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Quality inspection & Test Plan Comprehensive

INSPECTION AND TESTING PLAN


FOR
CONSTRUCTION MATERIALS

TESTING
The various tests shall be conducted as per table given below:
Brief Description / Test IS Code
1 Embankment/Structure back fill /RE soil
a) Sp. Gr. Fine, Medium & Coarse grained Soil IS 2720 (Part 3/Sec2)
b) Sp. Gr. Fine, grained Soil IS 2720 (Part 3/Sec1)
c) Sp. Gr. of Soil Specimen and Water Content of Soil. IS 2720 (Part 2)

d) Grain Size Analysis (Wet Sieving) IS 2720 (Part 4)


e) Atterberg limit (LL, PL, & PI) IS 2720 (Part 5)
f) Shrinkage Factors SI, SL IS 2720 (Part 6)
g) OMC, MDD using Heavy Proctor IS 2720 (Part 8)
h) Dry density moisture content relation by constant weight of soil
method IS 2720 (Part 9)
i) In-Site density by sand replacement method. IS 2720 (Part 28)
j) Consolidation properties IS 2720 (Part 15)
k) Lab CBR soaked and un soaked. IS 2720 (Part 16)
l) Field moisture equipment IS 2720 (Part 18)
m) Direct Shear Test IS 2720 (Part 13)
n) Organic matter IS 2720 (Part 22)
o) Free swell index of soil IS 2720 (Part 40)
p) Soluble Sulphate in soil BS : 1377 (Test 10/9)
2 Sub grade
a) Sp. Gr. Fine, Medium & coarse grained Soil IS: 2720 (Part 3/Sec2)
b) Alterberg Limit LL, PL & PI IS 2720 (Part 5)
c) Total Soluble Solids IS 2720 (Part 21)
d) Organic Matter IS 2720 (Part 22)
e) Calcium Carbonate IS 2720 (Part 23)
f) Cation exchange capacity IS 2720 (Part 24)
g) Silica sesquioxide ratio. IS 2720 (Part 25)
h) PH Value. IS 2720 (Part 26)
I) Total Soluble sulphate IS 2720 (Part 27)
j) Sand equivalent Values of Soil IS 2720 (Part 37)
k) Free Swell index of soils IS 2720 (Part 40)
l) Permeability IS 2720 (Part 17)

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m) OMC, MDD using heavy proctor IS 2720 (Part 8)


n) CBR (soaked and unsoaked) IS 2720 (Part 16)
o) Insitu density test by sand replacement method IS 2720 (Part 28)

1. Granular/ Sub-Base & WMM

As per design requirement a sub-base consisting of crushed aggregates, shall be provided. The well-graded
crushed material shall be as per the contract specifications. Ensure that the material is used as per
specification; the following tests shall be conducted as per table given below.

S.No Brief Description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
1. Sieve analysis IS 2386( part 1)
2. Atterberg limits i.e. LL, PL & PI IS 2720 (Part 5)
3. OMC & MDD using heavy proctor. IS 2720 (Part 8)
4. CBR (socked and un-soaked) IS 2720 (Part 16)
5. LAA IS 2386( Part 4)
6. ACV/AIV IS 2386 (Part 4)
7. Soundness Loss test IS 2386 (Part 50
8. Flakiness/Elongation test IS 2386(Part 1)
9. Water absorption IS 2386 (Part 3)
10. 10% fine value BS: 812 (Part 111)
11. Moisture content of loose material BS: 812 (Part 2)
12. Insitu density by Sand Replacement Method IS 2720 (Part 28 )
13. Material finer than 75 micron IS:2386 (Part 1)
14. Determination of specific Gravity IS: 2386 (Part 3)
15. Determination of Organic impurities IS: 2386 (Part 2)
16. Grading
GSB (D/L) Table 400-2 of MORT&H
GSB (U/L) Table 400-1 of MORT&H
WMM Table 400-11 of MORT&H
17. Physical requirements of coarse aggregate for WMM Table 400-10 of MORT&H

2. Coarse and Fine Aggregates (For Concrete)

S.No Brief Description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
1. Particle size and shape IS:2386-1963 (Part 1)
2. Estimation of deleterious materials and organic impurities IS:2386-1963 (Part 2)
3. Specific gravity, density, voids, absorption and bulking IS:2386-1963 (Part 3)
4. Mechanical properties IS:2386-1963 (Part 4)
5. Soundness IS:2386-1963 (Part 5)
6. Measuring mortar making properties of fine aggregates IS:2386-1963 (Part 6)
7. Alkali aggregate reactivity IS:2386-1963 (Part 7)

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8. Petrographic examination IS:2386-1963 (Part 8)


Coarse and fine aggregates from material sources for IS:383-1970
9.
concrete (second revision)
10. Gradation
Coarse Table 1000-1 of MORT&H
Fine Table 1000-2 of MORT&H
11. Concrete mix design IS:10262-1982 / SP23:1982
12. Code of practice for PCC & RCC IS:456-2000 of BIS

3. DBM/BC

S.No Brief Description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
1. Particle size and shape IS:2386-1963 (Part 1)
2. Estimation of deleterious materials and organic impurities IS:2386-1963 (Part 2)
3. Specific gravity, density, voids, absorption and bulking IS:2386-1963 (Part 3)
4. Mechanical properties (LAA/AIV) IS:2386-1963 (Part 4)
5. Soundness IS:2386-1963 (Part 5)
6. Sand equivalent of fine aggregates IS:2720 (Part 37)
7. Determination of stripping value of aggregates IS:6241-1971
8. Water sensitivity AASHTO T283
9. Gradation
DBM Table 500-10 of MORT&H
BC Table 500-18 of MORT&H
10. Physical requirements for coarse aggregate
DBM Table 500-8 of MORT&H
BC Table 500-17 of MORT&H
11. Sp. Gravity of coarse aggregate AASHTO T85
12. Sp. Gravity of fine aggregate AASHTO T84
13. Sp. Gravity of filler AASHTO T100
14. Stone polishing value of aggregate BS:812 Part 114

4. Water

The water used for general engineering practices shall conform to following tests.

Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
Suitable of water for General Engineering practice. IS: 456
PH value, acidity, alkanets, organic solid should sulphates etc. IS: 3025

5. Bitumen / Bituminous mixes

Bitumen used in bituminous shall be 60-70 and shall conform to following test as tabulated below.

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S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
1 Sp. Gravity at 27C IS 1202:1978, AASHTO T100
2 Water percent by mass IS 1211:1978
3 Flash point, closed and open temp, C IS 1448(P:691:1969)
4 Softening point C IS 1205:1978
5 Penetration at 25C, 100g, 5sec, 1/10 min IS 1203:1978
6 Penetration ratio at 4C & 25C -
7 Ductility test at 27C, cm IS 1208:1978
8 Paraffin wax content, % by mass IS 10512:1983
9 Frass breaking point, C, min IS 9381:1979
10 Loss on heating, thin film over test IS 1212:1978
11 Retained penetration at 25C IS 9382:1979
12 Matter soluble in trichloroethylene IS 1216:1978
13 Viscosity at
a) 60C poises IS 1206 (Part 2):1978
b) 135C; cost min IS 1206 (Part 3):1978
14 Maximum specific gravity of loose paving mixture ASTM 2041
Resistance to plastic flow of bituminous mixtures using
15 D-1559 of ASTM
Marshall apparatus
Resistance to plastic flow of bituminous mixtures using
16 D-5581 of ASTM
Marshall apparatus
Bulk specific gravity of compressed bitumen mixtures ASTM D-2726 or D-1188 or AASHTO
17
using ISD specimen T-166=00
18 Bituminous mix design MS-2 of Asphalt Institute
19 Bitumen Emulsion IS 8887

6. Cement

Cement used in various grades of concrete mixes in super and substructure (concluding points) shall conform
to the following test.

S.No. BRIEF DESCRIPTION OF TEST IRC/IS/AASHTO/BS CODE


In order of preference given in CA
1 a) Cement OPC grade 33,43, 53 (Preferably 43 grade) IS: 269, IS:8112, IS:12269
b) Determination of Fineness by dry sieving IS:4031 (Part 1)
c) Determination of Fineness BAP method. IS:4031 (Part 2)
d) Soundness Le Chatelier IS: 4031 (Part 3)
e) Determination of Consistency. IS:4031 (Part 4)
f) Initial & Final setting time. IS:4031 - (Part 5)
g) Soundness Auto Clave method IS:4031 (Part 3)

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i) Compressive strength 3,7 & 28 days IS:4031 (Part 6)


j) Determination of density IS:4031 (Part 11)

7. Steel

Steel for reinforcement and pre-stressing rebar and high strength steel wire to be used as reinforcement bar
in RCC and pre-tensioning concrete structure shall conform to the following requirements.

S.N Brief description of Test IRC/IS/AASHTO/BS Codes


In order of preference given in CA
1 Steel (Rebars)
a) Nominal mass & Cross Section; Tensile Strength and IS:1786,IS:1608
% elongation
b) Bent Test / re-bend Test IS:1599/1786
c) Chemical Analysis IS:228
d) Pull out test IS:2770(part 1)
2 Steel for Post/Pre tensioning
a) Cold rolled Cold Annealed Sheathing IS:513
b) Nominal & Cross Section, tensile strength and IS:1786 (Part I & II)
elongations.
c) Structural Steel IS: 2062-1999
d) Welding IS: 816-1969 & IS: 1323-1982
e) Rivets IS: 1148-1982, IS: 1923-1961 & IS: 800-
1984
f) Bolts And Nuts IS: 1363-1967 & 1367-1967
g) HTS wire strands IS: 6006
h) Elastromeric bearings IRC: 83-1987(Part-II), ASTM D-297(Sub
Sec.-10), ASTM D-297 (Appendix X-Z),
ASTM S-3482-78, IS: 3400 (Part-
II,I,X,IV,XIV,XX,III), IS: 226 (lamination)
i) Strip seal expansion joints IRC: 83 (Part-II), IS: 3400 (Part-III), IS: 226,
IS:2062
k) Hume pipes IS: 458 & IS: 3597
Note: All the other component to be used in the project should be as per MORT&H, IS and other
specifications approved by IE.

