as per specification7 Check that the plant is equipped with a functional dust collection system as per

specifications8 Determine if there are safety provisions for sample collection as per

specifications9 Check asphalt storage tanks and determine that they meet specifications. All

storage tanks, transfer lines, pumps etc. should have heating oil’s or should bejacketed and heated to maintain the asphalt at the required temperatures

10 Check batch plants and determine that it meets the requirements of thespecifications.

a) Check whether there are overflow chutes for the hot aggregate storage,which will prevent overflow between adjacent bins. Examine the chutes to seethat they are not clogged.b) Provisions for the binder to be introduced uniformly at the specified location

c) A timing device, which will indicate by audible or visual signal the expirationof the mixing period - check to ensure that the system is in working order.



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S.No PRODUCTION STAGE Checked

Item1 Maintain a daily plant record. Use a form approved by the Engineer2 Ascertain that the production rate for the mix plant does not exceed the

specifications.Production rates in continuous mix plants must not exceed those ratesestablished during the preceding aggregate weigh belt and asphalt metercalibration.

3 Monitor plant interlocks.4 Obtain the required certificates of compliance for all asphalt binder loads5 Observe aggregate storage and determine that it meets requirement set forth in

the specifications6 Determine that supplemental fine aggregate is kept dry and stored properly.7 Monitor and record the temperature of the asphalt and aggregate and determine

that it meets requirement set forth in the specifications. Any excessive moisturein aggregates may cause slump of flattened loads, accompanied by considerablebubbling or streaming of the mixture

8 Compare aggregate from all bins to determine that it meets specifications.Obtain samples of the aggregate prior to mixing with asphalt, and test for thegrading. Gradings used by the laboratory for mix design are based on volumeand not weight. When there is a difference of more than 0.2 between thespecific gravities of coarse material and fine material, the field sieve analysismust be adjusted to volume for comparison with the design curve

9 Observe the overall plant operation to see that dust or smoke is being controlledas specified

10 Observe plant productions to assume that a homogenous mixture is beingproduced check the aggregate gradation, mixture consistency, stability andbitumen content. If the mixture appears to be deficient in any of these respects,the condition should be discussed and rectified. For batch mixing, do notapprove a mixing time of less than 30 seconds unless the reason for such actionis adequately documented and based on tests for uniformity of 'aggregate andasphalt distribution. Mixing time in a continuous' flow mixer is a function oflength of the mixing area and the rate of drop in drier drum mixing. The mostefficient pug mill mixing is obtained when the level of material is at the top ofthe paddies, throughout the length of the mixer. Feed must be continuous anduniform for best results. Also it must be noted in the daily report

11 Monitor the temperature of asphalt. In batch plants ensure that the temperatureof the asphalt in the line does not drop more than 80C (150F). In continuous feedplants ensure that the temperature of the asphalt does not vary more than 280C(500F).

12 Check to ensure that all the equipments are functioning properly and within thespecifications. When automatic batch mixing is used, check to see that theautomatic equipment is functioning within specifications. When any continuousmixing plant (drier drum or drier drum pug mill) is used, check to see that thevibrating unit on the fine bin is in operation. Also ensure that the low-levelinterlock systems for the aggregate feeder bins and the asphalt storage arefunctional

13 Observe the operation of all weighing systems. Required scales and meters to beretested whenever there is any indication that there may be in errora) The weight of the material falling from the bin gates to the weighing hopperafter the gates are closed must be considered in the batching process. Checkthat the weigh box containing the total batch does not contact anything, which



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prevents a true indication of the batch weight.

b) Periodically check the batching by comparing the total weight of the batchesin a truckload with the platform scale weight for the some load (This can bedone only when the mixed materials are not kept in silos).

c) Check the asphalt scales frequently to make sure that there is no zero error;that the scale levers and knife edges move freely; and that there is no bind ordrag on the lever systems.

d) The accuracy of meter driven asphalt proportioning devices should be checkedby comparing meter totalized readings with asphalt tank stabbings and/or withthe combined aggregate totalized readings in conjuction with an onsite vehiclescales.

14 Observe storage of materials in silos to ensure that segregation is prevented,that specified temperatures are maintained, and that minimum silo levels aremaintained

15 Examine truck beds prior to loading to ensure that contaminating agents are notused and that parting agents are used sparingly

16 Ensure that the automatic aggregate asphalt proportioning system in continuousmix plants is operating

17 Record all information that will support payment and will assist in determinationof causes for out of specification materials.

S.No TRANSPORTATION STAGE Checked

Item1 Check whether truck beds are smooth and free form holes and depression2 Is there any leakage of gas or oil from trucks?3 Are trucks equipped with adequate covers?4 Do truck and paver operate together without interference?5 Is the method of coating of contact surfaces of truck beds agreed upon?6 Whether any provision for checking the temperature is made in the trucks.7 Whether any segregation takes place while loading the trucks from the plant.8 Check whether there is any spillage of mixed material while loading into the

trucks from the plant or at loading the pavers from the trucks. Any spillage shallbe removed and discarded.

9 Check the temperature of mix at the time of loading and unloading. If thereduction in temperature is substantial, the mix should be discarded

S.No BITUMEN DISTRIBUTOR Checked

Item1 Are the heaters and the pump in good working condition?2 Does the distributor have a volume calibration chart?3 Are spray bars and nozzles unlogged and set at the proper angle for application

of tack coat4 Is a proper thermometer provided to verify temperature?5 Whether a hand held spray hose with nozzle provided to tack irregular areas.



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S.No PRE-LAYING Checked

LAYING OPERATIONS

Item1 Ensure that the base of previous road surface has been prepared as specified,

remove all loose materials and have problems corrected2 Ensure that the prime coat/tack coat has been applied uniformly and properly.

Determine temperature of the asphalt material used for prime coat/tack coat.Check whether all vertical faces are coated

3 Ensure that tack coat material is being applied at the specified rate and at theproper distance in advance of the paving operation. Check distributor spray barheight and nozzle angle

4 Ensure that the tack coat is broken or cured prior to having wherever required5 Ensure that certificates of compliance have been received for each shipment and

that weight and load slips for each liquid asphalt load are accurate6 Determine the temperature of the air and record7 Examine the spreading equipment to determine whether it has the specified

attributes. Pay particular attention to pavers, which are variable in width, toensure that spreading and compacting components extend for the full width ofthe traffic areas lane to be paved

8 Examine rollers to determine whether they have the specified attributes. Ensurethat the specified number of rollers is available as decided during the trialcompaction. Check frequency of vibratory rollers to assure 30-40 impacts permeter with a tachometer. Whether a rubber tyre roller is used, verify themanufacturers recommended contact pressure

9 Ensure that all equipments required for checking bitumen content/density areavailable. Check for all hand equipments like, lutes, rakes and shovels

S.No DURING LAYING Checked

Item

1 Record measurements of air, surface and asphaltic mix temperatures. Cool airblowing can reduce the temperatures of the mix. A cold surface can suck heatout the mix extremely fast. This will be critical when the lift thickness is thin

2 Observe spreading:a) Check equipment being used to ensure it meets specificationsb) Monitor thickness and observe that the road/lane width is being metc) Record number of layersd) Check spread rate against theoretical ratee) Ensure that longitudinal joints are offset as specifiedf) Check whether the conveyor is exposed to make sure that material is on

the hopper conveyor at all timesg) Check whether paver hopper is near full at all times. Check flow gates

and augurs. Paver wings should not be dumped as large aggregatesaccumulate in the wings. Waste it at the end of the day

3 Confirm that rolling pattern and compaction effort determined during the trialtest are being met. Check breakdown rolling has been accomplished before



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minimum temperature is reached.4 Obtain a sample of the completed mixture from the mat behind the paving

machine and test it for extraction, moisture, and sieve analysisIdentify the samples to indicate both the stationing where they were taken andthe approximate area they represent.Analyze the test data at the earliest possible time. It is preferable that samplesrepresenting drier - drums or continuous mixing be tested in the field, in orderthat immediate corrective action can be taken for any deviations.For determining the uniformity of the mixture as placed - consider tests from themat at longitudinal intervals and not at transverse.For determining mixer efficiency - consider taking samples from the pug mill ordischarge gates of batch plant or from the discharge chute of drum-mixer plant.

5 Check the rolling temperature of mix during laying shall be 1200C - 1600C. It isan extremely important factor in compaction. Rolling should begin in sequencesas soon as mat will support the weight of roller without picking up material onthe drum or unduly marking of shoving the mat. Check that rolling is done at ashigh a temperature as possible, because highest initial densities are achieved athigh temperature optimal for rolling

6 Check transverse and longitudinal joints are constructed properly. Observeconstructions at cold transverse joints to see specifications are being met

7 Observe that the segregation and visual pavement deformities are being avoidedor corrected

8 Ensure that smoothness of the surface is as specified record measurements9 Check the edge alignment of the material being placed. Check is should not be

thin or thick compared to lift thickness10 Ensure that defective areas have not developed. Check pavement for pooling of

asphalt, bleeding, ravelling, rock pockets, consistent colour etc

S.No DURING TRAIL COMPACTION Checked

Item1 Use a test trip. The use of a compaction test strip before the start of a project

will head off problems before they arise. It will also provide information to theroller operator to establish the:

a) Roller pattern and speedsb) Frequency and amplitude settingsc) Density specifications for jobd) Number of passes, vibratory or static

2 Testing shall be done on a test strip, which is similar in condition and nature tothat of the project highway. Preferably a short length of the project road itself istreated as test strip

3 Testing should begin with the roller set at its recommended amplitude. If theunit bounces, or moves sideways, reduce the amplitude setting. If it is obviousthat particles are being fractured, reduce the amplitude

4 It should be obvious that maximum amplitude should not be utilized whenbeginning to roll a thin lift



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5 The use of the test strip is an educated trial and error process to determine themost productive procedure for a particular project

6 Even if density requirements are set by using the marshal or kneadingcompactor a test strip will still permit the contractor to develop the rollingpatterns, type of compactor etc. to meet the specifications

S.No DURING ROLLING Checked

Item1 Check the fuel tanks are full and there will be no delay during the day2 Check the water supply, spray bars and nozzles. Any clogged nozzles need to be

cleaned out before work beings3 Check the engine oil, hydraulic tank Grease the machine and inspect the drums

for any dent4 If the rollers are to be stopped for any length of time, park at an angle on a cool

part of the mat. Parking on a warm mat will most likely leave an indentation thatwill not roll out

5 At the end of a pass, while reversing, turn the roller into a slight curve prior tostopping avoid leaving a transverse ridge across the mat

6 When using a vibratory roller, check whether it is operated at a speed that willprovide at least one drum impact or more per 2.5 cm of travel. Ripples mayresult if this is exceeded

7 Never allow to vibrate when the roller is stationary; use-automatic vibration cutoff

8 Check whether deceleration /acceleration is being done smoothly while reversingdirection to avoid pushing or shoving the mat

9 Sharp turns shall be avoided otherwise it will cut the mat



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CHECKLIST No.11

TYPICAL CORRECTIVE ACTION PLAN FOR BITUMINIOUS LAYERS PLACEMENT

Test Item Corrective Action

Bitumen ContentIf test results are outside tolerance (±0.3% of specified or required) animmediate investigation will be conducted to determine the cause.Corrections will be made and material will be tested immediately toensure that the correction has been effective.

Aggregate

Gradation

If test results are outside tolerance an immediate investigation will beconducted to determine the cause. Corrections will be made tostockpiles, bins, bells or scales and material will be tested immediatelyto assure that the correction has been effective.

AggregateMoisture

When individual or composite aggregate moisture values differ fromthose of the plant computer, the plant computer will be adjusted toreflect the most recent aggregate moisture.

Asphalt

Temperature

If the asphalt temperature exceeds the permissible ranges (120°C to160°C) the plant operator will immediately take corrective action toraise or lower the temperature as required. Temperature will be closelymonitored to verify that the corrections were adequate.

Mix Temperaturein the Hot

Mix Plant

If the mix temperature exceeds 160°C the plant operator willimmediately take corrective action to lower the temperature as needed.Temperature will be closely monitored to verify that the correction wasadequate. Asphalt concrete- that exceeds 160°C shall not be used inthe work and shall be disposed off suitably.

