QUALITY CONTROL MANUAL

FOR

INFRASTRUCTURE PROJECTS
OF

ROADS & BRIDGES

Issued By

PIDB

PUNJAB PWD B&R

CONTENTS
CHAPTER NO.
1
2
3
4
5
6(a)
6(b)
7
8
9

SUBJECT

PAGES

Background and introduction

Setting up of Field Lab
Salient Features/ Specifications for road work
Salient Parameters for concrete works
Quality control tests and their frequency
Quality Assurance Formats (Worksheet and
Check list performs)
Check list for various activities
Control of Alignment, level and surface regularity
Guidelines of the Finalization of scope work
Recording of tests results and quality control returns

1-5
6-11
12-35
36-64
65-78
79-100
101-120
121-130
131-138
139-142

1.

BACKGROUND & INTRODUCTION

BACKGROUND & INTRODUCTION

Punjab Infrastructure Development Board (PIDB) has prepared an Integrated Infrastructure

Development Plan for various roads in Punjab. The plan envisages a capital expenditure exceeding Rs.
2000.00 crore for rehabilitating and widening of existing road network in the state. Such a massive
capital expenditure is probably being taken for the first time within the State of Punjab to improve the
condition of road network..
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 management system invokes commitment, procedures, processes and resources
essential for achieving the quality norms under broad parameters of specification and contract
provisions. It comprises of:
-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:
I
II

Suitability/Exploratory tests and

Routine test after proper joint sampling before the use of materials/ mix/ product in permanent
work.

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.
1.

Provisions for Quality Control in the Contract Agreement of Project:

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.
1.1.

Construction materials:
For major construction materials choice of brands have been given to Contractor for use
at Site, namely:

Cement:

VIKRAM; Sri or JK Brand (43 Grade Cement)

Reinforcing steel bars:

TMT/TOR steel Bars of Rashtriya Ispat Nigam;

TISCO or SAIL

Structural steel:

Sail, Rashtriya Ispat Nigam, TISCO or SAIL.

Bitumen of specified grade:

From approved Source of Govt. of India.

Emulsions of specified Grade: From approved source of Govt. of India.

Aggregates
.

1.2

Only from approved Quarries conforming to

grading for various items and meeting other
requirements laid down in MOST (MORT&H)
Specification for Road & Bridge work (up to date)

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.

1.3

Appointment of Quality Control Consultants

Quality control Consultants shall have a minimum experience of 5 years of conducting
and exercising quality control on major road and bridge works; maintains a fully
equipped and modem laboratory and must have previous experience of being consultant
on major road and bridge projects of MOST/MORT&H and State Govt.
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).
Necessary information on selection of Quality Control Consultant shall be furnished in
the following format.
1.

Name and style of the Consultant firm.

2.

Registration, if any.

3.

Approval, if any form the recognized institutions such as MOST(MORT&H), Pb.

PWD; B&R; IRC; World Bank; Asian Development Bank/CRRL.

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).

2.

7.

Details of staff: including names, their qualifications and experience as employed in

Main laboratory of consultant/laboratories established at completed projects.

8.

Details of staff proposed to be employed at Project laboratory including their names,

experience and qualification.

SETTING UP OF FIELD LAB

2.1
14/16

w
3 - 6

AGG.
TESTING
MACHINE

AGG/SOIL
GARDING
AREA

COMP.
TETING
MACHINE
TABLES &
CHAIRS

3 0
SHELF
AT
2'- 6
LEVEL

20/25

WATER
TANK

MARSHAL
D
STABILITY
3- 0
MACHINE
FOR
JOB MIX FORMULA

W
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

2.2

Field laboratory shall be manned by following Trained Staff;

Minimum Experience
1.

LAB attendants

2 Nos.

2 years

2.

LAB Assistant

1 No.

2 years

3.

Research Assistants

1 No.

5 years

4.

Engineer Incharge Lab.

1 No.

Const. Experience of 5 years

List of equipments required in laboratory is appended as Annexure 2.3

2.3
2.3.1

LIST OF EQUIPMENT TO BE PROVIDED IN SITE LABORATORY

General

S.No. Description of Equipment

No.

i)

Oven- Electrically operated, thermostatically controlled, range upto200C

(sensitivity 1C).

ii)
iii)
iv)

Platform balance(300 kg capacity)

1
Balance (20 kg capacity)- Self indicating type.
1
Electronic Balance; 0.6 kg capacity accuracy 0.1 gm; & 5 Kg. With accuracy
1 each
0.5gm;
Water bath- Electrically operated and thermostatically controlled with adjustable
shelves, sensitivity 1C.
Thermometers:

v)
vi)

vii)
viii)

ix)

Mercury-in glass thermometer ( range 0C to 250C).

Mercury-in-glass thermometer ( range 0C to 40C).
Mercury in steel thermometer with 30 cm stem ( range upto
300C
Gas Cylinder Burner.
Glasswares, spatulas, wire gauzes, steel scales, measuring
Tape, casseroles, karahis, enamelled trays of assorted sizes,
Pestle-mortar, porcelain dishes, gunny bags, plastic bags,
Chemicals, digging tools like pickaxes, shovels, etc.
Set of IS sieves with lid and pan for road works
Coarse Aggregate
450 mm diameter sieves
125,90,75,63,53,45,37,.5,31,26.5,22.4,19,16.5,13.2,
11.2,9.5,6.7,5.6, and 4.75 mm.

3
3
5
1

sets

Fine Aggregate
200 mm diameter sieves
4.75mm,2.36,2.0,1.18,710u,600u,425u,355u,300u,
180u,150u,90u and 75u.
For Cement Concrete Work
Coarse Aggregate
80mm,63mm,56mm,40mm,25mm,20mm,16mm,12.5mm,
10mm and 4.75mm,2.36mm.
x)
xi)
xii)

2 sets

2 sets

Water testing kit

First aid box
Physical Balance

2.3.2 For soils and aggregates

S. No. Description of Equipment
i)
Riffle Sample Divider. For Soils & Aggregates
ii)
Atterberg Limits (liquid and plastic limits) determination
Apparatus
iii)
Compaction Test Equipment 4.89 kg rammers ( Heavy
Compactive efforts)
iv)
Density by sand replacement method- Apparatus both Small & Big size.

No.
2
2

v)
vi)

1
1

vii)
viii)
ix)
x)
xi)
2.3.3

6
2

Speedy Moisture Meter complete with chemicals

Core cutter apparatus 10 cm dia, 10/15 cm height, complete
With doly, rammer etc.
Aggregate Impact Value Test aaaaratus
Flakiness and Elongation Test Gauges
Standard measures of 30, 15 and 3 liters capacity along with
Standard tamping rod
CBR Testing machine with accessories and CBR moulds & CBR core cutter.
As per IS2720-Part-XVI.
Field CBR test equipment as approved by CRRI

1
1
1
1
1

For bitumen and bituminous mixes

S. No.

Description of Equipment

No.

i)

Penertrometer automatic type adjustable weighing arrangements & needles as

per ISI1203-1958.
Riffle box-small size
Centrifuge type bitumen extractor, electric operated,
Complete with petrol/commercial benzene
Marshall stability test apparatus, complete with all
Accessories as per ASTM-1559-62.
Field density sand replacement apparatus with cutting tray,
Chisel, hammer and standard sand.
3 m straight edge Section 4*13/4

ii)
iii)
iv)
v)
vi)

1
1
3
3

vii)
viii)
ix)
x)
xi)
xii)
xiii)
2.3.4
S.No.
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
2.3.5
i)
ii)

Camber Templates
Core cutting machine with 10 cm dia diamond cutting edge
Vacuum pump and 3 specific gravity bottles
Ductility Test apparatus for Bitumen
Laboratory mixture for Bitumen mixes of 0.02 cum capacity
Electricity operated fitted with heating jacket.
Test trays for checking Primer/ Tack coats.
Hubbard- field stability test apparatus complete

3
1
1
1
1
5

For cement and cement concrete

Description of Equipment
Vicat Needle apparatus for testing setting times with plungers
Slump testing apparatus
Compression and Flexural strength testing machine of 200
Tonne capacity with additional dial for flexural testing
Table vibrator as per IS2514-1963
Air permeability apparatus
Vibrating hammer for vibrating dry mix as for Dry Lean
Cement concrete sub-base
Concrete mixer power driven of 1 cft capacity
Concrete mould 15*15*15 cm
Mould for testing compressive strength of cement 10*10*10 cm
Specific gravity balance & specific gravity Buckets as per IS-2386
-Part-III.
Diamond core cutting machine

No.
1
4
1
1
2
1
1
24
12 Nos.
2
1

Miscellaneous
Roughometer (automatically)
Profilograph for checking pavement unevenness

1
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.

2.4

TESTING KIT FOR SITE VISITS

1.
2.
3.
4.
5.
6.

Mason Thread
Plumb Bob
Aluminium heavy weight channel 6-0 straight edge
Vernier caliper
Spherometer
Road Market

7.
8.
9.
10.
11.
12.
13.
14.

Metallic Tape-30M.
Steel Tape-3M.
25*40 cm internal size steel frame with Angle iron straight edge on inner side.
Kassi
Hammer
Chiesels
Spatula
Trowel

3.

SALIENT FEATURES/
SPECIFICATIONS FOR ROAD
WORK

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.
No
.

1.

3.1

Parameters of specifications at a Glance

3.1

PARAMETERS OF IMPORTANT SPECIFICATIONS

Brief
Releva Bit Nom
Specifi nt
um inal
cation MOST en Size
Clause Co of
nte Agg.
nt
Ra
ng
e
GRAN 401
ULAR (Table SUB
400-1)
BASE
(Close
Grade
d)

Grading
Range
Grade

Require
ment of
job mix
formula

Grade
I
II

I.s. Sieve
Passings
75mm
100% 53mm
80100%
26.5mm 100%

OMC
Verses
Max.
Dry
Density
&
CBR

Compaction
ThickType
Ness of
Layer

Min.
Density

Re
ma
rks

of
Roller

Upto
Smooth
100mm
wheel
thick
ed
Above roller
100 (Wt 80

98% of Max. Dry

Density
GDI GDII
CBR Min Min
30
25

W
he
n
Dir
ect
ed
Str

GSB

2.

WET
MIX
MAC
ADA
M
WMM

70-100%
9.5mm 55-90%
50-80%
4.75mm 35-65%
40-65%
2.3mm 25-55%
30-50%
0.425mm 20-40%
15-25%
0.075mm 10-25%
3-10%
3-10%

406
(Trade
40010,
40011)

Sr.
No
.

Brief
Specification

Relevant BituMOST
men
Clause
Content
Range

3.

STRESS
ABSOR
BING
MEMB
RANE
Crack
preventi
on
course
(a) Hair
cracks
and
maps

522
Table
500-47

Modifi
ed
Binder
(SBS)

(Single
coat)

8-10
Kg per
10m2
area

53mm
100%
45mm 95-100%
26.5mm 22.4mm 60-80%
11.2mm 40-60%
4.75mm 25-40%
2.36mm 15-30%
600mm 8-22%
75mm 0-8%

PI
thick to to
100
225mm KN
Max.
Vibratory
roller

OMC
Verses
Max.
Dry
Density

Max Max
6
6

Upto Smoo
100mm th
wheel
ed
Roller

98% of Max Dry

Density

100 to Vibra
200mm tory
Roller

PI= Not more

Than 6

en
gth
sha
ll
be
Ve
rifi
ed
by
CB
R/
oth
er
Te
sts
in
La
bor
ato
ry

Nominal
Size of
Agg.

Grading Range
Grade Grade
IS
1
11
Sieve Passings

Requ
ireme
nt of
job
mix
form
ula

Compaction
Thick Type
Ness of
of
Layer Roller

Min.Fr Rem
ndity
arks

0.10m3
of
5.6mm
chips

N.A N.A

N.A

N.A

N.A

N.A

N.A

4.

cracks
upto
3mm
width
(b) Map
crack ir
alligator
cracks
3mm to
6mm.
All
types of
cracks
above
6mm
width
BITUMI
NOUS
MACA
DAM
B.M
(5075MM
Thick
layer)

5.

MIXED
SEAL
SURFA
CING
(TYPEB)
For
removal
of
undulati
ons &
Profile
Correcte
d of
Blackto
p
surface.

N.A
1012kg
per
10m2
area

0.11m3
of
5.6mm
chips

Single
coat as
inter
layer

1012kg
per
10m2
area

0.10m3
of
11.2mm
chips

N.A N.A

504

3.3%
to
3.5%
by
weight
of
total
mix.

19mm
crushed
aggregat
e

26.5mm

100%

19
13.2
4.75
2.36
0.3
0.075

90-100%
56-88%
16-36%
4-19%
2-10%
0-8%

(Single
coat)

Table
500-3,
500-4

512
(Table
500-26)

N.A N.A

N.A

N.A

N.A

N.A

N.A

19K
Quantity
g/10m2 Of
aggregat
e
0.27
cum
per 10m2

N.A

13.2mm
100%
11.2
88-100%
5.6
31-52%
2.8
5-25%
0.090
0-5%
mm

N.A

N.A

N.A

Opti
mum
Bind
er
Cont
ent
Vers
es
Max.
Dens
ity

Initial rolling
With 80 to 100
KN smooth
Wheeled roller.

95%
of
Max
Densit
y as
per job
mix
formul
a

Not
requi
red,
ratio
of
C.A
&F.
A are
to be
fixed
for
achie
ving
desir
ed
gradi
ng

Intermediate
Rolling with
Vibrating
Roller
Or
R-15T
Pneumatic
Roller
80-100kn
smooth
wheeled roller

Minim
um
2gm/C
ase
Comp
uters
( It
will
cover
min
24.44
m2
Area)

Note
:For
undu
latio
ns
upto
25m
m
M.S
S is
to be
Ado
pted.
For
Corr
ectio
n of
more
than
25m
m

6.

7.

