References Rail Vikas Nigam Limited: Standard Specifications for Materials and Works, Updated up to February 2015 Indian Roads Congress & Ministry of Road Transport and Highways: Specifications for Road and Bridge Works, 5th Edition, 2013 Research Design & Standards Organisation: Guidelines for Earthwork in Railway Projects, Guidelines No. GE : G-1, July 2003 Subramanian : Design of Steel Structures, 13th Impression, Oxford University Press, New Delhi, 2013 Pillai & Memon: Reinforced Concrete Design, 3rd Edition, Mc Graw Hill, New Delhi 2009 Santosh Kumar Garg: Water Supply Engineering, 10th Edition, Khanna Publishers,1998 Nicholas: Project Management for Business and Technology, 2nd Edition, Prentice-Hall of India, Noida, 2006 Mahesh Varma: Construction Equipment and its Planning & Application, 3rd Edition, Metropolitan Book Company, New Delhi, 1997 Gopal Ranjan and ASR Rao: Basic and Applied Soil Mechanics, 2nd Edition, New Age International (P) Limited, New Delhi, 2000ANNEXURE-I Inspection & Test Plan-Concrete Work Si. Check Parameters ‘Acceptance [Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client 1_| Portland Slag Cement Li | Chemical Tests a | Magnesium Oxide (MgO) 1S 455 184032 |MTC/External] At the beginning for! Max. 8% R R approval of exch source and change of source & MTC is required b_| Sulpher trioxide (SO) 1S 455 1s 4032_ |MTC/External| do Max. 3% R R b_| Sulphide Sulpher S) 1S 455 1S 4032_|MTC/External| do Max. 1% R R d_| Loss on Ignition 1S 455 1S 4032_ [MTC/External| do ‘Max. 5% R R €_| Insoluble Residue 1S 455 1S 4032 _ [MTC/External] do Max. 4% R R 1.2 | Physical Tests a | Fineness of Cement (By Sieving) 15 455 184031 [MTC/External] Hach consigament &| Min. 225M7/kg | R/W | R/W (part-1) once in a month b | Soundaess by Le-Chatelier method 18 455 IS 4031 |MTC/External| Once per source 10mm max. Rw | RAW (part-3) expansion ¢ | Standard Consistency 18 455 184031 | MTC/Internal | Each consignment & | Vicat plunger to c Ww (Part- 4) once ina month | penetrate at a point to 7mm from bot tom of vicatmould | Initial Setting Time TS 455 184031 | MTC/Internal | Each consignment &| Not less than ¢c Ww Part- 5) once in a month 30 min. ¢ | Final Setting Time 1S 455 1S 4031 _|MTC/Taternal | Bach consignment &| Not more chan c Ww (Part- 5) once in a month 600 min yarxauuy 60zSL. Check Parameters [Acceptance|Performance| Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client F | Compressive Strength at 3 days TS 455 184031 |MTC/Tnternal | Hach consignment &| Not less than G Ww (Part- 6) once in a month 16 Mpa g | Compressive Strength at 7 days 1S 455 154031 |MTC/Internal | Hach consignment &| Not less than G Ww (Part- 6) once in a month 22 Mpa h | Compressive Strength at 28 days 1S 455 184031 |MTC/Internal | Hach consignment &| Not less than c w Part- 6) once in a month 33 Mpa 2_ | Ordinary Portland Cement -43 & 53 grade 2.1 | Chemical Tests a | Ratio of percentage of lime to 188112/ | 184032 |MTC/Esternal| At the beginning for| 0.8 - 1.02 for R R percentage of silica, alumina & IS 12269 approval of each OPC-53 & iron oxide source and change in| 0.66 - 1.02 for source & MTC for OPC-43 each lot b [Ratio of percentage of aluminato | IS8112/ | 1S 4032 |MTC/Esternal| At the beginning for | Not less than 0.66 R R that of iron oxide Is 12269 approval of each source and change in source & MTC for each lot ¢ | Insoluble Residue TS 8112/ | 1S 4032 |MTC/Esternal] At the beginning for [Not More than 2% R R IS 12269 approval of each source and change in source & MTC for each lot d_ | Magnesia (MgO) 1S8112/ | 184032 |MTC/External] At the beginning for [Not More than 6%| R IS 12269 approval of each source and change in source & MTC for each lot Si. Check Parameters [Acceptance|Performance| Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client ¢ | Total Sulpher content (6O,) IS 8112/ | 184032 |MTC/External] At the beginning for Max.3% R R IS 12269 approval of each source and change in sousce & MTC for each lot f | Loss on Ignition TS8112/ | 184032 [MTC/External] At the beginning for Max.5% R R IS 12269 approval of each source and change in source & MTC for cach lot 2.2 | Physical Tests a | Fineness of Cement by sieving 1S 8112/ | 184031 |MIC/External] At the beginning for | Min. 225M"/kg | R/W | R/AW 1812269 | (part) approval of each source & change in source & one test per each consignment once in 2 month b [Soundness by Le-Chatelier method | 1S8112/ | 184031 |MYTC/Esternall At the beginning for | Less than 10mm | R/W | R/W 1S 12269 | (part-3) approval of each source & change in source & one test per each consignment once ina month ¢ | Standard Consistency 188112/ | IS4031 | MTC/Internal | At the beginning for | Vicat plunger to c Ww 1812269 | (Pare-4) approval of each penetrate at a point source & change in [5 to 7mm from bor| source & one test per| tom of vicatmould each consigament once in a month ole spalorg [emsnpuy jo voREatreydeyy 303 Yooqpuey] §.99U/SusT Tamxouuy ueSl. ‘Check Parameters Acceptance|Performance] Testing Frequency Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client | Initial Setting Time 1S8112/ | 184031 |MTC/Internal| At the beginning for | Not less than c Ww 1812269 | @art- 5) approval of each 30 min, source & change in source & one test per each consignment once in a month € | Final Setting Time 188112/ | 184031 |MTC/Internal| At the beginning for | Not more than 6 W 1812269 | art-5) approval of each 600 min source & change in source & one test per| each consignment once ina month F | Compressive Strength at 3 days 18 8112/ | 184031 [MTC/Internal| At the beginning for | _> 23 Mpa For c Ww 1S 12269 | (Part- 6) approval of each |OPC-43 &>27MPa| source & change