QC Frequency Test Plan (5th Revision)

QUALITY PLAN FOR CONSTRUCTION ACTIVITIES
MORT&H Specification IV Revision MORT&H Specificati

Sl. No. Check Parameter
Frequency Acceptance Criteria Frequency
1) At the beginning for approval of each 1) At the beginning for approval of each
source and change of source source and change of source
1 Earth Work in Embankment & Sub grade
1.1 Liquid Limit 70 % Maximum
1.2 Plasticity Index 2) 2 45 % Maximum 2) 2

Tests per 3000 m3 Tests per 3000 m3
1.3 Maximum Dry Density requirements for various works Items
Maximum Dry Density for 1) At the beginning for approval of each 1.52 g/cc Minimum 1) At the beginning for approval of each
1.3.1
Emb. up to 3m source and change of source source and change of source
Maximum Dry Density for

1.3.2 1.60 g/cc Minimum
Emb. more than 3m
Maximum Dry Density for 1) At the beginning for approval of 2)

each
2 1.75 g/cc Minimum 1) At the beginning for approval of 2)
each
2
1.3.3
Subgrade & Earthen Shoulders source and
Tests per change
3000 m3 of source source and
Tests per change
3000 m3 of source
6 % Minimum
California Bearing Ratio for
1.4 1) At the beginning for approval of each 1) At the beginning for approval of each
Subgrade Earthen Shoulders
2) 1 2) 1
Tests per 3000 m3 The size of coarse material should not exceed Tests per 3000 m3
1.5 Grain size analysis 1) At the beginning for approval of each 75mm in embankment and 50mm in subgrade 1) At the beginning for approval of each
No of samples
2) 2
0.5
No of samples
2) 2
0.5
1.6 Free Swelling Index Tests per 3000 m3 50% Maximum Tests per 3000 m3
1) At the beginning for approval of 2) 2 1. Material should be free from swamps

each 1) At the beginning for approval of 2) 2
each
Tests marshes and bogs
sourceper 3000
and m3 of source
change Tests
sourceper 3000
and m3 of source
change
1.7 Deleterious Constituents
2. Any soil that comes
under classification of OL,OI and OH is treated
as unsuitable
CORR Phase -II from Km 0+000 to Km30+500 Nemilicheri in NH-205 – Minjur-Ponneri-Panchetti (TPP) Road
1.8 Field Tests 1) 1 Test per 250 m3 1) 1 Test per 250 m3
Moisture Content Prior to
1.8.1 -2, +1 of OMC
Compaction
Field Dry Density of
1.8.2 Embankment Layers up to 6m 1) 1 Test per 1000 m2 95 % Minimum 1) 1 Test per 3000 m2
height
1.8.3 Embankment Layers more 1) 1 Test per 1000 m2 97 % Minimum 1) 1 Test per 3000 m2
than 6m height 1) 1 Test per 500 m2 1) 1 Test per 2000 m2
Field Dry Density of Sub grade
1.8.4 97 % Minimum
layers
Nothan
Mean Density should not less of samples
the
0.5
Nothan
the
0.5
........1.65
1.9 Acceptance Criteria Specified density + [ 1.65 - ----------------------] X SD Specified density + [ 1.65 - ---
..( No of samples)0.5 ..
No of samples0.5 No of samples0.5
2 Granular Sub-Base ( GSB)
Table 400-2 (Grading 1)

% Passing by
1) At the beginning for approval of each IS Sieve (mm) 1) At the beginning for approval of each
weight
75 100
53.00 -
26.50 55-75
2.1 Sieve Analysis
9.5 -
4.75 10-30
2) 1 Test per 2.36 - 2) 1 Test per

200 m3 400 m3
1) At the beginning for approval of each 0.425 - 1) At the beginning for approval of each
0.075 0-5
2.2 Liquid Limit 25 % Maximum

2.3 Plasticity Index 6 % Maximum
At the beginning for approval of each At the beginning for approval of each
2.4 California Bearing Ratio 2) 1 Test per 30 % Minimum 2) 1 Test per
200 m3 400 m3
2.5 10% Fines value 50 KN Minimum
2.6 Water Absorption < 2%
As above If water absorption value is > <12% (Na2So4) As above If water absorption value is >
2.7 Soundness Test
2% <18% (MgSo4) 2%
2.8 Field Tests

Moisture Content Prior to
2.8.1 1. 1 Test per 250 m2 -2, +1 of OMC 1. 1 Test per 400 m2
Compaction
2.8.2 1. 1 Test per 500 m2 98 % Minimum 1. 1 Test per 1000 m2
Compacted Layers
Mean Density should not less than the Mean Density should not less than the
1.65 ........1.6
2.9 Acceptance Criteria
Specified density + [ 1.65 - ----------------------] X SD Specified density + [ 1.65 - ---
.. No of samples0.5 .. No of sam
3 Wet Mix Macadam (WMM) No of samples0.5 No of samples0.5
% Passing by
IS Sieve (mm)
1) At the beginning for approval of each weight 1) At the beginning for approval of each
53 100
45 95-100
22.4 60-80
3.1 Sieve Analysis
11.2 40-60
4.75 25-40
2.36 15-30
1) At the beginning for approval
2) 1 Testofper
each 1) At the beginning for approval
2) 1 Testofper
each
0.600 8.-22
source
100 m3 and change of source source
200 m3 and change of source
0.075 0-8
3.2 Los Angles abrasion value source and change of source 40 % Maximum source and change of source
3.3 Aggregate Impact Value 30 % Maximum
2) 1 Test per 2) 1 Test per

