Вы находитесь на странице: 1из 153
National Cyclone R isk Mitigation Project National Cyclone R isk Mitigation Project (NC RMP) (NC
National Cyclone R isk Mitigation Project
National Cyclone R isk Mitigation Project
(NC RMP)
(NC RMP)
Revenue (D M) Department
Revenue (D M) Department
Government o f Andhra Pradesh
Government o f Andhra Pradesh

Third Party Q uality Audit(TPQA)

Government o f Andhra Pradesh Government o f Andhra Pradesh Third Party Q uality Audit(TPQA) in

in Joint

venture

with

Government o f Andhra Pradesh Government o f Andhra Pradesh Third Party Q uality Audit(TPQA) in
Third Party Quality Audit for Construction of Cyclone Shelters, Roads to Cyclone Shelters & Habitations,

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

Quality Assurance Plan

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 No

1

Original Ground as Embankment Foundation

6

2

Original Ground as Sub Grade (500 mm Thick )

6

3

Embankment up to 3m Height

7

4

Sub-grade in Cutting or Embankment (500 mm Thick)

7

5

Embankment Exceeding 3m Height

8

6

Additional Test on filling with in 600mm of Concrete Structures/ Cement Bound Materials

8

7

Back Filling to Sub-Surface Drains

9

8

Aggregate Drains

9

9

Granular Sub-Base

10

10

Water Bound Macadam Sub-Base / Base

11

11

Prime Coat and Tack Coat

13

12

Open Graded Premix Surfacing

13

13

Bituminous Macadam

14

14

Mix seal Surfacing

15

15

Semi Dense Bituminous Concrete

16

16

Cement Concrete Pavement

18

17

Cement for Structural Works

20

18

Coarse Aggregate for Structures

20

19

Sand / Fine Aggregate for Structures

22

20

Reinforcement Steel

23

21

Water for Concrete and Mortar

23

Structures 22 20 Reinforcement Steel 23 21 Water for Concrete and Mortar 23 in Joint Venture
Structures 22 20 Reinforcement Steel 23 21 Water for Concrete and Mortar 23 in Joint Venture
in Joint Venture with
in
Joint Venture
with

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

Quality Assurance Plan

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.

in Joint Venture
in
Joint Venture

1 | P a g e

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

Quality Assurance Plan

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

in Joint Venture
in
Joint Venture

2 | P a g e

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

Quality Assurance Plan

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.

in Joint Venture
in
Joint Venture

3 | P a g e

Third Party Quality Audit for Construction of Cyclone Shelters,

 

Roads to Cyclone Shelters & Habitations, Bridges and Culverts

Quality Assurance Plan

under NCRMP

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 accredited laboratory for testing

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

In case of failure like CBR tests, non-compliance of materials, suitable Non- Compliance report

will be issued to the concerned executive Engineer, PIU with copies to the PM, PIU. On receipt of

in Joint Venture
in
Joint Venture

4 | P a g e

Third Party Quality Audit for Construction of Cyclone Shelters,

 

Roads to Cyclone Shelters & Habitations, Bridges and Culverts

Quality Assurance Plan

under NCRMP

compliance it will be verified whether the required remedial measure is carried out or not. The acceptance

or otherwise of the Compliance will be intimated to the client.

During visits, TPQA will also conduct Quality Assurance prevention to all the Engineers and

contractors to enlighten the quality aspects of work As a part of QAP, TPQA has distributed booklets with all the items of work associated with NCRMP phase 1 works to all the Engineers and all the contractors

at the QA workshop conducted at Vijayawada on 28-06-2011.

The Booklet contains Specifications, Methodology, Dos and don ts and Acceptance criteria for all

types of works.

The subjects incorporated in the booklet are :

a)

Rural road construction as per MORD specification and IRC : SP: 20

b)

Road construction as per MORT & H specification

c)

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 detailing

f)

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 a reference 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.

in Joint Venture
in
Joint Venture

5 | P a g e

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

Quality Assurance Plan

Shelters & Habitations, Bridges and Culverts under NCRMP Quality Assurance Plan in Joint Venture 6 |

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

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 Value

1.

MDD & OMC (by heavy compaction)

IS:2720 (Pt 8)

1

test per 3000 Cum

MDD not less than 15.2kN/cum

2.

Moisture content during field compaction

IS:2720 (Pt 2) (speedy tester/nuclear meter)

Frequently

OMC+1% to 2% (for expansive clay on wet side of 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 Value

1.

MDD & OMC (by heavy compaction)

IS:2720 (Pt 8)

1 test per 3000 Cum

MDD not less than 17.5kN/cum

2.