DENSE
BITUMI
NOUS
MACA
DAM
DBM
(5075mm
thick
layer)

507
(table
500-8,
500-9,
500-10,
500-10,
500-11,
500-12)

SEMI
DENSE
BITUMI
NOUS
CONCR
ETE
SDBC
508
(table
For 35500-14,
40mm
500-15,
Layer
500-16)
thicknes
s
gradingI

Min.
4.5%
by
wt. Of
total
Mix

Min
4.5%
of
total
mix

25mm

13mm

10mm
For 2530mm
Layer
thicknes

Min.5.
0% of
Total
Mix.

37.5mm 100%
26.5
90-100%
19
71-95%
13.2
56-80%
9.5
--4.75
38-54%
2.36
28-42%
1.18
---0.60
----0.30 7-21%
0.15
--0.075 2-8%

Opti
mum
Bitu
men
conte
nts
V/s
Dens
ity
subje
ct to
Min
stabil
ity=9
KN
Flow
=24mm
Void
s=36%
Opti
mum
Bitu
men
conte
nt v/s
Dens
ity

19mm 100 100%

13.2 90-100% 90
9.5 70-90% 4.75 35-51%100%
2.36 24-39% 351.18 15-30% 51%
0.6 - 24-39%
0.3 9-19% 15-30%
0.15 0.75 3-8% 9-19% Min.
stabil
ity=8
.2
-KN
3-8%
Flow
=24mm
Void
s=35%

Intially with 810 T smooth

wheeled roller

98%of
design
ed
densit
y

Intermediate
Rolling with
Vibratory roller
Or
12-15 T
pneumatic
tyred roller.

Initial with 810 T smooth

wheeled roller
Intermediate
With vibratory
Roller
Or
12-15 T
pneumatic
tyred roller

98%
of
Design
ed
Densit
y

Thic
knes
s,
BM
is to
be
follo
wed.
Fille
r is
to be
used
43
grad
e
ceme
nt of
Vikr
am,
Sri
or
JK
bran
d.

Fille
r is
to be
used
43
grad
e
ceme
nt of
vikra
m,
sri or
JK
bran
d.

s
gradingII
BITUMI 509
NOUS
CONCR
ETE
Layer
Thickne
ss 30-45
min.9
(Gradin
g-2)

i
5% to
7% by
wt. Of
total
Mix.

13mm

(Table
500-17,
500-18,
500-19)

19mm 100%
13.2 79-100%
9.5 70-88%
4.75 53-71%
2.36 42-58%
1.18
34-48%
0.60 26-38%
0.30 18-28%
0.15
12-20%
0.075 4-10%

Opti
mum
Bitu
men
conte
nt
V/s
Dens
ity
Subje
ct to
Min.
Stabi
lity=
9
KN.

Initial with 810T smooth

wheeled roller
Intermediate
with vibratory
roller

98%
of
design
ed
densit
y

Or
12-15 T
Pneumatic
tyred roller

Fille
r is
to be
used
43
grad
e
Cem
ent
of
Vikr
am
Sri
JK
Bran
d.

Flow
=24mm
Air
Void
s=36%
9.

PRIME
R
COAT

502
( Table
500-1)

7.50K ---g.10m2

----

---

(M

C/SC)

10.

TACK
COAT

503
(Table
500-2)

CONCR
ETE
For
culverts
& Small
bridge.

2.5
Kg
Per
10m 2
(RC)

--

--20mm
Pb.
PWD
Specific
ation

40 100
20 59-67%
-10 56-44%
4.75 32-40%
2.36 25-31%
1.18 17-24%
600u 12-17%

Nomi --------------nal
Mix
1:11/
2 is
to be
used

Bitum
en
emulsi
on
compl
ying
with
IS8887--do-

Four
consec
utive
sample
s Av.
Streng
th

Grad
ing
curv
e of
aggr
egate
shou

300u
150u

M-20
concrete

DESIG
N MIX
CONCR
ETE
M25,M30,
M35 &
M40
Concret
es

Mixes
are to be
designed
for
required
slump &
to be got
approve
d on the
basis of
Trial
Mixes
strength
of 7/28
Days.
Plasticiz
ers, if
required,

7-11%
0-2%

should
be
20Mpa
+2Mp
a
where
as
Indivi
dual
Sampl
es of 3
Mould
s AV.
Streng
th
May
be
20
Mpa
+MPa

ld
fall
betw
een
stand
ard
gradi
ng
curv
e II
&
III.
The
desig
ned
curv
e
shou
ld
not
cut
or
Inter
ming
le
with
stand
ard
curv
es.

are to be
used of
make:
FOSRO
C/
ASIAN /
LABS.
3.2

3.2.1

BRIEF GIDELINES FOR CONSTRUCTION

EARTHWORK
(MOST SPECIFICATION CLAUSE 305)

The material to be used in embankments, subgrades, earthen shoulders and miscellaneous

backfills shall be soil, moorum, gravel, a mixture of these free from logs, stumps, roots,
rubbish, and any other ingredient likely to deteriorate or affect the stability of
embankment/subgrade.

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.

To obtain asequate compaction, the embankment shall be constructed in uniform layers.

Successive layers of embankment shall not be placed until the layer under construction has
been thoroughly compacted to satisfy the specified 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.
Type of work

Relative compaction as percentage of

Maximum. Laboratory dry density as per

I.S. 2720 (part 8)
Not less than 97.

(1) Subgrade and earthen

Shoulders
(2) Embankment

Not less than 95.

In case of failure under compaction, the bed will be considered for

(i)
(ii)
(iii)

Further rolling with slight water sprinkling.

Furrowing/ harrowing the top layer and rolling with sprinkling of water.
Removing the soil in soft area and replacing with approved quality and
recomposing the same.

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).

(a)

Compaction Control

Density test by Sand Replacement

(I.S. 2720 ( part 28).

(b)

Moisture Content.

As per I.S. 2720 ( Part-2)

(c)

Tolerance in surface layer

(+) 20mm and (-)25mm

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.

3.2.2

GRANULAR SUB BASE

(MOST SPECIFICATION CLAUSE 401)

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.

The mixing shall be done mechanically.

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.

(i)

Compaction

(ii)

Moisture content

(iii)

Tolerance in surface (+)10mm

level
(-)20mm

3.2.3

Specified compaction will

be 98% of maxm. Dry density
determined in lab as per
IS:2720 (Part 8)
As per I.S: 2720(Part2)

One test per 500m2 as

per IS: 2720 (Part28)
density tests.
One test per 200m2
MOST Table 900-1
(Clause 900-3)

WET MIX MACADAM

(MOST SPECIFICATION CLAUSE 406)

The work shall consist of laying and compacting clean, crushed, graded aggregate and
granular, premixed with water, to a dense mass on a prepared sub granular base in one or more
layers to necessary lines, grades and sections. The thickness of single compacted layer shall not
be less than 75mm. The thickness to be laid with compacting equipment shall be got approved
from the Engineer.

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 following tests shall be made for acceptance:

(i) Compaction

Specified compaction will be

One test per 500m2

(ii) Aggregate impact

value
(iii)

98% mexm. Dry density

determined in lab as per
I.S 2720 (Part 8)
Maximum 30% IS:2386
(Part 4)

Grading

As specified

iv) Flakiness and

elongation test

Maximum 30%
IS: 2386 (Part1)

v) Atterberg limit
vi) Tolerance

P.I >6
(+) 10mm (-) 10mm

3.2.4

as per IS:2720(Part28)
consisting of 10 density
tests.
One test per 200m3
of aggregate
One test per 1003 of
aggregate
One test per 1003 of
aggregate.
-doAs per Table 900-1 clause
900.3

PRIME COAT OVER WMM

(MOST SPECIFICATIONS CLAUSE 502)

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

(ii) Binder temperature
For application.

Two samples per lot subject to approval of Engineer.

At regular closer intervals.

(iii)
Rate of spread of binder
(iv)Tray Test

Two tests/day.
For control of rate of spread of Bitumen with
metal tray of 20cm*20cm.

3.2.5

TACK COAT

(MOST SPECIFICATION CLAUSE 503)

It shall consist of application of a single coat of less viscosity liquid bituminous material to an existing
bituminous road surface to preparatory to superimposition of a bituminous mix.
The binder shall be Bitumen Emulsion (RC grade) complying I.S. 8887 of type and grade as
Specified or directed by Engineer. The rate of application shall be as per contract and normal
range of spraying temperature for Bitumen Emulsion shall be 20c to 700 C.

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

(ii) Binder temperature for
application.
(iii)
Rate of spread of Bitumen
(iv)Tray Test

3.2.6

Two samples per lot subject to approval of Engineer.

At regular closer intervals
Two tests/day
For control of rate of spread of Bitumen.

BITUMINOUS MACADAM
(MOST SPECIFICATION CLAUSE 504)

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.

TESTS AT PLANT SITE

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

gradation test.

One test for 400 ton of Mix

(Minimum two tests / day / plant)

(ii)

Stability of Mix

(iii)

Aggregate Impact value

One test for 400 ton mix for

Marshal stability, flow, density void.
Three specimens to form one test
(Minimum two Tests / day / Plant)
One test per 50m3 of aggregate.

(iv)

Flakiness and elongation index

One test per 503 of aggregate.

(v)

Strippling value of aggregate

Initially one set of 3 specimens

for each source.

DAILY ROUTINE TESTS

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 days 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

Mix temperature exceeding 1700 C will rejected at Plant site.

Mix temperature coming down 300 C at plant site be looked into for immediate correction.
Mix having bitumen content more or less than 0.3% from job mix percentage will be reviewed

FIELD QUALITY CONTROL TESTS

(a)(i) stability of mix and flow
Minimum 840Kg
(average of three mould
prepared out of one mix)

For each 400 ton one test

three speciments
Minimum two test per plant /day

(ii) Flow
(b) Binder content
and gradation

2 to 4mm
As per mix design
per cent.

-doOne test for each 400 ton

Subject to minimum of two tests/
plant/ day.

Mix grading

As per mix design

One set of tests on individual

and mixed aggregate from drier
for each 400 ton subject to minimum two t
-est per plant/ day.
One test per 503 of aggregate.

(d) Aggregate Impact Value

(e) Flakiness Index and
Elongation of aggregate.

>30
(I.S.2386 (Part-4)
>30
(I.S.2386 (Part-I)

---do--

(f) Stripping value

Maximum retained
coating 95%

Initially one set of 3 specimen

from each source subsequently
when warranted.

(g) Density of compacted

layer

98% of Lab
density

(i)One test per 250m2

(ii)10% of density test shall be
done on edges.

(h) Surface level and

surface regularity.

MOST clause 901

Tests shall be done as per

Table 900-1 and 900-2.

3.2.6

SEMI DENSE BITUMENOUS CONCRETE

(MOST SPECIFICATION CLAUSE 508)
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.

Quality control tests shall include:

(a)
(b)

Stone Polishing Value

Rate of spread of mixed material

As required.
Regular checks on the weight of mixed
material and layer thickness.

(d)

Density of compacted layer

Water sensitivity of mix

One test for 250m2 area.

3.2.7

DENSE BITUMINOUS MACADAM

(MOST SPECIFICATION CLAUSE 507)

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)

Requirement for Dense Graded Bituminous Macadam.

Minimum Stability at 600 C
Minimum flow
Maximum flow
Compaction level ( No. of blows)

9.0Kn
2.0mm
4.0mm
75 blows on each of the two
Faces of the specimen.

Percent air voids

Percent voids in mineral aggregates
Percent voids filled with Bitumen

3-6
10 to 12
65-75

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
(MOST SPECIFICATION CLAUSE 509)

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.

Minimum Stability at (600 C)

Flow
Compaction level ( No. of blows)

9.0KN
2 to 4 mn
75 blows on each of the two
Faces of the specimen.

Percent voids in mineral aggregates

Percent voids filled with Bitumen
Loss of stability on immersion in water
At 600 C

10 to 12
65-75
Min.75% retained strength

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.

3.2.10

MIX SEAL SURFACING TYPE B

(MOST SPECIFICATION CLAUSE 512)

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 130 0 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.
QUALITY CONTROL TESTS

(a) Quality of Binder

Two samples per lot to be subjected to all tests.

(b) Aggregate impact value

One test for 50m3 of aggregates

Flakiness index and elongation

index of aggregates
(d) Stripping value

(e) Water absorption of aggregates

(f) Grading of aggregates

-doInitially one set of 3 representative

specimen of each source of supply.
--doOne test for 25m3 aggregates

(g) Stone polishing value

(h) Temperature of binder at
application

As required
All regulars close intervals

(i) Binder content

Two tests per day

(j) Rate of spread of mixed

material

Regular control through checks as material

and layer thickness.

4.

SALIENT PARAMETERS FOR

CONCRETE WORKS

SALIENT PARAMETERS FOR CONCRETE WORKS

4.1

MIX DESIGN

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.
a)

Code of practices to be followed:

b)

d)

Gradation of different component of course aggregate as 20 and 10mm should be determined

to find out a mixing ration to give gradation as stipulated in table 2 of IS 383-1970.
Grading zone of fine aggregate should be determined and fine aggregate as per IS 383-1970.
Specify gravity of Coarse aggregate and fine aggregate as per I.S. 2386 has to determined.
Water absorption of Coarse aggregate and fine aggregate to be determined as per I.S. 2386.
free moisture of Coarse and fine aggregate has also to be found out.
Selection of water content Ratio
Free water-cement ratio for desired mix grade shall be determined from Figure I in I.S.102621982. The same shall be adjusted for compacting factor and sand zone as per Table 6. The
water content shall be determined accordingly.

(c)Cement Content

Cement content will be worked out from required quantity of water and water cement ratio.

Fine aggregate & Coarse aggregate contents

Finally Coarse and fine aggregate content is found out applying equations from 3.5.1 of I.S.
10262-1982. Due allowance for water absorption by Coarse aggregate and free moisture in
sand shall be considered. Trial mixes shall be prepared on the basis of above mix and
compressive strength of 150mm cube is determined at 7 days and 28 days cube strength. On
observing the quality of mix, workability(to meet required slump) and cube strength, mix
design will be finally condidered.

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)
c)
d)
e)
f)
e)
4.2.2

Cross-sectional area
0.2% proof. Stress.
Yield stress
Ultimate tensile strength.
Elongation test on 1800 bend test
Rebound test.

