Quality Assurance Plan For Tunnel Construction Works

NATIONAL HIGHWAYS AUTHORITY OF
INDIA
Four Laning of Parwanoo - Solan Section of NH-22

(Now NH-5) FROM Km.67.000 to Km.106.139 on
EPC mode under NHDP Phase-III in the state of
Himachal Pradesh
Quality Assurance Plan for

Tunnel Construction Works
EPC CONTRACTOR: -
M/S. G.R. INFRAPROJECTS LIMITED
Guidelines for a Quality Assurance Plan for Construction Works
TABLE OF CONTENT
TOP SHEET...................................ORGNIZATION CHART
1. INTRODUCTION…………………………………………………………………………5
2. IMPLEMENTATION METHODS………………………………………………………5
2.1 Process Management............................................................................................5
2.2 Process Qualification.............................................................................................6
2.3 QA/QC Process Qualification.............................................................................7
3. INSPECTION AND TESTING………………………………………………………...10
3.1 AIM.......................................................................................................................................10
3.2 SCOPE..................................................................................................................................10
3.3 RESPONSIBILITY..............................................................................................................10
4. CONTROL OF INSPECTION, MEASURING AND TEST EQUIPMENT………10
4.1 AIM.......................................................................................................................................10
4.2 SCOPE..................................................................................................................................11
4.3 RESPONSIBILITY..............................................................................................................11
4.4 IMPLEMENTATION METHODS...................................................................................11
4.4.1 Equipment Selection...........................................................................................11
4.4.2 Identification........................................................................................................11
4.4.3 Calibration............................................................................................................12
4.4.4 Documentation....................................................................................................13
4.4.5 Handling and Preservation................................................................................13
4.4.6 Measures in case Equipment is out of Calibration..........................................13
4.4.7 Master Templates and Comparative Reference...............................................13
4.4.8 Management of Standard Devices and Reference Equipment......................13
4.4.9 List of Plant & Equipment...........................................................................14
5. INSPECTION AND TEST STATUS………………………………………………….15
5.1 AIM.......................................................................................................................................15
5.2 SCOPE..................................................................................................................................15
5.3 RESPONSIBILITY..............................................................................................................15
5.4.1 Identification of the Inspection and Test Status...............................................15
5.4.2 Approval of Quarries and Borrow Areas................................................................16
5.4.3 Selection of Borrow Area.....................................................................................17
5.4.4 Transport of Materials.........................................................................................17
5.4.5 Development/ Redevelopment of Borrow Pits and Quarries............................18
5.4.6 Approval of Materials............................................................................................18
5.4.7 Approval of Natural Materials................................................................................19
Page 2
PROJECT: ROAD TUNNELING WORK FOR THE “FOUR LANING OF PARWANOO-SOLAN SECTION OF NH-22 (NOW-5) FROM KM 67.000 TO KM 106.000 UNDER
NHDP PHASE -III IN THE STATE OF HIMACHAL PRADESH”,
5.4.8 Approval of Processed Materials............................................................................19

5.4.9 Approval of Manufactured Materials.....................................................................19
5.5.0 Approval of Designed Materials.............................................................................19
5.5.1 Revocation (Withdrawal) of Material Approvals...................................................20
5.5.2 Reporting and Recording Material Approvals........................................................20
5.5.3 Sampling of Materials............................................................................................21
5.5.5 Sampling Guidelines..............................................................................................21
5.5.6 Preparation and Storage of Samples.......................................................................21
6. CORRECTIVE AND PREVENTIVE ACTION………………………………………22

6.1 AIM.......................................................................................................................................22
6.2 SCOPE..................................................................................................................................22
6.3 RESPONSIBILITY..............................................................................................................22
6.4.1 Actions following internal Audits.....................................................................23
6.4.2 Actions following Client Complaints...............................................................23
6.4.3 Actions following the Detection of a Non-Conformity..................................23
6.4.4 Actions following the Periodical Quality Analysis made by the Quality Engineer
……………………………………………………………………………………..23
6.4.5 Actions following the Quality System Review................................................24
6.5 CHECKING THE RESULTS OF CORRECTIVE AND PREVENTIVE ACTIONS. 24
6.6 FILING.................................................................................................................................25
7. INTERNAL AUDIT……………………………………………………………………..25
7.1 AIM.......................................................................................................................................25
7.2 SCOPE..................................................................................................................................25
7.3 RESPONSIBILITY..............................................................................................................25
7.5 Tunnel Details Planning & Schedule Work..............................................26

7.5.1 Tunnel Project Outline.....................................................................................26
7.5.2 Detailed Methodology for Construction of Tunnels...............................................26
7.5.3 Working period......................................................................................................27
7.5.4 Sequence of works.................................................................................................27
8. TRAINING OF PERSONNEL.........................................................................................27
8.1 AIM.......................................................................................................................................27
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8.2 SCOPE..................................................................................................................................28
8.3 RESPONSIBILITY..............................................................................................................28
8.4.1 Identification of Training Needs.......................................................................28
8.4.2 Planning of Training...........................................................................................29
8.4.3 Personnel assigned to Special Activities...........................................................29
8.4.4 Documentation....................................................................................................30
9. SERVICING………………………………………………………………………………30
9.1 AIM.......................................................................................................................................30
9.2 SCOPE..................................................................................................................................30
9.3 RESPONSIBILITY..............................................................................................................30
9.4.1 General Information............................................................................................30
9.4.2 Technical and Logistical Support......................................................................31
9.4.3 Technical Servicing of the Works......................................................................31
9.4.4 Resolving Complaints.........................................................................................31
10. STATISTICAL TECHNIQUES………………………………………………………...32
10.1 AIM.......................................................................................................................................32
10.2 SCOPE..................................................................................................................................32
10.3 RESPONSIBILITY..............................................................................................................32
11.0 INSPECTION & TEST PLAN....................................................................................36-51
12.0 NCR FORMATE............................................................................................................52
13.0 CHECK LIST..................................................................................................................53-62
14.0 QUALITY CONTROL TEST FORMATE.................................................................63-85
LIST OF FIGURES
Figure 2-1-1: General Procedure for the Construction of a Structure and the Control of its
Quality..........................................................................................................................................09
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1. INTRODUCTION
M/s Gr. Infraprojects Ltd Construction Company of India has undertaken the job of
ROAD TUNNELING WORK FOR THE “FOUR LANING OF PARWANOO-SOLAN
SECTION OF NH-22 (NOW-5) FROM KM 67.000 TO KM 106.000 UNDER NHDP
PHASE -III IN THE STATE OF HIMACHAL PRADESH”. This plan provides the
description of Quality Assurance to be implemented to ensure that all the
excavation, concreting works and the overall construction works of Tunnels are in
accordance to the Contract Requirements, Specifications, Drawings and Design.
To implement a quality assurance plan for the construction of the TUNNEL

PROJECT, GR Infraprojects Ltd has to recruit the following personnel:
A Senior Project Manager
A Project Manager -Tunnel
A Quality Manager/Engineer
Tunnel Engineers
Safety Manager
Store Keepers
QA Supervisors
The abbreviations used in this manual are as follows:
QA Quality Assurance
QC Quality Control
NC Non-Conformity
Inspections and test requirements including the means and methods to be utilised
2. IMPLEMENTATION METHODS
2.1 Process Management

