Quality Assurance Plan Sparco For Sulemanki PDF

Rehabilitation & Upgradation of Sulemanki Barrage Quality Assurance Plan
TABLE OF CONTENTS

Sr. No. Description
PREFACE
ABBREVIATIONS
Section-1. QUALITY ASSURANCE ACTIVITIES
1. 1. Contractor s Submi ttal s
1. 2. Earthwork
1. 3. Concrete Work
1. 4. Bored Cast-I n-Si tu R. C. C. Pi l es
1. 5. Pi l e Load Test
1. 6. Stone Pi tchi ng & Stone Apron
1. 7. Bri ckwork
1. 8. R. C. C. Pi pes & Layi ng
1. 9. Steel Sheet Pi l es
Section-2. QUALITY CONTROL/QUALITY ASSURANCE TESTING
2. 1 Types of Materi al Tests
2. 2 Testi ng Arrangements/Equi pment
2. 3 Testi ng Requi rements
Section-3. RECORD/REPORTING DOCUMENTS
3. 1 Laboratory Record/Reporti ng Documents
3. 2 Fi el d Record/Reporti ng Documents (Fi el d Inspect i on/
Testi ng)
Section-4. SAFETY REQUIREMENTS
Section-5. STANDARDS & PROCEDURES


PREFACE
This Quality Assurance Plan (QAP) is an effort to outline the activities of the Contractor
in adequate details for the guidance of its staff and other relevant Personnel, during the
construction activities of the project to satisfy the requirements of Contract. It requires
that individuals have clearly defined responsibilities and lines of communication to enable
all aspects of the work activities to be assessed and accepted and if a problem is discovered,
the solution is quickly found. QAP cannot replace the experience of reasonable and
responsible staff; however it can help them in selection of timely and sequential line of
various activities and in keeping and maintaining retrievable record documentation. This
QAP is specially designed for Rehabilitation and Upgrading of Sulemanki Barrage
Project
The Contractor is, in particular, responsible for the Quality Control of the Works as per
Contract Specification . Consultants supervision and surveillance does not relieve the
Contractor of his contractual obligations. The basic purpose of QAP is to ensure that the
Quality Control System is in place and performing to the requirements of Contract
documents, during the construction period.
The quality requirements are based on provisions for technical specifications as per
contract documents for R&U of Sulemanki Barrage. Maximum efforts have been exerted in
making QAP an acceptable and tangible document for all levels of execution and supervisory
staff and novice to experience. Technical notes are provided at places to develop field staffs
approach and insight for a useful and effective supervision, without undermining adherence
to the contract specification.
The Contract Documents are the basis for this QAP, therefore, where an ambiguity is
detected between the procedures and requirements of QAP and content of Contract
Documents then the latter takes the precedence.

The following are the objectives while formulating QAP.
To define and adopt a sequential and systematic quality assurance line of action with
participation of the other stake holders for ensuring of all submittals, procurement,
execution of works and other on and off site construction activities. These activities may
also include material supply, testing and reporting envisaged in the specification of the
project.
To maintain auditable record of all tests, inspections, procedures and corrective
measures and any other information considered helpful.
To define the assignment and responsibilities of the Contractors field staff and other
relevant personnel at site with respect to Quality Assurance of the project viz a the
Contractors Quality Control Programme and their interaction with the client and the
Consultant.
To prevent non-conformities through proactive Quality Assurance.


ABBREVIATIONS
A.C.I. American Concrete Institute
A.R.E. Assistant Resident Engineer
AASHTO American Association for State Highway and Transportation
Officials
ASTM American Society for Testing Material
B.S. British Standards
C.M.E. Construction Management Engineer
C.R.E Chief Resident Engineer
E.R. Engineers Representative (Consultants)
FR Field Record Document (Inspection Note/Testing etc.)
Geotech. Engr. Geotech Engineer
Insp. Inspector
The Engineer Consultants
LOA Letter of Acceptance
LR Laboratory Record (Testing etc.)
M.E Material Engineer
NSL Natural Surface Level
P.M Project Manager
PD PMU Project Director (Clients Representative)
PIDA Punjab Irrigation & Drainage Authority
PMU Project Management Unit
Q.C.S. Quality Control Section
(Geotech/Mat. Engr. + Field Lab.)
R.E Resident Engineer
SOP Survey of Pakistan
TBM Temporary Bench Mark


1.1 CONTRACTORS SUBMITTALS
1.1.1 Objective
The objective of this Section is to guide the field staff of the Contractor regarding different
submissions to be made in the form of check requests, test requests, approval requests and
authorization requests for execution of work. These submissions will be made by for
methodological construction execution works.
1.1.2 Applicability
The Contract Documents for R&U of Sulemanki Barrage require the Contractor to submit
certain documents to the Consultants, i.e. before, during and after the execution of the
works. These documents / write-ups may include;
Work Programmes (As per Contract specifications)
Quality Control Test Results (As per Contract specifications)
Drawings and data for Equipment (As per Contract specifications)
Installation Instructions for Equipment (As per Contract specifications)
Operation and Maintenance Manual for mechanical equipment (As per Contract
specifications)
Manufacturers Certificates for various Construction Materials like water stops,
bearing pads, expansion joint fillers and sealants.

The submittals for various items of Project Works are provided in the checklist CKL-1.1
Checklist for Contractors Submittals for the guidance of the Contractors field staff.


CKL 1.1 (1) CHECKLIST FOR CONTRACTORS SUBMITTALS

General
Sr. No. Submittal Document Format Time For Submission
1.1 Contractors work
Programme including
arrangements, order and
timings
Contractors Format
As per Specification
Within 28 days of delivery
of LOA and updates when
required
1.2 Details of the
Programme and
Resource Schedule
Contractors Format
As per Specification
Within 28 days of delivery
of LOA
1.3 Request for Survey
check by the Contractor
Contractors Format Prior to commencement of
works
1.4 Contractors Quality
Control Programme
works
These submissions shall be made by the Contractor to The Engineer for prior review,
who shall forward these to the Consultants for detailed review and agreement/advice.



Earthworks and Caring & Handling of Water
2.1 Plan for Protection and
Diversion Works
*

Contractors Format Prior to Construction of
protection and diversion
works
2.2 Plan for Dewatering of
foundations to be
submitted direct to The
Engineer
Contractors Format Prior to Commencement
of dewatering operations
2.3 Materials Source
Approval
*

Contractors Format Prior to commencement
of component of work
2.4 Quality Control/
Assurance Tests to be
submitted direct to The
Engineer
Consultants QAP
Specified Formats
As per requirements of
specifications and QAP
2.5 Job Safety Analysis as
per HSE requirements
Contractors Format Prior to start
Construction
*
These submissions shall be made by the Contractor to The Engineer for detailed review
and agreement/advice.



Concrete Works
3.1 Method Statement Contractors Format Prior to Construction
3.2 Mill test Certificates for
Steel Reinforcement
Manufacturers
Format
Along with delivery of steel
at site
3.3 Bar Bending Schedule FR-06 3 days Prior to
Commencement of
fabrication of Re-Steel
3.4 Quality Control Tests for
Concrete works
Consultants QAP
Specified Formats.
As per requirements of
specifications and QAP
3.5 Manufacturers
Certificate for Rubber
water stops, bearing
pads joint filler and
sealants
Manufacturers
Format
Prior to procurement
3.6 Job Safety Analysis as
per HSE requirements
Contractors Format Prior to start Construction



Bored Cast-in-Situ R.C.C. Piles
5.1 Method Statement Contractors Format
As per Specifications
Prior to commencement
of work
5.2 Date of Survey and
Location
of work
5.3 Protective Measures Contractors Format Prior to
commencement of
work
5.4 Placement Schedule Contractors Format Prior to commencement
of work
5.5 Approval for Source of
Material
of work
5.6 Pile Construction Record QAP Format Within 24 hours of
completion
5.7 Quality Control Tests QAP Specified Format Within 24 hours of the
completion of Tests
5.8 Job Safety Analysis Contractors Format Prior to commencement
of work
These submissions shall be made by the Contractor to The Engineer detailed review and
agreement/advice.