Cement
Cement to be used, shall be any of the following with prior approval of the Engineer
(with brands limited to Vikram/JK/Sri)

OPC 33 grade confirming IS 269.

OPC 43 grade confirming to IS 8112.
OPC 53 grade confirming to IS 12269

Each lot of supply of cement shall be accompanied with test certificate from the manufacturer and
shall be subject to following tests.
a)
b)
c)
d)
4.2.3

4.2.4

4.2.5

Fineness test
Consistency test.
Initial and final setting time.
Compressive Strength test.

Coarse aggregate
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.
Fine aggregates
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.
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.

4.2.6

Form work
All form works for concrete shall be properly designed and planned as per IRC:87 Guide lines
for Designs and Erection of false work for Road Bridges. The contractor shall furnish the

detailed information and design of form work for approval with necessary calculations. Design
shall confirm to IRC:67, In case of Prestressed concrete Superstructure, careful consideration
shall be given to loads on props due to prestressing.
Form work shall be strong and joints shall be leak-proof. Staging shall consist of pipe work of
steel with non-tempering joints having adequate cross bracings and diagonal bracings in both
directions. Staging shall be provided with appropriately designed base plate resting on firm
strata. There shall be no play between any of the members of the staging and it shall be
securely fixed.
For distribution of load transfer to the ground through staging, an appropriately designed base
plate shall be provided which shall rest on firm sub stratum.
On completion of form work, contractor shall inform for inspection and approval of Project
Engineer. Invariably in all concreting, form work shall be examined with respect to stability,
workmanship, and dimensional correctness as per drawings and design. All form works shall
be thoroughly cleaned immediately before concreting. Precaution as per MOST clause 1506
shall be duly compiled and ensured.
Removal of formwork:- Programme for removal of form work ( i.e. de-shuttering and decentering) shall be finalized by contractor for scrutiny and approval. Removal shall not be
taken without prior approval. Time of removal of form work shall be as under (minimum).

a) Walls, Piers, abutments, columns and vertical faces of :

structural members

48 hours

b)
c)
d)
e)

3 days
14 days
7 days
28 days

4.2.7

Soffits of Slabs ( with props left under)

Props (left under slabs)
Soffits of Girders (With Props left under)
Props (left under girders)
Steel Reinforcement:

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.

4.3

TEST AND STANDARDS OF ACCEPTANCE

Concrete shall confirm to surface finish and tolerance for respective component as:

COMPONENT

TOLERANCE
a) Variation in dimension
b) Misplacement from
specified position in plan
c) Surface irregularities
measured with 3 metre Straight
edge.
d) Variation at level at top

(+) 50mm
(-) 10mn
15mm
5mm
+25mm

a)Variation in C/S dimension

b) Position in plan
c) Variation of levels at top
d) Variation of reduced levels
of bearing areas
e) Variation from plumb
overall full height.
f) Surface irregularities
measured with 3 metre Straight
edge
All surfaces except bearing
areas Bearing areas

(+) 10mm
(-) 5mm
10mm
10mm
5mm
10mm

a) Upto 2 metre and including

2 metre.
Over 2 metre

5mm

b) Variation in overall length

and overall length between
bearings
c)Permissible surface
irregularity under measured
with 3 metre straight edge or
template

Shall not exceed

10mm0.1% of
span length whichever is
lesser.
5mm

a) Variation in thickness of top

and bottom slab for box
Girder, top and bottom fringe
or T-Girders or slabs

-5mm to +10 mm

(b) Variation in web thickness

-5mm to +10mm

Variation in overall depth or

width
d) Variation in overall length
and length between bearing

5mm

e) Permissible irregularities
when measured with 3 metre
straight edge or template.

5mm

5mm
3mm

Shall not exceed 10mm

0.1% of span length
whichever is less

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
Contents of IRC:SP:47-1998 Guidelines on Quality Systems for Road Bridges shall be
applicable for major bridge work.
4.5 The following guide lines are given for quality assurance of construction of bridges:
a)
b)
c)

For construction of H/L Bridge/ ROBs minimum quality assurance level Q-3 is to be
achieved.
For construction of culvert and small bridge minimum quality assurance level Q-2 is to be
achieved.
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.

4.6 EXTRACTS OF IRC SP :47 :1998

Sr. no.

Item

1.
1.1

MATERIALS
General
a)Material from natural
sources

Normal QA
Q-2

High QA
Q-3

Extra High QA
Q-4

Small or medium
scale purchases
from large and
established
suppliers/traders.

As in Q-2. Also bulk

purchase form source

As in Q-3, but
may also set up
own source for
supply.

Source mutually
agreed to between
contractor and
owners project
terms and
documented

Independent testing
/acceptance by
contractors& owner
Q.A teams and
documented.

As in Q-3, but
with additional
(third level)
testing/
acceptance by
independent
agency (such as
PMC or
Approved Testing
Laboratory)

Same as Q-3
May rely on local
experience and
knowledge of the
past performance
for coarse and fine
aggregates and
water.
b) Factory
manufactured items
including cement, steel
bearings, expansion
joints etc.

Manufactures tests
certificate accepted
with sample check
by independent
agency for
incorporation in
structure.

Testing/ acceptance at
the start of the project
as well as at specified
frequency.
Same as Q-3
Manufactures test
certificates with sample
checks for initial
acceptance only.

Regular testing at
specified sampling
frequency during
construction

Set up mutually agreed

QA methods at two
levels for
inspection/testing to
cover the specific
purpose order.

As in Q-3, but
may also have
additional
independent QA
checks at source
(third level
check)

As in Q-3, but
third level
checking by
checking by
checking
appointment of
specialized
agency for
innovative
aspects.
As in Q-3

ISO:9000
certificate not
essential for
manufactured
items.

In case the
manufacturer has
ISO:9000 certification,
he may be given
preference.
Same as Q-3

c) Records for all

materials

Record of sources
and purchase dates
for all items.
For
Manufactured
items record of

As in Q-2. Also record

of issue of
manufactured materials
and location of use.

manufacturers test
certificate.
d) Testing facilities

1.2

Testing from
nearby established
test
houses/laboratories.

Physical testing
facilities at site. For
chemical & Special
tests as per Q-2. Use of
chemical testing kits for
quick checks at site are
to be preferred.

At the beginning
for mix design &
for every charge of
source.

At the beginning for

mix design and for
every
change
of
source/stack and for
every major structural
element.

a) Aggregate coarse
aggregates Grading

Other physical tests

(crushing value
abrasion moisture
contents etc.)

For selection of
source if in doubt.

At the beginning for

mix design and for
every change of source

Deleterious contents

For selection of
source if in doubt

Mandatory for selection

of source & whether
there is change in
source of supply.

As in Q-3, with
property
equipped testing
facilities and
laboratory at site
under control of
QA personnel of
contractor &
owner
(independent of
production team).
As in Q-3, but if
necessary with
increase
frequency ,
(testing at site
laboratory).
As in Q-3,(two
level checks at
site laboratory).
Same as Q-3

Aggregate reactivity
b) Fine aggregate
(sand)
Grading

Other physical tests

(crushing value
abrasion moisture
contents etc.)

Not Applicable

At the beginning
for mix design &
every change of
source
For selection of
source if in doubt.

Same as Q-3

Mandatory for selection

of source and whether
there
At the beginning for
mix design and for
every change of source.

At the beginning for

mix design and for
every change of source.

As in Q-3, but if
necessary
with
increased
frequency,(testing
at site laboratory)
As in Q-3 (two tier
checks
at
site
laboratory)

Same as Q-3

1.3

1.4

Deleterious contents

For selection of
source if in doubt

For control of chlorides

etc.

Simple but frequent As in Q-2

chemical checks at
site for
effectiveness
External laboratory
checks/control (two
level control)

Water Suitability
Chemical analysis

Cement Normal
physical and chemical
tests.

At the beginning
Carried out if in
doubt

Manufacturers
certificate
acceptable &
testing in case of
doubt or nonavailability of
certificate.

Mandatory for selection

of source & whenever
there is charge in
source of supply.

Same as Q-2
Mandatory at the
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-2 and at
frequency of each new
consignment &
documented. Special
tests will be required
for special for special
cements.

As
in
Q-2,
supported
by
checking at testing
laboratory at site.

Same as Q-2 As in
Q-3, but at increase
frequency during
working.

As in Q-3, testing
carried out at site
laboratory &
independently
crosschecked at
predetermined
frequency.
Same as Q-3

Form of purchase
storage, transportation,
and use within
acceptable time limit.

1.5

Admixtures
a)Approval

Trade purchases,
intermediate
storage in dry and
covered place,
transportation and
use of factory
filled, machine
stitched bags.

May be permitted
under specialist
supervision in
which case follow
Q-3 controls.

Supply from factory

with direct
transportation from
factory to site godown /
silos. Transportation
and Transshipment
supervised and
documented.

Independently carried
out acceptance testing
after field trails for each
sources.

As in Q-3, with
additional
independent tests.

i) Chloride

Re-trials with change in contents.

Source of Cement.

Routine checking by
testing for every batch
of admixture.

ii) Spectroscopic
signature of
accepted product
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
and production controls
at site

Dosage to be
Same as Q-2
finalized after field
trial mixes, special
mechanical devices
to be used for
dispensing.
Frequent checks for
specific gravity.
Continuous
monitoring of work
ability of concrete.
Visual inspection
of concrete after
striking forms for
local defects
(including delayed
setting).

1.6

c) Training of site staff

by manufacturer.

Proper training of
site staff in use as
well as quality
control, plus
periodic visits by
manufacturers
expert.

Same as Q-2

Reinforcing Steel

Once at beginning

As in Q-2, and for each

As in Q-2, but
visits b experts at
close frequency.

As in Q-3, but
further

Normal Physical tests

and for every

change in source in
addition to
manufacturers
certificate.

consignment

supplemented by
random checking
by QA team.

Same as Q-2
Chemical Composition

Welding

Once at beginning
and if in doubt for
any source.
Not ordinarily
permissible at site.

Same as Q-2

Welding to be done
only by qualified and
tested welders.

As in Q-3, but
welders to be
periodically
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.
1.7

Prestressing Steels/
Anchorage systems &
cable anchorage
assembly:
Same as Q-2.
a) General ( for all
items of prestressing
including equipment.)

In a sealed and
moisture proof
godown with
minimum openings
store above ground
level on raised
supports or in
racks.

Same as Q-2

Storage

Such godown will

have humidity
control

Same as Q-2

Same as Q-2

In additional
vapour face
inhibitors and / or

water soluble oils

to protect steel.
Compatibility of
various components.

Suitability of
anchorages for use
with wires /
standards (meeting
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 &

care taking

Also the
manufacturer to
supply special
assistance at site, if
required, to train
and supervise
personnel at work.

Same as Q-2

b) HT Wires/ stands
Mechanical Properties (
Tensile Strength, Proof
Stress).

Manufacturers test
Certificate can be
accepted.
Additional Testing
if in doubt.

In addition to
manufacturers
certificate, tests done
on random samples for
a lot of 50 T, or part
there of and witnessed
by independent QA
team of random.

As in Q-2, but
compatibility
established at site
as required by
QA team.

Same as Q-2

As in Q-3, but
every coil,
Sample testing
witnessed by
independent QA
team at specified
frequency.

Same as Q-2
Modules of Elasticity

Insist for
manufacturers
certificate giving
stress. Strain curve
& modules of
elasticity. Sample
testing witnessed
by independent QA
team.
Contact with
contaminated
surfaces avoided.

Same as Q-2

c) Anchorage System
( Chemical
Composition & Heat
Treatment,
Supplementary Tests).

Permitted using
anchirage or
established
manufactures of
long standing based
on certification of
suitability &
quality by
manufacturer.

As in Q-2, but
supported by
manufacturers detailed
QA plan ( which can be
verified by purchaser if
necessary).

Not normally
required.

Manufacturers
certificate.

As in Q-3, but in
addition QA
plans should be
independently
checked by QA
team and verified
at manufacturers
facilities.

d) Cable Anchorage
Assembly
(Acceptance Testing)
Static Tensile test &
load transfer test.

Manufacturers
certificate and
certificate by
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.

Not normally
Dynamic Test for
Cable/anchorage
assembly

Manufacturers
certificate of testing

Also independent
laboratory testing as per
FIP Code, once for new

As in Q-3, plus
any additional
test than a QA
team may
required

system of anchorage/
cables.

e) Sheathing cable Dust

Supply

Purchase from,
manufacturers with
metallic sheathings
coated with water
soluble rustpreventive oil.

Same as Q-2

Workability and
transverse bending test
as per IRC:18

Test certificate by
the Manufacturer
for each lot to be
furnished.

As in Q-2, but
additional independent
test to be done on
random samples.

Any other materials

(like expansion joints,
bearings, railing etc.)

Manufacturers
Certificate
supported by
sample testing.

As in Q-2 with higher

frequency of testing
and
QA plan of
manufacturer to be
initially approved.

Normally not to be
used. If used same
as Q-3

To be accepted by
competent technical
authority for use thoeity
for use after full
testing at laboratory/
and field trials.

1.8

1.9
New Materials

Special specification
for properties testing
and acceptance criteria
to be evolved and laid
down for use at site.

2.

As in Q-3 but
preferable to
fabricate
sheathing freshly
at site at the
required rate.
As in Q-3, but at
higher frequency
plus any
additional test
that QA team
may require.
As in Q-3 with
implementation
of QA plan of
manufacturer to
be audited by QA
team of owner to
the extent
depending on the
importance of the
team.
As in Q-3
Supplemented by
independent
checking by QA
team of specialist
consultants.

2.1

WORKMANSHIP
General Controls
( Direct & Indirect )
a) working &
supervision

Same as Q-2
Skilled and
semiskilled
workers.

Skilled workers having

special training and
working under
experienced
supervisors. ( where
trade qualifications are
existing should be
insisted upon).

Periodic vision
from owner of his
agent.

Full time supervision

from contractor as well
as from owner or his
agent.

Periodic check by
designer during
site visit.

As in Q-2, but at
predeter mined stages
and frequency.

As in Q-3 but
with occasional
supervision by
expert external
agency.
As in Q-3 expect
in case of bridges
having new
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.
b) Use of Mock-ups

Not ordinarily
required.