200 m3 1000 m3
3.4 Flakiness & Elongation Index source and change of source . If water 30 % Maximum source and change of source . If water
absorption value is > 2% absorption value is > 2%
3.5 Soundness Test 1) At the beginning for approval each <12% (Na2So4)
2) 1 Testofper 2) 1 Testofper
1) At the beginning for approval each
200 m3 and change of source
source <18% (MgSo4) 500 m3 and change of source
source
Specific Gravity and Water

3.6 2 % Maximum for water absorption
absorption
3.7 Plasticity Index 2) 1 Test per 100 m3 6 % Maximum 2) 1 Test per 200 m3
3.8 Field Tests

3.8.1 1) 1 Test per 500 m2 98 % Minimum 1) 1 Test per 1000 m2
Compacted Layers
........1.65 ........1.65
3.8.2 Acceptance Criteria Specified density + [ 1.65 - -----------------------] X SD Specified density + [ 1.65 - ---------------------
.. No of samples0.5 .. No of samples0.5
4 Asphalt Works No of samples0.5 No of samples0.5

4.1 Prime Coat
4.1.1 Quality of Prime Coat emulsion Manufacturer's Test Certificate
2) 2 Tests per Lot 2) 2 Tests per Lot
4.1.2 Field Tests
1) 1 Test per 500m2 and not less than 2

4.1.3 Rate of Spread 6Kg-9Kg per 10 Sqm 1)3 Tests per day
Tests per day
4.2 Tack Coat
4.2.1 Quality of Tack Coat emulsion -
2) 2 Tests per Lot 2) 2 Tests per Lot
4.2.2 Field Tests
3.0 to3.50kg/10m2 over concrete surface
1) 1 Test per 500m2 and not less than 2 2.5 to 3.0 kg/10m2 over granular surface
4.2.3 Rate of Spread of Binder 1) 3 Tests per day
Tests per day treated with primer
2.0 to 2.5kg/10m2 over bituminous surface
4.3 Aggregates
4.3.1 Cleanliness (Dust) Max 5% passing 0.075mm sieve
35 % Maximum
Los Angeles abrasion value
2) 1 Test per 50 30 % Maximum 2) 1 Test per
4.3.2 a) DBM
m3
350 m3
b) BC
Aggregate Impact Value
2) 1 Test per 50 a) 27 % Maximum 2) 1 Test per
4.3.3 a) DBM
m3 b) 24% Maximum 350 m3
b) BC
Three tests on agregates for each 400 Three tests on agregates for each 400
4.3.4 Sand Equivalent Test + of mix subject to two tests per plant + of mix subject to two tests per plant
per day per day
30 % Maximum
2) 1 Test per 50 2) 1 Test per
4.3.5 Flakiness & Elongation Index
m3 350 m3
Sodium Sulphate-12% Maximum
4.3.6 Soundness
Magnesium
Sulphate-18% Maximum
2 % Maximum for water absorption

Specific Gravity and Water 1) At the beginning for approval of each 1) At the beginning for approval of each
4.3.7
absorption source and change of source source and change of source
4.3.8 Stripping Value Minimum retained coating should be 95%
4.3.9 Stone Polishing Value 50 % Minimum
4.4 Bitumen VG-30 Grade 1) At the beginning for approval of each 1) At the beginning for approval of each
2) Two 2) Two
4.4.1 Absoult Viscosity (Poise) tests per lot 2400 tests per lot
2) Two 2) Two
4.4.2 Kinematic Visocity(cSt) tests per lot 350 tests per lot
2) Two 2) Two
4.4.3 Penetration tests per lot 50 -70 tests per lot
2) Two 2) Two
4.4.4 Ductility tests per lot 40 Cms Minimum (After TFOT) tests per lot
2) Two 2) Two
4.4.5 Softening Point tests per lot 470C Minimum tests per lot
2) Two 2) Two
4.4.6 Specific Gravity tests per lot 0.99 Minimum tests per lot
2) Two 2) Two
4.4.7 Flash point tests per lot 220 0C Minimum tests per lot
Three test on agregates for each 400 Three test on agregates for each 400
4.4.8 Sand Equivalent Test plus of mix subject to two tests per plus of mix subject to two tests per
plant per day plant per day
4.5 Dense Bituminous Macadam (DBM) Nominal Aggregate Size
40mm Grade-1
Layer thickness 80-100mm

Percent passing Percent passing
Sieve Designation Grade 1 Grade 2
1) At the beginning for approval 1) At the beginning for approval
No of samples0.5 No of samples0.5
45mm 100 -
37.5mm 95-100 100
4.5.1 Sieve Analysis 2) A set of 2) A set of
three specimens for each 400 tons of 26.5mm 63-93 90-100 three specimens for each 400 tons of
mix subject to a minimum of 2 tests per mix subject to a minimum of 2 tests per
19mm - 71-95
13.2mm 55-75 56-80
4.75mm 38-54 38-54
2.36mm 28-42 28-42
300micro 7-21 7-21
75micron 2-8 2-8
Modified Marshall Method
4.5.2 Marshall Stability
1) At the beginning for approval 20.25KN Minimum 1) At the beginning for approval
4.5.3 Flow 3 mm Minimum
4.5.4 Air Voids 2) A set of 3%-6% 2) A set of
three specimens for each 400 tons of three specimens for each 400 tons of
4.5.5 Voids in mineral aggregate 12% Minimum
mix subject to a minimum of 2 tests per mix subject to a minimum of 2 tests per
4.5.6 Voids filled with Bitumen plant per day 65 % - 75 % plant per day
4.5.7 Min. Bitumen Content 4.0 % for Grade - I, 4.5% for Grade - II
4.5.8 Field Tests
Control of mix temp. at the