in | for OPC-53 source & one test per| each consigament once in a month g | Compressive strength At 7 days 1S 8112/ | 184031 |MTC/Internal| At the beginning for | > 33 Mpa For c Ww 1812269 | @art- 6) approval of each |OPC-43 &>37MPa source & change in | for OPC-53 source & one test per: each consignment once in a month h | Compressive strength At 28 days 188112/ | 184031 | MTC/Internal| At the beginning for |_ > 43 Mpa For c Ww 1812269 | Part- 6) approval of each |OPC-43 &>53MPa| source & change in | for OPC-53 source & one test per’ each consignment once ina month Sl. Check Parameters ‘Acceptance [Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor [Client 3_| Coarse Aggregates a | Sieve analysis 15 383 1S:2386 Taternal | At the beginning for] AS per IS:383 c Ww (Part 1) approval of each Table-2 source & change in source & one test per each every day | Flakiness Index/ Elongation Index 1S 383 1S:2386 Taternal | Atthe beginning for | Max.25% of c Ww (Part 1) approval of each | combined FI source & change in source & once in a month ¢ | Deletesious Materials 1S 383 1S:2386 External | At the beginning for | 1S 383 Table-1 RW PRA art 2) approval of each source & change in source d_ | Specific Gravity and Water absorption} IS 383 1S:2386 | External/ [Once per source then] Values as per mix c Ww art 3) Internal once in 2 month design e | Aggregate Impact Value 1S 383 1S:2386 | External/ | At the beginning for | 45% by weight c Ww (Part 4) Internal, approval of each source & change in source f | Aggregate Crushing Value 1S 383 1S:2386 | External/ | Avthe beginning for| 45% by weight c (Part 1) Internal, approval of each source & change in source @ | Aggregate Abrasion Value 18 383 1S:2386 External | Atthe beginning for| Max. 50% RAW | RAV Part 1) approval of each source & change in source zz siolorg [emsnpuy jo uonuuatua|dury soy YoogpuEH szodUNsUG Tamxouny elasi. Check Parameters [Acceptance|Performance] Testing Frequency Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client h | Soundness TS 383 1S:2386 External | Acthe beginning for | Max. 12% with RW | RAW (Part 5) approval of each Na,SO, & sousce & change in | 18% with MgSO, source 4 | Fine Aggregates a | Sieve analysis 1S383 | _18:2386 Internal | At the beginning for | IS 383 Table-4 c Ww Pare 1) latest| approval of each edition source & change in source & one test per each every day b | Deleterious Materials S383 | 18:2386 | External Once per source | IS 383 Table-1 Rw LRAT (Part 2) latest editions ¢ | Specific Gravity and 15383 | 15: 2386 Tnternal [Once per source then] As Required c Ww Water absorption (Part 3) latest once ina month editions d |Silt & Clay Content cPWD’s | AS Per Internal [Once per source then] Max. 8% G Ww [Specification] CPWD once in a day by volume clause 3.1.4.2 Append-D € | Soundness IS: 383 | 1S:2386 External | At the beginning for | Max. 10% with R/W | R/W (Part 5) approval of each NaSO, & source & change in | 15% with MgSO, source & once in a month 3. | Water a | pH Value HIS: 456-2000] 1S 3025 Internal | Atthe beginning of | NotLess than | C/R/W | W/R Part-I) approval of each source & change in source Si. Check Parameters [Acceptance|Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client b | Organic lS: 456-2000] 1S:3025 External | Acthe beginning of | Max. 200mg/1 RW | R/W (Part 18) approval of each source & change in source ¢ | Inorganic HS: 456-2000] 1S:3025 External | Atthe beginning of | Max. 3000mg/I RW | RAW (Part 18) approval of each source & change in source d | Sulphates (es SO) ls : 456-2000 1S:3025 External | Acthe beginning of | Max. 400mg/I RW R/W (Part 24) approval of each soutce & change in source Chlorides (es Cl) fis: 456-2000f 18:3025 External | Atthe beginning of | Max. 500mg/I RW RAW (Part 32) approval of each source & change in source Suspended matier fis : 456-2000) 1S:3025 External | At the beginning of | Max. 2000mg/I RW [RW (Part 17) approval of each source & change in source 6_| Reinforcement Steel (Fe500D) 6.1 | Chemical Tests a | Carbon 1S: 1786- fI8:228 Part] MTC/ | Acthe beginning of | Max.0.25%for | R/W | R/W 2008 External | approval of each Fe500D source & change in source/MTC for each lot b | Sulphur 1S: 1786- |IS:228 Part] MTC/ | Atthe beginning of | Max. 0.040% for | R/W | R/W 2008 External approval of each Fe500D source & change in source/MTC for each lot rie snoolorg [emsnpuy Jo voReaureydury 10) yooqpurpy Sz20uiMus Lamxouny sizSl. Check Parameters ‘Acceptance |Performance] Testing Frequency Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client ¢ | Phosphorous IS: 1786- fiS:228 Part) = MTC/ — | Atthe beginning of | Max. 0.040% for | R/W | R/W 2008 External approval of each Fe500D source & change in source/MTC for each lot d | Sulphur and Phosphorous TS: 1786- | 18:228 MIC/ | Atthe beginning of | Max.0.075% for | R/W | R/W 2008 External approval of each Fes00D source & change in source/MTC for each lot 6.2 | Physical Tests a | 0.2% Proof stress/yield stress 1S: 1786- | IS: 1608 - MTC/ [One test per lot Max] Min. 500N/mm? | R/W | R/W 2008 2005 External |25MT upto 10mm dial & Max. 40MT above 10mm dia)/MTC for each lot b | Blongation on gauge length 5.65 VA | IS:1786- | IS: 1608 - MTC/ ‘Once per source Min. 16% for RW | RAW where A=Cross sectional area of test | 2008 2005 External Fe500D piece c | Tensile Strength 18: 1786- | IS: 1608 - MTC/ — [One test per lot (Max, Min.550N/mm? | R/W | R/W 2008 2005 External [25MT upto 10mm dial for Fe500D & Max. 40MT above ‘10mm dia) d_| Total elongation at maximum force | IS: 1786- | IS: 1608 - MIC/ ‘Once per source Max. 5% for R/wW RAW on gauge length 5.65 VA where 2008 2005 External Fe500D A=Cross sectional area of test piece ¢ | Bend Test IS: 1786- | 1S: 1599 - MTC/ — [One test per lot(Max.