8. Bricks

Bricks used in substructure shall conform to the following requirements.

S.No Brief description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
1. Bricks Dimension IS:1077
Determination of Efflorescence IS:3495(Part 3)
Determination of Absorption IS:3495(Part 2)

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Determination of Comp. Strength IS:3495(Part 1)


Determination of Warpage. IS:3495(Part 4)

9. Admixtures

Admixture used in concrete work shall confirm to the following requirements.

S.No Brief description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
a. Chloride content IS : 6925
b. Uniformity test IS : 9103
1. i) Dry material content IS : 9103
ii) Ash content IS : 9103
iii) Relative density IS : 9103

10. Cement Concrete

Cement concrete of various grade used in PCC / RCC / PSC shall confirm to the following requirements.

S. No Brief description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
a. Design mix of various grade of concrete SP : 23 , 1982 / IS : 10262, 1982
1 b. Consistency of concrete (slump) IS : 516 / IS : 1199
c. Cube compressive strength. IS : 516 / IS : 1199

11. RE Wall Accessories

RE Wall accessories shall confirm to the following requirements.

S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
BSEN: 10025:1993 / ISO: 1459:1973 / ISO:
1 Steel Lugs 1460: 1992 / ISO: 1461: 1973 / BS: 729:
1971 and Reinforced Earth Specifications.
2 Lifting Anchors Reinforced Earth Specifications.
3 EPDM Rubber Pads Reinforced Earth Specifications.
Carbon Steel Reinforcing Strips (Hot Dip BSEN: 10025:1993 / ISO: 1459:1973 / ISO:
4 1460: 1992 / ISO: 1461: 1973 / BS: 729:
Galvanized)
1971 and Reinforced Earth Specifications.
5 Nut & Bolts BS: 3692: 2001 / BS: 729: 2001 &
Reinforced Earth Specifications.
6 Foam Reinforced Earth Specifications
7 Geo textile Reinforced Earth Specifications

12. Back Fill Materials

Backfill material behind RE Wall shall confirm to the following requirements.

S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
1 a. Angle of internal friction IS: 13326, Part-I / Technical Specification of
Reinforced Earth

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IS: 383, 1970 / Technical Specification of Reinforced


b. Gradation
Earth
IS: 2720, Part-VIII / Technical Specification of
c. Proctor Density
Reinforced Earth
d. Resistivity Test Technical Specification of Reinforced Earth
e. Field Compaction Test IS: 2720, Part-29 / Technical Specification of
Reinforced Earth

13. Elastomeric Bearings:

S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
1. Steel Insert IS: 226
2. Raw Elastomer Table 2000-1 of MORT&H, Chloroprene (CR)
Ash Content ASTM D-297 (Sub-section 10)
Adhesion Strength (Elastomer to steel
IS: 3400 (part XIV)
plastics)
Sp. Gr. Test ASTM D-297 (Sub-section 15)
Polymer content test ASTM D-297 (Sub-section 10)
Identification of polymer ASTM D-297 (Sub-section 15)
Shear Modulus MORT&H
a) Level 1 acceptance testing Section 2005.3.1 of MORT&H
b) Level 2 acceptance testing Section 2005.3.1 of MORT&H
c) Any acceptance testing Section 2005.3 of MORT&H

14. Pot PTFE Bearings

Pot PTEF Bearing shall confirm to the following requirements.

Sl. No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
a. POT
i) Structural Steel IS: 226 / IS: 2062
ii) Caste Steel IS: 1030
iii) Stainless Steel AISI: 304 / AISI: 316 L
1 b. PTFE BS: 3784
c. Elastomer
i) Hardness IS: 3400 (Part II)
ii) Minimum tensile strength IS : 3400 (Part I)
iii) Minimum elongation at break IS : 3400 (Part I)

15. Bentonite

Bentonite shall confirm to the following requirements.

S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
1 a. Density To be confirmed
b. PH value IS: 3025

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c. Silt content IS: 2720 (Part IV)


d. Liquid limit IS: 2720 (Part V)
e. Mass con viscosity To be confirmed

16. Retro Reflective Road Marking Paint

Retro Reflective Road Marking shall confirm to the following requirements.

S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
Thermoplastic Material
a) Luminance AASHTO M 249
b) Drying Time AASHTO M 250

1. c) Skid Resistance BS: 6044


d) Yellow ness index AASHTO M 249
e) Cracking resistance at low temperature MORT&H
f) Softening Point ASTM D 36

g) Flow resistance AASHTO M 249

Reflection of Glass Beads


a) Gradation BS: 6088

2. b) Round ness BS: 3262 (Part I)


c) Refractive index MORT&H
d) Free Flow MORT&H
9 Thick ness MORT&H

17. Curing Compound

Curing Compound shall confirm to the following requirements.

S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
ASTM C 150 / ASTM C 156 / ASTM C 309 /
1 Drying Time
BS: 7542
2 Water Retention MORT&H

3 Specific Gravity (At 28C) -


ASTM C 150 / ASTM C 156 / ASTM C 309 /
4 Water Loss
BS 7542
5 Aspect -

18. Mastic Asphalt

Mastic Asphalt shall confirm to the following requirements.

S.No Brief Description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
1. Particle size and shape IS:2386-1963 (Part 1)
2. Estimation of deleterious materials and organic impurities IS:2386-1963 (Part 2)
3. Specific gravity, density, voids, absorption and bulking IS:2386-1963 (Part 3)

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4. Mechanical properties (LAA/AIV) IS:2386-1963 (Part 4)


5. Soundness IS:2386-1963 (Part 5)
6. Sand equivalent of fine aggregates IS:2720 (Part 37)
7. Determination of stripping value of aggregates IS:6241-1971
8. Water sensitivity AASHTO T283
Gradation
9. a. Coarse Aggregate Table 500-30 of MORT&H
b. Fine Aggregate Table 500-31 of MORT&H
10. Physical requirements for coarse aggregate Table 500-3 of MORT&H
11. Sp. Gravity of coarse aggregate AASHTO T85
12. Sp. Gravity of fine aggregate AASHTO T84
13. Sp. Gravity of filler AASHTO T100
14. Penetration at 25C, 100g, 5sec, 1/10 min IS 1203:1978
15. Softening point C IS 1205:1978
o
16. Loss on heating for 5 hrs. at 163 C IS 1212:1978
17. Solubility in trichloroethylene IS 1216:1978
18. Ash (Mineral Matter) IS 1217:1978

19. Crash Barrier Accessories

Crash Barrier Accessories shall confirm to the following requirements.

S.N Brief description of Test IRC/IS/AASHTO/BS Codes


In order of preference given in CA
G.I. Pipes
a) Dimensions IS: 1239(part 1), 1990
1 IS: 1239(part 1 & part 2), 1990 & IS: 1608,
b) Tensile Strength, % elongation and Bend Test
1995
c) Galvanisation Test IS: 1239(part 1), 1990
M.S. Plate & M 16 U Bolt
2 a) Tensile Strength, % elongation and Bend Test IS: 2062, 1999 & IS: 1608, 1995
c) Chemical Analysis IS: 2062, 1999 & IS: 1608, 1995

20. Pole sulphide Sea lent and other material for filler type expansion joints

Pole Sulphide Sea lent and other material for filler type expansion joints shall confirm to the following
requirements.

S.No Brief Description of Test IRC/IS/AASHTO/BS CODE


In order of preference given in CA
1. Steel Plate Sliding Expansion Joints Section 1900 of MORT&H
2. Filler Joints Section 2605 of MORT&H / IS: 1838
3. Elastomeric Slab Seal Expansion Joint

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a) Steel Inserts IS: 226


b) Elastomer IRC: 83(part II)
Strip Seal Expansion Joint
a) Steel (Edge Beam) Steel Grade Rst 37-2 of German
Standard
4. b) Chloroprene IRC: 83(part II) / Table 2600-1 of
MORT&H
c) Anchorage Steel IS: 2062, 1999
d) Anchorage Loop IS: 2062, 1999

21. Retro Reflective Traffic Sign

Retro Reflective Traffic sign shall confirm to the following requirements.