4.5.9 1) 1 Test per every load of mix 1400C Min 1) 1 Test per every load of mix
time of Laying
4.5.10 Field Density of Asphalt layers 1) 1 Test per 250 m2 98 % Minimum 1) 1 Test per 700 m2
........1.65 ........1.65
4.5.11 Acceptance Criteria Specified density + [ 1.65 - --------------------------------] X SD 5.16 Specified density + [ 1.65 - ---------------------
.. No of samples0.5 .. No of sample
4.6 Bitumen VG-40 Grade 1) At the beginning for approval
No of of each 0.5
samples 1) At the beginning for approval
No of of each 0.5
samples
2) Two 2) Two
4.6.1 Penetration tests per lot 40 - 60 tests per lot
2) Two 2) Two
4.6.2 Absoult Viscosity (Poise) tests per lot 3200 tests per lot
2) Two 2) Two
4.6.3 Kinematic Visocity(cSt) tests per lot 400 tests per lot
2) Two 2) Two
4.6.4 Ductility tests per lot 40 Cms Minimum (After TFOT) tests per lot
2) Two 2) Two
4.6.5 Softening Point tests per lot 50 0C Minimum tests per lot
2) Two 2) Two
4.6.6 Specific Gravity tests per lot 0.99 Minimum tests per lot
2) Two 2) Two
4.6.7 Flash point tests per lot 220 0C Minimum tests per lot
Three test on agregates for each 400 Three test on agregates for each 400
4.6.8 Sand Equivalent Test plus of mix subject to two tests per plus of mix subject to two tests per
4.7 Bituminous Concrete (BC)
% Passing by
IS Sieve (mm)
weight
26.50 100
19.00 79-100
1) At the beginning for approval 13.20 59-79 1) At the beginning for approval
9.50 52-72
4.7.1 Sieve analysis 4.75 35-55
2) A set of three specimens for each 2) A set of three specimens for each
400 tons of mix subject to a minimum 2.36 28-44 400 tons of mix subject to a minimum
of 2 tests per plant per day 1.18 20-34 of 2 tests per plant per day
0.600 15-27
0.300 10.-20
0.150 5.-13
0.075 2.-8
4.7.2 Marshall Stability 12 KN Minimum
4.7.3 Flow 2.5 mm - 4 mm
1) At the beginning for approval 1) At the beginning for approval

4.7.4 Air Voids 3%-5%
2) A set of three specimens for each 2) A set of three specimens for each
4.7.5 Voids in mineral aggregate 400 tons of mix subject to a minimum 14 % Minimum 400 tons of mix subject to a minimum
of 2 tests per plant per day of 2 tests per plant per day
4.7.6 Voids filled with Bitumen 65 % - 75 %
4.7.7 Min. Bitumen Content 5% Min
4.7.8 Field Tests
Control of mix temp. at the

4.7.9 1) 1 Test per every load of mix 120-1450C 1) 1 Test per every load of mix
time of Laying
4.7.10 Field Density of Asphalt layers 1) 1 Test per 250 m2 98 % Minimum 1) 1 Test per 250 m2
........1.65 ........1.65
4.4.11 Acceptance Criteria Specified density + [ 1.65 - --------------------------------] X SD Specified density + [ 1.65 - ---------------------
.. No of samples0.5 .. No of samp
5 Cement OPC53 Grade
1) At the beginning for approval
No of of each 0.5
samples 1) At the beginning for approval
No of of each 0.5
samples
5.1 Chemical Tests source and change of source source and change of source
5.1.1 Chlorides(as cl) 1) At the beginning for approval of each 0.05 % Maximum 1) At the beginning for approval of each
Ratio of alumina to that of iron 1) At the beginning for approval of each 1) At the beginning for approval of each
5.1.2 0.66 Minimum
Oxide source and change of source source and change of source
5.1.3 Magnesium (MgO) 1) At the beginning for approval of each 6.0 % Maximum 1) At the beginning for approval of each
Sulphuric Anhydrade 1) At the beginning for approval of each 3.0 % Maximum 1) At the beginning for approval of each
5.1.4
(% by mass) source and change of source source and change of source
5.1.5 Loss on Ignition 1) At the beginning for approval of each 5.0 % Maximum 1) At the beginning for approval of each
5.1.6 Insoluble Residue 1) At the beginning for approval of each 3.0 % Maximum 1) At the beginning for approval of each
5.1.7 Lime saturation factor 0.66 - 1.02

5.2 Physical Tests
5.2.1 Standard Consistency 1) At the beginning for approval of each

2) Not Specified 1) At the beginning for approval of each
2)
source
One and
test perchange of source
lot subject to a maximum source
One and
lot subject to a maximum
of 500Tonnes of 500Tonnes
5.2.2 Initial Setting Time 1) At the beginning for approval of each