| No rupture or Rw R/W 2008 1985 External |25MT upto 10mm dia) cracks visible on & Max. 40MT above| the bent portion 10mm dia)/MTC for each lot SL Check Parameters Acceptance|Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client £ | Re-Bend Test IS: 1786- | IS: 1599- MTC/ — [One test per lot (Max,| No rupture or RW | R/W 2008 1985 External |25MT upto 10mm dialcracks visible on th & Mex. 40MT above] re-bent portion ‘10mm dia)/ MTC for each lot g | Nominal Mass/Rolling Margin TS: 1786- | IS: 1608 - MTC/ — | Once per Lot/Batch | As Per IS 1786: g Ww 2008 2005 Internal 2008 Table-2 7_| Chemical Admixture Dey material content for liquid and | 1S: 9103- | 15: 9103 - MTC/ | Atthe beginning on | Within 3% of the] R/W | R/W solid admixture 1999 | Annexure | External | the basis of source | value stated by the selected and subse- manufacturer quently with change of source/MTC per each lot b | Ash content 1S:9103- | 1S: 9103 - MIC/ ‘| Atthe beginning on | Within 1% of the | RAW | RAW 1999 | Annexure] External | the basis of source | value stated by the selected and subse- | — manufacturer. quently with change of source/MTC per cach lot ¢ | Relative Density IS: 9103- | 18:9103 - MTC/ | Atthe beginning on | Within 0.02 of the] R/W | RAW 1999 | Annexure] External | the basis of source | value stated by the selected and subse- | manufacturer quently with change of source/MTC per each lot d_ | Chloride ion content 1S: 6925 | IS: 6925 MTC/ | Atthe beginning on | Within 2% by R/wW | RAW External | the basis of source | weight of the selected and subse- | admixtare. quently with change of source/MTC per each lot oz siolorg [emasnpyy Jo voperuaureydeyy 303 yooqpuepy Sasu/Bus Tamxoury LizSi. (Check Parameters [Acceptance|Performance| Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client e |pH IS 9103:1999| 18: 9103 - MTC/ | Atthe beginning on | Within tif the | R/W | R/W (Ammend-1)] Annexure | External | the basis of source | value stated by the selected and subse- | manufacturer quently with change of source/MTC per each lot 8 | Concrete a | Mix design 1S 10262/IS] 1S: 10262 ] Internal | At the beginning on 15: 456 c Ww 456 2009/ the basis of source 1S : 456-2000 selected and subse- quently with change of source. b [Batching Plant Calibration TS 4926:2003| 18 4926:2003| Internal [Once every 3 moaths| _IS : 4926:2005 c Ww b | Workability of fresh concrete ‘As specified | 1S: 1199 Internal ‘As required ‘As per design c Ww - 1959 (reaf- firmed 2008) d | Setting Time of Conerete 1S:9103- | 1S: 8142 Internal ‘Once per grade ‘As required Cc Ww 1999 | - 1976 (reaf- firmed 2007) €_| Permeability test of concrete TS __|IS:3085-1965| Internal | 60 samples per grade| <= 25 mm. c W. £ | Compressive Strength 1S:516 [[S:516-1959 Internal | As Per IS 456 clause ] As Per IS 456 G Ww (reaffirmed 15.2.2 (Table-11) 2008) 9 | Piling Works 9.1 | Bentonite suspension in Bored cast-in-situ piles a | Liquid Limit TS 1$:2720 |External/MTC] Once per source > 400% R/W | RAW Past - 5) b | Sand Content TS 1S:2720 | External/ | Once persource/ | The sand content| R/W | R/W @art 37) & |MTC/Internal per Lot lof Size > 0.075mm| (Part-4) shall not be more than 1% Sl. Check Parameters Acceptance|Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client | Density TS [1S2720- Part| Excernal/ | Once perLoté& As | Fresh bentonite | R/W | R/W 14 | MTC/Tnternal| per site requirement | density shall not exceed 1.05 g/ml d_| Marsh Cone Viscosity TS |AsperTech.| External/ | Once per Lot & As | 30-40 seconds RW | R/W Specification | MTC/Internal | per site requisement © | pH Value TS) 1S2720@Part| Esternal/ | Once per Lot & As [Beeween 9 and 11.5) R/W | R/W 26) | MTC/Internal | per site requirement 9.2 [Testing of Piles (Uniform diameter) 9.2.1] Vertical load test on single pile Tnitial Load Test TS: 2911 | 1S:2911 Tnternal | No.as per contract |) Test load 2.5 times] C/R/W | R/W (Part-4) - requirement working load as (Reaffirmed decided by Client. 2006) 1b) Safe load to be ~ llesser of the following] i) Two-thirds of final load at which total displacement attains a| lvalue of 12mm unless} otherwise specified. ii) 50% of final load a1 which total displace- ment equals 10% of pile diameter unless otherwise specified. Routine Load Test 1S:2911 | 18: 2911 External 1.5 to 2 pe. of Diestloadto | C/R/W | RW (Part) - total No. of piles in | be minimam 1.5 (Reaffirmed contract or Nos. as_|times working load. 2006) decided by Client ii) Maximum settle- ment at test load shall not exceed 112mm ualess other wise specified. siz swolorg pemsnpey Jo vonevaura|duy x03 yooqpuer] Ss00uiSuy TamsxouuySi. Check Parameters [Acceptance|Performance| Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client 9.2.2) Lateral Load Test on single Pile a | Initial Load Test 1S:2911 | 18: 2911 Tnternal [No. as per contractual] ) Test load 25 times] C/R/W | R/W Past-4) - requirement working load as (Reaffirmed decided by Client. 