CBR at 97% MDD

IS:2720 (Pt 16)

1 test per 3000 Cum

As in Special Specifications

3.

Maximum particle size

IS:2720 (Pt 4)

Frequently

50mm

4.

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. = Minimum Heavy Compaction Refers Modified Proctor Tests.

Conversion

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 density

1.52 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 in Tones or kgs can be converted by the relation, 10kg/sq.cm = 1N/sqmm = 1MPa

Factors:

in Joint Venture
in
Joint Venture

7 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Table 3: Embankment up to 3m Height

Sl. No.

Test

 

Test Method

 

Minimum Frequency

Specified Value

1.

Gradation/Sand Content

IS:2720 (Pt 4)

 

1

test per 3000 cum

As in special specification

2.

Maximum Particle size

IS:2720 (Pt 4)

 

2

test per 3000 cum

75mm

3.

MDD & OMC (by heavy compaction)

IS:2720 (Pt 8)

 

2

test per 3000 cum

MDD not less than 15.2 kN/cum

4.

M.C. during field compaction

IS:2720 (Pt 2) (Speedy tester/nuclear meter)

 

2

test per 3000 cum

OMC + 1% to 2% (on wet side of OMC 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

1

test per 1000 sqm

150mm to 250mm

compaction test

 

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

 

Sl. No.

Test

 

Test Method

 

Minimum Frequency

Specified Value

1.

Gradation/Sand Content

IS:2720 (Pt 4)

 

1-2 test per 3000 cum

As in Special Specifications

2.

Maximum Particle size

IS:2720 (Pt 4)

 

1-2 test per 3000 cum

50mm

3.

MDD & OMC (by heavy compaction)

IS:2720 (Pt 8)

 

1 test per 3000 cum

MDD not less than 17.5 kN/cum

4.

CBR at 97% MDD

IS:2720 (Pt 16)

 

1 test per 3000 cum

As in special specification

5.

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

1 test per 1000 sqm

100mm to 250mm

compaction

8.

Classification

IS:1498

 

1 test per 3000 cum

Expansive clay not allowed*

NOTE:

embankment/ cutting just below the Subgrade shall be removed and filled with CNS soils.

* 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 the

in Joint Venture
in
Joint Venture

8 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Table5: Embankment Exceeding 3m Height

Sl. No.

Test

 

Test Method

Minimum Frequency

Specified Value

1.

Gradation/Sand Content

IS:2720 (Pt 4)

 

2 test per 3000 cum

As in Special Specifications

2.

Classification

IS:1498

 

1 test per 3000 cum

As in Special Specifications

3.

LL & PI

IS:2720 (Pt 5)

 

1 test per 3000 cum

As in Special Specifications

4.

Maximum Particle size

IS:2720 (Pt 4)

 

Frequently

75mm

5.

MDD & OMC (by heavy compaction)

IS:2720 (Pt 8)

 

1 test per 3000 cum

MDD not less than specified value in design

6.

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( at

95%

 

least one

test

in every

layer)

8.

Layer thickness (compacted)

By

scaling

during

compaction

1

test per 3000 Cum

150mm to 250mm

test

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

Sl. No.

 

Test

Test Method

Minimum

Specified Value

 

Frequency

1.

Soluble Sulphate content (expressed as

BS:1377 (Pt

As required

Max 1.9 g per litre

SO3)

3:1990)/IS:2720(27)

2.

Total

Sulphate

content

(expressed

as

BS:1377 (Pt 3:1990)

As required

Max 0.5% by mass

SO3)

in Joint Venture
in
Joint Venture

9 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Table7: Backfilling to Sub-Surface Drains

Sl.

       

No.

Test

Test Method

Minimum Frequency

 

Specified Value

 

1.

Grading of filter material

IS:2720 (Pt 4)

Each batch

   

% Passing

 

NOTE:

Sieve Size

     

i) Use Class I filter if soil in trench is fine grained (eg. silt, clay or mixture thereof).

 

Class I

Class II

Class III

53mm

 

100

45mm

 

97-100

ii) Use Class II filter if soil in trench is

26.5mm

 

100

coarse silt to medium sand or sandy type. iii) Use Class III filter if soil in trench is gravelly sand.

22.4mm

 

95-100

58-100

11.2mm

 

100

48-100

20-60

5.6mm

92-100

28-54

4-32

2.8mm

83-100

20-35

0-10

 

1.4mm

 

59-96

0-5

710mic

 

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

 

Sl.

       

No.

Test

Test Method

Minimum Frequency

 

Specified Value

 

1.