2) 30 minutes Minimum 1) At the beginning for approval of each
2)
source
One testand
perchange of source
One testand
perchange of source
5.2.3 Final Setting Time 2) 600 minutes Maximum 2)

One test per lot subject to a maximum One test per lot subject to a maximum
5.2.4 source and
Cement Mortar cubes Compressive change of source
Strength source and change of source
Compressive Strength
5.2.4.1 1) At the beginning for approval of each

2) Not less than 27 Mpa Strength 1) At the beginning for approval of each
2)
source
One testand
perchange of source
One testand
perchange of source
i) At 3 days of 500Tonnes of 500Tonnes
5.2.4.2 ii) At 7 days 1) At the beginning for approval of each

2)
source
One testand
perchange of source
One testand
perchange of source
5.2.4.3 iii) At 28 days 1) At the beginning for approval of each

2)
source
One and
One and
5.2.5 Specific Gravity 1) At the beginning for approval of each

2) 3.15 Minimum 1) At the beginning for approval of each
2)
source
One and
One and
5.2.6 Fineness of Cement 1) At the beginning for approval of each

2) 10 % Maximum 1) At the beginning for approval of each
2)
source
One testand
perchange of source
One testand
perchange of source
Soundness
5.2.7 2) 10 mm Maximum 2)
(Le-Chatlier method) One test per lot subject to a maximum One test per lot subject to a maximum
6 Concrete Works
6.1 Coarse Aggregates - IS:383
% Passing by
IS Sieve (mm)
weight
source and change of source 80 100 source and change of source
Sieve analysis for all in
6.1.1 2) 2)
aggregate 40 95-100
Once test for every days work of each Once test for every days work of each
fraction of coarse aggregate 20 45-75 fraction of coarse aggregate
4.75 25-45
0.600 .8-30
0.150 0-6
6.1.2 Flakiness Index 35 % Maximum
2) 2)
Once in a month Once in a month
% Passing by
Deleterious
weight
Materials
(Maximum)
Coal& Ignite 1
1) At the beginning for approval of each Clay Lumps 1 1) At the beginning for approval of each
6.1.3 Deleterious Materials source and change of source source and change of source
Material finer than
3
75 microns sieve
Soft Fragment -
Shale -
Total 5
6.1.4 Water absorption source and change of source 2 % Maximum source and change of source
6.1.5 Aggregate Impact Value 45% Max
2) 2)
Once in a month Once in a month
6.2 Fine Aggregates - IS:383
% Passing by
IS Sieve (mm)
weight
10 100
4.75 90-100
Sieve analysis for fine 2.36 60-95
6.2.1 source and change of source source and change of source
aggregate Zone - I
1.18 30-70
0.600 15-34
0.300 5.-20
0.150 0.-10
% Passing by
IS Sieve (mm)
weight
10 100
4.75 90-100
Sieve analysis for fine 1) At the beginning for approval of each 2.36 75-100 1) At the beginning for approval of each
6.2.2
aggregate Zone - II source and change of source source and change of source
1.18 55-95
0.600 35-59
0.300 8.-30
0.150 0-10
% Passing by
IS Sieve (mm)
weight
10 100
4.75 90-100
Sieve analysis for fine 1) At the beginning for approval of each 2.36 85-100 1) At the beginning for approval of each
6.2.3
aggregate Zone - III source and change of source source and change of source
1.18 75-100
0.600 60-79
0.300 12.-40
0.150 0-10
% Passing by
Deleterious
weight
Materials
(Maximum)
Coal& Ignite 1
Clay Lumps 1
6.2.4 Deleterious Materials source and change of source source and change of source
Material finer than
3
75 microns sieve
Soft Fragment -
Shale 1
Total 5
Material finer than 75 micron
6.2.5 source and change of source 3 % Maximum source and change of source
sieve
Specific Gravity and Water
6.2.6 source and change of source - source and change of source
absorption
7 Water - IS:456
7.1 Chemical Tests
7.1.1 PH Value source and change of source 6 Minimum source and change of source
7.1.2 Sulphates (So3) source and change of source 400 mg /liter Maximum source and change of source
500 mg /liter Maximum for psc concrete

7.1.3 Chlorides (Cl) source and change of source source and change of source
2000 mg /liter for concrete not embedded steel
NaOH (Neuterlisation with Maximum of 5ml of 0.02 normal NaOH to
phenolphthlein as indicator) neutralise 100ml of water
HCl (Neuterlisation with methyl Maximum of 25ml of 0.002 normal H2So4 to
orange as indicator) neutralise 100ml of water
7.2 Physical Tests
7.2.1 Suspended matter 2000mg /liter Maximum
7.2.2 Organic matter 200mg /liter Maximum
7.2.3 In-organic matter 3000mg/ liter Maximum
8 Steel (Fe500)- IS:1786
8.1 Chemical Tests
8.1.1 Carbon 0.30 Maximum
8.1.2 Sulphur 0.055 Maximum
8.1.3 Phosphorous 0.055 Maximum
8.1.4 Sulphur+Phosphorous 0.105 Maximum
8.2 Physical Tests