The execution processes are entrusted to well-trained personnel capable of using the
equipment correctly and safely and with the skills necessary to produce good
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workmanship
Personnel are provided with the necessary instructions and documented information
to be able to define execution/utilization methods and work criteria.
The Personnel /processes utilised for the construction are qualified whenever
required.
The suitability of the equipment used in the process is guaranteed by the
maintenance work performed on it, which is documented by the Mechanical
Engineer.
In order to carry out the processes correctly, refer to the following documents:
 Work schedule – this identifies the various construction phases, their order
and duration;
 Drawings and technical specifications – these contain the technical
references required for the work activities;
 Procedures and operational instructions (i.e. Method Statements) – these lay
down the methods according to which the work is to be performed and
are drawn up only when required as a back-up to the usual routine
procedures and the training already given to personnel;
 Safety Manual – this contains the rules and regulations governing
behaviour with a view to foreseeing potential risk situations and
safeguarding the health of the workers;
 Quality Plans – these establish the inspections and tests required and how
they are to be conducted in order to verify the conformity of the product
constructed.
These documents shall be made available to the personnel by the

Construction/Tunnel Manager before and during the construction process. Personnel
shall be familiar and have gone through thoroughly with these documents and the
instructions
The inspections and tests with which the conformity of the processes and works with
respect to the requirements is verified are conducted in compliance with the
conditions laid down in the applicable “Quality plans”
The inspection and testing records are completed, identified, collected and kept as
records.
2.2 Process Qualification

Process qualifying activities are planned by the Technical Department Site in the
Method Statement and related quality plans, which define the following:
 Materials and equipment to be used
 Environmental conditions in which the process is to be carried out
 Alternative methods to be used
 Personnel responsible for the process, the control and relative qualification
 Checks to be run on the products used and on the process control parameters
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 Control equipment and methods

 References to standards or other application regulations
 Documents to be issued at the end of the process qualification
The Production/ Tunnel Manager together with the Quality Manager organises
the inspection and testing in accordance with the corresponding documents.
The inspections and tests are conducted under the supervision of the QA
Supervisors and their results will be assessed.
The QA Supervisors together with the Technical Department Site decides whether to:
 Consider the process qualified or not;
 Proceed to run further tests, defining how these are to be planned.
At the end of each process subjected to qualification the QA Supervisors issues a
Report containing the following:
 Data and information relative to the process to be qualified
 Tests run and the results obtained
 The parameters to be monitored during the process in order to ensure that the
requirements laid down in the technical specifications have been met
 Qualifications obtained by personnel.
The Technical Department Site draws up operational instructions for the processes
qualified. These lay down a pre-set working method.
The records relative to process qualification are filed by the Technical Department
Site, while the QA/QC Documents are in addition filed by the Quality Engineer.
2.3 QA/QC Process Qualification

The relation between the production process and the quality assurance and control is
shown on Figure 2-1-1 - General Procedure for the execution and Construction of
Tunnels and associated Structure and the Control of its Quality“.
Two distinct steps are distinguished for the QA/QC Concept:
1. Quality Control (QC): Quality Control is defined here as the actual
inspections carried out for each activity such as laboratory works, concrete
works, etc. The quality control is carried out by the person responsible for QC.
The quality control is described and reported on quality records.
2. Quality Assurance (QA): Quality Assurance is defined here as the overall
process of assuring the required quality of the construction of TUNNEL
PROJECT. The quality assurance is carried out by QA supervisors which make
sure that the quality control inspections have been carried out properly and
according to this manual, and that they are reported in an acceptable manner.
The quality assurance describes among other things the following:
 Where the quality control shall be carried out in the execution and
construction process;
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 The way of how such quality control forms are handled, communicated,
reported, filed, etc.

 How non-conformities shall be dealt with; how corrective action shall be
carried out;
The general inspection procedure is as follows:
1. Quality controls and inspections along the detailed instructions as per
procedure are carried out by the assigned QC persons daily or as required
otherwise. The respective quality control forms are filled in, as required,
during the carrying out of the work and are signed by the persons
responsible for QC and assigned to this work.
2. The quality control forms are sent to the respective department head which
reviews the content of the forms. If a non-conformance has occurred the
procedures of “Control of Non-conforming Products” are followed.
3. The department head forwards the original quality control form to the
responsible QA supervisor (see respective Organization Chart on Figure 2-
1) and a copy to the technical department. He keeps a copy in his own files.
4. Technical Site Department:
 The technical site department reviews the QC forms and files a copy of
them in its central QC filing archive.
 If a non-conformance has occurred the respective item is put on the
Non- Conforming Register.
 The technical department makes sure that the required corrective
actions are carried out so that the non-conformance can be removed
from the Non- Conforming Register.
5. The QA supervisor reviews the QC form and signs it for acceptance. He files
the form in the QA/QC central filing archive.
The technical site department applies with the QA supervisor if a
construction activity is ready to have the final tests carried out, after
making sure that all QC controls and corrective actions have been
carried out. The QA supervisor fills out the required QA forms as soon
as possible. The originals of these QA forms are filed in the central
QA/QC filing archive. A copy is sent to the technical site department.
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Start
Planning of
Construction
Technical Dept.
Page 9PROJECT: ROAD TUNNELING WORK FOR THE “FOUR LANING OF PARWANOO-SOLAN SECTION OF NH-22 (NOW-5) FROM KM 67.000 TO KM 106.000 UNDER
Preparation/C
Preparation of
ollection of
Method Statement
New/Existing
QC
Technical Dept. For
ms
Technical and
QA/QC Dept.
Preparatory Works
N
o
Production Dept.
Pre-
Construct
ion
Chec
k
o.k.?
Yes
Production
Production Dept.
Post-
Constructi
on
Chec
k
o.k.?
No
Corrective Action Yes
No
Production Dept.
F
i
n
a
l
Chec
k
o.k.?
Y
e
s
E
n
d
Figure 2-1-1: General Procedure for the Construction of a

Structure and the Control of its Quality
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3. INSPECTION AND TESTING
3.1 AIM
This procedure defines how inspection and testing for the execution and
permanent civil works of the TUNNEL PROJECT shall be carried out and which
additional instructions, method of statements are to be used for the single
activities.
3.2 SCOPE
This procedure covers the inspection and testing of all execution activities and
permanent civil works and the respective permanent materials used for these
works. It also applies to the general activities such as execution, construction
works and surveying activities.
3.3 RESPONSIBILITY
GR. INFRAPROJECTS LTD is responsible for:

 The development, establishment and implementation of this process
ensuring that the processes established hereinafter and in the respective.
 Instructions are followed.
 Making sure that the quality controls are carried out.
 Preparing the respective quality plans and QC forms.
The corresponding person in charge for QC is responsible for: Carrying out the
quality control getting training to be able to carry out the quality control
The QA Supervisor has to:
 Carrying out the quality assurance
 Making sure that the quality controls are carried out along the
prescribed standards or procedures and that are carried out in an
acceptable manner.
4. CONTROL OF INSPECTION, MEASURING AND TEST