Grading of aggregate

IS:2720 (Pt 4)

Each batch

   

% Passing

 

Sieve Size

Type A

 

Type B

63mm

 

100

37.5mm

100

 

85-100

19mm

 

0-20

9.5mm

45-100

 

0-5

in Joint Venture
in
Joint Venture

10 | P a g e

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

Quality Assurance Plan

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 Value

 

1.

Grading for close-graded material

IS:2720 (Pt 4)

Each batch

Sieve

Size

 

%

Passing

NOTE: For required grading, see special specification of concerned project

Grading I

Grading

Grading III

 

II

75mm

100

 

 

53mm

80-100

 

100

26.5mm

55-90

70-100

100

9.5mm

35-65

50-80

65-95

4.75mm

25-55

40-65

50-80

2.36mm

20-40

30-50

40-65

0.425mm

10-25

15-25

20-35

0.075mm

3-10

 

3-10

3-10

2.

Grading of coarse graded material

IS:2720 (Pt 4)

1

per 200cum

 

Specified Value

 

NOTE: For required grading, see special specification of concerned project

     

%

Passing

Sieve

Size

Grading I

Grading

II

Grading III

 

75mm

100

 

53mm

 

100

100

26.5mm

55-75

50-80

9.5mm

 

4.75mm

10-30

15-35

25-45

2.36mm

 

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 single source.

3.

Ten percent fine value (wet)

BS:812 (Pt 111)

1

per 200 cum

Min 50kN

in Joint Venture
in
Joint Venture

11 | P a g e

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

Quality Assurance Plan

Sl. No.

Test

Test Method

Minimum Frequency

Specified Value

4.

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, III

7.

MDD & OMC

IS:2720 (Pt18)

As required

8.

MC for field compaction

Speedy tester/Nuclear meter

1 per 250 sqm

2% to + 1% of OMC

9.

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 200cum

Max 12%

9.

Plasticity index of binding material

IS:2386 (Pt 5)

1 per 25cum

Less than 6

10

Grading of coarse aggregates

IS:2386 (Pt 1)

 

Grading

Sieve

Sieve

% Passing

No.

Range

Size

by weight

in Joint Venture
in
Joint Venture

12 | P a g e

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

Quality Assurance Plan

Sl. No.

Test

Test Method

Minimum Frequency

 

Specified Value

 
 

In general visual inspection of the aggregates shall be made and not weathered rock samples should be allowed.

   

1.

90-45mm

125mm

100

90mm

90-100

63mm

25-60

 

45mm

0-15

22.4mm

0-5

2.

63-45mm

90mm

100

63mm

90-100

53mm

25-75

45mm

0-15

22.4mm

0-5

3.

53-

63mm

100

22.4mm

53mm

95-100

45mm

65-90

22.4mm

0-10

11.2mm

0-5

11.

Grading for screenings

IS:2386 (Pt 1)

1 per 100cum

A.

13.2mm

13.2mm

100

11.2mm

95-100

5.6mm

15-35

180mic

0-10

B.

11.2mm

11.2mm

100

5.6mm

90-100

180mic

15-35

Table 11: Prime Coat and Tack Coat

in Joint Venture
in
Joint Venture

13 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Sl. No.

Test

 

Test Method

Minimum Frequency

Specified Value

1.

Quality of primer

IS:73, IS:217 & IS:8887

2 sample per lot

Special Specifications

2.

Binder temperature for application

At regular interval

Special Specifications

3.

Rate of spread of binder

Tray

Test/Depot

Tray

One test/500sqm and not less than 2 per day

Max variation 2.5%

Test

Table 12: Open Graded Premix Surfacing

       

Minimum

 

Sl. No.

Test

Test Method

Frequency

Specified Value

1.

Quality of binder

IS:73

2

per lot

Special Specifications

2.

Los Angeles Abrasion Value or Aggregate Impact Value

IS:2386 (Pt 4)

1

per 50cum

LAA max 40%, AIV max 30%

3.

Flakiness Index and Elongation Index (combined)

IS:2386 (Pt 1)

1

per 50cum

Max 30%

4.

Coating and stripping

AASHTO: T182/IS : 6241

3

per source

Min retained coating 95%

5.

Soundness in Sodium Sulphate and Magnesium Sulphate

IS: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 55

8.

Grading of 13.2mm chippings

IS:2386 (Pt 1)

1 per 25cum

100% passing 22.4mm & retained on

11.2mm

9.

Grading of 11.2mm chippings

IS:2386 (Pt 1)

1 per 25cum

100% passing 13.2mm & retained on

5.6mm

10.