S.No. Brief description of Test IRC/IS/AASHTO/BS Code


In order of preference given in CA
Traffic Sign Post
a) Reinforcing steel IS: 1786, 1985
1. b) Bolts, Nuts & Washers IS: 1364 & IS: 1367
c) Plates & Support Sections IS: 226 & IS: 2062
IS: 736, Gr. 24345 / Section 1900 of
d) Aluminium Sheets
MORT&H
Traffic Retro-Reflective Sign Sheeting
a) High Intensity grade Sheeting ASTM E: 810 / Table 801 of MORT&H
2.
b) Engineering grade Sheeting ASTM E: 810 / Table 802 of MORT&H
c) Colour IS: 5 / Section 800 of MORT&H

22. Pile Load Test of Board Piles

Pile Load Test of


Board Piles shall
IRC/IS/AASHTO/BS Code
confirm to the Brief description of Test
In order of preference given in CA
following
requirements.S.No.
IS: 2911(part IV) & Section 1113 of
1 Initial Load Test
MORT&H
IS: 2911(part IV) & Section 1113 of
2 Routine Load Test
MORT&H

FREQUENCY OF TESTS
This section describes the types and frequencies of various quality control tests conducted on unbiased
samples collected form field / quarry / source. The EPC Contractor Material Engineer and Supervision
Consultant Material Engineer shall ensure that frequencies of test are maintained as brought out this section
and in subsequent sections. Supervision Consultant Material Engineer shall do test sampling on unbiased
basis. Tests shall be conducted as per relevant code in field Testing Laboratory established by Contractor at
site camp under independent supervision of Supervision Consultant Material Engineer. Confirmatory test if
desired by IE shall be carried out at Independent Laboratory like IIT Kharagpur, METARCH. Any sub-

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standard material incorporated in work should be identified immediately and Supervision Consultant would
inform the Contractor in writing to carryout removal from site. The frequencies of various tests to be
conducted shall be as per relevant code and MORT&H specification.

23. Borrow Area

Borrow area shall be marked in grid fashion and demarcated & fenced. The borrow area shall be along to the
proposed depth. These pits shall be logged and plotted for proper identification of source of material sampled.
The mathematical model to approve the borrow area the unbiased random samples shall be taken for various
test as per table given below.

Type of Test to be conducted and No. of sample and sample test size.
Gradation, LL, PI, MDD & OMC (Each) 2 Tests 3000 cum soil.
Minimum one test on source or change of source or as and when
Deleterious content test.
required.
Moisture content test One test for every 250 cum.
CBR soaked/un soaked small factor One test for every 3000 cum.
Compaction control Six test each for area upto 6000 sq. m of embankment shoulder
Ten test each for area upto 500 sqm of subgrade
Moisture Control (field moisture
equipment)

24. GRANULAR SUB-BASE

Type of Test to be conducted. No. of sample and sample test size.


Gradation. One test per 200 cum.
Atterberg limit One test per 200 cum.
Moisture content prior to compaction 1 test per 250 Sq m per layer
Density of compacted layer 1 test per 500 sq m per layer.
Deleterious matter As required
CBR. As required

25. WET MIX MACADAM

Type of Test to be conducted. Frequencies


Aggregate impact value. One test per 200 cum
Gradation/OMC/Proctor One test per 100 cum
Flakiness elongation index One test per 200 cum
Atterberg limit test (LL/PI) One test per 100 cum
Density of compacted layers One test per 500 cum

26. CEMENT CONCRETE

Type of Test to be Frequencies

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conducted.
Job mix design for type of Prior to commencement of work or as on required basis due to charge in off
concrete grade gradation
Slump Test One sample on commencement of work or as on required basis.
One sample consist of 3 Sample Quantity
specimens each for 1 1-5 cum
cube/beam 2 6-15 cum
3 16-30 cum
4 31-50 cum
4+1 51 and above and one
Additional test for every 50 cum One sample for days work.
Gradation of coarse and fine One per day or on as required basis.
aggregate
Quality tests on aggregates On required basis or on change of source or at least once in month on
stockpile not less than 3000 cum capacity

27. STEEL

Type of Test to be conducted. Frequencies


2% proof strength test One test per tot of 10 tonne.
Elongation test -do
Visual Inspection On regular basis on each bar defector bars to be
discarded.
Quality of Geo synthetics material Once on arrival of consign must or as required basis
Determination of angle of pristine between IS 13326 (Part I) as required basis.
compote fill and reinforcing element.

28. PRIMER COATING AND TACK COATING

Type of Test to be conducted. Frequencies


Spray rate One test set per 500 sqm and not less than two set tests per
day
Quality of binder This sample per lot or as required basis
Binder temperature for application During spraying or as required basis (At regular closed
intervals)

29. DBM/BC MIX

Type of Test Frequencies


Quality of binder. Initially two sample per lot subsequently on as required basis.
Aggregate Impact Value One test per 50 cum or at least one test for one production day.
Flakiness/ Elongation Index -do-

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Stripping value Initially one set of 3 samples from each source and subsequently on required
basis or change of source.
Soundness (Magnesium Initially one determination by each method from each source and
and Sodium Sulphate) subsequently on required basis or change of source.
Water absorption Initially one set of 3 samples from each source and subsequently on required
basis or change of source.
Sand Equivalent Test As on required basis.
Plasticity Index As on required basis.
Mix Gradation One set of tests on individual constituents and mixed aggregates from the
dryer for each 400 tones of mix subject to a minimum of two tests per plant per
day.
Stability of Mix A set of 3 Marshal specimens per 400 tonnes of mix production subject to a
minimum of two sets per plant per day.
Water sensitivity of mix As on required basis
Swell test on mix As on required basis for bituminous concrete.
Stone polishing value As on required basis for bituminous concrete or change of source.
Temp control On running of hot mix and laying by paver as on required basis.
Binder Content One test @ 400 tonnes of mix subject to a minimum of two tests per day per
plant.
Rate of spread of mixed Regular control on actual laying.
material
Density of compacted layer One test @ 250 Sqm area
Percentage of fractured When gravel is used, one test per 50 cum of aggregate.
faces

30. CEMENT

Type of Test Frequencies


a. Physical Test
i) Fineness One test per week no. for each brand of cement
ii) Soundness by Le-
One test per week no. for each brand of cement
chatelier method
iii) Soundness by Outo-
One test per week no. for each brand of cement
clave test method.
iv) Initial setting time One test per week no. for each brand of cement
v) Final setting time One test per week no. for each brand of cement
vi) Compressive strength for
One test per week no. for each brand of cement
721 hour
vii) Compressive strength
One test per week no. for each brand of cement
for 1682 hour
viii) Compressive strength
One test per week no. for each brand of cement
for 6724 hour
ix) Consistency of standard
One test per week no. for each brand of cement
cement paste.

b. Chemical Test
i. Ratio of percentage of One test for each brand of cement.
lime to percentages of silica,
alumina & iron oxide.
ii. Ratio of percentage of One test for each brand of cement.
alumina to that of iron oxide.

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iii. Insoluble residue, percent One test for each brand of cement.
by mass
iv. Magnesia, percent by One test for each brand of cement.
mass
v. Total sulphur content, One test for each brand of cement.
calculated as sulphuric
anhydride (SO3), percent by
mass.
vi. Total loss on ignition One test for each brand of cement.

vii. Total chloride content, One test for each brand of cement.
percent by mass

31. Water for concreting

Type of Test Frequencies


Water for concreting
Neutralisation of 200 ml At approval of source subsequently at every change of source.
sample of water using
phenolphthalein as an
indicator with 0.1 Na-OH.
Naturalisation of 200 ml At approval of source subsequently at every change of source.
sample of works using
methyl orange as an
indicator with 0.1 N Hcl.
Organic At approval of source subsequently at every change of source.
Inorganic solids At approval of source subsequently at every change of source.
Sulphates (as SO3) At approval of source subsequently at every change of source.
Chlorides (as Cl) At approval of source subsequently at every change of source.
Suspended matter At approval of source subsequently at every change of source.

32. Admixture

Type of Test Frequencies


Dry material content One test per batch
Ash content One test per batch
Relative density One test per batch
Chloride ion content One test per batch
PH One test per batch

33. Hume Pipe

Type of Test Frequencies


a. Overall length 8 tests for lot size up to 50
b. Internal diameter of pipes 13 tests for lot size 51 to 100
20 tests for lot size 101 to 300
c. Wall thickness
32 tests for lot size 301 to 500
d. Deviation from straight
50 tests for lot size 501 & above
2 tests for lot size up to 50
a. Hydrostatic test
3 tests for lot size 51 to 100
b. Three Edge bearing test 5 tests for lot size 101 to 300
c. Absorption test 7 tests for lot size 301 to 500
10 tests for 101 size 501 and above

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

34. Bricks

Type of Test Frequencies


Dimensions One test for 20 bricks for each source.
Compressive strength One test for each source.
Water absorption One test for each source.
Efflorescence One test for each source.

35. RE Wall Accessories

Type of Test Frequencies


a. Carbon Steel Reinforcing Strips
(40X5 mm)
(Hot Dip Galvanised)
5 tests per lot.
i) Chemical compositions
(Lot of 20 M.T.)
5 tests per lot.
ii) Tensile strength
(Lot of 20 M.T.)
5 tests per lot.
iii) Yield strength
(Lot of 20 M.T.)
5 tests per lot.
iv) Elongation
(Lot of 20 M.T.)
5 tests per lot.
v) Galvanization
(Lot of 20 M.T.)
b. Steel Lugs
i) Chemical composition 5 tests per lot
(Lot of 10 M.T.)
ii) Tensile strength 5 tests per lot
(Lot of 10 M.T.)
iii) Yield strength 5 tests per lot
(Lot of 10 M.T.)
iv) Elongation 5 tests per lot
(Lot of 10 M.T.)
v) Galvanization 5 tests per lot
(Lot of 1000 nos. )
c. Lifting Anchors
Mechanical properties 5 tests per lot
(Lot of 10,000 nos.)
d. Nuts & Bolts

Chemical analysis 5 tests per 10,000 pieces


Mechanical properties 5 tests per 10,000 pieces
Galvanization 5 tests per 10,000 pieces
e. EPDM Rubber Pads
Short Hardness A tests 5 tests per lot
(Lot of 1000 nos.)
f. FOAM
Density 1 test per lot
(Lot of 2000 metre)
g. Geotextile
Mechanical hydraulic properties 1 test per lot
(Lot of 2000 sq. metre)

36. RE Wall Backfill Materials:

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Type of Test Frequencies


a. Angle of internal friction At approval of source
Subsequently at every change of source.
At approval of source
b. Gradation Subsequently at every change of source.
At least one sample per 3000 m3
c. Maximum Dry Density At approval of source
(MDD) Subsequently at every change of source.
d. Physio-chemical
At approval of source
requirement
Subsequently at every change of source
(Resistivity tests)
For every 500 sq. m of compacted area.
e. Field Compaction Test
Minimum two tests at each level of compacted layer.

