Chapter13: QAP's KUWASIP 1/10

QUALITY ASSURNCE PLAN

QUALITY ASSURANCE PLAN FOR THE MANUFACTURE OF DUCTILE IRON PIPES, INSPECTION & TESTING PLAN
Sl Agency
Component/ Type of Quantum of Reference Acceptance Format
No Charcterstics check Category Remarks
Material Check Check Documents Norms of Record M B TPI
.
RAW MATERIAL CONTROL
1 BF Liquid Metal or % C, SI, % MN, % Major Chemical 1/lot or Batch Asper Asper MTC T V V
pig Iron S, % P Manufacturers Manufacturers
Standard Standard
2 Ferrosilicon % S,% AL Major Chemical 1/lot or Batch Asper Asper MTC T V V
Manufacturers Manufacturers
Standard Standard
3 Silica San/ River Sieve Analysis Major Chemical 1/lot or Batch As per IS 8329 - As per IS 8329 - MTC T V V
Sand Compaction 2000/ IS-383 2000
4 Magnesium Purity of Mg Major Chemical 1/lot or Batch As per IS 8329 - As per IS 8329 - MTC T V V
2000 2000
5 Zinc Purity of Zn Major Chemical 1/lot or Batch Asper Asper MTC T V V
Manufacturers Manufacturers
Standard Standard
6 Cement Material conformation Major Physical & 1/lot or Batch As per IS 8112 As per IS 8112 MTC T V W Samples could be
Chemcial drawn from finished
pipes also
7 Butumen Paint Specfic Gravity Major Specific 1/lot or Batch Asper Asper MTC T V V
grarvity Manufacturers Manufacturers
Standard Standard
PROCESS CONTROL
1 Heating Treatment Temperature Major Physical 100% Asper Asper Heat T V V
recording time cycle Manufacturers Manufacturers Treatment
Standard Standard Chart
2 Zinc coating Depsoit of zin Major Physical 1 per Batch As per IS 8329 - As per IS 8329 - Manufacture T V V
2000 2000 rs Internal
Record

______________ _________
CONTRACTOR EMPLOYER
 Chapter13: QAP's KUWASIP 2/10
Sl Agency
Component/ Type of Quantum of Reference Acceptance Format
No Charcterstics check Category Remarks
Material Check Check Documents Norms of Record M B TPI
.
INSPECTION AND TESTING
1 Visual As per IS 8329-2000 Major Visual 100% As per IS 8329 - As per IS 8329 - Manufacture T V W See Note
2000 2000 r Report
2 Dimensional As per IS 8329-2000 Major Measurement 100% As per IS 8329 - As per IS 8329 - Manufacture T V W See Note
2000 2000 r Report
3 Mechanical Test As per IS 8329-2000 Major Physical As per IS 8329 - As per IS 8329 - As per IS 8329 - Manufacture T W W See Note
2000 One test/ 2000/IS 11606 2000 r Report
Batch
4 Hydrostatic Test As per IS 8329-2000 Major Physical 100%, As per IS As per IS 8329 - As per IS 8329 - Manufacture T W W See Note
8329 - 2000/IS 2000/IS 11606 2000 r Report
11606
5 Lining Thickness As per IS 8329-2000 Major Physical As per IS 8329 - As per IS 8329 - As per IS 8329 - Manufacture T V W See Note
2000/IS 11606 2000/IS 11606 2000 r Report
6 Bitumen Coating As per IS 8329-2000 Major Physical Random Check As per IS 8329 - As per IS 8329 - Manufacture T V W See Note
thickness 2000/IS 11606 2000 r Report
7 Compression Test of As per IS 8329-2000 Major Physical As per IS 8329 - As per IS 8329 - As per IS 8329 - Manufacture T V W One per lot
Cubes 2000/IS 11606 2000/IS 11606 2000 r Report
8 Gasket fittment & As per IS 8329-2000 Major Physical One per lot As per IS 8329 - As per IS 8329 - Manufacture T W W
leak tightness test 2000/IS 11606 2000 r Report
9 Marking on pipes As per IS 8329-2000 Major Physical Random Check As per IS 8329 - As per IS 8329 - Manufacture T V W
2000/IS 11606 2000 r Report

Legend:-

T= Testing M= Manufacturer MTC = Material Test certificate

V= Verification B= KUWS&D Board
W= Witness TPI= Third Party Inspection
Note: - 1. the manufacturer shall carry out 100 % inspection on final product
2. All measuring instruments & test equipments shall be caliberated periodically and record shall be put
to IA for verificatio.
3. Cement used for lining shall conform to IS 8112 or IS 12330 depending on the usuage of pipeline.
4. The rubber gasket shall conform to IS 5382 / 1985.
5. The tolerance shall be brought to the notice of employer beore accepting the pipes.