Pile Load Test
6.1 Method Statement Contractors Format Prior to commencement of
Test
6.2 Calibration Certificate
for Test Apparatus
Test
6.3 Pile Construction
Record
QAP Format Within 48 hours of
completion of pile
construction
6.4 Pile Load Test Record
and Report
Contractors Format As soon as possible after
completion of the Test.
6.5 Job Safety Analysis Contractors Format Prior to commencement of
work



Mechanical Equipment
7.1 QAP Contractors Format After 28 days of
Commencement of Works
7.2 Work Schedule, Method
Statements & List of
Contractors submittals
Contractors Format After 28 days of
Commencement of Works
7.3 Request for Approval of
Sub-contractor for M & E
Works
Contractors Format Prior to procurement of
Gates and Hoists
7.4 Design calculations &
Shop Drawings for
Mechanical & Electrical
Plants
Contractors Format Prior to start of
fabrication of each
component of work
7.5 Manufacturers Schedule
& Method Statements
Contractors Format Prior to start of
fabrication of each
component of work
7.6 Installation Schedule and
Detailed Procedure
Contractors Format At start of each
component of work
7.7 Operation and
Maintenance Manual
Contractors Format When gates and gearings
have been installed
7.8 As Built Drawings Construction
Drawings
45 days after Certificate of
Completion
7.9 Job Safety Analysis Contractors Format Prior to commencement
of work


1.2 EARTHWORK
1.2.1 Objective
Objective of this Section is to provide the recommended guidelines to the Contractors field
staff for their guidance in performing quality assurance of earthwork for structures and for
the canal embankments etc. pertaining to the Permanent Works

This Section covers the open cut/foundation excavations, foundation backfills for the
structures and earthwork for irrigation canal embankments. The recommended guidelines
can also be used for other similar works and earthwork required for diversion
arrangements.
1.2.2 Construction Equipment
Selection of type of excavation and compaction equipment must be done wisely keeping in
view the bulk of work and efficiency of the equipment and that the selected equipment is
capable and adequate to perform the required earthwork. The following may be deployed as
per the nature of work involved;
Excavators
Dozer and Rippers
Tractors with implements
Front End Loaders
Dragline Excavators / Cranes
Dump Trucks
Motor Graders
Water Bowser
Dewatering Arrangements
Compactors(Rollers)
Flood Light Arrangements
1.2.3 Inspection
Setting out details on site as per design will be the responsibility of the field staff.
The Consultants through their own field staff shall check the setting-out accuracy,
survey control for NSL and design levels by joint survey with Contractor. These
surveys shall be carried out by Contractors surveyors in the presence of

Consultants Inspectors. The site inspector .shall monitor the excavation slopes for
stability and compaction of the sub grade and fills, etc.
If the Contractor encounters wet or slush, he is required to report to the Consultants
Site Engineer who will jointly inspect the site, evaluate according to Earthwork Sub
Clause of Technical Specifications of Contract Documents and submit their
recommendations for approval by the Engineer.
The Control of moisture and compaction of soils in the embankment of canals and
compacted earth consists of inspection of the material used, checking the amount
and uniformity of the soil moisture, maintaining the thickness of layer, and finally
determining the percentage of relative Dry Density of the compacted fill.
The relative Dry Density of the compacted fill is determined on the basis of Field
Density Tests and the Reference Laboratory Compaction Tests. The Field Density
Tests shall be performed by the Contractors staff as and when directed by the
Engineer In-charge or Site Inspectors.
Tests at critical areas shall be carrying out by Consultants staff and verified in
Consultants Field Laboratory.
The Standard/Modified Proctor Compaction Tests are used as Reference Laboratory
Tests for fine grained clayey soils. These tests shall be performed at the Contractors
Field Laboratory.
The Maximum and Minimum Dry Density Test results (from external laboratory) are
used as Reference Laboratory Tests for cohesion less sandy soils.
The soils having less than 12% passing No. 200 sieve are defined as sandy or non-
cohesive soils.
The Site Inspector should see that all perishable matter and any soil which may
become unstable upon saturation, such as highly organic soils, loose silts, very fine
sands/silts and expansive clays etc. are not present in the foundations. These soils
either need to be removed or improved to the extent necessary to provide a safe,
stable foundation or sub-grade under operating conditions.
A good bond between the foundation and first layer of fill is achieved by moistening
the foundation rather than using a very wet embankment layer.
For Quality Assurance (QA) of earthwork operations the Staff shall proceed in
accordance with CKL-1.2(1) Checklist for Structural Excavations and CKL-
1.2(2) Checklist for Canal Earthworks.

An important function of inspection is to determine when and where to make Field
Density Tests. These tests should be made in areas where degree of compaction is
doubtful.
Areas of doubtful density are sometimes detected by observation. Possible locations
of insufficient compaction include:
The junction between areas of mechanical tamping and rolled earth fill
embankment along abutments or cut-off walls.
Areas where rollers turn during rolling operations.
Areas where too thick a layer is being compacted.
Areas where improper moisture content exists in the soil.
Areas where less than specified number of roller passes were made.
Areas where oversized rock which has been overlooked, is contained in the
fill.
Areas containing material differing substantially from the average.
1.2.4 Specified Limits for Degree of Compaction
While performing control over compaction the limits given below from specifications should
be observed.
Compaction Requirements
Description Cohesive Soils Cohesionless Soils
Backfill around Structures
above foundation level
90% Modified Proctor Dry Density 70% Relative Density
Special Backfill and Fill
beneath Structures
(Foundations)
Foundation under Canal
Embankment / Sub-grade
for Lining
Canal Embankments
(Main or Branch)
Disty/Minor
embankments

1.2.5 Frequency of Control Tests
The recommended tests, their procedures, frequency and the required facilities for an
effective quality control/assurance of earthwork are presented in Section 2.3 Testing
Requirements. The contractors field staff is required to ensure that these tests are
performed as per specified frequencies in the recommended laboratories or at site. The field
tests should be performed in the presence of the Engineers site Inspector and the results
recorded immediately on completion of the test, duly signed by the authorized
representative of the Contractor and Consultants. An independent record of the tests
should also be maintained by consultants field staff, in addition to the submittals of the
Contractor.
1.2.6 Safety
The Contractor is to ensure and monitor compliance of the requirements of the Law of
Pakistan for safety, health and environment impact, in the domain of the construction
contract. For safety check proceed in accordance with CKL-5.1 Safety.


CKL 1.2 (1) CHECKLIST FOR STRUCTURAL EXCAVATIONS
Sr.
No.
Issues Action by
Record/Reporting
Document
1. Level of TBMs established by the
Contractor, Confirm by Survey Control.

Engineers Rep.

Contractors
Surveyor

Survey & Level
Book and FR-02
2. NSL by checking of the survey data and
record entries. Check and approve by
Survey Control.
3. Complete setting out/layout. Check by
Survey Control and Dimensional
Inspection.
4. Location and level of level pegs, Check
by visual inspection and Survey
Control.
5. Location of spoil or dump for excavated
material. Optional Check by Visual
Inspection.
Lab Technician
FR-02
6. Deployment of proper Equipment.
Discuss with Contractor and Ensure.
Lab Technician
FR-02
7. Adequate dewatering to desired levels,
before start of excavation below water
table. Water level to be maintained 3 ft.
below the lowest foundation level.
Ensure by physical inspection
Lab Technician
FR-02
8. Complete information about condition
of soil i.e. dry, wet or slush. Check by
physical inspection and record
observations.
Lab Technician
FR-02
9. Stability of excavated slopes. Ensure by
physical inspection.
Lab Technician
FR-02
10. Final levels of excavated surfaces and
record entries. Check by Survey Control
and make record entries.
Engineers Rep.
Contractors
Surveyor
Survey & Level
Book and FR-02
All actions should be taken in accordance with the Contract Specifications and Contractors
Work Methodology as approved by the Engineer.


CKL 1.2 (2) CHECKLIST FOR CANAL EARTHWORKS
Sr.
No.
Issues Action by
Record/Reporting
Document
1. Level of TBMs established by the
Contractor to be checked jointly.

-Engineers Rep.
-Contractors
Surveyor

Survey & Level
Book and FR-02
for comments
2. NSL by checking of the survey data and
make record entries by Joint Survey.
3. Complete setting out/layout. Check by
Survey Control and Dimensional
Inspection.
4. Location and level of level pegs, Check
by spot visual inspection and Survey
Control.
5. Final levels of excavated surfaces.
Check by Survey Control.
6. Deployment of proper equipment.
Discuss with Contractor and Ensure
Lab Technician
FR-02 for
comments
7. Clearing, Grubbing and Stripping.
Ensure by physical inspection.
Lab Technician
FR-02
8. Approval of backfill material
(excavated or borrowed). Check by
physical Inspection or Test Procedures.
Lab Technician Field
Lab.
FR-02/Letter
LR-01, 03
9. Compaction control during execution
Check by physical Inspection and Test
Procedures.
Lab Technician FR-03/A, FR-
03/B, FR-03C,FR-
02, LR-05
10. Records of all Tests made during time
period. Update periodically.
Lab Technician FR-04
FR-05
LR-05


1.3 CONCRETE WORK
1.3.1 Objective
Objective of this section is to provide the recommended guidelines, sequential
inspection procedures and other relevant information to the field staff of the
Contractor for their guidance in quality assurance of reinforced concrete and pre-
stressed concrete pertaining to the permanent works being executed at site.
1.3.2 Applicability
This section covers Plain Cement Concrete (P.C.C.) the Reinforced Cement Concrete
(R.C.C.) and pre-stressed concrete works for permanent structures as well as pre-
cast works as shown on the drawings and as directed by the Project Manager.
The Contractor must ensure that the equipment is adequate to perform the concrete
work.
1.3.4 Inspection
1) For quality assurance of construction activities the Consultants Supervisory
Staff shall proceed in accordance with CKL-1.3 (1) Checklist for concrete
work.
2) For effective Quality Control, the Contractor is required to perform certain tests
at different stages of the concreting process. These tests include tests to be
performed on concrete ingredients, before start of the concreting works, tests to
be performed during construction stages and the tests to be performed
subsequently in the Contractors Field Lab. or in any other approved external
laboratory.
3) A list of tests, the test procedures, test frequencies and the proposed testing
arrangements are provided in Section 2.3 Testing Requirements.
4) The required Record/Reporting Documents for the Consultants Field Staff are
also listed in Section 2.3 Testing Requirements.
5) To maintain an auditable and retrievable record of all Inspection Tests, Non-
compliance and Corrective Actions etc. the provided proformas must be used by
the Consultants Supervisory Staff.