37. H. T. Strand:

Type of Test Frequencies


a. Physical Tests: At approval of source
Subsequently at every change of source.
Nominal diameter For each reel.
Breaking strength, 0.2%
proof load, %age One test for each batch for every 5 nos. of coil / reel.
elongation, relaxation loss.
At approval of source
b. Chemical test
Subsequently at every change of source

38. Sheathing Ducts:

Type of Test Frequencies


Workability Test At least 3 samples for one lot of supply (not exceeding 7000 metre length).
Transverse Load Rating
At least 3 samples for one lot of supply (not exceeding 7000 metre length).
Test
Tension Load Test At least 3 samples for one lot of supply (not exceeding 7000 metre length).
Water Loss Test At least 3 samples for one lot of supply (not exceeding 7000 metre length).

39. Elastomeric Bearings:

Type of Test Frequencies


Steel Insert: Two tests per lot/ Change of source
Raw Elastomer Content Two tests per lot/ Change of source
Ash Content Two tests per lot/ Change of source
Adhesion Strength (Elastomer to steel
Two tests per lot/ Change of source
plastics)
Sp. Gr. Test Two tests per lot/ Change of source
Polymer content test Two tests per lot/ Change of source
Identification of polymer Two tests per lot/ Change of source
Shear Modulus
a) Level 1 acceptance testing Two tests per lot/ Change of source
b) Level 2 acceptance testing One tests per lot/ Change of source
c) Any acceptance testing

40. Pot Bearing:


Type of Test Frequencies
a. POT

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Quality inspection & Test Plan Comprehensive

i) Structural Steel Two tests per lot/ Change of source


ii) Caste Steel Two tests per lot/ Change of source
iii) Stainless Steel Two tests per lot/ Change of source
b. PTFE Two tests per lot/ Change of source
c. Elastomer
i) Hardness Two tests per lot/ Change of source
ii) Minimum tensile strength Two tests per lot/ Change of source
iii) Minimum elongation at break Two tests per lot/ Change of source

41. Expansion Joint (Elastomeric):

Type of Test Frequencies


1. Steel Plate Sliding Expansion Joints
2. Filler Joints
3. Elastomeric Slab Seal Expansion Joint
a) Steel Inserts
b) Elastomer
4. Strip Seal Expansion Joint
a) Steel (Edge Beam)
b) Chloroprene
c) Anchorage Steel
d) Anchorage Loop
4. Steel Plate Sliding Expansion Joints

42. Bentonite:

Type of Test Frequencies


a) Liquid Limit (IS 2720 Part V 1965) One test for each lot
b) Sand Content One test for each lot
c) Relative Density One test for each lot & each activity
d) Free Swell Index One test for each lot
f) Density One test for each lot & each activity
g) Marsh Cone Viscosity One test for each lot & each activity
h) PH value One test for each lot
i) Silt content One test for each lot

43. Road Marking Paint:

Type of Test Frequencies


I ) Daylight Luminatce Ktisk s Once for each lot

II) Daylight luminanu yellow Once for each lot

III) Drying Time Once for each lot


IV) Skid Ratid Once for each lot
V) Yellowness Index Once for each lot

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

VI) Cracking resistance at low temperature Once for each lot


VII) Softening Point Once for each lot

VIII) Plow Resistance Once for each lot


IX) Reflection of Glass Beds
a) Gradation
b) Rouedness Once for each lot
c) Refractive Index
d) Free Flow
X) Thickness Once for each lot

44. Curing Compound

Type of Test Frequencies


a) Density at 30oC One test per batch
b) Flow time in B-4 Ford One test per batch
Cup
c) Flash point [Approx.] One test per batch
d) Drying time [ ASTM C One test per batch
156]

45. Mastic Asphalt

Type of Test Frequencies


Quality of binder No. of samples per lot and tests as per IS : 73 & IS : 8887 as applicable.
Aggregate Impact Value One test per 50 cum or at least one test for one production day.
Flakiness/ Elongation Index -do-
Stripping value Initially one set of 3 samples from each source and subsequently on required
basis or change of source.
Water absorption -do-
Grading of aggregates Two tests per day per plant both on the individual constituent and mixed
aggregates from the dryer.
Water sensitivity of mix Initially one set of 3 samples from each source and subsequently on required
basis or change of source.
Soundness (Magnesium Initially one determination by each method from each source and
and Sodium Sulphate) subsequently on required basis or change of source.
Percentage of fractured When gravel is used, one test per 50 cum of aggregate.
faces
Binder content and Periodic, subject to minimum of two tests per day per plant.
aggregate grading
Control of temperature of At regular close intervals.
binder and aggregate for
mixing and of the mix at the
time of laying and rolling
Rate of spread of mixed Regular control through checks of layer thickness.
material
Hardness number One tests for each 400 tonnes of mix subject to a minimum of two tests per
day.

46. Crash Barrier handrail accessories


Type Of Tests Frequencies

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

G.I. Pipes
a) Dimensions IS: 1239(part 1), 1990
b) Tensile Strength, % elongation and Bend Test IS: 1239(part 1 & part 2), 1990 & IS: 1608, 1995
c) Galvanisation Test IS: 1239(part 1), 1990
M.S. Plate & M 16 U Bolt
a) Tensile Strength, % elongation and Bend Test IS: 2062, 1999 & IS: 1608, 1995
c) Chemical Analysis IS: 2062, 1999 & IS: 1608, 1995

47. Pole sulphide Sea lent and other material for filler type expansion joints
Type Of Tests Frequencies
Steel Plate Sliding Expansion Joints Section 1900 of MORT&H
Filler Joints Section 2605 of MORT&H / IS: 1838
Elastomeric Slab Seal Expansion Joint
a) Steel Inserts IS: 226
b) Elastomer IRC: 83(part II)
Strip Seal Expansion Joint
a) Steel (Edge Beam) Steel Grade Rst 37-2 of German Standard
b) Chloroprene IRC: 83(part II) / Table 2600-1 of MORT&H
c) Anchorage Steel IS: 2062, 1999
d) Anchorage Loop IS: 2062, 1999

48. Retro Reflective Traffic Sign


Type Of Tests Frequencies

Traffic Sign Post


a) Reinforcing steel IS: 1786, 1985
b) Bolts, Nuts & Washers IS: 1364 & IS: 1367
c) Plates & Support Sections IS: 226 & IS: 2062
d) Aluminium Sheets IS: 736, Gr. 24345 / Section 1900 of MORT&H
Traffic Retro-Reflective Sign Sheeting
a) High Intensity grade Sheeting ASTM E: 810 / Table 801 of MORT&H

b) Engineering grade Sheeting ASTM E: 810 / Table 802 of MORT&H

c) Colour IS: 5 / Section 800 of MORT&H

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Parameters of Important Specifications

Sl. Brief Relevant Bitumen Nominal Grading Range Require- Compaction Min. Density Remarks
No. Specification MOST Content size of ment of
Clause Range Agg. job mix Thick- Type of
Grade formula ness of Roller
Layer
I II

I.S. Sieve Passings


1. GRANULAR 401 --- --- OMC Upto Smooth As per contract 1. When
SUB BASE (Table verses 100mm wheeled requirement & directed,
(Close 400-1) 75mm 100% --- Max. Dry thick Roller Job Mix Formula the strength
Graded GSB) 53mm 80-100% 100% Density (Wt. 80 (JMF) shall be
26.5mm 55-90% 70-100% & CBR Above to 100 verified by
9.5mm 35-65% 50-80% 100 to KN) CBR/other
4.75mm 25-55% 40-65% 225mm GD I GD II tests in
2.36mm 20-40% 30-50% thick Vibratory laboratory.
0.425mm 10-25% 15-25% CBR Min Min
Max. Roller 30 30
0.075mm 3-10% 3-10% 2. L.L. & PI of
PI
Max Max material
LL 6 6 passing
425
Max Max
25 25 (0.425mm)
sieve

2. WET MIX 406 --- --- 53mm 100% OMC Upto Smooth As per contract
MACADAM (Table 45mm 95-100% Versus 75mm. wheeled requirement &
WMM 400-10, 26.5mm --- Max. more Roller Job Mix Formula
400-11) 22.4mm 60-80% Dry than (JMF)
11.2mm 40-60% Density 75 to Vibratory Material
4.75mm 25-40% 200mm Roller passing
2.36mm 15-30% PI = Not more 0.425mm
600 8-22% than 6 sieve
75 0-8%

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Brief Relevant Bitumen Nominal size Grading Range Requirement Compaction Min. Remarks
No. Specification MOST Content of Agg. of job mix Thick Density
Clause Range Grade Grade formula Type of
I I Roller