______________ _________
CONTRACTOR EMPLOYER
 QUALITY ASSURNCE PLAN
PRODUCT NAME: AC PIPES & SPECIALS

Sl Component/ Quantum of Reference Acceptance Format

Charcterstics check Category Type of Check Agency Remarks
No. Material Check Documents Norms of Record

RAW MATERIAL CONTROL

1 Asbestos Fibre Conformance to Critical Physical Tests One per Manufacturers Manufacturers Test certificate Manufacturer Review by IA
TA(P) Standards consignment own Standard own Standard from supplier
& fiber test
records
2 CEMENT Chemical Major Chemical One per IS 269-1989 or IS 269-1989 Test certificate Manufacturer --do--
2.1 Composition Analysis consignment IS:8041/1978 from supplier
IS:455/1976
IS:1486/1976

2.2 Physical properties Major Physical Tests One per IS 269-1989 or IS 269-1989 Cement Test
consignment IS:8041/1978 records
IS:455/1976
IS:1486/1976

2.0 PROCESS CONTROL FOR A.C. PRESSURE PIPES & COUPLINGS

2.1 Milling of Asbestos Moisture Cement Major Physical test Once in shilft Manufacturers Manufacturers Lab records Manufacturer Review by IA
Fibre own Standard own Standard
2.2 Vat & Slurry Percentage / volume Major Physical test 4 times per shift Manufacturers Manufacturers Lab records
consistency own Standard own Standard
2.3 Sieve filtrate & Percentage / volume Major Physical test 1 times per shift Manufacturers Manufacturers Lab records Manufacturer
cone water colids own Standard own Standard
2.4 Forming Thickness Measurement Major Potentio meter 100% Manufacturers Manufacturers process Manufacturer
control own Standard own Standard records
2.5 Felt speed Control Major Speed Control Round the clock Manufacturers Manufacturers Lab records Manufacturer
control own Standard own Standard
2.6 Calendering Control Major Time Control Round the clock Manufacturers Manufacturers process Manufacturer
control own Standard own Standard records
2.7 Dimen onal check Measurement by Major Measurement 100% --do-- --do-- --do-- --do--
at Green stage vernier calippers

2.8 Temp control at Control Major Thermo couple Continuous --do-- --do-- Lab records --do--
Dwell and roller sensing
conveyers
2.9 Curing of green Recording the QTY Major Counting the 100% --do-- --do-- curing day --do--
pipes size and period maturity date records
3.0 Machining & testing of pipes
3.1 Pipe finishing Turning, Fac inc & Major Measurement 100% IS 1592:1989 IS 1592:1989 Pipe finishing --do--
Chamering report
3.2 Visual check for Uniformity Major Visual 100% IS 1592:1989 IS 1592:1989 Inspection Manufacturer Audit check by
finish Report IA IA
3.3 Work Hydralic Pressure tightness Major Hydralic --do-- --do-- --do-- --do-- --do-- --do--
Pressure tightness test as per the class pressure test as
Test of pipes per IS 5913/89

3.4 Hydralic Bursting Bursting stress Major Bursting Test As per IS 7639/75 --do-- --do-- --do-- --do--
Test
3.5 Transverse Crushing stress Major Chemical Test As per IS 7639/75 --do-- --do-- --do-- --do--
Crushing Test
3.6 Longitudinal Beding Test Major Bending Test As per IS 7639/75 --do-- --do-- --do-- --do--
Wending Test
(Upto 150mm dia
pipe only)
3.7 Strightness Test Measurement Major Physical As per IS 7639/75 --do-- --do-- --do-- --do--
Measurement
3.8 Internal Regularity Regularity Major Physical As per IS 7639/75 --do-- --do-- --do-- --do--
Test Measurement
3.9 Other dimensions Major Measurement Samples as per IS --do-- --do-- --do-- --do--
like diameter, 2500 PPI/Level/
length, thickness AQL 2.5
etc.,
4.0 A.C. COUPLINGS Length Measurement Major Physical 100% TA(P) TA(P) Standard PF Section Manufacturer
Cutting the Standard
required length
4.2 Coring, Grooving & Uniformity Major Measurement 100% TA(P) TA(P) Standard PF Section Manufacturer
Chamforing with calipers Standard

4.3 Curing of Counting of Qty. size Major Counting the --do-- --do-- --do-- Lab records Manufacturer
Couplings & period maturity period IA

4.4 Testing of Testing Hydraulically Major Visual check for As per IS --do-- --do-- Lab records Manufacturer
Couplings with pipe any leak 7639/1975 IA

4.5 Dimensions Major Measurement IS:2500 P&J/IL Firms own Firms own Inspection Manufacturer
II/AQL 2:5 Normal design design Report IA
4.6 Marking Marking Major Stenciling 100% --do-- --do-- As per Manufacturer
contract IA

5.0 RUBBER SEALING RINGS FOR AC COUPLING & CID JOINTS:

5.1 Visual Examination Smooth Finish and Visual checking As per IS 5382- IS 5383-1985 IS 5383-1985 Test Report Manufacturer
Identification 1985 IA
5.2 Dimensions Measurement Measurement --do-- IS 10292-1988 IS 10292-1988 --do-- --do--

5.3 Hardness Measurement Major Physical As per IS 5382- IS 5382-1985 IS 5382-1985 Test Report of --do--
1985 supplier
5.4 Stretch Test ---- ---- ---- ---- ---- ---- ---- --do--
5.5 Compression set "Tests will be conducted at any reputed Laboratories of India, on samples drawn by IA"
Test
5.6 Water Immersion "Tests will be conducted at any reputed Laboratories of India, on samples drawn by IA"
Test
6.0 CID JOINTS
6.1 Visual Examination Free from surface Major Visual As per IS As per IS As per IS Test Report Manufacturer
defects 8794:1988 8794:1988 8794:1988 IA
6.2 Dimensional Measuirement Major Measurement --do-- --do-- --do-- --do-- --do--
verification with calipers
6.3 Mass of joints Weightment Major Weightment --do-- --do-- --do-- --do--

6.4 Hydrostatic Test Hydraulic Test with Major Hydralic --do-- As per IS As per IS --do-- --do--
respect to class of pressure test 8794:1988 8794:1988 and
joints and IS 1592- IS 1592-1989
1989

6.5 External Coating Coating Major Visual check Random IS 8794:1988 IS 8794:1988 --do-- --do--

6.6 Tensile Test Major UTM 1/Lot IS 8794:1988 IS 8794:1988 --do-- --do--

6.7 Hardness Test Hardness Major BHN IS 2500 PE II IS 8794:1988 IS 8794:1988 --do-- --do--
Level IV/AQL 2.5
7.0 ACCEPTANCE CRITERIA TESTS
Final Inspection/Test for A.C. Pressure Pipes
7.1 Visual Examination Finish and marking Major Visual 100% by As per IS As per IS 1592- Inspection --do--
Manufacturers 1592-1989 1989 and SO Report
and SO norms norms

7.2 Dimensions and Measurement Major measurement 100% by As per IS As per IS 1592- Inspection --do--
Tolerances by calipers Manufacturers 1592-1989 1989 Report
instrumentd and SO norms
7.3 Strightness Test --do-- Major Measurement Samples as per As per IS As per IS 1592- Inspection --do--
by strightness IS:7639/1975 1592-1989 1989 Report
tester and SO norms
7.4 Internal Regularity Uniformity Major Disc Test --do-- --do-- --do-- --do-- --do--
Test
7.5 Work Hydralic Hydraulic pressure Major Hydraulic --do-- --do-- --do-- --do-- --do--
Pressure Tightness as per the class of pressure test
Test pipes
7.6 Transverse Crushing stress Major Physical Test --do-- --do-- --do-- --do-- --do--
Crushing Test
7.7 Hydralic Bursting Brustiing Stress Major Physical Test --do-- --do-- --do-- --do-- --do--
Test
7.8 Longitudinal Beding stress Major Physical Test --do-- --do-- --do-- --do-- --do--
Bending Test (Upto
150mm dia pipe
only)

Note: - 1. Internal report shall be submitted to IA for secrutiny before commencement of inspection
2. All measuring instruments & test equipments shall be caliberated regularlyand put put to IA for
scrutiny.
3. Manufacturer shall submit safely as per IS 11769 P&I/1987 to IA for scrutiny
 QUALITY ASSURANCE PLAN
PRODUCT NAME: R.C.C. PIPES:

Sl. Component / Characteristics Quantum of Reference Acceptance

Category Type of Check Format of Record Agency Remarks
No. Material Check Check Documents Norms

1.0 RAW MATERIAL CONTROL

1.1 Cement : 1. Chemical Critical Chemical 1 / Lot IS : 12330 IS : 12330 (See Supplier's TC 1.Supplier 1.Scrutiny of records
Analysis (See note 2) note 2) 2. IA by IA
2. Counter check by
IA on receit at
manufacturers place.

2. Physical - do - By sieve 1 / Lot - do - - do - - do - - do - - do -

a. Fineness
b. Standard - do - Lab Test 1 / Lot - do - - do - - do - - do - - do -
consistency

c. Setting Time - do - Lab Test 1 / Lot - do - - do - - do - - do - - do -

consistency

d. Soundness - do - Lab Test 1 / Lot - do - - do - - do - - do - - do -

e. Compressive - do - - do - 1 / Lot - do - - do - - do - - do - - do -
strength

1.2 Aggregatge a. Deleterious Major Lab Test 1 / Lot IS : 383 IS : 383 a. Supplier's TC a. Supplier's Scrutiny of records by
materials b. Manufacturer's TC IA
Register b.
Manufacturer's
b. Soundness - do - - do - - do - - do - - do - - do - - do -
Register - do -

c. Specific gravity - do - - do - - do - - do - - do - - do - - do - - do -
d. Grading & size - do - - do - - do - - do - - do - - do - - do - 1.Scrutiny of records
by IA
2. Random physical
verification by IA
Sl. Component / Characteristics Quantum of Reference Acceptance
Category Type of Check Format of Record Agency Remarks
No. Material Check Check Documents Norms
1.3 Water Solubility of Water in Major - do - Once in a year IS : 456 IS : 456 Govt. Test Lab Manufacturer Scrutiny of TC by IA
concrete works
1.4 Reinforcement a. Chemical Major - do - 1 / Lot IS :432 Pt.I or IS :432 Pt.I or a. Supplier's TC a. Supplier 1.Scrutiny of records
IS : 432 Pt.II IS : 432 Pt.II or b. Manufacturer's b. IA by IA
or IS : 2862 any Register 2. Counter check by
IS : 2862 any grade IA at manufacturer
grade (see place
note 4)
b. Physical Major UTM 1 / Lot IS :432 Pt.I or IS :432 Pt.I or a. Supplier's TC a. Supplier 1.Scrutiny of records
IS : 432 Pt.II IS : 432 Pt.II or b. Manufacturer's b. IA by IA
or IS : 2862 any Register 2. Counter check by
IS : 2862 any grade IA at manufacturer
grade (see place
note 4)
c. Dimension Major Measuring APL 2.5 DSP/ IL - do - - do - - do - - do - 1.Scrutiny of reports
Instruments II IS:2588 PT-1 by IA
2.Audit check by IA

1.5 Rubber Rings a. Dimensions Critical - do - - do - IS : 5382 Type IS : 5382 Type I, Supplier's Report 1.Supplier 1.Scrutiny of reports
I, Natural or Natural or 2. by IA (see note 5)
Isporene Isporene Manufacturer
b. Physical Test Critical Lab Test 1 / Lot - do - - do - Supplier's TC 1. Supplier 1.Scrutiny of TC by IA
2. IA 2. Counter check by
IA on receipt at
manufacturer place.

c. Polymer Critical Lab Test 1 / Lot - do - - do - Supplier's TC 1. Supplier 1.Scrutiny of TC by IA

identification 2. IA 2. Counter check by
IA on receipt at
manufacturer place.
d. Corrossion Test Details are yet to be
advised
2.0 PROCESS CONTROL

2.1 Concrete or a. Quality of Cement Critical Analysis of 1 / Batch or shift IS: 458 IS: 458 Manufacturer's a. 1.Scrutiny of records
Mortar concrete CL 4.5.1 CL 4.5.1 register Manufacturer by IA
b. IA 2. Random check IA
Sl. Component / Characteristics Quantum of Reference Acceptance
Category Type of Check Format of Record Agency Remarks
No. Material Check Check Documents Norms
b. Compression Critical Compression 3 / Batch IS : 458 IS : 458 Manufacturer's a. 1.Scrutiny of records
Strength (at 28 days) test register Manufacturer by IA
b. IA 2. Random test to IA
(see note 1)
2.2 Caging a. Weight of cage Critical By weighing M/C One per design IS : 458 IS : 458 Manufacturer's a. 1.Scrutiny of records
register Manufacturer by IA
b. IA 2. Random test to IA
(see note 1)

b. Dimension Major Measuring One each IS : 458 IS : 458 Manufacturer's a. 1.Scrutiny of records
Instruments pipe/mould register Manufacturer by IA
b. IA 2. Random check IA

2.3 Concreting of a. Speed Major RPM Indicator One each Manufacturers Manufactuerers Manufacturer's 1.Manufacturer
pipe pipe/mould own std own std register
b. Thickness of core Major Spike Guage One each IS : 458 IS : 458 Manufacturer's 1.Manufacturer 1)Secrutiny of
pipe/mould register 2. IA Register by IA
2) Random check by
IA
3.0 FINAL INSPECTION & TESTING
3.1 Final Cured a. Surface cracks, Major Visual 100% IS : 458 IS : 458 Manufacturer's 1.Manufacturer 1. Audit check on
Pipe projection in bore etc. register and test 2. IA sample by IA
report
b. Dimension Major Measuring 100% IS : 458 IS : 458 Manufacturer's 1.Manufacturer 1. Audit check on
instruments & register and test 2. IA sample by IA
Guages report

c. straightness of bore -do- Gauge 100% IS : 458 IS : 458 Manufacturer's 1.Manufacturer 1. Audit check on
register and test 2. IA sample by IA
report
d. Hydrostatic test Critical Pressure test 2% IS : 458 IS : 458 Manufacturer's 1.Manufacturer See note 6
with pump register and test 2. IA
report
e. Absorption test Critical As per IS: 3597 for each pipe IS : 458 IS : 458 Manufacturer's 1.Manufacturer
on specimen register and test 2. IA
report
Sl. Component / Characteristics Quantum of Reference Acceptance
Category Type of Check Format of Record Agency Remarks
No. Material Check Check Documents Norms
f. Three Edge Bearing Critical As per IS: 3597 On samples as IS: 3597 IS: 3597 Manufacturer's 1.Manufacturer See note 7
test per IS : 458 register and test 2. IA
report
g. Marking Major Visual 100% IS : 458 IS : 458 Manufacturer's 1.Manufacturer
register and test 2. IA
report

4.0 STAMPING & SEALING

4.1 Stencilling IA Legibility of stamp and Major Visual 100% - - - 1.Manufacturer
stamp proper location for 2. IA
easy identification

5.0 PACKING & DESPATCH :- To ensure no damages to pipes during transit, loading & unloading.

NOTE:
1. Proper co-relation must be established by approved agency for cube strength between vibratory and centrifugal process in case pipes are manufactured by
Centrifugal proces. In absence of the same, conversion factor for 28 days compressive strength of cube shall be taken as 1.25 (refer clause 4.5.1 of IS : 458)

2. Only sulphate resisting portland cement to IS:2330/1988 shall be used if the RCC pipes are used for UGD works.

3. Manufacturer should conform the bore-well and co-relate with test certificate. In case new borewells are planned to be added, the water from the same shall be
tested before being used.

4. The manufacturer shall advise in advance the type of polymer proposed to be used for Rubber rings and shall maintain the same polymer for the entire batch.

5. Sample of Rubber Rings procured shall be used for Hydrostatic Test.

6. Pipes used for Three Edge Bearing test shall not be included in the accepted lot. In case no failure occurs during this test, the maximum test load shall be
recorded. The Sl. Nos. of these pipes shall be indicated in Inspection Certificate to ensure that these are not received at site and laid by mistake.

7. Manufacturer shall give a copy of Internal test reports before inspection commenced by IA

8. All measuring insturments and test equipments shall be caliberated periodically and records shall be put upto IA for verification.