Introduction of

Quality Control &

Quality Assurance in
Highway project
(Sampling of
Materials for Lab
testing)

R.A. Singh,B. Tech (Hons), Seuj Ban Path, Fatasil Ambari, Ghy-25
Former Chief Engineer P.W.D. (Roads), Assam
Chartered Engineer & Consultant, Ph. 94355-52579

Quality assurance is basically defined as those planned and systematic exercises

executed to ensure that the product meets the specification. The quality
assurances cover up all the aspects of road development, design, construction,
maintenance and Rehabilitation. It forms the crux of the whole process of a
successful road development system. In a broader sense quality assurance is an
organised action which objective with respect to highway engineering, is to
ensure that the product, the pavement, is of envisaged level of serviceability and
it would fulfill the expectation of road user for the entire period, it is designed for.
In other words the quality assurance is a form of quality inspection or quality audit
whereas in quality control, the quality of future product is regulated and it involves
a number of activities in order to build up and regulate the product and performed
by executing agencies at execution stage. [It may be further stated that
ascertaining of quality of materials and carrying out exercise to obtain the quality
product while laying is a quality control and whether test conducted while
executing the work, is verifying, correct or not, is quality assurance].
1) Elements of Quality Assurances System
The need for the quality assurance system is the desire to have appropriate
returns to the investment made in the term of appropriate design, specification
construction practices and quality control during construction. In case of road
pavement quality assurance system may be said to have the following.
a) Proper assessment of requirement of the road pavement.
b) Choice of quality material and design.
c) Development of appropriate Technical Specification and acceptance criteria.
d) Choice of construction method / equipment plant.

e) Field supervision and quality control.

f) Assessment of quality of finish pavement.
g) Periodic inspection and maintenance measures.
2) Assessing Requirement of a Road project.
Proper assessment of road project within the frame works of fund available
is to be made which would include, design criteria, design life, minimum
acceptable service life & riding for the service period.
3) Choice of Quality Material & Design.
The selection of material to be incorporated in the pavement is based on
its cost, and its suitability to meet the design parameters.
Development of Specification and acceptance criteria.
The different category of roads, have its own specification and standard,
Even then quality assurances group has to examine whether any addition
to it is needed or not, in the condition the project is going to be executed
for.
Choice of construction method.
The selection of right type of equipments is the key to obtaining
the desired product.
Inspection of Quality control.
Quality control is a exercise involving inspection & testing of materials,
production process, ascertaining variation from predetermined standard,
acceptance or rejection of work.
Assessing Quality of Finished pavement.
An exercise need to be conducted to examine whether desired quality of
end product has actually bee achieved.

4) Periodic inspection and maintenance measure:Periodic inspection is to be caused on walking along the road in stretches, and not traveling in vehicle.
Quality assurances commences at the very beginning of planning the project.
i)

Preparation of DPR- Fixation of P.B.M. tied with G.T.S. and checking the design of Geometric
standard. The DPR is to be checked so as to ensure that provision made in the DPR would meet
up the requirement in the project, Moreover it reflects the ground realities too.

ii) Bridges:- It is to be seen whether H, DATA have been correctly collected or not, Prior to collection
of DATA one permanent B.M. is to be fixed at safe location tied with G.T.S. and subsequent data
should be based on this, Moreover corresponding railway bridges H. DATA need to be collected
and compare with it.
After finalization of span arrangement, the location of Bore holes along with R.L. of termination
of Boring is to be finalized and thereof SSI work is to be awarded to.
iii) Contract:- Prior to issue of notice inviting tender, the specification being incorporated in is to be
thoroughly checked in order to ensure the accomplishment of intended purpose of the project.
The choice of equipment to be deployed for execution of different component is to be finalized at
N.I.T. Level itself.
5) Inspection and quality control:- Checking of profile of the road to be constructed is to be done
with respect to designed profile. The setting of Horizontal curves is to be checked at site along
with toe line..
Materials:- Sources of different materials as mentioned in DPR are to be identified and quality of
materials against each source is to be ascertained to.
(i)

Soil for building embankment:- Tests to be conducted, are sieve analysis, Atterberg limits (LL,
PL) Dry density & C.B.R. and these tests are to be also conducted for G.S.B. construction.

ii)

Stone Aggregate:- W.B.M:- Impact, Flakiness test, water absorption, specific gravity, Gradation
& soundness test if needed.

