QUALITY ASSURANCE MANUAL CONSTRUCTION OF CONCRETE STRUCTURES | (Bridges & Fiyovers) CENTRAL PUBLIC WORKS DEPARTMENT 7 CPWDIEO2- FOR GOVERMENT OF INDIA ose eee eee ee eeCHAPTER -1 CHAPTER -2 CHAPTER -3 CHAPTER -4 CHAPTER -5 CHAPTER -6 CHAPTER -7 INDEX INTRODUCTION GUIDELINES FOR USING THE MANUAL QUALITY ASSURANCE PLAN FOR BASIC CONSTRUCTION MATERIALS 3 32 33 34 35 36 37 38 QUALITY ASSURANCE PLAN FOR SITE ACTIVITIES 41 42 43 4a 43 46 47 48 49 Materials from Natural Rescurces Steel / Iron Chemicals Bitumen Prestressing Pipes Other Materials Assembled Accessories 14 5-13 15-86 18-37 38-45 46-57 58-61 62-68 69-72 B81 82-86 87-100 Mix Design including Trial Mix and acceptance criteria 91 RCC work Piling ‘Embankment construction Water Bound Macadam ‘Wet Mix Macadam Bituminous Works (BM, DBM, AC) Mastic Works Reinforced Earth Works IN HOUSE /ON SITE TESTING FACILITIES 5.1 52 53 Materials Site Activities Calibration of Equipment OUTSIDE / INDEPENDENT TESTING FACILITIES SITE DOCUMENTS 92 93 94 95 96 97-98 9 100 101 - 130 105-118 119-124 125 131-151 153-182CHAPTER -8 CHAPTER- 9 CHAPTER - 10 CHECKLISTS AND TEST PROFORMAS 8.1 Checklists 8.1.1 Checklist for Source/Agency Approval 8.1.2 Checklist for Site Activities 8.1.3 Checklist for Launching Girder 8.14 Checklist for Launching Operation 8.2 Test Proformas METHOD STATEMENTS NON CONFORMING PRODUCTS AND PROCEDURES vi 183-276 183-237 187-204 208-223 224-228 229.237 238-276 277-300 301-310CHAPTER - 1 INTRODUCTIONINTRODUCTIO! Central Public Works Department is a premier construction agency of the Govt. of India, which has been entrusted with the task of building several challenging projects all over the country. The Department had taken up the construction of no. of flyovers in Delhi with a specific view to reduce the construction time so as to minimize traffic disturbances usually faced during construction. Amongst the materials for construction of Flyover, cement concrete is being used widely world over. Four concrete flyovers using precast segmental technology were recently completed and on the basis of the experience gathered, it was decided to prepare a uniform and generalized Quality Assurance Manual (QAM) to be followed in the future flyover projects with specific reference to precast prestressed concrete using segmental technique. This QAM has been prepared to complete the general procedures and guidelines to be followed by the construction supervision personnel in carrying out all aspects of the Construction Supervision tasks. This Manual mainly provides procedures for carrying out tasks related to inspections, testing and reporting. However, this manual does not deal with day-to-day technical requirements, nor does it provide solutions to technical problems, as the Specifications and other Contract Documents usually administer these technical issues. The document is Jargely based on the norms set up by Indian Road Congress Publication IRC: SP : 47-1998. Since precast segmental flyovers fall into category of Innovative Technology, the manual has been based on Class Q-4 of the publication. A concept of Level of testing has been introduced in order to cover up levels of testing of materials and products depending upon various factors. Every effort has been made to evolve this Manual so that adherence to its guidelines will result in efficient, safe and consistent supervision of the works in strict conformity with the Specifications and other Contract requirements. This has led to the basic framework of this Manual being based on construction supervision procedures consistent with standard intemational practices for construction of important flyover projects of this type, with specific guidelines and forms where appropriate, being generated based on standard practices in India in conformity with MORTH and IRC standards and guidelines. n all cases, however, it is important that all users of this Manual understand that the contract documents including the specifications are the controlling documents for the supervision of the construction.Although the intention of this Manual is to provide efficient, safe, high quality construction, adherence to the adopted guidelines does not necessarily guarantee that these attributes are achieved. Therefore, the users are cautioned to exercise judgement based on good engineering practice in all cases rather than blind adherence to the adopted guidelines. This also points to the urgent need to periodically review and update relevant guidelines and procedures, and hence the Manual is to be seen as an evolving guide.CHAPTER -2 GUIDELINES FOR USING THE MANUAL2A GUIDELINES FOR USING THE MANUAL This Quality Assurance Manual is a document, by use of which, the total quality of the construction of flyover will be managed as per the Q 4 standards of IRC: SP: 47. This Publication of the Indian Roads Congress gives the guidelines for achieving the quality of construction of roads, flyovers and bridges and provisions of Q 4 system guides the suppliers and producers for achieving the end product with extra high quality assurance. As also mentioned in the Chapter 1 i.e, Introduction that while constructing costly structures for public use, it is desirable that the strong and durable structures needing minimum maintenance are constructed. Therefore, it is essential that during execution, the works be managed in such a manner that the best possible quality is achieved. Every agency, whosoever is involved in the construction, and in whatever capacity it may be, shall aim for achieving the best quality. This shall require the quality management planning in advance Every activity during the construction is necessary to be planned and monitored closely Further it is not only the planning and monitoring, but also the documentation of activities, which plays a very vital role in assuring and achieving the high quality standards, This manual is divided into 10 chapters and this chapter elaborates the guidelines for the use of the manual. Chapter 3 to 8 guides the user regarding the testing of basic ingredients and site activities, while chapter 9 has coverage of method statements of activities commonly involved in the construction of a flyover. Chapter 10 covers the non- conforming praducts and procedure to be followed for deciding their acceptance or rejection, Quality Assurance Plan (QAP) for Basic Construction Materials Every construction activity starts with the use of basic materials which may be either in raw shape like earth, sand, stone aggregates, etc. or manufactured materials like cement, steel or bitumen or assembled for accessories like bearings or expansion joints. Materials to be procured at site for use in any site activity have been covered in Chapter 3. Efforts have ‘been made to include each and every material that is required (o be procured at site for theuse in site activities like concreting work, raising embankments or laying wearing courses. Chapter 3 has been titled as Quality Assurance Plan for Basic Construction Materials. The chapter has been classified into different parts on the basis of the type of materials and their source. QAP includes the tests that every material has to undergo before it is accepted and approved for use in the work. QAP is given in 5 columns. Column 1: It lists the name of the test that a material is essentially to undergo before accepting it as fit for use in the work Column 2: It gives the frequency of the testing of materials. A material once approved is required to be tested periodically to ensure the uniformity in its quality and to ensure that the does not deteriorated after initial acceptance Column 3: Depending upon the type of material and its use in the structure, it is mandatory that some materials are repeatedly tested in the site laboratory and also independently tested from some outside approved reputed laboratory. Column 3 of QAP indicates the check level of the test, which is to be performed on the material First Level ie. Level 1 indicates the tests performed by the contractor before requesting the department for accepting the material. This test may be in the shape of Manufacturer's Test Certificate (MTC) on the basic tests at random conducted by the manufacturer or it may be the tests got conducted by the contractor at his own level before requesting the department for its approval Next Level ic. level 2 indicates the tests to be conducted by the department in order to ensure satisfaction regarding the suitability of the material in view of the test certificates submitted by the contractor. These testing may be at the site laboratory if the facilities could be created or got done by an outside laboratory if the facilities are not possible to create in the site laboratory.-Depending upon whether the tests have been conducted at site laboratory or outside laboratory, Level 2 is classified in two categories i.e. Level 2A and Level 2B. Level 2A is for2.2 the tests conducted at site laboratory and level 2B is for the tests conducted ‘outside the site laboratory as necessary facilities could not be made available at site. There are some materials like cement and steel, which are more sensitive than other materials. For such sensitive materials, in order to have more confidence, it is always desired that such materials are got tested from an independent source. This level of testing the sensitive material from an independent source has been classified as Level 3. It is essential that such an independent source should be a well-reputed laboratory equipped with proper controls like temperature, humidity etc. essential for the specific material testing and also equipped with well- qualified staff, from whom an expert opinion can be obtained, As per the above levels, the need of the level required for testing the material is given in this column, Column 4: It gives the reference of the Bureau of Indian standard or Indian Roads Congress standard or some other equivalent recognised standards which the material is expected to meet. Also these standards depict the test procedure of the test to be performed, ‘Column 5: The acceptance standards of the materials are given in this column, ‘The materials shall be accepted for use on the work only after the testing of the material as per this Quality assurance plan. Like the materials, various construction stages are also required to undergo testing/checking before the items are accepted and payments to the contractor released. QAP for all these site activities is given in Chapter 4 of the manual and all the activities are detailed out in 4 columns.2.3 Column 1: It lists the names of the test that every activity is essentially to be subjected before its acceptance. Column 2: It gives the frequency of the testing of materials or the lot size for which testing is required to be done. Column 3: It gives the reference of the Indian standard or other equivalent applicable standards which the item is expected to meet. Also these standards depict the test procedure of the test performed, ich may be decided by the department. Column 4: The acceptance standards are given in the column 4 of this QAP. It is only after the completion of the testing of the items/site activities as per this Quality assurance plan that a particular work is accepted. In House/On Site Testing Facilities While Chapter 3 and 4 cover the QAP for the construction materials and the site activities, their testing facilities are covered under Chapter 5 and 6. For prestigious projects like flyovers and bridges, it is essential that in house testing laboratory is created so as to perform the tests which ase comparatively easier to perform with simple setup or are required to be conducted very frequently. Often the nature of the test is such that immediate results are needed. Such facilities should be created in the site-testing laboratory. Details of all such tests are furnished under Chapter 5 of the manual, All the materials for in house testing are detailed in this chapter under 4 columns. Column | gives the details of the test to be performed in house i.e. site laboratory. Column 2 gives the size of the sample of each material to under go a test and the standard which gives the standard testing procedure is, ‘mentioned in next column 3. While testing the material, the readings during the testing are required to be recorded in a proper manner. In order to simplify the recording and to record every data essential to record, data sheets have been created. The formats of these data sheets are given in Chapter 8. For the sake of convenience, all the required facilities for conducting the test are furnished in column 4. At the end of the Chapter 5, all the facilities 1024 2.5 2.6 ad the standards essential to be provided in site laboratory are summed up and indicated in this Chapter. Outside independent Testing Facilities Since the total tests required to meet the Quality Assurance Pian given under Chapter 3 and 4 are large in oumber and require extensive equipment & personnel set up, all the testing facilities can not be provided at site. Moreover as per the QAP give under chapter 3, many test are to be done at level 3, which means testing by an independent agency. Many reputed Test Houses conduct these tests. For the sake of convenience of the users, some of the reputed test centres are given in Chapter 6 and information about the testing facilities available in these centres has been compiled as ready reckoner. It is furnished in tabulated form, which is quite convenient to consult and use. Wherever the required testing facility is available, it is shown in a tick mark (“) against that test house and the test to be conducted. Site Documents During the currency of a project, itis essential to keep certain documents at site for making permanent record of each and every item related to the project. Such items may include tests conducted at site, instructions issued to the contractor, record of drawings issued to the contractor, inventory of the material at site and so on, All such site documents play a vital role not only in assuring the quality of the work, but also in making the total management of the project comparatively easier. For the sake of the user, all these documents with a unique identification number have been listed under Chapter 7 of the manual with a format for each of them, The record of all such documents kept at site is to be stored in the Master Register of the Chapter 7 Check Lists and Test Proformas For the efficient execution of the work, it is essential to ensure that the work done at various stages is done as per the standard procedure. Omitting compliance of any check is likely to create troubles in accomplishing the activity with the desired quality standards. onl27 Hence in order to ensure a proper follow up of the construction methodology, checks are conducted at all important stages. To control such tests, checklists are evolved and have been given under Chapter 8 for all the important items of the work. The site staff are required to fill up the relevant checklist while allowing the contractor to proceed with the operation of the particular work. Itis not only the execution of the item that the checklists are made use of, but also for the approval of the agency/suppliers for various sub contracts. The checklists have been separately formulated for this purpose and given in the same chapter. Further, for the in house testing facilities as given under chapter 5, the formats for the data sheets for performing various tests are given in chapter 8 and all the test proformas/data sheets have to be given a unique identification number for proper record of all the tests results, All the formats of the test proformas are required to be docketed in a separate register titled as Check lists/Test Proformas Record for which a format has been given as a site document under Chapter 7. Method Statements Chapter 9 incorporates method statements for site activities. These statements are given for only guidance purpose. It is essential that the contractor submits his own method statement depending upon his setup and arrangement of the type of the machinery for each and every item before proceeding with its execution and gets it approved from the department. Generally for the specialised items like bearings, expansion joints, reinforced soil work, jaunching of segments, specialised agencies are engaged and depending upon their experience & way of wotking, the method statements can be given by those selected specialised agencies. However, some common items like Piling and its testing, Pile Caps, Bituminous Works, Installation of bearings and Expansion Joints, Embankment, WBM etc. have been covered in this chapter and it is desirable that the execution of each and every activity be started only after the method statement is approved and available with the site staff, 122.8 Non Conforming Products and Procedures The last Chapter i.e. Chapter 10 covers the procedure to be adopted for the non-conforming products. While working at site, situation occurs when some particular item/product does not fulfil certain test standards, but the same is otherwise acceptable as it passes other alternative tests. On fulfillment of alternative test, such products are generally accepted at lesser cates than accepted in the contract. The procedure to be followed for accepting such products is agreement rates or reduced rates is well explained in this chapter. ‘The above guidelines are framed for the convenience of the site staff to follow the manual and make effective use of it. Once the various formulations of the manual are followed strictly, system of IRC. SP: 47 is hoped that the end results shall be of a extra high quality as desired under Q4 13CHAPTER -3 QUALITY ASSURANCE PLAN for BASIC CONSTRUCTION MATERIALSP for Basic The first step towards ensuring good quality construction is to get good quality basic materials required to be used in the construction activities. These materials may be raw materials like Aggregates, Sand, Earth or Water, processed materials like Cement, Bitumen, Geotextile, Sealant etc or processed and assembled materials like Bearings and Expansion Joints. This shall also require prior approval of the source or supplier for the individual material or product as given under chapter 8 In order to ensure that material used in construction is of high quality and meets the codal requirements of BIS, IRC or MOST as applicable, a seties of tests have to be carried out at regular frequencies. The testing has to be done first at the level of the supplier / manufacturer or the conteactor, This forms the first level check The testing may be done jointly with the client or the client may do the testing independently in the site laboratory. This forms the second level check The material is also got tested from reputed independent laboratories, This forms the third level check This chapter gives the level of testing required for the various materials as well as the frequency of such testing Extensive testing of the basic materials shall ensure that only the best quality materia! is cleared for use on the work so that extra high quality construction can be done. 17 1965 CPWOr2002—34,3.1 Materials from Natural Resources 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 For Concrete Works 3.1.1.1 Coarse Aggregates 3.1.1.2 Fine Aggregate 3.1.1.3 Water Aggregates for Road work (Non Bituminous Sub bases and Bases) a) Granular Sub Base b) Water Bound Macadam c) Wet Mix Macadam Aggregates for Road work (Bituminous Base and Surface Courses) a) Bituminous Macadam b) Dense Graded Bituminous Macadam c) Bituminous Concrete d) Mastic Asphalt Earth for Embankment Lime (for Bituminous Works) 18 1965 CPwo2002—38opuy ssouryey J pure uoTeBuo|y paurqusos Jo anpea uINUIXEPY % SE xepuy worw8uoiq pus xopuy ssourpety (q s-0 wa Sty 07-0 ua OL ool- 8 un $71 ‘azys [euyuION oor una 0Z man SZ s-0 um sup 02-0 unt Ot 001 - $8 ww 07 ams jeuywion, 001 un OF ur 0Z Gn8}94 Aq) Bupssed vopeudyseq aBuyuaaieg Aas SI Suypep siskjery aaag (e ve 399M 8 UL 990 *Z amos Jo aBuayD + £96 pue somos yoe> ued) 981 Jo yeaoidde 105 advqs, OL61-€8E I Burumseq MP WT] PUvads ayouuvd (1 POT Spuwpuwsg eouesdessy | sepog you | ND Aouanbary wo, SayeBoiBBy asse0D PETE SHAOM 99190.) 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These tests for various activities comprise its QAP. The results of these tests shall be reported as per the proformas given in chapter 8 and the various checks required to be made at different stages have also, been given chapter 8. A standardised procedure for carrying out the activities have to be viewed as a whole in order to ensure the complete QAP of any particular activity. 8941 4.2 43 45 4.6 4.7 48 Mix Design including Trial Mix and acceptance criteria RCC work Piling Embankment construction Water Bound Macadam Wet Mix Macadam Bituminous Works (BM, DBM, AC) Mastic Works Reinforced Earth WorksJoaraRi used 10 gw 0S Joy | smd + ¢ € ed € - yiSuang onstraizeseUD z paytsadg ajdues ue yo wBuang z 1 edn ¢ sojdures — (,w) + yBuang onsuooeeyy payredg = sajdues odoz Jo 91019009, LOI aaningastio? » Jo dnosB Aue jo wBuans weap “t | -1Z : UT ON = jo-hid)|- aaumdasoy (Zz, sojdures op ase} ye wos} UONRIASG prepurng x po"I + BUEN uaoeIeYD payloads = yBuang Uap 18IE], uo J01e] 09 W Pur So 403 PAN HL 7 SSW Pur Sp 40} PN £1 ‘Ob WW PUP SEW “OL JO, RaW ZI “SZ W 40} Be WIT = urease WaLIND, urerepy wound + yiBuaNg w8uans onsuaiseseyy paytoads = ySuang ueapy 198se | Tepareur Kuz Jo 203005 uray 0002 aBueys Aronaiog‘z | wBIe, (e Aqentyy | -1Z : OUI UBIsop As9A9 Joy] x Te (1 BpoD> aouerdasay | suasajoy Aousnbasg, way, BLA aoueydaooy pur XT [ELL Surpnyouy usisaq XW TP 1‘ays10U09 anya paytoads amp Jo 5°16 (puow pouopreyy (q ane payioads at Jo 25°16 syom eur ou | ar0sDu00 ysouy (@ aspugye Aysueq (s 1y8!9q WHN9T | peoy soy s yuo pue guuigs! 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OOS 405 | sjoueg Jo Zu 00S 405 (1IIDeq sjoueg JO ZW OOS 405 | Jo anoyaeqad, teampnas (¢ 39, moO TINd ding (Z wL mo nnd 807 (1 aauerdasoy apog aauer3}9y Aauanbasy, aL wrayskg WIeT Prs0yuLyY 6'pCHAPTER -5 IN HOUSE /ON SITE TESTING FACILITIESIn House / On Site Testing Facilities A Filed laboratory shall be set up at the site of work 10 take up testing of the basic construction materials like Coarse aggregates, Fine aggregates, Water, Cement. Soil, Earth, Concrete etc. The objective is to carry out certain basic tests on the materials so as to ensure that they satisfy the requirements of extra-high quality. The laboratory, in general, is required to have the following equipment. 1. Square hole Sieves of Size 80mm, 63 mm, SOmm, 40 mm, 31.5 mm, 25mm, 20mm, Lémm, 12.5mm, \Gnun, 6.3mm, 4.75mm Fine mesh, wire cloth sieves of size 3.35 mm, 2.36mm, 1.18mm, 600, 300, 150u, 75} ‘Thickness Gauge Length Gauge Balance (for a load of 1000g +1) Balance (more than 3 Kg capacity) with 0.1 % accuracy Oven (100 to 110 °C Capacity) A stout water container ‘Two dy soft absorbent cloths each not less than 75 x 45 cm, 10. A shallow trey not tess than 650 cm? IL. An airtight container 12. Cylindrical metal measure of 11.5 cm 6, 18 cm height 13, Metal containers 15 cm $, 20 cm height 14, Cylindrical metal measuce of 1, 3, 15 and 30 | capacity 15, Cylindrical Calibrating container with an internal dia. 100 mm and depth of 150 mm 16, Metal Tray (300 mm square and 400'mm deep) with 100 mm Hote (7. Graduated Glass Cylinder (150 to 200 mi capacity) 18, 15 cm @ open-ended steel cylinder, with plunger and base plate 19. Tamping Rod of 16mm 6, 60 cm length and rounded at one end 20. Tamping steel Bar 16mm in diameter, 0.6 m length and buttet pointed at the lower end 21, Compressive strength testing machine capable of applying a load of 40 T 22. Soft Brush 23, Pycnometer 24. Means of warm air 25. FiltenPapers 26, Funnel 27. Flask of glass or non corrosive metal 28, Specialised Testing Kits for testing Chlorides and Sulphates 29, pH testing Strips 30. Titration Equipment with Pipette 31. Vicat Apparatus PEI AnaLn 33. Vibrating Machine 34. Cube Moulds of 50 mm amd 150 mm size Cube moulds 39. Standard Weights 36. Water Bath 10337. Gauging Trowel 38. Planetary Mixer 39. Flow Table 40. Pocking Rod 41. Standard Sand 42. Vernier Caliper 43. Micrometer 44, Small sand Pouring Cylinder 45. Tools for excavating Earth 46. Plane Surface : Class or Perspex Plate 47. Cylindrical Stee! Core Cutter 48. Slamp Cone 49.Container with mixing arrangement 50. Concrete Prisms 51. Danial’s Gauge 52. Cassgranda Apparatus 53. Proctors Mould 54. Thermometer 55. Steel Tape 56. Hammer 57. Workability Test Apparatus 58, Transverse Load test Apparatus 59. Tension Load test Apparatus 60. Water Loss Test Apparatus 61. Weights 62, Hand Pump and Pressure Gauge 63. Soldering Iron with Solder 64, MS Plate : 65. Load cells and meters 66. Jacks and Pumps of suitable capacity as per the design capacity of Pile and RE soil sytem 67. Dial Gauges 68. Stop Watch 69. Benzene The above list is only 1 directive list and it is required to be supplemented with the specific requirement of the project. The equipment / testing machines shall be maintained in good working condition and calibrated at regutar intervals to maintained accuracy of testing. The site laboratory shall be under the change of a person of the. rank of Assistant Engineer with supporting qualified staff to assist him in testing of material. In addition to these equipments, the codes/standards as given in the end of the chapter may also.be kept at site for the reference purpose as and when ngeded required. 1045.1 Materials 5.1.1 Coarse Aggregates 5.1.2 Fine Aggregates 5.1.3 Water 5.1.4 Cement 5.1.5 Concrete 5.1.6 Earth 5.1.7 Plasticiser 5.1.8 Reinforcement Bars 5.1.9 Epoxy 5.1.10 Bentonite 5.1.11 Bitumen 5.1.12 RCC Pipes 5.1.13 Prestressing Hardware 5.1.13... MS Sheathing 5.1.13.2 HDPE Sheathing 5.2 Site Activities 5.2.1 Piling 5.2.2 Bentonite Slurry $.2.3 Embankment Construction 5.2.4 Bituminous Works 5.2.5 Concrete 5.2.6 Reinforced Soil Works 5.3 Calibration of Equipment tosLor Jo pro] v Buykidde jo aqqedea uIyseyy Supsoy aaissodwoy “p) ‘ua 9uo ye papunos ue yi8ua] wo Q9 ‘6 Wg J0 poy Suidurey jeoupurcs * seq pue JaBunjd yim ‘sepuyo ea1s papua-uado $ wo ct Zp dyBtoy wr9 I“ Wo Jo aunseau! jeyeu peoupuyjkD eurmuos YSN UY “1 29 059 £961- ane, woeduy (2 anjeA Smyseay (Pp ump sso rou Kan moyreys y “6 | Al ued 98¢z: SI] 3 00¢9 sopadoag reaueyso, “€ “wo gy XSL weMp $89] 10U Yow sipofo qwagiosge Yos Lup oms “g “aUFEIUOD JoIeM INOIS YW “L “uso wus £961- Aysuag 9 vondsosqe £9 went s0ss9] JO 19ySeR AIM “9 | MI Hed 98Ez: SI] 300z| s9wM ANACIN oNPAdS *Z (Arpedeg 3 $ Aoeanooe 2% 179 Wate (An1zede9 xopuy uonesuoyg (2 fy ¢ ue iow) soureg “> xapyy SsOUPFELT (G a8nep muy “f a8neD ssOUIYL -Z wg] “wg Z| “Hg, sareBai8Sy “mwoz ‘unugz. “wu STE Jo 3uiperp pur azig (& “uur Op “untug “um Eg "wruDg £961 aZIg Jo SPAS JOH aenbg “}| -7ueq 98Er: SI) F 0007 adeys 9 71S apied “T ‘Buysay, Joy Fas {se pasenbas juoudinbaysa apog aauasajay | ajdureg S189, SHETSITTY BSIEOD TTSAapurjco Suumnseow! 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QOS ve 40 siguout ¢ £1949 2900, qurjg BuIysIEG (1 (CRRA | wopEIqED Jo MouEnbaag aNpER/ Tamdinby | TORETTTED esLIST OF CODES AND STANDARDS IS CODES DESCRIPTION 1S. 73 :1992 ‘Specification for paving bitumen (second revision} IS: 228 (Part-3) -1987 Method of chafical analysis of steels: Part 3 Determination of phosphrous by alkalimetric method (third revision) IS: 228 (Part-9) - 1989 Method of chemical analysis of steols: Part 9 Determination of sulphur in plain carbon steels by evolution method (third revision). IS: 383-1970 Specification for coarse and fine aggregates from natural sources tor concrete (second revision) IS: 455-1989 Specification for Portland slag cement (fourth revision) (Amendments 2) a) IS: 456:2000 Code of practice for plain and reintorced concrete. IS: 458:1988 Specification for precast concrete pipes (with and without reinforcement ) (third revision) (Amendments 2) IS: 516:1959 Method of test for strength of concrete (Amendments 2) Is: 702 Specification for industrial bitumen (second revision) (Amendment 1) IS: 1030:1989 Carbon steel castings for general engineering purpose (fourth revision) Amendment 1) IS: 1080:1986 Code of practice for design and construction of shallow foundations on soils (other than raft, ring ad shell) (second revision), IS: 1195-1978 Specification for bitumen mastic for flooring (second revision) IS: 1202-1978 Determination of specific gravity (Amendment 1) IS: 1203:1978 Determination of penetration (Amendments 3) IS, 1208:1978 Determination of softening point. IS: 1206 (Part-2) - 1978 Determination of viscosity: Part 2 Absolute viscosity. IS: 1206 (Pan-3) - 1978 Determination of viscosity: Part 3 Kinematic viscosity. IS; 1208:1978 Determination of ductility 1S; 1209:1978 Determination of flash point and fire point. IS; 1211-1978 Determination of water content (Dean and Stark method). IS: 1212:1978 Determination of loss on heating. 1S: 1216:1978 Determination of solubility “in carbon disulphide trichloroethylene (Amendment 1). 126Is: 1498 : 1500:1983 2 1501:1984 1586:1988 : 1608:1972 : 1683:1972 : 1786-1985 : 2062-1999 : 2386 (Part : 2386 (Part 2386 (Part : 2386 (Part 2386 (Part 2386 (Part : 2386 (Part : 2629-1985 : 2633-1986 : 2645-1975 : 1239 (Part 1) - 1990 1)-1963 1)-1963 {1963 WW)-1963 V)-1963 Vil)-1963 Vill)-1963 Mild steel tubes, tubulars and other wrought steel fittings : Part 1 Mild steel tubes (fifth revision) (Amendment 1) Classification and identification of soils for general engineering purpose (first revision) (Amendments 2). Method for Brineil hardness test for metallic materials (second revision) (superseding IS 1789:1961, 1S1790:1961 and IS 3054:1965). Method of Vickers hardness test fer metallic materials Method of Rockwell hardness test for metallic material (Scales A-B-C-0-E-F-G-H-K) (Second revision) Method for tensile testing of steel products (first revision) (Amendment 1). Method for tensile testing of steel sheet and strip of thickness 0.5 mm to 3 mm (first revision). Specification of high strength deformed steel bars and wires for concrete reinforcemest (third revision) (supersdeding 1S 1139:1966) (Amendment 1). Steel for general structural purpose (fourth revision) (supersedes |S 225:1975). Method of test for aggregates for concrete : Part 1 Particle size and shape (Amendments 2) Method of test for aggregates for concrete : Part 2 Estimation of deletenous materials and organic impurities (Amendment 1) Method of test for aggregates tor concrete : Part 3 Specific gravity, density, voids, absorption and bulking. Method of test for aggregates for concrete : Part 4 Mechanical properties (Amendments 3) Method of test for aggregates for concrete : Part 5 Soundness. Method of test for aggregates for concrete : Part 7 Alkali aggregate reactivity. Method of test for aggregates for concrete : Part 8 Petrographic examination) Recommended practice for hot-dip galvanzing on iron and steel (first revision) (Amendment 1). Method for testing uniformity of coating of zinc coated articles (second revision). Specification for integral _cement waterproofing compounds (first revision) (Amendment 1). 127Is IS: iS: Is: : 2720 Part 2 2720 Part 4 : 2720 Part 5 : 2720 Part 8 2720 Part 16 2720 Part 27 2720 Part 28 : 2911 (Part 4) : 3025(Part 17) 3025(Part 18) : 3025(Part22) 3025(Part 23) : 9026(Part24) 3025(Part32) 9597 :1985 1985 1S: 4031 (Part 2) : 1988 Methods of test for soils : Part 2 Determination of water content (second revision) (Amendment 1) Methods of test for soils : Part 4 Grain size analysis (second revision) Methods of test for soils : Part 5 Determination of liquid and plastic limit (sécond revision) Methods of test for soils : Part 8 Determination of water content - dry density relation using heavy compaction (second revision) Methods of test for soils : Part 16 Laboratory determination of CBR (second revision)} Methods of test for soils : Part 27 Determination of total soluble sulphates (first revision) Methods of test for soils : Part 28 Determination of dry, density of soils inplace, by the sand replacement method (first revision) Code of practice for design and construction of pile foundations : Part 4 load test on piles (first revision) (Amendment 1) Methods of sampling and test (physical and chemical) for water and wastewater: Part 17 Non-filterable residue {lotal suspended solids) (first revision) Methods of sampling and test (physical and chemical) for water and wastewater : Part 18 Volatile and fixed residue (total filterable and nonsflterable) (first revision) Methods of sampling and test (physical and chemical) for water and wastewater : Part 22 Acidity (first revision) Methods of sampling and test (physical and chemical) for water and wastewater : Part 23 Alkalinity (first revision) Methods of sampling and test (physical and chemical) for water and wastewater : Part 24 Sulphates (first revision) Methods of sampling and test (physical and chemical) for water and wastewater : Part 32 Chloride ({irst revision) Methods of test for concrete pipes (first revision) Methods of physical tests for hydraulic cement : Part 2 Determination of fineness by specific surface by Blaine air permeability method (first revision) (28 +Is: Is: 1S: Is: is: Is: : 4031 (Part 3) : 1988 : 4031 (Part 4) : 1988 4031 (Parts) : 1988 : 4031 (Part 6) : 1988 4032 : 1985 : 4736-1986 : 4984-1995 6241 : 6745:1972 6911:1992 9103:1999 9381:1979 9382:1979 42118 (Part l)-1987 12269:1987 1968 CPWO/2002—10A Methods of physical tests for hydraulic cement : Part 3 Determination of soundness (first. revision) {Amendmentt) Methods of physical tests for hydraulic cement : Part 4 Determination of consistency of standard cement paste (first revision) (Amendment 1) Methods of physical tests for hydraulic cement : Part 5 Determination of initial and final setting times (first revision) (Amendment 1) Methods of physical tests for hydraulic cement : Part 6 Determination of compressive strength of hydraulic cement (other than masonry cement) (first revision) (Amendment 1) Method of chemical analysis of hydraulic cement (first tavision) Hot-dip zinc coatings on mild steel tubes (first revision) {Amendmentt) Specification for high density polyethylene pipes tor potable water supplies, swage and industrial effluents (third revision) Method of test for determination of stripping value of toad aggregates Method of determination of mass of zinc coating on zinc ‘coated iron and steel articles (Amendments 3) Stainless steel plate, sheet and strip (first revision) Specification for admixtures for concrete Methods for testing tar and bituminous materials : Determination of FRAASS breaking point of bitumen Methods for testing tar and bituminou:. materials Determination of effect of heat and air by thin film oven tests Specification for two parts polysulphide based sealants : Part 1 General requirements Specification for 53 grade ordinary Portlan: cement (Amendments 2) 129IST OF IRC CODES IRC-18-2000 Design Criteria for Prestressed Concrete Road Bridges (Post-Tensioned Concrete) (Third Revision). IRC-21-2000 Standard Specification and Code of Practice for Road Bridges, Section Ill- Cement Concrete (Plain and Reinforced) (Third Revision). | 1RC-83 Part-I Standard Specification and Code of Practice for Road Bridges, Section 1X - Beaings, Part-(: Metallic Bearings (First Revision), | IRC-83 (Part-II) -1987 Standard Specification and Code of Practice for Road Bridges, Section IX - Bearings, Part-ll: Elastomeric Bearings IRC-107-1992 Tentative Specification for Bitumen Mastic Wearing Courses. IRC-SP:47 Guidelines on Quality Systems for Road Bridge (Plain, Reinforced, Prestressed and Composite concrete) IRC-SP:57 Guidelines for the Use of Dry Lean concrete as Sub- 7 base for Rigid Pavement. . MORTH Specification for Road and Bridge Works 2001 (fourth ; revision). dio 130 1985 cPWor2002—108CHAPTER -6 OUTSIDE / INDEPENDENT TESTING FACILITIESOutside / Independent Testing Facilities Extensive testing of the materials used for construction is a pre-requisite for attaining high quality of the work. This shall require specialised tests, physical, chemical, ultrasonic, x-ray and various other types of tests which can not possibly be carried out in a site laboratory without adding high-costs on the project. These tests also require specialised personnel who regularly deal in such testing. Therefore, the need arises for carrying out the tests in outside laboratories. ‘These laboratories may be in the Government sector, Semi-Government of Private sector. The oviside laboratories shall be shart listed before hand. In case of laboratories in the private sector, the past record and reputation of the laboratory must invariably be given due consideration. The infrastructure in these laboratories can be inspected before they are short-listed. However every laboratory may not have the facility for carrying out all the required tests. This chapter gives an overview of the available testing facilities in various reputed laboratories given below. AES Testing & Research Laboratories (AES) Central Road Research Institute (CRRI) Dethi Test House (DTH) Indian Institute of Technology Delhi (ITD) National Council for cement and Building Materials (NCCBM) Regional Testing Centre (RTC) Sunbeam Auto Limited (SAL) Shri Ram Institute for Industrial Research (SRI) SAA ween ‘This information will facilitate selection of a laboratory for any particular testing. 133s s YS vyyvyrys Ss x +,y yyy s ‘ yy YO yD To be Ascertained ‘S Ss x YS yyoyys xx x+y NS ‘ Sy yy yyys sonsodoig Sunyey FeuOW (J ssoupunog (9 aumstOYY sORUTS puE vondiosge sore my “Aussuoq Ing ‘AuAeiD oytads (9 sqevoreyy snouaajaq (4 adeys po’ azig apm (e sayedoadsy auyy (7 uoneurureg x1q YOQTED QAI) APY MOLY HAW Ausuag aioraPYD JyNeAPKH, sadid addH @ ° o @ | rs | WS OL Fel Sa ° 16 cewor2ue7 =11 ane-—-- s Xapuy SSPUMOT19A (1 ouURIstsaL MOL (> autog Buyuayos. (f aunvesadusan ‘moj ve aoueisisay 3urye1 (1 SOURISISSY PIAS (4 amy Bukig (3 (ysy eg) aoueuwirr, Gg swoudtg woqiax (9 sims MOUy 7 aeUOGIeD WNID|ED (Pp quaquo9 apixoid wut], (9 sprag sein (4 suaiuca apuig Stupeg apsefdoursayy, (87 ras "IVs La WADON | quit HLG rio sav PSISA, es2sn0y FTL, 147S may plabry (q wal is (e aoweg (0€ aoueisisoy ea}UWayD (9 uonisodwon 49914. (P qBuang apsuay (9 wsPEM (o ssampryy (& ataxaway (67 ras ‘WS OLt WON qu wid rad sav PSs, sasnoH OL 148,Axparers yeuowsuoun | way 01 20ur say (2 uoneduoig (p wduang aysuay, (> Aysuaq (q wuoy (e (ouariag ony BAP, AlOg) AALd (ZE Yyres +S Soy S qwaqueD ysy (3 SoINpOW FEDS (5 SureBy paress|ooov (9 1s uorssandmod wntixen, (p eaug Te uoneSuoig wu (9 IW ssoupseH (e “spBuang aqisuay, win sounoyseyg sua.1dos0yy5 (1E vas ‘VS Ona WOON! Quit rao = Sat ésosnon WL 149Yuyoryyys wnduang anyssardwos aewniy, (8 WBuang vosaypy |G snynpow onserg. (2 ‘So[npow Zeays (P Way peoTlency (9 way uorsuaung (q uonoadsul jensia (e sSujreag samoserq (pe x yyy x Yayo S Bupsay jousew Moy (F S29] uonensuag ang soy otuoseni (2 wal uonouy (P way peoqteoman, (2 aonying NUS [91S ssa|UFEIS. (q aounsafop euorsusuig (e s8upteag YAld-LOd (££ ris ‘vs OL WOON qui Ha sav TAAL Csasnoy 1591, 150wiarsks jonuos 40 noddns oj Buueag. (p ssaunydty sare (2 waiskg adeacyouy (q urog a8pq ce swutof uosuedxg feag ding (se ris vs 1a WOON: au HG rao sav Tsay, sasnoH OL islCHAPTER -7 SITE _ DOCUMENTSSite Documents Effective documentstion, of sl the activities on a project is of utmost inp It not only saves valuable time sind energy but also helps in keeping a track of the various, activities and to ensure that nothing is missed. For example, it shall be useful to keep documentation of mavements of drawings to ensure fi ect / latest revisions are adopted for execution. The docum-ssation of st seconds shai help in checking. that the tests ate carried out at the required frequency and ne test is missed sc as to get quality output. Documentation of all the materials as inventory record shall assist in resource planning and ensure availability of mate times. Separate record for bulk ttems of high importance, like cement and steel, have to be maintained. These records indicate whether the consumption of these materials is as per the design requizemeats er net. The instructions given by then site staff to the exeenting ageney and its compliance hav to be recorded fo ensure that no instruction is lost sight of. Similarly instructions from senior officers and the consultants during their inspection and the consequent action have to be recorded, Standard formats have been developed tor documentation of the various important activities and given in this chapter. Proper documentation shall vo a long.way is meeting the ends of high quality in the work. Page No.Name of Work Agreement No. Name of Agency Stipulated date of start Stipulated date of completion 7.1 MASTER REGISTER RECORD Ss. Title of Register ‘Volume [Identification] Date of | Docketing no. | Signature No. no. Issue 156 Continued on Page no. Page No.7.2 SITE_ORDER RECORD I. S.No. 2. Date & Time of Instructions 3. Instructions To 4. Instructions S.No. Action Required ‘Action Taken, ‘Signature | 1 Signature Signature Date Date For Contractor For Department Name Name Reviewed by : Comments: ‘Signature 187 Continued on Page no. Page No.7.3 DRAWINGS _ RECORD Details of Drawings | Reseipt of Tesue oF ‘Status oF | Coniracior's Drawings Drawings Drawings | Signature Drawing | Title of | Date of | Novof | Issue [ No. of | (Advance / no. and its| Drawing | Receipt | Copies | Date | Copies | Good for Revision { Construction) Continued on Page nv, Page No. .7.4DAILY PROGRESS RECORD 1. Date 2. Whether conditions (a) Temperature (b) Rainfall (©) General Weather (i) Sunny (ii) Cloudy iii) Windy (b) Humidity! 3. Details of Work Done Maximum ........ Minimum.. mm S.No. Item Executed ‘Quantity |" Location 1 2 3 4, Any Special difficulties / happening : Signature Signature Date For Contractor For Department Name Name 159‘Type of Cement 7.5 CEMENT STORE RECORD Monthly Receipt/issue for Opening Balance Part ‘A’ «bags Date [Quantity Received | Quantity consumed | Balance at | Purpose] Signature Source | Batch | No.of }Tsued | Rewmned] Net] the end of ls lel No. | Bage consumed] the day 8 i (vo. of Bags) Seals) Total Part ‘B’ te‘Theoretical and Actual Consumption statement S.No. | _ Period Tems of Work Quantity] Theoretical] Actual | Difference From] To, Executed) Cement | Cement | between the (cum) | Required | Consumed] theoretica! (o.of Bags) | (o.0f B2g5)| and actual; Consumption: o Signature zl Signature ‘ Date Date 5 For Contractor: For Department Name Name ‘Continued on Page no. Page No. ..... 161 4969 CFWOI2002—128Type of Steet Monthly Receipt/Issue for the month 7.6 STEEL REINFORCEMENT RECORD Designation of Steel Bar ...... mm TMT. Dae] Qua Sour | Quanity | Actives | Concumption | — Difference Rese (MT) | forwhich | ofsteelas per | etween MT) issued | steel measurement | quantities issued (tt) | measured and issued (MT) 1 4 | | | | : ara ro 3 i | | | Signature Signature Date Date : For Contractor For Department Name Name Continued on Page no. é Page No. 162 1965 CPWO200—128|. Grade of Concrete 2. Cement Content as per Design Mix 7.7 CUBE TEST RECORD M Kg/cum ‘S. |Sample] Size of [ Age of | Representative ‘Wet Concrete | ‘Cube Test No| No. | cube | cubes | structural Member | _ Property (days) “Femperawre | Samp | Loadat | Area | Coapressive Failure Strongth T. 2 3 4 5. | : i Mean Standard Deviation Range [cece ‘Comments : Signature ‘Signature Date Date For Contractor For Department Name Name Continued on Page no. Page No. .. 1637.8 OTHER TESTS RECORD Signature : Signature Dat Date For Contractor For Department Name Name Continued on Page no. Page No.7.9 EQUIPMENT CALIBRATION RECORD |. Name of Equipment (a) Make (b) Model (1 Capacity (d) Identification No, 2. Frequency of Calibration 3. Date of last Calibration 4. Next due date of Calibration 5. Agency performing the Calibration 6. Reference of issue of Calibration ceniticate 7. Reference of filing the Calibration Certificate Signature Signature Date : Date For Contractor For Department Name Name Connie on Barge aa Page No. los7.10 INSPECTION RECORD - 1, Date and Time of Inspection 2. Venue of Inspection 3, Name and Designation of Inspecting Authority 4. Reference of Inspection Note 5. Remarks of Inspecting Authority 6. Communication of Inspection Remarks 6.1 Remarks taken over 10 Site Order Book, Page No. 6.2 Remarks conveyed to contractor vide letter No. ...... dated. dated. 7. Whether needful action ‘aken by contractor (Yes/No/No action required) 8. Compliance recorded in Site Order Book at Page No... dated Recorded by Reviewed _by Signature Signature : Date t Date : Name & Name & Designation Designation ‘Continued on Page n0. Page No. 166,7.11 NON-CORFORMING ITEMS RECORD 1. Item No. (as per Bill of Quantities ) 2. Brief details of the item a - 3. Name of designation of the Authority deciding the nor conformation : Name Designation .. Reference No. 4. Reason of non-conforming 5. Nature of Non Confirmation 6. Comments . Yes = No NIA 6.1 Whether the item is structurally sound 6.2 Whether the item can be accepted at Reduced rates, 6.3 Whether the item requires demolition and re-execution, 64 Remarks indicating the action done by the contractor and the view of department. Signature Signature Date 5 Date For Contractor For Department Name Name Continued on Page no. . Page No. .i ® 7.12 QUALITY AUDIT RECORD 1. Date of Quality Audit 2. Venue of Inspection 3. Department of Auditing Team 4. Head of Audit Party . 5. Other members of the Audit Team . Name Designation @ co) Gi) 6. Reference of Audit Report 7.No. of Paras 8. 1“ Reply to Audit Rep: Reference of Reply Rejoinder to reply No. of para dropped Paras outstanding, Signature | Signature Date : Date For Contractor: For Department Name Name 2nd Reply to Audit Report Reference of Reply Rejoinder to reply No. of para dropped Paras outstanding Signature 5 : Signature : Date Date : 2 For Contractor: For Department: Name Name * d Reply to Audit Report ' 168Reference of Reply Rejoinder to-reply No. of para dropped Paras outstanding Signature Date, Date . For Contractor: For Department Name Name 4th Reply to Audit Report Reference of Reply a Rejoinder to reply No. of para dropped Paras outstanding Signature Signature Date Date For Contractor For Department Name Name Continued on Page no... Page No. 1697.43 HINDRANCES RECORD « From] To [Whether _ | Reasons of | Action Net Effect Hindrance | Hindrance | initiated to | on the ison the . remove the | Project critical Path) Hindrance Signature Signature el Date Date a For Contractor For Department Name Name Continued on Page no. .. Page No. 1707.14 CONSULT! RD 1. Name of consultant Name of visiting Representative Venue of visit Date and Time of visit Duration of visit Purpose of visit mays Observations/Comments/Advice 8. Action to be taken by the Department/Contrcator Signature zl Signature Date fl Date For Consultant = For Department Name : Name Continued on Page no. «1. 1717.15 SITE-CORDINATION MEETINGS RECORD 1. Coordination Meeting no. . Venue of Meeting . Date and Time of Meeting 2. 3 4, Name of Chairman and Designation 5. Name of Other Participants ‘Name of Participants | Designation | Organisation | Telephone | Signature - a 2 7 . 4 Ae 6. 1. | oe 6. Person to issue Minutes of Meeting oer rh 7. Reference of Minutes of Meeting 8. Reference of Action Taken Report Continued on Page no... Page No. .. 1727.16 CHECK LISTS / TEST PROFORMAS RECORD & i73 SNo. | Title of Check List? | Identification | Purpose of ] Reference of | Reference of Test Proforma Number Checklist? | approval recording of Test sample _ Proforma checklist Signature Signature Date Date For Consultant For Department Name Name Continued on Page no. Page No.7.17 INVENTORY RECORD 1. Name of Item 2. Total Quantity Required 3. Source 4, Minimum Size of One Lot [S. Date Previous[Additional [Cumulative [ssued” CumulativeBalance Present Balance] INo. uantityQuantity (Quantity Consumed issue utstanding Requirement)Deficit rocured anti i Continued on Page 00 Page No. 174 ,, Name of item observed Quantity of item observed 1 2. 3._ Starting Time 4. Closing Time 5. Various Ingradients Observed (a) Materials 7.48 ACTUAL.GBSERVATIONS RECORD S.No. Type. — Quantity 2 3 (®) Labour S.No. ‘CategoryMType of Labour ‘Quanity (co) Machinery S.No. “Type of Machinery From To 2 3. ; Signature Date For Department Name Continued on Pag? no. ...-. Page No.1, Name of Mock Up 7.19 MOCK UP__ RECORD 2. Trial No. SNo. Checks Observations ‘Acceptable 7 Not Acceptable/ Suggestions SP pEeNe ‘Supporting system Form Finish Surface Finish Dimensions Result : Mockup approved for Execution / Another trial required as per the suggestions Any Other Comments: Signature Date For Contractor Name Signature Date For Department Name 176 Continued on Page no. ..Page No. 720 GUARANTEE BONDS/INSURANCES RECORD 1, Name of ftem 2. Reference of Guarantee Bond approval 3. Date of submission of Bond 4. Whether the bond accepted (Yes / No /'N.A.) 5, |. Reference of Acceptance 6. Period of Bond 7. Extension of Bond/Insurance Signature Fl Signature Date 3 Date For Contractor: For Department Name Name 7 1965 CPWDr2002—1387.24 Safety Aissurancs'Recbrd Date of napon: Dane nd Designation of th cer pstoming peso eee [Next date due for Inspection S.No, | Item of Inspection and the required standards Yes/No/N/A 8) Provision of ladder not steeper than 1:4. For height upto 3.6m height above ground or floor 2 a For height more than 3.6m above ground or floor 8) Whether guide rail properly provided and secured. bb) Are the working platform, gangway and stairways adequatcly stifT ©) Is working platform, gangway or stairway i) Closely boarded ii) Adequatety width i Suitably fastened a ' A ‘or opening in the working area i) Whether suitably fenced or provided with minimum 90cm high railing 4 : P Prevention of danger. electrical equipm: i) Is the material stacked causing danger or inconvenience to { public ii) Necessary fencing and lights provided to protect the public. ravatic Trenching more in des * i) Tsat least | ladder for each 20m length provided at least 90cm above ground surface. ii) Is the length of ladder sufficient extend from the bottom to 178 1965 CPWO/2002—138w) ” ‘Are the sides of wenches secured by amber bracing Is there any excavated material within 1.5m, Is any undermining or undercuting done. 6, Asphaltic works Are worker provided with protective footwear. gloves and protective goggles. » Cement ‘Are workers handling cement provided with protective goggles ar gloves. a Welding works Are the workers provided with protective eye shield. and footwear. i ‘ity ” vw loistil Do the machines including their attachment, anchorage and supports have good mechanical construction, sound material and adequate sieength free from patent defect and kept in working onder Dees every rope has adequate strength and free fom patent deleets 1s the operator properly qualified Is safe working load marked on machines Are efficient safeguards provides to motors, gearing, ‘ransmission, electric wiring and other dangerous part Does the workers wear any metallic item while employed on any electrical installation, Are the safety provisions displayed on a notice board at the prominent place at workspace, Are the workers provided with safety helmets of specific colour. Are the workers found with safety belts while working at heights Is the work area will illuminated, Is the work area suitable barricaded with adequate height. Does the necessary cautionary sign board installed at site 179Remarks of the Inspecting Officer Signature Date For Contractor Name 180 Signature Date For Department Name Continued on Page 90...7.22 Labour Welfare Record 1. Date of Inspection : 2. Name and Designation of the Officer performing Inspection : 3. Last date of Inspection : 4. Next date due for Inspection : S| hem Ye Wat No. applicable oi a fi) 6 packets of sterilized cotton wool {ii) 1 (60mi) bottle containing a 2% alcoholic sok iy) Salvolatile having the dose and mode of administration indicated on the label {roll of adhesive plaster 1 30 gms.) bottle of potassium permanganate crystals { pair of scissors { bottle containing 100 tablets (each of $ gms.) of aspirin i) Ointment for burns x) bottle of suitable surgical antiseptic solution ») | Arrangement for recoupment done ©) | Location ofFirst~ Aid Box : 4) | Person responsible for keeping the box ©) | Is the person-in-charge trained in first-aid treatment 2 Water 1) Is fit for drinking and cold water available Is it easily accessible Is the sauce well chlorinated before water is drawn, WW) Is the source dust and waterproof anid properly covered Toilets and Urinals i) Ate the adequate numbec toilets and urinals properly covered and paritioned available as per following requirement ‘oilers | per 25 males or females up to 100 and 1 per 50 male or female 100 Ucinals 1 per 50 males or females up to 500 and | per 100 beyond 500 males or females 181‘Are these property lighted Are these facilities properly maintained in a clean and sanitary condition at all times. a ii) i) i ” is rest }) Is the shelter of adequate space available separately for men and women labourers 3 Are sufficient rooms for litle children available ‘Ae the rooms kept clean well lighted and ventilated. 6 | Canteens Is adequate canteen facilities provided by the contractor Is the canteen maintained in clean and proper sanitary conditions. Is the dining space adequate. Is the suitable food stuff available Is it running on No profit, No loss basis. ~ i Ax 7] Anti-Malarial Precautions sutficient precautions taken up for filling any borrow pits and a etivides Remarks of the Ensperting Otfiver Signature Signature Date ‘ Date For Contractor: For Department Name Name 182CHAPTER 8 CHECKLISTS AND TEST PROFORMASCheck-Lists and Testing Proformas Proper check lists and test proformas play a vital role in not only ensuring the quality control but also for proper documentation of the project. At the end of the project, it will be only the documents which will help in knowing the quality assurance system adopted in that project. In order to ain the uniformity in the documentation of the total project, some have been given in this chapter along with the testing prsformas. Check lists are framed for the selection of the sub agencyfsupplier etc. and also for ensuring the specifications to be followed in the execution of the work. while the test proformas are to be to be used while conducting any test at site. lo acder to ensure that the material, whether raw or assembled. intended to be used on the flyover construction meets the quallity standards, the first step is to select a supplier / manufacturer who has the required infrastructure to produce quality material, This includes machines, testing facilities etc. The supplier should also have the capacity to supply the required volumes of material while maintaining consistence in quality. Certain checks shall have to be carried out in order 10 select and approve one more Suppliers or manufacturers for the material t0 be used in the construction. This shall save the trouble of having to run from one source to the other for getting good quality material. While framing the checklists, emphasis has been paid 1 cover all these basie parameters which are of high importance for the selection of the supplier or specialised agency. Some checks for approving sources for different type of materials have been given here. ‘The quality contrat however does not end with the approval of the source. The material procured from the approved sources needs to be checked frequently for its quality by carrying out certain tests. These tests and their Testing frequency have been mentioned in chapter 3. The formats for reporting the results of the tests are given in this chapter. While framing the test proformas for the material testing, the emphasis has been given to the BIS codes which are applicable for the acceptance of the material in the work before the selection as well as during the execution of the work Similarly, it has to be ensured that the site activities Tike piling. concreting. embankment construction, pre-stressing. road work, surfacing, installation of bearings and expansion joints etc. are carried out in a way that the end product satisfies the quality standards. This can be ensured by having checks at different stages as the activity progresses. These checks shall have to be tabulared and separately recorded for further reference. These have been incorporated in the form of “Checklist for Site Activities”. Test proformas for reporting of test results whenever required during an activity’ are also given this chapter. While framing the checklists FoF the site activities. emphasis has been given to ensure that the all the site activities are done as per the prescribed specifications for them. 185In the test: proformas, space has been provided at the top for the identification number. While conducting tests at certain frequencies, unique identification number may be given to the test proformas used every time. 1868.1.1 Checklist for Source/Agency Approval 8.1.1.1 Coarse Aggregates 8.1.1.2 Fine Aggregates 8.1.1.3, Water 8.1.1.4 Cement 8.1.1.5 Reinforcement/Strands 8.1.1.6 Epoxy 8.1.1.7 Geotextile 8.1.1.8 Plasticiser 8.1.1.9 Granular Sub base 8.1.1.10 Backfilling material (earth) 8.1.1.11 Bitumen 8.1.1.12 Prestressing system 8.1.1.13 RE/RS Wall 8.1.1.14 Thermoplastic Paint 8.1.1.15 Bearings 8.1.1.16 Expansion Joints 8.1.1.17 Hot Mix Plant 1878.1:1.1 Checklist for source approval for - Coarse Aggregate. S.No. Particular : Remarks 1 ‘Name and address of the supplier = | information regarding the other ongoing works where the material is being supplied by this supplier Report obtained from the clients referred at S.No. 2 4 What is the petrography of the parent rock? Is it acceptable? x Will adequate quantity be available for the complete project’? 6 Have the aggregates been got tested from reputed laboratory as per IS: 383 as per chapter 3 of the manual.? (a copy of the test certificate may be attached) , 7. ‘Are adequate crushing and transporting facilities available with the supplier/crusher? igned Date For Name. Contractor 1888.1.1.2 Checklist for source approval for - Fine Aggregate. S.No. Particular Remarks io ‘Name and address of the supplier = information regarding the other ongoing works where ' the material is being supplied by this supplier Report obtained from the clients referred at S.No. 2 a What is the type of aggregates, (i) Crushed rock. Gi) River sand. 5S Will adequate quantity be available for the complete project? 6 Have the aggregates got tested from reputed laboratory as per IS : 383 as per chapter 3 of the manual.? (a copy of the test certificate may be attached) 7 Are adequate washing and transporting facilities available with the supplier? Signed Date For | Contractor 189 : ent RESP RE TE8.1.1.3 Checklist for source approval for - Water ‘S.No. Particular Remarks 1 ‘Whaat is the source of supply? (i) Bore well ) Supply of local body Gil) Tankers 2. Has the water been got tested from reputed laboratory as per chapter 3 of the manual? (a copy of the test certificate may be attached) 3. Will adequate quantity be available from the source for the duration of construction? 1901.1.4 Checklist for source approval for - Cement approved list of the clients, S.Now Particular Remarks H Name and address of the manufacturer/supplier = 2 Whether the supplier/manufacturer is among. the Information regarding the other ongoing works where the material is being supplied by this supplier: a Report obtained from the clients referred at S. No. 2: | 5. Whether the material satisfies the test requirement as | per chapter 3 of the manual. | Ca copy of the test certificate may be attached) ie. ‘Whether the supplier Gan supply the material in desired size of the lot as per the site schedule. Signed a Date For Contractor Name | 1948.1.1.5 Checklist for source approval for — Reinforcement/Strands No. Particular Remarks ‘Name and address of the manufacturer/supplier : z Whether the supplier/manufacturer is among the approved list ofthe clients? x Information regarding the other ongoing works where the material is being supplied by this supplier: 4. Report obtained from the clients referred ai S. No, 2: 3 Whether the material satisfies the test requirement as per chapter 3 of the manual. (a copy of the test certificate may be attached) 6 Whether the supplier can supply the materfal in desired size of lot as per the site schedule. For Name Contractor 1928.1.1.6 Checklist for source approval for - Epoxy 1965 CPWD/2002—148, 193 S.No. Particular Remarks 1 ‘Name and address of the manufacturer/supplier = 2 ‘Whether the supplier/manufacturer is among the approved list of the clients. 3 Information regarding the other ongoing works where the material is being supplied by this supplier: a Report obtained from the clients referred at S. No. 2: Ss Whether the material satisfies the test requirement as per chapter 3 of the manual. (a copy of the test certificate may be attached) 6 ‘Whether the supplier can supply the material in desired size of lot as per the site schedule? 7. Whether the manufacturer has given the method statement for its application. (attach a copy of the method statement) 8 Has the manufacturer furnished any guarantee? 9. Will the manufacturer's authorised representative be present during the application of epoxy? For Contractor Name8.1.1.7 Checklist for source approval for - Geo-Textile ‘material is being supplied by this suppl S.No. Particular Remarks T Name and address of the manufacturer/supplier 2 Tnformation regarding the other ongoing works where the 3. Report obtained from the clients referred at S. No. 2: 4. Whether the material satisfies the test requirement as per | ASTM D-4355 as per chapter 3 of the manual (a copy of the test certificate may be attached) 3 Is the material indigenous or imported? Is the supply easily available in market. 6 Can the agency supply the required quantity of material in the stipulated time? Signed Date For Contractor Name 1965 CPwo/2002—148,8.1.1.8 Checklist for source approval for — Plasticiser S.No. Particular Remarks Name of the Product : 2 Type of Product (super plasticiser/ water reducing admixture / retarder etc.) 3. Name and address of the manufacturet/supplier 4 Period for which the product is in use: 5. Information regarding the other ongoing works where the ‘material is being supplied by this supplier: 6. Report obtained from the clients referred at S. No. 2: 7. ‘Whether the material satisfies the test requirement as per 1S :9103 as per chapter 3 of the manual. (a copy of the test certificate may be attached) 8 Can the agency supply the required quanti stipulated time as per the site requirement? Signed Date For Name Contractor 1958.1.1.9 Checklist for source approval for ~ Granular Sub-Base Material S.No. Particular Remarks Name and address of the supplier : Information regarding the other ongoing works where the material is being supplied by this supplier Report obtained from the clients referred at S.No. 2 Does the agency have arrangement to supply coarse ‘aggregates and moorum? Whether the material satisfies the test requirement as per chapter 3 of the manual? (a copy of the test certificate may be attached) Can the agency supply the required quantities as per the site schedule? Does the agency have adequate arrangements to. transport the material to the site? Does the agency have equipment like Motor grader, vibratory roller for laying of GSB? IF not, what is the arrangement of the contractor? [Sena t~C ty tepals ‘Amount of Water for Standard Consistency of crm Mean value of Amount of Water .. LL Standard Consistency (P) = (AJB) x 100 =. Remarks (if any) : Signed Signed Date PO Date For Contractor For Department Name Name 250Identification No.[_[.[ | 8.2.14 Test Proforma for determining the Initial and Final Setting Time of Cement Sample No. _: | Date of Sampling : ] Quantity of: Method of Testing 21S: 4031 (Part ) cement Source 5 Date of Testing : Tobeused : Sampling and Testing By : in structure Weight of each samples: [Sample 1 | Sample 2 {in Gms.) . A Standard Consistency (P) = Percent 85 % of P= 0.85 xP = Percent Initial Setting Time Initial Reading of Stop Watch (To) for sample I = . Minutes for sample 2 .. Minutes S.No. | Reading of Stop | Penetration of needle from the | Is the penetration between 5= Watch bottom of Vicat Mould (in mm) __| 0.5 mm (Yes/No) ? ‘Sample 1 ‘Sample 2 ‘Sample 1 ‘Sample 2 T. 2. 3. 4. 5. Reading of Stop Watch with Penetration between 5 + 0.5 mm from bottom of Vicat mould (T1) Sample | =. + minutes Sample 2 =... minutes I Seng Time (T= T1 To for Sample P50... minutes minutes Mean Value of Initial Setting Time = .. Acceptable Value Results : Accepted /Not Accepted Remarks (if any) : . 251inal Setting Time Initia) Reading of Stop Watch (To) for sample I Minutes for sample 2 Minutes ‘S.No. | Reading of Stop | Does the Annular attachment | Does the Needle makes an Watch makes sn impression on the impression on the surface of surface of test block (Yes/No) ? _| test block (Yes/No) ? ‘Sample 1 ‘Sample 2, ‘Sample 1 ‘Sample 2 T. 2. 3. 4 3. Reading of Stop Watch when Annular attachment does not make an impression while the needle make an impression on the surface of test (T2} -» minutes Sample | minutes Sample 2 =....... Final Setting Time (11) =2~-To for Sample minutes minutes ‘Mean Value of Final Setting Time Acceptable Value = Results : Accepted Not Accepted ‘Remarks (if any) : Signed Signed Date : Date For Contractor: . For Department Name Name 252Identification No. 8.2.15 Test Proforma for determining the Soundness of Cement 7 Sample No: Date of Sampling ‘Quantity of ‘Method of Testing :1S: 4031 (Part 3) cement Source Date of Testing Tobeused : ‘Sampling and Testing in structufe |.By : Weight of each samples Sample 2 Gin Gms.) ......0 Standard Consistency (P) 78% of P= 0.78 xP Date and Time of immersing the sample in water For Sample 1 Date... Time... For Sample2 Date A. Initial Reading after 24 hours Date and Time of taking initial Reading For Sample 1 Date ............ Time . For Sample2 Date ......... Distance between the indicator points (D1) For Sample 1 = ...---....fm, For Sample 2 = B. Final Reading after boiling for 3 hours Date and Time of taking Final Reading For Sample 1 Date ......e.. Time Distance between the indicator points ( D,) For Sample | = For Sample 2 = Expansion of Cement = D; ~ Dy ForSample2 Date For Sample | = ..-...-.tttm For Sample 2 =. Mean Value of Expansion of Cement = mam Acceptable Limits = mom Results Accepted / Not Accepted Remarks (if any) Signed Fi ‘Signed Date : * | Date For Contractor: For Department Name Name 253Identification No. 8.2.16 Test Proforma for determining the Compressive Strength of Cement | Sample No. Date of Sampling : | ‘Quantity of Method of Testing 21S: 4031 (Part 6)> cement. Source f Date of Testin; Tobeused = ‘Sampling and Testing in structure By ° ' oO Quantity of Cement 2008 Quantity of Sand 600 g ‘Standard Consistency (P) = Percent Required Water content (w) = (P/4) +3 = ..Percent ‘Amount of Water to be added = 2 x w Percent Date and Time of keeping the sample in moist closet room Date ... seseee imme, Date and Time of submerging the samples in clean fresh water Date . Time... Date and'Time of testing of Specimens Date oes ccsceseesen Time ... seseeente ‘Az X-area of specimen = 70.6 x 70.6 mm = 4984.36 min? SNe. | Maximum | Compressive ] Variation in isVd<10 Load Strength | compressive _| (Yes/No) Applied (P) | C= (P/A) | Strength te (in N) (in Nim’) | Vee (CC) x 100 Cn 7 3 Mean Compressive Strength = Age of sample = ‘Acceptable Value = Results Accepted / Not Accepted Remarks (if any) : ‘Signed ‘Signed Date : Date For Contractor For Department Name Name 254Identification No. |[ 8.2.17 Test Proforma for Strip Pull Out Test in Reinforced Soil Wall Sample No. : Date of Sampling Height of Back fill ‘Method of Testing Source of Strips _: Date of Testing Embedded length: Sampling and Testing of Strip By Ram area of Jack = mm? Maximum Test Pressure for Strip Pull out. = = (Keon “Applied Pressure] Applied Force] Dispalcement Reading (Kajem" ) Gam) Net Displacement attest Pressure mm ‘Acceptable Value mm - Results : Accepted / Not Accepted Remarks (if any) : ‘Signed i ‘Signed Date . Date For Contractor For Department Name Name 255Identification No. } 8.2.18 Test Proforma for Lug Pull Out Test from Reinforced Soil Wall Panel Sample No. i Date of Sampling Tdentification ot: Method of Testing . RE Wall Panel Source of Lugs: Date of Testing Grade of Concrete: ‘Sampling and Testing of RE Panel By Ram areu of Central Hole Jack Minimum Force for Lug Pull out at failure ‘Applied Pressure ‘Applied Force (Ke/m* @ Load at Failure Miniroum accepted Load at Failure Results : Accepted / Not Accepted Remarks (if any) Signed Signed ; . Date Date For Contractor For Department Name Name 2568.2.19 Test Proforma for Bentonite Slurry Identification No.| | | | ‘Sample No Date of Sampling - Pile No. Method of Testing Source _ Date of Testing i ‘Sampling and Testing By ‘Sample No. | Specific Gravity | pH Value | Mars Cone Viscosity : | — | 3. Mean Value ‘Acceptable 1.025 Minimum 9.5 to 12 30 to 40 Limits Results + Avcepted / Not Accepted Remarks fitany) Signed Signed Date Date For Contractor For Department Name Name 1965, cPWO/2002—18AIdentification No.|_| LI 8.2.20 Test Proforma for testing the Epoxy Bonding Agent ‘ Date of Sampling Method of Testing e [Sample No. ‘Quantity of Epox; \ Source Date of Testin; _ To be used in ‘Sampling and Testing structure By 1. Pot Life of Epoxy Bonding Agent 1. Ambient Temperature during Testing = 2. Duration of Mixing =o) [Time since completion of Mixing (in Minutes) | aeeceeeereererse ees e| Pot Life of sample of Epoxy Minutes Recommended Pot Life ‘minimum 20 Minutes Results. : Accepted / Not Accepted 7 Remarks (if any) 2. Open Time of Epoxy Bonding Agent 1. Ambient Temperature during Testing = ..........8C ‘Specimen | Time since Remarks No. completion of (Concrete Failure/ Mixing (in Minutes) Joint Faiture) _l Open Time of sample of Epoxy sees Minutes Recommended Open Time inimum 60 Minutes Results : Accepted / Not Accepted Remarks (if any) 258 1965 CPWO/2002—1881, Ambient Temperature during Testing = ic] 2. Sample filled in gutter of Daniel’s gauge after 10 minutes of 3 minutes mixing, S.No. ] Time reckoned from Sag (in mm) start (in Minutes) Sag Flow of Epoxy Recommended sag Flow Results : Accepted / Not Accepted Remarks (if any) 4. Angle of Internal Friction (Squeezability) 1. Ambient Temperature during Testin, oC 2. Quantity of Bonding Agent 3140 mm Ss. Load (in Kg.) ‘Area of Spread ‘Acceptable Values of the No. in. mm?) area of Spread (in mm”) 1 15 3000_ minimum 2. 200, 7500_minimum 3. 400 10000. imum Results. : Accepted / Not Accepted Remarks (if any) : 5. Curing rate of Epoxy Bonding Agent 1. Ambient Temperature during Testing oC 2. Size of Cubes = 50 mm x SO mm x 50 mm. Caring Failure Load (in KN) [Mean Load|Compressive | Acceptable Time [Specimen |]Specimen 2)Specimen 3| at Failure | Strength | Values. hrs.) (kN) (Nérwm’) | N/mm’) 12 Minimum 20 24 Minimum 60 168 (Minimum 75 Results : Accepted / Not Accepted Remarks (if any) 2596. Compressive Strength of Epoxy Bonding Agent 1. Ambient Temperature during Testing = .... "Cc 2. Size of Cubes = 50 mm x 50 mm x SO mm 7 . Age of Failure Load (in KN) |Mean Load| Compressive | Acceptable Specimen [Specimen |]Specimen 2]Specimen 3| at Failure | Strength | Values . hrs.) KN) | (Nimm’) _| (N/mm?) 24 Minimum 60. 168 Minimum 75 Results : Accepted / Not Accepted Remarks (if any) 7. Bonding of Cured Bonding Agent to Concrete surface 1, Ambient Temperature during Testing = ..........%C 2. Compressive Strength of Prism should be approx. 40 N/mm? ‘Specimen No. Remarks (Conerete Failure | J Joint Failure) 7 Recommendations : Total fracture of concrete paste should occur (concrete failure) with no evidence of bonding agent failure (Joint Failure) | Results : Accepted / Not Accepted Remarks (if any) 8. Tensile Bending strength of Epoxy Bonding Agent 1. Ambient Temperature during Testing = ......+..u.2C ; 2. Compressive Strength of Prism should be approx. 40 N/mm? Specimen No. Remarks (Concrete Failure / Joint Failure) Recommendations : Total fracture of concrete paste should occur (concrete failure) with no evidence of bonding agent failure (Joint Failure), Results = Accepted / Not Accepted Remmarks (if any) 2609. Shear strength of Epoxy Bonding Agent Ambient Temperature during Testing = °c ‘Specimen No, | Load at Failure | Shear Stress (kN) (Némamn’) Recommendations : Minimum Shear Stress = 12 N/mm? Results : Accepted / Not Accepted Remarks (if any) : 10. Heat resistance of Epoxy Bonding Agent {Ambient Temperature during Testing = Shear Stress (Nimm’) Specimen No. Recommendations : Minimum Shear Stress = 10 N/mm? at 56°C Results : Accepted / Not Accepted Remarks (iF any) 11. C of Epoxy Bondin: ent Colour of Epoxy Bonding Agent Recommendations : Colour should be similar to adjoining concrete Results : Accepted / Not Accepted Remarks (if any) : ‘Signed Hi Signed Date 5 Date For Contractor For Department Name. Name 261Identification No. 8.2.21 Test Proforma for testing the MS Sheathing . Sample N te of Sampling _ z — Length of ‘Method of Testing TIRC 18 : 2000 ‘ Sheathing Appendix-1A. Source 5 Date of Testing : | To be used in 5 ‘Sampling and Testing structure By 1. Workability Test of Sheathing Length of Sheathing test piece Dia. of Sheathing Radius of Bent No. of cycles Condition of sealing joints after 3 cycles (any failure or opening of Joints) Recommendations : No failure or opening of Joints after 3 cycles Results : Accepted / Not Accepted + Remarks (if any) 2. Transverse Load Rating Test Length of Sheathing test piece Dia. of Sheathing Applied Load Permanent Deformation ° Recommendations : Permanent Deformation is less than 5 % Results. : Accepted / Not Accepted a Remarks (if any) : 2623. Tension Load Test Length of Sheathing test piece = Dia. of Sheathing Applied Load 100 m mm soeseeeN Condition of joints and couplers (any deformation of Joint or slippage of couplers) Recommendations : No deformation of Joint or slippage of couplers is to be noticed Results : Accepted / Not Accepted Remarks (if any) : 4, Water Loss Test Length of Sheathing test piece Dia. of Sheathing Applied pressure Duration of Applied pressure minutes Loss of Water Recommendations : Maximum loss of water = 1.5 % Results : Accepted / Not Accepted Remarks (if any) Signed Hi Signed Date F Date For Contractor: For Department Name Name 263Identification No. 8.2.22 Test Proforma for testing the HDPE Sheathing ducts ‘Sample No. Date of Sampling : Length of Method of Testing FIRE : 18-2000 Sheathing Appendix ~ 1B [Source Date of Testing B To be used in Sampling and Testing: structure By 1. Bond Test Daa Sample 1 Sample 2 | Sample 3 Dia. Of Duct (mm) ‘Anchorage Efficiency Failure Capacity of tendon(in Mpa) 95 % of failure Capacity (in Mpa) Load at Failure (in Mpa) Length of Duct (in mm.40 times the dia. of duct) Strength of Grout (in N/mm? Minimum 27 N/mm” [Mean Load at Faiture (in Mpa) Recommendations Faijure capacity of bond shall be atleast equal to the anchorage efficiency or 0.95 of failure capacity of the tendon, Results : Accepted / Not Accepted Remarks (if any) 2. Compressive Test Size of cube = 300 mm Load applied over concrete bloc! the loss of Wall thickness KN, Pulling of strand = 200 mm Data ‘Sample Sample 2 Sample “Measurements of the indentation formed. ‘Mean value of the indentation formed Recommendations Results : Accepted / Not Accepted Remarks (if any) ‘The residual thickness of the duct shall not be less than 1.5 mm, Tiened Signed : Date Date For Contractor For Department Nan Name “264Identification No. [] 8.2.23 Test Proforma for determining the crushing and Impact Value of aggregates Sample No. = Date of Sampling ; Quantity of |: Method of Testing 2 IS : 2386 (Part IV) — Aggregate 1963 (for aggregates . larger than 10 mm) Source 7 Date of Testing : Tobeused = Sampling and Testing By : in structure Quantity of sample : 1. Aggregate Crushing value - A= Weight of surface dry sample = gms. B = Weight of fraction passing the2.36 mm Sieve gms. Aggregate Crushing Value = (B/A) x 100 =...... Recommended Value . Results : Accepted /Not Accepted Remarks (if Any) 2. Aggregate impact valu A= Weight of oven dried sample gms. B = Weight of fraction passing the2.36 mm Sieve = gins. Aggregate Impact Value = (B/A) x 100 = Recommended Value = Results : Accepted /Not Accepted Remarks (if Any) : ‘Signed : Signed Date Date For Contractor: For Department Name Name 265Identification No. [ 8.2.24 Test Proforma for determining the silt Content of fine aggregates Sample No. Date of Sampling : Quantity of Method of Testing 21S : 2386 (Part PV) — Aggregate 1963 (for aggregates larger than 10 mm) Source Date of Testing To be used Sampling and Testing By in structure ‘Quantity of sample | 'S. No. | Height of Silt above the | Height of sand below | Percentage | Acceptable sand layer (in mm) | the Silt layer (in mm) _ of Sil Limits A B (ABB) x 100 Results : Accepted /Not Accepted Remarks (if Any) : Signed Signed Date Date For Contractor For Departmem Name NameIdentification No. 8.2.25 Test Proforma for Testing the Plasticiser Sample No. : Date of Sampling 5 Quantity of Method of Testing 21S : 9103 - 1999 Plasticiser Source : Date of Testing : Tobeused : Sampling and Testing By : in structure Quantity of sample : 1. Compressive Strength (percentage of Control Sample) Grade of Concrete = M I 2. Age of Concrete Cubes days 3. Size of cube S. | Sample No. ‘Compressive Strength of concrete No. ‘Control Concrete Concrete with Plasticiser ncretePlasticiser | Failure | Strength Failure | Strength | as percentage of enrol ‘oncrete with | Load at [CompressiveLoad at Compressive Compressive Strength| control Sample opens Recommended Value of the compressive Strength as percentage of control sample : 3 days =125 % minimum, 7 days = 125 % minimum, 28 days = 115 % minimum. Results : Accepted /Not Accepted Remarks (if any) : Signed Signed Date E Date For Contractor: For Department: Name Name. 2672. Loss of Workability slump in mm, (deviation from control sample) 1. Grade of Concrete = M S.No. ‘Slump of concrete (in mm) ‘Control Concrete] after 15 minutes Concrete with Plasticiser after 2 h Svaeno Recommended Value of the deviation in slump from control sample : The slump at the end of 2 hours should not be lesser than that of control concrete after 15 minutes. Results : Accepted /Not Accepted Remarks (if Any): Signed Signed Date Date For Contractor For Department Name, Name. 268Identification No. 8.2.26 Test Proforma for Anchorage Efficiency Test on Prestressing System ‘Sample No. Source To be used in structure Date of Casting of beams = Method of Testing Date of Testing Testing By [N of Beams : : FIP Recommendations UTS of the Strand Jack Details : Make and Type Last calibrated on ....... Ram area Strand free Length = Strand Make ‘Sample | Pressure in Bars Load (in T) Tack Stroke No. _| initial Final Initial _[ Final, Initial _[ Final Elongation (in mam) Remarks Mean UTS of Strand 269Sue aN qwounredag Jog JoyeNUOD Jo ae awe poudis pousis 3 CKue 1) syreuoy pardacoy 1ony pardaooy : sinsoy Aiqurasse uopuar JO SL DOT -SINTTE Te PEC] = Aouatonyyg afesoysuy = woneSuoyy aBeuaaieg sseeeerseee ge UORTUSUQT ay “teeter = HONGONIOT 0127, : 1 ur] eur [1 Teor | rener | reuld [ tener | reve [envy aUOWanoW, -neap | Biipeai (s98ps; (anu ut) “ON pueng a8pom asnep uonesuorg ayong yore (Lup peot | sig ur aunssaig | adueg 7777 SHEN PUES = yiBusy 204 puens + Alquiasse uopuat jo gin remoy 1: PUBS JO SLA URaur [emo ad] wopuay, aL ITTY 270Identification No. 8.227 Test Proforma for Load Transfer Test on Prestressing System Sample No. = Date of Casting of bloacks Method of Testing : FIP Recommendations Source Date of Testing : Tobeused : Testing By in structure No. of Blocks Crack Width Record (mm} Cycle No. Face | Face 2 Face 3 Face 4 ‘Crack no, | Width | Crack no. | Width | Crack no. | Width | Crack no. | Width ‘Atg0 & UTS ‘At [2% UTS ‘At80 % UTS ‘At 2% UTS ‘At 80% UTS ‘AU 12% UTS ‘At 80% UTS, ‘Ac 12% UTS ‘At 80 % UTS ‘At 12 % UTS ‘At80 % UTS ‘At 12% UTS ‘At 80 % UTS ‘At 12 % UTS ‘At 80 % UTS ‘AL I2% UTS. ‘At 80% UTS ‘At 12% UTS ‘At 80 % UTS AcH0 % UTS anReading Cycle JLoad Gn Ty Strain Strain gauge Readings (micro strains) no. {se of UTS)| Orientation [Face Tle Face 2 | Face 3 1 0% Horizontal Vertical 20% | Horizontal Vertical 40% | Horizontal 3 ‘Vertical q 60% | Horizontal 3 Vertical 2 80% | Horizontal & Vertical Ey 2 12% Horizontal i Vertical 80% | Horizontal & Vertical a 3 12% Horizontal = Vertical 3 80% Horizontal 2 Vertical 4 12% | Horizontal Vertical 80% | Horizontal ‘Vertical g & ‘Acceptance Criteria : 1. Crack width at first level of 80 % of UTS 2. Crack width at last level of 12 % of UTS 3. Crack width at final cycle at 80 % of UTS 4, Measured Failure Load (F,) LAKE = Gi) Fp x fee M/F co = Results : Accepted /Not Accepted Remarks (if any): Signed : Signed Date : Date For Contractor: For Department Name Name. 272Identification No. 8.2.28 Test Proforma for Vertical Load Test on Piles Test Pile No. ..... Date of Testing Jack Details : Make and Type Last calibrated on Ram Dia. | Division = Recording of Deflection Date and | Pressure] Load Dial Gauge Reading | Average | Average | Remarks Time applied | (in MT) (in mm) Reading | settlement (Kgicr A_|B_ [c [D (inmm)_| (in mm) Pressure Building | up Pressure Released. Recommended Value : Maximum Deflection = 12 mm Results : Accepted /Not Accepted Remarks (if any) : Signed Signed Date Date For Contractor For Department Name Name 273 1965 CPWOI2002—198Identification No. |_| [| TT { [TU] 8.2.29 Test Proforma for Lateral Load Test on Piles Test Pile No. . Date of Testing Jack Details = Make and Type Last calibrated on Ram Dia. . 1 Division = .. _Recording of Deflection Time Pressure [Load | Dial Gauge Reading (in mm) | Remarks 1 applied, | (in MT) . (p/m?) Test Pile | Reaction Pile Pressure | Building up i Initial Reading j Final Reading Pressure Released Recommended Value : Maximum Deflection at Peak Load = Smm Results : Accepted /Not Accepted Remarks (if any) : Signed 5 Signed Date : Date For Contractor: For Department Name Name 274 7 1965 cPwor2002—198Identification Ne 8.2.30 Proforma for Grouting Record in sheathings Name of Work : .. ‘Span No Date of Prestressing... Type of cement : .... Water Cement Ratio (Max. 0.45): Name and amount of Admixture (if used). ‘Temperature : Mixing Water. Time : Start ....... Equipment : Grout Mixer . Cable duct sDiameter Volume of Grout (in Its.) Grouting Pressure . Cement Consumption : Theoretical Pregrouting Checks : Free of blockage : |. Inlet (Yes/No) . 3. Vents (Yes/No) . Leakage observed : (Yes/No) . If cable duct blocked : Remedial measures : Grouting observations : Passage of grouts through vents Passage of grouts through outlets Any equipment failure Post Grouting Checks : Probing by stiff wire : Results : Accepted /Not Accepted Cable No. : Date of Grouting ... Date of manufacture: Grout Finish Grout Pump . Length . Regrouting ........ = Actual 2. Outlet (Yes/No) .......3- 4. Cable ducts (Yes/No) Sealed (Yes/No) .. (Yes/No) .. Remarks : Signed : Signed Signed Date Date Date For system supplier For contractor For Department Name Name Name 215SUleN, BaneNT i - eT uaunmdag 40g L OENLOD tod 2 sonddns traysss sog or awa 5 awa \ poudig pousis paudig , | ' 3 I S +ebekelele als : > 2 % Pe PRISSPESBT ET ereE/e E/E (E/E/E(E/S(E(E(ELFIE g sel Ele le EB) E\SE & & Ble(e et els = eye elke Fl eiraiSlS/ FSS) s) Fs) aye) } ete : ne] 5B las Sy esPl Tl elalelalFlalal?lae}s)e} 3 8 RE| SE |e le ices se) 13) “)eycrele cleat il? Bay) es jte el else| o> <7) es) 3s 2 geal = E\ER) » = 2 {= 2 aoe if alaige |” | g] 2 s : t elele 3 : By & Fi 4 z | & a glvl 3 WOR way Ei, & ie 274) 2 (067 Jo ainssaid | 9) Jo snssaud E 4 aa ‘ayy ae (usu) ayy ve (Was) . 3) 22 | a) 3) uotsuaxg uorsuanxg, (unui) | souanbos Bi 3 xy sSurpeay sSupeay oneduorg | Suissans ai = 3 spe atneg | yey ane |parensey | 24° + Buissans Sunny 5 ais an So slurs meng = shop gz 1 upuang aqn Bupgoer Butz aunscad a8ne8 poyoody 2 sdung or Bugasouos Jo omep 18], IO/By, = (SLA) pag ap suaL 43H ‘Y= 21qR9 Jo pua Wary SAE ¢ PASH MALY Jo SHIEH Japnp/ weurerg : Burssans Jo ain ayp ye yBuans aqno aSesnay ‘y = 249 Jo pua yoT ‘ou Buymeap aauanbas Buissanig “oN uedig aa,0K JO MUEN, TL] “oN WoneoyHuepr sa[qeo au Jo p10sax Suyssasysarg JO} PMIOJOI [ETSCHAPTER 9 METHOD STATEMENTSO11 9.2 93 94 95 96 9.7 98 99 9.10 OAL Bored Cast-In-Situ Piles Load Test on Piles Casting of Pile Caps Dense Bituminous Macadam and Bituminous Macadam Bituminous Concrete 25mm Bitumen Mastic Work POT-Cum-PTFE Bearings and Vertical Elastomer Bearings Strip Seal /Modular Strip Seal Expansion Joints Earthen Embankment Water Bound Macadam Segment launching 21991D 9.12 OLS 916 918 * 919 9.1.10 Od 9.12 91.9 914 91S 9.1 | METHOD STATEMENT FOR INSTALLATION OF BORED CAST-IN-SITU PILES . Pile point will be marked on the ground with Total Survey Station. ‘The Rotary boring machine will be moved to pile location and positioned w.r.t. pile center point ensuring verticality of mast with in-built indicator panel facility or with spirit level. After boring of about 5 to 6 mtr. Temporary steel casing or approx. 5m depth will be placed in plumb position and checked with help of spirit level. Boring shall be carried out using rotary auger/bucket up to the tip of pile. The depth of the bore shall be checked with a steel wire and tape. ‘The sides of bore hole shall be stabifized even during boring by use of bentonite slurry through out its length. The level of bentonite suspension shall be maintained up to approx. 1.0M above the bottom level of temporary casting at the top. The bottom of bore hole shall be cleaned thoroughly using bucket. Full length of stecl reinforcement cage with spacer blocks will be lowered into the borehole. 8° / 10" dia remmie pipe shall be lowered into bore hole keeping the bottom of tremmie approximately 300mtn above pile bottom level The bore hole shall again be cleaned by bentonite circafation by pumping fresh bentonite solution of a specific gravity of at least 1.025. The adequacy of pump for flushing piles more than 20 mtr deep will be ensured. After ensuring that the out coming bentonite slurry is clean and consistency of the same is almost equal, (density to be measured & maintained ) as that of fresh bentonite slurry, the bentonite circulation will be stopped. If bore is left without concreting for more than two hours, it shall be flushed again. Hopper will be placed on tremmie pipe. Ready mix concrete of required grade with 150 to 180mm slump shall be brought by transit mixers Concrete shall be poured through tremmie pipe (directly from transit mixerrin the hopper). Concreting shall generally be poured with minimum interruption. However, under unavoidable circumstance if the operation has to be suspended temporarily, then 280the tremmie pipe shall be raised and lowered slowly from the time to time to avoid setting of concrete around it. 9.1.16 Sacrificial concrete at top will be cast for atleast Im. 9.1.17 The temmie pipe shall be removed in stage during pouring of concrete ensuring that the tremmie bottom is always within the concrete. The operation shall be continued tll the entire length of pile is cast 9.1.18 The boring machine shall be brought back to location and temporary casing shall be removed using casing adapter. 9.1.19 Bore soil / bentonite mud shall be removed with the help of loader and tippers. 2819.2 METHOD STATEMENT- LOAD TEST ON PILES. 9.2.1 9.2.2 9.23 9.2.4 925 9.2.6 927 92.8 9.29 9.2.10 9.211 9.2.12 9.2.13 9.2.14 ‘The initial load test to be carried out as per IS-2911 Part-4- 1985, ‘The Kentledge structure shall be designed according to the applicable loads. A pit of 12Mx12M shall be excavated up to 2m below the ground level. Further, pit about 3 M x 3 M shall be excavated around the test pile up to about 150mm below the test level of 1.40 M height below the bottom level of previous pit. ‘The pile shall be chipped off in order 10 remove the weak concrete and finished smooth at the test leve] with the same grade of concrete as in the pile. ‘The supports for the main girders shall be made of RCC and the top level shall be maintained at a pre-determined level, so that there is a gap of about 50mm. between the jack assembly and the soffit of the main girders at the zero-load position. Sketch is shown in the drawing. ‘The jacks shall be placed over M.S. Plates on the pile, so that the center of gravity of the jacks is over the center of the M.S. Plates and over the center of the pile. The Kentledge structure be placed in position as per design. The girders shall be tack-welded with reinforcement bars so as to keep them in position during the loading. The Kentledge shall be covered with M.S. plates of 4mm thickness. It is fo be ensured throughout the process of loading that the kentledge load shall be concentric with the center of the pite. The Kentledge shall be loaded with sand bags/precast concrete blocks/sand. Datum bars shall be provided with its supports at a distance of 5M from the edge of the piles. The supports shall be embedded in concrete into the ground. The datum bars shall be made of rigid stracture steel material. The datum bars shall be so arranged as to accommodate dial gauges at three edges of the pile, the edges making apex points of an equilateral triangle. ‘Three numbers of magnetic stands shall be placed on the pi mentioned above. The magnetic stands shall be placed on M. pile surface with some adhesive material. at the apex points as Plates fixed to the ‘The dial gauges to be used for the test shall be of 0.01mm sensitivity. ‘The die gauges sal be Fixed withthe arms ofthe magnetic stands and shall be adjusted at ‘0° reading. 28292.15 92.16 9.217 9.2.18 92.19 9.2.20 9.2.21 92.22 92.23 ‘The test shall be carried out by applying series of vertical downward increment loads, each increment being of about 20% of the test load on the pile. Taking of measurement or displacement in each stage of loading shall be maintained till rate of displacement of the pile top is either 0.1mm in first 30 ‘minutes o 0.2mm in first one hour or till 2 hours whichever occurs firs. ‘The load shall be applied until the maximum test load is reached or the settlement exceeds 10% of the pile dia, whichever occurs earlier. The test load shall be maintained for 24 hours and hourly readings shall be taken. ‘The toad shal! be started to be released in the reverse order of the increment applied. Each load stage shall be maintained for 30 minutes and the readings shall be recorded. A graph shall be ploted showing loads on X-axis and corresponding, displacements on Y-axis and the same shall be presented along with the load test Record Form. A sample proforma for recording of observation is given. Pressure shalt be applied through 2 Nos. electrically operated hydraulic jacks, each of SOOMT capacity which are synchronized to work together. Pressure gauge and dial gauges shall be got calibrated prior to testing from a reputed laboratory approved Engineer-in-Charge.93 93.1 9.3.2 93.2 93.3 93.4 METHOD STATEMENT FOR CASTING OF PILE CAPS ‘The casting of pile caps will be taken up for pile groups cleared from all the routine tests i.e, Integrity Tests, Vertical Load Tests & Lateral Load Tests if the piles of that pile group are to be tested for any one of more of this tests, Before ‘that the verticality and shift of the individual pile will be checked and recorded in the test given under chapter &, SHUTTERING MATERIAL - Pre-fabricated standard stee! plate (1200 x 500 or 600 x 900 mm) will be joined with the help of bolts. Suitable packing to be provided to prevent leakage between successive plates, INSPECTION AND INSTALLATION OF SHUTTERING : ‘The shuttering will then be supported by struts at suitable intervals to render the whole arrangement rigid. The straightness, line and level will be checked as per drawing. Before fixing of shuttering, it would be properly cleaned and the surfaces shall be treated with shuttering oil. Final cleaning of the enclosure will be done with compressor just before the casting of concrete. The position of reinforcement of pile cap and pier dowels will be checked with respect to the centerline of the bridge and the centerline of shuttering as well. To support the dowels of piers, staging shall be erected with scaffolding pipes to the full height at the opposite sides of the pile cap along the major axis of pier. This staging will be done at a suitable location outside the pile cap shuttering at for placing reinforcement of piers, one full set of links will be placed each, at the base (on the bottom layer reinforcement of Pile Cap), inside th template of the starter & at one place for the whole height of pier. A coat of cement will be applied on these dowels. POURING AND COMPACTION : Casting will be done with crane & bucket arrangement or difectly by transit mixer and chute, Pouring of concrete will be done in inclined layers. Concrete shall be deposited just on top of the top seinforcement layer. Compaction will be carried out by needle vibrators. The concreting shali be continued from one end and laid at such a speed that the unfinished face remains plastic. If under any circumstances concrete of the preceding layer looses its plasticity, a coat of cement siurry will be applied on this concrete surface to start further concreting. Small pieces of reinforcement would be inserted party inside the concrete top surface so that protruded portion may be used for proper supporting of the props/turn buckle of the pier. These shall be cut up to one inch below the concrete, painted with epoxy paint and surface repaired with epoxy mortar afterwards. PIER DOWEL AND CASTING OF STARTER : The checking of pier Dowel & Casting of starter will be done with a template (350mm or so high). The template will be in accurate lines, placed on chairs and well supported. These cchairs will be welded to the top layer reinforcement of pile cap. The starter will be poured in the same aperation of pile cap casting. The alignment and location of starter will be checked again before casting of starter. 2849.3.8 DESHUTTERING AND INSPECTION : De-shuttering will be done after 24 hours and inspection of the de-shuttered surface shall be carried out immediately and remedial action of the surfaces, if any, shall be done with the concurrence of the department, 9.3.6 CURING : After de-shuttering, the vertical surfaces shall be wrapped with Hessian cloth and curing will be done by water spraying . The top surface will be inundated for 14 days by making a bund of 50mm height in cement mortar all round its periphery. 28594 METHOD STATEMENT FOR DENSE BITUMINOUS MACADAM (INCLUDING BITUMINOUS MACADAM). 94.1 94.2 943 944 945 046 947 9.4.8 949 9.4.10 ‘The work shall be carried out as per IRC:27. The DBM will be taken up when a) The WBM has completely dried for approach area and after completion of curing period of the bridge deck in Viaduct portion. b) Before starting with DBM, the WBM surface will be checked & rectification if required will be done by removing the whole depth for the affected area & rectifying the same with new material. However, in case of minor undulation in WBM/Bridge deck surface, priming coat application will start as usual & extra amount of DBM material required will be filled. The surface will thoroughly be cleaned from dust, ©) The weather is dry having temperature more than 10°. Job mix crushed stone, stone dust, hydrated lime & bitumen will be used as per Jjob mix formula. Mixing will be done in a hot mix plant , Capacity of the plants shall be of the order of 30T per hours. The surface of WBM shall be thoroughly cleaned of all dust & oil etc. Spreading : Spreading will be done with paver finisher order wide areas, however for narrow areas manual spreading will be done after approval of Engineer-in- Charge. Rolling: Initial rolling will be done by 8 to 10 T static roller, Intermediate rolling & finishing rolling will be done with vibro roller. Rolling will be done from outer edge to inner edge. The roller shall proceed on the fresh materials with rear wheel leading so as to minimise the pushing of mix & each pass of roller shall over tap ‘on preceding one by half the width of rear wheel. The paver will spread 2.7mtr. ‘wide material up to the decided length. The wheel of roller shall be kept most to prevent the mix adhering to them. Rolling wifl continue till field density is achieved to 98% of laboratory density in Marshal mould. Joint preparation : All transverse joints shall be cut & painted with hot bitumen & Jongitudinat joims shalt be heated to 80°C to start next operation, Temperature requirement ; a) Temperature at the time of laying shall be between 120° C to 160°C. b) Rolling operation to be completed within ing temp. 100°. Surface Accuracy : With an edge of 3. mtrs The maximum allowable undulations shall be less than 6mm & 10mm in transverse & longitudinal 286ee directions respectively. However maximum number of undulation exceeding 6mm in any 300mtrs. In longitudinal length shalf not exceed 20. 94.11 Rectification : The surface accuracy shall be checked immediately after rolling surface irregularities which fall outside the specified tolerance as stated above shall be rectified by removing not less than 10 sqm area & relaying with fresh materials. In no case shall depressions be filled up with screen or binding material, 2879.5 | METHOD STATEMENT FOR BITUMINUS CONCRETE 9.5.1. The work shall be carried at as per IRC: 29. 9.5.2. The job will be taken up over completed bituminous macadam as enumerated in bituminous macadam work after application of tack coat. 9.5.3 Same methodology will followed from as at serial no. 9.3.2 to 9.3.1 except that for surface finish 3 mtrs. Edge should an undulation less than 3mm in any direction. 28896 9.6.1 9.62 “9.63 964 9.65 9.6.6 9.67 9.6.8 969 9.6.10 9.6.1 METHOD STATEMENT FOR 25MM BITUMEN MASTIC WORK ‘The work shall be carried out as per IRC: 107 Start: The job will be taken up when. 4) iinous concrete work s over and has dried (b) ‘The weather is dry having temperature more than 10°C. ‘Cleaning: the surface shall be thoroughly cleaned. Spots rich in binder shall be scraped because this binder will soften under high application temperature. This area shail be repaired by the same mix of bituminous concrete. ‘Tack Coat: Application of tack coat with 80 / 100 or 60/70 grade bitumen @7.5 to 10kg/sq.m. Job Mix: Material will be mixed and used as per job mix formula. Mixing will be done in mastic cooker. Wheel hatrows, wooden trowels, eavy wooden floats suitable hands tool gauges and angle irons required 10 contain mastic in desired width and thickness are required at site. Spreading : Bitumen mastic shall be deposited directly on the prepared base with chicken wire mesh immediately in front of spreader which is spread by means of wooden float to the required thickness. Surface finish : The bituminous mastic surface has got very fine texture on spreading hence provides litle resistance to skidding. Therefore approved quality ‘of 9.5mm pre-coated stone are pressed on to the surface @ 0.005 M? per 10 M* with a spacing not more than 10cm center 10 center. These stone chips will protrude 3 to 4 mm from the surface. Joint Preparation : An excess quantity of hot bitumen mastic is applied on the existing joints and are trimmed to make then flush with the sarface of other sides. ‘Temperature requirement + The following temperatures. jes. shall be carried out as per the (@) Mixing and cooking 200°C (b) Laying temperature 170°C (c) Anti skid aggregate pressing temperature 80" to 100° C. Surface Accuracy : The finished surface shall be checked with an edge of 3 murs. and the maximum allowable undulations shall not be moré than 4mm in any direction. 5 ‘Traffic movement : Traffic will be allowed when the bitumen mastic has cooled down to ambient temperature. vagscmupicn—2? 28997 974 972 973 974 975 976 977 978 979 9.7.9.1 METHOD STATEMENT FOR INSTALLATION OF POT-CUM-PTFE BEARINGS AND VERTICAL ELASTOMER BEARINGS GENERAL Care should he faken-during installation of the bearings to per functioning in accordance with the design scheme, To prevent contamination, dismantling of the bearings at site is not advisable. ‘The load:is to be transferred on to the bearings only when the bedding material * ‘has developed sufficient strength. ‘That is the props for the formwork can only be removed after elapse of appropriate time. In special case this can be ensured by suitable devices like jack etc. ‘Temporary clamps and shims (introduced to maintained designed pre-setting and ‘working clearance) should be removed at an appropriate time, before the bearing is required to permit movement Permitted installation tolerance of the bearing from the plane of sliding has to be : maintained The cement based free flow noushrink grout of quality approved by the Engineer-in-Charge and the epoxy based grout whichever is specified should be used at the site. For the proprietary grout mixes appropriate instructions from the ‘manufacturer may be followed specially regarding the following : Preparation - concrete cleaning, roughening, presoaking etc. Forms - sturdiness, leak proofing, shape, header, funnel, vents etc. Bearing base - cleaning etc. Placement - mixing, consistency, time period, finishing ete. Protection - curing, ambient temperature etc. SEATING OF BEARING Seating of bearings shall be as per manufacturer's instructions. b IN-SITU CASTING OF SUPERSTRUCTURE , Formwork around the bearing should be carefully sealed to prevent leakage. c 2909.7.9.2. Sliding plates should be fully supported and care taken to prevent tilting, displacement or distortion of the bearings under the weight of wet concrete. 9.7.9.3 The bearings should be protected during concreting operation. Any mortar contaminating the bearing should be completely removed before it sets. 9.7.10 SEATING OF POT BEARING 9.7.10.1 Using Template 9.7.10.2 Template with required rigidity and matching holes corresponding to the base of the bearing to be used. 9.7.10.3 All the Anchors are fitted to the lower face of the template using the anchor screws but with steel washer replacing the elastomer washers. Separate screws may be used in case of inconvenience in the length of the original anchor screws. 9.7.10.3 The template assembly to be located with regard to level and alignment. It is to be ensured that the top of the anchors fie in a horizontal plane at the required elevation. The anchors may be tied/welded to reinforcements to avoid displacement during concreting, 9.7.10.4 Concreting of the pedestal/pier cap is done to a level leaving a gap of 20-25 mm below the template. 9.7.10.5 The template and steel washers are removed prior to placement of the bearing assembly with temporary clamps. The bearings assembly is fitted to the anchiors with the help of anchor screws and elastomer washers. Check Jevel at the bearing. 9.7.10.6 The gap below the bearing assembly is grouted with cement based grout. Refer to C1.L.6 above. 9.7.10,2. Without Template with Gap 9.7.10.2.1 Pockets commensurate with the sizes of the anchors shall be kept in pedestals during concreting of the same. The pedestal shall be cast approximately 25 mm short of the required finished level. 9:7.102.2 Anchors are fitted to the bearing bottom with elastomer washers and anchor screws. ‘The bearing assembly is seated in the location on steel chairs/packs, The anchors fitted below the bearing will go into the pockets in the bed block. Check level and alignment of the bearing. It is also to hhave ensured that the bearing seats in a horizontal plane. 9.7.10.2.3 The gap below the bearing assembly including anchor pockets is grouted with cement based grout. 97.103 Without Template without Gap 291 1985 CPWOI2002~2197.103.1 Elongated pockets commensurate with the sizes of the anchors shall be kept in pedestals during concreting of the same. The geometry and location of the anchor pockets (with tapered funnel extension if required) shall be such that after placement of the bearing the pockets can be successfully grouted. The pedestal shall be cast 5.- 15 mm protruding out of the required finished level. The required level shall be achieved by > chipping before placement of the bearing. Excellent control will be required at the site for casting dead level or | - 3 mm down from the required level. 9.1.10.3.2 The pedestal top is chipped. Semi dry mortar pack or epoxy mortar with quartzite sand is spread over the bed block. Anchors are fitted to the bearing bottom with elastomer washers and anchor screws. The bearing assembly is seated in the location keeping level and alignment. 9.7.10.3.3 The anchor pockets are grouted with cement based grout. Refer to cl. C.1.6 above. 9711 SEATING OF PIN BEARING 97M Backing plate with studs welded on the face opposite to the seating of the hearing will be delivered by the manufacturer. 972 This backing plate is to be accurately positioned on the reinforcement grid of the pedestal and leveled. L 97 Studs may be tack welded/tied-to the reinforcements to keep the backing plate in proper location during casting. OT Depth of embedment of the backing plate in the concrete will be as per relevant drawing, 97.115 ‘The round base of the pot (bottom) of the Pin Bearing assembly will be connected to the backing plates by anchor screws after concreting of pier cap/pedestal. 976 In order to ensure successful transfer of large horizontal forces to be resisted by the Pin Bearing, great care should be taken in detailing the reinforcement in the structure and the superstructure adjacent to the studs in the backing plate. 97.12 SEATING OF ELASTOMERIC BEARING (For installation on a non-horizontal plane) 97.121 Elastomeric bearings will be delivered with mild steel backing plate 4 fastened to the bearing from the manufacturer. 97.122 Template of 6 mm mild steel plate and of size same as bearing holding : base plate with matching holes for the anchor screws are to be used. 29297.123 9743 97.131 9713.11 97.13.12 97.13.13 9.7.13.2 97.13.22 97.13.23 97.13.24 Anchors are to be fitted to the templates with the anchor screws but with mild steel washers in place of elastomer washers. The above template assembly is to be fitted in the formwork at its proper location and in a vertical plane. Alter casting of the pedestal and removal of the formwork, the template is, to be removed. Face Plate fhout template in situ casting The sub-assembly of elastomeric bearing with the mild steel backing plate is to be fitted to the embedded Anchors with anchor screws and elastomeric washers replacing the steel washer. A clear gap is required between the stainless steel face of the elastomeric bearing and that of the vertical face of the face plate with Stainless Stee! (SS) top installed on the projection below the soffit. This shall be achieved by inserting removable steel shims of thickness as per the drawing, during preparation of the formwork before casting of the superstructure. ‘The face plate with Stainless Steel top and pack plate are assembled with the anchors with elastomeric washers and anchor screws. The assembly is (o be fitted ifi the formwork at its proper location and in a verticat plane. The removable steel shims are to be removed at an appropriate time after the casting of the superstructure. With Template wit Grouting ‘Template of 6 mm mild steel plate and of size same as for face plate with ‘SS top and matching holes for the anchor screws are to be used. Anchors are to be fitted to the templates with the anchor screws but with mild steel washers in place of elastomer washers. Separate screws may be used in case of inconvenience in the length of the original anchor screws. The above template assembly is to be fitted in the formwork for the superstructure at its proper location and in a vertical plane. After removal of the superstructure formwork, the template is to be removed. The faceplate with the required thickness of pack plate is to be loosely fitted to the anchors embedded in the projection below the superstructure, with elastomer washers and anchor screws. ‘The sub-assembly of elastomeric bearing with the mild steel backing plate is to be fitted to the embedded anchors in the pedestal with anchor screws and elastomeric washers replacing the steel washer this time. 29397.13.25 ‘The required clearance between the stainless steel face of the elastomeric bearing and that of the vertical faceplate installed on the projection below the soffit is to be checked. After adjustment of the required working clearance the small gap between the vertical face of the projection below the soffit and the back of the face plate (with pack plates if any) are to be grouted with epoxy grout. 29498 98.1 98.2 98.3 98.4 98.5 98.6 98.7 988 98.9 9.8.10 METHOD STATEMENT FOR INSTALLATION OF STRIP SEAL/ MODULAR STRIP SEAL EXPANSION JOINTS INSTALLATION ‘The Joint shall be installed by the manufacturer / supplier only. ‘Taking the width of gap for movement of the joint into account, the dimensions of the recess in the decking shall be established in accordance with the drawings of design data of the manufacturer. The surface of the recess shall be thoroughly cleaned and all dirt and debris removed. The exposed reinforcement shall be suitably adjusted to permit unobstructed lowering of the joint into the recess. ‘The recess shall be shuttered in such a way that dimensions in the drawing are maintained. The formwork shall be rigid and firm. Immediately prior to placing the joint, the presetting shall be inspected. Should the actual temperature of the structure be different from the temperature provided for presetting, correction of the presetting shall be done. After adjustment, the brackets shall be tightened again. ‘The joint shall be lowered in a pre-determined position. Following placement of the joint in the prepared recess, the joint shall be leveled and finally aligned and the anchorage steel on one side of the joint welded to the exposed reinfarcement bars of the structure. Upon completion, the same procedure shall be followed for the other side of the joint. With the expansion joint finally held at both sides, the auxiliary brackets shall be released, allowing the joint to take up the movement of the structure, Controtled concrete having strength not less than that in superstructure subject to the minimum of M35 shall be filled into the recess. The packing concrete must feature low shrinkage. Good compaction and careful curing of concrete is particularly improvement, After the concrete has cured, the movable installation brackets and shuttering still in place shall be removed. The chloroprene seal shall be field installed in continuous lengths spanning the entire roadway-width. To ensure proper fit of the seal and increase the ease of installation, dirt, spatter or standing water shall be removed from the steel cavity using a brush, scraper or compressed air. The seal shall be installed without damage to the seal by suitable hand method or machine tools. ‘As soon as the concrete in de tecess has become initially set, a sturdy ramp shall tbe placed over the joint to protect the exposed steel beams and neoprene seals from site traffic. Expansion joint shall not be exposed to traffic loading before the ccartiage way surfacing is placed. ‘The carriage way surfacing shall be finished flush with the top of the steel sections. The actual junction of the surfacing / wearing coat with the steel edge section shall be cleaned beforehand. It is particularly important to ensure thorough and careful compaction of the surfacing in order to- prevent any premature depression forming in it. 295 1965 CPwor2002—22099 99.1 9.9.2 993 994 99.5 99.6 997 METHOD STATEMENT FOR CONSTRUCTION OF EARTHEN EMBANKMENT. Setting out: After Cleaning the site where embankment is to be constructed, the limits of embankment / sugared shall be marked on the ground by fixing pegs ‘on both sides at regular intervals. The embankment / subgrade shal! be built sufficiently wider (approx Im on each side) than the design dimension, Preparation of foundation of embankment: The original ground shall be leveled, scarified, sprinkled with water and than compacted by rolling to achieve at least 75% of the maximum dry density (MDD) of the difference between the top of sub grade and ground level is less than 0.5m and the ground does not have a density of at least 97% the MDD, the ground shall be loosened upto 0.5m below the proposed sub grade level, water to OMC and compacted to 97% of the MDD. Laying / Spreading Earth : ‘The embankment and sub grade shall be laid in layers not exceeding 20cm compacted thickness over the entire embankment width, finished by a mortar grader having hydraulic control. Maintaining Moisture Content : ‘The M.C. (moisture content) of each layer shall be checked. If the earth is too wet, it shall be spread for drying and if it is too dry, water chall be spin welded so that the OMC is obtained. Compaction ; Each layer shall be compacted with a roller of 8 to 1OMT capacity (0 at least 95% of the MDD in fower layers and 100% of the MDD in top layers. The field density shall be checked as specified in chapter 8. Finishing : The shoulder / verges and site slops shall be dressed so as to conform to the alignment , levels, cross-section and dimensions shown in the approved drawing. ‘Turfing : The site slops shall be turfed as per specifications of the contract. 296 1965 cewor2002—2289.10 9.10.1 9.10.2 9.10.3 9.10.4 9.10.5 9.10.6 METHOD STATEMENT FOR WATER BOUND MACADAM Preparation of Base: The surface of the sub grade / sub-grade base to receive the water bound macadam bound macadam course shall be prepared to the specified lines and cross fall (camber) and made free of dust and other extraneous material. Any ruts or soft yielding pfaces shall be corrected in an approved manner and rolled unti) firm surface is obtained if necessary by sprinkling water. Any sub-base / base/surface irregularities. where predominant, shall be made good by providing appropriate type of profile corrective course (leveting course) . Spreading Aggregate: The aggregate shall be spread uniformly to proper profile by suing templates placed across the road six meters apart, in“uch quantities that thickness of each compacted Igyer is not morythan 100mm for grading | and 75 mm for grading 2 and 3 as specified clauSe-404.2.5 MOST specification for road and bridge works. Checking of Surface : ‘The surface of the aggregates spread shall be carefully checked with templates and all high or low spots remedied by removing or adding aggregates as may be required. The surface shall be checked frequently with a straight edge while spreading and rolling so as to ensure a finished surface as per approved drawings. Compaction : Compaction shai be done with three wheeled power rollers of 80 to 100KN capacity or tandem or vibratory rollers of 80 t0 100KN static weight as approved by the Engineer-in-Charge. Except on super elevated portions where the rolling shall proceed from inner edge to the outer, rolling shall begin from the edges gradually progressing towards the center. First the edge/edges shall be compacted with roller running forward and backward. The roller shall then move inward parallel to the center line of the road, in successive passes uniformly lapping preceding tracks by at least one half width Rolling shall be discontinued when the aggregates are partially compacted with sufficient void space in them to permit application of screenings. The rolled surface shalt be checked transversely and longitudinally, with templates and any irregularities corrected by loosing the surface, adding or removing necessary amount of aggregates and re-rolling until the entire surface conforms to desired cross fall (camber) and grade. In no case shall the sue of screenings be permitted to make up depressions. Application of Screenings : After the coarse aggregate ha been rolled, screening to completely fill the interstices shall be applied gradually over the surface. Dry rolling shall be done while the screening are being spread. The sereening shall be uniformly spread in thin layers at a slow and uniform rate followed by dry rolling and brooming. ~ Sprinkling of water and grouting : After the screenings have been applied, the surface shall be copiously sprinkled with water, swept and rolled. Hand brooms shall be used to sweep the wet screenings into voids and to distribute them evenly. The sprinkling, sweeping and.rolling operation shall be continued. 297a 9.10.7 9.10.8 9.109, with additional screenings applied as necessary until the course aggregate has been thoroughly keyed well set in its full depth and a grout has been formed of screenings. Application of binding material : After application of screenings the binding material shall be applied in thin layers, copiously sprinkle with water and the regulting slurry swept with brooms and rolled. Setting & Drying : After the final compaction of water bound macadam course, the pavement shall bé allowed to dry overnight. Next morning hungry spots shall be filed be screening and binding material, lightly sprinkled with water and rolled. ies as per thetolerance specified in clause 902 of MOST specification rig and surface finish : The surface finish shall be checked for a regi for ¥8Ad and bridge works. ° 2989.11 METHOD STSTEMENT FOR LAUNCHING OPERATION 9.11.1 PREPARATORY WORK 1.) At the casting yard, before a segment is removed from the casting bed, the centre line of the segment will be marked on each segment and the levels of the steel plate fixed at each corner of the segment will be recorded. Each segment will have a painted identification mark. 2.) The segments will then be separated, placed on the stacking bed. Each pre- stressing duct will be cleaned and checked by passing a dolly to ensure that there is no blockage. 3.) Top and side inserts will be fixed. The top insert is fixed by pre stressing with BBRV tendons and the side insert through a pin bolted to the inserts already placed inside at the time of concreting. 9.11.2 LAUNCHING OPERATION STAGE | STEP | 1.) Foundation for each trestle will be prepared. 2.) Trestle will be erected and secured to the foundation. Each trestle will have a 100- ton jack with lock nut safety device. 3.) Erect Launching Girder trusses, place them over the jacks on each trestles ensuring perfect alignment. The two trusses will then be connected to each other and levelled by means of jacks. The lock nuts of each jack will be tightened, Crab trolley will then be installed on top of the L.G. Cross beam trolleys will be installed over wooden packing at the bottom chord of each L.G. truss. Two - working platforms movable on wheels will be hung from the L.G. assembly. Install pot PTFE bearings over the top of the pier as per the manufacturer instructions and lock them to prevent rotation. 4.) Transport and lift pier segment and place it over the bearing ensuring thatthe pier segment is properly in position and in longitudinal and cross gradient. Lock the bearing / pier segment against longitudinal and transverse movernent. 5.) Place auxiliary support over the pier segment as per the drawing. Support the bottom chord of the L.G. by tightening the 200-ton jacks placed on the. auxiliary support and tighten the lock nuts. STEP 2 1.) Lift segment | by crab trolley from the trailer. 2.) Move segment I to its correct longitudinal position and rotate it as required. 3.) Attach vertical hangers of predetermined fength. The hangers can be made of BBRV wire cables having type F60 anchors fixed to the top cross beam trolley of each L.G. truss and type B60 stressing anchor attached to the two inserts fixed to the segment. 4.) Repeat the above operations 1 to 3 for each segment in the predetermined sequence. 299 |—~@e ———@ - 5.) Bring next segment close to the pier segment by sliding the transverse cross beam trolley over waoden blocks by using a hand operated winch. Tilt it to the correct gradient by means of turnbuckle. Tilt it in longitudinal and transverse directions by adjusting the height of the hangers by means of jacks. Minor adjustment for shifting the segment in transverse direction can be made by using screw jacks to push the F60 anchor head. The shear keys of the segments should match. This is referred to as dry matching. 6.) Repeat operations | to 5 for each segment to dry match the entire bridge unit. Step 3 1.) Pull back the segments away from the pier segment using the hand winch creating a gap of 500 mm on either side of pier segment. 2.) Bring segments closer and make final adjustments to ensure a perfect match. Pull away the segments again to create a gap of 500 mm between segments. 3.) Fix foam washers around each sheathing duct to prevent leakage of epoxy glue into the duets. 4.) Apply epoxy glue to both contact surfaces and bring back the two segments togetine. 5.) Install pre stressing cables (BBRV) of predetermined length between top and side insert frames of the segments. 6.) Provide temporary ve stressing on top and bottom with the predetermined Jacking force. This 1s carried out by use of 4 jacks each installed at the 2 top and 2 side insert frames connected through a manifold. The jacks are connected in pair to two power packs. The Prestressing is to be carried out within the pot life of the epoxy. 7.) At the time of temporary pre stressing a dolly is placed in each sheathing duct to ensure that the glue does not block the ducts. 8.) Repeat operations 2 to 7 for all the segments in predetermined sequence till the ‘whole bridge unit is erected. STEP 4 |) Install P.T. tendons by manually pushing strands into the ducts, Pre stress each tendon as per the requirement. 2.) Release the jacks at auxiliary support and then at the trestles to release the vertical hangers. Remove the crab trolley, hangers from L.G. 4.) Lift the L.G. truss one by one by crane and install them over the next trestle of, required height. STAGE2 Follow all the steps of Stage 1 to complete all the bridge units and then cast the connecting segments as in situ segments. Prestressing is done after the in-situ segments as per the design as per the step 4 of Stage I. 300CHAPTER — 10 NON CONFORMING PRODUCTS AND PROCEDURESCONFORMING PRODUCTS AND PROCEDURES In broad terms, for the Quality Assurance of the finished works it is necessary for the materials and workmanship to comply with the Contract requirements. Non-compiying works shall be rejected. ‘The statement above is true in general terms but special difficulties arise in the case of concrete, where the non-compliance may only be known after 28 day cube test results. In these cases removal, re-execution or rectification of the work is usually difficult, Therefore separate procedures are laid out below for non-complying concretes. A similar situation may also arise when test results of some materials arrive after the same has already been incorporated in the project. This happens when certain materials like Admixture which require Jong term tests, such as development of compressive and flexural strength over | year and Jength change aver | year, to be performed and the construction can not wait for them. Other such example is long term corrosion resistance test on coatings. Many a times test results may get delayed accidentally and the material may have been incorporated in the project. All such situations need to be dealt with in a careful manner This section describes procedures for the same, Conerete works ‘The primary means by which Quality Assurance shall be achieved is by the procedures described in Chapters 3, 4 and 6 . 10.1.1, Non-compliance Other Than Strength or Finish In the event that any requirement other than strength and standard of finish is not met then the following procedure shall be followed:- 303) 2 3) 4) 5) The Contractor shall be ni writing by the following means :- ied without delay verbally and in a) Retum of the Request for Inspection form signed “not approved" with the reasons for rejection stated. b) Issue of a Site Instruction or Site Works Order or letter stating the facts and confirming that the works are not approved. Approval to cary out concreting of a similar nature shall be withheld. ‘The Contractor shall be asked for his proposals to rectify the non-compliance which may involve resubmission of materials, new trial mixes, revised method statement, The acceptance or rejection of any unapproved concrete work shall be referred to the Engineer. When satisfied with the measures taken to ensure future compliance the Engineer shall confirm approval to continue concrete for - permanent works. 10.1.2 Non-Compliance with Strength requirements y ‘The Specifications for concrete recognises the statistical possibility of cube failures and thus limits of mean, standard deviations, minirium values of strength are specified. A single isolated unsat- isfactory cube result is not usually cause for rejection. The rejection criteria is as set out in the Contract agreement. 3042) 3) 4) 5) In onder to provide assurance against strength failures the procedures described in Chapter 4 shall be observed. In the event of cube failures outside the provision of the Contract then the non-compliance procedures described in the specifications shall be followed. In addition the following procedures shall be followed :~ a) Approval of concrete of simnilar works shall be withheld. b) All aspects of concreting shall be reviewed. c) ‘The cause of failure shall be identified and measures taken to remedy the problem. ‘The repait/ rectification procedures for commonly arising defects should be covered by tender specifications, from which the contractor shall be asked to state his exact proposals for rectification. It shall be ensured that the faulty work is made good following approved method and retested and/or inspected. The fact of non-compliance & rectification means as proposed should be conveyed to the Engineer and for review & opinion about a) acceptability of Contractor's proposal. b) further non-destructive testing, if any. ©) acceptability in case strength is achieved at a later age (c.g. 90 days). 3054) —_scceptability at the level of strength achieved for the stress levels in concerned members. ©) rejection of concrete. 10.13 Non-Compliance with Finish Requirements In order to prevent occurrence of unacceptable standard of finish the procedures for formwork and trial panefs described in shall be followed. This will involve preparation of scaled Mock up trials if provided for in the contract or ordered by the Engineer in case of specific doubts (see chapter for records of Mock ups). ‘Where the required finish is not anained then the non- compliance procedure described in the Specifications shall be followed. In addition the following procedures shall be followed : a) Approval of similar formwork shall be withheld. b) —_Allaspects of formwork shall be reviewed. c) The cause of poor finish shall be identified. 10.2 Works other than concrete 10.2.1 Procedure ‘The procedure for acceptance of finish works for earthworks, formwork, Feinforcement, coatings on reinforcement, materials for concrete, prestressing and bridge finishing works are straightforward and shall be as follows: 306a 1, Regular awa special testing, logging of results and inspections shall determine compliance os non-compliance. 2. Any non-compliance: shall without delay be notified to the Contractor. This shall be done both verbally and in writing by the following means :- a) Return of the Request for Inspection form signed “not approved" with the reasons for rejection stated. b) _ Issue of a Site Inspection or Site Works Order or letter stating the facts and confirming that the works are not acceptable for inclusion in the permanent works. 3. The Contractor shall be asked to state his exact proposals for rectification and it shall be ensured that the faulty work is made good and retested or inspected as decided by the Engineer. It is mandatory that all instances of works outside the Specifications are recorded in writing to the Contractor. This ensures that :- 1) The Contractor is imefutably informed. 2) A record of non-compliance is built up to give a general guide to the Contractor's performance. ‘The Quality Assurance Manager shall summarise the following information for each category of work :- 1) The total number of inspections and tests. 307° 2) The number of “first time" approvals ie. the number of times the material or workmanship is approved on the first test or inspection. 3) The number of second, third, fourth etc, inspections or tests of the same work required before final approval. 4) The percentage of first time approvals, second, third, etc. over suitable time intervals. From the above infagmation, the Engineer shall review the Contractor's superintendence and take action where necessary to improve matters. From increases or decreases in the number of first time approvals, the improvement or deterioration in Contractor's performance can be mekicorsi. ‘The record of repair/rectification, retesting, inspection & acceptance shall be kept as part of “as built” documentation. Record of all references to designers for opinion/rectification and approvals given by them. Record of compliance to the modifications in procedures, testing etc, if any, shall be properly maintained 10.2.2 Admixtures In case the material test show non compliance prior to its use then the complete material lot _ shal! be removed from the site at once and the procedure stated above shall be followed. But, in case results arrive after the particular Admixture has been used ia the concrete then the contractor shall be required to give his methodology of rectification, strengthening and get it approved by the Engineer before execution, Such a rectified structure shati be subject to appropriate tion destructive testing, if felt necessary by the Engineer. If no satisfactory method is found then the structural members incorporating the 308ion compliant material shall be dismantled at no cost to the ownerclient. In the case of proprietary materials such as Admixture, Bearings, Expansion joints etc the respective manufacturer shall invariably be consulted for analysis of the problems and possible rectification measures. 10.2.3 Cement and Other Materials The procedure indicated above shall be adopted. 10.2.4 Load Test on the Bridge In case load test of the bridge is carried out either as per the original tender requirement or due to rectifications and the same fails to pass then the following procedure shall be followed. i) Contractor to propose elaborate scheme of strengthening the bridge components not passing the test criteria ii) {satisfactory strengthening is not possible but it is found that the bridge can be allowed with lesser load rating which may be acceptable to the ‘owner, the same shall be done with prior written approval of the Owner/Engineer and a suitable penalty may be charged from the contractor, iii) In case none of the above two conditions are applicable then the non conforming bridge components shall be demolished and removed from the site at no extra cost to the owner. 10.2.5 Pile Foundation ‘The procedures to deal with non compliance of the construction materials of piles shall be as detailed in the above clauses. However, construction tolerances, which will be as defined in clause 1116 of MOST Specifications for Road and Bridge ‘Works (third revision) unless specified otherwise in the tender document. In case the 30910.2.6 articular limits of tolerances are exceeded, the contractor shall be required to remove/abandon such piles/foundations at no extra cost to the owner. In case, for any unavoidable reasons, it is decided to retain the non complying piles/foundations, a check of structural safety shall be made by the contractor. If all the bridge components are still found to be safe, the same may be retained after payment of suitable penalty by the contractor to the owner. ‘Well Foundations Similar to piles the procedure to deal with the non compliant materials shall be the same as in the case of pile foundations described above. Tilt and shift of well is a very common problem with well foundations. In case tilt and/or shift of well exceeds the limits specified in clause 1207.8 of MOST Specifications for Road and Bridge Works (third revision) unless specified otherwise in the tender document, the contractor shall be required to remove/abandon such well/foundation at no extra cost to the owner. In case, for any unavoidable reasons, it is decided to retain the non complying well/foundation, a check of structural safety shall be made by the contractor. If all the bridge components are still found to be safe, the same may be retained after payment of penalty as per clause 1212 of, MOST Specifications for Road and Bridge Works (third revision) unless specified otherwise in the tender document by the contractor i the owner. Any additional costs incurred on this ‘account shall be borne by the contractor. MGIPRRND—-1965 CPW0/2002—1650 30