HCC Management System

Segment Quality Management Plan

Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
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Project:
4 laning of KM 92+000 to KM 138+000 of Lucknow – Ayodhya Section
of NH-28 in Uttar Pradesh, India

Client:
NATIONAL HIGHWAYS AUTHORITY OF INDIA

Segment Quality Management Plan

Cross Drainage Works – Pipe Culverts

HCC N 39 17 03
Revision No.: 0
Date of Revision: 24 April 2006

DOCUMENT RELEASE AUTHORIZATION

Prepared by QC Engineer : __________________________________

(Manjunath Pillay)

Approved by Project Manager : __________________________________

(Priyaranjan)

Reviewed by Project Chief Engineer : __________________________________

(Priyaranjan)

Issued by Document Controller : __________________________________

(Manjunath Pillay)

Issued as: CONTROLLED COPY / UNCONTROLLED COPY for information purpose

(appropriate status to be highlighted)

____________________________________________________________________________________________

HINDUSTAN CONSTRUCTION CO. LTD

HINCON HOUSE, LAL BAHADUR SHASTRI MARG,

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 HCC Management System
Segment Quality Management Plan
Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
_____________________________________________________________________________
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VIKHROLI (WEST), MUMBAI- 400 083, INDIA

I. History of Revisions

Chapter/clause
Revision
Revision date no. & text Reason for revision
No.
affected
0 24 April 2006 First Issue

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 HCC Management System
Segment Quality Management Plan
Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
_____________________________________________________________________________
_

1.0 PURPOSE:
The purpose of this Segment Quality Plan for Construction of Cross Drainage Works is
to provide details of the Construction Methodology, Quality Assurance & Control
System/Procedures adopted by H.C.C. and its Sub-contractor’s/Supplier’s in
execution of Cross Drainage Works i.e., Pipe Culverts at various locations/stretches as
shown in the Construction Drawings.

2.0 SCOPE:
The Scope of this Segmental Quality Plan covers the following activities:

(i) Cutting, removing and disposing of all materials such as trees, bushes,
shrubs, stumps, roots, grass, weeds, top organic soil etc., which in opinion of
the Engineer are unsuitable for incorporation in the works, from the area
within Toe line containing road embankment drains, cross drainage
structures and such other areas as may be specified on the drawing or by the
Engineer.

(ii) Excavation necessary for construction of CD Works complete as per

Technical Specification Clause 301 & loosening and re compaction of the
original ground /sub grade up to the required depths as directed by the
Engineer and as per M.O.R.T.H. Clause 305.3.4.

(iii) Selection of various Construction Materials, Testing of Materials,

Approvals, and Quarry Selection, testing and approval of various grades
of materials etc.

(iv) Construction of Cross Drainage Works Pipe Culverts with approved

materials/methods etc. complete as per M.O.R.T.H. Section 2900 and also
as per other relevant sections of M.O.R.T.H applicable for Concrete Works
as specified in Construction Methodology.

3.0 DEFINITIONS :
The words like Contract, Contractor, Engineer (Synonymous to Engineer’s
representative), Drawing, Employer, Government, Works, Worksite used in this
Quality Plan shall be considered to have the meaning as understood from the
definitions of these terms given in the General conditions of the contract. For other
general definitions pertaining to HCC Quality Management System, refer Project
Quality Plan, HCC P 39 17 01.

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 HCC Management System
Segment Quality Management Plan
Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
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The following abbreviations shall have the meaning as set forth below:

M.O.R.T.H : Ministry of Road Transport & Highways

PCC : Plain Cement Concrete
RCC : Reinforced Cement Concrete
BOQ : Bill of quantities
CBR : California Bearing Ratio
PI : Plasticity Index
MDD : Maximum Dry Density
OMC : Optimum Moisture Content

4.0 CROSS REFERENCES:

This Segment Quality Plan shall be read in conjunction with the following documents:

1) M.O.R.T.H – Specifications for Road and Bridge Works (Fourth Revision)

2) Contract Bid Document, Volume – II (Technical Specifications)
3) Construction Programme and Cash Flow –
4) Various BIS/ASTM/ BS Standards/Codes cross-referred elsewhere in this
Segment Quality Plan.