Mix Moisture

If the mix moisture exceeds 1%, the plant operator will note themoisture content and corrective action will be taken to reduce themoisture in the mix. Aggregate piles may be spread to dry, aggregatetime in the heater may be increased, etc.

Sub-gradePreparation

If inspection indicates that the sub-grade is not prepared as specified,and as required, immediate action will be taken. Sub grade problemswill be corrected-dried, cleaned, compacted, graded, etc. Asphaltconcrete will not be placed until the corrections have been made andthe Engineer has inspected and approved.



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Prime/Tack Coat

If inspection indicates that the prime or tack coat material orapplication arc not in accordance with the specifications immediatelyaction will be taken,. Prime coat will be re-applied, changed, time for“break” will be lengthened, etc. Bituminous layer will not be placeduntil the corrections have been made and the Engineer has inspectedand approved.

AmbientTemperature

If physical measurements indicate that the ambient temperature isless than specified (13"C), the paving foreman will be notified andplacement will cease as soon as safety concerns have been providedfor.

Mix Temperature

at the Time of

Laying

If physical measurements indicate that the mix temperature is belowthe temperature, which the paving foreman has requested forplacement and breakdown, corrective action will be takenimmediately. Cool mix will be returned to the plant, the operation willbe changed to correct the situation which is causing the problem, andBituminous mix will be held in covered trucks and not windroweduntil necessary.

In-place Density

If field density determination indicates that the bituminous layer isnot being placed to a minimum relative density (if specified),immediate action will be taken. Roller operations will be investigatedand may be changed, plant will be notified and mix quality will beexamined, temperature will be determined, etc. Density will be testedimmediately following the corrective action to assure that the actionhas been effective.



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CHECKLIST No.12

CHECK LIST FOR TEMPORARY DIVERSIONS

S.No PRE – CONSTRUCTION STAGE CheckedItem

FORMATION1 Check drawings and specifications given in the contract. If site conditions and

estimated period of use so dictate, recommend improvement2 Check alignment for gradients and curves. The alignment should be marked in

the same way as formation3 Carryout checks as given in Check list No. 1 and 24 The general provision laid out in Clause 112 of MOST (111 of MORD for Rural)

Specifications may be adhered to


WBM, PIPE CULVERTS AND SURFACE DRESSING1 Carryout all checks given in Check list No. 1 and 22 For WBM check the following:

a) Stone metal laid in correct thickness.b) Adequate compaction is done.c) Blindage spread evenly and adequately watered.

d) Surface re-rolled.3 For CD works carryout checks as per Check list No. 14 and 154 For surface dressing check the following :

• Surface cleaned and made dust free.

• Tack coat correctly applied as per specifications, uniformly and without anyuncovered gaps.

• Mixture spread evenly to required thickness and compacted. Test compactionby field density test.

• Manila ropes or wooden markers laid on edges to improve compaction.

• Seal coat applied if provided for


Item1 Check dimensions of completed work2 Check periodic maintenance earned out



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CHECKLIST No.13

CHECK LIST FOR ROAD FURNITURE

S.No FENCES CheckedItem

1 Review the plans, special provisions and right of way agreements for any specialdetails

2 Compare the planned location with actual conditions in the field to ensure thatfences, gates, openings etc will serve the purpose, as intended

3 Fences should not obstruct flow in streams or drainage areas4 Check that the areas in which fences are to be placed are graded and that high

points, which interfere with placing of wire mesh are excavated5 Examine the fence material so that it satisfies requirements6 Observe the placing of fence posts and measure the spacing. Observe the

placement of corner posts and pull posts to ensure that they are placed atrequired locations and in accordance with specified details. Also check that theproper type and number of brace posts and diagonal wires are used

7 The barbed wire mesh is placed on the property owner’s side. For chain linkfence, the fabric is generally placed on the highway side

8 Ensure that fencing is snubbed or guyed at all grade depressions as specified

S.No MARKERS AND DELINEATORS CheckedItem

1 Review the list of markers and delineators shown on the plans2 Examine the markers and delineators to ensure that they are as specified.

Required certificates of compliance shall be obtained from quality controlinspectors

3 Observe the installation to ensure that it is performed as specified. Checkinstallation of target plates and ensure washers are used and that the nuts arenot tightened to the extent that the enamel is cracked

S.No Item CheckedRAILINGS AND BARRIERS GENERA

1 Make a careful review of the required details. Review the locations in the field.2 Review the stakes and layout work. Ascertain the offsets and flares are as per

the plans

S.No Item CheckedMETAL BEAM GAURD RAILING

1 Measure woods posts or concrete posts, they should satisfy the standards2 Ensure that bolt holes in treated posts are filled with grease when required3 Observe backfilling of post holes to see that this is performed as specified. Posts

should be set to the full depth shown on the plans4 Measure the spacing of posts and ensure they are as per specifications



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5 Ensure that the blocks for metal beam guard railing are toe nailed to timberposts and properly fixed with nuts and bolls on the concrete posts

6 Ensure that rail elements are lapped so that the exposed ends will not faceapproaching traffic. Check bolts for tightness

7 Measure the height of the railing or barriers above the ground to ensure that itis as shown on the plans

8 Ensure that connections to bridge railings, retaining walls, abutments or otherflat surfaces are made as specified

9 Ensure that anchor assemblies are constructed as specified. Cable clips shouldbe installed in the proper directions and tightened to the required torque

10 Where posts are installed in loose soil or near the edge of embankments, it maybe necessary to use longer posts

11 Concrete anchors and footings must be built according to the dimensions shownon the plans. Check holes immediately prior to placing concrete

12 Bolts must be long enough so that nuts are threaded completely into the bolt.Be sure that no more than 12mm of bolt is exposed on the traffic side of the rail

13 Ensure that flares are constructed as per the plans

S.No CONCRETE BARRIERS Checked

Item

1Check that no concrete barriers or railing is placed on new structures until thefalse work is released

2Review the provisions for closing the temporary gaps in barriers duringconstruction

3 Check the forms whether they conform to the guidelines and specifications

4When extrusion or slip form machineries are used in concrete barrierconstruction, inspect the grade upon which the machine will ride to determine ifit is smooth enough to prevent foreseeable violations of specified tolerances

5Check the relevant specifications and check lists for producing, placing, finishingand curing cement concrete to be used

6Equipment and concrete design should be such, in extended or slip form barrierplacement, that no hand finishing other than the light brush finish is required. Itis desirable to have the traffic face surface of the barrier as smooth as possible

S.No PIPE HAND RAILING Checked

item

1 Determine that materials and methods used in anchorage and connections areas specified and as shown in the drawings

2 Ensure that cables, chain link fabric and tension wires are connected properly,stretched and tightened as required

3 Check railings for proper alignment, appearance and workmanship



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S.No LANE MARKINGS Checked

Item

1 Review the signing and marking plans, any special requirements and otherstandard details

2 Inspect the equipment for specification compliance. Determine methods forchecking spread rates of paint and glass beads, application temperatures ofthermo plastic materials and maximum temperature of paint

3 Check pavement temperature prior to application of thermoplastic material.Check atmospheric temperature and conditions prior to applying paint

4 Check condition of the pavement prior to application. The pavement should bedry and clean

5 Check whether the stencils will produce correctly dimensioned pavementmarkings

6 Check the layout work. Determine whether the pavement markings will becorrectly located

7 Ensure that the thermoplastic material is placed within the correct temperaturerange. Thermoplastic material heated to excessive temperatures can flash andsplatter when exposed to air. Temperature gauges mounted on heatingequipment should be checked for accuracy

8 Check the lane stripe for correct width and edge definition, lengths of gaps andindividual stripes, alignment and correct super imposition of second coats

9 Any drips, over spray, improper markings, and material tracked by traffic shallbe removed

10 Check applied thermoplastic material for compliance with thickness requirements11 Check application rates for glass beads and paint.12 Check thermoplastic markings for workmanship as they are applied. Bumps

resulting from overlaps in extruded materials should not be permitted



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CHECKLIST No.14

CHECK LIST FOR PIPE CULVERTS

The works can be of two types, extension or new construction. In the case of pipe culverts themark out, excavation, bedding and placing of the pipes are most important and any mistake inthese activities cannot be corrected except by complete removal and reconstruction.


1 Test the soil and see if the safe bearing capacity matches design value. Properbedding shall be provided below the pipes as per section 1100 of MORDspecifications for rural roads and as per section 2900 of MORT&H StandardSpecifications for MDRs, SHs and NHs.

2 Pipes shall be tested in accordance with IS: 458 (Concrete pipes with andwithout reinforcement) for the relevant clauses like NP3 and NP4

3 Check for the identification marks left on the pipes while inspection and testingof pipes were carried out in the manufacturing plant

4 Check for any cracks in the pipes, which might have been caused duringtransportation or loading and unloading


ItemEXCAVATIONThe excavation should be as per drawings but the following should be checked :

1 The length of excavation caters for the number of pipes plus the spacing ofpipes, which should be half the diameter of the pipes but not less than 45cms

2 The depth of excavation should cater for the following :Cushion above pipe of minimum 600mm of half the dia. or the pipe includingpavements.If the required cushion is not available due to low embankment embed the pipein concrete. A minimum of 200mm thick PCC or 150mm RCC all round the pipeshall be provided. The grade of concrete should be as per table 5 of IS-456:2000Granular/concrete bedding and foundation depending upon the height ofembankment as per relevant IRC clauses, if necessary.1/3 of pipe dia or 300mm will be buried below nala bed to prevent scour.

3 The distances between trenches for foundation of headwalls are such that itsuits the proposed pipe lengths.

S.No Foundation and Bedding Checked

Item

1 Check excavation is correct.2 Check mix proportion of PCC is as specified.3 Check thickness and material of bedding is as specified.4 Check cradles are provided for resting of pipe joints.



with

5 Check length of pipe is same as the distance between the outer surfaces of theheadwalls.

6 Check proper foundation in case of Black Cotton/Soft soil and concrete beddingin case of rocky strata is provided.

S.No Placing of pipes CheckedItem

1 Check spacing between pipes is not less than 1/2 dia. of pipe or 50 cms,whichever is more.

2 Check pipes do not protrude beyond the headwalls.3 Check cross slope of pipes is as per design.4 Check joints of pipes properly done using collars or other methods as per

specifications. Joints shall be sealed with mortar, rubber gaskets or other sealingmaterials.

5 Check pipe joints properly cradled. Joints shall be kept covered and damp for atleast 4 days.

S.No Head walls CheckedItem

1 Check headwall foundation is as per drawing.2 Check headwall constructed as per design. If the same is of un-course rubble

ensures headers are used.3 UCR masonry cannot be constructed properly to have a watertight joint at outer

surface of pipe at headwalls. In that case the pipes should be encased in M20grade Concrete as per Table 5 of IS 456:200 near the headwalls to preventfloodwater from entering around the pipes.

4 Ensure curing for 7 days.

S.No Filling earth over Pipes CheckedItem

1 Ensure the culvert is filled with approved earth in layers not more than 30cms,watered and compacted.

2 Ensure filling material free of boulders and black cotton or other unsuitable soils.3 Initial compaction should be done manually.4 Rolling to be done only after 30cm of earth has been laid over the pipes.

General

In general embankment is formed to the full height as required in the profile and plan drawings.Then the pipe culverts are marked and excavated for pipe laying. The formed embankment is cut toslope, preferably not steeper than 3(Horizontal):1(Vertical) on the either side of the embankment tothe proposed pipe foundation ensuring base width of 750mm on either side of pipe at thefoundation level and, there after, to cut serrations/benches in the slope duly moistened and thenearth fill be placed in layers and compacted. This will ensure better compacted embankment oneither side of the pipes. In case pipes are laid before embankment is constructed, the portionbetween the pipe rows and for a width of 0.6 to 0.75m on either side of the pipe shall be backfilledwith coarse granular materials and rolled along with earthwork.