EQUIPMENT
4.1 AIM
The aim of this procedure is to define the methods used by Gr.Infraprojects Ltd
for managing and calibrating inspection, measuring and test equipment used for
the execution and construction of the permanent civil works and associated
structures of Tunnels, with the aim of ensuring that its uncertainty is known and
consistent with required measurement capability.
4.2 SCOPE
This procedure covers all inspection, measuring and test equipment (including
testing software and comparative references) used by Gr.Infraprojects Ltd. to
control conformity of the permanent materials used for the civil works to
the specified requirements of the technical reference documentation.
4.3 RESPONSIBILITY
The Technical Site Department of GR.INFRAPROJECTS LTD is

responsible for:
 Selecting the equipment
 Having the equipment calibrated if external controls have to be

used
The Quality Engineer is responsible for:
 Identifying the equipment
 Preserving the calibration documentation
The Operator is responsible for:
 Calibrating the equipment
 Preserving and handling the equipment with care
4.4 IMPLEMENTATION METHODS
4.4.1 Equipment Selection

The selection of inspection, measuring and test equipment is carried out by taking
into account the measurements which must be performed and the accuracy
required, as defined in the Technical Reference Documentation (Manuals,
Technical Specifications, Drawings, etc.).
4.4.2 Identification
All major inspection, measuring and test equipment present on the work site is
recorded on the appropriate Quality Plan for Calibration of Inspection, Measuring
and Test Equipment, prepared and kept up to date by the Technical Site
Department of GR. Infraprojects Ltd.
All inspection, measuring and test devices are identified by means of a company
serial/ asset number attached to them before use.
For each device a “Calibration Form“, prepared by GR. Infraprojects Ltd or from
the agency that device is calibrated is compiled. This contains all the necessary
information for calibration.
The “Calibration Form” shows unique identification number, thus permitting the
corresponding device to be identified.
Operators of inspection, measuring and test equipment ascertain that the devices
are properly identified. If identification is lacking, they have to inform the
Technical Site Department, who verifies the cause of this and sees to it that
identification is made.
4.4.3 Calibration
All major inspection, measuring and test equipment undergoes periodic
calibration against certified standard equipment.
The initial calibration frequency is decided by the Technical Site Department
together with the Quality Engineer and the Operator taking into account the use
of the equipment and the manufacturer’s instructions. The calibration frequency is
recorded on the “Calibration Form” of each device.
The Technical Site Department is responsible for calibrating all the equipment.
The “Calibration Form” indicates the reference documentation for performing the
calibration. Calibration can be carried out externally or on site, each time referring
to the recognised international standards. For on-site calibration in which
recognised methods or manufacturers’ User’s Manuals are not available,
procedures must follow specific instructions issued by the Technical Site
Department.
Calibration outcome and assessment is recorded on the “Calibration Form” of the
respective device.
If the outcome of the calibration is positive, a “Calibration Tag” is attached to the
device. This indicates the calibration status and shows the calibration expiration
date. Inspections, measuring and tests shall be performed exclusively with
calibrated equipment within the validity period.
If inspection, measuring and test equipment gives results which do not seem
reliable, this should be reported to the Quality Engineer, who will instruct that the
device in question undergoes unscheduled calibration. In the case of a negative
outcome, the appropriate measures are taken.
Unscheduled calibration is also recorded on the “Calibration Form”, though in
this case the “Calibration Tag” is not updated.
Calibration operations are carried out under environmental conditions which
ensure the required accuracy.
In the case that a testing device is not used for a period longer than that between
two consecutive calibrations, the phrase “not used” and the relative period must
be written on the “Calibration Form”.
In the case that moving a device from one place to another may have
compromised its calibration, the device must undergo new calibration, which is
recorded on the “Calibration Form” as a note.
4.4.4 Documentation
Calibration data as well as all information which identifies equipment is recorded
on the “Calibration Forms”. The “Calibration Forms” together with the relative.
“Calibration Reports” issued internally to the company or by external agencies are
filed by the Quality Engineer.
Filing of documentation is carried out in accordance with “Control of Quality
Records”.
4.4.5 Handling and Preservation

Inspection, measuring and test equipment is preserved in such a way that it
maintains its suitability and required degree of accuracy. During equipment use
and handling all the necessary precautions are taken to ensure its integrity
(cleaning, protection from jarring, heat, etc.).
Operators are responsible for the correct handling and preservation of inspection,
measuring and test equipment.
4.4.6 Measures in case Equipment is out of Calibration

If equipment does not to meet the required standards or is out of calibration, the
Quality Engineer instructs the required measures for the repair or replacement.
Works which were controlled with this equipment are held to be non-conforming
and handled according to “Control of Non-Conforming products” in order that
the respective departments may assess the results of the inspections,
measuring and tests that were carried out.
If equipment is repaired, it is controlled and calibrated again before being used.
The outcome of this operation is recorded on the “Calibration Form”, and a
new “Calibration Tag” is attached to the device. The Quality Engineer then
assesses whether the previous calibration frequency is to be maintained. In the
case that a change is made, the “Calibration Form” and quality plan must be
updated.
4.4.7 Master Templates and Comparative Reference

Master templates and comparative references used for the purposes of control
during production and test operations are identified and documented in the same
way as other equipment. They are controlled at predetermined intervals of time.
The outcome of the control is recorded on the “Calibration Form”.
4.4.8 Management of Standard Devices and Reference Equipment

Standard devices and reference equipment, used as standards of comparison for
calibrating inspection, measuring and test equipment, are periodically verified
and calibrated in order to ensure congruity with national and international
standards, or, in the absence of these, with the manufacturer’s references.
Calibration frequency of this reference equipment is determined by the Technical
Site Manager and the Quality Engineer. Upon expiration of the period of the
calibration validity, the equipment is verified again or replaced.
“Calibration Reports” issued by calibration centres are filed by the Quality
Engineer.
4.4.9 Tentative Equipment’s Mobilization for Tunnel work
As per the work plan and the relevant contract provisions, the deployment of tentative
equipment exclusively for Tunnel work is as per given below:
Refe Name Model Quant

renc ity
e
1 Drill Jumbo - 2 Boom & Centre Sandvik DT 1
Bucket 820
2 Shotcrete Machine – Robo jet Normet 01
3 Dry Shotcrete machine - Universal 02
4 Concrete Pump Schwing 01
BP350D
5 Tunnel Loader/Backo JCB 01
6 Excavator Valvo 02
7 Dumper Man 03
8 Total Stations ( Profiler & Total SOKKIA/NIK 01
Stations) KON
9 Auto Level - 02
10 Explosive Van provided by TATA LHD 02
Lisioncer
11 Grouting Stationery local pump 02
12 Grouting Mai Pump Atlas Copco 1
Mai
Pump/Tecniw
ell
13 Tractor 01
14 Trailers 01
15 Grader CAT/BEML 01
BG 605
16 Transit mixer Schwing 2
Stetter
17
18 Immersive Concrete Vibrators DYANAPAC/ 2
KILLICK
19 Steel Formwork Gantry (10M 02
Traveller)
20 Batching Plant (18cum/Hour) Liebherr/ 01
Conmat
21 Hydraulic Excavator PC200 1
The no end of type of above equipment may vary as per site requirement during
Construction of Tunnel.
5. INSPECTION AND TEST STATUS
5.1 AIM
The aim of this procedure is to distinguish the inspection and test status of
permanent material, works or parts of works related to Tunnel construction
works, with a view to indicating their "Conformity" or "Non-Conformity" to
contract specifications, as proved by the inspection and tests performed.
5.2 SCOPE
This procedure covers the entire "scope of work" for the ROAD TUNNELING
WORK FOR THE “FOUR LANING OF PARWANOO-SOLAN SECTION OF NH-22
(NOW-5) FROM KM 67.000 TO KM 106.000 UNDER NHDP PHASE -III IN THE STATE
OF HIMACHAL PRADESH”.
5.3 RESPONSIBILITY
The Production/Tunnel Manager is responsible for maintaining the identification
marking on site of the inspection and test status intact.
5.4.1 Identification of the Inspection and Test Status