iii) P.C. & Seal Coat:- Grading, Impact, Flakiness test, water absorption specific
gravity, stripping value, Bulk Density.
iv) Bituminous materials:- Straight run bitumen- penetration, softening point,
ductility, specific gravity, viscosity.
v) Emulsion- Emulsion test as per IS 8887-2004.
Design:- Design of GSB, such as gradation and degree of compaction is to be
finalized & similarly mix design of bituminous mixes is to be finalized prior to
execution.
6. Bridges:- The centre line X-X & Y-Y direction is to be fixed in the line of G.A.D.
and B.M. is to be verified. Source of coarse as well as fine aggregate is to be
located and properties of the same are to be ascertained. Thereafter mix design for
control concrete is to be finalized. After that weigh batcher, slump cone, etc are to
be brought to the site, If subsequent change in source of material, grade and make
of cement becomes unavoidable, fresh design of mix is to be done.
Quality Policy:- The overall quality intensions and direction to be issued to the
organization, as would be expressed by top management.
Quality Management:- The quality is the body management that determines and
implements the quality policy. The basic parameters of quality management are:i) The arrangement of desired quality, requires the commitment and participations of
all members of the organization whereas the responsibility for quality managements
belongs to top management.
ii) Quality managements includes strategic planning, allocation of recourses, quality
planning operation and evaluation of the product.
7. Requirements set out in the project should reflect need of road users.
i) For effectiveness, the quality assurances usually requires a continuing evaluation
of factors that affect the adequacy of the design or specification as well as
verification and audit of production, installation and inspection operation. One senior
executive expresses thus In fact our attitude towards quality is perfunctory.

We senior are responsible for poor quality of the product. In the beginning we insist for adherence to quality
but later on tell the same worker to produce the targeted out turn even ignoring the quality.
ii) The Other short-coming in quality assurance is the impression crated in quality control staff is that for any
lapse in quality control and subsequent processing of data to assurance quality, the staff on duty would be
accountable, This factor often compels them to manufacturer the data which satisfy the norms. But it puts
question mark to integrity of the data. Clear picture immerges only when certain portion fails prematurely,
otherwise it speaks of bright performances.
Frequency of Test and Acceptance criteria for earthwork, sub grade, granular sub-base, base
course & wearing course.
Test
1)Earthwork
i. Placement moisture
content.
ii) Degree of compaction.
iii) CBR on Sub-grade on
remolded sample.
2)Granular subbase/base/ wearing
course.
i) Sieve analysis.
ii) Plasticity index.
iii) Placement moisture.
iv) Degree of
compaction.
v) CBR
3)W.B.M. Course
i) Impact value.
ii) Grading.
iii) Flakiness.
iv) PI of binding
materials.
v) PI of materials passing
425 mic. Sieve.
4)Wet Mix Macadam.
i) Impact value.
ii) Grading.
iii) Flakiness index.
iv) PI of materials
passing 425 mic. Sieve.
v) Density of compacted
layer.

Test Method

Frequency

IS-2720-Part 2
IS-2720-Part 20
IS-2720-Part 16

1 in 300 sqm. for each layer.

1 in 1000 sqm. for each layer.
As required.

IS-2386
IS-2720
IS-2720
IS-2720
IS-2720

Part
Part
Part
Part
Part

200 m3, minimum of 2 test per

IS:2386
IS:2386
IS:2386
IS:2720
IS:2270

(Part
(Part
(Part
(Part
(Part

4)
1)
1)
5)
5)

1 in
day
1 in
day
1 in
day
1 in
day
1 in

IS:2386
IS:2386
IS:2386
IS:2720

(Part
(Part
(Part
(Part

4)
1)
1)
5)

1
1
1
1
1

in
in
in
in
in

200 m3
100 m3
200 m3
25 m3
100 m3

1
1
1
1
1

in
in
in
in
in

200
100
200
100
500

1
5
2
28
16

IS:2720 (Part20)

200 m3, minimum of 2 test per

250 m2, minimum of 1 test per
500 m2, minimum of 1 test per
1000 m3

m3
m3
m3
m3
m2

Acceptance criteria
For fine grain soil+2% of OMC.
For course grain soil 1.5% of
OMC
In lower level 95% and in top
97% of part-8.
As required.
As required.
+ 1.5%
100% of PD
As required.
As
As
As
As
As

per
per
per
per
per

required.
required.
required.
required.
required.

As
As
As
As

per
per
per
per

required.
required.
required.
required.

As per required.

Bituminous construction (Prime coat & Tack coat)

5)

i) Quality of binder

ii) Temperature of binder for

cut back when used.
iii) Rate of spread of binder.

IS:8887 viscosity,
sieve test, storage
stability, particle
charge residue
and test on it.
As per design.

1 test per lot

As per required.

Regularly

As per required.

1 test for 500 m2 not less than 2

test per day.

As per required.

Laying of test track:

After ascertaining the quality & properties of building materials, spreading of one layer of different
components of embankment/ pavement for stretch 30 m in length & 3.75 m in width and it should be
compacted at parameter determined in the laboratory with the help of compacted equipment proposed
to be utilized, In this operation, the loose thickness to be spread, nos of passes of road rollers to obtain
the desired degree of compaction at O.M.C. that is achieved in the field either adding of water or drying
by acriation as the case may be similarly factors for compaction of G.S.B. and base are to be
determined.
Table 5
Frequency of Test for Bituminous Macadam
Sl No

Test

Quality of binder

2
3
4
5

Temperature of binder
Aggregate impact value
Flakiness index
Stripping of aggregate

