QUALITY ASSURANCE PLAN

PROJECT:
DMRC Contract no. BC21 – Part Design & Construction
of Viaduct & Structural work of Five Elevated Stations
(Garden Estate, Sikandarpur, DT City Centre, IFFCO
Chowk and Sushant Lok) on Qutab Minar – Gurgaon
corridor of Delhi MRTS Project

CLIENT:
DMRC
CONTRACTOR:
M/s. ITD – ITD Cem JV

REFERANCE CODE:
IRC: 83 (PART III) - 2002

BY

DYNAMIC PRESTRESS (I) PVT. LTD.

CORPORATE OFFICE:
72, MAHAVIR CENTRE, SECTOR 17,
VASHI, NAVI MUMBAI – 400 7005
WORKS:
E-46, MIDC, SATPUR, NASIK – 422 007

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 QUALITY ASSURANCE PROCEDURE
1.0 Introduction:

The DYNAMIC POT/PTFE Bearings shall be manufactured to high standards both in

terms of material quality and workmanship. Tests on raw materials and finished
bearings shall be carried out as per procedures described in this document.

1.1 Reference Code :

IRC 83 (PART III) – 2002

2.0 Inspection Procedure:

2.1 Inspection and testing of the bearings shall comprise of following two types of tests:

2.1.1 Type test :

Type test, which includes inspection and testing as per Cl. 3.2 shall be carried out on
bearings of each type and load capacity selected at random by the inspector once for
each lot. Each type of bearings shall be treated as separate lots. The ‘term’ Lot
means total quantity of bearings offered for inspection at a time. The Lot should not
exceed 25 Nos. of bearings.

2.1.2 Routine test :

Routine test, which includes inspection and testing as per Cl. 3.1, 3.2 and 3.3 shall be
carried out by the manufacturer for the bearings of each lot under acceptance.

2.2 The various inspection and tests may be classified into the following categories:

2.2.1 Raw Material Inspection.

2.2.2 Inspection of Finished Bearings.

2.2.3 Process Inspection.

3.0 Details of Tests

3.1 Tests on Raw Materials:

Tests on raw materials shall be conducted as per Table – I.

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3.2 Inspection of finished bearings:

3.2.1 Inspection of overall dimension:

The overall dimension of any finished bearing shall not exceed the following tolerance
limits:

 Plan dimension of Bearing : -0 mm to +5 mm

 Overall Height of assembled Bearing : -0 to +3 mm
 Height of Elastomeric Pad : -0 to 5%
 Thickness of any machined : -0 to +1 mm
steel component
 Overall dimensions of any unmachined : Class 2 of IS:4897
Cast steel component

3.2.2 Tests on finished bearings: (As per IRC: 83 (Part III) – 2002 Cl. 928.6.2.3)

At least one or pair of bearings (depending on the requirement) of each type and
different vertical load capacity selected at random shall be load tested as described
below:

3.2.2.1 Vertical load test: (As per IRC: 83 (Part III) – 2002 Cl. 928.6.2.3.1)

Bearings shall be load tested for vertical load equal to 1.25 times the specified design
load. The test load shall be applied and held for 30 minutes. The vertical deflection
under sustained load shall not increase by more than 4% of Elastomeric pad
thickness. The load shall then be removed and the bearing shall be dismantled and
examined.

3.2.2.2 Friction test: (As per IRC: 83 (Part III) – 2002 Cl. 928.6.2.3.2)

A pair of sliding bearing selected at random shall undergo friction test. Friction test for
sliding shall be performed at constant vertical design load. The horizontal load shall
then be applied till sliding occurs. The Co-efficient of friction () shall be determined
on the basis of applied vertical load and horizontal load. The measured sliding
coefficient of friction shall not exceed 3% .The value of Co-efficient of friction shall not
exceed 2/3rd of the value specified in Cl. 926.2.4.2 of IRC : 83 (Part – III) – 2002
depending on the actual average pressure on PTFE due to the applied vertical load.