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 HCC Management System
Segment Quality Management Plan
Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
_____________________________________________________________________________
_

5.0 RESPONSIBILITIES:

Responsible personnel for execution of the Segment of Cross Drainage Works are as per
the following Responsibilities Matrix and also as per the Project Organization Chart:

S. Activity Description Performing Checking/ Approving

No. Verifying
01 Preparation Construction Works Manager Engineer
Methodologies. Mgr./Section- (Quality
in-charge Management)
02 Identification of Source Works Manager Engineer
for Construction Materials Mgr./Section- (Quality
for CD Works. in-charge Management
03 Testing of Samples & QC Manager / Engineer
Approval and Trial Mixes Engineer /Lab QC Engineer
etc. Technician
04 Survey & Setting out Surveyor Works Engineer
works. Mgr./Section-
in-charge
05 Preliminary/Excavation Section-in- Works Engineer
Ground preparation charge / Site Mgr./Section-
Works. Engineer in-charge
06 Trial Mixes and QC Engineer Manager Engineer
Sampling/Testing of (Quality
Cubes and Design Mix Management )
07 Preparation of BBS/ Section-in- Works Engineer
Placing of Reinforcement charge / Site Mgr./Section-
in place etc. Engineer in-charge
08 Placing Shuttering and all Section-in- Works Engineer
other charge / Site Mgr./Section-
fixtures/embedment/ Engineer in-charge
pipes etc. as per drawing
09 Placing of Concrete and Section-in- Works Engineer
Post-concrete activities, charge / Site Mgr./Section-
curing, finishing etc. Engineer in-charge
10 Testing of Soils/Cubes / Lab QC Engineer Engineer
Pipes etc. Technician
11 Clearance to release/final Section-in- QC Engineer Engineer
approval charge / Site
Engineer

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 HCC Management System
Segment Quality Management Plan
Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
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6.0 PROCEDURE :

6.1 Site Clearance Works :

Site Clearance, Grubbing, Dismantling of existing structures and disposal of
unserviceable materials at designated areas and stacking of serviceable materials for
use in Embankment Construction works etc. shall be carried out as per M.O.R.T.H
Technical Specification, Section – 200.

6.2 Survey and Setting Out Works :

After the Site has been cleared as per Clause 201, the limits of excavations shall be
set out true to lines, curves, slopes, grades and sections as shown on the drawings or
as directed by the Engineer and as per established Bench Marks / Co-ordinates.
All the Survey Instruments used shall be calibrated periodically as per Calibration
Plan. Survey Check Reports / other relevant data shall be maintained in relevant
Inspection formats.

6.2 Construction of Pipe Culvert :

The foundation bed for Pipe Culverts shall be excavated true to the lines and grades
as per the drawings. In case of high embankment where the height of filling is more
than three times the external diameter of the pipe. The Embankment shall first be
built to an elevation above the top of the pipe equal to the external diameter of the
pipe, and to width on each side of the pipe not less than five times the diameter of
the pipe, after which the trench shall be excavated. For the construction of head wall,
setting for the excavation shall be done as per M.O.R.T.H Clause 301.3.1 and
excavation shall be carried out as per M.O.R.T.H Clause 304. Granular sand filling in
foundation shall be done. Bed PCC ( M 15 Grade nominal Mix ) for head wall shall
be done over compacted sand bedding. Head wall shall be constructed by using
P.C.C and all the material used in the work shall confirm to the requirements laid
down in section 1000 of M.O.R.T.H. . Bedding for pipe shall be prepared by granular
filling. Over the compacted granular fill 100mm thick M 15 grade PCC shall be laid.
Slope of the bedding shall be as per drawing.

