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    construction of concrete structures (bridges & flyovers)

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    construction of concrete structures (bridges & flyovers)

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    © All Rights Reserved
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    4 просмотров314 страниц

    Quality Assurance Manual

    Загружено:

    venkateswara_v_1
    construction of concrete structures (bridges & flyovers)

    Авторское право:

    © All Rights Reserved
    Скачайте в формате PDF или читайте онлайн в Scribd
    Отметить как неприемлемый контент
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    QUALITY ASSURANCE MANUAL CONSTRUCTION OF CONCRETE STRUCTURES | (Bridges & Fiyovers) CENTRAL PUBLIC WORKS DEPARTMENT 7 CPWDIEO2- FOR GOVERMENT OF INDIA ose eee eee ee ee CHAPTER -1 CHAPTER -2 CHAPTER -3 CHAPTER -4 CHAPTER -5 CHAPTER -6 CHAPTER -7 INDEX INTRODUCTION GUIDELINES FOR USING THE MANUAL QUALITY ASSURANCE PLAN FOR BASIC CONSTRUCTION MATERIALS 3 32 33 34 35 36 37 38 QUALITY ASSURANCE PLAN FOR SITE ACTIVITIES 41 42 43 4a 43 46 47 48 49 Materials from Natural Rescurces Steel / Iron Chemicals Bitumen Prestressing Pipes Other Materials Assembled Accessories 14 5-13 15-86 18-37 38-45 46-57 58-61 62-68 69-72 B81 82-86 87-100 Mix Design including Trial Mix and acceptance criteria 91 RCC work Piling ‘Embankment construction Water Bound Macadam ‘Wet Mix Macadam Bituminous Works (BM, DBM, AC) Mastic Works Reinforced Earth Works IN HOUSE /ON SITE TESTING FACILITIES 5.1 52 53 Materials Site Activities Calibration of Equipment OUTSIDE / INDEPENDENT TESTING FACILITIES SITE DOCUMENTS 92 93 94 95 96 97-98 9 100 101 - 130 105-118 119-124 125 131-151 153-182 CHAPTER -8 CHAPTER- 9 CHAPTER - 10 CHECKLISTS AND TEST PROFORMAS 8.1 Checklists 8.1.1 Checklist for Source/Agency Approval 8.1.2 Checklist for Site Activities 8.1.3 Checklist for Launching Girder 8.14 Checklist for Launching Operation 8.2 Test Proformas METHOD STATEMENTS NON CONFORMING PRODUCTS AND PROCEDURES vi 183-276 183-237 187-204 208-223 224-228 229.237 238-276 277-300 301-310 CHAPTER - 1 INTRODUCTION INTRODUCTIO! Central Public Works Department is a premier construction agency of the Govt. of India, which has been entrusted with the task of building several challenging projects all over the country. The Department had taken up the construction of no. of flyovers in Delhi with a specific view to reduce the construction time so as to minimize traffic disturbances usually faced during construction. Amongst the materials for construction of Flyover, cement concrete is being used widely world over. Four concrete flyovers using precast segmental technology were recently completed and on the basis of the experience gathered, it was decided to prepare a uniform and generalized Quality Assurance Manual (QAM) to be followed in the future flyover projects with specific reference to precast prestressed concrete using segmental technique. This QAM has been prepared to complete the general procedures and guidelines to be followed by the construction supervision personnel in carrying out all aspects of the Construction Supervision tasks. This Manual mainly provides procedures for carrying out tasks related to inspections, testing and reporting. However, this manual does not deal with day-to-day technical requirements, nor does it provide solutions to technical problems, as the Specifications and other Contract Documents usually administer these technical issues. The document is Jargely based on the norms set up by Indian Road Congress Publication IRC: SP : 47-1998. Since precast segmental flyovers fall into category of Innovative Technology, the manual has been based on Class Q-4 of the publication. A concept of Level of testing has been introduced in order to cover up levels of testing of materials and products depending upon various factors. Every effort has been made to evolve this Manual so that adherence to its guidelines will result in efficient, safe and consistent supervision of the works in strict conformity with the Specifications and other Contract requirements. This has led to the basic framework of this Manual being based on construction supervision procedures consistent with standard intemational practices for construction of important flyover projects of this type, with specific guidelines and forms where appropriate, being generated based on standard practices in India in conformity with MORTH and IRC standards and guidelines. n all cases, however, it is important that all users of this Manual understand that the contract documents including the specifications are the controlling documents for the supervision of the construction. Although the intention of this Manual is to provide efficient, safe, high quality construction, adherence to the adopted guidelines does not necessarily guarantee that these attributes are achieved. Therefore, the users are cautioned to exercise judgement based on good engineering practice in all cases rather than blind adherence to the adopted guidelines. This also points to the urgent need to periodically review and update relevant guidelines and procedures, and hence the Manual is to be seen as an evolving guide. CHAPTER -2 GUIDELINES FOR USING THE MANUAL 2A GUIDELINES FOR USING THE MANUAL This Quality Assurance Manual is a document, by use of which, the total quality of the construction of flyover will be managed as per the Q 4 standards of IRC: SP: 47. This Publication of the Indian Roads Congress gives the guidelines for achieving the quality of construction of roads, flyovers and bridges and provisions of Q 4 system guides the suppliers and producers for achieving the end product with extra high quality assurance. As also mentioned in the Chapter 1 i.e, Introduction that while constructing costly structures for public use, it is desirable that the strong and durable structures needing minimum maintenance are constructed. Therefore, it is essential that during execution, the works be managed in such a manner that the best possible quality is achieved. Every agency, whosoever is involved in the construction, and in whatever capacity it may be, shall aim for achieving the best quality. This shall require the quality management planning in advance Every activity during the construction is necessary to be planned and monitored closely Further it is not only the planning and monitoring, but also the documentation of activities, which plays a very vital role in assuring and achieving the high quality standards, This manual is divided into 10 chapters and this chapter elaborates the guidelines for the use of the manual. Chapter 3 to 8 guides the user regarding the testing of basic ingredients and site activities, while chapter 9 has coverage of method statements of activities commonly involved in the construction of a flyover. Chapter 10 covers the non- conforming praducts and procedure to be followed for deciding their acceptance or rejection, Quality Assurance Plan (QAP) for Basic Construction Materials Every construction activity starts with the use of basic materials which may be either in raw shape like earth, sand, stone aggregates, etc. or manufactured materials like cement, steel or bitumen or assembled for accessories like bearings or expansion joints. Materials to be procured at site for use in any site activity have been covered in Chapter 3. Efforts have ‘been made to include each and every material that is required (o be procured at site for the use in site activities like concreting work, raising embankments or laying wearing courses. Chapter 3 has been titled as Quality Assurance Plan for Basic Construction Materials. The chapter has been classified into different parts on the basis of the type of materials and their source. QAP includes the tests that every material has to undergo before it is accepted and approved for use in the work. QAP is given in 5 columns. Column 1: It lists the name of the test that a material is essentially to undergo before accepting it as fit for use in the work Column 2: It gives the frequency of the testing of materials. A material once approved is required to be tested periodically to ensure the uniformity in its quality and to ensure that the does not deteriorated after initial acceptance Column 3: Depending upon the type of material and its use in the structure, it is mandatory that some materials are repeatedly tested in the site laboratory and also independently tested from some outside approved reputed laboratory. Column 3 of QAP indicates the check level of the test, which is to be performed on the material First Level ie. Level 1 indicates the tests performed by the contractor before requesting the department for accepting the material. This test may be in the shape of Manufacturer's Test Certificate (MTC) on the basic tests at random conducted by the manufacturer or it may be the tests got conducted by the contractor at his own level before requesting the department for its approval Next Level ic. level 2 indicates the tests to be conducted by the department in order to ensure satisfaction regarding the suitability of the material in view of the test certificates submitted by the contractor. These testing may be at the site laboratory if the facilities could be created or got done by an outside laboratory if the facilities are not possible to create in the site laboratory.-Depending upon whether the tests have been conducted at site laboratory or outside laboratory, Level 2 is classified in two categories i.e. Level 2A and Level 2B. Level 2A is for 2.2 the tests conducted at site laboratory and level 2B is for the tests conducted ‘outside the site laboratory as necessary facilities could not be made available at site. There are some materials like cement and steel, which are more sensitive than other materials. For such sensitive materials, in order to have more confidence, it is always desired that such materials are got tested from an independent source. This level of testing the sensitive material from an independent source has been classified as Level 3. It is essential that such an independent source should be a well-reputed laboratory equipped with proper controls like temperature, humidity etc. essential for the specific material testing and also equipped with well- qualified staff, from whom an expert opinion can be obtained, As per the above levels, the need of the level required for testing the material is given in this column, Column 4: It gives the reference of the Bureau of Indian standard or Indian Roads Congress standard or some other equivalent recognised standards which the material is expected to meet. Also these standards depict the test procedure of the test to be performed, ‘Column 5: The acceptance standards of the materials are given in this column, ‘The materials shall be accepted for use on the work only after the testing of the material as per this Quality assurance plan. Like the materials, various construction stages are also required to undergo testing/checking before the items are accepted and payments to the contractor released. QAP for all these site activities is given in Chapter 4 of the manual and all the activities are detailed out in 4 columns. 2.3 Column 1: It lists the names of the test that every activity is essentially to be subjected before its acceptance. Column 2: It gives the frequency of the testing of materials or the lot size for which testing is required to be done. Column 3: It gives the reference of the Indian standard or other equivalent applicable standards which the item is expected to meet. Also these standards depict the test procedure of the test performed, ich may be decided by the department. Column 4: The acceptance standards are given in the column 4 of this QAP. It is only after the completion of the testing of the items/site activities as per this Quality assurance plan that a particular work is accepted. In House/On Site Testing Facilities While Chapter 3 and 4 cover the QAP for the construction materials and the site activities, their testing facilities are covered under Chapter 5 and 6. For prestigious projects like flyovers and bridges, it is essential that in house testing laboratory is created so as to perform the tests which ase comparatively easier to perform with simple setup or are required to be conducted very frequently. Often the nature of the test is such that immediate results are needed. Such facilities should be created in the site-testing laboratory. Details of all such tests are furnished under Chapter 5 of the manual, All the materials for in house testing are detailed in this chapter under 4 columns. Column | gives the details of the test to be performed in house i.e. site laboratory. Column 2 gives the size of the sample of each material to under go a test and the standard which gives the standard testing procedure is, ‘mentioned in next column 3. While testing the material, the readings during the testing are required to be recorded in a proper manner. In order to simplify the recording and to record every data essential to record, data sheets have been created. The formats of these data sheets are given in Chapter 8. For the sake of convenience, all the required facilities for conducting the test are furnished in column 4. At the end of the Chapter 5, all the facilities 10 24 2.5 2.6 ad the standards essential to be provided in site laboratory are summed up and indicated in this Chapter. Outside independent Testing Facilities Since the total tests required to meet the Quality Assurance Pian given under Chapter 3 and 4 are large in oumber and require extensive equipment & personnel set up, all the testing facilities can not be provided at site. Moreover as per the QAP give under chapter 3, many test are to be done at level 3, which means testing by an independent agency. Many reputed Test Houses conduct these tests. For the sake of convenience of the users, some of the reputed test centres are given in Chapter 6 and information about the testing facilities available in these centres has been compiled as ready reckoner. It is furnished in tabulated form, which is quite convenient to consult and use. Wherever the required testing facility is available, it is shown in a tick mark (“) against that test house and the test to be conducted. Site Documents During the currency of a project, itis essential to keep certain documents at site for making permanent record of each and every item related to the project. Such items may include tests conducted at site, instructions issued to the contractor, record of drawings issued to the contractor, inventory of the material at site and so on, All such site documents play a vital role not only in assuring the quality of the work, but also in making the total management of the project comparatively easier. For the sake of the user, all these documents with a unique identification number have been listed under Chapter 7 of the manual with a format for each of them, The record of all such documents kept at site is to be stored in the Master Register of the Chapter 7 Check Lists and Test Proformas For the efficient execution of the work, it is essential to ensure that the work done at various stages is done as per the standard procedure. Omitting compliance of any check is likely to create troubles in accomplishing the activity with the desired quality standards. onl 27 Hence in order to ensure a proper follow up of the construction methodology, checks are conducted at all important stages. To control such tests, checklists are evolved and have been given under Chapter 8 for all the important items of the work. The site staff are required to fill up the relevant checklist while allowing the contractor to proceed with the operation of the particular work. Itis not only the execution of the item that the checklists are made use of, but also for the approval of the agency/suppliers for various sub contracts. The checklists have been separately formulated for this purpose and given in the same chapter. Further, for the in house testing facilities as given under chapter 5, the formats for the data sheets for performing various tests are given in chapter 8 and all the test proformas/data sheets have to be given a unique identification number for proper record of all the tests results, All the formats of the test proformas are required to be docketed in a separate register titled as Check lists/Test Proformas Record for which a format has been given as a site document under Chapter 7. Method Statements Chapter 9 incorporates method statements for site activities. These statements are given for only guidance purpose. It is essential that the contractor submits his own method statement depending upon his setup and arrangement of the type of the machinery for each and every item before proceeding with its execution and gets it approved from the department. Generally for the specialised items like bearings, expansion joints, reinforced soil work, jaunching of segments, specialised agencies are engaged and depending upon their experience & way of wotking, the method statements can be given by those selected specialised agencies. However, some common items like Piling and its testing, Pile Caps, Bituminous Works, Installation of bearings and Expansion Joints, Embankment, WBM etc. have been covered in this chapter and it is desirable that the execution of each and every activity be started only after the method statement is approved and available with the site staff, 12 2.8 Non Conforming Products and Procedures The last Chapter i.e. Chapter 10 covers the procedure to be adopted for the non-conforming products. While working at site, situation occurs when some particular item/product does not fulfil certain test standards, but the same is otherwise acceptable as it passes other alternative tests. On fulfillment of alternative test, such products are generally accepted at lesser cates than accepted in the contract. The procedure to be followed for accepting such products is agreement rates or reduced rates is well explained in this chapter. ‘The above guidelines are framed for the convenience of the site staff to follow the manual and make effective use of it. Once the various formulations of the manual are followed strictly, system of IRC. SP: 47 is hoped that the end results shall be of a extra high quality as desired under Q4 13 CHAPTER -3 QUALITY ASSURANCE PLAN for BASIC CONSTRUCTION MATERIALS P for Basic The first step towards ensuring good quality construction is to get good quality basic materials required to be used in the construction activities. These materials may be raw materials like Aggregates, Sand, Earth or Water, processed materials like Cement, Bitumen, Geotextile, Sealant etc or processed and assembled materials like Bearings and Expansion Joints. This shall also require prior approval of the source or supplier for the individual material or product as given under chapter 8 In order to ensure that material used in construction is of high quality and meets the codal requirements of BIS, IRC or MOST as applicable, a seties of tests have to be carried out at regular frequencies. The testing has to be done first at the level of the supplier / manufacturer or the conteactor, This forms the first level check The testing may be done jointly with the client or the client may do the testing independently in the site laboratory. This forms the second level check The material is also got tested from reputed independent laboratories, This forms the third level check This chapter gives the level of testing required for the various materials as well as the frequency of such testing Extensive testing of the basic materials shall ensure that only the best quality materia! is cleared for use on the work so that extra high quality construction can be done. 17 1965 CPWOr2002—34, 3.1 Materials from Natural Resources 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 For Concrete Works 3.1.1.1 Coarse Aggregates 3.1.1.2 Fine Aggregate 3.1.1.3 Water Aggregates for Road work (Non Bituminous Sub bases and Bases) a) Granular Sub Base b) Water Bound Macadam c) Wet Mix Macadam Aggregates for Road work (Bituminous Base and Surface Courses) a) Bituminous Macadam b) Dense Graded Bituminous Macadam c) Bituminous Concrete d) Mastic Asphalt Earth for Embankment Lime (for Bituminous Works) 18 1965 CPwo2002—38 opuy ssouryey J pure uoTeBuo|y paurqusos Jo anpea uINUIXEPY % SE xepuy worw8uoiq pus xopuy ssourpety (q s-0 wa Sty 07-0 ua OL ool- 8 un $71 ‘azys [euyuION oor una 0Z man SZ s-0 um sup 02-0 unt Ot 001 - $8 ww 07 ams jeuywion, 001 un OF ur 0Z Gn8}94 Aq) Bupssed vopeudyseq aBuyuaaieg Aas SI Suypep siskjery aaag (e ve 399M 8 UL 990 *Z amos Jo aBuayD + £96 pue somos yoe> ued) 981 Jo yeaoidde 105 advqs, OL61-€8E I Burumseq MP WT] PUvads ayouuvd (1 POT Spuwpuwsg eouesdessy | sepog you | ND Aouanbary wo, SayeBoiBBy asse0D PETE SHAOM 99190.) 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