I.S. Sieve Passing

3. PRIMER 502 (Table 7.50 Kg. --- --- --- Bitumen


COAT 500-1) per emulsion
2
10m complying
(MC/SC) with IS-
8887

4. TACK COAT 503 (Table 2.50 Kg. --- --- --- --- - do -
500-2) per 10m2
(RC)

5. STRESS 522 Table Modified


ABSORBING- 500-47 Binder
INTER LAYER (SBS)
MEMBRANE Table
Crack 500-44
prevention
course (to
restrain cracks
to reproduce)
(Single
3
(a) Hair cracks coat) 8-10 Kg 0.10m of 11.2mm 100% N.A. N.A. N.A. N.A.
2
& maps per 10m 5.6mm
cracks upto area nominal size 2.8mm 0%
3mm width chips
(Single
3
(b) Map crack or coat) 10-12 Kg 0.11 m of 11.2mm 100% N.A. N.A. N.A. N.A.
2
alligator per 10m 5.6mm
cracks 3mm area nominal size 2.8mm 0%
to 6mm chips
Single
3
(c) All types of coat as 10-12 Kg 0.10 m of 13.2mm 100% N.A. N.A. N.A. N.A.
cracks above inter layer per 10m2 11.2mm
6mm width area nominal size 5.6mm 0%
chips

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Brief Relevant Bitumen Nominal size Grading Range Requirement Compaction Min. Remarks
No. Specification MOST Content of Agg. of job mix Thick Density
Clause Range Grade Grade formula Type of
I I Roller

I.S. Sieve Passing

6. BITUMINOUS 504 3.3% to 19mm 26.5 100% Optimum Initial rolling As per
MACADAM 3.5% by crushed 19 90-100% Binder with 80 to 100 contract
B.M (table 500- wt. of aggregate 13.2 content KN smooth requirement
3, 500-4 total Mix 4.75 verses Max. wheeled roller. & Job Mix
(50-75mm 2.36 Density Formula
thick layer) 0.3 Intermediate (JMF)
0.075 Rolling with
Vibrating
Roller or R-
15T pneumatic
Roller and
finish rolling
with 6-8
Tonnes
smooth
wheeled
tandem rollers.

7. DENSE 507 (table Min. 25mm 37.5mm 100% Optimum Initially with 8- As per Filler is to be
BITUMINOUS 500-8, 4.5% by 26.5 90-100% Bitumen 10 T smooth contract used 43 grade
MACADAM 500-9, wt. of 19 71-95% contents v/s wheeled roller. requirement cement of
DBM 500-10, total Mix 13.2 56-80% Density & Job Mix Vikram, Sri or
(50-75mm 500-11, 9.5 -- subject to Intermediate Formula JK Brand.
thick layer) 500-12) 4.75 38-54% Min stability = Rolling with (JMF)
0
2.36 28-42% 9 kN at 60 C vibratory roller
1.18 -- Flow = 2- Or 12-15 T
0.60 -- 4mm Air pneumatic
0.30 7-21% Voids = 3-6% tyred roller and
0.15 -- finish rolling
0.075 2-8% with 6-8
Tonnes
smooth
wheeled
tandem rollers.

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Brief Relevant Bitumen Nominal Grading Range Requirement Compaction Min. Remarks
No. Specification MOST Content size of of job mix Thick Density
Clause Range Agg. Grade Grade formula Type of
I I Roller

I.S. Sieve Passing

GD-I GD-II
8. SEMI DENSE 508 Min 13mm 19mm 100% -- Optimum Initially with 8- As per Filler is to be
BITUMINOUS (Table 4.5% of 13.2 90-100% 100% Bitumen 10 T smooth contract used 43 grade
CONCRETE 500-14, total Mix. 9.5 70-90% 90-100% contents v/s wheeled roller. requirement cement of
SDBC 500-15, 4.75 35-51% 35-51% Density & Job Mix Vikram, Sri or
For 35-40mm 500-16) 2.36 24-39% 24-39% Intermediate Formula JK Brand.
layer thickness 1.18 15-30% 15-30% Min stability = with vibratory (JMF)
Grading-I Min 10mm 0.60 --- --- 8.2 kN at roller Or 12-15
0
5.0% of 0.30 9.19% 9.19% 60 C Flow = T pneumatic
For 25-30mm total Mix. 0.15 -- -- 2-4mm Air tyred roller and
layer thickness 0.075 3-8% 3-8% Voids = 3-6% finish rolling
grading-II with 6-8
Tonnes
smooth
wheeled
tandem rollers.

9. BITUMINOUS 509 5% to 13mm 19mm 100% Optimum Initially with 8- As per Filler is to be
CONCRETE (Table 7% by 13.2 79-100% Bitumen 10 T smooth contract used 43 grade
500-17, wt. of 9.5 70-88% contents v/s wheeled roller. requirement cement of
Layer 500-18, total Mix. 4.75 53-71% Density & Job Mix Vikram, Sri or
thickness 30- 500-19) 2.36 42-58% subject to Intermediate Formula JK Brand.
45 min. 9 1.18 34-48% Min stability = with vibratory (JMF)
(Grading 2) 0.60 26-38% 9 kN roller
0.30 18-28% Or
0.15 12-20% Flow = 2- 12-15 T
0.075 4-10% 4mm Air pneumatic
Voids = 3-6% tyred roller.

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Brief Relevant Bitumen Nominal Grading Range Requirement Compaction Min. Remarks
No. Specification MOST Content size of of job mix Thick Density
Clause Range Agg. Grade Grade formula Type of
I I Roller

I.S. Sieve Passing

10. MIXED SEAL 512 19 Quantity 13.2 100% Not required As per Note: -
2
SURFACING Kg/10m of 11.2 88-100% ratio of C.A & Specificatio For
(TYPE-B) (Table aggregate 5.6 31-52% F.A are to be n undulations
For removal of 500-26) 1.27 cum 2.8 5-25% fixed for Wheeled roller upto 25mm
2
undulations & per 10m 0.090mm 0-5% achieving M.SS is to be
profile desired adopted.
corrected of grading
Blacktop For correction
surface. of more than
25mm
thickness BM
is to be
provided.

Quality Control tests and their Frequencies

CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR SUB-BASES AND BASES (EXCLUDING BITUMEN BOUND BASES)
Sl. Type of Test Frequency (Min.)
No. Construction
1 Granular (i) Gradation One test per 200 cum
(ii) Atterberg limits One test per 200 cum
(iii)Moisture content prior to compaction One test per 250 cum
(iv)Density of compacted layer One test per 500 cum
(v) Deleterious constituents As required
(vi) C.B.R. As required
2 Wet Mix (i) Aggregate Impact Value One test per 200 Cum of aggregate.
Macadam (ii) Grading One test per 100 Cum of aggregate.
(iii) Flankiness and Elongation Index One test per 200 Cum of aggregate.
(iv) Atterberg limits of portion of aggregate passing 425 micron sieved One test per 100 cum of aggregate.
(v) Density of compacted layer One test per 500 Cum of aggregate.

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Quality inspection & Test Plan Comprehensive

CONTROL TESTS AND THEIR BITUMINOUS FREQUENCY FOR BITUMINOUS WORK TEST ON BITUMINOUS CONSTRUCTIONS:

The tests and their minimum frequencies for the different types of bituminous works shall be as under:

Acceptance criteria

The acceptance criteria for tests on density and Marshall stability shall be subject to the condition that the mean value is not less than
specified value plus:

[1.65 - _________1.65__________] times the standard deviation


(No. of samples)0.5

Sl. Type of Test Frequency (Min.)


No. Construction
3 Prime Coat / (i) Quality of binder Number of samples per coat and tests as per IS:73, IS:217 and IS
Tack coat 8887 as applicable.
(ii) Binder temperature for application. At regular close intervals.
(iii) Rate of spread of Binder. One test per 500 m3 and not less than two tests per day.
4 Seat Coat / (i) Quality of Binder Same as mentioned under Serial No. 1
surface
Dressing
(ii) Aggregate Impact Value / Los Angles One test per 50m3 of aggregate.
Abrasion value
(iii) Flakiness Index and Elongation Index One test per 50m3 of aggregate.
(iv) Stripping value of aggregates. (Immersion Initially one set of 3 representatives specimens for each source of
Tray Test) supply. Subsequently, when warranted by changes in the equality
of aggregates.
(v) Water absorption of aggregates. Initially one set of 3 representatives specimens for each source of
supply. Subsequently, when warranted by changes in the equality
of aggregates.
(vi) Water sensitivity of mix. Initially one set of 3 representatives specimens for each source of
supply. Subsequently, when warranted by changes in the equality
of aggregates. (if required).

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Type of Test Frequency (Min.)


No. Construction
(vii) Grading of aggregates. One test per 25m3 of aggregate.
(viii) Soundness (Magnesium and Sodium Initially, one determination by each method for each source of
Sulphate) supply, then as warranted by change in the quality of the
aggregates.
(ix) Polished stone value. As required.
(x) Temperature of binder at application. At regular close intervals.
(xi) Rate of spread of materials. One test per 500m2 of work, and not less than two tests per day.
(xii) Percentage of fractured faces. When gravel is used, one test per 50m3 of aggregates.
5 Bituminous (i) Quality of Binder Same as mentioned under Serial No. 1
Macadam
(ii) Aggregate Impact Value / Los Angles Same as mentioned under Serial No. 1
Abrasion value.
(iii) Flakiness Index and Elongation Index. Same as mentioned under Serial No. 2
(iv) Stripping Value Same as mentioned under Serial No. 2
(v) Water sensitivity of mix. Same as mentioned under Serial No. 2
(vi) Grading of aggregates. Two tests per day per plant both on the individual constituents
and mixed aggregates from the dryer.
(vii) Water absorption of aggregates. Same as in Serial No. 2
(viii) Soundness (Magnesium and Sodium Same as mentioned under Serial No. 2
Sulphate)
(ix) Percentage of fractured faces. Same as mentioned under Serial No. 2
(xi) Control of temperature of binder and As regular close intervals.
aggregate for mixing at the time of laying
and rolling.
(xii) Rate of spread of mixed material. Regular control through checks of layer thickness.
(xiii) Density of compacted layer. One test per 250m2 area.
(x) Binder content and aggregate grading. Periodic, subject to minimum of two tests per day per plant.