Permanent material, civil works or parts of civil works can be:
 awaiting inspection
 checked and found to be conforming checked and found to be non-
conforming
 Accepted "conditionally" while awaiting completion of the inspections
and tests required.
Their status is displayed by means of:

 cards, labels, stamping, paint
 storage in special marked-off areas, identified either with a
“Conforming” or “Non-Conforming” sign or marked in a clear,
unambiguous manner on the site plan
 Issue and completion of inspection record forms
"Conformity" is visually identified by means of a "green" card and "Non-
Conformity" by a red card, while the "Conditional" status is shown by a white
card. The "awaiting inspection" control condition is not distinguished by a
particular identification mark.
Permanent material, civil works or parts of civil works for which the test status
cannot be traced, are considered to be "awaiting inspection" and hence subjected
to inspection and may have to be tested a second time.
Status identification is maintained throughout the construction phases. It is the
duty of the Production/Tunnel Manager to manage the various phases
ensuring that identification is always kept intact and to ensure that only civil
works which have passed the required inspections and tests, or whose release has
been authorised following Non-Conformity, are accepted.
5.4.2. Approval of Quarries and Borrow Areas
The Contractor is to obtain approval from the AE for each Quarry and Borrow Area to be
used in the Project prior to commencement of quarrying and/ or borrow area excavation
activities. The primary aspects to be considered by the AE in granting approval are:
 The proposed materials meet the specification requirements

 The contractor has legal approval by the owner to excavate/ remove materials from the
proposed quarry/ borrow area.
The steps to be followed for approval of each Quarry/ Borrow Area are:
1. The Contractor is to complete the “Materials Sources Data” giving details regarding
size, location, orientation and access for the proposed quarry/ borrow area (rough
map to be drawn).
2. The results of laboratory tests conducted on the materials jointly sampled with the QA
Engineer (or his designated representative) are to be summarized on the approval
form, and complete copies of all tests are to be attached to the form.
3. The Contractor shall attach to the completed “Materials Sources Data” form, his
proposed “Environmental Management Plan” for development, use and closing down
of the proposed quarry/ borrow area. Photographs of the sources site, including
access roads, etc., should be included with the proposal so that the base line
conditions of the quarry/ borrow area are clearly established.
4. Based on the Contractor’s proposal, and on the site inspection team’s comments,
the AE will (within 5 days after receipt of the proposal) reply to the Contractor in
accordance with one of the following:
 The proposed Quarry/ Borrow Area is approved as proposed.

 The proposed Quarry/ Borrow Area is approved subject to one or more
required changes/ additions etc (to be detailed by the QA Engineer).
 The Contractor is requested to revise and resubmit all or part of the proposal
submittal, giving details of required changes, additional requirements, etc.
 The proposed Quarry/ Borrow Area is rejected.
With regard to approval of Quarries and Borrow Areas, the PM shall pay particular attention
to requirements of the Environmental Management Plan particularly with regards to:
5.4.3. Selection of Borrow area

 Borrow Areas not to be within the Project Right-of-Way
 Borrow Areas preferred in non-productive, barren lands, raised lands,
waste lands, etc.
 Borrow Areas to be located on agricultural land should first have the top
150mm minimum removed and stockpiled. The stockpiled topsoil is to be
replaced and spread over the original areas after excavation for borrow is
completed.
 For quarry areas, particular care is to be taken to ensure that testing (and
approval) is given only for areas to be indicated on the plan for which the
materials have homogeneous properties. Similarly, the depth and extent of
overburden to be removed prior to quarrying is to be accurately measured
and clearly indicated.
5.4.4. Transport of Materials

 All movements and access of equipment to be stationed in the designated
areas are to cause minimum compaction of the soil (in critical areas/
situations, the PM may require that all such equipment have tracks rather
than wheels).
 All transport vehicles should have covered sides and tailgates to prevent
spillage of materials.
 All transport vehicles are to select appropriate routes and delivery times,
and are to adopt safe driving habits so as to ensure minimum of
inconvenience to affected village inhabitants, and to reduce accident
potential. The Contractor is responsible for the repair/ maintenance of all
roads and facilities damaged by his transport equipment.
5.4.5. Development/ Redevelopment of Borrow Pits and Quarries
 Both during and following completion of the excavation activities in the
borrow areas, the PM shall inspect the areas to ensure that the borrow pits
and access roads are properly graded and drained to ensure minimum
erosion, and to prevent run-off from either collecting or from damaging
adjacent properties. All existing trees within the boundary of the quarry/
borrow areas should be preserved and protected.
 Temporary stockpiles of blasted quarry materials and borrow areas soils
are to be located so as to ensure smooth flow of traffic within the areas
and for access to main roads, and are to be designed so as to minimize
contamination and damage from rainfall/ run-off etc.
 Borrow Areas (except in cases where the landowner has agreed that the
borrow pit is to be excavated so as to form an appropriate pond for
agricultural purposes), will be redeveloped by filling and providing 150mm
thick layer of preserved topsoil.
 Consultant’s Q.A. Engineer shall continue to monitor the quarry/ borrow
materials both by periodic sampling and testing of the materials as well as
by “visual” assessment. As soon as tests indicate any significant change in
a material’s property, or if a change is suspected visually, then the material
properties are to be certified by testing and if the variation(s) is considered
to be significant, then a new application for approval of source must be
lodged, and the above procedure repeated.
It is to be noted that all field activities for the above are not to commence until appropriate
Request for Inspection Forms are completed, submitted and approved.
5.4.6. Approval of Materials
All materials proposed by the Contractor to be used in the Project Works are to be first
approved. In general, there are four types of materials to be approved.
(1) Natural Materials – materials with little or no processing except for perhaps screening
for oversize and removal of unsuitable particles, etc. An example of this is soil
embankment materials.
(2) Processed Materials – materials that require significant processing, including removal
of unsuitable particles, crushing, screening and perhaps, blending of sizes. These
materials are homogeneous, but with specified gradations.
(3) Manufactured Materials – especially homogeneous construction materials, like
Portland cement and admixture that are used for blending with natural materials to
obtain a concrete mix.
(4) Designed Materials – materials that involve the mixture to specific proportions of two
or more different, natural, processed or manufactured materials to obtain a modified
material giving a set of desired specific properties.
Approval of each of the above material types is required, however the requirements for
obtaining approval of materials for each type differs slightly:
5.4.7Approval of Natural Materials
Natural materials are mined (i.e., excavated) and hence the first step, following assurance
that the material is acceptable for its intended purpose, is to obtain approval for the Quarry.
Approval of the material for construction is then obtained by submittal of test results for all
tests required by the Specifications (i.e., to prove that the material meets all minimum
properties required).
5.4.8Approval of Processed Materials
Approval of processed materials follows that noted above for “natural” materials, except
that usually the specifications are tighter (e.g. the material may also have to meet stringent
gradation limits), and a greater variety of tests (and production/ storage) conditions are
required to be met.
5.4.9Approval of Manufactured Materials
Approval of manufactured materials, based on specific Specifications requirements, is