6) The Engineer is to ensure that the required tests are performed by the
Contractor in accordance with the specified procedures and in the presence of
his representative. He is required to maintain a complete record of these test
results independently.
1.3.5 Classes of Concrete
Concrete for several structures and part thereof shall have 28-day compressive
strength of 6 12 cylinders at least equal to the minimum allowable strength
shown in the following Table:

Class Nominal Mix*
Compressive Strength at 28-days
Cylinder Strength
A 1:1:2 5000 Psi
A 1:1 :3 4000 Psi
B 1:2:4 3000 Psi
C 1:2.5:5 2500 Psi
D 1:3:6 2000 Psi
E 1:4:8 1200 Psi
* Actual Mix Ratio will be determined after Concrete Mix Design carried out in accordance
with relevant Sub-Clauses of Technical Specifications of Contract Documents.
1.3.6 Concrete Slump
For various structural components the concrete shall have the following slump:
Class Structural Component Slump
A Pre-cast concrete 2 to 4
B Concrete Piles 5 to 7
C Canal Lining 1 to 3
C Cut-off Walls 2 to 4
B and C
General Reinforced Concrete for Bridge & other
Structures
2 to 4
C Plain Concrete 2 to 4
D Fill Concrete 2 to 4
E Blinding/Lean Concrete 2 to 4

1.3.7 Nominal Maximum Aggregate Size
The nominal maximum aggregate size to be used in various structural components
shall be as follows: (Technical Specifications 5.2)
General Use
Nominal Maximum
Aggregate Size
Blinding/Lean Concrete and Canal Lining "
Maximum dimension of Structure less than 12 "
Maximum dimension of Structure more than 12 1
1.3.8 Concrete Mix Design
The mix proportions for class of concrete mentioned in the specifications are
nominal. The concrete mix design is required to be carried-out by the contractor
under supervision of Engineers representative at field laboratory using cement,
sand and aggregates from the approved source of supply.
Required average strength fcr used as the basis of selection of concrete proportion,
shall be in accordance with ACI 318 and provided in the under mentioned Table.

Specified Compressive Strength fc (PSI) Required Compressive Strength f cr
(PSI)
Less than 3000 f c +1000
3000 to 5000 f c +1200
Over 5000 f c +1400

The concrete mix design for each class of concrete in addition to mix proportion will
also provide water-cement ratio by weight (exclusive of water absorbed by the
aggregate) which will be determined on the basis of producing concrete having
suitable workability, density, impermeability, durability and the required strength.
1.3.9 Concrete Pour Authorization
The contractor is required to submit two copies in two different colours (white and
pink) of Concrete Pour Authorization (CPA) Request Form FR-07 before starting
concrete for any component of a structure. The Engineer should check all the items,
before allowing pouring of concrete. In case of deficiency, that would be marked on
the CPA slip and returned to the Contractor for rectification. The same CPA slip will
be finally signed on satisfactory rectification. Pink copy will be


retained by the Engineer for reference and record. Contractors copy (white) should
be kept at site by the Contractor.
1.3.10 Safety
Proceed in accordance with CKL-5.1 Safety.


CKL 1.3 (1) CHECKLIST FOR CONCRETE WORKS
Sr.
No.
Issue Action by
Record/Reporting
Document
1. Physically inspect all the
Reinforcement Steel procured by the
contractor and confirm adherence to
the Specifications by Test Procedures.
Lab Technician Manufacturers
Certificate and/or
External Lab.
Format.
2. Physically inspect, cement procured by
the contractor and confirm adherence
to the Specifications by Test
Procedures.
Lab Technician Manufacturers
Certificate and/or
External Lab.
Format.
3. Physically inspect, fine and coarse
aggregates and confirm adherence to
the Specifications by Test Procedures.
Lab Technician Ref. Section 2
4. Deployment of proper equipment.
Discuss with Contractor and Ensure
Lab Technician FR-02 for
comments.
5. Receive Concrete Pour Authorization
C.P.A. Request from the contractor.
6. Check all items of C.P.A. as per
requirements of specifications and
Drawings and approve.
7. Mixing, Transportation and Pouring of
Concrete. Check by Physical Inspection
and Test Procedure.
8. Compressive Strength of Concrete
Cylinders. Check by Test Procedures.
Lab Technician. Ref. Section 2
FR-09, LR-07
9. Record of all Tests made during the
period. Update Periodically.
Lab Technician. Ref. Section
FR-10
All actions should be taken in accordance with Contract Specifications and Contractors work
methodology as approved by the Engineer.


1.4 BORED CAST-IN-SITU R.C.C. PILES
1.4.1 Objective
Objective of this Section is to provide the recommended guidelines, sequential inspection
procedures and other relevant information to the field staff of the contractor, for their
guidance in performing Quality Assurance of Bored Cast-in Situ R.C.C. Piles for Structures
pertaining to the Permanent Works, being executed.
1.4.2 Applicability
This Section covers the construction of bored Cast-in-Situ R.C.C. Piles for Pile Load Tests,
and Working Piles for various Structures, pertaining to the Permanent Works being
executed by the Contractor.
The Contractor must ensure the adequacy of the deployed equipment for performing
the job.
1.4.4 Inspection
The field staff is required to ensure setting-out accuracy, perform survey control for
NSL and design levels. The required surveys are carried out by the Contractors
Surveyors along with the Engineers representative.
Each Pile shall be placed with its top being within 2 inches (50.8 mm) of the correct
position as shown on the Drawings.
Pile shall be cast as accurately as possible to the vertical. The maximum allowable
deviation from the vertical shall not exceed 0.5 degrees (1:114).
Pile heads shall be cut to the levels shown on the Drawings and the cut shall be level,
smooth and horizontal.
No pile boring shall take place within 48 hours of the concreting of any pile which is
within a radius of 10 ft.
Drilling of holes shall be done by straight or reverse rotary rig or any other suitable
method.
After completion of drilling operations the borehole length shall be checked and
recorded.

The contractor may use Bentonite Slurry for stabilizing the hole.
A manufacturers certificate showing the properties of the bentonite powder must
be submitted by the Contractor.
Concrete shall be placed within thirty minutes after it has been mixed.
The concrete temperature should be maintained within 90
0
F (32
0
C) and
41
0
F (5
0
C).
Pouring of concrete shall be done by efficient tremie technique.
The rate of placing concrete in the bentonite stabilized Hole shall not be less than 30
ft. per hour or more than 50 ft. per hour.
The discharge end of the tremie shall be kept submerged continuously in the
concrete and it shall be kept full of concrete to a point well above the water surface.
The tremine shall not be moved horizontally during a placing operation.
Anchorage arrangements for lowering of re-steel cage and tremmie shall be
sufficiently strong to avert slipping down/free fall of cage or tremmie pipe.
The contractor shall not be permitted to place concrete while it is raining. Should it
rain while the concrete placement is already in progress, the contractor shall carry
on, with proper and sufficient precautions, the concrete placement operations until
the pile is completed. The contractor shall cover the already placed concrete, while
under settling conditions with polythene or similar impervious sheets.
The Engineer must maintain an independent record of Pile Construction as per FR-
11 in addition to the submissions by the Contractor.
1.4.5 Safety
The Contractor should monitor compliance of the works with requirements of the Law of
Pakistan for safety, health and environment impact, in the domain of the construction

CKL 1.4 CHECKLIST FOR BORED CAST-IN-SITU R.C.C. PILES
Sr.
No.
Issues Action by
Record/Reporting
Document
1. Location and rating of SOP or Canal
Bench Marks. Confirm handing over by
the client.
2. Receive request for Survey check by the
Contractor.
Lab Technician
Contractors
Format
3. Contractors Method Statement of
Construction of Piles. Study, Analyse and
approve.
4. Levels of TBM established by the
Contractor. Confirm by Joint Survey.