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 mixing

Frequently

150 o C to163 o C 155 o C to163 o C 130 o C to160 o C

b) Aggregate at the time of mixing

Frequently

Frequently

c) Discharge temperature of mix

 
in Joint Venture
in
Joint Venture

14 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Minimum

Frequency

Sl. No.

Test

Test Method

Specified Value

12.

Rate of spread of mixed material

Site check of materials and layer thickness

Regularly

Min 20mm thick

Table 13: Bituminous Macadam

Sl. No.

 

Test

Test Method

 

Minimum Frequency

 

Specified Value

1.

Quality of binder

 

IS:73

2

per lot

Special Specifications

 

2.

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

IS:2386 (Pt 1)

1

per 50cum

30% max

 

(combined)

 

4.

Stripping value of aggregate. If the minimum retained coating is <95% Retained Tensile Strength Test shall be carried out specified value is min 80%

AASHTO T:182/IS : 6241

3

per source

Min coating 95%

 

5.

Soundness

in

Sodium

Sulphate

and

IS:2386 (Pt 5)

1

per 50cum

Max 12%/18%

 

Magnesium Sulphate

 

6.

Water absorption

 

IS:2386 (Pt 3)

1

per 50cum

Max 2%

7.

Grading aggregates

 

IS:2386 (Pt 1)

2

per day/plant both on

 

% Passing

Grading I

Grading II

individual constituents

Sieve Size

Grading 1

Grading 2

Nominal aggregate size Layer thickness

40mm

19mm

and mixed aggregates from the dryer

45mm

100

80-100mm

50-75mm

26.5mm

75-100

100

 

22.4mm

60-95

75-100

 

11.2mm

30-55

50-85

5.6mm

15-35

20-40

2.8mm

5-20

5-20

90micron

0-5

0-5

8.

Grain size analysis

   

2

tests/ day/plant

Max 5% passing 75 micron

9.

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 II with tolerance 0.3% by weight of total mixture

in Joint Venture
in
Joint Venture

15 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

10.

Temperature control:

   

Varies with the type of penetration bitumen

a) Binder at mixing time

At frequent intervals At frequent intervals At frequent intervals At frequent intervals At frequent intervals

30 - 40

60 - 70

80 -100

b) Aggregate at mixing time

160-170

150-165

140-160

c) Discharge temperature of mix

160-175

150-170

140-165

d) Laying temperature

Max 170

Max 165

Max 155

e) Temperature at completion of rolling

Min 130

Min 125

Min 115

 

Min 100

Min 90

Min 80

11.

Layer thickness

Site check

 

Special Specifications

 

12.

Density of compacted layer

 

1

per 250cum

Special Specifications

 

Table 14: Mix Seal Surfacing

 

Sl. No.

Test

Test Method

Minimum Frequency

 

Specified Value

1.

Quality of binder

IS:73, 217, 454

2

per lot

Special Specification

 

2.

Quality of aggregate

Table 24 (Test 2 to 6)

1

per 50cum

3.

Grading of aggregates

Sieve analysis

1

per 50cum

 

% Passing

 

Sieve Size

Type A

Type B mix

mix

13.2mm

100

11.2mm

100

88-100

5.6mm

52-88

31-52

2.8mm

14-38

5-25

90mic

0-5

0-5

4.

Rate of binder for mix per 10sqm

Site check

2

per day

Type A: 22kg; Type B: 19kg

 

5.

Rate of aggregate per 10sqm

Site check

2

per day

0.27 cum for Type A & B

 

6.

Temperature control:

     

a) Binder before mixing

Frequently

150 o C to163 o C 155 o C to163 o C 130 o C to160 o C Min 100 o C

 

b) Aggregate before mixing

Frequently

c) Mix on discharge

Frequently

d) Completion of rolling

Frequently

7.

Thickness after compaction

   

Min 20mm

Table 15: Semi Dense Bituminous Concrete

in Joint Venture
in
Joint Venture

16 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Sl.

       

No.

 

Test

Test Method

Minimum Frequency

 

Specified Value

 

1.

Quality

of

binder

(grade

30/40

to

IS:73

2 per lot

     

80/100)

 

Special Specifications

2.

Los Angeles Abrasion or Aggregate Impact Value

 

IS:2386 (Pt 4)

1 per 50cum

 

LAA 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 Sulphate

 

IS:2386 (Pt 5)

As required

 

Max 12%/18%

 

7.

Sand equivalent value

 

IS:2720 (Pt 37)

As required

 

Not less than 50

 

8.

Stone polishing value

 

BS:812 (Pt 114)

As required

 

Not Less than 55

 

9.