2006) b) Safe lateral oad to Jbe the least of the fol-| lowing (displacement being read at cut-off level of the pile): i) 50% of the final jload at which the total] isplacement increases to 12mm unless speci-| fied otherwise ii) Final load ae which the total displace- ment corresponds to 5mm unless specified otherwise. ii) Load cossespond- ing to any other displacement as per performance require- ments b | Routine Load Test 1S:2911 | 1S:2911 External 1.5 to 2 pe of )Testloadto | C/R/AW [RAV Part-4) - total No. of piles in | be minimum 1.5 (Reaffirmed contract or Nos. as_ times working load, 2006) decided by Client fii) Maximum settle- ment at test load shall not exceed 12mm unless other| wise specified. Si. Check Parameters ‘Acceptance|Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client 10 | HDPE DWC drainage pipes a | Dimension test TS 1: 14930 | External For cach source As Specified R R Part 1 & 2) b | Compression test TS 1s: 14930 | External For each source 450 N (min) R R art 1 & 2) ¢ | Shore Hardness D TS 1: 14930 | External Foreach source | Average shore R R (Part 1 & 2) hardness 48 hours d [Density test TS IS: 14930 | External For each source ‘As Specified R R (Part 1 & 2) T1_| Mechanical Coupler Ultimate Tensile Strength For each source > 565 Mpa R R 12 | High Tensile strands (HT) a | Dia of strand HTC wire 15.2 mm| TS [iS:14268-1993 External | Once per source/ | 1S:14268-1995 RW R/W MTC | Nominal mass of strand TS |[S:14268-1995 External | Once per source/ | 18:14268-1995 RW | R/W MTC ¢ | Modalus of elasticity TS |[S:14268-1995) External | Once persource/ | 18:14268-1995 Rw | RAW MIC d_| Breaking strength of strand TS [1S 1521:1972| External | Once persouree/ | 18:14268-1995 Rw RW MTC € | 0.2% Proof load TS [115211972] External | Once per source/ | 1S:14268-1995 R/W | R/W MTC £ | Elongation TS _[3$1521:1972[ External | Once per source/ | 1S:14268-1995 RW R/W MTC g_|1000 his relaxation properties TS ___[1S:14268-1995| External__| Once per source | _IS:14268-1995 R/AW__ | RAW 13 | HDPE ducts (107mm ID for 19k15, 86mm ID for 12k15) a | Density TS TS 2530 MTC Per Lot/Per Batch | 0.94-0.96 g/cm3 R R @230c oe spaloig jemsnpuy jo voREuaws2|duy 109 yooqpuEFY §199u/Sug [amxouuy leeSl. Check Parameters Acceptance |Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client b | Tensile strength at yield TS |BSENISO| MTC Per Lot/Per Batch | 20-260 N/mm* R R 527-3 ¢ | Elongation at yield TS [IRS concrete] MTC Per Lot/Per Batch | 7% (minimum) R R (BS EN ISO 527-3) bridge code- 1997(Adden- dum & cor rigendum slip no.5 Dated 19.11.2001) d_ | Mek flow index (IS: 2530) TS [appendix 1B] MTC Per Lot/Per Batch | 0.4-0.6 g/10 min, R R of IRC:18- (Temperature 2000 190°C under) € | Charpy impact strength of notched TS |BSENISO| MTC PerLot/Per Batch [At 23°C: 10 Kj/me| —R R specimen 179 At40°C: 4 Kj/m? £ ]Cofficient of Thermal expansion for [TS | DIN53 752] MTC Per Lot/Per Batch | 1.50°10-4/C R R 200°C-800°C g | Environmental stress crack resistance} TS ASIM MTC Per Lot/Per Batch | At 70°C: 192 hts R R D-1693 h | Thickness of the wall TS — [IRSconcretel MTC Per Lot/Per Batch | 2320.3 mmas R R bridge code- manufactured and 1997 (Adden- minimum 1.5mm dum & cor- after loss in the rigendum slip compression test no.5 Dated for duct size upto 19.11.2001) 160 mm OD i | Shore Hardness D TS |@SENISO| MTC Per Lot/Per Batch 3 sec- 60 R R (BS EN ISO 2039-1) 2039-1) minimum, 15 sec- 58 minimum Sl. Check Parameters Acceptance|Performance] Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor [Client 14 | PTFE Bearing 14.1 Physical Tests a_| Plan dimension TS Internal__| MTC for each lot Oto Smm R R b_ | overall height TS Internal | MTC foreach lot Oto 3mm R R ¢_| Flatness TS Internal | MTCforeachlor | 0.00041, L= R R Length is direction of measurement | Surface finish TS MORTH- |” Tnternal | MTC foreach lot [Ra<0.25pmas per] R R specifications 1S 3073 € [Load test vertical & horizontal includ] TS _| for sond and External | MYC foreach lot [A test load of 1.25 R R ing rotation capacity bridges latest times the design edition, IRC head their shall be 83 part I 100% recovery. f | Friction test TS External | MTC foreach lot | The sufficient of R R friction shall be less than of equal to 0.05 at the design load g | Form TS External | MYC foreach lot [Without dimples or| R lthe ratio of dimples to the gross area Se ieaan should Socbe mote than 25%, depth of cavity not more than 2mm h_ [Density at 23 22°C TS MORTH- External | MTC foreachlot_| 2.13 to 2.19 g/cc R R i_| Tensile strength at break TS (PegReatons for External MTC foreach lot_| 24 MPa (min) R R j_| Elongation at break TS ‘ee edition External MTC for each lot_| 300% (Minimum) R R k_ | Resistance to heat TS — | IRC85portl, | External | MTC foreachlot [No signof meling) — R R BS: 3784, BS: & loss in mass shall 6564 Pare 2 not exceed 0.5% ee SNPUT Jo uOREIUaWE|Ceuy 305 yoogpUEHY saeeuI3usT 2 & [omxouuy eeeSi. ‘Check Parameters [Acceptance Performance] ‘Testing Frequency Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor [Client 14.2| Chemical Tests — Cast Steel (For bearings grade 280-520 W) a | Chemical composition External | MC foreach lot | C-0.25% Max. R R External | MTC foreach lot_| Mn — 1.20 Max. R R External | MTC foreach lot_| Si—0.60 Max. R R External | MTC foreachlor | P-040 Max, R R External | MTC foreach lot_| S— 0.035 Max. R R 15:1050__/15:1030:1989 | sternal | MTC foreach lot _|_Ni— 0.40 Max. R R External | MTC foreach lot_| Cr—0.35 Ma: R R Bxternal__| MTC foreach lot_| Cu—0.40 Max. R R External_| MYC foreachlot_| Mo—0.15 Max. R R External | MTC foreach lot_| _V—0.05 Max. R R b_| Chemical test -Mild Steel liS 2062: 19991S: 2062 :1999| External | _MTC foreach lot_[Table-1 of IS: 206] R 15 | Brick Test a | Dimension Analysis 18:1077- [IS:1077- 1992] Internal | Once of 50 bricks | L= = 80mm, Cc Ww 1992 for 50000 bricks | W= + 40mm, H= 40mm b | Efflorescence Is077- | 1S:3495 External _ | External lab Report | Shall be Moderate R RW 1992 (Part-3) per lot c | Compressive strength 1s1077- | 183495 Internal [Once of 15 bricks for| Min. 7.5 N/mm? @ Ww 1992 (Pact-1) 50000 bricks d | Water absorption Is1077- | 1S:3495 Internal [Once of 15 bricks for! Maximum 20% c Ww 1992 (Part-2) 50000 bricks Si. Check Parameters [Acceptance|Performance| Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor [Client 16 | Strip Seal expansion joint