Documente Academic
Documente Profesional
Documente Cultură
FOR
INFRASTRUCTURE PROJECTS
OF
Issued By :
CONTENTS
PIDB will restrict itself to provide the funds for the construction of road works and will be
involved in broad monitoring of the Projects. The works would be taken up by Public works
Department, Building and Roads Branch. This would help in capacity building of the PWD. The role
of PIDB is similar to a lending agency and in order to have a judicious use of funds PIDB would have
a proper supervision and monitoring system during the execution of the projects. Quality control is an
important requirement of highway construction for ensuring quality and creating able nation assets.
The need for quality control has unchecked in recent times due to a significant increase in traffic
intensities, increase in repitition of axle load and level of service expected by road user. Quality
control leads to improved quality and uniformity, and ensuring a more economical utilization of
materials, also affords a significant reduction in user costs in terms of lower costs of vehicle operation,
transportation and maintenance.
-Quality assurance
-Material Testing
-Quality Control
Quality assurance programme is achieved through use of suitable materials, specification and
execution of work under overall supervision of Technical Committee overseeing the construction
activities starting from setting out of alignments and controlling all construction activities with
meticulous care upto full completion. The contractor is to prepare, plan and program, make
arrangement for plant, machinery, materials and manpower etc. for carrying out different activities
within the stipulated time period as per laid down specifications in a most appropriate workmanship
and bad engineering practices.
‘Material testing’ refers to laboratory tests conducted on all material right from water, soil to
cement and steel which are planned for incorporation in the works to ensure that they satisfy the
standards set in IS/ IRC/ MOST ( MORT & H) specifications. Material testing have two operational
stages:
‘Quality Control of various activities is done through various field tests including those at plant
site, laying/compaction etc.
The volume gives brief outlines of proposed quality control including brief salient features of
specification for road and concrete work; frequency of tests, checklist performa for start of different
activities, reporting of test results to achieve quality assurance.
As per clause 33.2 of the General conditions of Contract agreement, for works, costing more
than Rs. 200 Lacs, it is mandatory
(1) To engage a competent and independent Quality Control Consultant by the Contractor to be
approved by the CE (IP)
(2) To establish a fully equipped laboratory at Site by the Contractor, which shall be managed by
the trained staff by the said Quality Control Consultant.
(3) Contractor shall supply a copy of the agreement entered with the Quality Control Consultant to
the CE (IP) and generally the fee for Quality Control consultant should be between 0.5 to 1%
of the Contract value.
(4) The payment to the Quality Control Consultant shall be released by the CE (IP) as per
agreement and such payments shall be recoverable from the Contractor out of running
payments.
(5) Running payments are subject to the production and attachments of Quality Control reports,
tests and checks conducted by Quality Control Consultant.
(6) The execution of work by the contractor shall also be subject to surprise, random tests and
checks by the Project Engineer / his representative & other higher authorities.
(7) In case of failure of Contractor to ensure Quality assurance on part or whole of the work, the
CE (IP) is empowered to select and engage other consultant deemed fit or Quality Control Lab.
of PWD (B&R) for such works.
The costs incurred for such alternative shall be recoverable from Contractor and will be
chargeable to work.
For major construction materials “choice of brands’ have been given to Contractor for use
at Site, namely:-
1.2 SPECIFICATIONS:-
The work shall be carried out as per specifications detailed in “MOST / MORT & H
specifications of Road & Bridge works” (up to date) duly supplemented with “IRC
Guidelines” and relevant provision of AASHO/ ASTM standards as and where required.
Nomelclature of each item has been broadly laid down in Bill of Quantities of work,
however in case of any variation/ discrepancy the relevant provision of above specified
standards shall have precedent.
The contractor shall submit complete Bio Data of ‘Quality Control Consultant” with
necessary documents and performance certificates from the authority for whom worked
previously for approval of the Chief Engineer (IP).
2. Registration, if any.
4. Yearly turnover
5. Projects handled in the last 5 years ( with copies of the agreements and performance
certificate from authority for such consultances).
6. Address and Details of Laboratory facilities available with consultant firm. ( List to
be attached of equipment).
7. Details of staff: including names, their qualifications and experience as employed in
Main laboratory of consultant/laboratories established at completed projects.
2.1
14’/16’
w
3 - 6”
AGG. AGG/SOIL
TESTING GARDING
MACHINE AREA
COMP.
TETING 3’ – 0
MACHINE 20’/25’
SHELF
TABLES & AT
CHAIRS 2'- 6”
LEVEL
WATER
TANK
MARSHAL
D
STABILITY
3”- 0”
MACHINE FOR
JOB MIX FORMULA
3’- 6”
A suitable plan of (14’*20’) to (16’*25’) size field lab has been evolved. For accommodating necessary
equipments, testing areas and Seating arrangements of Trained Staff. Any suitable size in these Limits be
adopted for setting up field lab at site.
TRAINED STAFF/ITS EXPERIENCE
Minimum Experience
2.3.5 Miscellaneous
i) Roughometer (automatically) 1
ii) Profilograph for checking pavement unevenness 1
2.3.6 Laboratory at reach plant site shall be set up as per requirements with appropriate
apparatus from above list which may be supplemented as per relevant I.S. code / IRC
Guidelines /MOST specification for road and bridge works/ AASHO and ASTM
standards.
1. Mason Thread
2. Plumb Bob
3. Aluminium heavy weight channel ‘6-0 straight edge
4. Vernier caliper
5. Spherometer
6. Road Market
7. Metallic Tape-30M.
8. Steel Tape-3M.
9. 25*40 cm internal size steel frame with Angle iron straight edge on inner side.
10. Kassi
11. Hammer
12. Chiesels
13. Spatula
14. Trowel
3. SALIENT FEATURES/
SPECIFICATIONS FOR ROAD
WORK
3.0 The road work shall be executed in accordance with MOST / MORT&H.
Specifications for Road & Bridge works ( revision upto date) duly supplemented with
AASHO/ASTM standards as and where required. The important parameters for the
various items of work are briefed here in after. It is mandatory to achieve the laid down
parameters duly supported with field tests.
Sr. Brief Relevant Bitu- Nominal Grading Range Requ Compaction Min.Fr Rem
No Specifi- MOST men Size of Grade Grade ireme Thick Type ndity arks
. cation Clause Cont- Agg. IS 1 11 nt of Ness of of
ent Sieve Passings job Layer Roller
Range mix
form
ula
3. STRESS 522 Modifi
ABSOR Table ed
BING 500-47 Binder
MEMB (SBS)
RANE
Crack
preventi
on
course
(a) Hair (Single 8-10 0.10m3 N.A N.A N.A N.A N.A N.A N.A
cracks coat) Kg per of
and 10m2 5.6mm
maps area chips
cracks
upto
3mm
width N.A
(b) Map (Single 10- 0.11m3 N.A N.A N.A N.A N.A N.A
crack ir coat) 12kg of
alligator per 5.6mm
cracks 10m2 chips
3mm to area N.A
6mm.
© All Single 10- 0.10m3 N.A N.A N.A N.A N.A N.A
types of coat as 12kg of
cracks inter per 11.2mm
above layer 10m2 chips
6mm area
width
4. BITUMI 504 3.3% 19mm 26.5mm 100% Opti Initial rolling 95%
NOUS to crushed mum With 80 to 100 of
MACA 3.5% aggregat 19 90-100% Bind KN smooth Max
DAM by e 13.2 56-88% er Wheeled roller. Densit
weight 4.75 16-36% Cont y as
of 2.36 4-19% ent Intermediate per job
B.M Table total 0.3 2-10% Verse Rolling with mix
(50- 500-3, mix. 0.075 0-8% s Vibrating formul
75MM 500-4 Max. Roller a
Thick Dens Or
layer) ity R-15T
Pneumatic
Roller
5. MIXED 19K Quantity 13.2mm 100% Not 80-100kn Note
SEAL g/10m2 Of 11.2 88-100% requi smooth :-
SURFA aggregat 5.6 31-52% red, wheeled roller For
CING e 2.8 5-25% ratio Minim undu
(TYPE- 512 0.27 0.090 0-5% of um latio
B) cum mm C.A 2gm/C ns
For per 10m2 &F.A ase upto
removal (Table are to Comp 25m
of 500-26) be uters m
undulati fixed ( It M.S
ons & for will S is
Profile achie cover to be
Correcte ving min Ado
d of desir 24.44 pted.
Blackto ed m2 For
p gradi Area) Corr
surface. ng ectio
n of
more
than
25m
m
Thic
knes
s,
BM
is to
be
follo
wed.