Grading of mixed aggregate

 

IS:2386 (Pt 1)

2

per day

Sieve

% Passing by weight

   

Size

Grading I

 

Grading II

19mm

100

 

--

13.2mm

90-100

 

100

9.5mm

70-90

 

90-100

4.75mm

35-51

 

35-51

2.36mm

24-39

 

24-39

1.18mm

15-30

 

15-30

600mic

--

 

--

300mic

9-19

 

9-19

75mic

3-8

 

3-8

10.

Job mix formula

 

By mix design

Every

change

of

As per Design

 
 

material

 

11.

Requirements of mix

 

ASTM D-1559

tests per day or per 400 tone of mix

2

S. No.

Description

Requirement

 

1.

Marshall stability

Mn. 8.2 kN @

 

60

o c

in Joint Venture
in
Joint Venture

17 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Sl.

       

No.

Test

Test Method

Minimum Frequency

 

Specified Value

       

2.

Marshall flow

2-4mm

3.

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 and Min 5% for Grading II

       

7.

Compaction level No. of blows

75 blows / face

12.

Permissible variations from JMF

See Table 28 (item 11)

 

13.

Temperature Control:

     

a) Binder

Same as Table 24 (10)

 

b) Aggregate

 

c) Discharge temperature

d) Laying temperature

e) Completion of rolling

14.

Control of binder content and gradation

Bitumen extraction and sieving (Appendix 5 of

2

per day

JMF

IRC:SP-11)

 

15.

Layer thickness

Site check

1

per 250sqm

Special specifications

 

16.

Density of compacted layer

Density of core

1

per 250sqm

Min 98% of Marshall specimen

 

Table 16: Cement Concrete

Sl. No.

Test

Test Method

Minimum Frequency

Specified Value

in Joint Venture
in
Joint Venture

18 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Sl. No.

 

Test

Test Method

 

Minimum Frequency

 

Specified Value

1.

Cement (Physical and Chemical tests)

 

1

per source of supply and

 

a)

Portland Slag Cement

IS:455

occasionally for long or improperly stored batch. Also manufacturer s certificate required.

As per relevant IS

2.

Los Angeles Abrasion or Aggregate Impact Value 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 coarse aggregate

b) Deleterious constituents in fine aggregate

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

1 per source per month

 

1 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-reactive

9.

Grading of aggregates

IS:2386 (Pt 1)

1 per source per month

IS:383

10.

Maximum size of aggregate

IS:2386 (Pt 1)

1 per source per month

25mm

11.

Concrete mix design

IS:10262 and

1 per source

a)

Compressive strength/flexural strength as per Special Specifications

IS:SP23

IS: 455 1989 IS: 10262

1 per source

 

With Portland slag cement confirming to IS 455 with slag more than 50%, W/C ratio of 0.45 to

0.5%.

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 water

14.

Acidity limit by titration

IS:3025

1 per source

Max 2ml NaOH to neutralize 200ml water

15.

Solids in water

IS:3025

1 per source

Maximum limits per liter:

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

in Joint Venture
in
Joint Venture

19 | P a g e

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

Shelters & Habitations, Bridges and Culverts under NCRMP

Quality Assurance Plan

Sl. No.

Test

Test Method

Minimum Frequency

Specified Value

16.

Concrete cube test (7 day & 28 day)

IS:516

cubes per 150cum or day or batch

2

min

6

per

Special specifications

17.

Concrete beam test (7 day & 28 day)

IS:516

beams per 150cum or min 6 per day or batch

2

Special specifications

18.

Core strength of hardened concrete

IS:516

Engineer s discretion

Special specifications

19.

Slump test (for workability)

IS:1199

1

per dumper load initially and

 

per alternate dumper subsequently

1

As per IS 456

20.

Thickness measurement of trial length

Core sampling

3 cores per trial

Special specifications

21.

Thickness determination

Leveling

Grid points of 5 to 6.25m x 3.5m

 

Special specifications

22.

Verification of level of form

Site check

5.0m to 6.25m

± 2mm

23.

Texture depth

Sand patch

5

measurements in 50m length

1 ± 0.25mm

method

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 in a vehicle or the quantity discharged during one minute from a continuous mix.

Table 17: Cement for Structural Works

       

Minimum

 

Sl. No.

 

Test

Test Method

Frequency

Specified Value

1.

General requirement

 

1

per

 

a)

Portland slag cement

IS:455

consignment if

 

old stock or

Relevant specifications

improperly

handled

2.

Total chloride content

Test certificate from manufacturer

1

per source

 

required

 

Max 0.05%

in Joint Venture
in
Joint Venture

20 | P a g e

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

Quality Assurance Plan

Minimum

Frequency

Sl. No.

Test

Test Method

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%