a_| Hardness TS TS MTC MTC for each lot TS R R b_| Tensile Strength TS TS MIC MTC for each lot TS R R ¢ | Blongation at Break TS TS MTC MTC for each lot TS R R d_| Tar Propagation Strength TS TS MIC MTC for each lot TS R R @ Longitudinal TS TS MTC MTC for each lot TS R R (i) Transverse TS TS MTC MTC for each lot Ts R R e_| Shock Elasticity TS TS MTC MTC for each lot Ts R R f_| Abrasion TS TS MTC MTC for each lot TS R R g | Residual Compressive Strain TS TS MTC MTC for each lot TS R R (2h/70°C/30% Strain) h [Ageing in hot air TS TS MTC MTC for each lot TS R R (@ Mas. change in hardness TS TS MTC MTC for each lot TS R R (b) Max, change in Tensile strenght TS TS MTC MTC for each lot TS R R (Q Max. change in elongation TS TS MTC MTC for each lot TS R R i | Ageing in Ozone TS TS MTC MTC for each lot TS R R (24h/50 pphm/25°C/20 %) strain |_| Swelling behaviour in oil TS TS ‘MIC ‘MIC for each lot TS R R (@) Volume change TS TS ‘MIC MTC for each lor TS R R (b) Change in hardness TS. TS MIC MIC for each lot TS R R kk | ASTM oil No.3 TS. TS MTC MIC for each lot TS R R @ Volume Change TS TS MTC MTC for each lor TS R R (b) Change in hardness TS. TS MTC MTC for each lot TS R R 1_| Cold Hardening Point TS TS ‘MIC MIC for each lot TS R R eet susolorg [emsnpyy jo vonemuauuerdeyy 303 Yooqpury] s499u/Suz yeanxauuy seeInspection & Test Plan- Railway Embankment Work SL. Check Parameters [Acceptance|Performance] ‘Testing Frequency Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client 1_| Barthwork/Subgrade a | Grain Size analysis TS 18 2720 Internal | Two tests per 3000 | As required G R/W (Part-4) cum of soil b | Atterberg Limits TS 1S 2720 Internal | Two tests per 3000 | As required G R/W _(Part-5) cum of soil ¢ [MDD & OMC TS 18 2720 Internal | Two tests per 3000 | Min. 15.2 KN/cum c RW (part-8) cum of soil | for embankment & Min. 17.2 KN/cum for subgrade d_ | Moisture content TS 1S 2720 Internal {Iwo tests per 250 cum) Within + 2% of c R/W _{part-2) of soil omc e | Free Swelling Index TS 18 2720 Taternal AS Required Less than 50% c RW (part-40) F | Soaked CBR TS IS 2720 External | Two tests per 3000 Min. 10% R RW (Part-16) cam of soil @ | Field Density TS 1S 2720 Internal [One test per 1000 m*| 98% of MDD for S RW (Part-28) area for embankment| embankment & 500 m? area for subgrade SI. Check Parameters ‘Acceptance [Performance] Testing Frequency Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client 2_| Blanketing material. (Stone Dust) Sieve Analysis of Blanketing Material | TS TS 2386 Internal [One test per 500 cum] Grade- AIS S W (part-1) of quantity | Sieve - % passing 40 mm - 100 20mm - 100 10mm - 95-100 4.75 mm - 92-99 2mm - 65-90 600 mic - 33-50 425 mic - 40 212 mic - 16. 75 mic - 00-12 | Uniformity coefficient From Graph TS Internal [One vest per 500 cum] UNIFORMITY C Ww of quantity COBFFICIENT (Cu), IN NO CASE] SHOULD BE LESS THAN 7 ¢ | Coefficient of curvature From Graph] TS Taternal [One test per 500 cum | COEFFICENT c Ww of quantity —_ | OF CURVATURE, (Co) SHOULD BE IN BETWEEN 1 AND 3 d_ | Relative Density TS [182720 pare] Internal | One test per 200m | Relative Density | C/R | R/W 14, 28 & 29 area should be at least 70% iad sxoaloag [einsnpuy Jo oRmUaUTa|dury 105 YooqpuEsy 53001 yamxeuny LeeInspection & Test Plan - Road Work ‘st Check Parameters [Acceptance|Performance] Testing Frequency ‘Acceptance | Agency/ Scope of 0. Standard | Standard Criteria Inspection Contractor | Client 1_|Barthwork/Subgrade Grain Size analysis TS IS 2720 Internal | Two tests per 3000 | As required € R/W Part-4) cum of soil “Atterberg Limits TS 18 2720 Internal | ‘Two tests per 3000 | As required c RW (Part-5) cum of soil MDD & OMG TS 1S 2720 Internal | ‘Two tests per 3000 | Min. 15.2KN/cam Cc RW (patt-8) cum of soil for embankment &| Min, 17.2kN/cum : for subgrade Moisture content TS 15 2720 Internal — [Two tests per 250 cum] As required c RW (part-2) of soil Free Swelling Index TS 1S 2720 Internal ‘AS Required Less than 50% c RW (part-40) Soaked CBR TS 1S 2720 External | Two tests per 3000 Min. 10% R R/W (Part-16) cam of soil Field Density TS 1S 2720 Internal [One test per 1000 m*| 95% of MDD for e RW (Part-28) area for embankment| embankment & & 500 m? area for | 97% for subgrade subgrade 2_| Granular Sub base (GSB, Gr-I) Gradation TS MORTH | Internal | One test per 400m? [As per mozth Table] C Ww Clause 401 400-1 Ten Percent fines Value TS BS:812 Taternal Once Per Source | Minimum 50kN c Ww Part-I) ‘Auerberg Limits TS 1S 2720 Internal | One test per 400 m Max. 6 G w (Part-5) Water absorption Test TS 1S 2386 Internal ‘Once Per Source Max. 2% c w Part-3) Sl. Check Parameters Acceptance|Performance| Testing Frequency Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Clieat Moisture content prior to compaction! TS 1S 2720 Taternal | One test per 400 m | Within 1 to 2% Cc Ww P P P (Part-2) below the OMC Soaked CBR TS 1S 2720 External ‘As Required Minimum 30% R RW Part-16) Density of compacted layer TS 1s 2720 Internal | One test per 1000 [98% of MDD ¢c Ww (Part-28) Sqm compacted area 3__| Wet Mix Macadam (WMM) Gradation TS 1S 2386 Tnternal [One test per 200 cum] MORTH Table c Ww (Part-1) of aggregate 400-13 ‘Aggregate Impact Value TS 1S 2386 Tnternal | One testper 1000 | 30% Maximam Cc Ww (Part-4 cum of aggregate Combined FI & EI TS 1S 2386 Taternal [One test per 500 cum) 35% Maximum Cc Ww (Part-1) of aggregate Atterberg Limits TS 1S 2720 Internal [One test per 200 cum Max. 6 c Ww (Part-5) of aggregate Density of compacted layer TS 1S 2720 Internal One set of three | 98% of MDD oi Ww (Part-28) tests per 1000 m? compacted area 4 | Prime Coat/Tack Coat “Temperature of binder TS By Digital | Internal Regular at