Beruflich Dokumente
Kultur Dokumente
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)
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.
3. DBM/BC
4. Water
The water used for general engineering practices shall conform to following tests.
Bitumen used in bituminous shall be 60-70 and shall conform to following test as tabulated below.
6. Cement
Cement used in various grades of concrete mixes in super and substructure (concluding points) shall conform
to the following test.
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.
8. Bricks
9. Admixtures
Cement concrete of various grade used in PCC / RCC / PSC shall confirm to the following requirements.
15. Bentonite
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.
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-
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.
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)
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
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
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.
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
32. Admixture
34. Bricks
37. H. T. Strand:
42. Bentonite:
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
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
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%
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
4. TACK COAT 503 (Table 2.50 Kg. --- --- --- --- - do -
500-2) per 10m2
(RC)
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
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.
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
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.
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
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.
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.
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:
Quality Assurance
Road 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.
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
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.
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)
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)
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.
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.
b) HT Wires / stands
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.
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
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.
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.
Same as in Q-3.
Formwork / design made and
b) Design Check Spot check. approved independently.
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