For-Q-3 quality mock

ups are required only
for certain elements
(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.

Mock-up should use

actual proposed
methods of

As in Q-3, but
made mandatory
for all difficult
and important
zones.

construction, including
plant and equipment.
Mock-up should use
actual proposed
methods of
construction including
plant and equipment.

Also, mock-ups
dealing with new
techniques to be
carried our under
supervision of
expert external
agency

As in Q-3
No work on structure
should be permitted
before demonstrative
mock-up.

As in Q-3.
2.2
Concrete mix design.

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

Mix design
performed at
beginning of work
or for new source
of materials with
subsequent Q.C. as
per code and by
experienced
supervisors.

As in Q-2 with
minimum two level
controls.

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.
2.3
Fabrication and fixing
of reinforcement.

2.4
Fabrication & fixing of
presenting cables.

Same as Q-2
Site bending by
Same as Q-2
skilled workers
with regular
checking by
qualified supervisor
Bar bending
schedules are made
and checked
before use.

Same as Q-2

Correct placement
of reinforcement
and provision of
proper cover
checked
independently
before concreting.

As in Q-2, but checked

and documented by QA
team.

Normally not
applicable. If used
follow Q-3
practices.
Modules established
initially (acceptance
test)

Relaxation Test

Manufacturers
certificate

As in Q-2 expect
bar bending
schedule made by
design office
only.
Same as Q-3.

Modulus
established
initially and
verified by work
by work test.

As in Q-3, also
tests to be
Testing & certification witnessed by
essential for 1000 hours contractors/
test by independent test owners/owners
house.
QA team.
Same as Q-3.

Chemical Composition

Manufacturers
Certificate can be
accepted with

As in Q-2, plus testing

by independent agency
on random sample

Packing

Transportation

special with special

testing, if in doubt.

basis.

Packing with two

layer for water
proofing and
mechanical
protection.

Same as Q-2.

Transport vehicle
check.

Same as Q-2

Same as Q-2

Same as Q-2

Protection from
environment of
physical damage.
Suitable of coil size/
weight for use at size.

Coils handled by
mechanical devices
prohibiting
movement by
rolling.

Same as Q-2
Same as Q-2

The wire/ strand

should and be free
of skinks or
deformations and
straight.
a) Clearing

b) Preparation of
steel /cables.

Only unrusted
steel can be used.
Should be free rust
Light on wires (not
strands) can be
removed, wires cleaned
and used.
Pre-fabricated and
sheathed cable can be
permitted.

However, post threaded

wires/ strands just
before stressing are to
be preferred.
Cables strictly prepared
on raised/ clean
benches and kept free
from dust at all times.

Only post
threading of
wires/ strands
permitted (with
exceptions if
unavoidable).

Same as Q-3

As in Q-3.
Cable Layout giving
co-ordinates at close
intervals as needed by
fixing requirements
(and not by theoretical
curves or equations
alone), and supported
firmly in place, Post
threaded cable ducts
should be held against
floatation during
concerting
Layout and leak
tightness of sheathing
to be independently
checked and
documented by owners
Q.A. Team of his agent.

c) Laying & supporting

2.5
FORMWORK
a) Materials

Any Suitable
Same as Q-2.
materials meeting
codal requirement s
and capable of
giving specified
form finish.

As in Q-3, with
additional
checking and
testing required
by QA teams
sample checking
by expert external
agency.
As in Q-2 with
regularly and
properly
maintained
shuttering with
limited reuses.
Shuttering
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

Spot check.
b) Design Check

Formwork/ design
made and approved
independently.

Same as Q-3.

c) Specialist System.

Specialized
formwork systems
need not be insisted
upon.

Specialised formwork
system, to be preferred
with properly trained
carpenters/ fitters.
Same as Q-3.

d) Experienced
carpenters/fitters.

Semi- skilled/
Skilled carpenters.
Fitters under
supervisory staff.

Frequent check by
e) Tolerances, geometry carpenters/fitters
and leak tightness
and checking of
checks.
important members
by supervisory
staff.

Skilled carpenters/
fitters under
supervisory staff with
the work supervisory
additionally by owners
supervisors and agents.

Check for all members

by supervisory staff.

As in Q-3. Also
check for quality
of shutter
surfaces before
reuse &
document
clearance.
Same as Q-3.
Same as Q-3.

f) Deshuttering

Under supervisory
staff for important
members.

As in Q-2. The system

should provide should
provide for gradual
uniform and shockfree
deshuttering
arrangements.
Same as Q-3.

Not applicable
g) Formwork for special
structure.

2.6
Mixing/ Conveyance,
placing /Curing of
concrete.

Site mixing by
mixers or batching
plant near site.
Occasional two tier

As per design
requirement under
control of qualified
staff, with additional
supervision by owners
supervisor or agents.
Checks by QA team till
procedure at site are
established.

As in q-2 under two

level controls, upto
200m length bridge
beyond which batching

Batching plant is
mandatory
Occasional
checks by expert
external agency.

control and
documented.
Transportation by
head loads trollies
or by mechanized
vehicle permitted.

Experienced
concerting gangs
under supervisory
staff.
Placing concrete
and compacting
under supervisory
staff.
2.7
Stressing Cables

Stressing equipment

Normally not
applicable if used
follow Q-3
practices.

plant is mandatory.
Use specialized
equipment for
transportation. The
adverse effects of the
methods of
conveyance(segregation
delys stiffening of mix
etc.), should be
regularly monitored
controlled and
documented.
As in Q-2, with tow
level controls. Also
regular control by
qualified staff. Method
of control by pour card
recommended.
As in Q-2. Also regular
control by qualified
staff. Surveillance by
QA team.

As in Q-3

Same as Q-3.

Same as Q-3
Efficacy of
methods to be
regularly checked
and
demonstrated.

As in Q-3 in
presence of
independent
expert or by QA
team.

Stressing equipment
calibrated tested and
certified by
manufacturer/supplier.
Checking and
recalibrated at site at
regular predetermined
frequency by qualified
staff under supervision
of owner and his agent. Same as Q-3 with
surveillance by
Only under strict
expert agency / or
supervision of stressing QA team.
supervision and site
engineer. The
manufacturer to supply
special assistance at site
to train personnel and
supervise work
Same as Q-3.

Sample basis check for

elongation/pull in of all
wires/ strands in the
cable assembly
(uniformity of
stressing).
In-site check on losses
by stressing from on
side jack using as
active and other as a
passive jack on a
sample basis.
(For long cables and
high total deviation the
passive jack may not
register pressure within
strock length of active
jack For such cases
special tests or
provision of short
cables may be required.

Check of friction and

wobble losses.

2.8
Grouts & Groutings
a) Grouting of
Prestressing Cables.
Composition and
Physical properties

Normally not
applicable. If used
then follow Q-3
practice.
At the beginning of
work for designing
suitable grouts.
Physical properties to
be verified once in a
week or with change of
batch of cement of
admixture.
By visual inspection

Workers/ Supervisor

As in Q-3 which
check for every
operation.

Equipment tested &

passed for satisfactory
performance regularly.

As in Q-3 but
tested and
documented for
every operation.
As in Q-3 with
testing witnesses
by independent
QA team.
Same as Q-3.

Trained staff under

qualified
Supervision.
Surveillance by QA
Team.

As per item 5.5

Fluidity test bleeding

characteristics during
working
Equipment

As in Q-3 with
additional tests as
required by QA
team.

Where used as per item

5.5
Where used as per item
5.5

Admixtures

Normally not required.

If used follow q-4.

b) Grouting with non

cementitious special
material.

c) Cement Grouting for

bolts and fixing
apparatus.
iii) Workability of
fresh concrete slump
test.
Iv) Thickness
determination.
v) Thickness
measurement for
trail length
vi) Verification of
level of string line in
the case of slip from
paving and steel
forms in the case of
fixed from paving

Use of special
perpacked high
strength non-shirnk
grouts preferred.
IS : 1199

As in Q-2 with regular

sample check for
efficiency.

Materials like
grease, powder
coatings, or other
specially
formulated mixes
should be used
only after through
testing for
suitability
including long
term effects and
by following
specially
developed
suitable methods
under expert
supervision.
As in Q-3 with
increased
frequency of
checking.

Once test per each dumper load at boyh

Batching Plant site and paving site initially
when work starts subsequently sampling
may be done from alternate dumper.
From the level data of concrete pavement
surface and sub-base at grid points of
5/6.25mx3.5m.
3 croes per trail length.
String line or steel forms shall be checked
for level at an interval of 5.0 m or 6.25 m.
The level tolerance allowed shall be +2 mm.
These shall be got approved 1-2 hours
before the commencement of the concerting
activity.

4.7 FREQUENCY OF TESTS FOR CONCRETE WORKS

1. Cement

Physical and Chemical

Tests.

IS :269
IS:455
IS:1489
IS:8112
IS:12269

2. Coarse and
fine aggregates.

i) Gradation

IS:2386
(Pt.1)

ii) Deleterious
Constituents

IS:2386
(Pt.2)

i) Los Angles Abrasion value or

aggregate Impact test.

IS:2386
(Pt.4)

ii) Soundness

IS:2386
(Pt.5)

iii) Alkali Aggregates reactivity.

3.Coarse
Aggregate

4. Water

Chemical Test..

IS:2386
(Pt.5)
IS:456

5. Concrete

i) Strength of concrete.

I.S.516.

ii) Core strength on hardened

concrete.

IS516

Once for each source of

supply and occasionally
when called for in case
of long/ improper
storage Besides the
contractor also will
submit daily test data
on cement released by
the manufacturer.
Once test for every
days work of each
fraction of coarse
aggregate and fine
aggregate initially may
be relaxed later at the
discretion of the
Engineer.
Once test for every
days work of each
fraction of coarse
aggregate and fine
aggregate initially may
be relaxed later at the
discretion of the
Engineer.
Once for each source of
supply and
subsequently on
monthly basis.
Before approving the
aggregates and every
month subsequently.
--do-Once for approval of
source of supply
subsequently only in
case of doubt.
2 cubes and 2 beams
per 150m3 or part there
of (one for 7 day and
other for 28 day
strength) or minimum 6
cubes and 6 beams per
days work whichever
is more.
As per the requirement
of the Engineer only in

case of doubt.
iii) Workability of fresh concrete
slump test.

IS:1199

iv) Thickness determination

v) Thickness measurement for trail

length.
vi) Verification of level of string line
in the case of slip from paving and
steel forms in the case of fixed from
paving.

5.

Once test per each

dumper load at both
Batching Plant site and
paving site initially
when work starts
subsequently sampling
may be done from
alternate dumper.
From the level data of
concrete pavement
surface and sub-base at
grid points of
5/6.25mm*3.5m.
3 croes per trail length.
String line or steel
forms shall be checked
for level at an interval
of 5.0 m or 6.25m. The
level tolerance allowed
shall be 2 mm.
These shall be got
approved 1-2 hours
before the
commencement of the
concerting activity.

QUALITY CONTROL TESTS

AND THEIR FREQUENCY

QUALITY CONTROL TEST & THEIR FREQUENCY

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 Contractors 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

Table 1- Control tests on Borrow Materials : Pre-Construction

Sr.
No.
a.

Test

Test Methods

Gradation

b.

Plasticity Index

c.

Modified proctor

d.

CBR (on a set of 3 specimen)

e.
f.

Deleterious Constituents
Natural Moisture
Content

IS:2720
Part IV-1965
IS:2720
Part V-1963
IS:2720
Part VIII-1965
IS:2720
Part XVI-1965
IS:2720 Part XXVI-1988
IS:2720
Part II-1973

Minimum Desirable
Frequency
1-2 tests per 8000 cum of soil
1-2 tests per 8000 cum of soil
1-2 tests per 8000 cum of soil
One test per 3000 cum
AS required
One test for 250 cum of soil.

Table 2- Control tests for Compaction of embankment/Fill: During Construction

S.No.

Test

Test Method

a.

Moisture Content before

Compaction
Compacted Layer

IS:2720
Part II-1973
Part XXVIII-1966

b.

Minimum Desirable
Frequency
2-3 tests per 250 cum of
loose soil
One test per 1000 cum for
embankment construction
and one test per 500 cum
for subgrade compaction.

Control tests for embankment/ Fill : Post Construction:

Tolerance in Surface Level

Max. no. of undulations permitted in any 300m length, exceeding 18 mm
Max. permissible variation from specified profile under camber template.

5.2

Granular Sub-Base

Table3-Control tests on Sub-base materials: Pre-Construction

S.No.

Test

Test Method

a.

c.

Aggregate Impact Value or Los Angles

Abrasion value
Plasticity Index of filler Material
Gradation
Water absorbtion of Aggregates

d.

Deleterious Constituents

f.

CBR test( Soaked)

IS:2386
PartIV-1963
IS:2720
Part V-1963
IS:2386
Part III-1963
IS:2720
Part XXXVII-1968
IS:2720 Part XVI1965

b.

Minimum
Desirable
Frequency
One test per 200
cum
One test per 25
cum
One test per 200
cum
As required
As required

Table4- Control tests on Sub-base Materials : During Construction

S.No.

Test

Test Method

a.

Moisture Content Before compaction

b.

Density of Compacted Layer

IS:2720
Part II-1973
IS:2720
Part XXVIII-1966

c.

Thickness of Compacted layer

Minimum Desirable
Frequency
One test per 250 cum
One test per 250 cum
As required

Control tests for Granular Sub-Base : Post Construction

Tolerance in Surface Level

10mm

Max. permissible undulation ( with 3 m straight edge)

8mn

Max. no. of undulations permitted in any 300 m length, exceeding

30

Max. permissible variation from specified profile under camber template 12

5.3

Wet Mix Macadam

Table5-

Control tests On Base Materials: Pre-Construction

S.No.

Test

Test Methods

a.

Los Angles Abrasion value/A.I.V.

b.

Grading of Aggregates and Screening

c.

Flakiness Index of aggregates

d.

Plasticity of binding Material

IS: 2386
Part IV-1963
IS:2386
Part I-1963
IS:2386
Part-1983
IS:2720
Part V-1970

Minimum Desirable
Frequency
One test per 200 cum
One test per 100 cum
One test per 200 cum
One test per 25 cum

Table6- Control Tests for Base Course

S.No.