6 Dense (i) Quality of Binder. Same as mentioned under Serial No. 1


Bituminous
Macadam/
Semi Dense
Bituminous
Concrete/

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Type of Test Frequency (Min.)


No. Construction
Bituminous
Concrete.
(ii) Aggregate Impact Value / Los Angles Same as mentioned under Serial No. 2
Abrasion value.
(iii) Flakiness Index and Elongation Index. Same as mentioned under Serial No. 2
(iv) Stripping value
(v) Soundness (magnesium and Sodium Same as mentioned under Serial No. 2
Sulphate)
(vi) Water absorption of aggregates. As in Serial No. 2
(vii) Sand equivalent test Water sensitivity of As required.
mix.
(viii) Plastic Index. As required.
(ix) Polished stone value. As required for Semi Dense Bituminous Concrete / Bituminous
Concrete.
(x) Percentage of fractured faces. Same as mentioned under Serial No. 2
(xi) Mix grading One set of tests on individual constituents and mixed aggregate
from the dryer for each 400 tonnes of mix subject to a minimum of
two tests per plant per day.
(xii) Stability of Mix For each 400 tonnes of mix produced, a set of 3 Marshal
specimens to be prepared and tested for stability, flow value,
density and void content subject to a minimum of two sets being
tested per plant per day.
(xiii) Water sensitivity of mix (Retained Tensile Same as mentioned under Serial No. 2
Strength)
(xiv) Swell test on the mix. As required for the Bituminous concrete.
(xv)Control of temperature of binder in boiler, At regular close intervals.
aggregate in the dryer and mix at the time
of laying and rolling.
(xvi) Control of binder content and grading of the One test for each 400 tonnes of mix subject minimum of two test
mix. per day per plant.
(xvii) Density of compacted layer. One test per 250m2 area.
7 Mastic (i) Quality of binder. Same as mentioned under Serial No. 1
Asphalt
(ii) Aggregate Impact Value / Los Angles Same as mentioned under Serial No. 2

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Type of Test Frequency (Min.)


No. Construction
Abrasion value.
(iii) Flakiness Index and Elongation Index. Same as mentioned under Serial No. 2
(iv) Stripping value Same as mentioned under Serial No. 2
(v) Water sensitivity of mix. Same as mentioned under Serial No. 2
(vi) Grading of aggregates. Two tests per day per plant both on the individual constituents
and mixed aggregates from the dryer.
(vii) Water absorption of aggregates. Same as in Serial No. 2
(viii) Soundness (Magnesium and Sodium Same as mentioned under Serial No. 2
Sulphate)
(ix) Percentage of fractured faces. Same as mentioned under Serial No. 2
(x) Binder content and aggregate grading. Periodic, subject to minimum of two tests per day, per plant.
(xi) Control of temperature of binder and At regular close intervals.
aggregate for mixing and of the mix at the
time of laying and rolling.
(xii) Rate of spread of mixed material. Regular control through checks of layer thickness.
(xiii) Hardness number One test for each 400 tonnes of mix subject to a minimum of two
tests per day.
8 Modified (i) Softening Point. Initially on submission thereafter daily if site blended, weekly if
Binder pre-blended.
(ii) Penetration at 25 0C and 40C Initially on submission thereafter daily if site blended, weekly if
pre-blended.
(iii) Elastic Recovery. Initially on submission thereafter daily if site blended, weekly if
pre-blended.
(iv) Ductility Initially on submission thereafter daily if site blended, weekly if
pre-blended.
(v) Flush Point. Initially on submission thereafter daily if site blended, weekly if
pre-blended.
(vi) Fraass Breaking Initially on submission.
(vii) Viscosity at 1500C Initially on submission.
(viii) Thin film oven test, penetration, softening
point, elastic recover of residue, loss on
beating.

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Type of Test Frequency (Min.)


No. Construction

FREQUENCY OF QUALITY CONTROL TESTS FOR PAVING QUALITY CONCRETE:


9 Cement Physical and chemical tests Once test each tests source of supply and occasionally when
IS:269 called for in case of long / improper storage. Besides the
IS:455 Contractor also will submit daily test data on cement released by
IS:1489 the manufacturer.
IS:8112
IS:12269
10 Coarse and Gradation One test for every days work of each fraction of coarse aggregate
Fine IS: 2386 and fine aggregate, initially may be relaxed later at the discretion
Aggregates (Pt. 1) of the Engineers.
Deleterious Constituents One test for every days work of each fraction of coarse aggregate
IS: 2386 and fine aggregate, initially may be relaxed later at the discretion
(Pt. 2) of the Engineers.
Water Absorption IS: 2386 Regularly as required subject to a minimum one of test a day for
(Pt. 3) coarse aggregate and two tests a day for fine aggregate. This
data shall be used for correcting the water demand of the mix on
daily basis.
11 Coarse i) Los Angles Abrasion value or aggregate Once for each source of supply and subsequently on month
Aggregate impact test IS:2386 (Pt. 4 ) basis.
ii) Soundness IS:2386 Before approving the aggregates and every month subsequently.
(Pt. 5)
iii) Alkali aggregate reactivity. IS:2386 (Pt. 7) Before approving the aggregates and every month subsequently.
12 Water Chemical Tests IS:456 Once for approval of source of supply, subsequently only in case
of doubt.
13 Concrete i) Strength of Concrete 2 cubes and 2 beams per 150m3 or part thereof (one for 7 days
IS: 516 and other 428 days strength) or minimum 6 cubes and 6 beams
per days work whichever is more.
ii) Core strength on hardened concrete As per the requirement of the Engineer, only in case of doubt.
IS:516
iii) Workability of fresh concrete-Slump Test One test per each dumper load at both batching plant site and
IS:1199 paving site initially when work starts. Subsequently sampling may
be done from alternate dumper.

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sl. Type of Test Frequency (Min.)


No. Construction
iv) Thickness Determination From the level data of concrete pavement surface and sub-base
at grid point of 5/6.25 m x 3.5 m
v) Thickness measurement for trial length. 3 Cores per trial length.
vi) Verification of level of string line in the case String line or steel forms shall be checked for level at interval of
of slip form paving and steel form in the case 5.0 m or 6.25 m. The level tolerance allowed shall be +- 2mm.
of fixed form paving. These shall be got approved 1-2 hours before the
commencement of the concreting activity.

Quality Assurance Standards

Quality Assurance

Road Work

1.0 Earth work

S. Item Nominal QA Normal QA High QA Extra High QA (Q-4)


No. (Q-1) (Q-2) (Q-3)
a) Tests for density As per MOST As per MOST As per MOST Same as Q-3.
Spec., each compact layer
b) Geometry Check Final Layer Final Layer All Layer Same as Q-3.
c) Equipment Static rollers required Vibratory rollers preferred Vibratory rollers mandatory. Vibratory rollers mandatory.

2.0 Non-Bituminous Work


Granular Sub-Bases:
S. Item Nominal QA Normal QA High QA Extra High QA (Q-4)
No. (Q-1) (Q-2) (Q-3)
a) Material -- Premix preferred Premix to suitable grading as Same as Q-3.
per mixed design required.
b) Laboratory Tests -- Random sampling and Each layer to be sampled from Same as Q-3.
testing location and tested all as per
MOST
c) Geometry -- Top Layer All Layers As per Q-3.

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Quality inspection & Test Plan Comprehensive

S. Item Nominal QA Normal QA High QA Extra High QA (Q-4)


No. (Q-1) (Q-2) (Q-3)
Checks

3.0 Bituminous Work

Granular Bases / Binder Course Bases:

S. Item Nominal QA Normal QA High QA Extra High (QA Q-4)


No. (Q-1) (Q-2) (Q-3)
MATERIAL
a) Aggregate Hand broken Crushed preferred Crushed and screamed Same as Q-3
acceptable mandatory.
b) Binder Quality Accept manufacturer Same as Q-1 Quality source-test every Quality source; test every
TC, conduct routine consignment at arrival. consignment, employ third party if
tests. reqd.
WORKMANSHIP
a) Paving Manual procedure Mechanical paver Sensor paver mandatory. Same as Q-3.
acceptable preferred
b) Compaction Static equipment Vibratory Equipment Vibratory Equipment Same as Q-3.
acceptable preferred preferred
c) Geometry Checks Top layer All layers All layers All layers

Wearing Course Asphalt / Concrete:

S. Item Nominal QA Normal QA High QA Extra High QA (Q-4)


No. (Q-1) (Q-2) (Q-3)
a) Material / Hand broken Crushed aggregate Crushed / screened Same as Q-3.
Aggregates aggregate acceptable preferred aggregate mandatory
b) Mixing Site mixing Plant mixing Plant mixing mandatory Same as Q-3.
acceptable preferred
c) Paving Manual Acceptable Paver Preferred Paver Mandatory Paver Mandatory
d) Compaction Static equipment Vibratory Equipment Vibratory Equipment Same as Q-3.
acceptable preferred Mandatory
e) Geometry Checks Top Layer Top Layer All Layers All Layers using
Sophisticated

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

S. Item Nominal QA Normal QA High QA Extra High QA (Q-4)


No. (Q-1) (Q-2) (Q-3)
Equipment.