close 20° to 70° CAW/R | W/R [Thermometer] intervals Rate of Spray TS Trey Test | Internal | Three tests perday | 0.60kg/m*for | C/W/R | W/R prime coat & 0.20kg/m? for tack coat 3 _| Dense Bituminous Macadam (DBM)/ Bituminous Concrete (BC) Gradation TS TS 2386 Internal JOne test per 400mt off MORTH Specifica] C/W/R | W/R (Part-1) mix subject to min. 2 |tions Table : 500-10 ests per day per plant] (Grading-1) syoaloig jemsnpuy Jo voReUaUD|duyy 103 Yooqpuefy ssa9u/Hu5] [amxouuy zzSI. Check Parameters [Acceptance |Performance] ‘Testing Frequency ‘Acceptance | Agency/ Scope of No. Standard | Standard Criteria Inspection Contractor | Client Combined FI & EI TS TS 2386 Internal [One test per 350 cum] Max. 35% cw | WR (Part-1) of mix aggregate. Aggregate Impact Value TS 1S 2386 Internal [One test per 350 cum] Max. 27% ciw | W/R (Part-4) of mix aggregate. Water absorption Test TS 1S 2386 Internal | One test per source Max. 2% caw | w/k (Part-3) of aggregate Soundness Test TS 1S 2386 External | One test per source | Max. 12% with R RW (Pare-5) of aggregate sodium sulphate & Max. 18% with magnesium sulphate Plasticity index TS 1s 2720 Internal | One test per source Max. 4% caw RAW Part-5) of agerepate Quality of binder TS 181201 to | MIC/ One test per lot 60/70 grade RAW | RAW 1S 1220 External ds :73) Binder content TS | Asrequired | SiteLab | One test per 400 mt | Min. 4% by cw | WR lof mix subject to min weight of mix 2 tests per day per plant Stripping Value TS 1S 6241 Internal/ | One test per each | Min, retained R/W | R/W External source coating 95% Water Sens: TS AASHTO | Internal/ | One test per each Min. 80% RW | R/W 283 External source “Marshal Stability & voids analysis TS ASIM Internal | One test per 400 mt | Min, KN at RAW | RAW of mix, 60°C Density of compacted layer TS 1S 2386 Internal | One test per 700m? | Min. 98% of Lab | R/W | R/W (Part-3) area Density Abbreviations : C= Conduct, R = Review, W=Witness, MIC= Manufacturer Test Certificate , TS = Techaical Specification Inspection & Test Plan - Road Work Si. Description of Materials Character-| Type of | Frequency of [Acceptance Criteria] Reference Scope of No. istics Check Check Documents/ Inspection Specification | Contractor | Client 1_| Incoming Inspection of Raw Materials and Bought Out Items a_| Steel plates & Rolled Sections Dimension [Measurement] 100% Asperdrawing [MTC, Challlan, Lab] W R Physical Ap- [Visual Inspec-| 100% No pitting & heavy | Test Report & Site pearance tion rustin, Register Structural steel girder conforming to FE 410B(O) as per 1S: 2062- 2011 |Grade B and for cross fame the steel shall confirm IS: 226-1975 Mechanical for steel bridge. Tests - UTS, Built up sections Yield stress, elongation & bend test & Impact test Verify MTC Chemical Verify MTC Properties MTC-100% and Lab Test: each Invoice. are made from hot rolled plates One sample for] confirming to ASTM A 572 Gr 50 (345 MPA) steel hot rolled sections except beams are mill section complying with IS 2062 for 240 MPA yield for station structures. ce snpuy Jo uonequautoyduy 30 yoogpurgy s32eu/Sus] sioaloag, amnsouuy 1stSl. ‘Description of Materials Character- |" Type of] Frequency of |Acceptance Criteria] Reference Scope of g No. istics Check Check Documents/ Inspection Specification | Contractor | Client UT Visual UPatsite: | As per ASTM 578 One sample for|level B & Test Report] each Heat No in >/= 20mm p thk. & b | Welding Filler Wire/Electrodes/ [Specification] _Challan& 100% For GMAW: SFA/ | Site Register/ Ww R g Flux ete, Batch Test AWS A 5.18 ER-70S- Batch Test = Certificate /For SAW: SFA/AWS| Certificate 8 5.17 EM-12-K/For & SMAW: SFA/AWS 5.1 3 7018. > | HSFG Bolts, Nuts & Washers Dimension |Measurement] One sample in] As per drawing MTC, Challlan, Labl W R/W fe every lot ‘Test Report & Site 2 Register g Mechanical | Verify MTC | TC-100% and | IS: 1367 Part-II & 8 Properties Lab Test: One Test Report Bo sample per g Invoice . 2, d_ | Primer & Paints Specification] Batch Test 100% | Client Specification/| Site Register/ Ww R 5 Certificate Approved technical Batch Test & literature of Certificate 2 manufactaren = e | Stud Shear Connector Dimension |Measurement] Random | Client Specification/ |MTC, Challlan, Lab] W R 3 Relevant Code. | Test Report & Site 8 Register * Mechanical | Test MTC-100% Properties | Certificate | and Lab Test: One sample for each Batch/ Lot. si. Description of Materials Character-] Type of | Frequency of [Acceptance Criteria] Reference Scope of No. istics Check Check Documents/ | __Inspection _| Specification [| Contractor | Client 2_ | Pre-Manufacturing Process a_ | Procedure Qualification Record SAW Visual, NDT] 100% [AWS D1.1/Technical[Inspection Reports] Wo [W&R| QR) and DT Specification | / NDT Reports / Lab Test Certificate! SMAW | Visual, NDT[~ 100% and DT GMAW | Visual, NDT! 100% and DT | Welding Procedure Specification SAW | Verify Ap- 100% [AWS D1.1 /Technicall Approved WPS wo «WER (wPs) proved POR Specification SMAW | Verify Ap- 100% proved POR g GMAW | Verify Ap- 100% 8 proved PQR 5 ¢ | Welder Qualification Test Visual | Verify Ap- 100% AWSD1.1/ | Data Sheet/NDT wo oiWerR) proved WPS Technical Reports/Welder's Specification | Certificate & ID Card NDT | Verify Ap- 100% proved WPS 3_| Manufacturing Process a | Marking Dimension [Measurement] 100% ‘As per approved [Dimension Report| W R drawin, ‘Marking _|Measurement| 100% b | Canting Dimension [Measurement] Random | As perapproved [Dimension Report] W R drawing ¢ | Layout of Components & Joints Dimension | Visual & 100% As per approved [Inspection Repors| Wo [W&R| Measurement] drawing ieSl. Description of Materials Character- | Type of | Frequency of |Acceptance Criteria] __ Reference Scope of No. istics Check Check Documents/ Inspection 7 Tea - Specification _{ Contractor | Client igs, Fixtures & Templates Dimension | Visual & 100% As per approved Approved Drawing) W’ R/W _ ‘Measurement drawing e |Fitup Edge Prepa-| Visual 100% ‘As pet approved | Fit up inspection Ww O(W&R ration of drawing Report Joints Dimension [Measurement] 100% ‘Temporary | Visual 100% Support to lavoid Distor- tion £ | Welding Welding | Approved | Random — As per approved WPS| Internal inspection] W |W&R Parameters | WPS / Report (Carteat, | As per job Voltage, | requirement Travel Speed| etc) |Consumables| Specification | 100% Electrodes, Filler Wire, Flux etc) Welder's | Approved 100% ldentification| —Welder's Certificate & ID Card Approved | Visual 100% wes g. | Final Inspection Dimension |Measurement] 100% ‘As per approved | Final Inspection Ww W/R drawing Report/Approved Drawing Si. Description of Materials Character-| Type of | Frequency of [Acceptance Criteria] Reference Scope of No. istics Check Check Documents/ Inspection Specification | Contractor | Client VisualIn- | Visual 100% spection Distortion [Visual & Mea| 100% surement Alignment [Measurement] 100% Weld Size | Weld Gauge | Random Finishin, Visual 100% h [NDT DPT Visual 100% for | AsperAWSDI1 | Site Register/ wo [W&R Groave Joints DPT Report & 20% for Fil- let Joints. UT Visual 100 % for bevel! As per AWS D1.1 Site Register/ Ww AWW & Ry butt joint in UT Report case of Bridge Girder RT fee Random as per| As per AWSD1.1 | Site Register / wo [WER available posi- UT Report tion in case of Bridge Girder only [Hole Match-| Visual Random ing Camber Visual & Mea] 100% surement Seraightness [Measurement] 100% 4 | Surface Preparation and Painting a_ | Painting Primer ]Avg DFT (As] Minimum 3 ‘As per contact [Painting Inspection Ww R per manufac-| point for each | __ specification Report turer specifi- | mark No cation) Pee sioaforg jensnpuy jo Uoneyeiaydusy 105 yooqpuepy sz99uiBu, [unxouuy: seeS Description of Materials Character- | Type of | Frequency of [Acceptance Criteria] Reference Scope of 8 istics Check Check Dosameans/ Inspection & Specification [Contractor | Client Final Coat 3 | Match Marking latch Madl Visual In- | Visual Random | As per approved [Dispatch Clearance] W R spection drawing & contzol Report assembly & Abbrevi R= ‘i 7 3 reviations Be Reem, “Wiese RW ~ Review or Witness, DFT ~ Dry Film Thickness, UT — Ultrasonic Test, DT-Destructive test, £ graphy Test, — Dye Penetration test, NDT-Non Destructive Test, MTC — Manufacturer’sTest Certificate S 2 e 8 & = z 5 2 a § 2, a x & ANNEXURE-IL PROJECT : Contractor's Name PACKAGE : FABRICATION & ERECTION NI OF STRUCTURAL SHED FIELD QUALITY PLAN ITEM; STRUCTURAL STEEL DOC. NO. Si. Characteristics Type of] Instruments [Class of] Quantum/ | Referece Docu-| Formatof | Remarks No. Check Check | Frequencey |ment/Acceptance| Record of Check Standard 1.0 | RAW MATERIALS 1.1 | Ensure that the raw materials is as per | R/V B 100% | Test certificates &| Site Register specification 1S code 1.2 | Ensure that the raw material is free v B 100% = ms from defects like cracks, seams , laps , . laminations and pittin, g 2.0 |MARKING AND CUTTING g 2.1 | Ensure that the marking are done as per] V/M | Stee! Tape B 100% | Approved drawing| Site Register 5 requirement H 2.2 |Checke that cutting are done as per the | V -do- B 100% -do- -do- requirement 3.0 | FIT UP 3.1 | Ensure proper fit up before welding V/M |Measusing Tape] B 100% Approved dig | Site register 3.2 | Check the measuring of parts before v -do- B 100% -do- -do- welding as per Approved drawing 3.3 | Check that the gap is minimum for all | V/M -do- B 100% -do- -do- fillet welds < Imm 3.4 | Ensure that the butt weld joints are V/M | Measuring B 100% -do- -do- properly aligned and the offset is not Tape/ Guage to exceed 10% of the thickness of the thinner part of the joint. Maximum permitted value is 3.2 mm, 8 8SL Characteristics ‘Type of| Instruments ]Class of] Quantum/ | Referece Docu- | Formatof | Remarks No. Check Check | Frequencey ment/Acceptance| Record of Check Standard 4.0 | PREHEATING: 4.1 | Ensure pre heating is carried out V_ | Thermo chalk | C 100% Approved — | Site register wherever applicable using appropriate drawing & Tech- method nical Specifications| {WPS 5.0 | WELDING: 5.1| Ensure that the qualified welders and | V A 100% ASME Test report qualified welding procedures are used SEC. IX for all welding 5.2 | Ensure that the welding consumables v B 100% | Approved WPS/ | Site Register are as per Procedure Approved by Drawing Client 5.3 | Ensure proper edge preparation wher- |v [Bevel Protactoy © 100% -do- -do- ever required. 5.4 | Ensure Proper sequence of welding v B 100% -do- -do- 5.5 | Check that the temporary attachment/ | V B 100% i — weldments are removed by grinding before paintin 6.0 | NON DESTRUCTIVE TESTING 6.1 | Carry out MPT / UT / DPT as ap- V_ | Testing Equip-} A 100% |ASMESEC- VIII} — Report licable ment DIV-1éII 7.0 [CLEANING AND PAINTING 7A | Ensure that the surface is cleaned and | V C | Appendes-IIT| ‘Technical Speci- | Site register, painted 2s specification. fications, Method | Protocal Sheet Statement 7.2 | Paint thickness checking after each coat] M | EleoMeter |B Random -do- Protocal Sheet) Say, DFT for Ipimer 50 miczoa| & final DFT to be 150 micron st. Characteristics Type of| Instruments [Class of] Quantum/ | Referece Docu- | Format of | Remarks No. Check Check | Frequencey ment/Acceptance| Record of Check Standard 8.0 | FOUNDATION CHECKS : 8.1 | Ensure availability of permanent v c 100% = — Bench Mark. 8.2 | Check the foundations are castas per. | M | Measuring B 100% [Approved Drawing} — L.