A.R.E./Site
Inspector

Contractors
Surveyor
FR-02
for comments
5. Location of Piles as per approved
drawings. Check by Survey Control and
Dimensional Inspection.
6. Excavated ground Elevations for each
pile location by checking of the survey
data and make record entries by joint
survey.
7. Deployment of proper equipment as
described in the Work Methodology
submitted by the Contractor. Discuss
with Contractor and Ensure.
Lab Technician
FR-02
for comments
8. Ensure presence of Contractors
qualified experienced and competent
persons to conduct and supervise,
drilling and pile construction.
9. Check by physical Inspection and Test
Procedures, all materials to be used in
piling work.
Lab Technician. Ref. Concrete
work Section 4
Item 1.3.
10. Check by physical Inspection and Test
Procedure. The execution of drilling of
pile bore.
11. Receive concrete Pour Authorization.
Check all items and approve.
12. The execution of concreting of pile.
Check by physical Inspection and Test
Procedures.
LR-07
13. Update Periodically records of all Tests
made during time period.
Lab Technician. FR-10
LR-07
All actions should be taken in accordance with Contract Specifications and Contractors Work
Methodology as approved by the Engineer.


1.5 PILE LOAD TEST
1.5.1 Objective
procedures and other relevant information to the field staff of the consultants, for their
guidance in performing Quality Assurance of Pile Load Tests, being executed by the
Contractor.
1.5.2 Applicability
This Section covers the Pile Load Test on single vertical Piles for the design confirmation
and for the Proof Load Tests for Quality Assurance of working Piles.
1.5.3 Apparatus for Applying Loads
The apparatus for applying compressive Loads to the Test Pile shall be
constructed so that the Loads are applied to the central longitudinal axis of the
Pile, with minimum possible eccentric loading.
A steel Test Plate of at least 2 in. (50 mm) thickness shall be centred on the
Pile and set perpendicular to the longitudinal axis of the Pile.
The size of Test Plate shall not be less than size of the Pile.
The Test Plate shall be set in high-strength quick-setting grout.
The hydraulic jack shall be centred on the Test Plate with a steel Bearing
Plate of adequate thickness between the top of the jack ram and the bottom of
the Test Beam.
The complete jacking system including the hydraulic jack, hydraulic pump and
pressure gauge shall be calibrated as a unit before each test to an accuracy of
not less than 5% of the applied Load.
The hydraulic jack shall be calibrated over its complete range of ram travel for
increasing or decreasing applied loads.
If it is not feasible to calibrate the complete jacking system as a unit, the
pressure gauge may be calibrated independently in which case the jack piston
should be measured to verify the area.
If the hydraulic jack pump is to be left unattended at any time during the test, it
shall be equipped with an automatic regulator to hold the Load constant as pile
settlement occurs.

Calibration report shall be furnished by the contractor for all testing equipment
for which calibration is required which shall also show the temperature at
which the calibration was done.
1.5.4 Apparatus for Measuring Movements
All reference beams shall be independently supported with supports embedded
in the ground at a clear distance of not less than 8.0 ft. from the Test Pile.
If steel reference beams are used, one end of each beam shall be free to move
horizontally as the beam length changes with temperature variations.
Dial gauges shall have at least a 2-in (50 mm) travel.
The dial gauges shall have a precision of at least 0.01 in (0.2 mm).
Smooth bearing surfaces such as glass shall be provided for the gauge stems.
All the dial gauges, scales and reference points shall be clearly marked with a
reference number or letter to assist in recording data accurately.
1.5.5 Load Application by Hydraulic Jack acting against a Weighed Platform
Schematic setup for applying loads to Pile using Hydraulic Jack acting against
weighted Platform is shown in Fig. 1.6.
Centre over the Test Pile a Test Beam of sufficient size and strength to avoid
excessive deflection under Load. The clearance between the top of the Test Pile
and the bottom of the beam after deflection should be enough to accommodate
the necessary bearing plates and hydraulic jack.
Centre a Platform on the Test Beam with the edges of the Platform parallel to
the Test Beam supported by cribbing as far from the Test Pile as practicable but
in no case less than a clear distance of 5.0 ft.
Load the Platform with any suitable material such as soil with a total weight of
at least 10% greater than the anticipated maximum Test Load.
1.5.6 Test Loads
The Test Pile for Pile Load Test for confirmation of Pile design shall be loaded
up to 300%(or a max. of 200 Tons) of the Design Load or failure whichever
occurs first.
Cyclic loading sequence shall be used.
The Test Pile for Proof Load Test shall be loaded up to 150% of the Design
Load, by Standard Loading Sequence.

1.5.7 Standard Loading Sequence
Apply the Load in Increments of 25% of the Test Load (150% of Design Load).
Maintain each Load Increment until the settlement is not greater than 0.01 in
(0.25mm) per hour but not more then 2.0 hours.
After application of the total Test Load, if the Pile has not failed and the
settlement is not greater than 0.01 in (0.25 mm) per hour maintain the Load for
12.0 hours otherwise allow the Total Load to remain on the Pile for 24 hours.
After the required holding time, remove the Test Load in decrements of 25% of
the Total Test Load with 1.0 hour between the decrements.
If the Pile failure occurs continue jacking the Pile until the settlement equals
15% of the Pile diameter.
Pile is considered to have failed if settlement is more than 0.5 in(12.7mm).
1.5.8 Cyclic Loading Sequence
1
st
Cycle
Loading ( up to 100% of Design Load):
Load Increments of 25% of Design Load (i.e. 0%, 25%, 50%, 75% and 100%).
Each Load Increment to be maintained till the settlement rate is not more than
0.25 mm/hour or for a maximum of 2.0 hours.
Maintain 100% Load for one hour before unloading.
Unloading:
Unload with decrements of 25% of design Load (i.e. 100%, 75%, 50%, 25% and
0%).
Maintain each step for 20 minutes.
2
nd
Cycle
Loading:
1
st
Stage (up to 100 % of Design Load)
Up to 100% design Load use three steps 0%, 50% and 100%.
Each step to be maintained for 20 minutes.

2
nd
Stage (From 100% to 300% or a max. of 200 Tons)
Load increments of 25% each (i.e. 100%, 125%, 150%, 175%, 200%, 225%,
250%, 275% and 300% or a max. of 200 Tons).
Each Load increment to be maintained till settlement rate is not more than 0.25
mm/hour or for a maximum of 2 hours.

Maintain 300% (or a max. of 200 Tons) Load for 12 hours if settlement is not
more than 0.25 mm per hour otherwise for 24 hours.
Unloading:
Unload in 25% of design Load decrements (i.e.300%, 275%, 250%, 225%,
200%, 175%, 150%, 125%, 100%, 75%, 50%, 25% and 0%).
Maintain each step for one hour.

If the Pile fails, continue jacking the Pile till the settlement equals 15% of Pile dia.
Pile is considered to have failed if settlement is more than 0.5 in. (12.7 mm).
1.5.9 Safety
The Contractor is to ensure compliance with requirements of the Law of Pakistan
for safety, Health and Environment Impact, in the domain of the construction


CKL 1.5 CHECKLIST FOR PILE LOAD TEST
Sr.
No.
Issues Action by
Record/Reporting
Document
1. Details regarding Type of Load Test and
Loading Sequence
Geotech Engr./
Cont. site engineer
Letter/
Memorandum
2. The location of the Load Test Pile or
identification of Proof Load Test Pile.
Check by Visual Inspection and Survey
Control.
Geotech Engr./
Cont. site engineer
FR-02
3. Study and Analyse, contractors Method
Statement for Pile Test.
Geotech Engr./
Cont. site engineer
Contractors
Format
4. Check by Physical Inspection and Test
Procedures, construction of the Test Pile
for Load Test.
A.R.E./Geotech
Engr Cont. site
engineer
Ref. Section-5
LR-07
FR-11
Procedure. All Materials, Equipment and
arrangements for Loading Specification.
Cont. site engineer FR-02
6. Monitor/Inspect all stages of loading and
unloading of Test Pile and keep
independent records.
7. Submit Pile Load Test Record and
Report.
Contractor Contractors
Format
8. Submit Pile Load Test Report to
Geotech/Material Engineer.
Lab Technician Contractors
Format & Letter
9. Recommendations for further Piling
Work.
Geotech Engr. Letter/
Memorandum
10. Recommendations A.R.E. FR-02
or through
a letter
All actions should be taken in accordance with Part Two, Contract Specifications and
Contractors work methodology as approved by the Engineer.