Test

Test Method

a.

Moisture Content Before Compaction

b.

Density of Compacted Layer

IS:2720
Part-1973
IS:2720
PartXXVIII-1986

c.

Thickness of Compacted Layer

Minimum Desirable
Frequency
One test per 100 cum
One test per 500 cum
As required

Control tests for Wet Mix Macadam: Post Construction:

Tolerance in surface Level

10mm
Max. permissible undulation ( with 3m straight edge)
8mm
Max. permissible variation from specified profile under camber template 12mm

5.4

Dense Bituminous Macadam/ Semi Dense Bituminous concrete/ Bituminous concrete

Table 7-Control tests On Base Materials : Pre- Construction

S. No.

Test

Test Methods

a.

Los Angles Abrasion

Value/A.I.V.
Grading of aggregates and
Screening
Flakiness Index of Aggregates

IS:2386
Part IV-1964
IS:2386
Part I-1963
IS:2386
Part -1983

b.
c.

Minimum Desirable
frequency
One test per 200 cum
One test per 100 cum
One test per 200 cum

d.

Quality of binder

e.

Stability of mix.

f.

stripping value of
Aggregate

Is:73-1961

IS:6241-1971

Two Samples per lot

to be subjected to all
tests
Marshall stability test
for stability, flow
value, density
And void contents.
One test per 100 cum

Table8- Control tests for DBM/SDBC: During Construction

S. No.

Test

Test Method

a.

Quality of Binder

b.

Los Angles Abrasion

c.
d.
e.

Stripping Value of Aggregate

Flankiness Index of
Aggregate
Water Absorption of Aggregate

f.

Grading of all in Aggregates

IS:73-1961
IS:215-1961
IS:217-1961
OR 454 AS
APPLICABLE
IS:2386
Part Iv-1963
IS:6241-1971
IS:2386
PartI-1963
IS:2386
Part III-1963
IS:2386
PartI-1963

g.
h.

Temperature of Binder of laying and

rolling
Binder Content

Rate of Spread of Premix

j.

Density of compacted layer

k.

Mix grading

i.

Stability of mix.

Minimum Desirable
Frequency
As required

One test per 50 cum

One test per 50 cum
One test per 50 cum
One test per 50 cum
One test per 50 cum
Regularly

Extraction test with

Benzene

Sand Replacement
Method or from cores
cut by core Cutting
Machine

Two tests per day

Regular Control
through Checks on
Materials and thickness
Two tests per 500 Sq.m

One set of tests for

individual constituents
and mixed aggregates
from dryer for each 400
tones of mix subject to
minimum of two tests/
plant/day.
For each 400 tones of
mix produced, a set of
3 Marshall specimens
to be prepared and

tested for stability, flow

value density and void
content subject to a
minimum if two tests
being tested per plant
/day.
Control tests for dense Bituminous macadam: Post Construction:

5.5

Tolerance in surface Level

Max. permissible undulation ( with 3 m straight edge)
Max. no. of undulations permitted in any 300m length, exceeding 6mm
Max. permissible variation from specified profile under camber template

6mm
6mm
20
8mm

Bituminous Macadam

Table 9- Control Tests On surface Course :Pre-Construction

S.No. Test
Test Mehtods
a.

Los Angles Abrasion Value/A.I.V.

b.

Grading of Aggregates and Screening

C.

Flakiness Index of Aggregates

d.
e.

Quality of Binder
Stripping value of Aggregate

IS:2386
Part IV-1963
IS:2386
PartI-1963
IS:2386
Part-1983
IS:73-1961
IS:6241-1971

Minimum Desirable
Frequency
One test per 200 cum
One test per 100 cum
One test per 200 cum
One test per 50 cum
One test per 100 cum

Table10- Control Tests for AC: During Construction

S.No.

Test

Test Mehtod

a.

Quality of Binder

b.

Los Angles Abrasion Value/A.I.V.

c.
d.

Stripping Value of aggregate

Flakiness Index of Aggregate

e.

Water Absorption of Aggregate

f.

Grading of all in Aggregates

IS:73-1961
IS:215-1961
IS:217-1961
Or 454 as
applicable
IS:2386
Part IV-1963
IS:6241-1971
IS:2386
Part I-1963
IS:2386
Part III-1963
IS:2386
Part 1963

g.

Temperature of Binder of Laying and

Rolling
Binder Content

h.

Minimum Desirable
Frequency
As required

One test per 50 cum

One test per 50 cum
One test per 50 cum
One test per 50 cum
One test per 50 cum
Regularly

Extraction Test with

Two test per day

Benzene
I

Rate of Spread of Premix.

j.

Density of Compacted Layer

Sand Replacement
Methods or from cores
cut by core Cutting
Machine

Regular Control
through Checks on
Materials and
Thickness
Two tests per 500 Sq.

Control Tests for Bitumen Macadam: Post Construction:

Tolerance in Surface Level

Max. Permissible undulation ( with 3 m straight edge)
Max. no. of undulations permitted in any 300m length, exceeding 6 mm
Max. permissible variation from specified profile under camber template

5.6

6mm
6mm
20
8mm

Bituminous Concrete

Table9- Control Tests On Surface Course: Pre- Construction

S.No.

Test

Test Methods

a.

Los Angles Abrasion Value/A.I.V.

B.

Grading of Aggregates and Screening

c.

Flakiness Index of Aggregates

d.
e.

Quality of Binder
Stripping value of Aggregate

IS:2386
Part-1963
IS:2386
Part I-1963
IS:2386
Part-1983
IS:73-1961
IS:6241-1971

Minimum Desirable
Frequency
One test per 200 cum
One test per 100 cum
One test per 200 cum
One test per 50 cum
One test per 100 cum

Table 10-Control Test for B.C. : During Construction

S.No.

Test

Test Method

a.

Quality of Binder

b.

Los Angles Abrasion Value/ A.I.V.

c.
d.

Stripping Value of aggregate

Flakiness Index of Aggregate

e.

Water Absorption of Aggregate

IS:73-1961
IS:215-1961
IS:217-1961
Or 454 as
applicable
IS:2386
Part IV-1963
IS:6241-1971
IS:2386
Part I-1963
IS:2386

Minimum Desirable
Frequency
As required

One test per 50 cum

One test per 50 cum
One test per 50 cum
One test per 50 cum

f.

Grading of all in Aggregates

g.
h.

Temperature of Binder of Laying and

Rolling
Binder Content

i.

Rate of Spread of Premix

j.

Density of Compacted Layer

k.

Mix Grading

l.

Stability of mix.

Part III-1963
IS:2386
Part I-1963

One test per 50 cum

Regularly

Extraction test with

Benzene

Sand replacement
Method or from cores
cut by core Cutting
Machine

Two tests per day

Regular Control
through Checks on
Materials and
Thickness
Two tests per 500 Sq.

One set of tests on

individual constituents
and mixed aggregates
from dryer for each
400 tonnes mix subject
to is minimum of two
tests per plant per day.
For each 400 tonnes of
mix produced, a set of
3 Marshall specimens
to be prepared and
tested for stability,
flow value, density
and void contents
subject to a minimum
of two sets being
tested per plant per
day.

Control Tests for Asphaltic Concrete: Post Construction:

Tolerance in Surface Level

Max. permissible undulation ( with 3 m straight edge)
Max. no. of undulations permitted in any 300 m length, exceeding 6mm
Max. permissible variation from specified profile under camber template
The Project engineer, SE (QC), and CE (IP) reserve the right to direct for any additional that
may be required and it shall be binding on the contractor.

5.7

Structural Concrete

Table 11-Control Tests On Structural Concrete: Pre-Construction

S. No.

Test

Test Methods

Minimum
Desirable
Frequency

a.

Physical and Chemical

Tests for Cement.

b.

Gradation of Coarse and

Fine Aggregates

c.

Deleterious constituents
Of Coarse and Fine
Aggregates

d.

Water Absorption of
Coarse and Fine
Aggregates

e.

Los Angles Abrasion

Value or Aggregate
Impact test for Coarse
aggregates
Soundness for Coarse

f.

IS:269,IS:455,IS:1489,IS:8112,IS:12269 Once for each

source of supply
and occasionally
when called for in
case of
long/improper
storage. Besides,
the Contractor
also will submit
daily test data on
cement released
by the
Manufacturer.
IS:2386
One test for every
Part I
days work of
each fraction of
coarse aggregate
and fine
aggregate,
initially; may be
relaxed later at the
discretion of the
Engineer.
IS:2386
One test for every
Part II
days work of
each fraction of
coarse aggregate
and fine
aggregate,
initially; may be
relaxed later at the
discretion of the
Engineer.
IS: 2386
Regularly as
Part-III
required subject to
a minimum of one
test a day for
coarse aggregate
and two tests a
day for fine
aggregate. This
data shall be used
for correcting the
water demand of
the mix on daily
basis.
IS:2386
Once for each
Part-IV
source of supply
and subsequently
on monthly basis.
IS:2386
Before approving

g.

Aggregates

Part V

Alkali aggregate
reactivity for coarse
aggregate.

IS:2386
Part VII

Chemical tests for water

IS:456

the aggregates and

every month
subsequently.
Before approving
the aggregates and
every month
subsequently.
Once for approval
of source of
supply,
subsequently only
in case of doubt.

h.

Table12- Control tests for Structural Concrete During Construction

S.No.

Test

Test Method

a.

Strength of Concrete

IS:516

b.

Workability of fresh
concrete-slump test

IS:1199

c.

Chloride and Sulphate

content

d.

Density of Fresh
Concrete
Density of hardened
concrete
Permeability test

e.
f.

5.8

Minimum Desirable
Frequency
Quanity,m3
No. of Samples
1.5
1
6.15
2
16.30
3
31.50
4
51 and
4+additional
above
for each 50
m3 or part
thereof.
One test per each dumper load
initially and one test per alternate
dumper.
One test per each dumper load
initially and one test per alternate
dumper.
Four tests per each dumper load.
Four tests per each dumper load.

Clause 1716.5
MOST Specifications1997

One tests per each dumper load.

Structural Steel

Table13- Control tests On Structural Steel :Pre-Construction

a.
Physical and Chemical Tests IS:226,IS:2062,IS:11587, Once for each source of
for Steel
IS:1977,IS:8500,IS:961
supply and occasionally
when called for in case of
long/improper storage.
Besides, the Contractor also
will submit test data on steel
released by the

b.

c.
d.

Mechanical and Chemical

properties of Rivets, bolts,
nuts, washers, welding
consumables.
Rolling and Cutting tolerance
test
Quality of Paint

Appropriate IS
Code.

Manufacturer.
Once for each source of
supply and occasionally
when called for.

IS:1852

As required

Relevant IS codes.

Once for each source of

supply and occasionally
when called for.

Table 14-Control tests On Structural Steel : Post Construction

S.No.

Test

a.

Ultrasonic Testing for

Laminations in plates

b.
c.

Bolted Connections
Riveted Connections

d.

Destructive and Nondestructive tests on Welds

Test Methods

IS:4000
Clause 1905.7.4
MOST Specifications
1997
IS:7303 (Part-1), IS:
5334, IS:1182,
IS:4853,IS:3658

Minimum Desirable
Frequency
Once for each source of
supply and occasionally
when called for.

i)10% of the length of

longitudinal and transverse
butt welds in tension flanges
ii) 5% of the length of
longitudinal and transverse
butt welds in compression
flanges.
ii) All transverse butt welds
in webs adjacent to tension
flanges as specified by the
Engineer.

5.9

Sheathing Ducts

Table 15- Control tests On Sheathing Ducts

S.No.

Test

Test Methods

a.

Workability Test

b.

Transverse Load Rating Test

Appendix-1800/1 of
Specifications for
Roads and Bridges
MOST-1997
Appendix-1800/I of
Specifications for
Roads and Bridges

Minimum Desirable
Frequency
Three tests for one lot of
supply (not exceeding
7000 m length)
Three tests for one lot of
supply (not exceeding
7000m length)

c.

Tension Load test

d.

Water Loss Test

5.10

MOST-1997
Appendix-1800/I of
specifications for
roads and Bridges
MOST-1997
Appendix-1800/I of
Specifications for
Roads and Bridges
MOST-1997

Three tests for one lot of

supply (not exceeding
7000 m length)
Three tests for one lot of
supply (not exceeding
7000 m length)

Pile Foundation

Table 16- Control Tests On Pile Foundation

S.No.

Test

Test Methods

a.

Pile Load test

IS:2911(Part-IV)

5.11

Minimum Desirable
Frequency
Two tests for initial load
tests and 2% of the total
number of piles or 2
whichever is more for
routine load tests.

Well foundation

Table 17- control Tests On Well Foundation

S.No.

Test

Test Methods

a.

Tilts and shifts

Clause 1207.8 of
Specifications for
roads and bridges
MOST 1997

5.12

Minimum Desirable
Frequency
As required.

Elastomeric Bearings

Table 18- Control tests On Elastomeric Bearings

S.No.

Test

Test Methods

a.

Physical Properties

IS: 3400 (Parts I &

II)

b.

Maximum Compression Set

IS: 3400 (Part 10)

Minimum Desirable
Frequency
Two for each source of
supply and occasionally
when called for Besides,
the Contractor will also
submit test data released
by the Manufacturer.
Two for each source of
supply and occasionally
when called for. Besides,
the contractor will also
submit test data released

c.

Accelerated Aging

5.13

IS: 3400 (Part IV)

by the Manufacturer.
Two for each source of
supply and occasionally
when called for. Besides,
the Contractor will also
submit test data released
by the Manufacturer.

Mortar for Masonry Work

Table 18- Control Tests On Mortar

S.No.

Test

Test Methods

a.

Compressive Strength

IS:2250

b.

Consistency of Mortar

IS:2250

c.

Water Retenivity

IS: 2250

5.14

Minimum Desirable
Frequency
One sample for every 2 m3
subject to a minimum of 3
samples in a days work.
One sample for every 2 m3
subject to a minimum of 3
samples in a days work.
One sample for every 2 m3
subject to a minimum of 3
samples in a days work.