6. DENSE 507 Min. 25mm 37.5mm 100% Opti Intially with 8- 98%of Fille
BITUMI (table 4.5% 26.5 90-100% mum 10 T smooth design r is
NOUS 500-8, by 19 71-95% Bitu wheeled roller ed to be
MACA 500-9, wt. Of 13.2 56-80% men densit used
DAM 500-10, total 9.5 --- conte y 43
DBM 500-10, Mix 4.75 38-54% nts grad
(50- 500-11, 2.36 28-42% V/s e
75mm 500-12) 1.18 ---- Dens Intermediate ceme
thick 0.60 ----- ity Rolling with nt of
layer) 0.30 7-21% subje Vibratory roller Vikr
0.15 --- ct to am,
0.075 2-8% Min Or Sri
stabil or
ity=9 12-15 T JK
KN pneumatic bran
Flow tyred roller. d.
=2-
4mm
Voids
=3-
6%
7. SEMI 19mm 100 100% Opti Initial with 8- 98% Fille
DENSE 13.2 90-100% 90 mum 10 T smooth of r is
BITUMI 9.5 70-90% - Bitu wheeled roller Design to be
NOUS 4.75 35-51%100% men ed used
CONCR 2.36 24-39% 35- conte Densit 43
ETE 1.18 15-30% 51% nt v/s Intermediate y grad
SDBC 508 Min 13mm 0.6 - 24-39% Dens With vibratory e
(table 4.5% 0.3 9-19% 15-30% ity Roller ceme
For 35- 500-14, of 0.15 - - nt of
40mm 500-15, total 0.75 3-8% 9-19% Min. Or vikra
Layer 500-16) mix stabil 12-15 T m,
thicknes ity=8 pneumatic sri or
s -- .2 tyred roller JK
grading- 3-8% KN bran
I Flow d.
=2-
4mm
10mm Voids
For 25- Min.5. =3-
30mm 0% of 5%
Layer Total
thicknes Mix.
s
grading- i
II
8 BITUMI 509 5% to 13mm 19mm 100% Opti Initial with 8- 98% Fille
NOUS 7% by 13.2 79-100% mum 10T smooth of r is
CONCR wt. Of 9.5 70-88% Bitu wheeled roller design to be
ETE total 4.75 53-71% men ed used
Mix. 2.36 42-58% conte densit 43
Layer (Table 1.18 34-48% nt Intermediate y grad
Thickne 500-17, 0.60 26-38% V/s with vibratory e
ss 30-45 500-18, 0.30 18-28% Dens roller Cem
min.9 500-19) 0.15 12-20% ity ent
(Gradin 0.075 4-10% Subje Or of
g-2) ct to 12-15 T Vikr
Min. Pneumatic am
Stabi tyred roller Sri
lity= JK
9 Bran
KN. d.
Flow
=2-
4mm
Air
Voids
=3-
6%
9. PRIME 502 7.50K ---- ---- --- -
R ( Table g.10m2 Bitum
(M
COAT 500-1) en
emulsi
C/SC)
on
compl
ying
with
IS-
8887--
-
10. TACK 503 2.5 -- - - -do-
COAT Kg
(Table Per
500-2) 10m 2
(RC)
3.2.1 EARTHWORK
The selection material shall be made after conducting necessary soil surveys and laboratory
investigation as set out in IRC 36-1970. Only approved materials shall be utilized. Borrow
material for subgrade shall have designed CBR and other physical requirement.
The moisture content of each layer of soil at the time of compaction should be optimum
moisture content subject to permitted tolerance. (normally +1 percent to –2 percent).
After the moisture content has been adjusted, the soil shall be processed by means of grades,
harrows rotary mixer unless the layer is uniformly met. Clods or hard lumps shall be broken to
minimum size but in no case more than 75mm.
Compaction shall be done with vibratory roller of 80-100 KN static weight with plain or pad foot
drum or heavy pneumatic tyre roller of 15-30 tonne weight having tyre pressure of at least
7Kg./cm2
The general process of compaction consists of giving two passes without vibration followed by
three or four passes with vibration are thereafter one or two static pass to achieve requires
compaction. The maximum thickness of layer will be limited to 200mm (compacted). The speed of
the roller should be maintained at 60 metre/minute.
When the compaction is complete and surface appears perfectly in order and there are no
sign of moving /bulging/springing/yielding under roller wheel and level/line/grade is in
order, the quality shall be tested or compaction ( as per table) and moisture content.
After finally completing the process, the compaction tests shall be done.
After full compaction and when surface is found in perfect order, the surface shall be tested
for compaction and surface irregularity to be within below noted limits (MOST clause
903).
Subgrade should be compacted with due attention and care to achieve laboratory CBR
values determined on undisturbed samples cut from compacted subgrade in CBR mould
fitted with cutting shoe or on remoulded samples, compacted to the field density at the field
moisture content.
Work shall consist of laying & compacting well graded materials on prepared sub grade
in accordance with in requirements of MOST clause 401. The material shall be laid in are or more
layers as required.
The material shall be spread with the help of a motor grader with hydraulic control to
required slope, grade and line.
The sub base material shall consists of natural sand, moorum, gravel, crushed stone or
combination thereof, depending upon the grading required free from organic and
deleterious material.
Moisture content of the loose material shall be checked in accordance with IS:2720 (Part2)
and suitably adjusted. The moisture content at the time of compaction shall be within 1
percent above to 2 percent below the optimum moisture content.
Rolling may be done with the help of a smooth wheeled roller of 80 to 100 KN weight if
the thickness of compacted layer does not exceed 100mm. For a compacted single layer
upto 225mm a vibratory roller of minimum 80 to 100 KN static weight with plain drum or
pad foot drum or heavy pneumatic tyred roller of minimum 200 to 300 KN weight having a
minimum tyre pressure of 0.7 MN/m2. Rolling shall commence at the lower edge and
proceed towards the upper edge longitudinally for portions having uni-directional cross fall
and super elevation and shall commence at the edges and progress towards the centre for
portions having cross fall on both sides.
Each pass of the roller shall uniformly overlap less than one third of the track made in the
proceeding pass. The speed of the roller shall not exceed 5 Km per hour.
Rolling shall be continued till the density achieved is at least 98 percent of the maximum
dry density determined as per IS:2720 (Part8).
The surface on compaction shall be well closed, free from movement under compaction
equipment and from compaction panes ridges, cracks or loose material. All loose,
segregated or otherwise defective areas shall be made bad to the full thickness of layer and
recompacted.
The finished surface shall be checked for line, level and regularity.
Arrangement shall be made to the lateral confinement of wet mix by laying materials in
adjoining shoulders along with that of wet mix macadam layer.
Wet mix macadam shall be prepared in an approval mixing plant having provision for
controlled addition of water and forced/positive mixing arrangement like pugmill or
type mixer of concrete batching plant.
Water shall be added with due allowance for evaporation losses. The mixed material
should be uniformly wet and no segregation should be permitted.
The aggregated mix shall be spread uniformly and evenly by a paver finisher or motor
grade with hydraulic control capable of spreading the material uniformly all over the
surface. The surface shall be carefully checked with templates.
The rolling shall be done by a smooth wheel roller of 80 to 100 KN weight if the
thickness of single compacted layer does not exceed 100mm. For a compacted single
layer upto 200mm, the compaction shall be done with the help of vibratory roller of
minimum static weight of 80 to 100KN or equivalent capacity roller. The speed of the
roller shall not exceed 5 Km./ hour.
Rolling shall commence from the lower edge and progress gradually towards the upper
edge in portion having unidirectional cross fall/super elevation.
For portion with camber rolling should begin at the edge with the roller running for
ward and backward until the edges have been firmly compacted. The roller shall then
progress gradually towards the centre parallel to the centre line of the road.
Rolling should progress parallel to the centre line of the road, uniformly overlapping
each proceeding track by at least one third width.
If irregularities develop during rolling which exceed 12mm when tested with a 3m
straight edge, the surface would be loosened and premixed material added or removed
as required before rolling again.
Rolling should be continued till the density achieved is at least 98 percent of the
maximum dry density for the material.
The finished surface shall be well closed, from movement under compaction equipment
etc.
After final compaction, the road shall b allowed to dry for 24 hours. No vehicular
traffic of any kind should be allowed on the finished wet mix macadam surface till it
has dried and the wearing course laid.
The surface finish shall conform to relevant requirements of Chapter-7.