1.6 STONE PITCHING & STONE APRON
1.6.1 Objective
Objective of this Section is to provide the scope of applicability of the recommended
guidelines, sequential inspection procedures and other relevant information to the
Contractors field staff , for their guidance in performing quality assurance of stone
pitching and stone apron to the Permanent Work, being executed by the Contractor.
1.6.2 Applicability
This Section covers the placing of stone pitching and stone apron at the specified
locations as shown on the drawings. The recommended guidelines can also be used
for similar works elsewhere in the project, as directed by the Engineer.
The equipment specified in the contract Specifications are only to provide guideline
to assist the Contractor in the selection of proper equipment. The Resident Engineer
must leave the final selection to the contractor. The Contractor may deploy the
following equipment.
Excavators
Dozer and Rippers
Front End Loaders
Dump Trucks
Water Bowser
Dewatering arrangements
1.6.4 Inspection
For Quality Assurance (QA) of Construction activities the Contractors Staff
shall proceed in accordance with CKL-1.6 Checklist for Stone Pitching &
Stone Apron.
Base Filter Layer under Stone Pitching shall consist of well graded material
as specified in BOQ and shown on the Drawings.
The Stones individually shall weigh between 40-120 lbs with 80% shall be
80 lbs or larger and not more than 5% shall weigh less than 40 lbs.

All interstices in Stone Pitching/Apron shall be well filled with rock Spalls.
The rock Spall shall be rock fragments size between 2 inches and 4 inches.
The surface over which the base filter is to be placed shall be trimmed to the
proper lines and grades and shall be moistened with water and tamped or
rolled with suitable tools or equipment for the purpose of forming a firm
foundation. Wherever over-excavation occurs it shall be backfilled with
specially compacted fill.
The base filter layer shall be placed to a uniform thickness and finished to
reasonably smooth and even surface.
Stone used in the Stone Pitching/Apron shall be clean rough quarry stone
and shall be essentially free from dust, clay, vegetative matter and other
deleterious materials. The stone shall be hard, tough, durable, dense,
resistant to the action of water and air, and suitable in all respects for the
purpose intended. The stones shall be hand packed and placed and bedded
in such a manner that the completed stone pitching is stable and without
tendency to slide.
Construction of stone pitching shall commence at the lowest part of each
structure or section of a structure or canal and continue progressively
upward. The stones, largest of which shall be used at the bottob, shall be well
bedded on a layer of graded Graded Granular Material. In general the size of
the stone used shall have its major dimension the depth of the specified
pitching.
Large open spaces between the stone shall be avoided.
Stone shall be placed so as not to project above neat lines shown on the
drawings.
1.6.5 Quality of Stone
While performing control over procurement and placement of stone and filter
material, the following characteristics of stone and filter material from the
specifications must be observed.
Stone for pitching/Apron should be dense, sound, angular and resistant to
abrasion.

The loss in Los Angles Abrasion Test for large size Aggregates
(ASTM-C535-96) should not exceed 10% by weight at 200 revolutions or
40% by weight at 1000 revolutions.
The loss in Los Angles Test for small size Aggregates (ASTM-C131-96)
should not exceed 10% by weight at 100 revolutions or 40% by weight at
500 revolutions.
The Specific Gravity of stone (Saturated Surface Dry basis) shall be more
than 2.60.
1.6.6 Test Procedures Frequency and Facilities
The recommended test procedures their frequency and required facilities for an
effective quality control of stone pitching and stone apron are presented in
QAP/Stone/Test Procedures.
1.6.7 Safety
The Resident Engineer must from time to time check the listed item in CKL-5.1
Safety.


CKL 1.6 CHECKLIST FOR STONE PITCHING AND STONE APRON
Sr.
No.
Issue Action by
Record/Reporting
Document
1. Study and Analyse Contractors Method
Statement.

-A. R.E. Rep.
- Contractors
Surveyor
FR-02
2. Confirm by Survey Control Levels of
TBMs established by the Contractor.
3. Check by Survey Control and
Dimensional Inspection Complete
setting out/layout as per drawings and
specifications.
4. Check by visual Inspection and Survey
Control location and level of level pegs.
These should be clear of working area.
FR-02 for comments
Procedures. The Quality of Base Filter
Material, Pitching/Apron Stone and
Rock Spalls.
Cont. site engineer Test Results on
External Lab. Format
or Field Lab.
6. The material of Base Filter, Stone and
Rock Spall should be obtained from
approved source.
Cont. site engineer FR-02 for comments
7. Ensure by Physical Inspection
Placement of stone pitching and Stone
Apron.
8. Update Periodically Records of all Tests
made during the time period.
Cont. site engineer Test Record File
All actions should be taken in accordance with Part Two, Contract Specifications and
Contractors work methodology as approved by the Engineer.


1.7 BRICKWORK
1.7.1 Objective
guidance in performing Quality Assurance of Brickworks for Structures pertaining to the
Permanent Works, being executed by the Contractor.
1.7.2 Applicability
This Section covers the construction of Brickworks for brick masonry and brick lining for
various Structures, being executed by the Contractor.
The Resident Engineer must leave the selection of construction equipment to the
Contractor.
1.7.4 The Consultants Action
The Consultants field staff will take appropriate action as recommended in the checklist
CKL-1.7 Checklist for Brickwork.
1.7.5 Quality of Bricks
The bricks should be regular, uniform in shape and size.
Bricks over-burnt, under burnt and irregular should not be used.
All bricks in oven-dried condition should not absorb more than one sixth of
its weight when soaked for one hour in water at 70
0
F to 80
0
F and should
show no efflorescence on subsequent drying.
The average compressive strength of five (5) representative bricks should
not be less than 2,000 lbs/in
2
when tested in accordance with ASTM.C-67.
Each finished brick should be of standard size (9 x 4.5 x 3) first class and
weigh between seven (7) and nine (9) pounds.
All bricks should have a frog. 0.25deep on upper face.

Each brick for lining should have standard size (9 x 4.5 x 3) first class.
1.7.6 Mortar Composition
Mortar for all brickwork should have mix ratio as specified in BOQ and sufficient water to
produce the proper consistency.
1.7.7 Mortar Sand
Mortar Sand should be as per specifications of sand for concrete works.
1.7.8 Water
The water used for preparation of mortar should be free from objectionable quantities of
silt, organic matter alkali, salts and other impurities.
1.7.9 Safety
The Resident Engineer should monitor compliance of the contractor with requirements of
the Law of Pakistan for safety, health and environment impact, in the domain of the
construction contract. For safety check proceed in accordance with CKL-5.1 Safety.


CKL 1.7 CHECKLIST FOR BRICKWORK
Sr.
No.
Issues Action by
Record/Reporting
Document
1. Study and Analyse. Contractors Method
Statement.

- A.R.E. Rep.
- Contractors
Surveyor
FR-02
2. Check by Survey Control and Dimensional
Inspection, complete setting out/layout
as per drawings. FR-02 for
comments 3. Check by Physical Inspection and Survey
Control, location and level of level pegs.
These should be clear of working area.
4. Physically inspect Sand, Cement and
Bricks and confirm adherence to the
specifications by Test Procedure.
External Lab or
Field Lab Format
and FR-02 for
comments
5. Discuss with and Ensure, deployment of
proper equipment as described in the
Work Methodology submitted by the
Contractor.
A.R.E./Site
Inspector/ Cont.
site engineer
FR-02 for
comments
6. Check all items as per requirements of
specifications and drawings.
A.R.E./Site
Inspector/ Cont.
site engineer
7. Update Periodically, records of all Tests
made during the period.
A.R.E./Field Lab. Test Record Files
All actions should be taken in accordance with Contract Specifications and Contractors Work
Methodology as approved by the Engineer.


1.8 R.C.C. PIPES & LAYING
1.8.1 Objective
guidance in performing Quality Assurance of providing and laying R.C.C. Pipes, being
executed by the Contractor.
1.8.2 Applicability
This Section covers the Reinforced Concrete spun pipes and includes all pipe formed
culverts, inlets, conduits, underpasses etc.
The Resident Engineer must leave the selection of equipment to the Contractor.
1.8.4 Inspection
1.8.4.1 Quality of R.C.C. Pipes
Consultants field staff will take appropriate action as recommended in
Checklist CKL-1.8 Checklist for R.C.C. Pipes & Laying.
All materials, methods of manufacture strength requirements for concrete pipes
should conform to the requirements of ASTM C-76. Wall B. Class II.
The inspector must read the relevant sections of ASTM C-76, BS.5911 and
BS.2494 and thoroughly understand the requirements related to the R.C.C Pipes
specified on the Drawings.
The Manufacturers Certificate provided by the contractor should be studied
carefully, to check conformance to the ASTM C-76 requirements.
The joints for concrete pipes, bends and junctions shall be of spigot and socket
type as per clause 17 of BS.5911 and BS.2494.
The supplied R.C.C. Pipes should be inspected carefully and the rejection may be
made on account of any of the following:
Fractures or cracks passing through the shell, except for a single end crack
that does not exceed the depth of the joint.