generally given in two stages.
 Initial Approval – given prior to receipt of the materials based on submittal of

appropriate testing results confirmed by the manufacturer (note that claims by
manufacturers, or tests etc by distributors, etc are not to be accepted).
 Final Approval – given based on initial approval plus positive results being
obtained for all “acceptance” tests required by the Specifications, or as directed
by the QA Engineer.
5.5.0Approval of Designed Materials
Approval of “designed” materials for the present Project concerns those mix designs for
Portland Cement Concrete (for culverts, bridges etc). Due to the complexity of these
“mixed” materials, and the plants for producing the range of materials sizes, final approval
is deferred until completion of the following steps:
1. Approval of sources (generally quarries) for each of the processed material

constituents to be included in the final mix design.
2. Approval of each of the individual processed materials and manufactured materials to

be included in the final mix design.
3. Tentative approval of a laboratory based mix design, based on a mixture of approved

materials so that the mixture meets all Specification requirements.
4. Tentative approval of a plant mix design, based on proportioning of aggregate bins’

materials and manufactured materials to closely approximate the proportioning of
material types/ sizes finalized for the laboratory based mix design (so that the mixture
still meets the minimum Specifications requirements).
5. Based on successful laying of the mixes in accordance with the approved

Methodology, conformance of the placed mix to required placing temperatures, levels
and finish, etc., and conformance to quality control requirements as verified by
successful testing in accordance with the Specifications, the Concessionaire’s Q.A.
Engineer is to give final approval of the mix design (Job Mix Formula) based on the
plant mix proportions.
5.5.1 Revocation (Withdrawal) of Material Approvals
Following approval of the job mix formula, the PM and all field support staff shall continue
to monitor both the test results of the visual characteristics of the approved mix as placed to
identify at an early stage any significant change in the mix design that may adversely
influence the adherence of the approved mix design to the Specifications. A new mix
design (or adjustment of the plant proportioning of materials to re-establish the approved
job mix formula) will be required when it is observed that significant changes in the mix
design properties are causing the mix to no longer meet all Specification requirements. In
addition, a new mix design will be required when either the approval of a material source or
approval of one of the materials is revoked (i.e., withdrawn). Mix /Material approved shall
be revoked by the PM after due consultation with the Consultant’s Q.A. Engineer.
5.5.2 Reporting and Recording Material Approvals
The Contractor’s Q.A. Engineer shall notify in writing to the PM and the Consultant’s / I C
each time a new source, material and/ or mix design is either approved or the approval is
revoked. This information is to be included in the Monthly Quality Control Report to be
submitted with the Monthly Progress Report.
Records are to be kept by the Consultant’s Q.A. Engineer/ I C giving current approvals of
all Borrow Areas, Quarries (all types) and Mix Designs for all BOQ items. The current
summaries are to be included as part of the Monthly Progress Report.
5.5.3. Sampling of Materials
5.5.4 Sampling Requirements
All construction materials to be used in the permanent works are to be sampled jointly by
the staff of Consultant’s Q.A. Engineer and the Contractor prior to commencement of
the Works. This includes sampling for materials to be tested for proposing approval of the
material source as well as sampling of materials for approval of the individual construction
materials. In both cases, and for each instance, the Contractor must give notification of a
request for such sampling to the AE in advance (minimum 48 hours) by way of the
Request for Inspection Form (RFI). All assistance (e.g. sampling instruments and
equipment, sample bags, and labour etc) that is required for carrying out the sampling
activities are to be provided by the Contractor.
5.5.5 Sampling Guidelines
All sampling is to be carried out in accordance with instructions to be given by the

Consultant’s Q.A. Engineer. Sampling procedures are to follow recognized guidelines of
good engineering practice. These include:
 Obtaining samples from at least three areas.

 Ensuring that the sampled materials and locations are “typical” for the material to
be tested.
 Ensure that all overburden etc. is removed within the stockpiles rather than from
the surface (top, side or base of the stockpile) in order to avoid the collection of
segregated materials.
 Ensure that sufficient quantities are sampled to enable all tests to be conducted,
plus additional material, to be stored for subsequent testing if required.
 Ensure that each sample bag is marked/ labelled both inside and outside, giving
the sample number, material type, sample location, date and number of the bag,
as well as any additional information instructed by the Consultant’s Q.A.
Engineer or his authorized engineer.
5.5.6 Preparation and Storage of Samples
Samples collected are reduced and prepared as per Indian Standards (IS) methods, with
an additional sufficient quantity retained in appropriately sealed bags(s) or container(s) and
separately kept in the sample storage room of the laboratory for additional testing and/ or
future reference as required. Concrete samples in particular are to be carefully cured and
kept in the curing tank of the laboratory. Access to stored samples is under the strict direct
control of the Contractor’s Q.A. Engineer. Details of all samples stored are to be kept in a
Register to be administered by the authorized engineer of the Consultant’s Q.A. Engineer.
6. CORRECTIVE AND PREVENTIVE ACTION
6.1 AIM
The aim of this procedure is to determine the management methods of Corrective
and Preventive Actions implemented with a view to eliminating the causes
of already existing and potential Non-Conformities.
6.2 SCOPE
This procedure covers all the Corrective and Preventive Actions implemented
within the TUNNEL PROJECT.
6.3 RESPONSIBILITY
The Technical Site Department is responsible for:
 Determining the Corrective and Preventive Actions to be implemented
following internal audits
 Implementing the Corrective and Preventive Actions.
The Quality Engineer is responsible for:
 Making periodical analyses of the quality information and data gathered

for the
 Quality System Review
 Establishing Corrective and Preventive Actions
 Assessing the effectiveness of the Actions taken by the Heads of
Department checking during the closing of the "Non-Conformity
Report" the effective
 Implementation of the Corrective Actions taken checking the results of
these actions, Recording the Actions and filing them.
The Project Manager is responsible for:
 Taking Corrective and Preventive Actions together with the Executive

Officer following the Quality System Review
The Executive Officer is responsible for:
 Taking Corrective and Preventive Actions together with the Project

Manager following the Quality System Review
6.4.1 Actions following internal Audits

The Corrective and Preventive Actions taken as a result of Non-Conformities
detected are documented on the “Corrective and Preventive Action Report” form.
The Quality Engineer then records the Corrective and Preventive Actions in the
“Corrective and Preventive Actions Register”.
The Corrective and Preventive Actions are determined by the Head of
Department, their efficiency checked by the Quality Engineer. Subsequently, the
actions taken are assessed by the Quality Engineer and inspected in the course of
surveillance actions. If the Quality Engineer Judges the actions to be ineffective,
the Department concerned is bound to follow the recommendations made by him.
6.4.2 Actions following Client Complaints

