Chap. XI - Quality Control

Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and
widening to four lane divided highway from Km 120+000 to Km 228+000 of NH-11 (Jaipur – Mahua
Section).
CHAPTER 11
QUALITY CONTROL & QUALITY ASSURANCE
11.0 Methodology of Construction:-
11.1 General:-
The construction work was executed, in general, in accordance with the drawings,
technical specifications and instructions issued by the Engineer. Standard cross section
used during execution of the work is given Appendix 5.2.1, 5.2.2 & 5.2.3. Methodology
followed for execution of individual items of work, technical specification requirements
and actual achievements are summarized below.
11.2 Road Diversions:-
Wherever necessary, temporary road diversions near work sites were constructed to
ensure the unhindered and safe movement of existing traffic. Suitable junctions were
provided for smooth movement of Traffic at all exit and re-entry points of diversions with
the existing road.
The execution of the project was carried out in such a way that always 2-lane is
available for safe movement of traffic. Concessionaire has submitted the diversion plan
for the concurrence of IC and based on the concurrence Concessionaire has executed
the Road Diversions.
11.3 Setting out:-
Setting out of road and structures was done in accordance with the reference points of
the existing road and structures, temporary bench marks (TBMs), road cross-sections
and longitudinal profiles as provided in the DPR. The TBMs were established at a
regular interval generally within 200m. In addition, the Contractor had fixed pegs for
controlling the line at an interval of 10-20m as required.
11.4 Construction of Road Embankment:-
Material investigations of various borrow areas along the road were carried out to
identify suitable sources of materials for embankment, sub grade and shoulder
construction. Specified mandatory tests were carried out to determine suitability of the
borrow material and only the sources meeting specification requirement were selected
and approved. Details of the approved borrow areas are given in Appendix 11.4.1
All roadwork activities for the entire pavement construction were carried out in
accordance with the approved specifications. Original ground in excavation was tested
for in-situ density for a depth of 300mm below the sub- grade level and if the same was
Completion Report Independent Consultant ICT Pvt. Ltd.

Chapter – 11 (11-1)
Section).
found less than 95% of maximum dry density (MDD) the original ground was
recomputed to achieve a density of 95% of MDD.
Materials approved for construction of the embankment / sub grade were transported to
site of work by dump trucks, spread by combination of dozers and motor grader and
finally compacted by vibratory roller at appropriate moisture content in order to obtain
required degree of compaction.
Average results of some samples of existing ground and, embankment /sub-grade

construction are given table 11.4.1 below.
Table 11.4.1: Physical Characteristics of Existing Ground and Borrow
Material (For Embankment/ Sub-grade)
Results Obtained
Test Conducted Specification Limits
(Average)
Existing Ground Not Specified
Liquid Limit (%) 23.50 Not specified
Plasticity Index l(%) 7.20 Not specified
Free Swell Index (%) Not specified
Maximum Dry Density (gm/cc) 1.91 Not specified
Optimum Moisture Content (%) 10.80 Not specified
California Bearing Ratio (%) 12.90 Not specified
Field Density of Compacted layer (%) 95.80 >95
Borrow Material (Embankment/ Sub-
grade)
Sand Content (%) 34.00 <50
Liquid Limit (%) 23.50 < 45
Plasticity Index (%) 7.20 < 25
Free Swell Index 19.96 >1.52
Maximum Dry Density (gm/cc) 2.050 >1.75
Optimum Moisture Content (%) 8.50 Not specified
California Bearing Ratio (%) 14.11 >10
Field Density of compacted layer (%) 98.76 >97
11.5 Sub Grade Construction:-
Construction of 500mm thick sub grade was required at full road width at new construction
stretches
Sub grade material from approved borrow source was transported to site. The fill material
was spread in layers compacted thoroughly to achieve a density of 97% of Modified

Chapter – 11 (11-2)
Section).
Proctor. Re-compaction of the layer was got done, if any one individual density test result
is below 97% of MDD.
11.6 Construction of Granular Sub-base:-
As per design requirements, a Granular Sub-base (GSB) layer of thickness of 250 mm in

full width of carriageway and paved shoulder (TCS-1) and in widening portion (TCS-3), the
thickness of 323 mm was to be constructed in two layers. The material meeting-grading
requirement of MORT& H table 400-2 (Grading –2) was used. This requirement was
considered while selecting material and preparing job mix design of granular sub base
(GSB).
Crushed aggregates of 40mm, 20mm and 12 mm and 6mm nominal size were mixed in a
proportion of 40%, 20%, 20%, and 20% respectively. The material was mixed in the stack
yard and then transported to construction site. Lying of GSB material was done in full
width of carriageway and paved shoulder in two layers. Rolling was done longitudinally,
commencing at the outer edges of the pavement and progressing towards the center. On
super elevated portions or sections, rolling was commenced from the lower edge
progressing towards the higher edge. Vibratory rollers were used for the compaction
operations.
Field density test using sand replacement method was carried out and the layer was
accepted and approved only when the average dry density achieved was achieved at least
98% of maximum dry density (MDD).
The test result of size distribution tests of samples of the sub base material as per design
and as obtained is included in the test reports prepared under compliance under Schedule
J of Concession Agreement.
Other parameters for the sub base material were maintained in accordance with clause
401.2.2 of MORT&H specifications.
The average field results of some of the tests conducted to determine the physical
characteristic of sub -base material is given below.
Table 11.6.1: Physical Characteristics of Granular Sub base supplied from

source 1at CH 147+00 Quarry
Specification
Tests Conducted Obtained Value
Requirements
Liquid Limit (%) 20.75 <25
Plasticity Index (%) NP <06
Maximum Dry Density (gm/cc) 2.23 --
Optimum Moisture Content (%) 7.20 --
Water Absorption (%) 1.15 <2
California Bearing Ratio (%) 86.62 > 30
10% Fine Value (KN) 105 > 50

Chapter – 11 (11-3)
Section).

source at CH 204/00 Quarry- TDM
Specification
Requirements
Plasticity Index (%) 4.04 <06
10% Fine Value (KN) 195 > 50

source at CH 204/00 Quarry- GHF
Specification
Requirements
Plasticity Index (%) 4.04 <06
10% Fine Value (KN) 195 > 50
Rolling operations were continued till the density achieved was 98% of the MDD
determined as per IS: 2720 (part 8). Any areas of segregation or otherwise defective were
made good and re-compacted.
11.7 Shoulder Construction:-
This work consisted of providing sub grade selected material for shoulders to a width of
2.0 meter on either side of the carriageway. The selected soil from borrow areas of sub-
grade material was used for shoulder construction also. Soaked CBR (4 days) at 97% of
MDD for materials passing 19.00mm sieve was 13.31%, which was more than the
required minimum of 10%. The materials were brought to site by dump trucks from borrow
areas and dumped and spread by motor graders or dozers, water sprinkled and mixed and
brought to before being compacted. Oversize material and if any more than 75mm thick
and vegetative material were got handpicked during construction process. Vibratory and
steel wheeled tandem rollers were used for compaction. The rolling operations were
continued till the compaction achieved not less than 97%.