Load Test of Super Structure

Table 18
S.No.

Test

Test Methods

a.

Load Test on Super Structure

IRC SP:37

(A)

Minimum Desirable
Frequency
One Number

QUALITY
ASSURANCE
FORMATS

(WORKS SHEETS & CHECK LIST PERFORMAS)

6.

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).

PUNAJB PWD B&R

(PIDB PROJECTS)
6.1

WORKSHEET FOR BORROW MATERIALS

Name of Work :
Material Source :
Location
:
S
N
o
.

LocaTion
of
Borro
w
Area

KM in
which
Material
is used

Sand
Content
%

Grading
%
passing
through
4.75mm

60
0
mi
c

20
0
mi
c

15
0
mi
c

75
mi
c

P.I
Valu
e

Proc CBR
tor
Dens
ity

PUNJAB PWD B&R

(PIDB PROJECTS)
6.2

WORKSHEET FOR PLASTICITY INDEX TEST

(Reference : IS-2720-Part-V-1970)

Name of Work:
Kind of Material:
Material Source :

Date of Sampling
Sampled by
Date of Testing

:
:
:

De
Lete
rious

Na
tur
al
Mi
ist
ure

D
e
n
s
it
y

M
oi
st
ur
e
co
nt
en
t

Location
:
Natural MC :
(As laid down)

Tested by
Frequency

DETAILS OF TESTS
LIQUID LIMIT/TRIAL NO
A. No. of Blows
B. Container No.
C. Wt of Tare (gm)
D. Wet Wt of
Sample + Tare (gm)
E. Dry Wt of Sample +Tare (gm)
F. Wt of Water (D-E) (gm)
G. Wt of Dry Soil
(E-C) (gm)
H. Average % MC (F/Gx
100)
PLASTIC LIMIT/TRIAL NO
I. Container No.
J. Wt Wt of
Sample + Tare (gm)
K. Wet Wt of
Sample + Tare (gm)
L. Dry Wt of Sample
+ Tare (gm)
M. Wt of Water (K-L) (gm)
N. Wt of Dry Soil (L-J) (gm)
O. Average % MC (M/N*100)

Avg.

PUNJAB PWD B&R

(PIDB PROJECTS)
6.3

WORKSHEET FOR MOSITURE CONTENT TEST

(Reference :IS-2720-Part-II-1973-Second Revision)

Name of Work
Material Source
Location
Kind of material

:
:
:
:

Date of Sampling
Sampled by
Date of Testing
Tested by
Frequency
( As laid down)

:
:
:
:
:

DETAILS OF TESTS
Test No.
A. Container No.
B. Wt of Container

C.
D.
E.
F.

(gm)
Wt of container +
Wet Sample (gm)
Wt of Container +
Dry Sample (gm)
Wt if Water
(C-D) (gm)
Wt of Dry Sample(D-B) (gm)

Average % MC (E/F*100)
PUNAJB PWD B & R
(PIDB PROJECTS)
6.4

WORKSHEET FOR WATER ABSORPTION TEST

(Reference : IS-2386-Part-III-1963)

Name of Work
Material Source
Location

:
:
:

Date of Sampling
Sampled by
Date of testing
Tested by
Frequency
(As laid down)

:
:
:
:
:

DETAILS OF TESTS
ITEM
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)
6.5

WORKSHEET FOR MOISTURE DENSITY TEST

(Reference :IS-2720-Part-VII-1965)

Name of Work
Material Source

:
:

Date of Sampling
Sampled by

:
:

Average

Kind of Material
Location
Chainage

:
:
:

Date of Testing
Tested by
Frequency
(As laid down)

:
:
:

DETAILS OF TESTS
DRY DENSITY TEST/TRIAL NO.
A. Wt of Mould (gms)
B. Wt of Mould
+ Wet Soil (gms)
C. Wt of Wet Soil (B-A) (gms)
D. Volume of Mould (c c)
E. Wet Density of Soil
C/D (gms/c c)
F. Dry Density of Soil
{{C/100+L)} *100]/D
MOISTURE CONTENT
TEST/CAN NO
G. Wt of Can
H. Wt of Wet Soil
+ Can (gms)
I. Wt of Dry Soil
+ Can (gms)
J. Wt of Water (H-I) (gms)
K. Wt of Dry Soil (I-G) (gms)
L. Average % MC[(J/K)*100]

Average

Avg.

PUNJAB PWD B& R

(PIDB PROJECTS)
6.6

WORKSHEET FOR SIEVE ANALYSIS

(Reference :IS-2386-Part-I-1963)
Name of Work
Kind of Material
Location

:
:
:

Date of Sampling
Sampled by
Date of Testing
Tested by
Frequency
(As laid down)

Weight of Oven Dried Sample:

:
:
:
:
:
:

DETAILS OF TESTS
IS Sieve
Weight
Size
Retained
Mm/Micron (gm)

Cummulative Weight
Weight
Passing
Retained
(gm)

Percentage Percentage Percentage Specified

Retained
Cumulative Passing
Limits
Retained
(Laid

(gm)

down)

100 mm
90mm
80mm
63mm
50mm
40mm
25.0 mm
25.0 mm
16.0 mm
12.5 mm
10.0 mm
4.75 mm
2.36 mm
1.18mm
600
micron
425
micron
300
micron
150
micron
75
micron
Silt +Clay Content:

Weight of dried sample (W1 )

Weight of even dried sample retained

On 75micron Sieve (after washing)(W2)
Percentage of Silt + Clay Content

=
=(W1-W2) /(W)1)*100

PUNJAB PWD B & R

(PIDB PROJECTS)
6.7

WORKSHEET FOR SPECIFIC GRAVITY TEST FOR FINE AGGREGATES

Name of Work
Material Source
Location

:
:
:

Date of Sampling
Sampled by
Date of Testing
Testing by
Frequency
(As laid down)
FINE AGGREGATES

:
:
:
:
:

DETAILS OF TESTS
No.

ITEM/TEST NO

A.

Weight in air of Saturated Surface Dried

Sample (gm)
Weight in Air of Oven Dried Sample (gm)
Weight of Pycnometer Bottle
Filled with Water (gm)

B.
C.
D.
E.
F.
G.
H.

Average

Pycnometer Water +Sample (gm)

Percentage Water Absorption=[(A-B)/B]*100
Bulk Specific Gravity=[(A)/{A-(D-C)}]
Specific Gravity
=[(B)/{A-(D-C}]
Apparent Specific
Gravity=[(B)/B-(D-C)}]

PUNJAB PWD B&R

(PIDB PROJECTS)
6.8

WORKSHEET FOR SPECIFIC GRAVITY TEST FOR COARSE

AGGREGATES

Name of Work
Material Source
Location

:
:
:

Date pf Sampling
Sampled by :
Date of Testing
Tested by
Frequency
(As laid down)

:
:

COARSE AGGREGATES
DETAILS OF TESTS
S.No.
A.
B.
C.
D.
E.
F.
G.

ITEM/TEST NO
Weight in Air of Saturated Surface
Dried Sample (gm)
Weight in Air of Oven Dried Sample
(gm)
Weight of Sample in
Water (gm)
Percentage Water
Absorption =[(A-B)/B]*100
Bulk Specific Gravity=[(A)/(A-C)]
Specific Gravity
=[(B)/(A-C)]
Apparent Specific Gravity=[(B)/(B-C)]

Average

Observations:

PUNAJB PWD B& R

(PIDB PROJECTS)
6.9

WORKSHEET FOR SAND CONTENT TEST

(IS:2730 Part-IV-1965)

Name of Work
Kind of material
Source of Material
Location

:
:
:
:

Date of Sampling
Sampled by
Date of Testing
Tested by
Frequency
(As laid down)

:
:
:
:
:

DETAILS OF TESTS

S.No.
A.
B.
C.
D.

ITEM/TEST NO
Original Weight (gm)
Oven Dried Weight
(gm)
Oven Dried Weight Retained on 75
Micron IS Sieve
(After Washing) (gm)
Percentage of Sand
Content =[(C/B)*100]

Average

Observations:
PUNJAB PWD B&R
(PIDB PROJECTS)
6.10

WORKSHEET FOR FIELD COMPACTION TEST BY CORE CUTTER

METHOD
(Reference :IS-2720-Part-XXIX)

Name of Work
Source of material
Layer No.
Location

:
:
:
:

Station of Test

Date of Testing
Tested by
Frequency
:
(As laid down)

:
:

DETAILS PF TESTS
MAXIMUM DRY DENSITY/TEST NO.
A. Wt of Wet Soil + Core Cutter
B. Wt of Core
C. Wt of Wet Soil (A-B)
D. Volume of Core Cutter1000C.C.
E. Wet Density of Soil (C/D)
F. Dry Density of Soil [E/(100+M)]*100
G. M.D.D..OMC.
Relative Compaction =[(F/G)*100]=
MOISTURE CONTAINER NO.
H. Wt of Wet Soil +Container
I. Wt of Dry Soil +Container
j. Moisture Container (H-I)
K. Wt. Of Container
L. Wt of Dry Soil (I-K)
M. % of Moisture (J/L)*100

Average

Average

PUNJAB PWD B & R

(PIDB PROJECTS)
6.11

OBSERVATION SHEET FOR STRIPPING VALUE TEST

(Reference : IS: 6241-1971)

Name of Work
Aggregate Source
Location

:
:
:

Date of Sampling

Sampled by

Type of Aggrgate

Date pf Obsn

Type of Binder

Observed by

Percentage Binder Used:

Frequency
(As laid down)

Total Wt of Aggregate:
Total Wt of Binder :
Temp of Water Bath :
DETAILS OF OBSERVATIONS
DETAILS/OBSERVATION NO
Stripping Percentage as Observed

Average

from the Aggregates on Visual

Inspection
Limits

Value not to be
greater than
25%

Observations:
PUNJAB PWD B&R
(PIDB PROJECTS)
6.12

WORKSHEET FOR AGGREGATE IMPACT VALUE

(IS:2386 Part-IV-1963)

Name of Work
Kind of Material
Location

:
:
:

Date of Sampling
Sampled by
Date of Testing
Tested by
Frequency
(As laid down)

:
:
:
:

DETAILS OF TESTS
Sr.
No.
A.
B.

TRIAL NO

C.

Percentage weight Loss =[(A-B)/

(A)*100]
[Aggregate Impact Value (A/V)]

Initial Weight(gms)
Weight Retained After test
On Sieve No. 2.36mm (gms)

Average % Loss (A/V)=

Specification % Loss (A/V)=
Observations:

PUNJAB PWD B&R

(PIDB PROJECTS)
6.13

WORK SHEET FOR FLANINESS INDEX TEST

Average

(Reference :IS:2368-Part I-1965)

DETAILS OF TESTS
S.No.

Passing
Through
IS : Sieve

Retained on Is
Sieve

Wt of Sample
(Gms)

1
2
3
4
5
6
7
8
9

63mm
50mm
40mm
31.5mm
25mm
20mm
16mm
12.5mm
10mm

50mm
40mm
31.5
25mm
20mm
16mm
12.5mm
10mm
6.3mm

X1
X2
X3
X4
X5
X6
X7
X8
X9

Results:

Wt Passed
through
Thickness
gauge (Gms)
Y1
Y2
Y3
Y4
Y5
Y6
Y7
Y8
Y9

Percentage of
Flaky Particles
(Flakiness
Index)
(Y1/X1)*100
(Y2/X2)*100
(Y3/X3)*100
(Y4/X4)*100
(Y5/X5)*100
(Y6/X6)*100
(Y7/X7)*100
(Y8/X8)*100
(Y9/X9)*100

x(x1+..+x9) Y1+.Y9) (Y/X)*100=

(Flakiness Index)

Observations:

PUNJAB PWD B&R

(PIDB PROJECTS)
6.14

WORKSHEET FOR FIELD COMPACTION TEST BY REPLACEMENT

METHOD.
(IS-2720-Part-XXVIII-1966)

Name of Work
Source of Material
Chainage
Layer No.

:
:
:
:

Station of test

Proctor
Limits

Date of Testing
Tested by

:
:

Frequency
(As laid down)
Type of Test

:
:

Proctor/Mod

95/98/100% of MDD

DRY DENSITY/TEST NO
A. Wt of Soil (gm)
B. Wt of Sand Taken (gm)
C. Wt. Of Sand Left in Cylinder (gm)

Average

D. Wt of Sand in Cone (gm)

E. Wt of Sand in Pit [B-(C+D)] (gm)
F. Volume of Pit (E/Density of Sand)(c c)
G. Wet Density of Soil (A/F) (gm/c c)
H. Dry Density of Soil
[{G/(100+p)}*100](gm/c c)
I. MDD.. OMC.
J. Relative Compaction
MOISTURE CONTENT/CONTAINER NO.
K. Wt of Wet Soil +Container
L. Wt of Dry Soil +Container
M. Moisture Content in Sample (K-L)
N. Wt of Container
O. Wt of Dry Soil (L-N)
P. % of Moisture [(M/O)*100]

Average

PUNJAB PWD B & R

(PIDB PROJECTS)
6.15

CALIFORNIA BEARING RATIO TEST

(IS-2720-Part-XVI-1965)

Name of Work
:
Kind of Material
:
Location
:
Condition of Specimen:
Date Moulded
:
Date of Testing
:
Calibration Factor
:
Period of Soaking
:
Dry Density (gm/ c c) :
(Before Soaking)
Dry Density (gm/ c c) :

Date of Sampling
Sampled by
Soaked/Unsoaked
Providing Ring

:
:
:

Tested by
Frequency
(As laid down)

(After Soaking)
Percentage
Moisture Content
DETAILS OF TESTS
S.No

Dial
Gauge
Reading

Penetration
(0.01 mm)

Load Dial
Gauge
Reading

Load on
Plunger
(L) kg

Unit Load
Kg/sg.cm
(L/19.635)

Corrected
Unit Load
From Curve
kg/sq.cm

1
2
3
4
5
6
7
8
9
10
11
12

0
50
100
150
200
250
300
400
500
600
700
800

6.16

(X)
(Y)

PUNJAB PWD B & R

(PIDB PROJECTS)
WORK SHEET FOR BINDER CONTENT
DETERMINATION

Name of Work:
Kind of Material:
Material Source
Location
:

Date of Sampling
Sampled by

:
:

Date of Testing
Tested by
:
Frequency
:
(As laid down)

ITEM
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]

Observation : (Allowable Value from job Mix Formula=0.3%/0.5%)

PUNJAB PWD B & R

(PIDB PROJECTS)
6.17

WORKSHEET FOR MARSHAL STABILITYOBSERVATIONS

Average

Name of Work:

Date of Sampling

Chainage

Sampled by

Kind of Material:
Date of Testing :
(As laid down)

Tested by
STABILITY AND FLOW VALUE DETERMINATION

Mixing temperature, c

Grade of Bitumen (80-100)/(60-70):Pen, grade

Number of Blows on Either Side:

Flow Value Dial 1 Division

Compacting temperature, C :
:

Providing Ring Calibration Factor :

DETAILS OF TESTS
Sample No.