3.2.2.3 Rotation test: (As per IRC: 83 (Part III) – 2002 Cl. 928.6.2.3.3)

Rotation test for bearings shall be performed at constant vertical load equal to design
load and design rotation. The load shall be removed and bearing shall be dismantled
and examined.

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3.3 Process Inspection:

3.3.1 Test on Welding:

DP Test & visual inspection as per IS: 822.

3.3.2 Ultrasonic Test:

Major metallic component of Bearing, at least one bearings of each type shall be
ultrasonically tested for soundness as per Level: 3 of IS: 9565.

3.3.3 Corrosion Protection:

The following corrosion protection measures shall be adopted for all non-working
surfaces as per Cl. 927.3.2 & Cl. 927.3.3

1. Two coats of epoxy primer enriched with metallic zinc.

2. One intermediate coat of high build epoxy paint reinforced with MIO (Micaceous
Iron Oxide).

3. Two coats of high performance epoxy finish paint.

Total dry film thickness (D.F.T.) shall not be less than 160 microns.

3.3.4 Surface Hardness:

The mating surface of the piston and cylinder of bearings shall be metallurgically
hardened to not less than 350 BHN.

3.3.5 Steel (Cast Steel) Hardness:

The hardness of all major steel components shall be tested to determine the Brinnel
Hardness Number (BHN), which shall not be less than 150 BHN for cast steel.

3.3.6 Stainless steel sliding surface:

The Flatness & Surface finish of Stainless Steel plate will be checked.

a) Flatness : 0.0004L, where L = length in Direction of movement.

b) Surface Finish : Ra  0.25m as per IS: 3073.

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 TABLE - 1
SL Component to Test to be be conducted No. Of Reference Acceptance Criteria Testing Agency Remarks
No. be Tested samples Documents
1. Cast Steel  PHYSICAL TESTS: One integral IS: 1030-1998 IS: 1030-1998 Manufacturer’s Test certificates shall be
1. Ultimate Tensile Strength piece per Gr.280-520 W Laboratory provided.however,random
(UTS) heat tests may be carried out
2. Yield Stress by accepting authority on
3. Elongation (%) samples provided by the
 CHEMICAL TESTS - do - - do - - do - manufacturer.
C, Mn, Si, S & P - do -
 ULTRASONIC TEST - do - IS: 9565, Level 3 No crack detectable - do -

2. Elastomeric pad  PHYSICAL TESTS: From Manufacturer’s Manufacture’s Test

(Neoprene) 1. Hardness Batches at IS:3400 (Part II) IRHD 50 + 5 Laboratory certificate for the raw
2. Min. Tensile strength random IS:3400 (Part I) 15.5 N/mm2 material shall be provided.
3. Min. elongation at break IS:3400 (Part I) 400 %
4. Max. Compression set IS:3400 (Part X) As per IRC:83 (Part
5. Accelerated ageing IS:3400 (Part IV) II)-1987
3. Stainless Steel  CHEMICAL TESTS One piece AISI : 304 Test Certificate Independent Test certificate to be
C, Mn, Ni, S, Si, and P per lot of Laboratory furnished
procurement
4. PTFE 1. Tensile strength at break One per lot BS:3784 Test Certificate Manufacturer’s Manufacturer’s Test
(Dimpled) 2. Elongation at break of Laboratory Certificate shall be
3. Durometer Hardness procurement (CIPET, obtained.
4. Specific Gravity Ahmedabad)
5. Dimensional Stability
6. Resistance to Heat
5. Bolts Physical & Chemical Tests One for IS:1367 Test Certificate Manufacturer’s Manufacturer’s Test
Total lot Laboratory certificate shall be
furnished.
6. Paint - - - Test Certificate Manufacturer’s Manufacturer’s Test
Laboratory certificate shall be
furnished.
7. POM Seal  Physical & Mechanical One per lot Independent Test certificate to be
TESTS: of Laboratory furnished
1. Density procurement ISO:1183-1987 1410 kg/m3± 6 kg/m3
2. Melt flow index ISO:1133-1981 10 g/min 2.0 g/min
3. UTS ISO:572:2-1986 62 N/mm2min
4. Ultimate Stain ISO:572:2-1986 30 % minimum

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