Chapter – 11 (11-4)
Section).
To check the quality of material used for shoulders various specified tests like CBR, sieve
analysis, Atterberg limits and other tests were conducted regularly.
11.8 Wet Mix Macadam Base:-

As per design requirements, wet mix macadam (WMM) base was to be laid over the
prepared sub base, in accordance with Cl. 406 of MORT&H Specifications. The thickness
of WMM in new construction areas was 250 (laid in two layers) and in widened sections- it
was 325 mm.
11.8.1 Description:-
WMM material consisted of graded crushed aggregates of different nominal sizes blended
and mixed with water in wet mix plant, laid and rolled to a dense mass on prepared sub
base layer. The thickness of an individual layer was not less than 75mm and not more
than 150mm.
11.8.2 Physical Properties:-

The aggregate used were checked to confirm the physical requirements set forth in Table
400-10 of the MORT&H specifications. The averages of physical properties of some
samples of the WMM material are as follows:
Table 11.8.2.1: Physical Properties of Wet Mix Macadam Aggregates at Km

147/00 Plant
Results Specification
Test - Conducted
Obtained Requirements
Aggregate Impact Value (%) (Average)
21.19 30 % Max
Combined Flakiness & Elongation Index 26.91 30% Max
(%)
Maximum Dry Density (gm/cc) 2.235 ---
Optimum Moisture Content (%) 6.50 ---
Los Angles Abrasion Value(%) 21.19 40% Max
Water Absorption, Average (%) 0.515 2 Max
Plasticity Index of particles passing from
Zero 6 Max
425 micron (%)

204/00 Plant -GHF
Test - Conducted
27.78 30 % Max
(%)
Chapter – 11 (11-5)
Section).
Test - Conducted
Maximum Dry Density (gm/cc) (Average)
2.434 ---
4.48 6 Max
425 micron (%)

204/00 Plant -TDM
Test - Conducted
20.34 30 % Max
(%)
Maximum Dry Density (gm/cc) 2.312 ---
NP 6 Max
425 micron (%)
11.8.3 Gradation:-
The aggregates used in WMM confirm to the Grading requirements set forth in MORT&H
specifications. The average gradation of some samples obtained in the field is given
below.
Table 11.8.3.1: Gradation of WMM Aggregates of the Material obtained from

Plant at Km 147/00
% By weight passing the IS sieve

IS. Sieve Designation in mm
Average Value Specification Limits
53.000 100 100
45.000 98.66 95-100
22.400 66.68 60-80
11200 48.88 40-60
4.750 30.78 25-40
2.360 27.79 15-30
0.600 20.20 8-22
0.075 5.33 0-8

Chapter – 11 (11-6)
Section).
A Job Mix Design of WMM was prepared using trial and error method by blending the
materials of different nominal size aggregates in a proportion to get a well-graded mix from
course to fine. The design mix proportion of 40mm, 20mm, 12mm and 6 mm nominal size
aggregates was 30%, 17%, 25% and 15% respectively and Dust 13%.
Table 11.8.3.2: Gradation of WMM Aggregates of the Material obtained from Plant
at Km 204/00 GHF:-

53.000 100 100
45.000 98.06 95-100
22.400 72.80 60-80
11200 52.60 40-60
4.750 32.45 25-40
2.360 24.34 15-30
0.600 16.22 8-22
0.075 6.15 0-8
materials of different nominal size aggregates in a proportion to get a well-graded mix from
course to fine. The design mix proportion of All in Aggregate Type-I, All in aggregate Type-
II, 10mm and dust was 53%, 32%, 09% and 06% respectively and Dust 13%.
Table 11.8.3.3: Gradation of WMM Aggregates of the Material obtained from Plant
at Km 204/00 TDM:

53.000 100 100
45.000 98.66 95-100
22.400 66.68 60-80
11200 48.88 40-60
4.750 30.78 25-40
2.360 27.79 15-30
0.600 20.20 8-22
0.075 5.33 0-8

Chapter – 11 (11-7)
Section).
materials of different nominal size aggregates in a proportion to get a well-graded mix
from course to fine. The design mix proportion of 40mm, 20mm, 12mm and 6 mm
nominal size aggregates was 30%, 17%, 25% and 15% respectively and Dust 13%.
11.8.4 Mix Preparation:-
The wet mix macadam mix was prepared as per the Job Mix Design in the wet mix plant.
The moisture content was checked and controlled in such a way that it was well with in the
permissible limits during construction operations i.e during laying and compaction.
11.8.5 Spreading of Mix:-
Immediately after mixing in the plant the mix was brought to the construction site by dump
trucks and spread on the prepared sub base using Mechanical Paver/Motor grader to the
required line, and thickness.
For portions, where mechanical Paver could not be used, laying by Grader was done as
approved by the IC. The surface of the aggregate was then carefully checked and all high
or low spots remedied by removing or adding aggregates as required. Care was taken to
minimize segregation during laying.
11.8.6 Compaction:-
Immediately after spreading the mix, the surface was compacted to the required grade
and Cross fall / Camber uniformly with 10 MT capacity rollers (Vibromax). Speed of the
roller is restricted to 5 Km / hour.
Rolling was commenced from the outer edges and progressed towards the center in order
to get the required Camber and Cross fall.
Rolling operations were carried out till field density achieved was minimum 98% of
laboratory density (MDD). Failure portion was rectified immediately by giving additional
passes of roller or replacing the material is required.
After completion of all operations, the finished layer of WMM was protected by placing
boulders and taking other measures to prohibit traffic movement on the surface.
11.9 Prime Coat:-
This work consisted of application of a single coat of bituminous emulsion to a porous

granular surface of wet mix macadam. Specified viscosity of the emulsion at 60 o C was 140
to 500.Centistrokes.Physical properties of emulsion as per the available data of
independent test conducted is as follows:
Table 11.9.1 Physical Properties of Bituminous Emulsion

Chapter – 11 (11-8)
Section).
Sl.
Type of Test Average Result Specification Limit
No.
1 Residence of 600 micron IS Sieve (%) 0.02 0.05 max
2 Viscosity by Say bolt Furd Viscosity 140~500
NA
at 600C, (centistokes) (at 60o C)
3 Coagulation of Emulsion at Low
NA Nil
temperature
4 Storage stability after 24 hours (%) NA 1 Max
5 Particle charge NA Positive
6 Miscibility with water NA Nil
7 Test on Residue
a) Residue by evaporation 82 65 min
b) Penetration NA 60-210
c) Ductility (at 2o C/cm/min) NA 75 min
d) Solubility in tricloroethilene (%) NA 97.50 min
(Note: NA- Not available)

11.9.1 Application:-
The surface of the non-bituminous base course built with WMM (Wet Mix Macadam)
proposed to be paved was thoroughly cleaned by using brushes and compressed air.
Within 12 hours of the cleaning operation the surface was given a prime coat. Average
viscosity of emulsion when checked at site was found 271 centi-stroke.
Rate of spread was regularly checked in the field by placing iron tray on the surface and
carrying out weighing operations. The sample average value of application was 1.34
kg/m2 and was within the specification requirement of 1.2 to 1.5 kg/m2.
11.9.2 Construction Equipment:-

Emulsion sprayer was used for the application of prime coat. Care was taken to apply the
primer uniformly throughout the top surface of WMM.
At the locations where the prime coat got contaminated anywhere in any way by dust,
traffic or other means before laying a bituminous treatment or mix on the primed surface
was rectified by applying an additional coat of prime
11.9.3 Protection of Work:-
To prevent prime coat from damages due to the movement of vehicle, only ½ side of the
road was primed at a time and boulders were placed on the top of the primed surface until
bituminous layer covers it.
11.10 Tack Coat:-

Chapter – 11 (11-9)
Section).
This work consisted of the application of a single coat of bituminous binder on bituminous
surface prior to lying of 2nd Layer of Dense bituminous madam (DBM) or bituminous
concrete (BC).
11.10.1 Binder:-
Bituminous emulsion of the same grade and quality as used for prime coat was used for
tack coat also. The average rate of spray (sample average) of emulsion was 0.25 kg/M2
and was within the specification limits of 0.20 to 0.30 kg/M2.
11.10.2 Preparation of Base:-
The surface on which the tack coat was to be applied was thoroughly cleaned using
brooms, wire brushes and finally by using compressed air and made free from dust, dirt
and any extraneous material.
11.10.3 Application of Tack Coat:-

Tack coat was applied uniformly throughout DBM surface using bitumen sprayer/
distributor and was sprayed sufficient for the day work of DBM or BC.
11.10.4 Curing of Tack Coat:-

The tack coat was left to cure until all the volatiles have evaporated before any
subsequent construction was started. No plant or vehicle allowed on the tack coat other
than those essentials for the construction.
11.11 Dense Bituminous Macadam:-
Dense Bituminous macadam (DBM) was hot mixed, hot laid, plant mixture of well-graded
dried aggregates and bitumen which when compacted, formed a dense material.
This work of laying of bituminous macadam consisted of construction of a single course of
compacted crushed aggregates premixed with a bituminous binder laid immediately after
mixing, on a previously prepared base to the requirements of specifications and on
conformity with the lines, grades and cross sections as shown in the drawings.
11.11.1 Bitumen:-
Bitumen used for the purpose was of 60/70 grade as per IS: 73 and in accordance with
MORT& H specifications clause 504.2.1.
11.11.2 Stone Aggregate:-

Stone aggregates used for DBM were in accordance with clause 504.2.2 of MORT&H
specifications.

Chapter – 11 (11-10)
Section).
Table 11.11.2.1: Physical Properties of DBM Aggregates (Grading-1) at Ch.
147.000 GHF Plant.
Requirement
Sl. Observed result at
Description as per MOST
No. laboratory
table
1. Aggregate Impact Value Max 27% 20.52%
2. Flakiness & Elongation Max 30% 28.22%
3. Water Absorption (37.5 mm) Max. 2 % 0.428%
4. Water Absorption (19 mm) Max. 2% 0.580%
5. Water Absorption (13.2 mm) Max. 2% 0.653%
6. Water Absorption (5.5 mm) (Stone Dust) Max. 2% 1.094%
7. Bulk Specific Gravity 37.5 mm 2.62
8. Bulk Specific Gravity 19 mm 2.61
9. Bulk Specific Gravity 13.2 mm 2.603
10. Bulk Specific Gravity 5.5 mm (Stone Dust) 2.590
11. Apparent Specific Gravity 37.5 mm 2.65
12. Apparent Specific Gravity 19 mm 2.65
Table 11.11.2.2: Physical Properties of DBM Aggregates (Grading-2) at Ch.

147.000 SPECO Plant.
Requirement Observed
Sl.
Description as per MOST result at
No.
table laboratory
1. Water Absorption (37.5 mm – 19.0 mm) Max. 2 % 0.428 %
2. Water Absorption (19 mm – 13.2 mm) Max. 2 % 0.580 %
4. Water Absorption (5.5 mm – 0 mm) Max. 2 % 1.09 %
5. Bulk Specific Gravity (37.5 mm – 19.0 mm) 2.620
6. Bulk Specific Gravity (19 mm – 13.2 mm ) 2.610
7. Bulk specific Gravity (13.2 mm – 5.5 mm) 2.603
8. Bulk specific Gravity (5.5 mm – 0 mm) 2.590
9. Apparent Specific gravity (37.5 mm – 19 mm) 2.650
10. Apparent Specific Gravity (19 mm – 13.2 mm) 2.650
11. Apparent Specific Gravity (13.2 mm – 5.5 mm) 2.648
12. Apparent Specific Gravity (5.5 mm – 0) 2.666
13. Aggregate Impact value Max 27 % 19.62 %
14. Combined flakiness and Elongation Indices Max. 30 % 28.70 %
Table 11.11.2.3: Physical Properties of DBM Aggregates (Grading-1) at Ch. 204.000

TDM Plant.

Chapter – 11 (11-11)
Section).
Requirement
Sl. Observed result
Description as per MOST
No. at laboratory
table
1. Aggregate Impact Value Max. 30 % 18.95 %
2. Combined Flakiness and Elongation Indices Max. 30 % 22.50 %
3. Water Absorption (37.5 – 19.0 mm) Max. 2 % 1.09 %

LINNHOFF Plant-TDM
Observed
Requirement as
S. No. Description result at
per MOST table
laboratory
14. Combined flakiness and Elongation Indices Max. 30 % 21.74 %

SPECO Plant.
S. Requirement Observed
No Description as per MOST result at
. table laboratory

Chapter – 11 (11-12)
Section).
14. Combined flakiness and Elongation Indices Max. 30 % 25.73
11.11.3 Mix Design:-

For preparing the Job Mix Design of DBM aggregates of different sizes obtained from
the crusher plant were mixed at different proportions by trial and error method to get
final grading. The grading adopted in the design are given below.
Table 11.11.3.1: Gradation of DBM Aggregates (Grading-1) Adopted in Job Mix Design
at Km. 147.000 GHF Plant
1. 37.5 mm 30 %
2. 19 mm 16 %
3. 13.2 mm 17 %
4. 5.5 mm (Stone Dust) 37 %
5. Bitumen Content (60/70) 4.30 % By wt of total Mix (Minimum 4.0 % As per
(OBC) MORT&H)
6. Stability (Kgs) 31 > 20.25 KN (As per MORT&H)
7. Design Lab Density 2.348 gm/cc
8. Flow (mm) 5.2 mm (3 mm – 6 mm) as per MORT&H
9. Total air voids in the Mix 4.6 % (3% - 6%) As per MORT&H
10. Voids in Mineral Aggregates 13.72 % (Min 11.5%) As per MORT&H
(VMA)
11. Voids Filled with Bitumen 67% (65% - 75 %) As per MORT&H
(VFB)
0.5% dosages by wt of Bitumen, anti- stripping agent (DERBO-101) from M/s
Dharmsons Enterprises was added to bitumen in DBM Mix
Table 11.11.3.2: Gradation of DBM Aggregates (Grading-2) Adopted in Job Mix Design at Km.
147.000 SPECO Plant
1. 37.5 mm – 19 mm Size Aggregate 15 %
2. 19 mm – 13.2 mm Size Aggregate 20 %
3. 13.2 mm – 5.5 mm Size Aggregate 19 %
4. 5.5 mm 0 mm Size Aggregate 46 %
5. Bitumen Content (60/70) (OBC) 4.67 % By wt of total Mix (Minimum 4.5 % As
per MORT&H)

Chapter – 11 (11-13)
Section).
6. Stability 15.7 KN at 600C (> 9 KN As per MORT&H)
8. Flow (mm) 3.4 mm (2 mm – 4 mm) As per MORT&H
9. Total air voids in the Mix 3.1 % (3% - 6%) As per MORTH
10. Voids in Mineral Aggregates (VMA) 13.1 % (Min 12.7%) As per MORT&H
11. Voids Filled with Bitumen (VFB) 75 % (65% - 75 %) As per MORT&H
As per Anu Lab Test Report Anti Stripping Agent (DERBO-101) from M/s
Dharmsons Enterprises, 0.8% dosage by weight of Bitumen was added to the 60/70
penetration grade bitumen at DBM mix production stage at the HM plant.
Table 11.11.3.3: Gradation of DBM Aggregates (Grading-1) Adopted in Job Mix Design at
Km. 204.000 TDM Plant
1. 37.5 mm – 19 mm 28 %
2. 19 mm – 13.2 mm 10 %
3. 13.2 mm – 5.5 mm 25 %
4. 5.5 mm 0.00 mm 37 %
5. Bitumen Content (60/70) 4.25 % By wt of total Mix (Minimum 4.0 % As per
(OBC) MORT&H)
6. Stability (Kgs) 32.51 KN at 600C (Min 20.25 KN)
7. Design (gm/cc) 2.535 gm/cc
8. Flow (mm) 4.50 mm (3 – 6) As per MORT&H
9. Total air voids in the Mix% 4.20 % (3% - 6%) As per MORTH
10. Voids in Mineral Aggregates 12.51 % (11.5%) As per MORT&H
(VMA)%
11. Voids Filled with Bitumen 70.25 % (65 – 75) As per MORT&H
(VFB)%
0.7% dosages by wt of Bitumen, anti- stripping agent (DERBO-101) from M/S

Table 11.11.3.4: Gradation of DBM Aggregates (Grading-2) Adopted in Job Mix Design
at Km. 204.000 LINNHOFF Plant (TDM)
1. 37.5 mm – 19 mm Size 25 %
Aggregate
2. 19 mm – 13.2 mm Size 17 %
Aggregate
3. 13.2 mm – 5.5 mm Size 14 %
Aggregate
4. 5.5 mm 0 mm Size Aggregate 42% + Filler (Dust) – 2 %
5. Bitumen Content (60/70) (OBC) 4.60 % By wt of total Mix (Minimum 4.5 % As per
MORT&H)

Chapter – 11 (11-14)
Section).
6. Stability 15.5 KN at 600C (>9 KN As per MORT&H)
(VMA)
11. Voids Filled with Bitumen (VFB) 74% (65% - 75 %) As per MORT&H
As per the Anu Lab Agra and CEG test house Jaipur, 0.7% dosages by wt of
Bitumen, anti- stripping agent (DERBO-101) from M/S Dharmsons Enterprises
was added to bitumen in DBM Mix
Table 11.11.3.5: Gradation of DBM Aggregates (Grading-2) Adopted in Job Mix

Design at Km. 204.000 SPECO Plant (GHF)
1. 37.5 mm – 19 mm Size Aggregate 15 %
2. 19 mm – 13.2 mm Size Aggregate 24 %
3. 13.2 mm – 5.5 mm Size Aggregate 21 %
4. 5.5 mm 0 mm Size Aggregate 40 %
5. Bitumen Content (60/70) (OBC) 4.65 % By wt of total Mix (Minimum 4.5 % As
per MORT&H)
6. Stability 16.18 KN at 600C (> 9 KN As per MORT&H)
(VMA)
11. Voids Filled with Bitumen (VFB) 69 % (65% - 75 %) As per MORT&H
0.5% dosages by wt of Bitumen, anti- stripping agent (DERBO-101) from M/S

11.11.4Preparation of Bituminous Mix:-
Blending of clean and dry aggregates of different nominal size was done as per design
proportions. Necessary adjustment was done to get the desired result of the mixed
gradation. Aggregates were heated in the dryer of the hot mix plant to the specified
temperature, generally 150 o C to 160 o C. Temperature of bitumen when mixed with the
aggregates was maintained between 1500 C and 1650 C.
The quality aggregates and binder content was checked regularly
11.11.5Laying of Bituminous Mix:-

Chapter – 11 (11-15)
Section).
Asphalt paver of 9m wide laying capacity was used for laying of DBM. Lying of DBM was
done in Full width at a time and traffic allowed through the other half. Compaction
operations were done immediately after laying the mix, following the paver.
It was ensured that the temperature of the mix at the time of laying and compaction of
the DBM layer was well within the specified range. Compaction was completed before
the temperature was below 900 C. Entire compaction exercise was carried out
longitudinally commencing from the outer edges and progressing towards the center. At
super elevated curves rolling was commenced from the lower edge progressing towards
higher edge. Compaction was done by a smooth steel wheeled roller of 10 MT.
Compaction operations were continued till no further movement of DBM was noticed
under the roller.
Spread rate of DBM mix was regularly checked and controlled in order to achieve
required thickness after compaction. The density of the bituminous macadam was
checked by taking bituminous cores.
11.12 Bituminous Concrete (BC):-
Bituminous concrete (BC) consisted of well graded aggregates and Polymer modified
bitumen (PMB-40) with the Modifier ELAVALOY from DuPont, USA ,blended by M/s
Osnar Chemical Pvt Ltd mixed together max 1% dosages with 0.2% of
Catalyst( Phosphoric acid) in the base Bitumen 80/100 in hot mix plant, laid and
compacted to form a close graded premixed surfacing.
11.12.1 Mix Design (Grading-1) KM 147/00 Plant (TDM):-
Different trial mixes of aggregates of 19mm nominal size and 6 mm (dust) nominal size
aggregates collected from the crusher plant were carried out to obtain desired gradation
as specified in MORT&H Table-500-18(Grading-1). The final gradation adopted in the
design is given in table below.
Table 11.12.1.1: Mixing Proportion of BC Aggregates and PMB
Design
Sl.No Description
Value (%)
1 Crushed 19-13.2 mm Aggregates 45.00
2 Crushed 13.2-5.5 mm Aggregates 10.00
3 Crushed 5.5-0 mm Aggregates 43.00
4 Filler( Stone Dust) 2.00
Optimum Binder(PMB-40 with polymer Elvaloymax1%
5 dosage with 0.2% of catalyst(Poly- Phosphoric acid) in 5.00
the base bitumen 80/100 by Weight of Total Mix

Chapter – 11 (11-16)
Section).
11.12.2 Mix Design (Grading-2) KM 204/00 LINHHOFF Plant (TDM)
Different trial mixes of aggregates of 12mm and 6 mm (dust) nominal size aggregates
collected from the crusher plant were carried out to obtain desired gradation as specified
in MORT&H Table-500-18(Grading-2). The final gradation adopted in the design is given
in table below.
Table 11.12.2.1: Design Gradation of BC Aggregates.
IS Sieve Cumulative % by weight of total % Passing Adopted in the

Designation aggregates passing as per design -19.00mm-13.2mm-
(mm) MORT&H, Table, Grading -2 10%+13.2mm-5.5mm-32%
+5.5mm-0mm-56%
+Fillar(Dust)-2%
19.00 100 100
13.2 79-100 90.18
9.5 70-88 79.31
4.75 53-71 61.97
2.36 42-58 49.23
1.18 34-48 40.33
600 micron 26-38 31.77
300 micron 18-28 22.25
150 micron 12-20 14.91
75 micron 4-10 6.90
The physical properties of aggregates, bitumen and mix obtained while preparing Job
Mix Formula of BC are given in the Table below.
Table 11.12.2.2: Physical Properties of Aggregates and PMB-40 Obtained

During Preparation of JMF of BC
Obtained Specification
S. N Type of Test
Result Limits
I Aggregates
1 Aggregate Impact value (%) 17.24 24 Max
2 Specific Gravity of 19mm-13.2mm aggregates 2.709 ---
3 Specific Gravity of 13.2mm-5.5mm aggregates 2.643
4 Specific Gravity of 5.5mm-0mm aggregates 2.620
5 Water Absorption (%) Av of all above 0.766 1 Max
6 Flakiness and Elongation Index (%) 22.16 30 Max

Chapter – 11 (11-17)
Section).
7 Polished stone value 58.00 55 Min

II PMB-40 (as per Anu Lab Agra test certificate)
1 Penetration at 25 oC 47 30-50
o
2 Softening Point ( C) 61.3 60 Min
Elasto-recovery of half thread in ductilo-meter at 15 oC
3 79 50 Min
(%)
The mix proportion of different nominal size aggregates and binder content obtained
while preparing Job Mix Formula of BC are given in the Table below.
SN Description Design Value (%)

4 Filler( Stone Dust) 2.00
Optimum Binder(PMB-40 with polymer Elvaloy
max1% dosage with 0.2% of catalyst(Poly-
5 5.13
Phosphoric acid) in the base bitumen 80/100 by
Weight of Total Mix
Design Marshall Density of BC was 2.361gm/cc.
11.12.3 Mix Design (Grading-2) KM 204/00 SPECO Plant (GHF):-
Different trial mixes of aggregates of 12mm and 6 mm (dust) nominal size aggregates
collected from the crusher plant were carried out to obtain desired gradation as specified
in MORT&H Table-500-18(Grading-2). The final gradation adopted in the design is given
in table below.
Table 11.12.3.1: Design Gradation of BC Aggregates.

IS Sieve Cumulative % by weight of total % Passing Adopted in the
Designation aggregates passing as per design -19.00mm-13.2mm-15%
(mm) MORT&H, Table, Grading -2 +13.2mm-5.5mm-28%+5.5mm-
0mm-57%
19.00 100 100
13.2 79-100 90.67
9.5 70-88 81.48
4.75 53-71 63.41
2.36 42-58 48.84
1.18 34-48 38.97
600 micron 26-38 31.32
300 micron 18-28 24.34

Chapter – 11 (11-18)
Section).
150 micron 12-20 17.76

75 micron 4-10 7.87
The physical properties of aggregates, bitumen and mix obtained while preparing Job Mix Formula of
BC are given in the Table below.
Table 11.12.3.2: Physical Properties of Aggregates and PMB-40 Obtained During

Preparation of JMF of BC
Specification
S. N Type of Test Obtained Result
Limits
I Aggregates
1 Aggregate Impact value (%) 18.46 24 Max
Specific Gravity of 19mm-13.2mm
2 2.837 ---
aggregates
Specific Gravity of 13.2mm-5.5mm
3 2.611
aggregates
Specific Gravity of 5.5mm-0mm
4 2.651
aggregates
5 Water Absorption (%) Av of all above 0.846 1 Max
6 Flakiness and Elongation Index (%) 23.70 30 Max
7 Polished stone value 62.00 55 Min
PMB-40 (as per Anu Lab Agra test
II
certificate)
1 Penetration at 25 oC 45.67 30-50
o
2 Softening Point ( C) 61.5 60 Min
Elasto-recovery of half thread in
3 76 50 Min
ductilo-meter at 15 oC (%)
The mix proportion of different nominal size aggregates and binder content obtained while
preparing Job Mix Formula of BC are given in the Table below.
SN Description Design Value (%)

Optimum Binder(PMB-40 with polymer
Elvaloy max1% dosage with 0.2% of catalyst
4 5.07
(Poly- Phosphoric acid) in the base bitumen
80/100 by Weight of Total Mix
5. Filler(below 600 micron passing) As per MORT&H Clause 507.2.4 the
rock dust which was used 57% in the
BC mix contain mineral filler passing

Chapter – 11 (11-19)
Section).
600,300,75 micron complies grading
-2 of MORT&H, hence rock dust acts
as a mineral filler.
Design Marshall Density of BC was 2.387gm/cc. The Polymer modified binder (PMB-40) be
prepared with polymer Elvaloy from Dupont,USA and blended by M/s Osnar Chemicals Pvt.
Ltd.
11.12.4 Mix Preparation and Construction

Clean and dry aggregates were heated in the plant-heating chamber to specified
temperatures. The temperature of the PMB when mixed with the Aggregate was
maintained between 1500C to 1650C.
The dumped trucks transported the mix. Full care was taken to avoid any segregation
during transit and settling dust on the mix.
Asphalt Paver with sensors of laying capacity of 9m width was used for laying.
Compaction operations were done immediately after laying the mix, following the paver.
It was ensured that the temperature of mix at the time of compaction of the BC layer was
within the range of 900C - 1250C. No compaction was allowed to be carried out at
temperatures below 900C. Entire compaction exercise was carried out longitudinally,
commencing from the outer edges and progressing towards the center. At super
elevated curves, rolling was commenced from the lower edge and progressed towards
higher edge. Compaction was carried out by smooth wheeled rollers of 10 MT.
Compaction operation was continued till no movement of BC under the roller was
noticed. During the entire operation of lying, proper care was exercised to keep the
surface clean and avoid any dust settling on to the surface. Spread rate of BC mix was
regularly checked and controlled in order to achieve the compacted thickness of 40 mm
as per design
11.13 Pothole Repairs:-
Pothole filling work was carried out, periodically on un-tackled existing road stretches to
bring the road surface for traffic movement. Bituminous mix was used for potholes of
depth less than 100mm thick. Repair of deeper potholes was carried out using granular
material at bottom and bituminous mix on top as per provisions in the contract.
11.14 Profile Correction Course:-

Profile correction was carried out in overlay sections overlay sections, to bring the
overall profile cross fall of the existing road to the road geometry as per design. The
profile correction course (PCC) consisted of DBM material and was laid before laying
main layer of DBM of standard thickness as specified in the design based on the result
of BBD test as per IRC-81. In compliance to Clause 5.0 Schedule D of CA, over the PCC
as per requirement, a minimum of 50mm dense bituminous macadam and 40mm thick
bituminous concrete layer is provided as at places, where DBM was to be laid in two

Chapter – 11 (11-20)
Section).
layers, PCC layer was combined with the first layer of DBM. The PCC work was done as
per the laid down procedure for bituminous macadam.
11.15 Cross Drainage Works:-

There are total Structures are Major bridge-1No, Minor Bridges-17Nos and Total culverts
89 (Slab Culvert 35+30 =65 & Pipe Culvert 15+9 =24) along the road.
Concrete grades of M-15, M-20, M-25, M-30, M-35 and M-40 were used for construction
of culverts and bridges. The concrete mix was prepared at Batching Plant located at
GHF Quarry KM 147 and TDM quarry at Km 204. Regular test of concrete –gradation,
slump and compressive strength of concrete cubes were conducted. The average result
of some samples of the compressive strength test of concrete cubes casted during the
construction of bridges and culvert is found satisfactory
11.15.1 Repairs and Maintenance of Existing Bridges and Culverts Existing

Culverts:-
The existing Bridges and culverts have been extended as to match the new road cross
section. Minor maintenance works included clearing the vent way and water channel on
the upstream and downstream sides including clearing and grubbing and removal of
rubbish materials; rehabilitation of slab bottom and pointing/plastering of damaged
surface; reinstating cushion in pipe culverts; and repairing of protection works etc.
Major maintenance works included, in addition to the minor maintenance, reconstruction

of damaged walls head wall, wing wall, parapet wall and providing protection works- like
flooring cut off walls and side revetments etc.
11.15.2: Cement and Concrete Aggregates used for the Work:-

Ordinary Portland cement of Grade-43 of “Vikram Cement” brands was used for
concrete and masonry works. Coarse aggregate was obtained from the crusher plant
and sand was obtained from Banas River
The Concrete Mix design used during execution of the work are tabulated below
11.15.2.1: Mix Design M-15 at Quarry Ch. 147.000:-
A. DESIGN STIPULATION
1 Type Of Mix Design Mix
2 Grade of Concrete M 15
3 Characteristic cube compressive strength @ 28 15 Mpa

Days

Chapter – 11 (11-21)
Section).
4 Current Margin as per IRC:21 10 Mpa
5 Target Mean Strength = 15+10 = 25 Mpa 25 Mpa
6 Nominal Maximum Size of Aggregate 20 mm
7 Workability in terms of Slump @ placement 70 – 100 mm
8 Degree of Quality Control V. Good
B. SOURCE / TEST DATA FOR MATERIALS
1. Cement Type / Brand OPC – 43 Vikram Cement

2. Crushed Coarse Aggregates IJM Crusher Aggregates @ Km.
147
3. Natural Sand as Fine Aggregate Banas
4. Specific Gravity/Water Absorption of Materials
a. Cement 3.15
b. Natural Sand 2.611/0.710%
c. Coarse Aggregates 20 mm 2.608 / .835%
10 mm
2.577/ 1.097%
5. Gradation of Combined graded coarse aggregate as per IS 383 :
20 mm down : 10 mm down = 55% : 45%
6. Gradation of all in Aggregates as per IS 383 :
Coarse Aggregate : Fine Aggregate = 65% : 35%
7. Flakiness Index of coarse Aggregate : 14.52
8. Impact Value of Coarse Aggregate : 20.22
Note: Values As per in House testing.
Quantities Per Cubic meter of Concrete:
Free Water Content 130.00 Kgs.

Cement Content 260 Kg / Cum.
Natural Sand 701 Kg/ Cum.
20 mm down aggregate 711 Kg/ Cum.
Free Water Cement Ratio 0.50

Days

Chapter – 11 (11-22)
Section).

1. Cement Type / Brand Vikram – 43
2. Crushed Coarse Aggregates IJM Crusher Aggregates @ Km.
147

a. Cement 3.15
10 mm 2.577/ 1.097%
20 mm down : 10 mm down = 55% : 45%
Quantities Per Cubic meter of Concrete:

Chemical admixture (FOSROC SP 430 G8) 1.0% by Weight of Cement

Days

Chapter – 11 (11-23)
Section).
1. Cement Type / Brand Vikram – 43

2. Crushed Coarse Aggregates IJM Crusher @ Km. 147

a. Cement 3.15
10 mm 2.577/ 1.097%
20 mm down : 10 mm down = 55% : 45%
Quantities Per Cubic meter of Concrete:-

11.15.2.4 Mix Design M-30 at Quarry Ch. 147.000:-

Days
6 Nominal Mazimum Size of Aggregate 20 mm

Chapter – 11 (11-24)
Section).

1. Cement Type / Brand OPC–43 / Vikram Cement
a. Cement 3.15
10 mm 2.577/ 1.097%
20 mm down : 10 mm down = 55% : 45%


Days

Chapter – 11 (11-25)
Section).

a. Cement 3.15
10 mm 2.577/ 1.097%
20 mm down : 10 mm down = 55% : 45%


Days


Chapter – 11 (11-26)
Section).
a. Cement 3.15
10 mm 2.577/ 1.097%
20 mm down : 10 mm down = 55% : 45%


Days

1. Cement Type / Brand OPC-43 / Vikram Cement

Chapter – 11 (11-27)
Section).
2. Crushed Coarse Aggregates GHF Crusher aggregates.
a. Cement 3.15
c. Coarse Aggregates 40 mm 3.087 / 1.53%
20 mm 2.860/ 1.16%
10 mm 3.023/1.84%
40 mm : 20 mm down : 10 mm down = 48% : 36% : 16%

Chemical admixture (FOSROC SP 430 G 8) 1.10% by Weight of Cement

Days


Chapter – 11 (11-28)
Section).
2. Crushed Coarse Aggregates GHF
a. Cement 3.15
c. Coarse Aggregates 20 mm 2.860/ 1.16%
10 mm 3.023/1.84%
5. Gradation of Combined graded coarse aggregate as per IS 383 has been
enclosed
20 mm down : 10 mm down = 70% : 30%

Chemical admixture (FOSROC SP 430 G 8) 1.10% by Weight of Cement
11.15.2.8 Mix Design M-25 at Quarry Ch. 204.000

Days

1. Cement Type / Brand Vikram-43
2. Crushed Coarse Aggregates IJM Crusher

Chapter – 11 (11-29)
Section).
d. Cement 3.15
e. Natural Sand 2.611/0.77%
f. Coarse Aggregates 20 mm 2.860 / 1.16%
10 mm 3.023/ 1.84%
20 mm down : 10 mm down = 70% : 30%
6. Gradation of all in Aggregates as per IS 383
Quantities Per Cubic meter of Concrete :-

11.15.2.9 Mix Design M-30 at Quarry Ch. 204.000
Days


2. Crushed Coarse Aggregates GHF Crusher aggregate

Chapter – 11 (11-30)
Section).
a. Cement 3.15
10 mm 3.023/ 1.84%
20 mm down : 10 mm down = 70% : 30%
6. Gradation of all in Aggregates as per IS 383


Days

2. Crushed Coarse Aggregates GHF Crusher aggregates

Chapter – 11 (11-31)
Section).
a. Cement 3.15
10 mm 3.023/ 1.84%
20 mm down : 10 mm down = 70% : 30%

Days

2. Crushed Coarse Aggregates GHF Crusher aggregates
a. Cement 3.15

Chapter – 11 (11-32)
Section).
10 mm 3.023/ 1.84%
5. Gradation of Combined graded coarse aggregate as per IS 383:
20 mm down : 10 mm down = 70% : 30%

11.15.3 FILTER MEDIA:-
(A) 1) Base material (Back fill behind the abutment)
 Type of material : Sand

 Source : Banas River
 Location of Source : Tonk
2) Filter Material
 Type of material : Combination of 20 mm, 10mm, & Dust

 Class of filter media : Class – II as Table 300.3
 Source of material : IJM Crusher @ Km 147 LHS
Proportion of aggregate.
20 mm: 30 %
10 mm: 45 %
Dust : 25 %
(B) Acceptance as per MORTH clause No :2504: 2.2
The Filter Media must be satisfying the following factors:
1) D15 (Filter) 0.65 0.43 OK

D 85 (Base) <5 = 1.50 =
2) 4< D15 (Filter) 0.65
D 15 (Base) <20 = 0.16 = 4.06 OK

Chapter – 11 (11-33)
Section).
3) D50 (Filter) 9.0
D 50 (Base) <25 = 0.46 = 19.57 OK
FILTER MEDIA
Individual Passing Aggregate Proporation

Seiv (%) (%) Combine
MORT Mid
e 10m d
H Limit
Size 20 mm Dust 20 mm 10 mm Dust Gradatio
m Limits s
(mm) n
% 30 45 25
53 100 100 100 30.00 45.00 25.00 100.00 - -
45 100 100 100 30.00 45.00 25.00 100.00 - -
26.5 100 100 100 30.00 45.00 25.00 100.00 100 100
22.4 99.52 100 100 29.86 45.00 25.00 99.86 95-100 97.5
11.2 3.78 77.68 100 1.13 34.96 25.00 61.09 48—100 74
5.6 1.15 8.56 99.23 0.34 3.85 24.81 29.00 28-54 41
2.8 0.97 3.87 87.93 0.29 1.74 21.98 24.01 20-35 27.5
710 0.77 1.93 60.70 0.23 0.87 15.18 16.28 6-18 12
355 0.69 1.56 24.88 0.21 0.70 6.22 7.13 2-9 5.5
90 0.49 1.18 12.86 0.15 0.53 3.22 3.89 0-4 2
11.15.4 Reinforcement Steel:-
Reinforcement steel of grade Fe- 415, manufactured by Tata Iron &Steel Company and
Rastriya Ispat Nigam Limited(RINL) was used for the work. Physical properties as per
independent test conducted at National Test House at Jaipur are tabulated below.
Table 11.15.4.1: Physical Properties of Reinforcement Steel
12m
S.N Properties mm  10mm mm
m
1 Weight per meter (kg/m) 0.388 0.612 0.884 2.41
2 Yield Stress (N/ mm2) 528.6 538.5 497.7 504.9
Ultimate Tensile Strength at Break
2 622.9 636.3 617 594.8
(N/ mm2)
3 Elongation at Break (%) 20 26 20 21
0.2% Proof Stress, Ultimate Stress and Elongation at break for all sizes of steel bar were
found permissible limits.
11.15.5 RCC Hume Pipe:-

Chapter – 11 (11-34)
Section).
RCC Hume pipes used for culvert works were procured from Jain Spun Pipe, Biwani
(Haryana) The quality of pipes was verified by manufacturer’s certificate and by visual
inspection for any defects /cracks. The pipes were found conforming to the specification
requirements. The result of three edge bearing test of Hume pipes is given below.
Table 11.15.5.1: Test result of RCC Hume Pipe (Three Edge Bearing Test)
Load to be
Sl Load Applied
Pipe (size, type) / Test applied as per IS
No (KN/m)
458:2003 (kN/m)
 mm (NP4)
72.60KN/Rmt or
1 Load to develop 0.25 mm wide crack 175
174.24KN/2.4m
108.90KN/Rmt or
2 Ultimate load at break 265
261.36KN/2.4Rmt
11.16 Side drains

Earthen side drain has been constructed in most part of the road. In urban areas and at
certain locations of rural areas, covered lined side drain is constructed in urban section
on both sides in a length of 29100m and uncovered line drain is constructed in rural
sections. The drains are made of stone masonry and covered from the Top for the
purpose of footpath.
B – QUALITY ASSURANCE AND QUALITY CONTROL:-

11.17 General:-
For a successful implementation of any project, it is important to evolve and follow an
appropriate quality assurance system to ensure that the works are executed in
accordance with the specified Standards and designs. For a road construction Project,
where the material requirements range from ordinary soils for embankment to high
quality materials like asphalt concrete for pavement, putting in practice such a quality
assurance system assumes even greater importance. Not only detailed investigations
and tests are required to be conducted for selecting the most suitable materials for
construction, but also quality control tests at different stages of the work have to be
carried out with the two fold objectives, namely, that (i) all tests are carried out in
accordance with the prescribed standards and (ii) the test results conform to the laid
down specifications.
The Independent Consultant, during the entire period of services, had regularly monitor
and the conducted prescribed test and assisted the PIU and Concessionaire to follow a
proper system of quality assurance and quality control. As per TOR the duties of IC are
to supervise the work on a day-to- day basis as per the work programme of the
Concessionaire and to approve the material and workmanship of the works. During the

Chapter – 11 (11-35)
Section).
construction phase it is mandatory that IC, s Key Staff should check at least 25-30% of
Request of Inspection (RFI) and IC‘s Team leader himself should at least close 5-10% of
RFI. The details of the RFI checked during the month were submitted along with the
MPR of each month.
11.17.1 Quality Assurance System:-
The quality assurance system ensures the quality at following stages:
 Before incorporation of material in item of work

 During construction of the item of work, and
 Before acceptance of the item as part of the project
The quality assurance system controls the quality of the material, machine, operators
and supervisors of contractors. The system ensures that the materials to be used in the
work are from approved sources and are in accordance with the specifications. Similarly,
the quality of equipment is assured to be in accordance with the specifications. The
number and quality of personnel – the operators, technicians and supervisory staff of
contractors would require to be adequate, to carry out works properly and efficiently.
The process of workmanship was supervised by PIU with regard to materials, equipment
and personal. Carrying out quality control tests had been in practice a joint effort of
contractor, supervising engineer and technical staff of the TA consultants. In addition to
regular tests, separate (independent) tests were also carried out for technical audit
purpose.
Abstract of the tests and their frequency as per specification requirement, for source
approval of local materials, manufactured materials, and tests to be conducted during
construction along with specification limits is given in Appendices 11.17.1.1, 11.17.1.2 &
11.17.1.3 respectively.
Construction plants and laboratory equipment were required to be calibrated from time to
time. Suggested checklist of calibration of plant and lab equipment is depicted in
Appendix 11.17.1.4.
Job mix designs of different works (bituminous work concrete) also were required to be
prepared as the source or quality of material changed. Suggested checklist of the same
is illustrated in Appendix 11.17.1.5
Several activities were required to be executed in a proper sequence to complete a

particular work. Suggested Flow Chart of major items of work is depicted in Appendix
11.17.1.6.

Chapter – 11 (11-36)
Section).
All site activities (daily progress report), materials record and test reports, approvals
(RFI/RFA) required to be properly maintained at concessionaire office.
11.18 Quality Control:-
The quality control activities, in general, were conducted as per the specification
requirements. Obviously the delivery of quality product was the prime responsibility of
the contractor. Nevertheless, the supervising engineers had controlled the quality of
work vide witnessing tests conducted by the contractor’s engineers. The technical staff
of the audit consultants had regularly assisted supervising engineers to conduct quality
control tests. After the deployment of an additional technical staff from August 2006, an
improvement was noticed in quality control of materials and construction work as well.
Some of the tests of manufactured materials like: cement, steel bar, bitumen, etc were
conducted at outside laboratory by third party. Hume-pipe were tested in the at plant site
of the manufacturer.
Similarly, the contractor had conducted Roughness Index Test by Bump Integrator from
km 120+000 to km 229+000. Roughness Index of finished road was varying from 1600
mm/km to 2000 mm/km, which was within the maximum the permissible value of
2000mm/km.
The tests conducted, in general, were found satisfactory.
11.19 Independent Tests:-

Effort has been made to conduct the independent tests along with regular tests, so that
no rectification works would be required after construction. Any deficiencies were
instantly communicated to the Concessionaire so that instant rectifications were carried
out before the works proceeded to the consecutive item.
As in case of regular tests, the independent tests also showed that the quality of work
done, in general, was satisfactory.
11.20 Compliance of schedule J of CA:-

In compliance of the schedule J and Clause 16.1 of CA, Concessionaire has submitted
the Quality control test in two parts. The First one was after completion of 1 stMilestone
from Ch 120+00 to Km 175+00 and subsequently from Ch 175+00 to Ch 229+00 after
completion of balance stretch. Concessionaire also submitted the Bump integrator test
for MS-1 and the balance stretch at the time of completion of respective stretches. The
KM wise data placed in various files for handing over to NHAI.

Chapter – 11 (11-37)
Section).
Table 16.20.1: Details of Quality Control Test Records
Sl. Km Docket
No.
Details Km to
from Name
MS-1
1 Quality Control Test Record as per Schedule "J" 120.00 125.00 QC/1
MS-2
Quality Control Test Record SLABS AND PIPE
12 120.00 174.74 QC/12
CULVERTS MS-1 as per Schedule "J"
Quality Control Test Record
13 120.00 174.74 QC/13
MINOR BRIDGES MS-1 as per Schedule "J"
Quality Control Test Record GRADE
16 181.35 182.50 QC/16
SEPERATOR as per Schedule "J"
Quality Control Test Record Underpass as per
22 207.70 208.30 QC/22
Schedule "J"
Quality Control Test Record Underpass as per
25 219.45 220.08 QC/25
Schedule "J"

Chapter – 11 (11-38)
Section).
Quality Control Test Record SLABS AND PIPE
28 174.74 229.10 QC/28
CULVERTS MS-2 as per Schedule "J"

Chapter – 11 (11-39)

Chap. XI - Quality Control

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Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and

11.2 Road Diversions:-

11.3 Setting out:-

11.4 Construction of Road Embankment:-

Completion Report Independent Consultant ICT Pvt. Ltd.

Average results of some samples of existing ground and, embankment /sub-grade

11.5 Sub Grade Construction:-

Completion Report Independent Consultant ICT Pvt. Ltd.

11.6 Construction of Granular Sub-base:-

As per design requirements, a Granular Sub-base (GSB) layer of thickness of 250 mm in

Table 11.6.1: Physical Characteristics of Granular Sub base supplied from

Completion Report Independent Consultant ICT Pvt. Ltd.

Table 11.6.2: Physical Characteristics of Granular Sub base supplied from

Table 11.6.3: Physical Characteristics of Granular Sub base supplied from

11.7 Shoulder Construction:-

Completion Report Independent Consultant ICT Pvt. Ltd.

11.8 Wet Mix Macadam Base:-

11.8.2 Physical Properties:-

Table 11.8.2.1: Physical Properties of Wet Mix Macadam Aggregates at Km

Table 11.8.2.2: Physical Properties of Wet Mix Macadam Aggregates at Km

Table 11.8.2.3: Physical Properties of Wet Mix Macadam Aggregates at Km

Table 11.8.3.1: Gradation of WMM Aggregates of the Material obtained from

% By weight passing the IS sieve

Completion Report Independent Consultant ICT Pvt. Ltd.

% By weight passing the IS sieve

% By weight passing the IS sieve

Completion Report Independent Consultant ICT Pvt. Ltd.

11.8.4 Mix Preparation:-

11.8.5 Spreading of Mix:-

11.9 Prime Coat:-

This work consisted of application of a single coat of bituminous emulsion to a porous

Table 11.9.1 Physical Properties of Bituminous Emulsion

Completion Report Independent Consultant ICT Pvt. Ltd.

(Note: NA- Not available)

11.9.2 Construction Equipment:-

11.9.3 Protection of Work:-

Completion Report Independent Consultant ICT Pvt. Ltd.

11.10.2 Preparation of Base:-

11.10.3 Application of Tack Coat:-

11.10.4 Curing of Tack Coat:-

11.11 Dense Bituminous Macadam:-

11.11.2 Stone Aggregate:-

Completion Report Independent Consultant ICT Pvt. Ltd.

Table 11.11.2.2: Physical Properties of DBM Aggregates (Grading-2) at Ch.

Table 11.11.2.3: Physical Properties of DBM Aggregates (Grading-1) at Ch. 204.000

Completion Report Independent Consultant ICT Pvt. Ltd.

Table 11.11.2.4: Physical Properties of DBM Aggregates (Grading-2) at Ch. 204.000

Table 11.11.2.5: Physical Properties of DBM Aggregates (Grading-2) at Ch. 204.000

Completion Report Independent Consultant ICT Pvt. Ltd.

11.11.3 Mix Design:-

Completion Report Independent Consultant ICT Pvt. Ltd.

0.7% dosages by wt of Bitumen, anti- stripping agent (DERBO-101) from M/S

Completion Report Independent Consultant ICT Pvt. Ltd.

Table 11.11.3.5: Gradation of DBM Aggregates (Grading-2) Adopted in Job Mix

0.5% dosages by wt of Bitumen, anti- stripping agent (DERBO-101) from M/S

11.11.4Preparation of Bituminous Mix:-

11.11.5Laying of Bituminous Mix:-

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11.12 Bituminous Concrete (BC):-

11.12.1 Mix Design (Grading-1) KM 147/00 Plant (TDM):-

Table 11.12.1.1: Mixing Proportion of BC Aggregates and PMB

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Table 11.12.2.1: Design Gradation of BC Aggregates.