4.0 Concrete Work

The following guidelines are given for quality assurance of construction of bridges:

a) For construction of H/L Bridge / ROBs minimum quality assurance level Q-3 is to be achieved.

b) For construction of culvert and small bridge minimum quality assurance level Q-2 is to be achieved.

c) In special cases where very large span are involved or high performance concrete and new prestressing system are operative, the
quality assurance level will be kept Q-4.

5.0 Extracts of IRC SP: 47: 1998


Sr. Item Normal QA High QA Extra High QA
No. (Q-2) (Q-3) (Q-4)
1 MATERIALS
1.1 General
Small or medium scale purchases As in Q-2. Also bulk purchase As in Q-3, but may also set up own
a) Material from natural
from large and established from source. source for supply.
sources
suppliers/traders.

Source mutually agreed to between Independent testing/acceptance As in Q-3, but with additional (third
contractor and owners project terms by contractor & owner Q.A. level) testing / acceptance by
and documented. teams and documented. independent agency (such as PMC
or Approved Testing Laboratory

May rely on local experience and Testing / acceptance at the start Same as Q-3.
knowledge of the past performance of the project as well as at
for coarse and fine aggregates and specified frequency.
water.

b) Factory manufactured Manufacturers tests certificate Manufacturers test certificates Same as Q-3.
items including accepted with sample check by with sample checks for initial

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
cement, steel independent agency for incorporation acceptance only.
bearings, expansion in structure.
joints, etc.

Regular testing at specified As in Q-3, but may also have


sampling frequency during additional QA checks at source
construction. (third level check)

Set up mutually agreed QA As in Q-3, but third level checking


methods at two levels for by appointment of specialized
inspection / testing to cover the agency for innovative aspects.
specific purpose order.

ISO : 9000 certificate not essential for In case the manufacturer has As in Q-3.
manufactured items. ISO : 9000 certification, he may
be given preference.

c) Records for all Record of sources and purchase As in Q-2. Also record of issue Same as Q-3
materials. dates for all items. For manufactured of manufactured materials and
items record of manufacturers test location of use.
certificates

d) Testing facilities Testing from nearby established test Physical testing facilities at site. As in Q-3, with property equipped
houses / laboratories For chemical & special tests as testing facilities and laboratory at
per Q-2. Use of chemical testing site under control of QA personnel
kits for quick checks at site are of contractor & owner (independent
to be preferred. of production team.

1.2 Aggregate coarse


aggregates At the beginning for mix design & for At the beginning for mix design As in Q-3, but it necessary with
every charge of source. and for every change of source / increase frequency, (testing at site

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
stack and for every major laboratory).
structural element.

Grading For selection of source if in doubt. At the beginning for mix design As in Q-3 (two level checks at site
and for every change of source. laboratory)

Mandatory for selection of


Other physical tests For selection of source if in doubt source & whether there is Same as Q-3
(crushing value abrasion change in source of supply.
moisture contents etc.)
Mandatory for selection of
Deleterious contents Not applicable source and whether there Same as Q-3

Aggregate reactivity At the beginning for mix design & At the beginning for mix design As in Q-3, but if necessary with
every change of source and for every change of source. increased frequency, (testing at site
laboratory).

b) Fine aggregate (sand) For selection of source if in doubt. At the beginning for mix design As in Q-3 (Two tier checks at site
and for every change of source. laboratory)

Mandatory for selection of


Grading For selection of source if in doubt. source & whenever there is Same as Q-3
charge in source of supply.

Other physical tests


(crushing value abrasion
moisture contents etc.) Simple but frequent chemical checks As in Q-2 As in Q-2, supported by checking at
at site for effectiveness testing laboratory at site.
Deleterious contents External laboratory checks /
control (two level control)
For control of chlorides
etc.

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
1.3 Water Suitability At the beginning Carried out if in Same as Q-2. Mandatory at the Same as Q-2. As in Q-3, but at
Chemical analysis doubt beginning of project and increase frequency during working.
repeated (for chlorides and
sulphates) in between if any
change is perceived / suspected
in water quality (including
seasonal changes)

1.4 Cement Normal physical Manufacturers certificates acceptable As in Q-2 and at frequency of As in Q-3, testing carried out at site
and chemical tests. & testing in case of doubt or non- each new consignment & laboratory & independently cross-
availability of certificate. documented special tests will be checked at predetermined
required for special for special frequently.
cements.

Form of purchase Trade purchases, intermediate Supply from factory with direct
storage, transportation, storage in dry and covered place, transportation from factory to Same a Q-3
and use within transportation and use of factory filled, site godown / silos.
acceptable time limit. machine stitched bags. Transportation and
transshipment supervised and
documented.
1.5 Admixtures
a) Approval May be permitted under specialist Independently carried out As in Q-3, with additional
supervision in which case follow Q-3 acceptance testing after field independent tests.
controls. trails for each sources.

Re-trials with change in source i) Chloride contents.


of Cement.
ii)Spectroscopic signature of
Routine checking by testing for accepted product as basis of
every batch of admixture. comparison for production lots.

Manufacturers date / certificate


acceptable as basis of
comparison for production lot.

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
b) Dosage dispensing Dosage to be finalized after field trial Same as Q-2 Same as Q-2
and production mixes, special mechanical devices to
controls at site be used for dispensing.

Frequent checks for specific gravity

Continuous monitoring of work ability


of concrete

Visual inspection of concrete after


striking forms for local defects
(including delayed setting).

c) Training of site staff by Proper training of site staff in use as


manufacturer well as quality control, plus periodic Same as Q-2 As in Q-2, but visits b experts at
visits by manufacturers certificate close frequency.

1.6 Reinforcing Steel Normal Once at beginning and for every As in Q-2, and for each As in Q-3, but further supplemented
Physical tests change in source in addition to consignment by random checking by QA team.
manufacturers certificate.

Chemical composition Once at beginning and if in doubt for Same as Q-2 Same as Q-2
any source.

Welding Not ordinarily permissible at site. Welding to be done only by As in Q-3, but welders t be
qualified and tested welders. periodically tested and also welding
to be examined by experts after
Types of electrodes to be destructive tests.
specified for each purpose.

Random testing of welded joints


for strength.

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
1.7 Prestressing Steel /
Anchorage systems &
cable anchorage
assembly

a) General (for all items Same as Q-2 Same as Q-2


of prestressing
including equipment).

In a sealed and moisture proof


Storage godown with minimum openings store
above ground level on raised supports
or in racks.Such godown will have Same as Q-2 Same as Q-2
humidity control

Compatibility of various In Additional vapour face inhibitors


components. and / or water soluble oils to protect
steel

Suitability of anchorages for use with


wire / standards (meeting relevant Same as Q-2 As in Q-2, but compatibility
specifications) to be certified by the established at site as required by
manufacturer of anchorages. Also QA team.
compatibility of all other materials and
equipment to be thus certified /
cleared.

Methods of handling & Also the manufacturer to supply


care taking special assistance at site. If required, Same as Q-2 Same as Q-2
to train and supervise personnel at
work.

b) HT Wires / stands

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
Mechanical properties Manufacturers Test Certificate can be
(Tensile Strength, proof accepted. Additional Testing if in In addition to manufacturers As in Q-3, but every coil. Sample
Stress). doubt. certificate, tests done on random testing witnessed by independent
samples for a lot of 50 T, or part QA team at specified frequency.
thereof and witnessed by
independent QA team of
random.
Modules of Elasticity Insist for manufacturers certificate
giving stress. Strain curve & modules Same as Q-2 Same as Q-2
of elasticity. Sample testing witnessed
by independent QA team.

Contact with contaminated surfaces


avoided.
c) Anchorage System Permitted using anchorage or As in Q-2, but supported by As in Q-3, but in addition QA plans
(Chemical established manufactures of long manufacturers detailed QA plan should be independently checked by
Composition & Heat standing based on certification of (which can be verified by QA team and verified at
Treatment suitability & quality by manufacturer. purchaser if necessary). manufacturers facilities.
Supplementary Tests)

d) Cable Anchorage
Assembly (Acceptance
Testing)
Manufacturers certificate and
Static Tensile test & load Not normally required. Manufacturers certificate certificate by testing at independent
transfer test laboratory as per FIP Guide. Tests
May additionally require testing may be repeated at the beginning of
at site or at independent the proposed materials and
laboratory as per FIP Guide. witnessed by the representatives of
contractor / owner.

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
Dynamic Test for Cable / Not normally Manufacturers certificate of As in Q-3, plus any additional) test
anchorage assembly testing than a QA team may required.

Also independent laboratory


testing as per FIP Code, once
for new system of anchorage /
cables.

e) Sheathing Cable Dust


As in Q-3, but preferable to fabricate
Supply Purchase from manufacturers with Same as Q-2 sheathing freshly at site at the
metallic sheathings metallic required rate.
sheathings coated with water soluble
rust preventive oil. As in Q-3, but at higher frequency
As in Q-2, but additional plus any additional test that QA
Workability and Test certificate by the Manufacturer independent test to be done on team may require.
Transverse bending test for each lot to be furnished. random samples.
as per IRC : 18
1.8 Any other materials (like Manufacturers Certificate supported As in Q-2 with higher frequency As in Q-3 with implementation of QA
expansion joints, by sample testing. of testing and plan of manufacturer to be audited
bearings, railing etc.) by QA team of owner to the extent
depending on the importance of the
team.