source and change of source 8 % more than the actual 0.2% proof stress but source and change of source
8.2.1 Ultimate Tensile Strength
2) 1 not less than 545 Mpa 2) 1
Test per Consignment Test per Consignment
8.2.2 0.2 % Proof stress 500 Mpa Minimum
2) 1 2) 1
8.2.3 Elongation 14.50 % Minimum
2) 1 2) 1
8.2.4 Bend Test Bent to included angle of 135 0
2) 1 2) 1
8.2.5 Re-Bend Test Bent to included angle of 157.5 0
2) 1 2) 1
8.2.6 Elastic Modulus (Gpa) As Above 200 As Above
6.310 + 3% for 32mm dia
4.830 + 3% for 25mm dia
2.470 + 3%
for 20mm dia
Mass per meter run/ 1.580 +
8.2.7 5% for 16mm dia
2) 1 2) 1
Rolling margin 0.888 + 5% for
12mm dia
0.617 + 7% for 10mm
dia
9 Admixture (Super plasticiser)- IS:9103 0.395 + 7% for 8mm dia
9.1 Uniformity Tests

source and change of source Within 3% of the value stated by the source and change of source
9.2 Dry material content
2) 1 manufacturer 2) 1
source and change of source Within 1% of the value stated by the source and change of source
9.3 Ash content
source and change of source Within 0.02 of the value stated by the source and change of source
9.4 Relative Density
9.5 Chlorides ion content 0.20 % maximum
2) 1 2) 1
9.6 PH 7 to 8
2) 1 2) 1
10 Concrete
one test per each transit mixer at both one test per each transit mixer at both
batching plant and site initially when PCC 50 + 25 mm batching plant and site initially when
10.1 Workability of fresh concrete
work starts.Subsequently sampling may RCC 100 + 25 mm work starts.Subsequently sampling may
be done from alternate transit mixers M10 - 10 Mpa be done from alternate transit mixers
(1-5cum)/One set (1-5cum)/One set
M20 - 20 Mpa
(6-15)/Two sets (6-15)/Two sets
(16- (16-
M25 - 25 Mpa
30)/Three sets 30)/Three sets
Compressive Strength of (31-50)/Four sets (31-50)/Four sets
10.2 M30 - 30 Mpa
Concrete
51 and above 51 and above
M35 - 35 Mpa
4+1 4+1
M40 - 40 Mpa
additional set for each 50 m3 additional set for each 50 m3
M45 - 45 Mpa
11 Hume Pipes(NP-4) - IS:458
Tolerances in dimensions for

11.1 Over 95mm + 7mm, - 3.5mm
wall thickness
Tolerances in dimensions for source and change of source source and change of source
11.2 Over 600mm + 10mm
internal dia of pipe 2) 2)
As per IS: 458-2003 Table-22 As per IS: 458-2003 Table-22
Tolerances in dimensions for
11.3 .+ 1 % of standard length
overall length
Three Edge Bearing test (Load 1) At the beginning for approval of each 1) At the beginning for approval of each
to produce 0.25mm crack) source and change of source source and change of source
11.4 Working load 66.30 KN
1) 900mm 2) 2)
dia As per IS: 458-2003 Table-22 As per IS: 458-2003 Table-22
Three Edge Bearing test (Load
to produce 0.25mm crack)
1) 1000mm
dia
2) As per IS: 458-2003 Table-22 2) As per IS: 458-2003 Table-22
Three Edge Bearing test (Load source and change of source source and change of source
to produce 0.25mm crack)
1) 1200mm
dia 2) As per IS: 458-2003 2) As per IS: 458-2003
Table-22 Table-22
3mm/1Rm
11.7 Straightness Straightness
Maximum
11.8 Hydrostatic Pressure Test Pressure 1.50 N/mm2

Initial Permiability should not
exceed 2.0 cm3 and the difference
in any two readings during initial
11.9 Permiaility
readings should not be more than
0.8 cm3 , Final Permiability should
not exceed 0.3 cm3
Compressive Strength of
11.10 source and change of source 35 Mpa source and change of source
Concrete
12 Elostomeric Bearings
12.1 Tests on Elostomer
12.1.1 Hardness 60+5 IRHD
12.1.2 Minimum Tensile Strength 17 Mpa
12.1.3 Minimum Elongation at break 4
12.1.4 Maximum compression set 0.35
12.2 Accelerated ageing
12.2.1 Maximum change in hardness 15 IRHD
Maximum change in Tensile 1) At the beginning for approval of each 1) At the beginning for approval of each
12.2.2 -0.15
Strength source and change of source source and change of source
12.2.3 Maximum change in Elongation -0.4
12.2.4 Tests on finished bearings
12.3 Dimensions
12.3.1 Overall plan dimensions 1) All Bearigs -0, + 6 mm 1) All Bearigs
12.3.2 Total bearing thickness 1) All Bearigs -0, + 5 mm 1) All Bearigs
12.4 Parallelism
Of top surface of bearing with

12.4.1 respect to bottom surface as 1) All Bearigs 1 in 200 1) All Bearigs
datum
Of one side surface with

12.4.2 1) All Bearigs 1 in 100 1) All Bearigs
respect to the other as datum
Thickness of the individual

12.4.3 1) All Bearigs +20%(Max.2mm) 1) All Bearigs
internal layer
Thickness of the individual

12.4.4 1) All Bearigs -0, + 1 mm 1) All Bearigs
outer layer
Plan dimensions of the