The Corrective and Preventive Actions taken following Client complaints are
determined by the Project Manager. The Executive Officer and Quality Engineer
are notified of these actions and the latter assesses them and records them in the
“Corrective and Preventive Actions Register”.
6.4.3 Actions following the Detection of a Non-Conformity

Corrective Actions following Non-Conformities detected on site are determined
on the "Non-Conformity Report" as laid down in Procedure "Control of Non-
Conforming products".
Once Non-Conformity has been resolved, the Quality Engineer checks that the
Corrective Action taken has been implemented successfully.
6.4.4 Actions following the Periodical Quality Analysis made by the Quality Engineer
The quality information and data gathered deriving from:
 Results of internal Audits
 Client Complaints
 Quality System review
 Quality record documents
 Quality System, process and product Non-Conformity records
is examined by the Quality Engineer on a regular basis with a view to

pinpointing Non-Conformities which tend to be repeated as well as the more
serious ones which could jeopardise Quality standards.
On the basis of these examinations, the Quality Engineer determines the

Corrective and Preventive Actions required. After having consulted the
Heads of Department involved, the Quality Engineer formalises the Action by
filling out the "Corrective and Preventive Action Report" form and by
recording it in the "Corrective and Preventive Actions Register".
6.4.5 Actions following the Quality System Review

Before carrying out the Quality System Review, the Quality Engineer makes an
analysis of Corrective and Preventive Actions, internal Audits, Client Complaints,
Quality System, process and product Non-Conformities and transmits this
analysis to the Project Manager and Executive Officer to enable them, during the
Quality System Review, to evaluate and determine the Corrective and Preventive
Actions to be taken.
The Corrective and Preventive Actions resulting from the Quality System Review
are documented by the Quality Engineer who issues the "Corrective and
Preventive Action Report" form. They are recorded in the "Corrective and
Preventive Actions Register" and transmitted to the Departments concerned to be
implemented.
6.5 CHECKING THE RESULTS OF CORRECTIVE AND PREVENTIVE ACTIONS

In the course of the internal Audits and through surveillance actions the Quality
Engineer checks the results of the Corrective and Preventive Actions in order to
ascertain that:
 the time scale for their implementation has been respected
 they have been fully implemented
 The Quality System documents have been amended
 The actions have been effective.
If the Corrective and Preventive Actions have had a negative outcome, they are
replaced. These new Corrective and Preventive Actions are reported by the
Quality Engineer to the Project Manager and Executive Manager.
6.6 FILING
The Quality Engineer files the “Corrective and Preventive Action” forms.
7. INTERNAL AUDITS
7.1 AIM
The aim of this procedure is to define the methods and responsibilities for the
carrying out of the internal audits for this quality assurance manual.
7.2 SCOPE
This procedure covers the reviewing of the quality assurance manual utilised by
SAMMON INFRACORP. with a view to keep it updated and to improve the
procedures.
M/S -SAMMON INFRACORP Will be our Part of Tunnel Construction Work.
7.3 RESPONSIBILITY
The Management Board is responsible for:
 Ensuring that the internal audit is carried out periodically
 Ensure that improvements to the quality assurance system are
implemented
 Deciding on additional internal audits if they feel that such are required
The Executive Officer is responsible for:
 Carrying out the internal audit within the involved staff
 Implementing the proposed improvements found during the internal audit

The Executive Officer who is responsible for the carrying out of the internal audits
shall develop a system with which the quality assurance system as described in
this manual shall be checked. Emphasis shall be put on the one procedure which
is important at the time of the internal audit. This means e.g. that the civil works
are more important at the start of the project whereas the overall organisation will
become more important with time because of the interrelation between the major
sub-contractors. This also means that not all procedures must be ready at the start
of the project but shall be established in the course of the project so that they
reflect the actual conditions at that time.
The personnel from GR. Infraprojects Ltd. which is affected by the internal audit
shall be advised of the audit in advance. The points to be checked and the system
to be followed shall be made available to them.
The audit shall not disturb the on-going works. Results shall be collected however
if inaccuracies are observed they shall not be corrected on the spot but reported in
the Auditing Report and then be implemented through the existing QA/QC
organisation.
The Auditing Report shall be prepared within 30 days after the carrying out of the
internal audit. Improvements shall be implemented not later than 30 days after
the Auditing Report has been made available to the responsible departments.
Additional internal audits can be carried out if the results of such an internal audit
show that the quality reached is very poor and/or the quality assurance system is
not followed at large. The decision to have an additional internal audit shall be
taken by the management board.
7.5 Tunnel Details Planning & Schedule Work.
7.5.1 Tunnel Project Outline
The Road Tunnel is part of “Four Laning of Parwanoo-Solan Section of NH-22 (Now-
5) from Km. 67.000 to Km. 106.000 on EPC Mode under NHDP Phase-III in the State
of Himachal Pradesh”. As reported in section B of tender the tunnel portal are at
1+125 and 1+950 respectively on a green field road alignment.
Table 1: Portal Location details as per contract
Portal Chainage Length (m)
Parwanoo Portal …P1 CH 1+125

825 m
Solan Portal ………P2 CH 1+950
7.5.2Detailed Methodology for Construction of Tunnels

Basic Considerations
The methodology adopted for construction of Project area Tunnels takes into consideration
the construction schedule, the compatibility of construction equipment to site conditions
and quantities as well as utilization factor of the equipment within the scheduled
construction period. Mechanized construction has been planned so as to achieve consistent
quality at a faster rate.
7.5.3 Working period

The South West monsoon during July to September is less predominant and during hot
season disturbances occurring in March to June are more predominant. For underground
works 2 working shift has been considered. Assuming 26 working days per month total
working days considered yearly 312 days.
7.5.4 Sequence of works

General
The total length of tunnel envisaged under this project 825 m as per contract.
Size of Main tunnel – excavation size with Cross section approximate maximum area is
126 Sqm with horse shape.
Availability of tunnel faces is two, one from Parwanoo end, Portal P1 and other from Solan
end, Portal P2
After mobilization of resources, we will take up the excavation work in Portal approaches
& construction of Portal protection works. Portal construction work followed by
commencement of tunnel Canopy & after main tunnel excavation from main tunnel portal.
Tunnel will be excavated using drill and blast method in heading, benching & Invert
sections as per prevailing rock conditions and a per design section accordingly rock class
by using primary lining including shotcrete, wire mesh & rock bolts as per given in design
drawing provided by our tunnel designer M/s Indus Consultrans Pvt Ltd.
Concrete lining of tunnel will be taken up after completing the excavation and primary
lining with rock support. Construction activity will be sequenced in proper logical manner
so that all above structures are completed in time.
8. TRAINING OF PERSONNEL
8.1 AIM
The aim of this procedure is to define methods for identifying the training needs
of all the Personal and for the planning, implementation and recording of the
same.
8.2 SCOPE
This procedure covers all the personnel of GR. Infraprojects Ltd. involved in
activities affecting Quality.
8.3 RESPONSIBILITY
GR. Infraprojects Ltd is responsible for:
 Identifying and planning training for its one Personnel.
The selected Quality Engineer is responsible for:
 Approving the qualification of the personnel responsible for specific
processing and checking procedures and for filing the related
documentation.
The selected Project Manager is responsible for:
 Coordinating the training needs of the various personnel