1.9 New Materials Normally not to be used. If used same QA plan of manufacturer to be As in Q-3. Supplemented by
as Q-3 initially approved. To be independent checking by QA team
accepted by competent of specialist consultants.
technical authority for use
thoeity for use after full testing at
laboratory / and field trials.
Special specification for
properties testing and

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
acceptance criteria to be
evolved and laid down for use at
site.
2. WORKMANSHIP

2.1 General Controls (Direct


& indirect)
a) Working & supervision
Skilled and semiskilled workers. Skilled workers having special Same as Q-3
training and working under
experienced supervisors.
(Where trade qualifications ate
existing should be insisted
upon).

Full time supervision from


Periodic vision from owner of his contractor as well as from owner
agent. or his agent. As in Q-3, but with occasional
supervision by expert external
agency.
As in Q-2, but at predeter mined
stages and frequency. As in Q-3 expect in case of bridges
Periodic check by designer during site having new technology / design full
visit. time site representative of design
agency will be necessary.

Document inspection and Same as Q-3.


certification of certification of
compliance by designers
representative.

For Q-3 quality mock ups are


required only for certain
b) Use of Mock-ups Not ordinarily required. elements (typical slice and As in Q-3, but made mandatory for
difficult zones) which should be all difficult and important zones.

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
specified in tender document.
Mock-ups to be carried out in
presence of designer and QA
team of owner.

Mock-up should use actual


proposed methods of
construction, including plant and
equipment.
Also, mock-ups dealing with new
Mock-up should use actual techniques to be carried out under
proposed methods of supervision of expert external
construction including plant and agency.
equipment.
As in Q-3.
No work on structure should be
permitted before demonstrative
mock-up.
2.2 Concrete Mix design Mix design performed at beginning of As in Q-2 with minimum two As in Q-3.
work or for new source of materials level controls.
with subsequent Q.C. as per code and
by experienced supervisors.

Notes:

Full scale mock-ups of part of structure are made for various purpose as follows:

1) Verification of proper detailing and choice of concrete of mix and making modification in either or both to achieve satisfactory concreting.
2) To establish effective methods of transporting, placing and compacting.
3) Training of workers for operation in (2) above.
4) To demonstration efficacy of the overall construction operations in achieving its aim.

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
2.3 Fabrication and Site bending by skilled workers with Same as Q-2 Same as Q-2
fixing of regular checking by qualified
reinforcement. supervisor

Bar bending schedules are made and


checked before use. Same as Q-2 As in Q-2 expect bar bending
schedule made by design office
Correct placement or reinforcement only.
and provision of proper cover checked As in Q-2, but checked and Same as Q-3
independently before concreting. documented by QA team.
2.4 Fabrication & fixing Normally not applicable. If used follow Modules established initially Modulus established initially and
of presenting cables. Q-3 practices. (acceptance test) verified by work test.

As in Q-3, also tests to be witnessed


Relaxation Test Manufacturer certificate Testing & certification essential for by contractors / owners / owners QA
1000 hours test by independent test team.
house.
Same as Q-3.

Chemical Manufacturers Certificate can be As in Q-2, plus testing by independent


Composition accepted with special testing, if in agency on random sample basis.
doubt. Same as Q-2.
Same as Q-2.

Packing with two layers for water


Packing proofing and mechanical protection.

Transport vehicles check. Same as Q-2.


Same as Q-2.
Protection from environment of
physical damage.
Transportation
Coils handled by mechanical devices
prohibiting movement by rolling.
Same as Q-2.

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
The wire / strand should be free of Same as Q-2.
skinks or deformations and straight.

Suitable of coil
size/weight for use at
size. Should be free rust Light on wires (not
strands) can be removed, wires Only unrusted steel can be used.
cleaned and used.

a) Cleaning
b) Preparation of Pre-fabricated and sheathed cable Only post threading of wires/strands
steel / cables. can be permitted. permitted (with exceptions if
unavoidable).
However, post threaded wires/
strands just before stressing are to be
preferred.

Cables strictly prepared on raised /


clean benches and kept free from dust
at all times. Same as Q-3.

Cable Layout giving co-ordinates at


close intervals as needed by fixing
requirements (and not by theoretical
curves or equations alone), and
supported firmly in place. Post As in Q-3.
Threaded cable ducts should be held
against floatation during concreting.
c) Laying &
supporting Layout and leak tightness of As in Q-3, with additional checking
sheathing to be independently and testing required by QA teams
checked and documented by owners sample checking by expert external
Q.A. Team of his agent. agency.
2.5 FORMWORK

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
a) Materials Any Suitable materials meeting codal Same as Q-2. As in Q-2 with regularly and properly
requirements and capable of giving maintained shuttering with limited
specified form finish. reuses. Shuttering capable of
absorbing Air released from
concrete and providing good
insulation control thermal gradients
is to be used. If steel shutter are
used, plywood liners or provision of
sack rubbing after de-shuttering.

Same as in Q-3.
Formwork / design made and
b) Design Check Spot check. approved independently.

Specialised formwork system, to be Same as Q-3.


preferred with properly trained
c) Specialist System. Specialized formwork systems need carpenters / fitters.
not be insisted upon.
Skilled carpenters / fitters under
supervisory staff with the work
supervised additionally by owners Same as Q-3.
d) Experienced Semi-skilled / Skilled carpenters, supervisors and agents.
carpenters / fitters under supervisory staff.
fitters. Check for all members by supervisory
staff.
As in Q-3. Also check for quality of
shutter surfaces before reuse &
e) Tolerances, Frequent check by carpenters/ fitters As in Q-2. The system should provide document clearance.
geometry and leak and checking of important members for gradual uniform and shock-free de-
tightness checks. by supervisory staff. shuttering arrangements. Same as Q-3

f) De-shuttering Under supervisory staff for important


members.
g) Formwork for Not applicable As per design requirement under Same as Q-3
special structure control of qualified staff, with

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Quality inspection & Test Plan Comprehensive

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No. (Q-2) (Q-3) (Q-4)
additional supervision by owners
supervisor or agents. Checks by QA
team till procedure at site are
established.
2.6 Mixing / Conveyance Site mixing by mixers or batching As in Q-2 under two level controls, Batching plant is mandatory.
placing / Curing of plant near site. Occasional two tier upto 200m length bridge beyond Occasional checks by expert
concrete control and documented. which batching plant is mandatory. external agency.

Use specialized equipment for


Transportation by head leads trollies transportation. The adverse effects of As in Q-3.
or by mechanized vehicle permitted. the methods of conveyance
(segregation delays stiffening of mix
etc.), should be regularly monitored
Experienced concreting gangs under controlled and documented. Same as Q-3.
supervisory staff.
As in Q2, with two level controls. Also
regular control by qualified staff.
Placing concrete and compacting Method of control by pour card
under supervisory staff. recommended.
Same as Q-3. Efficacy of methods
As in Q-2. Also regular control by to be regularly checked and
qualified staff. Surveillance by QA demonstrated.
team.
2.7 Stressing Cables Normally not applicable if used follow Stressing equipment calibrated tested
Q-3 practices. and certified by manufacturer/
supplier.
As in Q-3 in presence of
Stressing equipment Checking and recalibrated at site at independent expert or by QA team.
regular predetermined frequency by
qualified staff under supervision of
owner and his agent.

Stressing Operations Only under strict supervision of


stressing supervision of stressing

Dir / Sanjay Sharma,


Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)
supervision and site engineer. The
manufacturer to supply special
assistance at site to train personnel
and supervise work.
Same as Q-3 with surveillance by
Sample basis check for elongation / expert agency / or QA team.
pull in of all wires / strands in the
cable assembly (uniformity of
stressing).

In-site check on losses by stressing


from on side jack using as active and
other as a passive jack on a sample
basis. Same as Q-3.
(For long cables and high total
deviation the passive jack may not
register pressure within strock length
Check of friction and of active jack. For such cases special As in Q-3 with additional tests as
wobble losses. tests or provision of short cables may required by QA team.
be required).
2.8 Grouts & Groutings. Normally not applicable. If used then At the beginning of work for designing As in Q-3 which check for every
a) Grouting of follow Q-3 practice. suitable grouts. Physical properties to operation.
Prestressing be verified once a week or with
Cables. change of batch of cement of
admixture.
Composition and
Physical properties. By visual inspection As in Q-3 but tested and
documented for every operation.

Fluidity test bleeding Equipment tested & passed for As in Q-3 with testing witnesses by
characteristics satisfactory performance regularly. independent QA team.
during working
Equipment Trained staff under qualified
supervision. Surveillance by QA team. Same as Q-3

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Quality inspection & Test Plan Comprehensive

Sr. Item Normal QA High QA Extra High QA


No. (Q-2) (Q-3) (Q-4)

Where used as per item 5.5. Where


used, as per item 5.5.
Workers / Supervisor
Normally not required, if used follow
Q-4. As per item 5.5
Admixtures

Materials like grease, powder


b) Grouting with non- Use of special per-packed high coatings, or other specially
cementitious strength non-shrink grouts preferred. formulated mixes should be used
special material. only after through testing for
suitability including long term effects
and by following specially developed
c) Cement Grouting suitable methods under expert
for bolts and fixing supervision.
apparatus
As in Q-3 with increased frequency
of checking.

Dir / Sanjay Sharma,

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