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CHECKLIST No.15

CHECKLIST FOR SLAB CULVERTS AND BRIDGES

S.No PRE CONSTRUCTION STAGE Checked

Item

FOUNDATION

1 Confirm line out and position of abutments2 Confirm sub-soil investigation has been carried out up to 3m below design

foundation depth and design assumptions match actual site conditions

a. Soil Investigation for foundation: IS: 1498, IS: 1888, IS: 1892, IS: 2131,IS: 2720, IS: 4434, IS: 1968 and IRC: 75

b. Foundations resting on Rock: IS: 5313, IS: 4464, IS: 7292, IS: 7317 andIS: 7746 for in-situ tests

3 Check drawings are available at site4 Check materials like aggregate, sand, cement, HYSD bars have been tested as

per Agreement specifications and test results are satisfactory5 Check adequate numbers of moulds are available for taking CC cubes for testing6 Check curing arrangements are adequate. In case, moist curing with water is to

be done, ensure availability of water, water gun, availability of sacks/ hessiancloth rolls for covering the exposed surfaces of concrete and spraying water tokeep these continuously wet for 14 days. In case, curing is to be done withmembrane forming curing compound, ensure availability of approved qualitycuring compound conforming to ASTM-C-309-81 Type-II with test certificatesand availability of mixing drum and power spray nozzle.

7 Check the required compressive strength of concrete for various items and mixdesigns are available

8 Check equipment and plant like weigh-batching machines, concrete mixers,water measuring arrangements, Vibrators etc. are available

9 Check quality control equipment like slump cones are available10 Check whether the area to be concreted is free from standing water. The area

shall be properly dewatered and kept clean before concreting11 If underwater concreting is to be done, ensure that the same is done through

termite pipes, or drop bottom buckets or any other approved methods12 Before concreting check the weather. If extreme weather concreting is to be

done, ensure necessary precautionary methods as stipulated in thespecifications. No concreting shall be done if the atmospheric temperature isabove 35°C or below 5°C. The temperature of wet concrete should be less than40°C and all necessary steps to control the concrete temperature particularlyduring hot weather concreting.

13 Ensure that proper platforms or pathways are laid for movement of people inand around the concreting area and they are sound and safe



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Item

1 Check and strictly ensure production of design mix concrete with theproportioning of cement, sand, and coarse aggregate in the concrete mixer byweight, measured addition of water by volume / weight, and addition ofadmixture, if specified, by volume / weight, duly adhering to the specified water-cement (W/C) ratio; mixing in mechanical mixer / batching plant to obtaincohesive mix of uniform colour & consistency; and the measurement as well asrecording of slump of concrete mix corresponding to W/C ratio.

2 Check the load tickets if concrete is delivered through transit mixers or agitators.Check and record slump of concrete at the production and delivery point. Theloss of slump should not be more than 25 mm.

3 Check that no additional water added during hauling or at delivery point withoutprior instructions. If additional quantity of water in the mix has to be added toovercome the difficulties of placement and compaction, the cement contentshould also be proportionally increased so that the water-cement (W/C) ratio asspecified is not exceeded

4 Check that the transported concrete is not segregated and contains no cementballs

5 Ensure that concrete is placed while fresh and before it has taken an initial set.Ensure that stiffening of concrete has not taken place in case of transportedconcrete

6 Observe the method of placing of concrete and ensure concrete to place withoutany segregation and it is being compacted by specified vibrators

7 Check that no over vibration takes place. Concrete shall be vibrated to the pointwhere mortar and water flush to the surface. Under vibration will leave rockpockets contact between the vibrator and any reinforcement should beminimum, if possible avoid such contacts

8 If concreting is done through chutes, ensure that segregation of mortar andaggregate does not take place. In case the drop height is more, a remixing ofconcrete shall be done before placing

9 Ensure that the drop of concrete shall not be more than 1.5 meters (as persection 1709).

10 In case of underwater concreting, ensure that extra 10% cement is added in themix over and above the required cement quantity as decided in the mix design.

11 If any use of admixtures is allowed, check whether they are being mixed as perthe specifications or approvals.

12 If concrete is pumped, ensure that approved type of pump is being used. Ensurethat no segregation takes place in pipes. Ensure that a continuous pumping isdone. In case of frequent stoppages, the pumps are to be cleaned properlyotherwise, the pumped material will remain in the pipelines. In that casecleaning will be very tedious concreting operation may have to be stopped tillthe pump and pipelines are cleaned

13 Ensure adequate CC cubes collected for testing, as per Cl.1716.2.



with


Item

1 Ensure curing earned out for 14 days2 Ensure CC cubes tested for 7 days and 28 days strength. In case of M: 35

concrete 56 and 90 days strengths must also be determined and foundsatisfactory.

S.No PRE CONSTRUCTION STAGE Checked

ItemABUTMENTS, PIERS AND SLABSIn addition to the pre-construction checks for foundation, the followingadditional checks will be carried out:

1 Formwork is of desired quality and rigidly fixed. Special care is required to betaken for second and subsequent lifts to avoid bulging and honeycombing atjunction of lifts

2 Confirm reinforcement is correctly tied as per drawings ensuring specified coverfor reinforcement is strictly maintained through provision of adequate number ofcover blocks / spacers / concrete chairs / supporting bars etc.

3 Approved type of vibrators are available and in working condition


1 Check slab thickness, wall thickness and the area to be concreted is clean fromforeign materials

2 Ensure mix design is followed.3 Carry out workability tests such as slump test to ensure correct water cement

ratio4 Ensure approved type of vibrators is used.5 In case of abutments and wing walls ensure weep holes are provided at specific

horizontal and vertical spacing6 Check the surface, in case of slab with straight edge. Remove any depressions

and irregularities7 Ensure adequate CC cubes (as per Table 1700.8) collected for testing8 Ensure that water is not used as a finishing aid. If approved, use approved

chemical finishing aids or evaporation retardants9 During placing of concrete, check for any movement or deformation of forms

have the permissible tolerance limits.10 Ensure that required cover for reinforcement is maintained and not disturbed

while placing concrete.



with


Item

1 Ensure date of casting painted on surface as soon as side forms are removed2 Ensure curing carried out for not less than 14 days.3 Ensure that the formwork/false work is removed after stipulated time.4 Ensure CC cubes tested as per laid down norms and the results are satisfactory.

S.No APPROACHES TO CULVERT/ BRIDGE CheckedItem

1 Ensure soil used for back filling is of approved material2 Ensure embankment built, up in layers of 30 cm compacted to 20cms. Test

compaction of each layer by field density test. 98% compaction is necessary.3 Ensure invert filters are provided at weep holes.

PROTECTIVE WORKS:

All checks as listed at Check list 2 will be carried out. If additional protective works likeaprons or flood protection bunds have been provided for in the designs, it will be verifiedthat these are constructed as per drawings and specifications.



with

CHECKLIST No.16

CHECKLIST FOR REINFORCEMENT INSPECTION

S.NO ITEM CHECKEDYES NO NA

1 Working drawing checked and approved

2 Latest revision being used

3 Bar bending schedules approved

4 Reinforcement steel material approved

5 Bar bending and cutting satisfactory

6 Formwork member spacing correct

7 ‘Corrosion treatment of bars is done by giving a coating

of cement - water slurry’ (cement wash). This is

necessary to protect the reinforcement from exposure to

highly saline atmosphere during storage, fabrication, and

use.

8 Bar sizes correct

9 Bar lap lengths correct

10 Bar laps at correct locations

11 Bar tied as specified (check proper quality binding wires are

used)

12 Bar assemblyrigid and adequately supported

(Including spacers/chair supports)

13 Cover to bottom bars correct

14 Cover to side bars correct

15 Cover to top bars correct

16 Cover blocks approved including fixing



with

CHECKLIST No.17

CHECKLIST FOR FORMWORK INSPECTION


1 Formwork design/drawing/sketch approved includingde-shuttering arrangements

2 Trial panel approved (if required)3 Formwork alignment correct4 Formwork levels correct, including screeds5 Formwork dimensions correct6 Formwork member spacing correct7 Formwork member material quality acceptable8 False work member sizes correct9 False work member spacing correct

10 False work member material quality acceptable11 Gaps between primary and secondary members

closed/wedged.12 Face boarding/plywood/metal thickness correct13 Joints between panels closed (no gaps)14 Joints between panels flush (no steps/lips)15 Panel flatness acceptable16 Gaps between secondary members and face17 panels closed18 Tie rod material and sizes correct19 Tie rod spacing correct19. Tie rods tight, face cones

flush20 Spacers between shutter surface tightly fitting21 Box outs, cast-in-items, ducts fixed correct, securely22 Pre-stressing sheathing and vents, alignments and

spacing of supports acceptable23 Empty sheathing secured against floatation24 Pre-stressing anchorage positions and fixing acceptable25 Chamfers/fillets sizes, straightness, fixing acceptable26 Formwork clean27 Formwork release oil material approved28 Form work release oil [Material applied correctly29 Construction joint preparation satisfactory30 Safe access constructed31 Adequate workspace provided for labour, equipment32 Shutter vibrator (if required) location and fixing

arrangements approved



with

CHECKLIST No.18

CHECKLIST FOR INSPECTION BEFORE APPROVAL TO CONCRETE


1 Method statement approved

2 Batching plant mixers in working order

(Separate dispenser for admixture, if required,

available)

3 Standby batcher in working order

4 Water, sand, coarse aggregate, cement, and admixture

approved

5 Water, sand, coarse aggregate, admixture, cement

Stock sufficient

6 Concrete conveying arrangement (including transit

mixers) available in working condition and of sufficient

capacity

7 Formwork/scaffolding approved

8 Reinforcement approved

9 Pre-stressing sheathing approved

10 Concreting equipment in working order

11 Standby crane, vibrators present

12 Tremie in working order (for under water work)

13 Concrete gang present, including carpenter, steel fixer,

mechanics and electricians

14 Access like walkways are provided

15 Safety arrangements adequate

16 Lighting provided

17 Communication between various points provided

18 Arrangements for arranging suspension/stoppage of

concrete provided

19 Curing arrangements made

20 Laboratory notified



with

CHECKLIST No.19

CHECKLIST FOR BATCHING AND POURING OF CONCRETE

S.No CONCRETE MIXING CheckedItem

1 Check the concrete grade and the respective mix Design already approved.2 Check the condition of aggregates to be used3 Check the weighing and water dispensing methods adopted during the mixing4 Check whether the mixer machine has been cleaned properly5 Check whether required mixing time is allowed.

S.No TRANSPORTATION/CONVEYANCE OF CONCRETE CheckedItem

1 Check whether the equipment is in proper working order.2 Check whether specified methods are being followed.3 Check whether the stipulated time limits are observed.4 Check whether non-conforming wet concrete is being rejected and disposed off.

S.No PLACING OF CONCRETE CheckedItem

1 Check whether the concrete is not segregated during pour. The height ofdropping is controlled. It should not exceed 1.5m.

2 Check whether the concrete is poured in layers of about 300 mm3 Check that the vibrator is applied systematically to compact uniformly and

adequately.4 Avoid over vibration.5 Concrete shall not be pulled or pushed. Pouring should be done close to the final

position6 Cold joints are not allowed to be developed7 Under water concrete shall be poured only by termites or pipeline.8 The forms are not displaced or deformed during the concrete pour and vibration9 No slurry loss. Suitable no. of carpenters should be present and watch formwork

during the pour10 The concrete is poured within the allowable time limits from the time of batching11 Concrete cubes are taken as required as per table 1700.8 of MORT&H(table

800.10 of MORD for rural) Check the curing arrangements whether they aresatisfactory



with

CHECKLIST No.20

Check list for Post Concreting Inspection

LOCATION:

Date of:

Date of pour: Date of side shutter stripped:

Curing: Method Class of finish specified:

Start Date: Finish Date:

Curing: Whether properly done as specified and curing register maintained.

1. Class of Finish:

2. Surface Defects :

(Honeycombing/sand No defectsStreaks/air bubbles/cold Minordefects joints) Major effects

Non Conformance Report No . Date:

3. Cracks: No cracks:

Cracks:

Nature of Cracks:

4. Any Other Defects:

5. If Cracking Noticed:

6. Position/Dimensions: Alignment S or NS

Levels S or NS

Dimension S or NS

- Non Conformance report No :

NS = Not Satisfactory, * S = Satisfactory

Inspected by Signed Date

(for Executing Agency)

Approved by Signed Date



with

CHECKLISTS FOR CONSTRUCTION OF CYCLONE SHELTERS

CHECKLIST No.21

S.No Check list for Excavation Checked

Item1 After closing of the traverse, survey lines shall be plotted 2 m away from the main

building line for reference work.

2 Theodolite shall be fixed on the survey point available on the grid of the building.

3 Opposite point of the peg shall be bisected.

4 One point shall be fixed at distance given in the drawings for footing. The same process

shall be done for the other side of the footing.

5 Lay out, alignment & size of the excavation pit shall be marked on the ground as per

drawing by considering 300 mm working space.

6 Diagonal of the footing shall be verified before starting of excavation.

7 Excavation shall be started after finalizing disposition place.

8 Excavation shall be done mechanically.

9 Depth of excavation shall be checked frequently by using level machine as given in the

drawing.

10 Side slope of the excavation pit shall be checked for safety point of view.

11 After getting sufficient depth, the same shall be verified & surface shall be dressed by

employing labours.

CHECKLIST No.22

S.No Anti termite treatment Checked

Item1 Proper dressing of the excavation pit shall be done. It shall be free from loose earth.

2 The bottom surface of the footing shall be rodded or channelling as given in the drawing.

3 Product for the anti termite treatment shall be approved in advance.

4 Check concentration of chemical emulsion before using.

5 Preparation of solution shall be done as per manufacturers specification & based on the

area to be treated at required rate of application.

6 Check that spraying equipments are in working condition.

7 The bottom surface and the sides (up to height of 300 mm) of the excavation made for

foundation shall be treated with chemical at the rate of 5litre per square meter surface

area.

8 Check for rate of application of the chemical emulsion.



with

CHECKLIST No.23

S.No Rubber soling Checked

Item1 The rubber should be hard, durable and free from other defects. The rubber should be of

suitable size and shape to give the required compacted thickness.2 The rubber is laid in vertical position of the sub-grade but closely packed by arranging the

stones.3 The filling of the interstices shall be done with quarry spawls / metal simultaneously with

the placing of the rubber.4 Ramming near the walls and column shall be done properly to the required level / slope,

camber etc.5 Compaction must be carried out with 3 tonne static roller.6 The finishing of the surface shall be done by trimming to required level / slope as per

requirement.

CHECKLIST No.24

S.No Plain Concrete. Checked

Item1 Carry out the study of the grade of concrete for PCC.

2 It shall be verified before starting PCC for sufficient availability of material, manpower &

machines3 Formwork & dimension for Plain concrete work shall be checked as per drawings.4 Mix proportion shall be displayed on the weight batcher & the same shall be

implemented.5 Mix for the PCC shall be laid on the surface at required thickness.6 Compaction of the concrete shall be done by using Rammer till expulsion of the air is from

the concrete is stopped.7 Carry out finishing at required thickness.

8 After 24 hours formwork of the concrete shall be removed.9 Curing shall be done sufficient period.



with

CHECKLIST No.25

S.No Shuttering: Checked

Item1 Use formwork, which is rigid and closely fitted, with sufficient strength to support wet

concrete.2 Ensure that centring plates, plants, planks or plywood are properly cleaned.3 Take care to apply suitable form release agent after proper cleaning of formwork, before

placing reinforcement.4 Ensure proper check for line, level and plumb before starting concreting activity.5 Shuttering to be checked in stage wise. i.e. as per the approved shuttering scheme 1st

– beam bottom – alignment and level and rigidity of staging to take the load. 2nd – Beam

sides.

3rd – slab shuttering and levels.

IV th – Fixing of side supports, bhida, etc. for rigidity.6 Special care should be taken to check column caps supports at junction of beams.

7 Pockets, insert to be carefully placed and check before placing concrete. Fixing of pockets

and inserts should be rigid to avoid displacement during concreting.

8 Use of Magic tape for gap filling.9 Provide extra supports at joints of wall plates beam bottom. Proper care must be taken to

prevent building if centring.10 Leave slab formwork undisturbed till concrete gains 70 % of required strength.11 Take care not to damage the concrete while striking the centring off.12 time period for removal of shuttering should be as detailed below:

a) Walls, columns and vertical side of beams - 16 to 24 hours

b) Slab - 3 Days

c) Beam soffits (props left under) - 7 days

d) Removal of props under the slab

– Spanning up to 4.5 m - 7 days

- Spanning more than 4.5 m - 14 days

e) Removal of Props under beams and arches

-Spanning under 6 m - 14 days - 14 days

- Spanning over 6 m - 21 days - 21 days

After deshuttering all the materials should be properly stacked and cleaned for next

repetition.



with

CHECKLIST No.26

S.No Reinforcement: Checked

Item1 Ensure that reinforcement bars are clean free from grease. Oil, paint, rust, dust or any

other objectionable foreign material.2 Ensure that all the reinforcement rods are thoroughly cleaned before fabrication, pitted

and defective rods are rejected.3 Ensure that straightening of bars is done without damaging the configuration, cutting,

bending should be as per Bar bending schedule (B.B.S)4 Ensure that the vertical distance between the successive layer of bars in beams or other

members are maintained by providing mild steel spacer sat required interval.5 Check reinforcement for size, spacing, location, numbers, overlaps, welding joints, hooks,

bent ups, rusting, greasing and ties as per drawings and bar bending schedule.6 Ensure staged overlaps, cold bending and anchorage, wherever necessary.7 Ensure that the reinforcement is kept in position by ghodies, chairs etc. during placing

and compaction of concrete.8 Ensure proper placement of cover blocks, embedded inserts and cut outs if any.9 Ensure that car ladders are provided on the reinforcement to avoid displacement of

reinforcement.10 ensure that before placing the concrete, the reinforcement is checked for bent up bars,

lap length, hooks, rings and distribution bars etc.11 Ensure proper binding of reinforcement.12 Ensure that the lap joints of bars are staged in about 40 % to 50 % in column, walls, etc. or

as specified.



with

CHECKLIST No.27

S.No Brick work : Checked

Item1 Ensure to have information regarding specification of cement mortar.2 Soak the bricks before starting the brick work.3 Mixing of mortar must be done properly and thoroughly with specified proportion of

ingredients on an impervious platform.4 Keep the frog up, while placing the brick.5 Fill the joints between the bricks properly. Ensure to carry out “RADO” at every 4th layer.

Supervise line, level and plumb from time to time during the day’s progress6 The joints must be raked to an average depth of 10 mm when mortar is green. If plaster

or pointing is not to be done, the joints should be struck flush.7 Proper hacking of RCC surface in contact with brick masonry must be done for proper

bond.8 Courses must be truly horizontal with suitable bond pattern to break the vertical joints.9 Suitable toothing or grooves or stepping to be provided for continuation of brick work10 Thickness of joint must be uniform and not more than 13mm min11 Disallow vertical joint filling by spreading mortar12 Masonry may raised up to 150 cm in a day. Raising with all connected brick work be

carried out at one level13 For 230 mm thick wall, maintain one face in line. This face can be pre planned to take all

kinds of single coat plasters. For higher thickness walls both faces should be in line14 First mark up layer of brick work needs to be laid in direct supervision for door / window /

any other opening to be kept accurately as per the drawings or layout15 Curing must be done for at least seven days or as laid down in specification

CHECKLIST No.28

S.No Solid Block Masonry: Checked

Item1 All block shall be soaked in advance prier to starting the work

2 All block work shall be plumb, square and properly bonded. The sides of block shall not bebroken

3 The thickness of courses shall be uniform with courses horizontal4 All connected work shall be carried out at nearly one level and no portion of the work

shall be left more than one course lower than the adjacent work5 Blocks shall be so laid that all joints are well filled with mortar as specified in specification.

The thickness of joints shall as per specifications6 The face joints shall be raked to a minimum depth of 10 mm by raking tools daily during

the progress of work when the mortar is still green, so as to provide a proper key for theplaster or pointing. When plastering or pointing is not required, the joints shall be struckflush.



with

CHECKLIST No.29

S.No Plasterwork: Checked

Item1 The type of plaster, number of coats, thickness required and cement mortar proportion

shall be as per specifications2 Ensure to water the brick wall properly start of plastering3 Ensure that the measurement box is ready for usage prier to start of work shall be done4 Deep and close hacking of the R.S.C surface for purpose of plastering must be done5 Chicken mesh at brick wall and R.C.C member must be provided6 Select suitable sand for different type of plasters7 Ensure that proper dry mixing of cement and sand is done on impervious platform8 Holes provided for scaffolding while executing brick work must be plugged or double

scaffolding must be used9 Level marking must be done in advance (Plaster thiya). Supervise line, level and plumb

from time before plaster starts setting.10 All the necessary tools required for execution of work available with the mason11 Watch the plaster line, level and plumb. Chip off concrete surface before starting plaster

and provide suitable groove12 Gaps around door and window frames must be filled properly13 Check the best coat of plaster prier to application of finishing coat of neeru, sagol or

cement14 While executing final coat of sand faced plaster or aggregate plaster due care must be

taken as to while the joints are to be provided at the end of day’s work

CHECKLIST No.30

S.No Doors / Windows: Checked

Item1 Ensure that wood used for the works is as per quality specified

2 BOQ of wood sizes should give adequate allowance for cutting and smoothening. BOQneeds to be double checked with carpenters before ordering

3 Only approved fixtures to be used4 Check whether verticals of door frames are minimum 50 mm below finished floor level5 With bottom spacer patti fixed, surface of window / door frame coming contract with

brick work / concrete needs to be painted with the material specified before fixing of theframe

6 The frame hold fast must be grouted with cement mortar rigidly7 Ensure that the glass is free from waves, bubbles and other defects. Check the thickness

of glass before fixing8 Check that doors / windows frames are erected in plumb, line, level and diagonals9 Ensure that the work of painting / oiling is started after approval of completed wood work10 Glazing must be fixed with out play with suitable wooden beading



with

CHECKLIST No.31

S.No Doors / Windows (Aluminium) Checked

Item1 Aluminium section shall be as per the sectional drawings provide or as specified in the

items. Each member of the D/W shall be well defined for its size, shape, and weight per

metre, profile and finished surface2 Fabricator shall be get fabrication drawings before starting the work3 Aluminium sections shall be defined for manufacturers like, Indal, Jindal, Hindalco or

equivalent4 Aluminium sections to be used for fabrication shall be well defined for anodizing (Matt

finish or Glossy finish), natural or color anodizing, section with powder coating in different

color etc5 Aluminium doors and windows shall be specified for panel material like Glass / Laminated

boards/ Box type aluminium lamination etc6 Only approved hardware fixtures shall be used as per specified and tender items7 Finished opening sizes should match perfectly with prefabricated D/W sizes. To ensure

about the exact dimensions, make up sample or templates (either from wood material

or M.S. material) shall be used8 In case, a dimension doesn’t match with the material supplied, openings shall be

rectified9 Arrangement for all approved hardware fitting as per the drawing shall be ensured before

fixing of the material10 Glazing shall be fixed to the extruded sections by means of extruded aluminium beading,

Glass panes shall be provided with rubber lining before fixing11 The aluminium frames shall be fixed to the masonry by means of aluminium lugs fixed to

the frame (by counter sunk galvanized machines screws) and the hole / pocket will be

grouted with M – 15 grade concrete as per drawing. In case of concrete wall, the frames

shall be fixed by 96 mm long, 12 mm dia metallic fasteners. Any steel material coming in

contact with aluminium shall be galvanized12 The windows / ventilators / doors shall be checked ensure smooth operation, perfect

level and plumb13 All aluminium D/W section should have protective film or coating. This film or coating can

be removed only at the time of handing over (on completion of all civil works including

painting).



with

CHECKLIST No.32

S.No Polished Kota Stone flooring: Checked

Item1 Polished Kota stone shall be selected from quarry (source) where stone available is

uniform in shade, hard and homogenous in texture, lamination, stone shall be machinepolished at cource and of required size and thickness

2 FARMA shall be in true size and right angle (with zero tolerance)and should be approvedby the engineer

3 Average out the sizes, from the supply and make suitable FARMA4 Hand dressing OR machine cutting of the edges shall be channel with fine sand as per the

requirement. Hand dressed stones shall be grinded in suitable with fine sand for obtainingsharp, straight edges

5 Initial check shall be done for with color shade by washing the surface in yard itself, it befollowed by stack the finished stone with at least 3 different marks I/II/III. While layingdue care should be taken to use assorted stones in different rooms. By this way colorvariation shall be adjusted room / Area wise

6 All broken edges /corner stones to be suitably used7 Area shall be scrapped/cleaned/washed before starting the mortar bedding, after

finalizing flooring pattern8 Preparation of mortar to the required proportion is essential. The thiayas shall be made

to required level and slope well in advance. Laying of mortar to suitable thicknesskeeping reference thiayas line dori shall be supervised form time to time

9 Neat cement paste shall be spread over mortar bedding and around the edges of thestone. Then the stone shall be fixed close to the previous stone and shall have a hairlinejoint. Stone surface shall be pressed / tapped gently with the wooden mallets till thestone is in true line and level. Cement paste at the edges at the will try to come out fromjoints, which should be scrapped off. Again joints shall be filled up with neat cement pasteto fill up the gaps and surplus mortar removed. Suitable color pigment to be used for jointsealing to match with the stone color

10 Flooring shall continue at least 10 mm inside the wall plaster line11 Any irregularities (othas) due to natural bends in stones should be restricted to 2 mm at

joints12 Curing of flooring shall be carried out for 7 days by sprinkling water or by wetting13 Polishing activity to follow only after adequate curing the sequence of polishing will be as

undera) 1st cut with rough emery stone – 80 No. to polishing m/c (heavy) which should

even out all irregularities (othas) plus OR minus. Normal cut of 2 mm is achievedwith this emery. Floor shall be washed and ragada is removed to check the joints.All joints shall be regrouted with cement paste. Setting shall be allowed for atleast 2 days.

b) 2nd and 3rd cut with finer emery stone. – 120/220 no. Joint grouting shall beattended for every cut of polishing; Normally 1 mm cut is achieved. Surface isfairy in level and without any scratch or chakkar lines of the mat chining.

c) Final light coat of polishing shall be done with masala (Oxalic Acid) to achieve thescratch less finished surface. Light polishing coat shall continue till the acceptableresult is achieved.



with

CHECKLIST No.33

S.No Tremix Flooring: Checked

Item1 Initial suitable layout of construction joints and isolation joints shall be decided prier to

start Tremix flooring2 The surface of the guide channels (on which the surface vibrator is supported) shall be

cleaned from concrete. Align the guide channels to true required level, panel castinglayout shall be strictly followed as per step 1

3 Concrete shall be placed and distributed evenly and as near the final level as possible4 Concrete shall be placed and vibrated with an immersion vibrator in front of screed

vibrator. Heaping of concrete in front of screed vibrator will be avoided5 Ensure that the areas close to channels and stop ends are carefully vibrated. Ensure not

distribute the concrete with the poker vibrator as it would create a risk of over vibrationand segregation

6 Surface vibration should start as soon as there is enough concrete in front of the screedvibrator. Screed vibrator is to be pulled from both ends

7 The filler pads as soon as the sufficient concrete surface is vibrated. Vacuum wateringprocess must start within 30 minutes from the time of start of concrete pouring

8 The filter pads are placed in such a way that there is at least 100 mm (4”) fresh concretevisible around the filter pads on all four sides. Filter pads should be overlapped with eachother at least 250 mm (10”)

9 Suction pad must be rolled open over the filter pads and dewatering must then start.Extent of dewatering is related to thickness of floor concrete i.e. Average 4 min. per inchthickness OR physical check of dewatering surface which should not give foot print whilewalking to be seen. Excess /less dewatering not advisable

10 While repeating dewatering process subsequently, suction pad must be rolled out atleast 300 mm over the vacuum dewatered area. Before spreading the suction pad ondewatered area, it is essential to give one pass of skim floater (with the disc) along theedge of the dewatered concrete

11 The central pipe of the suction pad shall the suction hose, which in turn shall beconnected to the vacuum pump. When the pump is started, vacuum will be createdbetween the top cover and filters pads. Excess water from the concrete will be takeninto the vacuum pump tank and discharged through p pipe away from fresh panel

12 After Vacuum dewatering, scrapping operation shall be made diagonally in twodirection over the concrete surface

13 The concrete, which is collected during scrapping, shall be used for adjusting small surfaceirregularities of the vacuum treated surface

14 The first finishing operation shall be done by floating with the skim floater attached with adisc

15 The second finishing operation shall be trowelling with skim floater attached with thetrowelling blades. Normally, trowelling is to be continued till the smooth surface finish isachieved without floater marks

16 Curing can be done by ponding, covering with plastic sheets or gunny bags. Curing mustbe done for at least 7 days

17 Groove cutting for construction joints or isolation joints shall follow the sequence oftremix flooring without much time lapse

18 Groove filling can be done with any elastomeric material subsequently, Groove cleaningand drying needs to be ensured



with

CHECKLIST No.34

S.No Oil bound distemper: Checked

ItemPreparation of surface:

1 The plastered surface shall be thoroughly cleaned with a brush to remove dust, dirt,grease, mortar dropping and other foreign matter and sand subsequently smooth withsand paper

2 New plaster surface shall be allowed to dry for at least four months before applications ofdistemper or one coat of while wash with white cement shall be done prier to painting

3 All unnecessary nails, hooks etc. shall be removed. Pitting in plaster shall be made goodwith plaster again and papered with a fine grade sand paper and made smooth

4 A coat of paint shall be applied over the patches. The surface shall be allowed to drythoroughly before the regular paint is applied. The surface affected by moulds, moss,fungi, algae lichens, efflorescence etc. shall be treated

5 A primer coat of cement primer of approved manufacturer shall be applied over theplaster surface in case of new work

6 The primer shall be applied with a brush on the clean, dry and smooth surface.Horizontal strokes shall be given first and vertical strokes shall be applied immediatelyafterwards. This entire operation will constitute one coat

7 A Coat of putty (lapi) shall be applied to the entire surface. Putty shall be prepared bymixing whiting chalk, primer/paint in required proportion as directed by the Engineer-in-Charge and Architect. The second coat of primer and putty shall then be applied an itshall thereinafter be allowed to dry for at least 48 hours. Fine sand papering is requiredfor both lapi coats

8 Any moisture in plaster will create problem of pealing off or swelling. Due cautioning tobe given to clients/consultant it they insist on painting to start during initial four monthsof drying. Fine sand papering is required for both lapi coats

. CHECKLIST No.35

S.No Oil bound distemper/Water bound distemper/Acrylic bound distemper: Checked

Item1 The distemper shall be diluted with mineral turpentine oil or any other prescribed thinner

in a manner recommended by the manufacturer only, sufficient quantity of distemper fora day’s work shall be prepared

2 On any surfaces, after the primer coat has dried for at least 48 hours, the surface shall belightly sand papered to make it smooth for receiving the distemper, taking care not to rubout the priming coat

3 Sufficient quantity of distemper shall be mixed to finish one room at time. The applicationof a coat in each room shall be finished in one operation and no work shall be started inany room, which cannot be completed on the same day

4 15-cm. double bristled distemper brush shall be used. After a day’s work, brushes shall bethoroughly washed in hot water soap solution and hung down to dry. Old brushes, whichare dirty and caked with distemper, shall not be used on the workProtective measure:The surface of doors, windows, ventilators of furniture and machines etc. and such otherpart of the buildings, which are not to be distempered, shall be protected from beingsplashed upon. On completion, surfaces shall be cleaned of distemper splashes, if any



with

CHECKLIST No.36

S.No White wash: CheckedItem

1 The wall to be painted must be thoroughly scrapped with sand paper

2 The first coat of white wash is to be done within 7 days of plaster3 The slaked lime must be screened through coarse cloth and the adhesive must be added

as specified. Lime must be soaked for 24 hours in advance4 application by spray, brush, coil brush to be decide in advance5 Lime coat must be applied with a brush and the desired sequence must be as under: One

stroke of brush from downward and another from bottom upwards over the first.

Similarly one stroke from right and other from the left over the first before the first dries6 Brush application needs criss – cross painting to avoid brush marks7 Machines, Doors, windows, floors etc. shall be covered from being splashed upon8 The cracks and holes are required to be filled with proper adhesive after the first coat9 Small quantity of ultra marine is o be added in last two coats of white wash10 There coats are to be applied over the plastered surface11 Subsequent white is to be applied only after preceding coat has become sufficiently dry

S.No Colour Washing: CheckedItem

1 Follow up steps 1 to 11 as white wash

2 The wash shall be prepared by adding required quantity of colour pigment to the lime

wash prepared under the head white wash3 The mineral colours not affected by lime shall be added to white wash4 The colour wash shall be done after preparation of sample of colour wash5 The surface to be colour washed shall be first treated with a priming coat of white wash6 Minimum two to three coats of colour shall be applied to attain uniform shade over the

whole surface

S.No Cement Paint: CheckedItem

1 Get the cement paint and shade approved

2 The surface should be thoroughly cleaned all loose materials be removed3 The surface should be watered thoroughly and should be allowed to drain off before

starting the cement painting application is b criss – cross direction till uniform color shade

is obtained4 The second coat shall be started after 2 hours of the first coat5 The entire surface shall be moist cured for seven days6 A grey and Blue pigment tends to fade off, so discuss with customer and clarity



with

CHECKLIST No.37

S.No Indian type water proofing terrace: CheckedItem

1 Ensure that the item and specifications of the work are studied before carrying out of thework

2 Water proofing material must be of make as specified /directed3 Check that the recommended waterproofing compound is mixed with mortar, which is

used for Roda fixing as well as final top finishing layer. (IPS)4 The parapets, walls, must be plastered before application of water proofing material.

Suitable vata and nose to be made as part of treatment5 Ensure surface scrapping and cleaning before start of activity. (Thorough cleaning of

terrace)6 Before staring this activity, ensure that the proper slop and level is checked for drainage.

Ridge and valleys to be marked properly and rain water down take points to be finishedwith waterproof mortar

7 The finished top surface must be smooth with Dori mark in both direction to give 1’X1’pattern

8 The openings, needs inverted kerbs to end IWP with Vata9 Av. recommended thickness for IWP is 150 mm-any extra thickness required for longer

slopes to be planned in advance. Water proofing shall be carried out in two layers10 During final layer, provide & lay minimum 40 mm thick IPS layer in cement concrete

(1:2:4) with maximum size of aggregate 3 to 6 mm. Simultaneously with polishing trowel,using CM (1:2)shall be applied

11 IWP thickness at lowest vally point (i.e. at the RWP mouth) should be 2 ½ “.12 IWP shall be cured for 21 days by flooding the water to 25 mm depth in panel of 1mX1m

formed by weak mortar bonding

CHECKLIST No.38

S.No Box type Water proofing: CheckedItem

1 For providing and laying Box type waterproofing treatment to floors and external surfacesof underground structures. Will comprise of waterproofing layer, layer, average 50/100mm thick for floors, using layers of kotah stones placed diagonally with staggered joints

2 Rough kotah stone shall confirm specification3 waterproofing consist of the following layers:

a) 20 mm thick cement sand mortar bedding with approved waterproofingcompound @ 4 % by Wright of cement shall be laid on PCC & 20 mm gradedaggregate free from impurities shall be spread on the floor.

b) 15 mm thick rough kotah stone to be laid diagonally with staged joints. Jointsshall be sealed by 1:1 cement mortar with approved waterproofing chemical.This shall project 300 mm all around RCC raft.

c) Well cured walls shall be treated in the vertical direction by fixing a layer of kotastones. Treatment shall be carried out 300 mm above the finished GL.

4 Treatment to floor and wall shall be scaled such that it is continues. Correct chamfers,correct slopes etc. shall be maintained by providing PCC in the ratio of 1:4:8 in requiredlocations

5 Corner laps in vertical and horizontal plane needs proper overlapping of the stone6 On final completion of stone fixing smooth waterproof cement plaster is done over the

rough stone7 Proper watering for 7 days shall be required



with

CHECKLIST No.39S.No Fabrication / Erection: Checked

Item1 Estimate the power requirement for peak quantum of work

2 Ensure availability of sufficient space for fabrication yard adequate lighting arrangementfor night work

3 The platform for fabrication is to be prepared before starting the work4 The approach road for unloading of the materials carrying the fabricated materials to the

site has to be proper and prepared and prepared in advance5 The site office and store space for fabricator must be completed in advance. Suitable

distribution board for power supply above to be provided6 Estimation of quantity of the structural steel must be carried out from approved shop

drawings. Carry out the analysis for cutting lengths to reduce the wastage7 Skilled qualified welders, fitters, gas cutter and technicians must be recruited for the job8 The welding, gas cutting, grinding etc. procedure must be approved before the start of

work9 The welding rods must be of approved make and quality, suitable for type of fabrication.

Adequate stocks to for all consumables to be maintained10 The layouts are to be checked and the zig is to be approved after assembling11 The centrelines are to be checked before erection and the erection sequence and

procedure is to be approved before start12 The members are to be properly aligned with proper tightening of bolts bracing sag rods,

ties etc to be erected simultaneously before alignment13 Grouting of the base is to be carried out after erection alignment. Grouting holes to be

provided in base plates14 Samples must be collected for establishing rolling margins weights difference and is

required to be recorded. Average 3 samples form every incoming lot of steel must becollected

15 Dimensional differences in rolled sections to be pointed out and recorded, (if more thantolerance level are found in material supplied.)

16 BOQ for nut bolts for connections to be prepared.

CHECKLIST No.40

S.No Rolling Shutter: Checked

Item1 Check that the dimensions and gauge of the material used for the shutter are as per

drawings. Normally shutter gauge, guide rails gauge, hood gauge needs to be specified.Only approved vendor to supply for maintenance of free service

2 Check whether the welding done is perfect and junctions are properly grooved3 Ensure that inserts, bolts, fixtures, fastening fittings are fixed in their position accurately

and in alignment4 Painting must be done by quality paint and number of coats should be specified5 Before placing and indent for procurement check the following.

a) Brick work opening size.b) Minimum 9” brick columns on both sides.c) Rolling shutter is to be fixed from inside or outside.d) Gear operation system for more than 10m2 size.e) Top shaft fittings e.g. springs, bearings, brush, gear warm.f) Adequate clearance above lintel for fixing top shaft and hood cover.



with

CHECKLIST No.41S.No Painting of structural steel works Checked

Item

Surface treatment:

1 All the surfaces of steel work to be painted shall be thoroughly cleaned of all loose millscale, rust, grease, dirt and other foreign matter. All welding, blurs, drilled holes, Gas cutedges need proper surface cleaning

2 Oil and grease removal shall be carried out either by solvent cleaning or by using alkalitype degreasing agents. To remove grease material the surface shall be cleaned withsolvents containing emulsifier

3 De rusting and de scaling of steel shall be carried out manually, mechanically, orchemicallyPrimer paint:Primer and finish paints shall be compatible with each other to avoid cracking andwrinkling.Painting:

1 Painting shall be carried out only on thoroughly dry surfaces. (Procure only approvedpaint product and also the approved colour shade).

2 No painting shall be done in frosty/foggy weather or when the humidity is high enoughto cause condensation on the surface to be painted

3 The application of paint film shall serve the twin purpose of protecting the steel fromcorrosion and giving the decorative appearance. A paint, which gives the steel adequateprotection over a long period together with good appearance, shall therefore beadopted. Procure only approved paint product and also the approved colour shade

4 Structural steel surfaces shall be given the first coat of primer at shop and the secondcoat after it is erected in position. Further, any abraded surfaces of the first coat duringtransport from shop to site and during erection needs to be attended with primer coats

5 Application of finishing paints shall be carried out within the shortest possible timeinterval after primer since the primer coats are too thin to give adequate corrosionprotection of the steel surface over a long duration

6 Painting shall be carried out by brushing or spraying7 At least 24 hours shall elapse between the applications of successive coats. Each coat

shall vary slightly in shade and this shall be got approved by the engineer8 Minimum dry film thickness of each coat of finish paint of synthetic enamel shall be as

specified in the respective item of work (average 40 microns).9 Surfaces inaccessible after assembly shall receive two coats of primer prior to assembly10 Surfaces inaccessible after erection, including top surface of purlins supporting sheeting

or top surfaces of floor beams supporting grating or chequered plate shall receive oneadditional coat of finish paint over and above the number of coats specified prior toerection

11 Suitable covering shall be as necessary to prevent paint from splashing on equipment,floors, walls, doors, windows, and fittings etc

Third Party Quality Audit for Construction of CycloneShelters, Roads to Cyclone Shelters & Habitations, Bridgesand Culverts under NCRMP


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TEST RESULTS REPORTING FORMATS

Sl.No. Description Form No.I EARTH WORK AND BORROW AREAS1. Atterberg Limits QC-12. Moisture Content QC-23 Moisture Content with Rapid moisture meter QC-34 Dry Density and Moisture Content Relationship – Modified Procter QC-45 California Bearing Ratio & Expansion Ratio QC-56. Free Swelling Index QC-67 SWELL PRESSURE TEST by CONSOLIDOMETER METHOD QC-78. Gradation of Aggregate QC-8II GRANULAR SUB BASE1. Gradation for Coarse Graded Granular Sub Base QC-92. Gradation for Close Graded Granular Sub Base QC-103. Ten Percent Fines QC-11

III AGGREGATES1. Specific Gravity & Water Absorption of Aggregates QC-122. Aggregates Impact Value QC-133. Los Angeles Abrasion Value Test QC-144. Soundness of Aggregates QC-155. Worksheet for Soundness QC-166. Flakiness Index and Elongation Index QC-177. Stripping Value of Road Aggregates QC-188. Tests on Fine Aggregates/Sand QC-199 Mortar Jar Test QC-20

IV BITUMINOUS WORKS1. Penetration Value of Bitumen QC-212. Ductility Test QC-223. Specific Gravity of Bitumen QC-234. Transverse Distribution of Primer/Tack Coat / Binder QC-245. Binder Content QC-25V CONCRETE1 Cement Test Record QC-262 Concrete Cube Record QC-273 Determination of Compressive Strength of Concrete Cores QC-28

VI Field Testing Formats1 Silt content of Fine aggregate QC-292 Gradation of Fine Aggregate QC-303 Moisture content in Aggregate QC-314 Gradation of WBM QC-325 Field density by Sand Replacement method QC-336 Field Density by Core cutter Method QC-347 Rebound hammer test results QC-35




with

ATTERBERG’S LIMITSTEST METHOD: IS: 2720 (PART-V)

QC-1Client :Consultant :Contractor :

Location/ Chainage :

Description of Material :

Source of the Material :

Sample No. :

Date of Sampling :

Date of Testing :

Sampled by :

OBSERVATIONSSL.NO. DESCRIPTION LIQUID LIMIT PLASTIC LIMIT

1 2 3 4 5 1 2 3 4 51 No. of Blows (n)2 Container No.3 Mass of Container +Wet Soil, W2

(gm)4 Mass of Container +Oven dried soil,

W3 (gm)

5 Mass Container W1 (gm)

6 Water ContentW2 – W3

% w = --------x100W3 – W1

LIQUID LIMIT (%) – FROM GRAPH PLASTIC LIMIT (%) PLASTICITY INDEX (%)

For the Contractor For the Engineer

REMARKS:

NO. OF BLOWS (LOG SCALE)

% M

OIS

TUR

E CO

NTE

NT

5




with






Sample No. :

Date of Sampling :

Date of Testing :

Sampled by :




W3 (gm)



% w = --------x100W3 – W1



REMARKS:


% M

OIS

TUR

E CO

NTE

NT

5




with






Sample No. :

Date of Sampling :

Date of Testing :

Sampled by :




W3 (gm)



% w = --------x100W3 – W1



REMARKS:


% M

OIS

TUR

E CO

NTE

NT

5




with

MOISTURE CONTENTTEST METHOD: IS: 2720 (PART-II) QC-2

Client :

Consultant :

Contractor :

Location / Chainage :

Description of Material : Date of Sampling :

Source of Material : Date of Testing :

Sample No. : Sampled By :

OBSERVATIONS

Sl. No. DESCRIPTION SAMPLE 1 SAMPLE 2 SAMPLE 3

1 DISH NO.

2 WEIGHT OF DISH, W1 GMS

3 WEIGHT OF DISH + WET SOIL, W2 GMS

4 WEIGHT OF DISH + DRY SOIL, W3 GMS

5 WEIGHT OF MOISTURE, (W2-W3) GMS

6 WEIGHT OF DRY SOIL, (W3-W1) GMS

7 MOISTURE CONTENT, w = [(W2-W3) / (W3-W1)] x 100 %

AVERAGE MOISTURE CONTENT:





with

QC-3MOISTURE CONTENT

TEST METHOD : IS : 2720 (PART - II)

Client :

Consultant :

Contractor :

Location / Chainage : Speedy Moisturemeter No. :

::


Source of Material : Date of Testing :

Sample No. : Sampled By :

OBSERVATIONS

Sl. No. DESCRIPTION SAMPLE 1 SAMPLE 2 SAMPLE 3

1 Moisture Meter Reading

2 Corrected Moisture Content (W)

AVERAGE MOISTURE CONTENT:


Third Party Quality Audit for Construction of Cyclone Shelters,Roads to Cyclone Shelters & Habitations, Bridges and Culvertsunder NCRMP


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DRY DENSITY AND MOISTURE CONTENT RELATIONSHIP – MODIFIED PROCTOR – IS: 2720 PART VIIIQC-4

Client/Engineer :Consultant :Contractor :


SAMPLE NO. : DATE:SAMPLE DESCRIPTION : LOCATION:Mould No.

MOISTURE CONTENT (%)

Wt. Mould + Wet Soil g.Wt. Mould g.Wt. Wet Soil g.Volume of Mould ccWet Density g/cc

Container NWt. Container + Wet Soil g.Wt. Container + Dry Soil g.Wt. Water g.Wt. ContainerWt. Dry soil g.

Moisture Content cc.Dry Density g/ccDESCRIPTION OF THE SAMPLE …………………………………………………………

Max. Dry Density (Max. d): g/cc Optimum Moisture Content=…………%

DR

Y D

ENSI

TY



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QC-5

CALIFORNIA BEARING RATIO & EXPANSION RATIOTEST METHOD: IS : 2720 (PART - XVI)

Client / Engineer :Consultant :Contractor :

Location / Chainage :Description of Material : Date of Sampling :Source of Material : Date of Testing :Sample No. : Sampled by :

Volume of Mould V = 2250 cm3 OBSERVATIONS

SLNO.

DESCRIPTIONMOULD NO. __ MOULD NO. __ MOULD NO. __

BEFORESOAKING

AFTERSOAKING

BEFORESOAKING

AFTERSOAKING

BEFORESOAKING AFTER SOAKING

1 Mass of Mould W1 (gm.)

2 Mass of Mould + Wet soil W2 (gm.)

3 Mass of Wet Soil W2-W1 (gm.)

4 Bulk Density b = (W2 - W1)/V(gm./cm3)

5 Container No.

6 Mass of Container W5 (gm.)

7 Mass of Container + Wet Soil SampleW3 (gm.)

8 Mass of Container + Oven Dried SoilSample W4 (gm.)

9 Water Content %w = [(W3-W4)/(W4-W5)]x100

10 Dry Density (100b)/(100+w)(gm./cm3)

Mould No.

Initial Dial gauge reading, ds (mm)Proving, Ring Capacity

Final Dial gauge reading, dt (mm)Height of specimen, h (mm) Proving Ring FactorExpansion ratio [(dt-ds)/h] x 100



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SL. NO.

PENETRATIONPROVING RING DIAL READINGS

MOULD NO. MOULD NO. MOULD NO.(mm) Dial gauge

reading(divs)

Unit Load(Kg/cm2)

Dial gaugereading (divs)

Unit Load(Kg/cm2)

Dial gaugereading(divs)

Unit Load (Kg/cm2)

1 0.5

2 13 1.5

4 2

5 2.5

6 47 5

8 7.5

9 10

10 12.5

Mould No. C.B.R at 2.5 mm in % C.B.R at 5.0 mm in % Remarks

Note: Standard Load Penetration, mm Unit Standard Load,kgf/cm2

Total Standard Load,kgf

2.5 70 13705 105 2055




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FREE SWELLING INDEXTEST METHOD: IS:2720 (PART – XXXX)

QC-6Client: Carriageway: L/RConsultant: Carriageway: L/RContractor:

Location/Chainage :

Description of Material : Date of Sampling:

Source of the Material : Date of Testing :

Sample No. : Sampled by :

OBSERVATIONS

SL. NO. LOCATION/CHAINAGE

DEPTH

HEIGHT OF THESOIL SPECIMENIN KEROSENE,

H1, MM

HEIGHT OF THESOIL SPECIMENIN WATER, H2,

MM

FREESWELLING

INDEXF.S.I.