Defects that indicate imperfect proportioning, mixing and moulding.
Surface defects indicating honeycombed or open texture.
Damaged ends, where such damage would prevent the making of a
satisfactory joint.
Failure to give a clear ringing sound when tapped with a light hammer.
Exposure of the reinforcement when such exposure indicates that the
reinforcement was misplaced.
1.8.4.2 Excavation and Laying
The excavation for pipeline should follow the lines and grades on the Drawings.
The maximum distance from sides of the trench and the barrel of the pipes
should be as shown on the Drawings.
1.8.4.3 Joints for Reinforced Concrete Pipes & Fittings
Joints for concrete pipes, bends and junctions shall be of the flexible spigot and
socket type as specified in clause 17 of BS 5911 incorporating rubber gasket
complying with BS 2494.
1.8.4.4 Bends in Pipelines
Where it is required to form a bend in a pipeline of more than 11 degrees, either
a precast pipe bend which meets the requirements of ASTM C76 shall be placed
or a manhole be installed to lessen the head loss.
Except where pipes are to be laid in a concrete or gravel bed, pipes including
bends shall be laid in a trench with the trench bed hand-shaped to support the
pipe throughout the length of its barrel. Sockets or collars along the pipeline
shall be accommodated by jointing holes formed in the bottom of the trench.
1.8.5 Safety
The Resident Engineer should monitor compliance of the contractor with requirements of
the Law of Pakistan for safety, health and environment impact, in the domain of the
construction contract. For safety check proceed in accordance with CKL-5.1 Safety.


CKL 1.8 CHECKLIST FOR R.C.C. PIPES AND LAYING
Sr.
No.
Issues Action by
Record/Reporting
Document
1. Submit Method Statement. Cont. site engineer FR-02 for
comments or
through letter
2. Study and Analyse, contractors Source
(Manufacturer) approval.
A.R.E./Site
Inspector / Cont.
site engineer
FR-02 and
Contractors
Format
3. Physically inspect the pipes supplied
and check, the Manufacturers Certificate
A.R.E./Site
Inspector/ Cont.
site engineer
FR-02
Manufacturers
Format
4. Check by Physical Inspection and Survey
Control, the line, grade and depth of
excavation etc. for Laying Pipes.
Site Inspector
Survey (Contr.)/
Cont. site engineer
FR-02
5. Physically Inspect, excavation Backfill. A.R.E./Site
Inspector
FR-02
6. Update Periodically, records of Tests or
Manufacturers Certificates during the
period.
A.R.E./Site
Inspector/ Cont.
site engineer
Record Files
All actions should be taken in accordance with Contract Specifications, Contractors Work
Methodology and other Contractors Submittals, as approved by the Engineer.


1.9 STEEL SHEET PILES
1.9.1 Objective
procedures and other relevant information to the field staff of the contractor, for their
guidance in performing quality assurance of Steel Sheet Piling required for the construction
of canal structures.

1.9.2 Applicability
This Section covers the furnishing, handling, transporting, cutting and driving Steel Sheet
Piles as shown on the drawings or directed by the Engineer in accordance with the Contract
Specifications.

1.9.3 Construction Plant
The Resident Engineer must leave the choice of the construction plant and temporary works
for the sheet piling to the contractor. The pile-driving and extracting equipment may be
either percussive or vibratory type. However, the method and the equipment proposed
should not result in ground resonance which might adversely affect neighbouring existing
structures or work under construction.
1.9.4 Inspection
For Quality Assurance of steel sheet piling construction activities, the
Consultants Supervisory Staff shall proceed in accordance with CKL-1.10
Checklist for Steel Sheet Piles.
Steel Sheet Piles section shall be AU-14 made by ARCELOR or equivalent section
approved by the Engineer.
Steel Sheet Piles shall be capable of being interlocked one with another, to form
a continuous wall or diaphragm.
Polystyrene sheets to be fixed at the top of sheet piles shall conform to ASTM D-
4. 549.

The Bituminous material for sealing steel sheet piling interlocks shall be
equivalent of the Noahs Pitch as manufactured by the Philip Carey
Manufacturing Company of USA.
Steel Sheet Piles which are of different types, cross-section, weight or length
shall be stored in separate stacks.
Piles during storage shall be supported clear from the ground on suitable
bearers.
The Piles shall be lifted and transported with adequate supports so that piles
are not distorted or damaged in transit.
The Piles shall be driven to lines, levels and dimensions shown on the Drawings.
The line of piles shall not vary from the true line by more than 2.0 inches.
The inclination of the plane of piles shall not vary from the true inclination by
more than 1 in 100.
The inclination of any pile in that plane shall not vary from the line of greatest
slope in that plane by more than 1 in 200.
The finished level of the tip of any pile shall not vary from the true level by more
than one inch.
The finished level of the bottom of any pile shall not vary from the true level by
more than 1% of the specified length of pile.
Piles shall be prevented from being driven below the true level during the
driving of neighbouring piles.
Pile driving shall not be assisted by jets of water or air directed into the ground
except with the approval of the Engineer.
Until the driving of a pile is completed, the Contractor shall not excavate below
existing ground surface adjacent to the pile unless such excavation is either
approved or ordered by the Engineer.
The Contractor with the approval of the Engineer may excavate a trench in
which the steel sheet piling is subsequently pitched and driven.
If such a trench is allowed to be excavated the void between the piles and
undisturbed ground shall be backfilled with reinforced cement concrete (1:2:4)
immediately after driving of the piles is completed.

Steel reinforcement to be provided for this concrete shall meet the minimum
steel reinforcement requirements set forth in the ACI code 318-05 or as
directed by the Engineer.
Steel Sheet Piles in the permanent works shall be free from holes, other than
those specified on the drawing or small holes less than inch diameter and not
more than 8.0 inches from the top of the Piles to assist in pitching the piles prior
to driving.
All welding of piles shall be in accordance with the requirements of B.S. 5135 or
an approved equivalent and splicing piles shall be full strength butt welds.
Steel Sheet Piling against which concrete is to be cast shall be clean and
watertight.
All such steel sheet piling shall be free from loose rust, loose-mill-scale, oil,
grease and earth or any other substance which is likely to prevent bonding
between the concrete and the piles.
The surface of steel piles, which shall not be buried in ground on completion of
work, shall be blast cleaned and painted with black bituminous paint applied in
two coats.
The first coat shall be applied within 2.0 hours of blast cleaning and the second
within 24 hours of application of the first coat.
Concrete capping beam shall be formed of reinforced cement concrete, as
specified and Cast-in-situ.


CKL 1.9 CHECKLIST FOR STEEL SHEET PILES
Sr.
No.
Issues Action by
Record/Reporting
Document
1. Confirm by Survey Control, level of
TBMs established by the Contractor.

-A.R.E. Rep.
- Contractors
Surveyor

Survey & Level
Book and
FR-02
2. Check and approve by Survey Control,
NSL by checking of the survey data and
make record entries by Joint Survey.
3. Check by Survey Control and
Dimensional Inspection, complete
setting out/layout.
4. Check by visual inspection and Survey
Control, location and level of level pegs,
these should be clear of working area.
5. Discuss and Ensure, deployment of
proper Equipment/ Plant for Sheet Pile
Driving.
A.R.E./ Site
Inspector/ Cont. site
engineer
FR-02
6. Ensure by physical inspection, Size,
Section and Quality of Steel Sheet Piles.
A.R.E./ Site
Inspector / Cont.
site engineer
FR-02
7. Check by visual inspection and Test
Results. Quality of Bituminous Material
for sealing steel piling interlocks.
A.R.E./ Site
Inspector Ext. Lab.
FR-02 and
Manufacturers
Certificate
8. Study and Comment, contractors
proposal for storing, handling and
transporting piles.
A.R.E./ Site
Inspector / Cont.
site engineer
Contractors Format
and FR-02
9. Study and Comment, contractors
proposal for weld procedures.
A.R.E./ Site
Inspector./ Cont. site
engineer
FR-02
10. Update periodically. Piling Record A.R.E./ Site
Inspector/ Cont. site
engineer
Contractors Format

R&U of Sulemanki Barrage Quality Assurance Plan

2.1 TYPES OF MATERIAL TESTS
The Quality Control/Quality Assurance tests are of three type i.e.

Tests to be performed at site
These tests are field specific and include the following:
Field Density Tests for compaction control.
Slump test for concrete.
Casting of concrete cylinders for compressive Strength Tests.
Gradation Analysis of concrete aggregates i.e. sand and coarse aggregates.
Los Angeles Abrasion Test for Stone.
Moisture Content of soil.
Temperature of concrete.