8.4.1 Identification of Training Needs
Personnel training needs are evaluated by the Head of each department involved
on the basis of the following criteria:
 Activities performed in the Department
 Areas of competence and qualifications necessary for the said activities to be
performed
 Knowledge of the Quality System in relation to management and
operational aspects
 Project organization
 Laws, regulations and standards
 Site and management processes
 Evaluation of the qualifications and knowledge of the personnel in
comparison with the required skills and mastery required for performing
the activities
The check of the personnel is based on:

 An evaluation of the activities performed by each individual in the past
 Assessment interviews with each individual
Training needs are assessed on an annual basis and in the following

circumstances:
 The arising of impelling external factors leading to a change or innovation in
the activities performed (e.g. new legislation and standards)
 Acquisition of different operational methods due to the introduction of new,
or different, technologies
 Change of duties
 Employing of new personnel
8.4.2 Planning of Training
The planning of the training involves the definition of:

 Topics
 Students
 Training methods (courses, seminars, etc.) Internal and external resources
utilized Person responsible for the training
 Activity program with duration and date and location of the training
Training may be conducted on Company premises with either Company or

external personnel, or on the premises of external, specialized
Companies. The requirements of the individual Departments are coordinated by
the Project Manager for the site and by the Executive Officer for the company
premises.
Generally, after theoretical training, the Personnel assigned to the new activities
are backed up by expert personnel for practical instruction in the field.
8.4.3 Personnel assigned to Special Activities

The Personnel assigned to special activities such as to processes, operations,
inspections, controls and testing which require special knowledge in:
 The comprehension and correct implementation of the procedures,
operational instructions and applicable standards as well as what is
specifically requested in the contract documentation.
 The correct use of tools.
 Is qualified on the basis of sufficient instruction and training in companies,
which are competent to conduct such training.
The certification of the qualification obtained will be checked by the Quality

Engineer before the Personnel begins the activities in question in order to establish
whether it fulfils standard and contractual requirements.
8.4.4 Documentation
Participation internal training courses is recorded on a “Training Record” form,
while participation in external courses is recorded by means of the “Certificate of
Attendance” issued at the end of the training course. Such documents are duly
filed by the Head of Department.
Personnel qualification documentation is filed by the Quality Engineer.
9. SERVICING
9.1 AIM
The procedure defines the methods and assigns the responsibilities for providing
servicing assistance to GR. according to the contract conditions and ensuring that
this assistance does, effectively, meet the requirements.
9.2 SCOPE
This procedure covers the servicing assistance for the construction of the
TUNNEL PROJECT.
9.3 RESPONSIBILITY
The Project Manger is responsible for:
 Providing technical and logistical assistance on site
 Resolving complaints
9.4.1 General Information

The servicing provided by other suppliers to Gr. Infraprojects Ltd. consists of the
following:
 technical and logistical support

 technical servicing of the works
 Dealing with complaints.
9.4.2 Technical and Logistical Support

The Project Manager, in accordance with what has been laid down in the contract,
makes the required logistical arrangements and places the required resources at
the disposal of the Technical Site Department.
The Project Manager authorizes the Technical Site Department to have free access
to the work site to enable them to carry out the activities laid down in the contract.
Additionally, the Project Manager ensures that the Technical Site Department is
also provided with:
 The technical information and services required by the contract;
 The technical and servicing documentation required by the contract (as built
drawings, operation and maintenance manuals, maintenance and disposal
schedules etc.).
The Project Manager nominated by Gr.Infraprojects Ltd. will be responsible for

the training of their Personnel, regarding the use and maintenance of the works
and connected plant.
9.4.3 Technical Servicing of the Works

During the construction of the works, after their consignment and throughout the
period established by the contract, the Project Manager will perform any
necessary maintenance work and repairs on the works as stated in the Contract
Conditions using his own Personnel or in cooperation with external Companies
with which he will stipulate specific contracts.
9.4.4 Resolving Complaints
The Project Manager will record any complaints. He will examine the complaining
to establish whether it is well-founded, identify its nature, determine the steps to
be taken in order to resolve the situation and plan their implementation.
Once these operations have been completed, the Project Manager will check that
the required effect is achieved; the results of this inspection and any further steps
which might prove to be necessary will be recorded.
The complaints and dates on which they have been completed, the Project
Manager will check that the required effect is achieved; the results of this
inspection and any further steps which might prove to be necessary will be
recorded.
The complaints and dates on which they have been successfully resolved are
recorded in a special register by the Project Manager.
Following this periodical monitoring or as a result of individual complaints,
suitable corrective or preventive actions will be implemented in accordance with
what has been laid down by “Corrective and preventive actions”.
9.4.5 VENDOR/AGENCY – For Supplying Material will be approved by
Authority Engneer. Only approved Source and approved material will be used
in Tunnel Construction work.
10. STATISTICAL TECHNIQUES
10.1 AIM
The aim of the present procedure is to define methods and responsibilities relative
to the use of Statistical Techniques.
10.2 SCOPE
This procedure covers all statistical techniques utilised for the construction of the
TUNNEL PROJECT with a view to keeping product processes and characteristics
under control.
10.3 RESPONSIBILITY
The Head of Department is responsible for:
 Issuing, when necessary, special Instructions for the application of the

Statistical Techniques
 Documenting the reliability of the methods not defined by reference
standards

For the application and control of the Statistical Techniques, refer to the standard
methods laid down in the respective national or international Standards.
If no reference standard for the methods exists, the Head of Department
will prepare the documentation necessary to prove the reliability of the method
adopted.
In order to facilitate the use of Statistical Techniques and control their application,
the Head of Department will, if necessary, issue special Instructions.
The Statistical Techniques designed to check:
 product characteristics
 processes
 Non-Conformities
And to elaborate the followings:
 Mean
 Standard deviation
 Control cards
 Diagram and bar graphs
 Sampling plans
These calculations may be integrated when necessary, for the resolution of