Inspection of mix, moisture, segregation will remain regular surveillance and any
suspicious, material will not be allowed to be carried to paver site. Weight of mix of
every tipper, time of mix delivery will be maintained and daily to be retained.
The work shall consists of application of single coat of low viscosity liquid bituminous material to a
porous granular surface preparatory to bituminous treatment.
The primer shall be bitumen Emulsion MC/SC grade complying with I.S. 8887 pf type and
Grade as specified or as directed by the Engineer.
The bituminous primer shall not be applied on a wet surface or during dust storm or under the
weather is foggy, rainy, windy, or unless the temperature in shade is less than 10C.
The primer distributor shall be pneumatic tyred self-propelled or towed pressure sprayer
equipped for spraying the material uniformly at specified rate and temperature.
The surface to be primed shall be swept clean, free from dust and shall be shaped to specified
line, grade and section. It shall be free from any irregularities and segregated materials.
The surface shall be allowed to cure for 24 hours following the application of primer and no
traffic shall be allowed during curing period.
Test to be carried during application of primer coat includes.
(i) Quality of Binder Two samples per lot subject to approval of Engineer.
(ii) Binder temperature At regular closer intervals.
For application.
The binder distributor shall be pneumatic tyred self-propelled or towed pressure sprayer
equipped for spraying the binder uniformly at specified rate and temperature.
The surface shall be cleaned of dust and any extraneous material before application of binder.
It shall be left to cure until all the volatiles have evaporated before any subsequent construction
is started. No plant or vehicles shall be allowed on the tack coat other than those essential for
the construction.
Test to be conducted during application of tack coat shall include.
(i) Quality of Binder Two samples per lot subject to approval of Engineer.
(ii) Binder temperature for At regular closer intervals
application.
(iii) Rate of spread of Bitumen Two tests/day
(iv)Tray Test For control of rate of spread of Bitumen.
The work shall consist of construction in a single course having 50mm to 75mm thickness of
compacted crushed aggregates premixed with bituminous binder on a previously prepared
base.
Proposal for Mix Design of BM will be submitted by Contractor one month before intended
date of start along with samples of different size of aggregates, bitumen and fillers.
Alternatives proposal with different gradations, without filler and different proportion of
bitumen will be made trial mixes till satisfactory results are established and final mix design
will be approved. Engineer shall have the right to take for fresh trial with needed modification
during the execution of work.
The bituminous macadam construction shall not normally be carried out when the atmospheric
temperature in shade is less than 100 C or when the underlying course is damp and wet.
Bituminous macadam shall be prepared in a computerised Hot Mix Plant which shall have
essential features as laid down is MORT & H specification /contract specification. All the
equipment, like Hot Mix-Plant, Paver, Rollers, tandom roller shall be checked for their work
worthiness daily.
Binder and aggregate temperature shall be consistent with proper mixing and laying of the mix.
The temperature of mix at the time of laying shall be in range of 1200 C to 1600 C.
Initial rolling shall be done with 80-100 KN static weight Smooth wheel roller followed by
intermediate rolling with vibratory roller of 80-100 KN static weight or pneumatic tyred roller
of 150-250 KN weight. Final rolling shall be done with 60-80 KN tandom roller with vibratory
system switched off. The rolling shall be continued till entire surface has been rolled to 95
percent of average laboratory density and rolling operation shall be completed in every respect
before temperature of mix falls below 1000 C.
Longitudinal joints and edges shall be constructed true to the delineatory line parallel to centre
line of road and all joints shall be cut vertical to the full thickness. Longitudinal and transverse
joints shall be offset by at least 250mm from those in the lower courses and the joint on the
top-most layer shall not be allowed to fall within the wheel path. All transverse joints shall be
cut vertically to the full thickness of the previously laid mix with asphalt cutter/ pavement
breaker and surface painted with hot bitumen before placing fresh material.
The following tests at plant site are to be conducted daily at plant site lab. and results follow the same
or next day.
(i) Binder content and One test for 400 ton of Mix
gradation test. (Minimum two tests / day / plant)
(ii) Stability of Mix One test for 400 ton mix for
Marshal stability, flow, density void.
Three specimens to form one test
(Minimum two Tests / day / Plant)
(iii) Aggregate Impact value One test per 50m3 of aggregate.
(iv) Flakiness and elongation index One test per 503 of aggregate.
Only approved material shall be used and same shall be checked before being fed in.
Temperature of mixed aggregate, bitumen and mix shall be checked at plant site from the first
load.
Sample for bitumen extraction and preparation of Marshall mould will be taken from second
tipper for adjustment of plant. If the result of extraction is much beyond limit, repeat test
should be taken immediately to affirm the accuracy.
Points to be attached to regularly in day’s work and result of checking duly recorded:
- Temperature of Bitumen in tank ( two hourly)
- Temperature of aggregate in drier ( four hourly)
- Discharge temperature of Mix ( every tipper wise)
- Discharge time and dispatch of mix ( every tipper wise)
- General appearance of mix specially with regard to coating, segregation and
appearance( every tipper wise)
- Check up slip should be given to every tipper. ( Tipper carrying mix dispatched
should not be entertained without check slip)
OTHER PRECAUTIONS
(a)(i) stability of mix and flow Minimum 840Kg For each 400 ton one test
(average of three mould three speciments
prepared out of one mix) Minimum two test per plant /day
(h) Surface level and MOST clause 901 Tests shall be done as per
surface regularity. Table 900-1 and 900-2.
The work shall consist of construction in single layer 25 to 40mm thickness of compacted
aggregates premixed with bituminous binder on a previously prepared bituminous surface.
Proposal for Mix design of semi dense bituminous concrete shall be submitted by
contractor as detailed in para 3.2.6 with grading of mixed aggregates conforming to
“Grading 1” of table 500-15 of MOST specification with minimum bitumen content of
4.5% by mass of total mix of specified grade with additional requirement of “Polished
stone value” of minimum 55” where the aggregates fail to meet the requirement of
water sensitivity in Table 500-14 then 2 percent of total weight of aggregate, of cement
shall be added without additional cost.
Other details as laid in para 3.2.6 shall be applicable. The newly laid surface shall not
be opened to traffic for at least 24 hours after laying and completion of compaction.
The work shall consist of construction in a single or multiple layer with single layer thickness
varying from 50 mm to 100mm of combined aggregates and filler premixed with bituminous binder
lain in a previously lain in a previously prepared bituminous surface.
Proposal for Mix design of dense bituminous concrete shall be submitted by the contractor as
detailed in para 3.3.6 before with grading of combined aggregate confirming to grading 2 of
table 500-10 having filler in the form of cement as approved by the Engineer with grading
conforming to requirement laid in table 500-9 and minimum bitumen cement of 4.5% by mass
of total mix of specified grade as approved by Engineer. The Mix design shall meet the below
noted requirement(Table 500-11)
Other construction details laid down in para 3.2.6 shall be applicable. The newly laid surface
shall not be opened to traffic for at least 24 hours after laying and completion of compaction.
Field and Plant site tests as laid in para 3.2.6 and 3.2.7 shall be applicable.
3.2.9 BITUMINOUS CONCRETE
The work comprises of construction in single layer of 25 to 100mm thickness of combined aggregates
with bituminous surface content as per job mix formula on previously prepared bituminous surface.
Proposal for mix design of Bituminous concrete shall be submitted by the contractor as
detailed in para 3.2.6 herein before with grading of combined aggregate confirming to grading
2 of table 500-13 having filler in the form of cement as approved by the Engineer with grading
comprising to requirements laid in table 500-9 and Bitumen content of minimum 5% by mass
of total mix of specified grade as approved by the Engineer. The mix design shall meet the
below noted requirements.
Other construction details described in para 3.2.6 shall be complied with. The newly laid
surface shall not opened to traffic for at least 24 hours after laying and completion of
compaction.
Field and plant site tests as laid in para 3.2.6 and 3.2.7 shall be carried out.
The work shall consist of laying and compaction of close graded premix surfacing material of 20mm
thickness composed of close graded aggregates with a bituminous binder on a pervious prepared
surface.
Mix proportions shall comprise of 0.27 cum of aggregates per 10 Square metre area with
grading conforming to type B of table 500-26 and 19.0 Kg. Of Straight run bitumen of
specified grade as approved by the Engineer per 10 Sqm. Of area.
Hot mix plant shall be used for preparation of mix. The Plant shall have separate drier
arrangement for heating of aggregates and mixing of aggregate and binder. The temperature of
binder at the time of mixing shall be in the range of 150 to 163 0 C and that of aggregates in the
range of 155 to 1630 C provided that the difference in temperature between the binder and
aggregate at no time exceed 140 C. Mixing shall be through to ensure a homogenous mixture in
which all aggregates are uniformly coated and discharge temperature is between 1300 C and
1600 C.
The mixed material shall be spread by a Paver and rolling shall commence with 80-100 KN
smooth when tandem roller. Rolling shall begin at the edge and progress towards center
longitudinally except that on the Super-elevated and unidirectional portion, it shall progress
from the lower to upper edge parallel to centerline of pavement. Rolling operation shall be
completed in every respect before the temperature of mix falls below 100 0 C. No traffic shall
be allowed on the road till the seal coat has been laid.
(a) Quality of Binder Two samples per lot to be subjected to all tests.
Proposal for concrete mix design shall be submitted by the contractor preferably one month in advance
before the intended date of use of concrete in order to complete sampling of coarse and fine aggregates
and cement and thereafter to proceed on checking of individual components and gradations and to
finalize mix design.
All requirements of IS 456-1978, IS 1313-1980, IS-383-1970 and IS 10262-1982 shall form basis for
mix design and proceed in the following manner.
(c)Cement Content
Cement content will be worked out from required quantity of water and water cement ratio.
4.2 MATERIALS
4.2.1 STEEL
The steel to be used as reinforcing bars shall be high strength (TMT Rebars) conforming to
grade FE-415 of I.S. 1786 of 1985. The steel to be used shall be arranged from original
manufactures of steel Billed namely SAIL/Rashtrya Ispat Nigam Limited/TISCO and supplies
shall be accompanied by Test Certificates from manufactures. The samples of steel will be sent
to any selected laboratory and tests to be conducted shall include:
a) Nominal Dia
b) Cross-sectional area
c) 0.2% proof. Stress.
d) Yield stress
e) Ultimate tensile strength.
f) Elongation test on 1800 bend test
e) Rebound test.
4.2.2 Cement
Cement to be used, shall be any of the following with prior approval of the Engineer
(with brands limited to Vikram/JK/Sri)
Each lot of supply of cement shall be accompanied with test certificate from the manufacturer and
shall be subject to following tests.
a) Fineness test
b) Consistency test.
c) Initial and final setting time.
d) Compressive Strength test.
Crushed gravel, natural gravel or a combination three of clean, hard, strong, dense, non porous
and durable shall constitute coarse aggregate. It shall confirm to IS 383 and tests will be carried
as per IS 2386 Part-VIII.
Natural sand ( clean and free of deleterious materials) shall conform to I.S. 383 and
conformity test shall be carried out as per I.S. 2386 Part I to VIII. Information shall be
submitted as per Annexure A of I.S. 383. Fineness modulus shall not be less than 2 nor greater
than 3.5 and shall confirm to either of the grading of Zone-I, Zone-II of Table 4 of I.S.383.
4.2.5 Water
It shall confirm to MOST clause 1010 expect that “in para © “ the permissible limit for
chloride (CI) shall be read as 250 mg/Itr. For structures having length more than or equal to 30
metre.
Placing of reinforcement shall be done in accordance with specification laid in MOST clause
1605. Reinforcing steel shall confirm to the dimensions, dias, spacing and shapes in the
approved bar bending schedules. Placing of reinforcement spacing, overlapping, spacer bars,
cover block, stays. Blocks. Chairs, supporting wires shall be property checked. The concreting
work shall be taken up only after approval of placing of reinforcement of Project Engineer.
Concrete shall confirm to surface finish and tolerance for respective component as:
COMPONENT TOLERANCE
a) Variation in dimension (+) 50mm
(-) 10mn
b) Misplacement from 15mm
specified position in plan
c) Surface irregularities 5mm
measured with 3 metre Straight
edge.
d) Variation at level at top +25mm
-5mm to +10 mm
a) Variation in thickness of top
and bottom slab for box Girder,
top and bottom fringe or T-
Girders or slabs
-5mm to +10mm
(b) Variation in web thickness
±5mm
© Variation in overall depth or
width Shall not exceed ± 10mm
d) Variation in overall length ±0.1% of span length
and length between bearing whichever is less
5mm
e) Permissible irregularities
when measured with 3 metre
straight edge or template.
Test samples for 7/28 days compressive strength shall be sampled and tested in following way.
a) Concrete for making test cubes shall be taken from a batch of concrete at point
of delivery as per IS 1199 ( Three test specimens shall be for each sample for
testing at 28 days. Additional cubes shall be taken to determine strength of
concrete at 7 days).
b) A random sampling procedure shall be adopted.
c) 150 mm cubes shall be made, cured and tested at the age of 7 and 28 days for
compressive strength as per I.S.516.
4.4 MAJOR ROAD BRIDGES
4.5 The following guide lines are given for quality assurance of construction of bridges:
a) For construction of H/L Bridge/ ROB’s 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.
1. MATERIALS
1.1 General
a)Material from natural Small or medium As in Q-2. Also bulk As in Q-3, but
sources scale purchases purchase form source may also set up
from large and own source for
established supply.
suppliers/traders.
Same as Q-3
May rely on local Testing/ acceptance at
experience and the start of the project
knowledge of the as well as at specified
past performance frequency.
for coarse and fine
aggregates and
water. Same as Q-3
b) Factory Manufactures test
manufactured items Manufacture’s tests certificates with sample
including cement, steel certificate accepted checks for initial
bearings, expansion with sample check acceptance only.
joints etc. by independent
agency for
incorporation in
structure. As in Q-3, but
Regular testing at may also have
specified sampling additional
frequency during independent QA
construction checks at source
(third level
check)
As in Q-3, but
Set up mutually agreed third level
QA methods at two checking by
levels for checking by
inspection/testing to checking
cover the specific appointment of
purpose order. specialized
agency for
innovative
aspects.
As in Q-3
ISO:9000 In case the
certificate not manufacturer has
essential for ISO:9000 certification,
manufactured he may be given
items. preference.
Same as Q-3
c) Records for all Record of sources As in Q-2. Also record
materials and purchase dates of issue of
for all items. manufactured materials
For and location of use.
Manufactured
items record of
manufacturers’ test
certificate.
As in Q-3, with
d) Testing facilities Testing from Physical testing property
nearby established facilities at site. For equipped testing
test chemical & Special facilities and
houses/laboratories. tests as per Q-2. Use of laboratory at site
chemical testing kits for under control of
quick checks at site are QA personnel of
to be preferred. contractor &
owner
1.2 a) Aggregate coarse (independent of
aggregates Grading production team).
As in Q-3, but if
At the beginning At the beginning for necessary with
for mix design & mix design and for increase
for every charge of every change of frequency ,
source. source/stack and for (testing at site
every major structural laboratory).
element.
As in Q-3,(two
Other physical tests For selection of At the beginning for level checks at
(crushing value source if in doubt. mix design and for site laboratory).
abrasion moisture every change of source
contents etc.)
Same as Q-3
Deleterious contents For selection of Mandatory for selection
source if in doubt of source & whether
there is change in
source of supply.
Same as Q-3
Aggregate reactivity Not Applicable Mandatory for selection
of source and whether
there
b) Fine aggregate
(sand) As in Q-3, but if
Grading At the beginning At the beginning for necessary with
for mix design & mix design and for increased
every change of every change of source. frequency,(testing
source at site laboratory)
As in Q-2,
For control of chlorides Simple but frequent As in Q-2 supported by
etc. chemical checks at checking at testing
site for laboratory at site.
effectiveness
External laboratory
checks/control (two
level control)
Same as Q-2 As in
Q-3, but at increase
1.3 Water Suitability At the beginning Same as Q-2 frequency during
Chemical analysis Carried out if in Mandatory at the working.
doubt beginning of project
and repeated ( for
chlorides and
sulphates) in between if
any change is
perceived/ suspected in
water quality (including
seasonal changes)
As in Q-3, testing
1.4 Cement Normal Manufacturers As in Q-2 and at carried out at site
physical and chemical certificate frequency of each new laboratory &
tests. acceptable & consignment & independently
testing in case of documented. Special crosschecked at
doubt or non- tests will be required predetermined
availability of for special for special frequency.
certificate. cements.
Same as Q-3
Form of purchase Trade purchases, Supply from factory
storage, transportation, intermediate with direct
and use within storage in dry and transportation from
acceptable time limit. covered place, factory to site godown /
transportation and silos. Transportation
use of factory and Transshipment
filled, machine supervised and
stitched bags. documented.