Water absorption

7
8
9

Grading of aggregate
Binder content
Thickness

Test Method
Penetration, Softening Point &
Ductility Tests for Paving Bituminous
(IS:73)
Penetration, Softening Point and
Elastic Recovery Tests for Modified
Bitumen
(IRC : SP 53)
Appendix 10.6 of RRM
IS: 2386 (Part 4)
IS: 2386 (Part 1)
IS: 6241 - 1971
IS: 2386 (Part 3)
IS: 2386 (Part 1)
Appendix 10.8 of RRM
-

Frequency
One test per lot

Regularly
1 test per 250 cum/source
1 test per 250 cum/source
1 set per 3 representative
specimens per source
1 set of 3 representative specimens
per source
1 test per 100 cum per day
2 tests per day per plant
Regularly

Table 6
Frequency of Test for Built- up Spray Grout/Modified
Penetration Macadam
Sl
No.

Test

Quality of binder

2
3
4
5

Temperature of binder
Aggregate impact value
Flakiness index
Stripping of aggregate

6
7

Aggregate grading
Water absorption

8
9
10

Soundness of aggregate
Rate of spread of binder.
Rate of spread of aggregates

Test Method
Penetration, Softening Point &
Ductility Tests for Paving Bituminous
(IS:73)
Penetration, Softening Point and
Elastic Recovery Tests for Modified
Bitumen
(IRC : SP 53)
Appendix 10.6 of RRM
IS: 2386 (Part 4)
IS: 2386 (Part 1)
IS: 6241 - 1971
IS: 2386 (Part 1)
IS: 2386 (Part 3)
IS:2386 (Part 5)
Appendix 10.7 of RRM
Appendix 10.10 of RRM

Frequency
One test per lot

Regularly
1 test per 250 cum/source
1 test per 250 cum/source
1 set per 3 representative
specimens per source
1 test per 100 cum of aggregate
1 set per 3 representative
specimens per source
1 test per source
1 test per 1000 sqm or per day
1 test per 1000 sqm or per day

Frequency of test for DBM, S.D.B.C. & B.C. refer Table 900-4 item 6, mastic asphalt item No. 7

Quantity of Sample Soil

Quantity of sample required for
Determination of water content
Size of particle more
than 90 P.C. passing

Minimum Quantity
of soil specimen to
be taken for test
massing (gm)

425 I.S. Sieve

2 mm I.S. Sieve
4.75 mm I.S. Sieve
9.50 mm I.S. Sieve
19 mm I.S. Sieve
37.5 mm I.S. Sieve

25
50
200
300
500
1000

Quantity of soil required for grain size

analysis
Maximum size of
material present in
substantial Quantity
mm
75
37.5
19
13.2
9.5
6.7
4.75

Mass to be taken for test

Kg
60
25
6.5
3.5
1.5
0.75
0.40

Minimum weights for sampling for Aggregate

Max size present in
substantial proportions
mm
63
50
40
25
20
16
12.5
10.0
6.3

Minimum weight of
sample dispatched for
testing
Kg
100
100
50
50
25
25
12
6
3

Sample to be sent to lab, asphalt

5 kg
Coarse aggregate
20 kg each
Fine aggregate
20 kg
Filler
8 kg
Nominal maximum size of particles passing
Sieve
minimum wt of field sample
Kg
2.36 mm
5
4.75 mm
5
9.5 mm
5
12.5 mm
10
19 mm
15
25 mm
25
37.5 mm
30
50.0 mm
40
63 mm
45
75 mm
60
90 mm
65

Collection of samples for Bituminous work.

a) Collection by consultant or Depth for preparation of D.P.R.
i) Selection of quarries based on its qualitative and quantitive aspect and a few testing
of sample will serve the purpose, the test to be corrected are impact & water
absorption etc.
ii) Collection by contractors for installation of crushing plants and evaluation of its
quality. Contractors should select the quarries that produces relatively higher
strength, less water absorption and less stripping values, as impact values of material
manufactured by crushing plants are generally less than sample manually preparedAfter selection of the quarry crusher plant is installed suitably. The contractor has to
adjust crushing after conducting F.I. test so that produce is not Flaky one.
iii) Prior to crushing it is better to determine the sizes of different components and start
manufacturing the same. It is done as preliminary design testing.
iv) Collection for design of mixes:- Material has to be stacked size wise at mixing
plant site, representative sample is to be taken from different stacks of respective
size. Mix up and take required quantity as per size after quartering the collected
sample.
b) Source Acceptance testing:- Source acceptance testing is often performed after the
award of the contract and has indicated the proposed source of all material and
asphalt. The main objective is to determine the most economical blend of materials
that will satisfy both gradation and mix design requirement of the specification.
Source acceptance test serve to assure the owner and contractor that the proposed
source of material will yield the paving mixture that meets specification and further will
permit the contractor to proceed with stock piling of the required material at Job sites.
c) Job mix control testing:- Job mix control testing is executed at the start of plant
production and in conjunction with the calibration of mixing plant for J.M.F. This is one
of the key points of design control for the paving construction since the Job mix
formula establish the actual gradation and asphalt content to be obtained in the
mixing plant.