Bitumen
Content
Percent

Maximum
Providing
Ring
Reading

Stability
Value (Kg)
Measured

Flow Dial
Reading
Corrected

1
2
3
Average%
1
2
3
Average%
1
2
3
Average%
PUNJAB PWD B & R
(PIDB PROJECTS)
6.18

WORKSHEET FPR MARSHAL STABILITY TEST

CALCULATIONS AND RESULTS

Name of Work
Locations
Job Mix Formula
No. of Blows

:
:
:
:

Date of Testing

Flow
Value
0.01 mm
units

DETAILS /SPECIMEN NO.

A. Bitumen by Wt of Aggregate %
B. Bitumen by Wt of Mix (%)
C. Aggregate by Wt of Mix (%)
D. Dry Wt of Specimen in Air Igm)
E. Dry Wt of Specimen in Water (gm)
F. Saturated Surface Dry Wt (1 min in water)(gm)
G. Volume of Specimen (F-E) (c c)
H. Bulk Density of Mix (D/G) (gm/c c)
I. Volume of Bitumen {(H*B)/SG of
Bitumen)*100(%)
j. Volume of Aggregates [{(H*C)/SG of Mix
aggregate)*100](%)
K. Air Voids in Mix. [100-(I+J)](%)
L. Total voids in Mineral Aggregates (VMA)(100-J)
(%)
M. Voids Filled with Bitumen [(I/L)*100] (%)
N. Corrected Stability (kg)
O. Flow (mm)

PUNJAB PWD B& R

(PIDB PROJECTS)
6.19

WORKSHEET FOR COMPRESSIVE STRENGHT TEST

(Reference IS-516-1959)

Name of Work

Date of

Construction Site

Casting

Location

Sampled by

Slump

Date of
Testing

Sample Received
At Lab by

(As laid
Down) :

DETAILS OF TESTS

S.No.

Area of

Weight

Density

Load

Strength

Required

Mould Sq.
cm

Strength
Gm

Gm/c c

Kg

Kg/sq.
Cm

Kg/sq.cm

1
2
3
4
5
6
7
8
9
10
11
12
Observations:

PUNJAB PWD B& R

(PIDB PROJECTS)
6.20

WORKSHEET FOR BRICKS TEST

(Reference : IS-3495-Part-I to V-1973 First Revision)

Name of
Work
Material
Source
Location
Chainage
Quality at
Site
Brand of
Bricks
6.21

:
:
:
:
:
:
:

Date of Sampling

Sampled by
Date of Testing
Tested by

:
:
:

Frequency
(as laid down)

WATER ABSORPTION TEST

Brick No
A. Original Dry
Wt (gm)
B. Wt of Brick
After Absorption
for 24 hrs

Average

(gm)
C. Wt of Water
Absorbed (A-b)
(gm))
D. Average %
Absorption
(C/A*100)
6.22

COMPRESSIVE STRENGTH TEST

Date of flushing bed Faces
With Cement-Sand Mortar
(1:1)
Brick No
E. Bed Face Area of
Brick (sq cm)
F. Maximum Load at Failure
In (kg)
G. Compressive
Strength (F/E)(kg/Sq cm)

Date of Testing

Tested by

Observations : (Limits : AVG. not less than 105 kg/sq. cm).

6 (B) CHECK LIST FOR VARIOUS

ACTIVITIES

Average

CHECKLIST FOR VARIOUS ACTIVITIES

The contractor is to plan and program, make arrangements for materials, labour, plant and machinery
etc. for carrying out various activities in respect of work to plan for completion of work with in stipulated time
period. The contractor is required to plan for daily output of various activities and items of work in most
desirable workmanship manner including meeting of specifications under the overall Supervision and to entire
satisfaction of Project Engineer-cum-Executive Engineer.
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
PUNJAB PWD B & R
(PIDB PROJECTS)
Name of Contractor
Name of Work
Code No.

:
:
:

CHECK LIST FOR EARTH WORK

Location _______________________
Date __________ Time ___________
RFI No. _______________________
SL
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

DESCRIPTION

REMARKS
NO

YES
Are sufficient number of dozers, graders and rollers
available at site.
Are there are pipes, conduits, wires, cables below
ground.
Is the site clean.
Clearing/ grubbing done properly?
Is natural ground compacted?
Is a draining layer required & has the area been
delineated?
Is the draining layer in place?
Are toe points as per cross section?
Is the cut material suitable for benching?
Is the layer properly watered?
Is the compacted layer ready to field testing?
Is the compaction of placed layer satisfactory and
ready for next layer?
Have the deficiency been to the contractor for
rectifications?
General Remarks:______
Quality
Control
Engineer

______
___________
Project
Project
Engineer
Engineer
(Contractor).
Form : F-2
PUNJAB PWD B &R
(PIDB PROJECTS)

Name of Contractor
Name of Work
Code No.

:
:
:
CHECK LIST FOR GRANULAR SUB BASE
Location _______________________
Date __________ Time ___________
RFI No. _______________________

SL.
NO.

DESCRIPTION

REMARKS
YES
NO

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Are sufficient number of graders, dozers and rollers for

spreading and compaction available.
Are the results of laboratory tests for the borrow
material within the project specification?
Is the material watered properly?
Is the material within the tolerances for size?
Is additional moisture required?
Are the number of passes of rollers, speed and
procedures correct?
Are the layers adequately placed and compacted?
Are there any crack on the surface due to excessive
fines or due to over rolling?
Is the compacted layer ready for field testing?
Is the compaction of the placed layer satisfactory and
ready for next layer
Has the layer been proof rolled?
ADDITIONAL CHECK ON SHOULDERS
Are the shoulders to correct slopes?
Are shoulders trimmed to correct width?
Has adjacent AWC been cleaned at shoulders edges?
Have the deficiencies been reported to the Contractor
for rectification?
General Remarks:____________________________________
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.

:
:
:
CHECK LIST FOR THE WET MIX MACADAM
Location _______________________
Date __________ Time ___________
RFI No. _______________________

SL.
NO.

DESCRIPTION

REMARKS
YES
NO

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Is there sufficient equipment for placing and compacting

the WMM?
Is the GSB approved for density and level?
Do the WMM grading confirm to MOST Specification.
Is the sub-base slightly moist prior to placing WMM
base?
Have the steel level pins plus wire been checked for
level before paver commences work?
Is there any segregation during laying of the WMM?
Is the loose lift thickness adequate to give the
specification final thickness?
Do the WMM base appear to have uniform moisture
content?
Are there cracks on the surface e due to the excessive
rolling?
Have the loose and segregated portions been rectified?
Is the WMM base ready for field testing?
Are the density test results satisfactory and is the WMM
base ready for prime coat?
Has the finished layer been proof rolled?
Have the deficiencies been reported to the Contractor for
rectification?
General Remarks:____________________________________
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.

:
:
:
CHECK LIST FOR PRIME COAT/TACK COAT
Location _______________________
Date __________ Time ___________
RFI No. _______________________

SL.
NO.
1.

DESCRIPTION
Is the weather & temperature suitable for Priming?

REMARKS
YES
NO

2.
3.
4.
5.
6.
7.
8.
9.
10.

Was compaction tested?

Is surface clean?
Has surface been lightly dampened?
Are any pool of water?
Are spray jets and pumps ok?
Any leakages?
Sufficient Trays available?
Is the thermometer on the sprayer ok?
Has the temperature of prime been checked?
(Recommended temperature 330 to 550)
Speed clock working?
Is the distributor traveling at recommended speed?
Pressure pump ok?
Have the deficiencies been reported to the Contractor for
rectification?
General Remarks:-

11.
12.
13.
14.

____________________________________
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.

:
:
:

CHECK LIST FOR DENSE BITUMINOUS MACADAM /BITIMINIOUS MACADAM

WORKS
Location _______________________
Date __________ Time ___________
RFI No. _______________________
SL.
NO.
1.
2.
3.
4.
5.
6.
7.

DESCRIPTION
Is the whether & temperature suitable for asphalting?
Is the paver in good working condition?
Is the stand by equipment available?
Is a prime or tract coat required prior to proceeding
with the DBM?
Is the WMM base course approved and primed and
cleaned to allow the laying of bituminous base course to
proceed?
Are the survey stacks and wire setup property to control
the width and level if asphalt?
Is the departure time, weight and temperature
mentioned in the delivery slip?

REMARKS
YES
NO

8.
9.
10.
11.
12.
13.
14.
15.
16.

Are the placement and compaction temperature with in

the specified range?
Is the rolling operation, i.e number of passes, speed,
weight contact pressure etc. correct?
Is there any segregation in the pavment?
Is there thermometer in site?
Is the loose lift thickness adequate to ensure the correct
layer thickness after compaction?
Have the cold construction joints been primed/ coated?
Have the DBM samples been collected for laboratory
testing?
Are the finished levels of DBM within the tolerance?
Have the deficiencies been reported to the Contractor
for rectification?
General Remarks:____________________________________
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.

:
:
:

CHECK LIST FOR BITUMINOUS CONCRETE /SEMI DENSE BITIMINIOUS CONCRETE

Location _______________________
Date __________ Time ___________
RFI No. _______________________
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.

DESCRIPTION
Is the paver in good working condition?
Is the stand by equipment available?
Is the underlying base course approved and cleaned to
allow the wearing course to proceed?
Is tact coat required prior to proceeding with the BC?
Is the whether satisfactory for lying the?
Are the survey stacks and wire setup property to control
the width and level if asphalt?
Is the departure time, weight and temperature
mentioned in the delivery slip?
Are the placement and compaction temperature with in

REMARKS
YES
NO

9.
10.
11.
12.
13.
14.
15.
16.

the specified range?

Is the rolling operation, i. e. number of passes, speed,
weight contact pressure etc. correct?
Is there any segregation in the payment?
Is there thermometer in site?
Is the loose lift thickness adequate to ensure the correct
the correct layer thickness after compaction?
Have the cold construction joints been primed/ coated?
Have the BC samples been collected for laboratory
testing?
Are the finished levels of asphalt within the tolerance?
Have the deficiencies been reported to the Contractor
for rectification?
General Remarks:____________________________________
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.

:
:
:
CHECK LIST FOR BITUMINOUS MIX DELIVEY & LAYING

Truck/ Tipper No.

Type of Mix.
Date / Time of
Leaving plant
Temperature
Delivery Slip Issued

:
:
:
:
:

Time of reporting at site

Temperature of mix.
KM/Lane of laying
Time of discharge
Temperature at the time of
Discharge
Time at departure

:
:
:
:
:
:
:

Yes/NO

______________

_______________

__________________

Representative of
CONTRACTOR

Representative of
Q.C ENGINEER

Representative of
PROJECT ENGINEER

Form : F-9
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor
Name of Work
Code No.

:
:
:
Location _______________________
Date __________ Time ___________
RFI No. _______________________
CHECK LIST FOR FORM WORK

SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

DESCRIPTION
Form Work design/ drawings approved including desheuttering
Trial panel approved ( if required)
Form work alignment correct.
Form work levels correct.
Form work dimensions correct.
Form work member spacing correct.
Form work member material quality acceptable
False work members spacing, sizes & quality
acceptable.
Gaps between primary and secondary members
wedged.
Joints between panels closed and flushed.
Panel flatness acceptable.
Tie rods spacing correct and properly tight
Spaces between shutter surface tightly fitted.
Box outs, cast-in-items, ducts, fixed correct, securely.
Pre-stressing shuttering and vents, alignment and
spacing of supports acceptable.
Empty sheating secured against floatation.
Pre- stressing anchorage position and fixing acceptable.
Chamfers (fillet sizes, straightness, fixing acceptable.)
Formwork clean
Formwork release oil material approved and applied.
Construction joint preparation satisfactory.
Contraction / Expansion joint preparation satisfactory.
Safe access constructed.
Adequate work space provided for labour, equipment.

REMARKS
YES
NO

25.

Shutter Vibrators (if required), location and fixing

arrangements approved.
General Remarks

______________
________________
QUALITY CONTROL PROJECT ENGINEER
ENGINEER
(CONTRACTOR)

_______________
PROJECT
ENGINEER

Form : F-10
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor
Name of Work
Code No.

:
:
:

Location _______________________
Date __________ Time ___________
RFI No. _______________________
CHECK LIST FOR REINFORCEMENT
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

DESCRIPTION

REMARKS
YES
NO

Working drawings with latest revision approved.

Bar schedules approval.
Reinforcing steel material approved.
Bar bending and cutting satisfactory.
Corrosion treatment of bars, if required, satisfactory.
Bar sizes correct.
Bar spacing correct.
Bar lap lengths correct.
Bar laps at correct location.
Bars ties as specified.
Bar assembly rigid and adequately supported.
Cover to bottom bars correct.
Cover to side bars correct.
Cover to top bars correct.
Cover blocks approved including fixing.
General Remarks

______________

________________

_______________

QUALITY CONTROL PROJECT ENGINEER

ENGINEER
(CONTRACTOR)

PROJECT
ENGINEER

Form : F-11
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor
Name of Work
Code No.