The Hume pipes shall be laid, as per drawing, where two or more pipes shall be
laid adjacent to each other; they shall be separated by distance as mentioned in the
drawing. The laying of pipe shall be carried out as per specification laid in
M.O.R.T.H clause 2904. The newly laid pipe shall be placed in such a way that these
will be joining gap of 13mm to 18mm.The our side and inside jointing gap shall be
filled with cement mortar in 1:2 ratio. Care shall be taken to fill all voids of the joints
from inside and outside and surplus mortar shall be removed. After jointing of pipe
as per M.O.R.T.H Clause 2906, the pipe shall be in a cradle constructed of concrete in
M 15 conforming to section 1700. The shape and dimensions of the cradle shall be as
per the drawing.

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 HCC Management System
Segment Quality Management Plan
Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
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_

6.4 Segment Inspection and Testing Process :

All the Inspection and Testing requirements for various activities in the present
segment shall be carried out as per relevant M.O.R.T.H Specifications & Contract
Technical Specifications, other Codes/Standards as mentioned in References Chapter
are identified in the form of Inspection and Test Plans.

These Inspection and Test Plans shall consists of type of Inspection and name of the
Test to be conducted for Product Realization, frequency of testing, acceptance criteria
and category of Inspection as mentioned in the legend of ITP.

Inspection and Test Plans shall be revised whenever there is any change in
methodology and specifications etc. Various Field and Laboratory Test Formats referred
in Inspection and Test Plans shall be maintained as per the frequency mentioned in
respective ITP’s for various activities.

Any Non-Conformity observed during Field Inspection and also during Testing of
Materials the same Non-Conformity shall be recorded in the specified Format and
necessary Corrective/Preventive actions shall be initiated to prevent such things in
future.

All Product Non-Conformities shall be observed, recorded, corrective/preventive

actions and closing of NCR’s shall be as per the established documented procedure
described in Project Quality Plan.

Various Document/Records required to be maintained for the present segment has

been presented in the subsequent chapter.

6.5 Segment Documentation Requirements:

The following document and records shall be and maintained to demonstrate the
compliance to established HCC Quality Management System in execution of present
Segment and also to meet the Contract Technical Specifications requirements.

Inspection and Test Plans:

The following Inspection and Test Plans for Flexible Pavements have been prepared in
line with the requirement specified in M.O.R.T.H Specifications and relevant Contract
Technical Specifications:

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 HCC Management System
Segment Quality Management Plan
Cross Drainage Works – Pipe Culverts
LMNHP-EW II (WB) - 3 HCC N 39 17 03
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1) Inspection and Test Plan for Inspection of Cross Drainage Works, HCC T 39 17 03
2) Inspection and Test Plan for Testing of Materials for CD Works, HCC T 39 17 04
Inspection and Testing Formats:
All the Inspection and Testing format as highlighted in attached list of Field Inspection
and Testing Formats shall be maintained.

Frequency of Inspection and Testing shall be as mentioned in relevant Inspection and

Test Plans.

General Document/Records:
The following general documents/records shall be kept maintained as per relevant
applicable HCC Quality Management Procedures:

1) Construction Schedules for the Segment

2) M.O.R.T.H and other Technical Specifications including relevant IS/BS/ASTM
Codes
3) Customer Field memos/notes/complaints etc including action taken status
4) Product Non-conformance Reports etc.

All the above document/records shall be maintained at appropriate locations with

proper and defined filing system which can be identified & traceable.

6.6Segment Safety & Environmental Requirements:

Hazard Identification, Risk assessment and Risk control measures for each and every
activities and sub-activities involved in the present Segment shall be identified and
necessary action plan shall be initiated.

Refer the following Documents for details about the Site Safety Management system:

Project Occupational Health and Safety Management Plan, HCC N 39 15 01

Environmental Aspects and Impacts associated with various activities and sub-activities
involved in the present segment and their mitigation/control measures shall be
identified and necessary measures shall be initiated.

Refer the following Documents for details about the Site Environmental Management
Plan:

Project Environmental Management Plan, HCC N 39 18 01

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