12.4.5 1) All Bearigs -3mm, + 0 1) All Bearigs
laminate
12.4.6 Thickness of laminate 1) All Bearigs '+10% 1) All Bearigs
Parellelism of the laminate

12.4.7 with respect to bearing base 1) All Bearigs 1 in 100 1) All Bearigs
as datum
12.5 Tests on brearings

12.5.1 Shear Modulus 0.80 to 1.20 Mpa
2) Two bearings per 2) Two bearings per
Lot Lot
12.5.2 Elastic Modulus -
1)
LotAt the beginning for approval of each 1)
LotAt the beginning for approval of each
12.5.3 Ultimate Compressive strength 60 Mpa Minimun
1)
LotAt the beginning for approval of each 1)
LotAt the beginning for approval of each
Test piece shows no evidence of peeling or near
12.5.4 Adhesion Strength the interface between rubber and reinforcement
layers
Lot Lot
13 Strip Seal Expansion Joints
13.1 Hardness 63 + 5 shore A
13.2 Tensile Strength 11 Mpa Minimum
13.3 Elongation at break 350 % Minimum
13.4 Tar Propagation strength Minimum 10 N/mm

13.5 Longitudinal
13.6 Traverse Minimum 10 N/mm
13.7 Shock Elasticity Minimum 25%
13.8 Abrasion Minimum 220mm3
Residual compressive 1) At the beginning for approval of each 1) At the beginning for approval of each
13.9 Minimum 28%
strain(22h/700C/30% strain) source and change of source source and change of source
13.10 Ageing in hotair (14day/700C)
13.11 Change in Hardness Maximum 5 Shore A
13.12 Change in Tensile Strength Maximum -20%
Change in elongation at 1) At the beginning for approval of each 1) At the beginning for approval of each
13.13 Maximum -20%
fracture source and change of source source and change of source
Swelling behaviour
13.14
in oil
Maximum 5%
13.15 Volume change
13.16 Change in hardness Maximum 10 shore A
13.17 ASTM oil No.3

Maximum 25%
13.17.1 Volume change source and change of source source and change of source
13.17.2 Change in hardness Maximum 20 shore A
13.17.3 Cold hardening point Minimum -350C
14 Thermoplastic Road Paint Material
1) Once at the beginning for approval of 1) Once at the beginning for approval of
14.1 Binder Content each source and change of source 18 % Minimum by weight each source and change of source
14.2 Glass Beads each source and change of source 30 - 40 % each source and change of source
14.3 Titanium Dioxide content each source and change of source 10 % Minimum each source and change of source
Calcium Carbonate and innert
14.4 each source and change of source 42 % Maximum each source and change of source
fillers
14.5 Day light luminance at 450C each source and change of source 65 % Minimum each source and change of source
14.6 Drying time each source and change of source 15 Minutes Maximum each source and change of source
14.7 Skid Resistance each source and change of source 45 % Maximum each source and change of source
14.8 Softening Point each source and change of source 102 + 9.50C each source and change of source
14.9 Flow Resistance each source and change of source 25% Maximum each source and change of source
14.10 Yellowness Index each source and change of source 0.12 Maximum each source and change of source
Percent Retained
Type-1 Type-2
0-3 -
Once at the beginning for No
approval of 0.5
of samples 39953.00 0-5No of samples
0.5 Once at the beginning for approval of 0.5
No of samples
each source and change of source and each source and change of source and
14.11 Gradation - 5-20
each consignment each consignment
65-95 -
- 30-75
0-10 10-30
- 0-15
Once at the beginning for approval of Once at the beginning for approval of
14.12 Roundeness Minimum 70% true spheres
Once at the beginning for approval of Once at the beginning for approval of
14.13 Refractive index Minimum 1.50
OR CONSTRUCTION ACTIVITIES
MORT&H Specification V Revision
Acceptance Criteria
50 % Maximum
25 % Maximum
1.52 g/cc Minimum
1.60 g/cc Minimum
1.75 g/cc Minimum
8 % Minimum
The size of coarse material should not exceed

75mm in embankment and 50mm in subgrade
No of samples0.5
50% Maximum
1. Material should be free from swamps

marshes and bogs
2. Any soil that comes

under classification of OL,OI and OH is treated
as unsuitable
-2, +1 of OMC
95 % Minimum
97 % Minimum
97 % Minimum
Nothan
the
0.5
........1.65
Specified density + [ 1.65 - ----------------------] X SD
..( No of samples)0.5
No of samples 0.5
Table 400-2 (Grading 1)

% Passing by
IS Sieve (mm)
weight
75 100
53.00 -
26.50 55-75
9.5 -
4.75 10-30
2.36 -
0.425 -
0.075 0-5
25 % Maximum
6 % Maximum
30 % Minimum
40% Max-Wet AIV Test according to IS:5640
< 2%
<12% (Na2So4)
<18% (MgSo4)
-2, +1 of OMC
98 % Minimum
Mean Density should not less than the

........1.65
Specified density + [ 1.65 - ----------------------] X SD
.. No of samples0.5
No of samples0.5
% Passing by
IS Sieve (mm)
weight
53 100
45 95-100
22.4 60-80
11.2 40-60
4.75 25-40
2.36 15-30
0.600 8.-22
0.075 0-5
40 % Maximum
30 % Maximum
35 % Maximum
<12% (Na2So4)
<18% (MgSo4)
2 % Maximum for water absorption
6 % Maximum
98 % Minimum