Testing of concrete cylinders is required to be done at the Engineers Field Laboratory. The
testing machine at site should be checked and approved by Geotech/Material Engineer of
the consultants.

Tests to be performed at Contractors Field Laboratory
The tests to be performed at Contractors Field Laboratory include the following:
Soil classification Tests
Compaction Tests
Gradation Analysis of Aggregates as required by R.E.
7 and 28 days compressive Strength Tests on concrete cylinders.
Unit Weight of aggregates.
Fresh Density of concrete.
Absorption and Compressive Strength of bricks.
Specific Gravity and Absorption of coarse and fine aggregates.
Los Angeles Abrasion Test for Coarse Aggregate
Soundness of Aggregate

Test to be performed at external laboratories/ Consultants laboratory

These tests can only be performed in specified off-site laboratories and include tests on
reinforcing steel, cement, abrasion, petrography, soundness of concrete aggregates, water
stop and any other tests required during any problem or dispute.

2.2 TESTING ARRANGEMENTS/EQUIPMENTS
2.2.1 Testing at Construction Site
The Contractor for an individual contract package shall be responsible for providing the
equipment and carrying out these tests in accordance with the Clause 4.3 under the direct
supervision and guidance of the Consultants supervision staff.
The contractor is required to provide and readily make available at construction site the
following equipment,
Earthwork:
Sand - Cone Density Apparatus, complete with base plate and sand bottle.
Density Core Cutter 4 dia, complete with collar and hammer.
Speedy Moisture Tester capacity 20.0 gm. Moisture range 0 20% complete with
electronic balance and plastic carrying case.
Balance Triple Beam 2610 gm capacity with readability of 0.10 gm.
Balance 30 Kgs capacity with readability 1.0 gm.
Drying Oven capacity 108 Litres.
Concrete Work:
Cylinder moulds for concrete 6 dia. Complete with tamping rod (5/8 in dia 20
long) and mallet.
Slump Test Equipment complete with tamping rod 5/8 dia and 24 long.
Curing Tanks These shall be constructed close to the construction site for storing
concrete cylinders till their transportation to the Laboratory for testing.
A reliable compression machine approved by the Consultants Material Engineer.
Thermometers to check fresh concrete temperature.
Note:
The Contractor shall ensure that sufficient No. of the above equipment is available at
site to satisfy the testing requirements of the quantum of work.
Computers with printers should be provided in laboratory.
2.2.2 Testing in the Engineers Field Laboratory

A material testing laboratory established at site should be equipped and adequately
staffed to carry out the field laboratory tests as per requirements defined in Section
2.1.
This Field Laboratory, established by the contractor and supervised by the
Consultants Quality Control / Assurance staff is to carry out the required tests
and maintain a systematic and retrievable record. Test record should be
computerized.
All Quality Control/Quality Assurance tests specified to be performed in the field
laboratory shall be carried at the designated Field Laboratory at site. (Individual
arrangements by the contractors for this category of tests shall not be acceptable.
The Contractors shall be responsible for providing and transporting the test
specimens to the laboratory under the guidance and supervision of the
Consultants Resident Engineer.
The contractors shall bear the cost of these tests as per rate list available at any
Field or external Laboratory specified by the Engineer.
2.2.3 Testing from External Laboratory
The Quality Control/Quality Assurance tests to be carried out from an external laboratory
defined in Section 2.1 are recommended to be carried out at laboratories mentioned
below or as directed by the Engineer. The cost of transportation and testing charges shall be
the Contractors responsibility.
Specified Laboratory.
Third Party verification


2.3 TESTING REQUIREMENTS
The test procedures and the test frequencies for the various construction works have been
summarized in the following tables.
Earthworks Table 2.3 (1)
Concrete works Table 2.3 (2)
Brickworks Table 2.3 (3)
Stone Pitching and Stone Apron Table 2.3 (4)

These tables are intended to provide comprehensive guidelines to the supervision staff as
well as Engineers Field Laboratory personnel.


Laboratory Record/Reporting Documents

3.1 Laboratory Record/Reporting Documents
( Field Laboratory )
Document No. Document Description

SOILS
LR-01 Particle Size Analysis of Soil
LR-02 Moisture Content of Soils
LR-03 Liquid Limit, Plastic Limit and Plasticity Index of Soils
LR-04 Specific Gravity of Fine Grained Soil Particles
LR-05 Laboratory Compaction characteristics of soils
CONCRETE
LR-06 Particle Size Distribution of Concrete Aggregates
LR-07 Concrete Compressive Strength
LR-08 Bricks Tests Report
LR-09 Specific Gravity of Coarse Aggregates
LR-10 Specific Gravity of Fine Aggregates
LR-11 Concrete Batching Plant Calibration
LR-12A Concrete Batching/ Pouring Record Summary
LR-12B Concrete Aggregate Moisture Content at Batching Plant
LR-13 Concrete Mix Design

Note: LR = Laboratory Record

Field Record/Reporting Documents
3.2 Field Record/Reporting Documents (for Field Inspection/Testing)
Document No. Document Description

FR-01 Field Note for Handing over Survey Reference Points/Bench Marks
FR-02 Field Note (General)
FR-03/A Field Density & Degree of Compaction of Non-Cohesive Soils.
FR-03/B Field Density & Degree of Compaction of Cohesive Soils by Sand Cone
Method
FR-03/C Field Density & Degree of Compaction of Cohesive Soils by Core Cutter
Method.
FR-04 Summary of Compaction Control Tests for Cohesive soils
FR-05 Summary of Compaction Control Tests for Cohesion less soils
FR-06 Format for Bar Bending Schedule
FR-07 Request for Concrete Pour Authorization
FR-08 Concrete Pour Authorization
FR-09 Concrete Cylinders/Cubes Casting and Delivery Report
FR-10 Summary of Cylinder/Cubes Test Results
FR-11 Bored-Cast-in-Situ Pile Construction Record

Note: FR = Field Record

4. SAFETY REQUIREMENTS
High Standards of safety for men/women and machine must be observed at all times. The
Contractor shall take reasonable measures to prevent members of the public from entering
areas in which maintenance/construction activities are being carried out by the Contractors
Equipment and personnel.


CKL 4.1 SAFETY REQUIREMENTS CHECKLIST
Sr.
No.
Issues Action
Record/Reporting
Document
1. Presence of underground utilities Visual Inspection

FR-02
2. Protective barrier on edge of excavation
line and Warning Signs
Visual Inspection
3. Showing where soft materials are
encountered, during excavation.
Visual Inspection
4. Employers property is properly protected Visual Inspection
5. - All work areas, walkways, platform
etc. are clear of scrap, small tools,
accumulation of mud, grease, oil or
slippery substances.
Ensure
6. - All Test Beams, Reaction Frames and
Platform for the pile load tests are
adequately supported at all times.
Ensure
7. - Only authorized personnel are
permitted within the immediate Test
area during Pile Tests.
Ensure
8. - All Reaction Loads are stable and
balanced, during pile load tests.
Ensure
9. - The Equipment in use by contractor is
in compliance with HSE regulations.
Ensure

5. STANDARDS & PROCEDURES
A list of ASTM and British Standards and Procedures, applicable to types of construction
works involved in R&U of Sulemanki Barrage project are presented in the following tables:
Table-5.1
Table-5.2
A copy of all these ASTM and British Standards can be made available to the Site Staff as and
when required.

LIST OF ASTM STANDARDS & PROCEDURES
Sr.
No.
ASTM Designation Title
Page
No.
PART 1
A FERROUS METALS
1 A 29/A 29 M-99
Std. Spec. for Steel Bars, Carbon & Alloy, Hot-Wrought &
Finished, General Requirements for
1
2 A 53-98
Std. Spec. for Pipe steel, Black & Hot Dipped, Zinc-Coated,
Welded and Seamless
23
3 A 416/A 416M-99
Sts. Spec. for Steel Strand, Un-Coated Seven-Wire for Pre-
Stressed Concrete
44
4 A 421/A 421M-98a
Std. Spec. for Uncoated Stress-Relieved steel Wire for Pre-
Stressed Concrete
49
5 A 501-98
Std. Spec. for Hot-Formed Welded & Seamless Carbon
Steel Structure Tubing
52
6 A 615/A 615M-96a
Std. Spec. for Deformed & Plain Billet Steel for Concrete
Reinforcement
58
7 A 980-97
Std. Spec. for Steel, Sheet, Carbon, Ultra High Strength
Cold Rolled
63
8 A 981-97
Std. Test Method for Evaluating Bond Strength for
15.2mm (0.6") Diameter Pre-Stressing Steel Strand Grade
270, Uncoated, Used in Pre-Stressed Ground Anchors.
65