:
:
:

Location _______________________
Date __________ Time ___________
RFI No. _______________________
CHECK LIST FOR CONCRETE WORK
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

DESCRIPTION
Mix design Approved.
Batching Plant/ concrete weight batcher in working
order.
Stand by mixer in working order.
Water, sand, coarse aggregate, cement and admixture
approved.
Water, sand, coarse aggregate, cement, admixture stock
sufficient.
Concrete conveying arrangement, (Transit Mixer) in
working condition and adequate capacity.
Form work approved.
Reinforcement approved.
Pre stressing sheathing approved.
Sufficient vibrator available in working condition.
Tremie in working order ( for under water work.)
Concrete gang present, including carpenter, steel fixer.
Access as provided adequate.
Safety arrangements provided.
Lighting arrangements provided.
Communication between various points provided.
Arrangement for stoppage of concrete provided.
Curing arrangements made.
Laboratory notified for sampling.
General Remarks

REMARKS
YES
NO

______________
________________
QUALITY CONTROL PROJECT ENGINEER
ENGINEER
(CONTRACTOR)

_______________
PROJECT
ENGINEER

Form : F-12
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor
Name of Work
Code No.

:
:
:
CHECK LIST FOR CONCRETE DELIVERY & POUR

1) CONCRETE DELIVERY AT BATCHING PLANT

Concrete grade
:
M
Tipper/ Transit Mixer No.
W/c ratio
:
Time
Cement content
:
Location
Maxm Aggregate Size :
mm
Admixture
:
Design slump
:
mm

2) POUR AT SITE

Member of structure
Slump
Discharge Started
Placement completed
No. of cubes taken
Placement Temperature
Ambient temperature
Weather condition

:
:
:
:
:
:
:

MM
hours
hours
0

C
C

______________

_______________

__________________

Representative of
CONTRACTOR

Representative of
Q.C ENGINEER

Representative of
PROJECT ENGINEER

:
:

Form : F-13
PUNJAB PWD B &R
(PIDB PROJECTS)
Name of Contractor
Name of Work
Code No.

:
:
:

Location _______________________
Date __________ Time ___________
RFI No. _______________________
CHECK FOR POST CONCRETEING INSPECTION
SL.
NO.

DESCRIPTION

1.
a)
b)

STRIPPING OF SIDE SHUTTERING.

Position / dimension of member.
Surface defects: honey combing / Air Bubbles/ cold
joints.
Cracks :Number and nature
Class of finish.
Any other defect.
EACH STAGE OF PRESTRESSING.
Position / dimension of member.
Surface defects: honey combing / Air Bubbles/ cold
joints.
Cracks :Number and nature
Class of finish.
Any other defect.
DE- CENTRING
Position / dimension of member.
Surface defects: honey combing / Air Bubbles/ cold
joints.
Cracks :Number and nature
Class of finish.
Any other defect.

c)
d)
e)
2.
a)
b)
c)
d)
e)
3.
a)
b)
c)
d)
e)

______________
________________
QUALITY CONTROL PROJECT ENGINEER
ENGINEER
(CONTRACTOR)

REMARKS
Satisfactory
Not
Satisfactory

_______________
PROJECT
ENGINEER

Form : F-14
PUNJAB PWD B &R
(PIDB PROJECTS)
CALIBRATION CHART OF BATCHING PLANT FOR AGGREGATE GAUGE CALIBRATED DATE :
Load
Applied
(KG)

DIAL GAUGE READING

TRIAL-1
Loading

UnLoading

0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
REMARKS :
PROJECT ENGINEER

TROA;-11
Loading
UnLoading

TROA;-111
Loading
UnLoading

AVERAGE

CONTRACTORS REPRESENTATIVE
Form : F-15
PUNJAB PWD B &R
(PIDB PROJECTS)

CALIBRATION CHART OF BATCHING PLANT FOR WATER METER CALIBRATED DATE :

SL.NO

TRIAL-1
METRE
Reading

WATER
Measured

TRIAL-11
METRE
Reading

WATER
Measured

TRIAL-111
METRE
WATER
Reading
Measured

Average

(LTRS)

(LTRS)

(LTRS)

(LTRS)

(LTRS)

(LTRS)

1.
10
2.
20
3.
30
4.
40
5.
50
6.
60
7.
70
8.
80
9.
90
10.
100
11.
110
12.
120
13.
130
14.
140
15.
150
REMARKS:

10
20
30
40
50
60
70
80
90
100
110
120
130
140
150

10
20
30
40
50
60
70
80
90
100
110
120
130
140
150

PROJECT ENGINEER:

CONTRACTORS REPRESENTATIVE

Form : F-16
PUNJAB PWD B &R
(PIDB PROJECTS)
CALIBRATION CHART OF BATCHING PLANT FOR CEMENT GAUGE CALIBRATED DATE :
Load
Applied
(KG)

DIAL GAUGE READING

TRIAL-1
Loading
0
50
100
150
200
250
300
350
400

UnLoading

TROA;-11
Loading
UnLoading

TROA;-111
Loading
UnLoading

AVERAGE

450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
REMARKS :
PROJECT ENGINEER

CONTRACTORS REPRESENTATIVE
Form : F-17
PUNJAB PWD B &R
(PIDB PROJECTS)

CALIBRATION REPORT
(Cube Testing Machine)
DATE OF CALIBRATION
GAUGE NO.
EQUIPMENT
FORCE MEASURING DEVICE
CERITFIED BY

TEMP.
CAPACITY
MODEL
SL. NO.
PLACE
REF.

SL.NO.

DEFLECTION
IN DIAL GAUGE
IN
PROVING RING

ACTUAL
LOAD
APPLIED

AVERAGE
OF THREE
READINGS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
NOTE : to obtain correct result positive (+) error to be subtracted, negative
be added to the indicated load readings on machine gauges.

INDICATED
LOAD ON
GAUGE
ERROR

(-) error to

PROJECT ENGINEER

CONTRACTORS REPRESENTATIVE
Form : F-18
PUNJAB PWD B &R
(PIDB PROJECTS)
RECORDS OF CALIBRATION OF EQUIPMENT

Name of Work
:
Name of Contractor
:
ITEM
Date Calibrated
& person
certifying
(for vendor of
contractor)

Date of
Next
Calibration

Date of
Inspection &
Person
approving
(for department
Result of
Inspection

* Frequency of Calibration for different equipment to be specified in advance.

PROJECT
ENGINEER

AUTHORISED REPRESENTATIVE
OF CONTRACTOR

Result of
Inspection

7. CONTROL OF ALIGNMENT , LEVEL

AND
SURFACE REGULARITY

7. CONTROL OF ALIGNMENT , LEVEL AND SURFACE REGULARITY

7.1 GENERAL
All works shall be constructed to the specified lines, grades, crosssections and dimensions. The objective is to achieve a well built pavement conforming to the required
horizontal and vertical profile, design thickness of different payment courses and stipulated standards of riding
quality.
Given here are the producers for checking and permissible tolerances in different cases.
7.2 HORIZONAL ALIGNMENT
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--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.
Allowable tolerances in respect in respect of horizontal alignment are recommended to be as follows:
(i)

Carriageway edges

10mm

(ii)

Edges of the road

40mm

way and lower layer of

pavement
7.3

SURFACE LEVELS OF PAVEMENT COURSES.

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 :

Subgrade

Sub- base
Flexible pavement

20mm
25mm

(+)
(-)

10mm
20mm

Base course for flexible pavement

(a) Bituminous course (+)
6mm
(-)
(b) Other than bituminous
Machine laid

(+)
(-)

(+)
(-)

6mm
10mm
10mm

Wearing course for flexible pavement

(a)
(b)

Machine laid
Manually laid (+)

(+)
(-)

6mm
6mm

10MM
(-)
10mm

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.
7.4

CONTROL ON LAYER THICKNESS

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.
7.5

STANDS OF SURFACE REGULARITY

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

Sr.
No.
1.

Type of Construction

Longitudinal Profile with 3 meter

straight Edge
Maximum

Permissible
Undulation mm.

Cross

Maximum

number of
Undulations

Maximum

Permissible
Variation form
Permitted in any
Specified
300 metre length
profile
exceeding mm. Under camber
18 16 12 10 6 template mm.

1.
1.
2.
3.

2.

3.

Earthen sub-grade
24
Stone soling/brick soling
20
Stablised soil
15
4.
Water bound macadam with
Over size metal(40 to 90mm size) 15
5.
Water bound macadam with
12
Normal size metal (20 to 50mm and
40 to 63 mm size) Penetration macadam
or BUSG

6.

Surface dressing (two coats)

12

4.

5.

6.

7.

8.

9.

30
-

30
-

30

15
12
12

30
-

30

12

20

7.

7.7

10

30

8.

Bituminous macadam

10

30@@ 6

9.

Bituminous Concrete

20@@ 4

10.

Cement Concrete

10@@ 4

Note:i.

7.6

over WBM (20-50 mm or 4063mm size metal)

Penetration macadam or
BUSG
Open graded premix carpet
20-25 mm thick

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.

Control of Transverse profile

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.

Control of Longitudinal Profile

The longitudinal evenness is specified in terms of the maximum permissible irregularity

under a straightedge. Typical designs for a metallic straight-edge and measuring wedge are
given in Fig.4. The sub-grade level.

The procedure to be followed for marking surface unevenness measurements with a

straight-edge is given at Appendix.I

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.

The maximum permitted number of surface irregularities shall be as per table7.2

Table 7.2
MAXIMUM PERMITTED NUMBER OF SURFACE IRREGULARITY

Surfaces of carriageway
And paved shoulders
Irregularity
Length (m)
75
National
Highways
Expressways
Roads of Lower
Category
3

20

Surface of lay-bays, areas and a

-ll bituminous base

4mm
300

75

7mm
300

40

18

4mm
75

300

40
2

75

18
60

700
300

4
27

2
6

(Category of each section of road as described in Contract)

The maximum allowable difference between the road surface and underside of a 3m straight-edge when placed
parallel with, or at right angle to the centre line of the road at points decided by the Engineer shall be:
For pavement surface (Bituminous and cement concrete)
For base course Bituminous
For granular sub-base/base courses
For sub-base concrete pavements

3mm
6mm
8mm
10mm

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.
(ii)

Granular subgrade: Same as at (i) above.

(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.

8.

SURVEYS STUDIES AND

PREPARATION OF DETAILED
PROPOSALS

From :
The Chief Engineer (IP),
Punjab PWD B&R Branch,
Chandigarh.

To
1.

The Project Engineer cum EE,

Central Works Division,
SAS Nagar.

2.

The Project Engineer cum EE,

Provisional Division,
SAS Nagar,

3.

The Project-Engineer cum EE,

Central Works Division,
ROPAR.

4.

The Project-Engineer cum EE,

C/W Division No.3
LUDHIANA.

5.

The Project-Engineer cum EE,

Provisional Division,

AMRITSAR, NAWANSHAHAR.
6.

The Project-Engineer cum EE,

R & D Division No.3,

LUDHIANA
7.

The Project- Engineer cum EE,

Provisional Division,
JALANDHAR.

Memo No. :
Dated :9.7.2000

IP/ CH/362-368

Sub: Execution of Road Project :Preparation of Detailed Proposal for Approval of Technical
Committee of PIDB.
Although Item Rate DNITs 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/Chief Engineer (IP)

DA/Guidelines

8.
8.1

GUIDELINES OF THE FINALIZATION OF SCOPE OF WORK

Earth work:

The Quantities of the E/W in the DNITs 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.
8.2

PROFILE CORRECTIONS

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.

8.4

PROVISION OF LAY BYES

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.

8.5

EXTENSION OF EXISTING CULVERTS AND SMALL BRIDGES

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.
8.6

ROAD SIGNAGE & OVERHEAD SIGNAGE

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

The proposal for traffic marking in thermoplastic paint shall include:

1. Providing of zebra crossing near schools, which is mandatory as per the orders of Honble
High Court.
2. Center line; Lay bye lines including non overtaking zones, if any.
3. Traffic marking at Traffic Signals/ Junction/Intersection.

9. RECORDING OF TEST RESULTS &

QUALITY CONTROL RETURNS

9.1

VALIDITY OF TESTS RESULTS/CERTIFICATES

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.

i)

Verification/confirmation of field test

Results

Pb. PWD (B&R Research

Lab. Nabha Road, Patiala.

ii) Job Mix formula for Bitumen Mixes,

GSB and WMM

I) Consultant Lab.
ii) Any other reputed laboratory
With the permission of Project
Engineer.

As above and reputed

Laboratory with the permission
of Project Engineer.

iii)
iv)

Concrete Mix Design

CBR, C & values of Earth work
and CBR of Granular Sub base sources

v)

Important materials of bridges such as :

a)
Bearings

At manufacturers Lab . in the

presence of representative of
Project Engineer.

b)

Prestressing strands (must accompany

with test certificates)

At Suppliers Laboratory

c)

Prestressing accessories, sheathing,end anchorages, cones

d)

Expansion joints
(From empanelled manufacturers of
MOST)

9.2

At suppliers laboratory (with

all accessories accompanied
with test certificate.
-

At suppliers laboratory

DUTIES OF QUALITY CONTROL CONSULTANT

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:
(A)

Prior approvals are obtained, well in time for:

Source of earth for embankment on the basis of suitability determined by grain size analysis,
OMC verses MDD, unconfined undrained compression values of C& and their possible trial
testings in field lab.

9.3

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.

(C)

Testing/ checking of Post Construction works as per desired frequency.

(D)

Keeping record of consignment of important materials and the manufacturers

Test certificates.

(E)

Occasional verification of test results of cement & steel from the independent
reputed lab.

(F)

Occasional checking of calibration of Machinery /Testing Equipments and

keeping its record.

(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.

MAINTENANCE OF QUALITY CONTROL RECORD

Following register shall be maintained for recording results:(i)

Record of consignment of Cement, Steel, Bitumen and Emulsion with manufacturers Test Certificates
details.

ii)

Approval of source of materials.

iii)

Approval of Job Mix Formula of Bituminous specifications and non bituminous specifications.

iv)

Approval of concrete mix design.

v)

Checking earth work in embankment.

vi)

Post construction test of Non Bituminous specifications.

vii)

Post construction test of bituminous specifications.

viii)

Compressive strength of cubes.

ix)

Slump at the time of pouring concrete.

(x)

Control of alignments and surface regularity.