As in Q-3, with
1.5 Admixtures May be permitted Independently carried additional
a)Approval under specialist out acceptance testing independent tests.
supervision in after field trails for each
which case follow sources.
Q-3 controls.
i) Chloride
Re-trials with change in contents.
Source of Cement.
ii) Spectroscopic
Routine checking by signature of
testing for every batch accepted product
of admixture. as basis of
comparison for
production lots.
Manufacturers’ date/
certificate acceptable as
basis of comparison for
production lot.
Same as Q-2
b) Dosage dispensing Dosage to be Same as Q-2
and production controls finalized after field
at site trial mixes, special
mechanical devices
to be used for
dispensing.
Continuous
monitoring of work
ability of concrete.
Visual inspection
of concrete after
striking forms for
local defects
(including delayed
setting).
As in Q-2, but
c) Training of site staff Proper training of Same as Q-2 visits b experts at
by manufacturer. site staff in use as close frequency.
well as quality
control, plus
periodic visits by
manufacturer’s
expert.
As in Q-3, but
1.6 Reinforcing Steel Once at beginning As in Q-2, and for each further
Normal Physical tests and for every consignment supplemented by
change in source in random checking
addition to by QA team.
manufacturer’s
certificate.
Same as Q-2
Chemical Composition Once at beginning Same as Q-2
and if in doubt for
any source.
As in Q-3, but
Welding Not ordinarily Welding to be done welders to be
permissible at site. only by qualified and periodically
tested welders. tested and also
welding to be
examined by
experts after
destructive tests.
Types of electrodes to
be specified for each
purpose.
Random testing of
welded joints for
strength.
Same as Q-2
Storage Such godown will Same as Q-2
have humidity
control
In additional
vapour face
inhibitors and / or
water soluble oils
to protect steel.
As in Q-2, but
Compatibility of Suitability of Same as Q-2 compatibility
various components. anchorages for use established at site
with wires / as required by
standards (meeting QA team.
relevant
specifications) to
be certified by the
manufacturer of
anchorages. Also
compatibility of all
other materials and
equipment to be
thus certified/
cleared.
Same as Q-2
Methods of handling & Also the Same as Q-2
care taking manufacturer to
supply special
assistance at site, if
required, to train
and supervise
personnel at work.
As in Q-3, but
b) HT Wires/ stands Manufacturer’s test In addition to every coil,
Mechanical Properties ( Certificate can be manufacturer’s Sample testing
Tensile Strength, Proof accepted. certificate, tests done witnessed by
Stress). Additional Testing on random samples for independent QA
if in doubt. a lot of 50 T, or part team at specified
there of and witnessed frequency.
by independent QA
team of random.
Same as Q-2
Modules of Elasticity Insist for Same as Q-2
manufacturer’s
certificate giving
stress. Strain curve
& modules of
elasticity. Sample
testing witnessed
by independent QA
team.
Contact with
contaminated
surfaces avoided.
As in Q-3, but in
c) Anchorage System Permitted using As in Q-2, but addition QA
( Chemical anchirage or supported by plans should be
Composition & Heat established manufacturers detailed independently
Treatment, manufactures of QA plan ( which can be checked by QA
Supplementary Tests). long standing based verified by purchaser if team and verified
on certification of necessary). at manufacturer’s
suitability & facilities.
quality by
manufacturer.
d) Cable Anchorage
Assembly
(Acceptance Testing)
Manufacturers
Not normally Manufacturers certificate and
Static Tensile test & required. certificate. certificate by
load transfer test. testing at
independent
laboratory as per
FIP Guide. Tests
may be repeated
at the beginning
of the proposed
materials and
witnessed by the
representatives of
contractor\
owner.
May additionally
require testing at site or
at independent
laboratory as per FIP
Guide.
As in Q-3, plus
Not normally Manufacturers any additional
Dynamic Test for certificate of testing test than a QA
Cable/anchorage team may
assembly required
Also independent
laboratory testing as per
FIP Code, once for new
system of anchorage/
cables.
As in Q-3 with
1.8 Manufacturers As in Q-2 with higher implementation
Any other materials Certificate frequency of testing of QA plan of
(like expansion joints, supported by and manufacturer to
bearings, railing etc.) sample testing. QA plan of be audited by QA
manufacturer to be team of owner to
initially approved. the extent
depending on the
importance of the
team.
As in Q-3
1.9 Normally not to be To be accepted by Supplemented by
New Materials used. If used same competent technical independent
as Q-3 authority for use thoeity checking by QA
for use after full team of specialist
testing at laboratory/ consultants.
and field trials.
Special specification
for properties testing
and acceptance criteria
to be evolved and laid
down for use at site.
2.
2.1 WORKMANSHIP
General Controls Same as Q-2
( Direct & Indirect ) Skilled and Skilled workers having
a) working & semiskilled special training and
supervision workers. working under
experienced
supervisors. ( where
trade qualifications are
existing should be
insisted upon).
As in Q-3 but
Periodic vision Full time supervision with occasional
from owner of his from contractor as well supervision by
agent. as from owner or his expert external
agent. agency.
As in Q-3 expect
Periodic check by As in Q-2, but at in case of bridges
designer during predeter mined stages having new
site visit. and frequency. technology/
design full time
site representative
of design agency
will be necessary.
Same as Q-3.
Document inspection
and certification of
certification of
compliance by
designers
representative. As in Q-3, but
made mandatory
Not ordinarily For-Q-3 quality mock for all difficult
b) Use of Mock-ups required. ups are required only and important
for certain elements zones.
(typical slice and
difficult zones ) which
should be specified in
tender document.
Mock-ups to be carried
out in presence of
designer and QA team
of owner.
No work on structure
should be permitted
before demonstrative
mock-up.
As in Q-3.
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 bot 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. Same as Q-2
As in Q-3, also
tests to be
Relaxation Test Manufacturers’ Testing & certification witnessed by
certificate essential for 1000 hours contractors/
test by independent test owners/owners
house. QA team.
Same as Q-3.
Protection from
environment of
physical damage. Same as Q-2
Only post
Pre-fabricated and threading of
b) Preparation of sheathed cable can be wires/ strands
steel /cables. permitted. permitted (with
exceptions if
unavoidable).
As in Q-3.
As in Q-2 with
regularly and
2.5 FORMWORK Any Suitable Same as Q-2. properly
a) Materials materials meeting maintained
codal requirement s shuttering with
and capable of limited reuses.
giving specified Shuttering
form finish. capable of
absorbing Air
released from
concrete and
providing good
Insulation t
control thermal
gradients is to be
used. If steel
shutter are used,
plywood liners or
provision of
sackrubbing after
deshuttering.
Same as Q-3
Same as Q-3.
As in Q-3. Also
check for quality
e) Tolerances, geometry Frequent check by Check for all members of shutter
and leak tightness carpenters/fitters by supervisory staff. surfaces before
checks. and checking of reuse &
important members document
by supervisory clearance.
staff. Same as Q-3.
Same as Q-3.
Batching plant is
mandatory
2.6 Mixing/ Conveyance, Site mixing by As in q-2 under two Occasional
placing /Curing of mixers or batching level controls, upto checks by expert
concrete. plant near site. 200m length bridge external agency.
Occasional two tier beyond which batching
control and plant is mandatory. As in Q-3
documented.
Transportation by Use specialized
head loads trollies equipment for
or by mechanized transportation. The
vehicle permitted. adverse effects of the
methods of
conveyance(segregation
delys stiffening of mix
etc.), should be
regularly monitored
controlled and Same as Q-3.
documented.
Experienced As in Q-2, with tow
concerting gangs level controls. Also
under supervisory regular control by
staff. qualified staff. Method
of control by pour card Same as Q-3
recommended. Efficacy of
Placing concrete As in Q-2. Also regular methods to be
and compacting control by qualified regularly checked
under supervisory staff. Surveillance by and
staff. QA team. demonstrated.
iii) Workability of IS : 1199 Once test per each dumper load at boyh
fresh concrete slump Batching Plant site and paving site initially
test. when work starts subsequently sampling
may be done from alternate dumper.
Iv) Thickness From the level data of concrete pavement
determination. surface and sub-base at grid points of
5/6.25mx3.5m.
v) Thickness 3 croes per trail length.
measurement for
trail length
vi) Verification of String line or steel forms shall be checked
level of string line in for level at an interval of 5.0 m or 6.25 m.
the case of slip from The level tolerance allowed shall be +2 mm.
paving and steel These shall be got approved 1-2 hours
forms in the case of before the commencement of the concerting
fixed from paving activity.
The Quality control consultant alongwith Project Engineer of Contractor at each site shall be responsible
to ensure that materials as used at site and work as executed meets the specification as laid down in the
Contract and relevant standards. The activities for compliance shall include:
a) Setting up of laboratories at site including plant site as per requirement and equipment from reputed
manufacturer confirming to IS or relevant standards.
b) Determining frequency, location, number and type of tests to be conducted.
c) Supervision of sampling and testing carried out at site and their record including to testing carried out
at other approved laboratories.
d) Checking regularly the calibration accuracy and operation of testing equipments and plants.
e) Checking on Contractor’s proposal for all materials to be incorporated in works and for materials
specified in the contracts, including labeling and recording particulars of samples and sokly storing
them in the laboratory until they are no longer required.
f) Checking the sampling, testing and inspection of all materials comply with the norms specified in the
Contract.
g) Checking details of all trail mixes and finalization of job mix formula including necessary
modifications as a result of variation in source of materials.
h) Asking any special tests that may be required.
i) Removal of improper materials, if necessary.
The equipment as required for a typical laboratory has been detailed in chapter-I. The number of each
equipment can be varied by the Project Engineer. The frequency for various quality control tests has
been detailed in table appeared herewith for guidelines. The Quality control consultant and Project
Engineer of the contractor will carry out 100% checking as per frequency indicated therein. The
Project Engineer will carry out at least 5% of the checking. S.E.(QC), Punjab PWD will also carryout
checking to his satisfaction and shall have the right to ask for additional tests as may be deemed fit.s
The contractor shall provide necessary co-operation and assistance in obtaining the samples for tests
and carrying out the field tests as require by the Project Engineer and SE (QC) including providing
labour, attendants, assistance in packing and any other assistance.
For work of embankment, subgrade and pavement construction of subsequent layer of same or
other material over the finished layer shall be done after obtaining permission from the Project
Engineer. The contractor shall carryout notification in the procedure of work, if found
necessary as directed by the Project Engineer / SE (QC) during inspection. Works falling short
of quality shall be rectified /redone by the contractor at his own cost, and defective work shall
also be removed from site of work by the contractor at his own cost.
5.1 Earthwork
5.4 Dense Bituminous Macadam/ Semi Dense Bituminous concrete/ Bituminous concrete
Table 7-Control tests On Base Materials : Pre- Construction
Table 18
6 (A) QUALITY
ASSURANCE
FORMATS
The quality assurance formats normally used in roard construction are detailed on following
pages. Project Engineer of Contractor would have to work out their own formats as per
requirement of Project with the approval of Project Engineer and SE (QC).
Name of Work :
Material Source :
Location :
DETAILS OF TESTS
LIQUID LIMIT/TRIAL NO 1 2 3 4 5
A. No. of Blows
B. Container No.
C. Wt of Tare (gm)
D. Wet Wt of
Sample + Tare (gm)
DETAILS OF TESTS
Test No. 1 2 3 4 5
A. Container No.
B. Wt of Container
(gm)
C. Wt of container +
Wet Sample (gm)
D. Wt of Container +
Dry Sample (gm)
E. Wt if Water
(C-D) (gm)
F. Wt of Dry Sample(D-B) (gm)
Average % MC (E/F*100)
DETAILS OF TESTS
ITEM 1 2 3 4 5 Average
A. Soaked Surface Dried
Weight of Aggregate
In Water (gm)
B. Wt of Oven Dried
Aggregate (gm)
C. Weight of Water
Absorbed (A-B)(gm)
D. Percentage of
Absorption
[(C/B)*100]
Observations:
PUNJAB PWD B&R
(PIDB PROJECTS)
DETAILS OF TESTS
DETAILS OF TESTS
FINE AGGREGATES
DETAILS OF TESTS
Tested by
Frequency :
(As laid down)
COARSE AGGREGATES
DETAILS OF TESTS
Observations:
Observations:
Station of Test :
DETAILS PF TESTS
Total Wt of Aggregate:
Total Wt of Binder :
Temp of Water Bath :
DETAILS OF OBSERVATIONS
DETAILS/OBSERVATION NO 1 2 3 Average
Stripping Percentage as Observed
from the Aggregates on Visual
Inspection
Limits Value not to be
greater than
25%
Observations:
DETAILS OF TESTS
DETAILS OF TESTS
Observations:
Proctor
Limits : 95/98/100% of MDD
(After Soaking)
Percentage
Moisture Content
DETAILS OF TESTS
ITEM 1 2 3 Average
A. Weight of Mix (gm)
B. Initial Weight of Filter Paper (gm)
C. Weight pf Mix after Extraction (gm)
D. Weight of Filter Paper after Extraction with
Fine Materials (gm)
E. Weight of Fine Materials (D-B)(gm)
F. Percentage of Binder Content
=[(A)-(C+E)](gm)
G. Percentage of Binder Content
=[(F/A)*100]
Chainage : Sampled by :
Kind of Material:
Name of Work :
Locations : Date of Testing :
Job Mix Formula :
No. of Blows :
Location : Sampled by :
Slump : Date of
Testing
Sample Received
At Lab by : (As laid
Down) :
DETAILS OF TESTS
Name of :
Work
Material Date of Sampling :
Source :
Location : Sampled by :
Chainage Date of Testing :
Quality at : Tested by :
Site :
Brand of : Frequency
Bricks : (as laid down) :
Brick No 1 2 3 4 5 Average
A. Original Dry
Wt (gm)
B. Wt of Brick
After Absorption
for 24 hrs
(gm)
C. Wt of Water
Absorbed (A-b)
(gm))
D. Average %
Absorption
(C/A*100)
Brick No 1 2 3 4 5 Average
E. Bed Face Area of
Brick (sq cm)
F. Maximum Load at Failure
In (kg)
G. Compressive
Strength (F/E)(kg/Sq cm)
The contractor is required to make various arrangements and tests of materials, including job mix
formula before starting of work everyday including proceeding with next activity on the completion of first
activity. Before any work is taken up ( i.e earthwork, GSB, WMM, Prime/tack coat, bituminous layers and
cement concrete) the Project Engineer or his representative or would check lists referred hereinafter and shall
allow for starting of the activity for that day.
Material daily report and Laboratory daily report shall be submitted by Quality control Engineer.
Basically all the test whether in field or in laboratory are to be conducted by the contractor either in the presence
of Supervisory personnel or Quality Control Engineer and the test results shall to be submitted in the
appropriate formats to the Project Engineer-cum-Executive Engineer. The Quality Control Consultant shall
conduct the tests independently to confirm the test results done by the contractor.
FORM F-1
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
SL DESCRIPTION REMARKS
NO. YES NO
1. Are sufficient number of dozers, graders and rollers
available at site.
2. Are there are pipes, conduits, wires, cables below
ground.
3. Is the site clean.
4. Clearing/ grubbing done properly?
5. Is natural ground compacted?
6. Is a draining layer required & has the area been
delineated?
7. Is the draining layer in place?
8. Are toe points as per cross section?
9. Is the cut material suitable for benching?
10. Is the layer properly watered?
11. Is the compacted layer ready to field testing?
12. Is the compaction of placed layer satisfactory and
ready for next layer?
13. Have the deficiency been to the contractor for
rectifications?
General Remarks:-
Form : F-2
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
____________________________________
Quality Project Project
Control Engineer Engineer
Engineer (Contractor)
Form : F-3
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
____________________________________
Quality Project Project
Control Engineer Engineer
Engineer (Contractor)
Form : F-4
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
____________________________________
Quality Project Project
Control Engineer Engineer
Engineer (Contractor)
Form : F-5
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
____________________________________
Quality Project Project
Control Engineer Engineer
Engineer (Contractor)
Form : F-6
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
____________________________________
Quality Project Project
Control Engineer Engineer
Engineer (Contractor)
Form : F-6
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Form : F-9
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
General Remarks
Form : F-10
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
General Remarks
Form : F-11
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
General Remarks
Form : F-12
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
CHECK LIST FOR CONCRETE DELIVERY & POUR
2) POUR AT SITE
Member of structure :
Slump : MM
Discharge Started : hours
Placement completed : hours
No. of cubes taken :
0
Placement Temperature : C
0
Ambient temperature : C
Weather condition
Form : F-13
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor :
Name of Work :
Code No. :
Location _______________________
Date __________ Time ___________
RFI No. _______________________
Form : F-14
PUNJAB PWD B &R
(PIDB PROJECTS)
1. 10 10 10
2. 20 20 20
3. 30 30 30
4. 40 40 40
5. 50 50 50
6. 60 60 60
7. 70 70 70
8. 80 80 80
9. 90 90 90
10. 100 100 100
11. 110 110 110
12. 120 120 120
13. 130 130 130
14. 140 140 140
15. 150 150 150
REMARKS:
PROJECT ENGINEER: CONTRACTORS REPRESENTATIVE
Form : F-16
PUNJAB PWD B &R
(PIDB PROJECTS)
REF.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
NOTE : to obtain correct result positive (+) error to be subtracted, negative (-) error to
be added to the indicated load readings on machine gauges.
Form : F-18
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Work :
Name of Contractor :
ITEM Date Calibrated Date of Date of Result of
& person Next Inspection & Inspection
certifying Calibration Person
(for vendor of approving
contractor) (for department
Result of
Inspection
7.1 GENERAL
Given here are the producers for checking and permissible tolerances in different cases.
The checking of horizontal alignment shall be done with respect to the centre line to the road as shown
on the plans. It involves checking the geometrics of the road way as well as edges or the various pavement
layers vis-à-vis the design centre line. Horizontal alignment can be controlled properly only if the centre line of
the road has been marked in the field by means of reference pillars on both sides of the centre line located as
frequent intervals along the straight and at all changes of horizontal curvature. Manner of doing so is explained
in IRC : 36-1970. To ensure compliance with plans, edges or each pavement layer should be delineated with
respect to the centre line before placement, with the help of pegs, strings of other tools.
Surface levels of pavement courses calculated with respect to the longitudinal and cross profiles shown
on the drawing shall be checked through grid leveling / spot leveling etc. from the sub grade upwards for each
successive layer. Actual levels of the different courses shall not vary from the design levels beyond the
tolerances indicated below :
Care shall be taken that the negative tolerance for wearing course indicated above is not permitted in
conjunction with the positive tolerance for base course if the thickness of the former is reduced by more than
6mm for flexible pavements.
For checking compliance with the above requirement for subgrade, sub-base and base course,
measurements of the surface levels shall be taken on a grid of points placed at 6-25 metre longitudinally and 3.5
metre transversely. For any 10 consecutive measurements taken longitudinally or transversely not more than
one measurements shall be permitted to exceed the tolerance as above, this one measurement being not is excess
of 5mm above the permitted tolerance.
For checking the compliance with the above requirement of bituminous wearing courses,
measurements of the surface levels shall be taken on a grid of points spaced at 6.25 metre along the length and
0.5 metre from the edges and at the centre of the pavement. In any length of pavement, compliance shall be
deemed to be met for the final road surface, only if the tolerance given above is satisfied for any point on the
surface.
Even though checks on surface level of pavement courses provide an indirect control on the layer
thickness, additional measures may be necessary to establish that the thickness of constructed course is in
accordance with specifications. These measures could be in the form of thickness blocks or cross as may be
applicable. Control on the spread of material also provides an indirect check on the layer thickness. Whereas
small deviations in thickness may be unavoidable, larger deviations would unduly vitiate the pavement design.
In general, the average thickness, should not be less than the specified thickness. In addition the spot
reduction thickness should not exceed 15mm in the case of bituminous macadam and 6mm in the case of
bituminous concrete.
The criteria for surface evenness, both for longitudinal and transverse
Profile have been reviewed and the latest recommendations approved by the Indian Road Congress in
August 1976 (Published in IRC: Special Publication 16 : 1977 “Surface Evenness of Highway
Pavements”) are indicated in table 7.1. During construction, the surface evenness should be controlled
as explained in paras 7.6 and 7.7.
Table 7.1
RECOMMENDED STRANDARDS FOR SURFACE
EVENNESS FOR PAVEMENT CONSTRUCTION
1. 2. 3. 4. 5. 6. 7. 8. 9.
1. Earthen sub-grade 24 30 - - - - 15
2. Stone soling/brick soling 20 - 30 - - - 12
3. Stablised soil 15 - - 30 - - 12
4. Water bound macadam with
Over size metal(40 to 90mm size) 15 - - 30 - - 12
5. Water bound macadam with 12 - - - 30 -
Normal size metal (20 to 50mm and
40 to 63 mm size) Penetration macadam
or BUSG
Note:i. For surface dressing in all cases, the standard of surface evenness will be the same as for the
surface receiving the surface dressing.
ii. @@ These are four machines laid surfaces. If laid manually due to unavoidable reasons,
tolerance up to 50% above the values in this column may be permitted at the discretion of the
Engineer in charge. However, this relaxation does not apply to the value of maximum
undulation for longitudinal profile mentioned in column 3 of the table.
iii. Surface evenness requirements in respect of both longitudinal and cross profile should be
simultaneously satisfied.
The checking of transverse profile should commence right from the sub grade level and
continued for each successive layer up to the top. Checking is done with the help of camber
boards/ templates a few typical designs of which are shown are Fig. 1,2 and 3.
The template in fig. 1 has adjustable reference pods so that the template can be pre-set for
any desired profile Fig. 2 shown a template in which the bottom piece for checking is
replaceable to correspond to the specified profile. These designs are meant usually for
checking the profile over a single-lane width. For two lane or multi-lane roads, generally
the checking operations will required to be carried out individually for each lane.
For obtaining correct transverse profile on the finished surface of layer, it is necessary that
the spread material (before compacting/finishing) should conform to the desired profile as
far as possible. Therefore, the profile of the spread material should be continuously
regulated with templates/ camber boards (placed perpendicular to the road centre line).
Normally, set of three temples should be used in series at an interval of about 10 metres.
Checking of the finished surface subsequently should be on the same lines. Additional
checks may be made where visual appearance suggests an excessive variation.
Straight-edge measurements are slow and rather tedious. Travelling and rolling type of
straight-edge as well as other improved devices have been developed in some other
countries for facilitating the work on control of surface evenness. A device available in
India for this purpose is the Unevenness Indicator developed at the Central Road Research
Institute. This is a traveling straight-edge type of device which pre-set according to the
specification for the surface under check, performs the following functions on being run by
two workmen along the lines of measurement at a walking speed of about 5 Km per hour.
i. Instantaneously indicates the size of irregularity through a pointer moving on a
graduate dial, to enlarged scale.
ii. Sounds a buzzer at locations where the irregularity is in excess of the maximum
permissible (as pre-set)
iii. Automatically marks, through colour spray, locations where the irregularity is in excess
of the permissible maximum (as pre-set).
The unit is simple to operate and is now readily available in the market. This
should be used wherever possible.
The criteria in column 4 to 8 ….. of Table 7.1 are meant to ensure that there are not
too many irregularities of a size one lower than the permissible maximum. This
check is exercised by counting the related irregularities as they occur and then
seeing whether there is excessive occurrence over any 300 mm length. Each
depression/hump is to be counted only once. Both straight-edge and Unevenness
Indicator methods are amenable to exercising of this control.
Table 7.2
National
Highways
Expressways 20 9 2 1 40 18 4 2
Roads of Lower
Category 40 18 4 2 60 27 6
3
Rectification
Where the surface regularity of subgrade and the various pavement courses fall outside the specified
tolerances, it shall be rectified in the following manners.
(i) Subgrade : Where the surface is high, it shall be trimmed and suitably compacted. Where the same is
low, the deficiency shall be corrected by scarifying the lower layer and adding fresh material and re compacting
to the required density.
(iii) Wet mix macadam sub base/ base : Where the surface is high or low, the top 75mm sgall be scarified,
reshaped with added material and recompacted.
(iii) Bituminous construction : For bituminous construction other than wearing course, where the
surface is low, the deficiency shall be corrected by adding fresh material over a suitable tack
coat if needed and recompacting to specification. Where the surface is high the full depth of the
layer shall be removed and replaced with fresh material and compacted to specification.
For wearing course, where the surface is high or low the full depth or the layer shall be removed and replaced
with fresh material and compacted to specification. In all cases, where the removal and replacement of a
bituminous layer is involved, the area treated shall not be less than 5 metre length and not less than 3.5 metre in
width.
To
Sub: Execution of Road Project :Preparation of Detailed Proposal for Approval of Technical
Committee of PIDB.
Although Item Rate DNIT’s from the execution of road Projects are based upon physical scope of work
and engineering design as approved by the Technical Committee including specification, however quantities of
various items as included in the DNIT are tentative and are liable to undergo some variation on account of
specified site conditions. Similarly on account of recent amendments in MOST/ Specifications for Road and
Bridge works and IRC guidelines, some additional items may be involved or completion of works.
Now, therefore it has been decided that before actual execution of work detailed designs and proposal
are prepared based on detailed surrey along the complete reach for the approval of the Engineer as provided
under the agreement. There surveys shall be conducted an completed preferably during the Mobilization period
of 21 days through the Contractual agencies for finalization of scope of earth work. Drainage profile
corrections. Road geometrics, provising of M.S. Railing in built areas etc.
Guidelines appended herewith are to be followed for the finalization of quantities of various items and
additional item, if any; so that the revises scope of on the basis of site conditions as per detailed measurements
at site be got approved from Technical Committee at the earliest and preferably before actual in various reaches.
The detailed proposal duly signed by the SDE incharge, Contractor or his authorized representative and certified
by the Project Engineer be submitted for each work. Efforts are to be made to start the work at the earliest ;
therefore full cooperation is to be executed to Contractor for the finalization of the scope of work and to check
for any variations.
Sd/-
DA/Guidelines Chief Engineer (IP)
The Quantities of the E/W in the DNIT’s are tentative and are to be finalized subject to following studies and
measurements.
1. Recording of existing levels of the centre line of the road at an interval of 15m and or proposed portions
of raising at an interval of 10 meter.
2. Recording of existing of levels of the cross section corresponding to the longitudinal section at center,
edges of the metalled portions, at edges of existing berms, and NSL on both sides and existing side
slopes positions.
3. Bench mark should be a permanent feature and in no case it should be culvert top or level Road
junction. Reduced B.M. should be a transferred at suitable intervals but not beyond more than 1 Km.
Strech.
4. Earth as and where typing in mounds/heaps on berms is to be shown in cutting & is to be properly
assessed with levels/ contours.
5. The existing longitudinal and cross section along with surplus earth available on berms is to be recorded
in MB, which should be duly signed by the Contractor, SDE, incharge and be verified by the Project
Engineer.
6. The proposal levels of finished road surface including widening /4 lanning and Raising portions &
berms etc. should be super imposed on the existing levels on separate graph sheets and the Proposal is
to be got approved before actual execution.
7. E/W in embankments is to be worked out, after giving credit of surplus earth available in cutting from
berms, if any excavation on account of widening portions.
8. On the approval of the proposal, the actual levels achieved at site are again to be entered in M/B for
actual quantities payable for excavation, cutting an embankments.
9. The sources of the earth for embankments purposes are to be identified & intimated by the contractor in
writing. The soil samples are to be tested at field lab for soil analysis. i.e. sand contents , liquid limit an
plastic limits, OMC & Proctor density with heavy compaction and soaked of sources soil. The actual
earth filling is to be started only after the approval source.
Whenever the profile corrections are required on the existing roads, the proposal should be supported with
following studies.
1. Were ever the road surface is having Map creaks or alligator cracks, such areas should be preserved.
The provision of crack prevention course (Stress Absorbing Membrane to inhibit the propagation of
cracks is to be made.
2. The camber corrections of the existing road surface, as per the site are to supported with correction of
involved is more than 25 mm thick, the same be rectified by B.M… if less than 25 mm & it is to be
corrected with Mixed Seal surfacing type B.
3. In case the road surface is undulatory & needs profile corrections, before strengthening, the proposal
should be supported with existing surface levels at an interval of 5’-10” in lateral direction and at
interval of 10 ft in longitudinal direction for working out average thickness of corrective layers.
8.3 DRAINAGE
Drainage of the road surface especially in the built up areas on the roads passing through
villages and in the urban areas is to be given top importance. By all means, no portion of the
road should be left without proper drainage, the absence of which is likely to damage the road.
For this purpose the following studies are required for final assessment:
1. All the built up in areas on the road passing through the road passing through urban areas be
identified, Its existing level along with plinth levels of construction on both side be marked. The
maximum inundation of road during people season and time for natural drainage be checked up
from the local people and recorded.
2. No raising in such areas be proposed more than the existing plinth levels of construction on both
sides.
3. The section of suitable drain as per MOST standards for the drainage of the discharge of rainwater
be proposed on both sides.
4. In case of built up areas of villages along the road, the drainage of the storm water through
proposed drain is to be made on roadside ditches beyond such areas.
5. For Urban areas, the stretches are long, thus it has to be studied that the discharge of drains through
side roads is not blocked. In such wherever culverts under side roads are required be proposed. The
disposal of rainwater as per natural gradients is to be ensured side.
6. Length of drain for all such reaches be clearly marked on plan including final disposal.
7. Wherever necessary, provision of catch pits and chutes be also made for draining the storm water in
to the parallel drains etc. be also made.
1. preferably near sales tax Barriers and Octoroi posts, provision of lay byes (150ft*12ft) size of both
sides of the road at suitable interval is to be kept, in open reaches.
2. The lay byes are to be finished with kerb and channels on outer edges.
3. Draining of such Lay byes shall be made away from the road.
4. Provision of all such lay byes should be marked on the plan, and the additional quantities of various
items involved be worked separately.
The proposal for widening of existing Culverts/bridges and that for new Culverts, if any, shall include.
1. Where ever the widening of the roads is form 17ft to 22ft, existing culverts/small bridges are to
be widened up to 33ft.
2. For widening a from 22ft to 33 ft existing culverts and bridges are to be widened up to 44ft.
3. New culverts, if required and are justified to be provided for cross drainage are to be identified
and to be include in the proposal.
4. For storm water drainage of the roads, through proposed surface drains, if culvert is required
under side in the same must be identified and be included in the proposal.
5. The foundation sub structure and super structure of the existing culverts/small bridges is to be
kept same as provided in case of existing culverts. In case the original drawings of
culverts/small bridges are not traceable, the existing sizes be checked at site and are to be
adopted after verification by Project Engineer.
6. For Super Structure such culverts /small bridge Nominal Concrete Mix (1:1 1/2 :3)is to be use,
with Fe 415 TMT/TOR steel reinforcement bars.
7. Construction of any H/L bridge covered in the Road Project shall be subject to the approval of
GAD and structural drawings by the CE(IP).
8. Longitudinal plan of the road showing all such extension of existing culverts/small Bridges and
construction of H/L bridges is to be prepared and submitted with proposal.
The proposal for road signage and over head signage shall include:
1. Regulatory Mandatory signboards to be provided at suitable places as per IRC Guide lines
their location and approx. numbers.
2. Warning and cautionary Signs as per IRC Guidelines, their location and approx. numbers.
3. Guide or Informatory signs as per IRC Guidelines, their location and approx. numbers.
4. Overhead gantry signboards are only to be provided in the important towns, where the state
highways bifurcate for information and guidance of traffic.
8.7 TRAFFIC MARKINGS
1. Providing of zebra crossing near schools, which is mandatory as per the orders of Hon’ble
High Court.
2. Center line; Lay bye lines including non overtaking zones, if any.
Checks & tests on quality Controls of Materials ; pre and post construction activities, involved in
the execution of works, as per required frequency and procedure shall be carried out regularly at
site and their record shall be maintained properly. Those tests which are beyond the scope of field
lab. or for the purpose of verification/confirmations of field tests, if required, such testings shall be
got done through following labs.
Record of all tests along with the supporting documents such as work sheets, check list proformas etc.
shall be properly maintained by the Quality Control Consultant at site in the field lab.
It will be the joint responsibility of the agency, Quality Control Consultant and Project engineer
to ensure that:
Source of earth for embankment on the basis of suitability determined by grain size analysis,
OMC verses MDD, unconfined undrained compression values of C& Ǿ and their possible trial
testings in field lab.
Granular Sub base material on the basis of OMC verses MDD & CBR.
For Wet Mix macadam on the basis of OMC v/s Max Dry Density.
Optimum Binder content verses Max. Density for Bituminous Macadam.
Optimum Bitumen Content verses Density subject to desired parameters of stability flow &
voids for DBM, SDBC and Bituminous soncrete.
Mix Designs.
(B) Checking the Quality of materials as per required frequency and keeping its
record.
(E) Occasional verification of test results of cement & steel from the independent
reputed lab.
(G) Filling and keeping record of check list proformas before the start of activities.
(H) Preparing of Quality Control returns and sending to the concerned authorities.
(i) Record of consignment of Cement, Steel, Bitumen and Emulsion with manufacturer’s Test Certificates
details.
iii) Approval of Job Mix Formula of Bituminous specifications and non bituminous specifications.