REMARKS

= (H2-H1)X 100H1

1234

5678

910

Free Swell Index (percent) Degree Of Expansion Degree Of SeverityLess than 50 Low Non-Critical50 to 100 Medium Marginal100 to 200 High Critical

More than 200 Very high severe




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SWELL PRESSURE TEST by CONSOLIDOMETER METHOD QC-7

Client:Consultant:Contractor:

Date of Sampling:

Date of Testing :


1. Details of soils sample : 2.Details of soil specimen :i) Location : i) Undisturbed or remoulded :ii) Boring No. : ii) Specific gravity of the soil :iii) Depth :iv) Visual description of soil :v) Liquid limit :

Plasticity index :vi) Percentage of soil fraction below 0’002 mm

NATURAL DENSITY MOISTURE CONTENTDescription Test-1 Test-2 Description Before

TestAfter Test

Weight of container- ring + weightspecimen

Weight of container + wet soil

Weight of container Weight of container +Dry Soil

Diameter of container Weight of containerInitial thickness of soil sample Weight of waterWet density in g/ml Weight of Dry soilDry density in g/ml Moisture content in percent

Time of starting Date

Elapsed time in hours Swelling dial Reading0

0.51248

121620243648607296




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GRADATION OF AGGREGATESTEST METHOD: IS:2720 (PART – IV)

QC-8

Client : Carriageway: L/R

Consultant : Carriageway: L/R

Contractor :

Location/Chainage :




OBSERVATIONS

IS SIEVEDESIGNATION

MASS OFSOIL

RETAINEDin gms.

CUMULATIVEMASS RETAINED

in gms.

CUMULATIVEPERCENTAGE

RETAINED

PERCENTAGEPASSING

REMARKS

45 mm

37.5 mm

26.5 mm

22.4 mm

19.00 mm

13.2 mm

11.2 mm

9.5 mm

5.6 mm

4.75 mm

1.80 mm

2.36 mm

300 mic

90 mic

75 mic

Pan

Total




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GRADATION FOR COARSE GRANULAR SUB-BASETEST METHOD: IS:2720 (PART – IV)


Location/Chainage :Description of Material : Date of Sampling:Source of the Material : Date of Testing :Sample No. : Sampled by :

OBSERVATIONS

IS SIEVEDESIGNATION

MASS OFSOIL

RETAINED (gm.)

CUMULATIVE MASS

RETAINED(gm.)


RETAINED

PERCENTAGEPASSING

LIMITS PERCENTAGE PASSING ISSIEVE FOR

GRADINGI

GRADINGII

GRADINGIII

75.0 mm 100 - -

53.0 mm - 100 1

26.5 mm 55-75 50-80 100

4.75 mm 10-30 15-35 25-45

0.075 mm < 10 < 10 <10

PAN

GRADATION CURVE

100

PER

CEN

TAG

E P

ASS

ING

90

80

70

60

50

40

30

20

10

00

SIEVE DESIGNATION (LOG-SCALE)




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GRADATION FOR CLOSE GRADED GRANULAR SUB-BASETEST METHOD: IS:2720 (PART – IV)



OBSERVATIONS

IS SIEVEDESIGNATION

MASS OFSOIL

RETAINED(gm.)

CUMULATIVEMASS

RETAINED(gm.)


RETAINED

PERCENTAGEPASSING

LIMITS PERCENTAGE PASSING ISSIEVE FOR

GRADINGI

GRADINGII

GRADINGIII

75.00 mm 100 - -

53.00 mm 80-100 100 -

26.50 mm 55-90 70-100 100

9.50 mm 35-65 50-80 65-95

4.75 mm 25-55 40-65 50-80

2.36 mm 20-40 30-50 40-65

0.425 mm 10-25 15-25 20-35

0.075 mm 3-10 3-10 3-10

PAN

GRADATION CURVE100

PER

CEN

TAG

E P

ASS

ING

90

80

70

60

50

40

30

20

10

00

SIEVE DESIGNATION (LOG-SCALE)




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TEN PERCENT FINESTEST METHOD: BS:812 (PART – III)

QC-11Client: Carriageway: L/R

Consultant: Carriageway: L/R

Contractor:

Location/Chainage :




OBSERVATIONS

S. NO. ITEM DESCRIPTIONSAMPLE

NO.1

SAMPLE

NO.2

SAMPLE

NO.3

SAMPLE

NO.4

SAMPLE

NO.5REMARKS

1 TOTAL SAMPLE TAKEN, M1 (gm.)

2 PASSING 2.36 MM SIEVE, M2 (gm.)

3 LOSS M1-M2 = M3 (gm.)

4 % FINES M = (M3/M1) X 100

5 TOTAL FORCE APPLIED, F (KN)

6 FORCE REQUIRED = [14F/(M=4)]

KN

FORCE REQUIRED FOR 10% FINES VALUE = KN.




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SPECIFIC GRAVITY & WATER ABSORPTION OF AGGREGATESTEST METHOD : IS: 2386 (PART III)


Location/Chainage :Description of Material : Date of Sampling :Source of the Material : Date of Testing :Sample No. : Sampled by :

OBSERVATIONS

SL. NO. DETAILSTEST NUMBER

MEAN VALUE1 2 3

1Weight of saturated aggregates and

basket in Water, W1 (gm)

2 Weight of basket in Water, W2 (gm)

3Weight of saturated surface dry

Aggregates in air, W3 (gm)

4Weight of oven dried aggregates in air,

W4 (gm)

5 Specific Gravity W4

W3 – (W1 – W2)

6Apparent Specific Gravity W4

W4 – (W1 – W2)

7Water Absorption (W3 – W4) x100

W4




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AGGREGATES IMPACT VALUETEST METHOD : IS: 2386 (PART IV)

QC-13Client:

Consultant:

Contractor:

Location/Chainage :




OBSERVATIONS

Sl. No. Description 1 2 3 Average Value

1Total Weight of the Aggregate

taken W1 (gm)

2Weight of Aggregate retained

on 2.36 mm I.S. Sieve, W2(gm)

3

Weight of Aggregates passing

through 2.36 mm I.S. Sieve

W3=W1-W2(gm)

4Aggregate Impact Value

(W3/W1) x 100%




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LOS ANGELES ABRASION VALUE TESTTEST METHOD: IS:2386 (PART – IV)



Contractor:

Sample Description :

Location : Sample No.:

Source : Date :

Cycle (33 R.P.N) 500 No. 1 2

Initial Weight A ………………..gm

Weight Retained after

Test on No. 12 SieveB ……………..gm

A – B x 100A

% By Weight Passing No. 12 Sieve …………..%

Remarks: _______________________________________________________________

_______________________________________________________________




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SOUNDNESS OF AGGREGATES(No. of Cycles – 5)

TEST METHOD : IS: 2386 (PART V)QC-15


Location: Sample No.:

Source: Date:

Sample Description: Kind of Solution:

Recording Test DataSieve Size Grading of

OriginalSamplePercent

(Retained)

Weight ofTest

FractionsBefore Test

(gms)

PercentagePassing

DesignatedAfter Test

WeightPercentage

LossRemarks

Passing Retained

Soundness of Fine Aggregates

150 mic -

300 mic 150 mic

600 mic 300 mic

1.18 mic 600 mic

2.36 mic 1.18 mic

4.75 mic 2.36 mic

10 mm 4.75 mic

Totals

Soundness of Coarse Aggregates

63 mm 50 mm

50 mm 40 mm

40 mm 25 mm

25 mm 20 mm

20 mm 12 mm

12 mm 10 mm

10 mm 4.75 mm

Totals




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WORKSHEET FOR SOUNDNESS TEST(No. of Cycles – 5) QC-16


Location : Sample No.:Source : Date :Sample Description:Reagent Used: Size of Aggregate: ______ mm to ______ mmWt. Of Sample

beforeImmersion (gm)

Cycle No. Temp. ofNa2SO4/ MgSO4

Solution (°C)

Immersion in Na2SO4/MgSO4 Oven Drying Qualitative Examination of Fractions of SampleCoarser than 20 mm sizeIn Out In Out

Date Time Date Time Date Time Date Time

Cycle -1

Cycle -2

Cycle -3

Cycle -4

Cycle -5




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FLAKINESS INDEX AND ELONGATION INDEXTEST METHOD : IS: 2386 (PART I)

QC-17Client:Consultant:Contractor:


OBSERVATIONS

Sl. No.

Passing through

I.S. Sieve in size

(mm)

Retained

on I.S.

Sieve size

(mm)

Flakiness Index Elongation Index

Weight of

the

aggregate

taken in

each

fraction

(gm.)

Weight of

aggregate

in each

fraction

passing

Thickness

gauge

(gm.)

Weight of

Non-Flaky

aggregate

taken in

each

fraction

(gm.)

Weight of

aggregate in

each fraction

not passing the

Length gauge

(gm.)

1 63 50

2 50 40

3 40 25

4 31.5 25

5 25 20

6 20 16

7 16 12.5

8 12.5 10

9 10 6.3

W: w: W1: w1:

(w/W) x100: % (w1/W1) x100: %

COMBINED F.I.+E.I.+________________%




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STRIPPING VALUE OF ROAD AGGREGATESTEST METHOD: IS: 6241

QC-18Client :

Consultant :

Contractor :

Quarry Identification No. : Sample No. :


Type of Binder : Date of Testing :

Percentage of Binder : Sampled by :

OBSERVATIONS

SL. No. Stripping Percentage Remarks

AVERAGE VALUE:

Remarks :




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TESTS ON FINE AGGREGATES / SANDQC-19

Client : Carriageway: L/RConsultant : Carriageway: L/RContractor :

SPECIFIC GRAVITY OF FINE AGGREGATES / SAND

DESCRIPTION 1 2 3 AVERAGEWt. of empty pycnometer (gms) A1Wt. of empty pycnometer + dry sand (gms) A2Wt. of empty pycnometer + dry sand + water (gms) A3Wt. of dry sand (gms) A2-A1=AWt. of Pycnometer + Water (gms) A4Wt. of wet sand (gms) A3-A4=BSpecific Gravity of Sand = A/(A-B)

Bulking of Sand

DESCRIPTION 1 2 3 AVERAGEInitial volume of sand in measuring cylinder (V1)Volume of Sand after submergence in water (V2)Percentage Bulking = ((V1-V2)/-1)*100

SIEVE ANALYSIS OF FINE AGGREGATES / SAND

I.S. Sieve Mass ofSand

Retained(gm)

%ageMass

Retained

Cumulative%age

Retained

%agePassing

I.S.Zone I

I.S.Zone II

I.S. Zone III

10 mm 100 100 1004.75 mm 90 - 100 90 - 100 90 – 1002.36 mm 60 - 95 75 - 100 85 – 1001.18 mm 30 - 70 55 - 90 75 – 100600 micron 15 - 34 35 - 59 60 - 79300 micron 5 -20 8 - 30 12 – 40150 micron 0 - 10 0 - 10 0 – 10Total Weight

FINENESS MODULUS:




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MORTAR TESTQC-20

Client :

Consultant :

Contractor :

Supplier : Date of Sampling :

Sample No. : Date of Testing :

Description of Material : Sampled by :

Description Trail-I(grams)

Trail-II(Grams)

Weight of Mortar taken in Sprit Jar1 W1

Dry Weight of Mortar in Sprit jar1 W2

% of Water Content in Mortar W (w1-w2/w1) x100

Wet weight of mortar in sprit jar2 W3

Wet weight of mortar after sieving W4

Dry weight of mortar after sieving W5

% of cement in mortar C [(w3-w5/w3)x100]-w

Weight of Sand taken W6

Wet weight of sand after sieving W7

Dry weight of sand after sieving W8

% of fines in Sand F ((w6-w8)/w6))x100

Actual Cement content in mortar C-F




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PENETRATION VALUE OF BITUMENTEST METHOD: IS: 1203

QC-21Client :

Consultant :

Contractor :

Supplier : Date of Sampling :

Sample No. : Date of Testing :

Description of Material : Sampled by :

OBSERVATIONS

SL. NO.TYPE OF

MATERIAL

TEMP

IN

(°C)

INITIAL

READING

1/10 MM

(R1)

INITIAL

READIN

G 1/10

MM (R2)

PENETRA

TION IN

1/10

MM

(R2-R1)

PENETRATIO

N IN 1/10

MM

(AVERAGE)

REMARKS




B24 | P a g e

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DUCTILITY TESTQC-22

Client: Carriageway: L/R


Contractor:

Selection / Control Sample: To be used:

Date of Sampling: Date of Test:

Sampled by: Tested by:

Sampled at: Tested at:

GRADE OF BITUMEN =Trial 1

Cm

Trial 2

Cm

Determination of ductility expressed as the

distance in centimeter to which a standard

briquette of bitumen under standard

conditions can be stretched before the

thread breaks.