particular problems.
Sampling methods which guarantee that the control is both significant and
representative are used for product control.
SAMPLE INSPECTION AND TEST PLAN
PROJECT:
CLIENT:
ACTIVITY: CONSTRUCTION MATERIAL FOR CONCRETE WORKS
INSPECTION AND TESTING CONTROLLING VERIFYING FREQUNCY OF
SL. NO. REMARKS
DESCRIPTION SPECIFICATION DOCUMENT INSPECTION
1 CEMENT
MTC/ INTERNAL LAB
a) COMPRESSIVE STRENGTH IS:4031 (PART 6) ONCE PER EACH WEEK
REPORT
MTC/ INTERNAL LAB EXTERNAL
b) INITIAL AND FINAL SETTING TIME IS:4031 (PART 5) ONCE PER EACH WEEK
REPORT LAB TEST
MTC/ INTERNAL LAB FOR EACH
c) FINENESS TEST IS:4031 (PART 1) ONCE PER EACH WEEK
REPORT 100 T
MTC/ INTERNAL LAB
d) SOUNDNESS TEST IS:4031 (PART 3) ONCE PER EACH WEEK
REPORT
REINFORCEMENT AND
2
STRUCTURAL STEEL
MTC/ EXTERNAL LAB ONCE PER EACH
a) ULTIMATE TENSILE STRENGTH IS:1786, 2062 EXTERNAL
REPORT BATCH
TEST
MTC/ EXTERNAL LAB ONCE PER EACH
b) YIELD STRENGTH IS:1786, 2062 REPORT FOR
REPORT BATCH
EVERY 100
PERCENTAGE OF ELONGATION MTC/ EXTERNAL LAB ONCE PER EACH
c) IS:1786, 2062 MT OR AS
TEST REPORT BATCH PER
MTC/ EXTERNAL LAB ONCE PER EACH REQUIRED
d) BEND AND REBEND TEST IS:1786, 2062
REPORT BATCH
3 FINE AND CORASE AGGREGATE
WATER ABSORPTION AND INTERNAL LAB
a) IS:2386(PART 3) MONTHLY
SPECIFIC GRAVITY REPORT
INTERNAL LAB
b) GRADTAION ANLYSSIS IS:2386(PART 1) DAILY
REPORT
INTERNAL LAB ONCE PER EACH
c) SOUNDNESS TEST IS:2386(PART 5)
REPORT SOURCE
INTERNAL LAB
d) AGGREGATE IMPACT VALUE TEST IS:2386(PART 4) DAILY
REPORT
INTERNAL LAB ONCE PER EACH
e) AGGREGATE ABRASION VALUE IS:2386(PART 4)
REPORT SOURCE
EXTERNAL LAB ONCE PER EACH
f) ALKALI AGGREGATE REACTIVITY IS:2386(PART 7)
REPORT SOURCE
4 WATER
ONCE PER EACH
EXTERNAL LAB
a) CHEMICAL TEST TABLE 1 OF IS:456 SOURCE& EVERY 3
REPORT
MONTH
5 CONCRETE
WORKABILITY OF FRESH INTERNAL LAB ONE TEST FOR EACH
a) IS:1199
CONCRETE REPORT BATCH OF CONCRETE
INTERNAL LAB
b) COMPRESSIVE STRENGTH IS:516 AS PER IS:456
REPORT
CORE STRENGTH ON HARDEN INTERNAL LAB
c) IS:516 AS REQUIRED
CONCRETE REPORT
6 CONCRETE ADMIXERS
EXTERNAL
PHYSICAL AND CHEMICAL MANUFACTURE'S LAB TEST
a) IS:9103 EACH BATCH
PROPERTIES TEST REPORT FOR EACH
BATCH
INTERNAL LAB
b) SLUMP AND SETTING TIME IS:9103 EACH BATCH
REPORT
GR INFRAPROJECTS LTD
QUALITY CONTROL LAB FREQUENCY
BAROG TUNNEL PROJECT

CONTROLLING
S.NO NAME OF TESTING SPECIFICATION
PARAMETER
A SAND & AGGREGATE

1 Moisture correction IS-2386 & IS-383 Daily
2 Sieve Analysis of Ca & Fa IS-2386 & IS-383 Daily
3 Impact Value IS-2386 & IS-383 Daily
4 Crushing Value IS-2386 & IS-383 Weekly
5 Flakkiness and Elongation of Aggregate IS-2386 & IS-383 Daily
6 Specific Gravity of Ca & Fa IS-2386 & IS-383 Monthly
7 Silt Content of Sand IS-2386 & IS-383 Daily
8 Bulk Density of Aggregate & Sand IS-2386 & IS-383 Weekly
B CEMENT
1 Cement setting Time Test IS-4031 Each Week
2 Cement Cube Casting IS-4031 Each Week
C ROCK BOLT
1 Swellex Bolt Pull Out Test 200 Nos
2 SN Bolt Pull Out Test 200 Nos
3 SDR Pull Out Test 200 Nos
D SHOTCRETE
1 Shotcrete Panel Casting ( Every) 200 cum
2 Shotcrete In-Situ Core Testing ( Every) 200 cum
3 Concrete Cube IS-516 As per IS code
4 Batching Plant Calibration 3 Months
5 Needle Penetration Test( Every) 200 cum
6 Slump Test Daily
E SFRS (STEEL FIBRE REINFORCEMENT SHORTCRETE)
1 SFRS Panel Casting 200 cum
2 SFRS In-Situ core Testing 200 cum
3 SFRS Thickness Test 200 cum
4 SFRS Cube Casting 100 cum
5 SFRS Density Test weekly
6 Needle Penetration Test 200 cum
7 Slump Test Daily

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Quality Assurance Plan For Tunnel Construction Works

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NATIONAL HIGHWAYS AUTHORITY OF

Four Laning of Parwanoo - Solan Section of NH-22

Quality Assurance Plan for

5.4.8 Approval of Processed Materials............................................................................19

6. CORRECTIVE AND PREVENTIVE ACTION………………………………………22

7.5 Tunnel Details Planning & Schedule Work..............................................26

To implement a quality assurance plan for the construction of the TUNNEL

A Senior Project Manager

A Project Manager -Tunnel

The abbreviations used in this manual are as follows:

2.1 Process Management

These documents shall be made available to the personnel by the

2.2 Process Qualification

 Control equipment and methods

2.3 QA/QC Process Qualification

reported, filed, etc.

Figure 2-1-1: General Procedure for the Construction of a

GR. INFRAPROJECTS LTD is responsible for:

4. CONTROL OF INSPECTION, MEASURING AND TEST

The Technical Site Department of GR.INFRAPROJECTS LTD is

 Having the equipment calibrated if external controls have to be

 Identifying the equipment

 Preserving the calibration documentation

The Operator is responsible for:

 Calibrating the equipment

 Preserving and handling the equipment with care

4.4 IMPLEMENTATION METHODS

4.4.1 Equipment Selection

4.4.5 Handling and Preservation

4.4.6 Measures in case Equipment is out of Calibration

4.4.7 Master Templates and Comparative Reference

4.4.8 Management of Standard Devices and Reference Equipment

Refe Name Model Quant

5. INSPECTION AND TEST STATUS

5.4 IMPLEMENTATION METHODS

5.4.1 Identification of the Inspection and Test Status

Their status is displayed by means of:

 The proposed materials meet the specification requirements

 The proposed Quarry/ Borrow Area is approved as proposed.

5.4.3. Selection of Borrow area

5.4.4. Transport of Materials

5.4.6. Approval of Materials

5.4.7Approval of Natural Materials

5.4.8Approval of Processed Materials

5.4.9Approval of Manufactured Materials

Approval of manufactured materials, based on specific Specifications requirements, is

 Initial Approval – given prior to receipt of the materials based on submittal of

5.5.0Approval of Designed Materials

1. Approval of sources (generally quarries) for each of the processed material

2. Approval of each of the individual processed materials and manufactured materials to

3. Tentative approval of a laboratory based mix design, based on a mixture of approved

4. Tentative approval of a plant mix design, based on proportioning of aggregate bins’

5. Based on successful laying of the mixes in accordance with the approved

5.5.1 Revocation (Withdrawal) of Material Approvals

5.5.2 Reporting and Recording Material Approvals

5.5.3. Sampling of Materials

5.5.4 Sampling Requirements

5.5.5 Sampling Guidelines

All sampling is to be carried out in accordance with instructions to be given by the

 Obtaining samples from at least three areas.

5.5.6 Preparation and Storage of Samples

6. CORRECTIVE AND PREVENTIVE ACTION

The Quality Engineer is responsible for: