APPENDIX: 16.17.1.

6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

1. FLOW CHART FOR THE CONSTRUCTION OF EMBANKMENT AND SUB-GRADE

Checking of Original
Start Borrow Earth
Ground Level by IC &
Approved
Contractor

Yes Embankment

IF STL-GL> 500 mm Collect samples Scarification, Spreading of Earth Check field

Watering
and carry out Grading and in layers(Compacted Moisture
MDD / OMC Compaction till thickness <200mm) Content
Test(lab) FDD>95%
No
Loosening of Earth
Surface and Rolling at FMC
Sprinkling Water close to OMC

NoON
PASS
Is the Clay Soil/Organic No Oo0
Soil/Marshy Soil for 500 mm
Approval by IC Ready Field Density Test (>95% Checking Levels;
Sub-grade Minimum)
for Next Layer for embankment) Tolerance Level in
Embankment
Yes Sub-grade

Remove the soil of sub-
grade and replace it by
approved borrow soil
Yeses
Collect Soil sample
Sieve Analysis, LL, PI Scarification/spreading Check for Field
and carry out Density
& Soaked CBR ,, ,Grading and Rolling Density (>97%) and
Test (MDD/ OMC)
requirements satisfied FMC close to OMC Level Tolerances

Fail Fail Pass

Checking for Level Field Density Test Rolling at FMC close Loosen Earth Surface; Approval by IC Ready
Tolerances of Sub-grade (>97% for Sub-grade) to OMC Sprinkling water for Next Layer

Pass

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

2. FLOW CHART FOR THE CONSTRUCTION OF GRANULAR SUB-BASE AND DRAINAGE LAYER

To Mix Design Test on Blended

P Identification of Collection of Fail
Individual Sieve Sample: Sieve
R Source by the Representative Analysis, Blending Analysis, LL, PI, Reject the
E CONTRACTOR Sample LAB and arriving at MDD/ OMC and Source
C correct proportions soaked CBR,10%
O Fine Values etc
N
S Pass
T
R Laboratory Testing Collection of Sample Mixing at site/ yard
U From Stock piles using Mechanical
C Equipment
T
I
O
N Suggest Suitable Tests on Sample:
Remedy for Addition or Fail Sieve analysis Pass Approval of the
ST Remixing of Materials Liquid Limit, PI, Stockpile for usage
A including stabilization MDD and Soaked
G CBR etc
E
Check for
Fail Completion
of
Earthwork
(Scarify)
C Fail
O
N Pass P Spreading, Grading
T Rolling at FMC and Watering (Material
R Approval by IC ready Source- Stock pile)
Field Density Test Checking Levels close to OMC
U for Next Layer
(FDD>98% of MDD)
C
T
O
N
Completion Report Independent Consultant ICT Pvt. Ltd
Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

3. FLOW CHART FOR THE CONSTRUCTION OF WMM LAYER

Identification of Quarries Contractor obtains Collection of samples Test on aggregate samples; Prepare Mix
by CONTRACTOR clearance from Coarse and f Fine ( Gradation, Aggregate Design
Local /central Aggregates from Impact Value, EI &FI, Sp.
Authorities to operate crusher /quarry sites Gr ,Water Absorption,
quarry Soundness LA Abrasion
YesS
Allow
for the
Trial run
Does the mix Trial If all materials are OK, Test on blended samples
Test for MDD and
confirm to the allow them for (Gradation, LL & PI, EI &
OMC
Specifications construction by mixing FI etc)
requirement? materials in the plant.
No

Complete Production
granular sub WMM Plant fully No Rectify Shortcomings &
base Layer Is the mix acceptable Yes
with respect to water Produce mix Operational with all perform Calibrations of the
No content & workability? Calibrations Plant
No
Is sub base layer Reject /adjust
completed, inspected the mix
and approved
Has the construction of Spreading of WMM material
Check Rate of spread/ layer
shoulders for lateral confine- uniformly over prepared sub-base
thickness and moisture content
Yes ment completed & approved using power / motor grader
OK
Brooming till all loose
Materials and dust are Test Field Density Scarify & Re-grade
removed Passss (FDD >98% of MDD) Fail
pASS
Checking with templates or 3 m long Rolling / Compaction using
Light sprinkling of water prior
straight edge and take levels Vibratory Roller
to the spraying of prime coat Pass Fail

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

4. FLOW CHART FOR PREPARATION OF MIX DESIGN FOR BITUMINOUS WORKS

Pass
Test on Bitumen : Penetration
Softening point, Viscosity, Flash
and Fire Point, Ductility etc.

Collection of Tests on Coarse and Fine Blending of Coarse & Arriving at

Aggregate Aggregates: Sieve Analysis, LA Test on filler Fine Aggregate, Filler Coarse, Fine
Samples and Abrasion, AIV, Flakiness & Gradation, PI to arrive at proportion Aggregate & Filler
Bitumen Samples Elongation, Coating & for specified gradation. Proportion Based
Stripping , etc., As required by on Blending Trials.
the Specifications

Mixing Aggregate and Heating Bitumen and

Testing Marshal Specimen Extruding of Aggregate separately for the
Bitumen, Temperature
at Control Conditions with Specimen , Repeat for 3.5, 4.0 4.5, preparation of Marshal
Difference> 140C. Preparation
measurement of Stability Measurement of 5.5% of Bitumen Specimen: Bitumen
of Marshal Specimen in pre-
and Flow (Specimen Kept Thickness and (Minimum 6 Temperature 150-
heated Moulds and
in Water Bath at 600C for Density of Marshall specimens for each 1630C(1600C); Total quantity
compacting with 75 Blows on
30 Minutes) Specimen bitumen content) of dry Aggregate 1200 g and
either side.
Bitumen 4% of 1200g

Analysis : Draw graphs of Determine Optimum Job Mix Formula

Bitumen content Vs Bitumen Content Check for all Coarse Aggregate __ %
Stability, Flow value, Based on Marshal requirements based on Fine Aggregate __% TO be Used
Percent Voids, Bulk Density ,Stability, optimum Bitumen Filler ( for SDBC)__% in HOT MIX
Density and Percentage Flow value, VIM, Content Bitumen Content __% PLANT
Aggregates Voids filled VMA, VFB etc as (By Weight of Dry Aggregate
with Bitumen as required required by the & total Mix)
by the specification. specification.

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

5. FLOW CHART FOR PRODUCTION OF BITUMINOUS MIXTURE

Use Laboratory Mix Design Values

Inspection of HOT MIX

PLANT comprising cold Adjustment of Gate Collection of Samples Measurement of
Aggregate Feeding System Calibration of Bins Openings for different from Bins, Conveyors Aggregate
with Vibrators, Conveyors, To operate at Capacity for Testing Gradation Temperature (155-
Drier Unit, Bitumen Supply Different Capacity and Adjusting 1630C) and Binder
Unit, Dust Control System accordingly Temperature 1630C
and Control Panel

Visual Inspection of Collection of Sample for Discharge Mixing in HOT MIX

Transporting the Mix Using Mix at Plant and
Good Condition Tipper covering the Mix
using Polythene
sheets
preparing Marshal Temperature of Mix PLANT (Difference
Specimen and Testing should be within 130- in Temperature of
for Bulk Density, 1600C Aggregate and
Stability, Flow, Bitumen Bitumen not > 140C
Content and Voids.

Delivery to Site/Paver with

Chalan

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

6. FLOW CHART FOR LAYING OF PROFILE CORRECTIVE COURSE (PCC) using WMM

Scarification of Existing Carry out Surveys after Compare the scarified level with the bottom level of
Bituminous surfaces Scarification and Compaction WMM . Find thickness of PCC at centre and edges.
( PCC thickness = Difference of the design bottom
level of WMM - Actual level after scarification and
compaction )
Scarification

Fail
Yes
Laying of PCC of required thickness
Check level and Field Check whether maximum thickness of
,Grading and Rolling following the
Density (FDD>98% MDD PCC>75 mm
procedure laid down in the specification

Pass
No

Approval by IC Ready Determine the thickness of No need to lay PCC as a separate layer,
for laying WMM 1st WMM 1st layer combine it with WMM first layer
layer

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6

Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
7. FLOW CHART FOR CONSTRUCTION OF BM, MSS & SDBC LAYERS
Preparation of the
Base (Free from Dust
and Foreign Matter
using Broom)
Construction of
Shoulder Testing.
No Traffic to be allowed till
density of compacted layer is
conducted
Check for levels and
their Tolerance - Level
(-) 6 to (+) 6 mm
Completion Report
APPENDIX: 16.17.1.6
228+000 of
NH-11 (Jaipur – Mahua Section).
Measurement During Paving and Initial Rolling by 8-10 T
Application Transporting Recording smooth wheel roller at
of Tack coat the Mix To the Temperature of the Mix between to speed 5kmph following
if required at paver be 120-1600C. Mix to be rejected if close to the paver.
places temperature is less than 120oC.
Thickness of laid Mix to be checked.
Temperature at shade before rolling
should not be less than 1000C. Base
should not be Damp/wet.
Rolling operation from edge to
centre overlap by half width of the Finish Rolling using smooth Intermediate rolling using
rear wheel Rolling to be done till wheel roller ( 8-10 ton) without 8-10 ton roller with
no marks are seen & before Mix vibration vibration.
temperature falls below 1000C
Fail Approval by IC
Rectify the defect as per Ready for next work
MORT & H clause 902.5 (V)
Pass
Independent Consultant ICT Pvt. Ltd
Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

8. FLOW CHART FOR CEMENT CONCRETE WORKS

Cement

Test Cube
Check For Check Timing of Slump OK
for
Fine Proportion Mixer Operation Test Compressive
Aggregates All Materials Strength
Approved

NO
Check whether any rectification can be
Coarse
done, other-wise reject the material and
Aggregates
remove from the site
(*)
Water
No Check whether the mix is
Reject the material and remove from the delivered site in time before
site the start setting

Formwork Check for appropriateness OKK Check for dimension

and adequacy of formwork including lines and
including centring and levels OK OK
shuttering

Reinforcement OK
Steel (Where Check for Bar Placement, Placement of
required) Bending, Binding, etc Concrete

Rectify Removal of Check for Bleeding Check For

Approval by
defects if formwork after Curing and Segregation and Compaction
the IC
any maturity period segregation

NOTE (*): If Test Results are not satisfactory, corrective action shall be taken as directed by the IC

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

9. FLOW CHART FOR CEMENT MORTAR APPLICATION WORKS

Cement Test Cube

YES for
Check For Check For
All Materials Consistency Compressive
Approved Proportion Strength
Test Results
Fine
Aggregate

Water (*)

Curing of Cement Placement of

Mortar Works Mortar For Use

Note (*) : If Test Results are not satisfactory, corrective action shall be taken as directed by the IC.

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6
 APPENDIX: 16.17.1.6
Improvement, Operation, Maintenance, Rehabilitation and Strengthening of existing 2 Lane Road and widening to four lane divided highway from Km 120+000 to Km
228+000 of
NH-11 (Jaipur – Mahua Section).

10. FLOW CHART FOR CULVERTS /CROSS DRAINAGE STRUCTURES

NO
Field Survey & Are the details matching Inform deviations to the design Approval of required
Details with contract drawings? IC/Employer changes by IC

YES
EXTENSION
Is the Culvert an Establish the Scrutinize working Demolish the head
Extension or new requirements drawings/method walls/wing walls Remove unsuitable material
Culvert? statement

NEW

Provide bedding
Establish foundation soil Review working Excavate for the Improve/treat Type of Lay pipes, seal
conditions drawings/method statement foundation foundation, if required Culverts all joints & pipe
collars
CD STRUCTURES

Check appropriateness Preparation, bending , Preparation and Erection Backfill with granular
Rectification
of the formation & placement and binding of Formwork materials and compact
Reinforcement of Reinforcement
PASS PASS YES
Allow the contractor for
Is the weather Are the supplies of the concreting
favourable for concreting Materials are adequate
Pass
No Check for soft pockets or
honey combing
Fail
Don’t allow Instruct contractor(s) to Rectify defects to
for concreting give method statement satisfy the
or repair or reconstruct requirements

Completion Report Independent Consultant ICT Pvt. Ltd

Appendix-16.17.1.6