Sr.
No.
Page
No.
PART 2
C CEMENTATIONS, CERAMIC, CONCRETE & MASONRY MATERIALS
9 C 29/C 29M-97
Std. Test Method for Bulk Density (Unit Weight) & Voids
in Aggregates
68
10 C 31/C 31M-98
Std. Practice for Making and Curing Concrete Test
Specimens in the Field
72
11 C 33-99 Std. Spec. for Concrete Aggregates 77
12 C 39-96
Test Method for Compressive Strength of Cylindrical
Concrete Specimens
85
13 C 40-99
Test Method for Organic Impurities Test in Fine
Aggregates for Concrete
90
14 C 42/C 42M-03
Std. Test Method for Obtaining and Testing Drilled Cores
and Sawed Beams of Concrete
92
15 C 67-02C
Std. Test Methods for Sampling & Testing Brick and
Structural Clay Tile
97
16 C 76-98a
Std. Spec. for Reinforced Concrete Culvert, Storm Drain
and Sewer Pipe
109
17 C 78-94
Std. Test Method for Flexural Strength of Concrete (Using
Simple Beam with Third-Point Loading)
120
18 C 88-99a
Test Method for Soundness of Aggregates by Use of
Sodium Sulphate or Magnesium Sulphate
123
19 C 97-96
Std. Test Method for Absorption and Bulk Specific Gravity
of Dimension Stone
128
20 C 109/C 109M-02
Std. Test Method for Compressive Strength of Hydraulic
Cement Mortars (Using 2-in/50-mm Cube Specimens)
130
21 C 117-95
Std. Test Method for Materials Finer than 75-m
(No. 200) Sieve in Mineral Aggregates by Washing
136
22 C 123-98 Std. Test Method for Light Weight Particles in Aggregate 140
23 C 127-01
Std. Test Method for Density, Relative Density (Specific
Gravity), And Absorption of (Coarse Aggregate)
143
24 C 128-01
Std. Test Method for Density, Relative Density (Specific
Gravity) and Absorption of Fine Aggregate
149

Sr.
No.
Page
No.
25 C 131-03
Std. Test Method for Resistance to Degradation of Small-
Size Coarse Aggregates by the Abrasion and Impact in the
Los Angeles Machine
155
26 C 136-01
Std. Test Method for Sieve Analysis of Fine and Coarse
Aggregates
159
27 C-138/C 138M-01a
Std. Test Method for Density(Unit Weight), Yield, and Air
Content (Gravimetric) of Concrete.
164
28 C 142-97
Std. Test Method for Clay Lumps and Friable Particles in
Aggregates
168
29 C 143/C 43M-98 Std. Test Method for Slump of Hydraulic Cement Concrete 170
30 C 144-93 Std. Spec. for Aggregate for Masonry Mortar 173
31 C 150-98 Std. Spec. for Portland Cement 175
32 C 171-97a Std. Spec. for Sheet Materials for Curing Concrete 180
33 C - 172 - 99 Std. Practice for Sampling Freshly Mixed Concrete. 182
34 C 191-01a
Std. Test Method for Time of Setting of Hydraulic Cement
by Vicat Meedle
185
35 C - 227 - 97a
Std. Test Method for Potential Alkali Reactivity of
Cement-Aggregate Combinations (Mortar-Bar Method).
191
36 C 231-97
Std. Test Method for Air Content of Freshly Mixed
Concrete by the Pressure Method
195
37 C 260-01 Std. Spec. for Air Entraining Admixtures for Concrete 203
38 C - 289 - 02
Std. Test Method for Potential Alkali -Silica Reactivity of
Aggregates (Chemical Method).
206
39 C 295-03
Std. Guide for Petrographic Examination of Aggregates for
Concrete
213
40 C - 309 - 98a
Std. Specification for Liquid Membrane-Forming
Compounds for Curing Concrete.
221
41 C 494/C 494M-99a Spec. for Chemical Admixtures for Concrete 224
42 C - 535 - 03
Std. Test Method for Resistance to Degradation of Large-
Size Coarse Aggregate by Abrasion and Impact in the Los
Angeles Machine.
233

Sr.
No.
Page
No.
43 C 566-97
Std. Test Method for Total Evaporable Moisture Content
of Aggregate by Drying
236
44 C 597-83 Std. Test Method for Pulse Velocity Through Concrete 239
45 C 881-99
Std. Spec. for Epoxy-Resin Base Bonding Systems for
Concrete
242
46 C 920-02 Std. Spec. for Elastomeric Joint Sealants 247

Sr.
No.
Page
No.
PART 3
D MISCELLANEOUS MATERIALS
47
D 422-63 (Re-
approved 1998)
Std. Test Method for Particles Size Analysis of Soils 250
48 D 427-98
Std. Test Method for Shrinkage Factors of Soils by
the Mercury Method
258
49 D - 572 - 88
Std. Test Method for Rubber Deterioration by Heat
and Oxygen.
262
50 D 698-00a
Std. Test Methods for Lab Compaction
Characteristics of Soil Using Std. Effort (12,400 ft-
lbf/ft
3
[600 KN-m/m
3
])
265
51 D 854-02
Std. Test Method for Specific Gravity of Soil Solids by
Water Pycnometer
276
52
D 1143-81 (Re-
approved 1994)
Std. Test Method for Piles Under Static Axial
Compressive Load
283
53 D 1556-00
Std. Test Method for Density and Unit Weight of Soil
in Place by the Sand Cone Method
294
54
D 1557-91 (Re-
approved 1998)
Test Method for Lab Compaction Characteristics of
Soil using Modified Effort [56,000ft-lbf/ft
3
(2,700
KN-m/m
3
)]
301
55 D 1751-97
Std. Spec. for Preformed Expansion Joint Filler for
Concrete Paving and Structural Construction
(Nonextruding and Resilient Bituminous Type)
309
56
D 1752-84 (Re-
approved 1996)
Std. Spec. for Preformed Sponge Rubber and Cork
Expansion Joint Fillers for Concrete paving and
Structural Construction
311
57 D - 1785 - 93
Std. Specification for Poly(Vinyl Chloride) (PVC)
Plastic Pipe, Schedule 40,80 and 120.
313
58 D 2216-98
Std. Test Method for Lab Determination of Water
(Moisture) Content of Soil and Rock
325
59 D 2419-02
Std. Test Method for Sand Equivalent Value of Soils
and Fine Aggregate
330
60 D - 2466 - 93
Plastic Pipe Fittings, Schedule 40.
339
61 D - 2467 - 93
Plastic Pipe Fittings, Schedule 80 Socket type.
345

Sr.
No.
Page
No.
62 D - 2487 - 00
Practice for Classification of Soils for Engineering
Purposes (USCS).
351
63 D - 2488 - 00
Practice for Description and Identification of Soils
(Visual-Manual Procedures).
363
64 D - 2937 - 00
Test Method for Density of Soil in Place by the Drive-
Cylinder Method.
374
65 D 4253-00
Std. Test Method for Maximum Index Density and
Unit Weight of Soils Using a Vibratory Table
379
66 D 4254-00
Std. Test Method for Minimum Index Density and
Unit Weight of Soils and Calculation of Relative
Density
394
67 D 4318-00
Std. Test Method for Liquid Limit, Plastic Limit, and
Plasticity Index of Soils
403

Table 6.2

LIST OF BRITISH STANDARDS & PROCEDURES
Sr.
No.
B.S. Designation Title
Page
No.
1 BS 12 : Part 2 : 1971 Specifications for Portland Cement (Ordinary and Rapid
Hardening)
1
2 BS 812 : 1967 Sampling & Testing of Mineral Aggregates, Sands and
Fillers.
21
3 BS 1377 : 1975 Soils for Civil Engineering purposes. 75
4 BS 1881 : Part 1 : 1970 Methods of Testing Concrete. Part 1: Methods of
sampling fresh concrete
222
5 BS 1881 : Part 2 : 1970 Methods of Testing Concrete. Part 2: Methods of testing
fresh concrete
231
Making & Curing test specimens
250
Testing concrete for strength.
264
Testing hardened concrete for other than Strength.
278
9 BS 1881 : Part 6 : 1971 Methods of Testing Concrete. Part 6: Analysis of
hardened concrete.
299
10 BS 2494 : Part 1 : 1955 Specification for Rubber Joint Rings for Gas Mains,
Water Mains & Drainage purposes
318
11 BS 2494 : Part 2 : 1967 Specification for Rubber Joint Rings for Gas Mains,
Water Mains & Drainage purposes. Part 2: Rubber Joint
Rings for Drainage Purposes.
323
12 BS 3681 : 1963 Sampling & Testing of Light weight Aggregates for
Concrete.
328
13 BS 4550 : Part 2 : 1970 Methods of Testing Cement - Part 2: Chemical Tests. 340
14 BS 5075 : Part 1 : 1974 Specifications for Concrete Admixtures Part 1:
Accelerating admixtures, retarding admixtures and
water reducing admixtures.
364

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