........1.65
Specified density + [ 1.65 - -----------------------] X SD
.. No of samples0.5
No of samples0.5
Manufacturer's Test Certificate
7.0Kg-10.0Kg per 10 Sqm
-
3.0 to3.50kg/10m2 over concrete surface
2.5 to 3.0kg/10m2 over granular surface treated

with primer
2.0 to 2.5 kg/10m2 over bituminous surface
Max 5% passing 0.075mm sieve
35 % Maximum
30 % Maximum
a) 27 % Maximum
b) 24% Maximum
35 % Maximum
Sodium Sulphate-12% Maximum
Magnesium Sulphate-18%
Maximum
2 % Maximum for water
absorption
Minimum retained coating should

be 95%
55 % Minimum
2400
350
50 -70
40 Cms Minimum (After TFOT)
470C Minimum
0.99 Minimum
220 0C Minimum
Nominal Aggregate Size
40mm Grade-1
Layer thickness 80-100mm

Percent passing Percent passing
Sieve Designation Grade 1 Grade 2
No of samples0.5
45mm 100 -
37.5mm 95-100 100
26.5mm 63-93 90-100
19mm - 71-95
13.2mm 55-75 56-80
4.75mm 38-54 38-54
2.36mm 28-42 28-42
300micro 7-21 7-21
75micron 2-8 2-8
Modified Marshall Method
9.0 KN Minimum
2 - 4 mm Minimum
3 % -5 %
Minimum % VMA as per Table 500-13
65 % - 75 %
4.0 % for Grade - I, 4.5% for Grade - II
1400C Min
92 % Minimum of Gmm

........1.65
Specified density + [ 1.65 - --------------------------------] X SD
.. No of samples0.5
No of samples0.5
40 - 60
3200
400
40 Cms Minimum (After TFOT)
50 0C Minimum
0.99 Minimum
220 0C Minimum
% Passing by
IS Sieve (mm)
weight
26.50 100
19.00 79-100
13.20 59-79
9.50 52-72
4.75 35-55
2.36 28-44
1.18 20-34
0.600 15-27
0.300 10.-20
0.150 5.-13
0.075 2.-8
12 KN Minimum
2.5 mm - 4 mm
3%-5%
14 % Minimum
65 % - 75 %
5.2 % for Grade - I, 5.4% for Grade - II
120-1450C
92 % Minimum of Gmm

........1.65
Specified density + [ 1.65 - --------------------------------] X SD
.. No of samples0.5
No of samples0.5
0.05 % Maximum
0.66 Minimum
6.0 % Maximum
3.0 % Maximum
5.0 % Maximum
3.0 % Maximum
0.66 - 1.02
Not Specified
30 minutes Minimum
600 minutes Maximum
Not less than 27 Mpa Strength
3.15 Minimum
10 % Maximum
10 mm Maximum
% Passing by
IS Sieve (mm)
weight
80 100
40 95-100
20 45-75
4.75 25-45
0.600 .8-30
0.150 0-6
35 % Maximum
% Passing by
Deleterious
weight
Materials
(Maximum)
Coal& Ignite 1
Clay Lumps 1
Material finer than

3
75 microns sieve
Soft Fragment -
Shale -
Total 5
2 % Maximum
45% Max
% Passing by
IS Sieve (mm)
weight
10 100
4.75 90-100
2.36 60-95
1.18 30-70
0.600 15-34
0.300 5.-20
0.150 0.-10
% Passing by
IS Sieve (mm)
weight
10 100
4.75 90-100
2.36 75-100
1.18 55-95
0.600 35-59
0.300 8.-30
0.150 0-10
% Passing by
IS Sieve (mm)
weight
10 100
4.75 90-100
2.36 85-100
1.18 75-100
0.600 60-79
0.300 12.-40
0.150 0-10
% Passing by
Deleterious
weight
Materials
(Maximum)
Coal& Ignite 1
Clay Lumps 1
Material finer than

3
75 microns sieve
Soft Fragment -
Shale 1
Total 5
3 % Maximum
6 Minimum
400 mg /liter Maximum
500 mg /liter Maximum for psc concrete
2000 mg /liter for concrete not embedded steel
Maximum of 5ml of 0.02 normal NaOH to

neutralise 100ml of water
Maximum of 25ml of 0.002 normal H2So4 to

neutralise 100ml of water
2000mg /liter Maximum
200mg /liter Maximum
3000mg/ liter Maximum
0.30 Maximum
0.06 Maximum
0.06 Maximum
0.11 Maximum
10 % more than the actual 0.2% proof stress

but not less than 485 Mpa
415 Mpa Minimum
14.50 % Minimum
Bent to included angle of 1350
Bent to included angle of 157.50
200
6.310 + 3% for 32mm dia
4.830 + 3% for 25mm dia
2.470 + 3%
for 20mm dia
1.580 +
5% for 16mm dia
0.888 + 5% for
12mm dia
0.617 + 7% for 10mm
dia
0.395 + 7% for 8mm dia
Within 3% of the value stated by the

manufacturer
Within 1% of the value stated by the

manufacturer
Within 0.02 of the value stated by the

manufacturer
0.20 % maximum
7 to 8
PCC 50 + 25 mm
RCC 100 + 25 mm
M10 - 10 Mpa
M20 - 20 Mpa
M25 - 25 Mpa
M30 - 30 Mpa
M35 - 35 Mpa
M40 - 40 Mpa
M45 - 45 Mpa
Over 95mm + 7mm, - 3.5mm
Over 600mm + 10mm
.+ 1 % of standard length
Working load 66.30 KN
3mm/1Rm
Straightness
Maximum
Pressure 1.50 N/mm2
Initial Permiability should not

exceed 2.0 cm3 and the difference
in any two readings during initial
readings should not be more than
0.8 cm3 , Final Permiability should
not exceed 0.3 cm3
35 Mpa
60+5 IRHD
17 Mpa
0.35
15 IRHD
-0.15
-0.4
-0, + 6 mm
-0, + 5 mm
1 in 200
1 in 100
+20%(Max.2mm)
-0, + 1 mm
-3mm, + 0
'+10%
1 in 100
0.80 to 1.20 Mpa
60 Mpa Minimun
Test piece shows no evidence of peeling or near

the interface between rubber and reinforcement
layers
63 + 5 shore A
11 Mpa Minimum
350 % Minimum
Minimum 10 N/mm
Minimum 10 N/mm
Minimum 25%
Minimum 220mm3
Minimum 28%
Maximum 5 Shore A
Maximum -20%
Maximum -20%
Maximum 5%
Maximum 10 shore A
Maximum 25%
Maximum 20 shore A
Minimum -350C
18 % Minimum by weight
30 - 40 %
10 % Minimum
42 % Maximum
65 % Minimum
15 Minutes Maximum
45 % Maximum
102 + 9.50C
25% Maximum
0.12 Maximum
Percent Retained
Type-1 Type-2
0-3 -
No of samples0.5 39953.00 0-5No of samples
0.5
- 5-20
65-95 -
- 30-75
0-10 10-30
- 0-15
Minimum 70% true spheres
Minimum 1.50

QC Frequency Test Plan (5th Revision)

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QUALITY PLAN FOR CONSTRUCTION ACTIVITIES

MORT&H Specification IV Revision MORT&H Specificati

1.1 Liquid Limit 70 % Maximum

1.2 Plasticity Index 2) 2 45 % Maximum 2) 2

Maximum Dry Density for

Maximum Dry Density for 1) At the beginning for approval of 2)

1) At the beginning for approval of 2) 2 1. Material should be free from swamps

Table 400-2 (Grading 1)

2) 1 Test per 2.36 - 2) 1 Test per

2.2 Liquid Limit 25 % Maximum

2.5 10% Fines value 50 KN Minimum

2.6 Water Absorption < 2%

2.8 Field Tests

3 Wet Mix Macadam (WMM) No of samples0.5 No of samples0.5

3.3 Aggregate Impact Value 30 % Maximum

2) 1 Test per 2) 1 Test per

Specific Gravity and Water

3.8 Field Tests

Field Dry Density of

4 Asphalt Works No of samples0.5 No of samples0.5

4.1.2 Field Tests

1) 1 Test per 500m2 and not less than 2

4.2 Tack Coat

4.2.2 Field Tests

3.0 to3.50kg/10m2 over concrete surface

2.0 to 2.5kg/10m2 over bituminous surface

4.3.1 Cleanliness (Dust) Max 5% passing 0.075mm sieve

2 % Maximum for water absorption

4.5 Dense Bituminous Macadam (DBM) Nominal Aggregate Size

Layer thickness 80-100mm

Control of mix temp. at the

4.7.2 Marshall Stability 12 KN Minimum

4.7.3 Flow 2.5 mm - 4 mm

1) At the beginning for approval 1) At the beginning for approval

4.7.6 Voids filled with Bitumen 65 % - 75 %

4.7.7 Min. Bitumen Content 5% Min

4.7.8 Field Tests

Control of mix temp. at the

5.1.7 Lime saturation factor 0.66 - 1.02

5.2.1 Standard Consistency 1) At the beginning for approval of each

5.2.2 Initial Setting Time 1) At the beginning for approval of each

5.2.3 Final Setting Time 2) 600 minutes Maximum 2)

5.2.4.1 1) At the beginning for approval of each

5.2.4.2 ii) At 7 days 1) At the beginning for approval of each

5.2.4.3 iii) At 28 days 1) At the beginning for approval of each

5.2.5 Specific Gravity 1) At the beginning for approval of each

5.2.6 Fineness of Cement 1) At the beginning for approval of each

6.1 Coarse Aggregates - IS:383

7.1 Chemical Tests

500 mg /liter Maximum for psc concrete

8 Steel (Fe500)- IS:1786

8.1 Chemical Tests

8.2 Physical Tests

8.2.6 Elastic Modulus (Gpa) As Above 200 As Above

9.1 Uniformity Tests

Tolerances in dimensions for

2) As per IS: 458-2003 Table-22 2) As per IS: 458-2003 Table-22

12.1 Tests on Elostomer

12.2 Accelerated ageing

12.2.4 Tests on finished bearings

12.3.1 Overall plan dimensions 1) All Bearigs -0, + 6 mm 1) All Bearigs

12.3.2 Total bearing thickness 1) All Bearigs -0, + 5 mm 1) All Bearigs

Of top surface of bearing with