Average

Result : Ductility Value =

IS: 1208 – (1979)

Clients/Consultants Representative Representative




B25 | P a g e

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SPECIFIC GRAVITY OF BITUMENTEST METHOD: IS: 1202

QC-23

Client:

Consultant:

Contractor:

Location/Chainage :




OBSERVATIONS

SL. NO. DESCRIPTION SAMPLENO.1

SAMPLENO.2

SAMPLENO.3 AVERAGE

1 Weight of Pycnometer (W1 )

2 Weight of Pycnometer + Sample (W2 )

3 Weight of Pycnometer + Sample + Water (W3)

4 Weight of Pycnometer + Full of Water (W4)

5 Weight of Sample (W2 - W1)

6 Specific Gravity of Sample(W2 - W1)

(W4 - W1 ) – (W3 - W2 )




B26 | P a g e

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RATE OF SPREAD – PRIMER/TACK COAT/BINDERTEST METHOD: IS: 1707

QC-24Client:

Consultant:

Contractor:

Location/Chainage : Date of Testing :

Description of Material : Spray Pressure (PSI) :

Source of the Material : Vehicle Speed (m/min) :

Spreading Temperature : Specified Rate of Spread :

OBSERVATIONS

Sl. No. Pad No. Chainage(Km)

OffsetfromC/L(m)

Area ofPad(m2)

Wt. ofEmpty

Pad(Kg)

Wt. ofPad +

Material(Kg)

Wt. ofMaterial

(Kg)

Rate ofSpread

(Kg/m2)

% Variationfrom

Specification

OverallMean

(Kg/m2)

1 2 3 4 5 6 7 8=7-6 9=8/5 10 11

Remarks:




B27 | P a g e

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BINDER CONTENTTEST METHOD: IRC: SP - 11



Contractor:

Location/Chainage :



Sample No. :

Date of Sampling :

Date of Testing :

Sampled by :

OBSERVATIONS

Sl. No. Description Sample 1 Sample 2 Sample 3 Remarks

1. Weight of mix, W (gm.)

2. Weight of sample (Bowl + Mix)

before extraction, W1 (gm.)

3. Weight of sample (Bowl + Mix) after

extraction, W2 (gm.)

4. Weight of filter paper before

extraction, W3 (gm.)

5. Weight of filter paper after

extraction, W4(gm.)

6. Bitumen content by wt. Of mix % =

[(W1 – W2) – (W4 – W3)]/Wx100




B28 | P a g e

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CEMENT TEST RECORD

QC-26Client:


Contractor: Carriageway: L/R

Brand : Manufacturing Week :

Type : Date of Receipt at Site :

Grade : Date of Sampling/Testing :

Lot No.: Testing at Temperature : 27°C 2°C

CONSISTENCY PROPERTIES

1 2 3 Average

Normal Consistency (%)

Initial Setting Time (Minutes)

Final Setting Time (Minutes)

MORTAR CUBE COMPRESSIVE STRENGTH

1 2 3 Average

Compressive Strength – 3 days







B29 | P a g e

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CONCRETE CUBE RECORDQC-27

Client: Carriageway: L/RConsultant: Service Road: L/RContractor:

Structure No : Brand of Cement :

Location : Grade of Cement :

Element : Water Cement Ratio :

Lift R.L. : Proportion of Mix :

Date of Casting : Cement per Batch :

Grade of Concrete : F.A. per Batch :

Required Strength at 28 days : C.A. per Batch :

Quantity of Concrete : Water per Batch :

Slump of Concrete : Sampled by :

CUBE COMPRESSIVE STRENGTH TEST

I.D. No. Area of Cube (cm2) S.S.D. Wt.,(gm)

Density,(gm/cm3)

7-days comp. Strength(__/__/__)

28-Days Comp. Strength(__/__/__)

Load (kg) Strength(MPa)

Load (kg) Strength(MPa)

123456789101112131415

Remarks:




B30 | P a g e

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QC-25

Height(H)

Diameter(D)

1

2

3

4

5

Consultant

SignatureName and Designation

COMPRESSIVE STRENGTH OF CONCRETE CORES( IS : 516 and 1199)

PACKAGE NUMBER =

AverageStrength

SI.No.

Chainage /Offset thickness

avgthicknessof cc Core

CoreWeight gm

Core Dimensions

H/DRatio

UltimateLoad(KN)

CompressiveStrength of

Core( C )

N/mm2

CorrectionFactor(F)

CompressiveStrength ofConcrete(C*F )

EquivalentCube

Strength(N/mm2)

(C*F*1.25)

Acceptance Criteria as per IS:456-2000:

1) Concrete in the member represented by a core test shall be considered acceptable if the average equivalent cube strength of thecores is equal to at least 85 percent of the cube strength of the grade of concrete specified for the corresponding age and no individualcore has a strength less than 75 percent.

2) Equivalent cube compressive strength = 1.25 x corrected cylinder compressive strength as per IS 516 – 1956 (Reaffirmed1999)

Name of work =

Agreement number=

Location: Date of Testing :

Sampled by :Age of Core:

Grade of concrete: M Date of Sampling :

Contractor


Dept.Engineer




B31 | P a g e

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QC-29

Consultancy Services for Third Party Quality Audit (TPQA) forNational Cyclone Risk Mitigation Project (NCRMP)

Client: NCRMPPlace of work:Agreement No.Name of work

SILT CONTENT IN SAND

Sample No: Sampling Date:

Source/Location:TestingDate:

Tested By:

Trial No. 1 2 3Total Volume of Sand TakenVolume of Sand after SubmergingVolume of Silt after SubmergingSilt Content, %Average Silt Content, %

Silt Content = (Volume of Silt After Submerging) X 100(Volume of Sand After Submerging)

Acceptance Criteria Specified : _____________________________________

Remarks:

Consultant Contractor Dept. EngineerSignature Signature Signature

Name and Designation Name and DesignationName and

Designation



B31 | P a g e

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QC-29






Tested By:




Remarks:



Designation



B31 | P a g e

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QC-29






Tested By:




Remarks:



Designation



B32 | P a g e

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QC-30Client: NCRMPPlace of work:Agreement No.Name of work

SIEVE ANALYSIS FOR FINE AGGREGATE(IS 383)

Document No: Date Sampled:

Sample Location: Date Tested:

Source of Material:

Sample Taken:

Sieve Size(mm)

MaterialRetained

(gm)

CumulativeWeightretained

(gm)

Materialretained

(%)

Finespassing

(%)

Specified Limits

Zone I Zone II Zone III Zone IV

10.000 100 100 100 100

4.750 90 - 100 90 - 100 90 - 100 95 - 100

2.360 60 - 95 75 - 100 85 - 100 95 - 100

1.180 30 - 70 55 - 90 75 - 100 90 - 100

0.600 15 - 34 35 - 59 60 - 79 80 - 100

0.300 5 - 20 8 - 30 12 - 40 15 - 50

0.150 0 - 10 0 - 10 0 - 10 0 - 15

Pan

Consultant

Contractor Dept.Engineer

Signature Signature Signature

Name and Designation Name and Designation Name and Designation



B33 | P a g e

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QC-31

M O IS T U R E C O N T E N T

(F IN E A G G R E G A T E & C O A R S E A G G R E G A T E )

Pa cka g e N o : D a te o f sa m p lin g :

S ou rce : D a te o f te s t in g :

Lo ca t io n :

F in e A g g re g a te

D escr ip t io n 1 2 A ve ra g e

W t. o f W e t A g g reg a te W 1(g m s)

W t. o f D ry a g g reg a te W 2(g m s)

M o is tu re C on ten t (W 1-W 2)/W 2 * 1 0 0 (% )

C o a rse A g g re g a te - 2 0 m m


W t. o f W e t A g g reg a te W 1(g m )

W t. o f D ry A g g reg a te W 2(g m )


C o a rse A g g re g a te - 1 0 m m


W t. o f W e t A g g reg a te W 1(g m )

W t. o f D ry A g g reg a te W 2(g m )


Fo r th e C on tra c to r F o r th e E n g in ee r



B34 | P a g e

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QC-32


GRADATION FOR WBM

Document No: Date Sampled:

Sample Location: Date Tested:

Source of Material:

Sample Taken:

Sieve Size(mm)

MaterialRetained

(gm)

CumulativeWeightretained

(gm)

Materialretained

(%)

Materialspassing

(%)

Specified Limits for grading

I II III

125.0 100 - -

90.0 90-100 100 -

63.0 25-60 90-100 100

53.0 - 25-75 95-100

45.0 0-15 0-15 65-90

22.4 0-5 0-5 0-10

11.2 - - 0-5

Pan - -

Consultant Contractor Dept.EngineerSignature Signature Signature




B35 | P a g e

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QC-33

ClientPlace of work:Agreement No.Name of work

FIELD DENSITY TEST BY SAND REPLACEMENT METHOD(IS 2720, Part - 28)

SECTION RFI No. Date:

Chainage

Representing Test Chainage

Offset from Center line (m)

Layer No. of Level.

Source of Material (Name & Chainage)

FIELD DENSITY

Pouring cylinder No

Weight of wet material from hole (Ww) g

Weight of sand + cylinder before pouring (W1) g

Weight of sand + cylinder after pouring (W2) g

Weight of sand in cone (W3) g

Weight of sand in hole (W4=W1-w2-W3) g

Bulk Density of Sand (Ya) g/cc

Bulk Density of Material (Yb=(Ww/W4)xYa) g/cc

MOISTURE CONTENT (By Rapid Moisture Method)

Speedy Moisture meter No.

Moisture Meter Reading %

Corrected moisture content (W) %

RESULTS

Field MDDYd = 100 xYb/(100+W) g/cc

Lab max dry density g/cc

Optimum moisture content %

Compaction obtained %

Compaction required %

Pass/Fail

Consultant Engineer ContractorDept. Engineer



B36 | P a g e

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QC-34

Client NCRMPPlace of work:Agreement No.Name of work

FIELD DENSITY TEST BY CORE CUTTER METHOD(IS 2720, Part - 29)

SECTION Date:

Chainage

Representing Test Chainage

Offset from Center line (m)

Layer No. of Level.

Source of Material (Name & Chainage)

FIELD DENSITY

Core cutter No. -Internal diameter cmInternal height cmWeight of empty Core cutter (W1) gWeight of Core cutter with soil (W2) gWeight of wet soil (W2- W1) gVolume of cutter (V) cm3Bulk density (Yb) = W2-W1 / V g/ccMoisture Content (By Rapid Moisture Meter)

Speedy Moisture meter No.

Moisture Meter Reading %

Corrected moisture content (W) %

Field MDDYd = 100 xYb/(100+W) g/cc

Lab max dry density g/cc

Optimum moisture content %

Compaction obtained %

Compaction required %Remarks:

Consultant Engineer Contractor Dept. Engineer

Third Party Quality Audit for Construction of Cyclone Shelters, Roads to Cyclone Shelters &Habitations, Bridges and Culverts under NCRMP Quality Assurance Plan

B37 | P a g e

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QC-35

Consultancy Services for Third Party Quality Audit (TPQA) for National Cyclone Risk Mitigation Project (NCRMP)Client :Name of work :Package No.

REBOUND HAMMER TEST ( Non Destructive Test for Concrete) IS : 13311 (Part 2) 1992Site Name : Date of Testing :Chainage: Grade of Concrete :Position ofHammer :SNo Location Description

Number of Readings Taken

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16Avg.

Comp. Strength(N/mm2)

1Rebound No.


2Rebound No.


3Rebound No.


4Rebound No.


5Rebound No.

Comp. Strength(N/mm2)The estimation of strength of concrete by rebound hammer method cannot be held to be very accurate and probable accuracy of prediction of concrete strength in a structure is

± 25 percent.Remarks :Consultant Contractor Dept.EngineerSignature Signature Signature


Documents

QAP Volume -1