-01 requirement. tape 8.3 | Check the orientation of the founda. | V c 100% Approved dig | site register | Civil Agenacy tion 8.4 | Check the top level of foundation v/M | Levelinsteu- |B 100% | Approved Drg/ | L-01 | Civil Agenacy pedestals with respect to permanent ment Techaical Specifi- benchmarks cations 8.5 | Check the center to center distance M_ |Measuring Tape] B 100% Approved Dig | L-01 | Civil Agenacy of column foundation pedestals with respect to the reference axis. 8.6 | Check the diagonals beeween column | M_ |Measusing Tape| B 100% Approved Dig | L - 01 foundations pedestals. 9.0 | ERECTION COLUMN PRE - ASSEMBLY v c 100% _ _ CHECKS : 9.1 | Ensure cleaning of Base plate and M_ [Measuring Tape] B 100% Approved Dig L-02 HSFG bolt area 9.2 | Check the Individual columa pieces for] V B 100% Approved Drg identification. Match mark, column No & condition of the column joints. 9.3 | Ensure columas are pre-assembled as. | V 100% per match marks and centre line already punched on the columa pieces and re- spective splice plate wherever applicable. 9.4 | Check camber, sweep, match mark M_~ [Measuring Tape) A 100% Approved Drg | 0L-03 and total length after trial assembly of columns. Bet isupuy jo vonuwawolduy 10} Yoogpuery szeouiug & qremxauuy ox4Si. Characteristics ‘Type of | Instruments [Class of] Quantum/ | Referece Docu- | Format of | Remarks No. Check Check | Frequencey }ment/Acceptaned Record of Check Standard 10.0 | ROOF TRUSS PREASSEMBLY CHECKS. 10.1| Ensure roof trusses are pre-assembled | V _ B 100% Approved Drg L-04 as per match mark and C-G line punched on top and bottom angles. 10.2| Check the following L-04 a) Camber M = [Measuring Tape! B 100% Approved Drg b) Sweep M_ [Measuring Tape! B 100% Approved Drg ©) Alignment of CG line punch mark | M [Measuring Tape] B 100% [Approved Drawing! and the match mark given on the top & bottom angles. Permitted deviation] in C.G line matching is + /—5mm d) Horizontal level of assembled roof | M_ Measuring Tape! B 100% Do truss with water level with respect to centre line punch mark on end gusset plate face. Permitted deviation is +/- 5mm. ©) Total length of assembled roof truss] M_ [Measuring Tapel B 100% Do between faces of end gusset plates at top & bottom (Permitted deviation is +/- 5mm. £) End plates are aligned and in one M [Measuring Tapel B 100% Do plane on both the ends. 10.3 | Ensure foundation bolts are free from | V B 100% Approved drg | Protocol | Cube Comp. damage and foundation bolt packets are strength Check- free from defects and foreign material. ing 10.4| Ensure the level of bottom of base v B 100% -do- Protocol plate. 10.5 | Ensure proper orientation of column. v B 100% -do- Protocol Si. Characteristics ‘Type of | Instruments |Class of] Quantum/ | Referece Docu-| Formatof | Remarks No. Check Check | Frequencey |ment/Acceptance, Record of Check Standard 10.6 | Ensure the center line of base plate Vv B 100% ‘Approved dig | Protocol | Cube Comp. coincides with foundation pedastal axis strength Check- (both in X & Y axis ) ing 10.7| Ensure the erection of horizontal v B 100% -do- beams / girders and vertical bracings. 10.8| Check elevations of columns M Aato level A 100% - do- L-06 Plumb bob / theodolite 10.9| Check verticality of columns. M A 100% -do- 1-05 10.10| Ensure proper tightening of foundation| c 100% -do- Protocol bolts with lock muts. 10.11] Ensure grouting of the base plate M/V| Plumbbob/ |B 100% Approved Drg, L-07 bottom after ensuring verticality of theodolite columns. '10.12| Ensuze erection of second pieces of all] V G 100% Approved Drg columns. {10.13| Ensuge erection of interconnecting M q 100% -do- members. 110.14] Ensure proper butt welding at Moment | M. B 100% -do- connection s and erection weldin; 11.0 | Ensure the following during the erection| of roof trusses a) Proper handling to avoid damage & | V C 100% = distortion to assembled trusses. b) Aligament of box: holes berween v Spit Tewls | ig 100% _ ater Level columns and truss gussets. Rovian ©) Slope of truss as per drawing: he | PORE ene B 100% Drawing 6) Tightness of bolts. vM B 100% - ©) Truss to truss connecting members | V c 100% Drawing including puslins, ore spolorg [eensnpuy Jo voneuaWaiduyy 103 yooqpurpy s99u/Tug TL anxouuy WeSi. Characteristics ‘Type of | Instruments [Class of | Quantum/ | Referece Docu- | Formatof | Remarks No. Check Check | Frequencey ment/Acceptancd Record of Check Standard 12.0| WELDING & NDT a) Welder Qualification Test V/T A 100% | ASME SEC—IX | Test Report b) Ensure recommended welding con- | -V A 100% | Approved list of | Material Pass- sumable and methods are employed Consumable | ing register ©) Ensure following NDT Checks are Sice register carried out on Fabrication & erection| welds. O1. Weld visual check v B 100% | ASME SEC-V & VI 02. Back gauging PT for Butt welds | V A Random -do- 03. Final PT Checking v A Random, -do- NDT REQUIREMENTS FOR RT / UT / PT’ / MPT ON WELDS AS COLUMNS, CRANE GIRDER FRAME, BEAM, TRUSS ETC. 1.00 BUTT WELDS 1.01 100% DP for root run after back gouging, 1.02 On carbon steel where thickness is greater than 32mm , 100% UT shall be carried out, 20 FILLET WELDS: 2.01 25% weld length on crane girder and column shall be subjected to Magnetic Particle Testing, 2.02 On all other fillet welds, Penetrant ‘Test shall be done on minimum 5% weld length at random with minimum of 300mm at each location. PREPARED BY REVIEW BY APPROVED BY Name Singnature ANNEXURELII ITEM —: STRUCTURAL STEEL SUB-ITEM : FABRICATION & Contractor's Name FIELD QUALITY PLAN (TOLERANCES) DOC. NO. ERECTION 1.0 ERECTION TOLERANCES A) PERMISSIBLE TOLERANCES IN ERECTED STEEL COLUMNS : +/-15MM B) PERMISSIBLE TOLERANCES IN ERECTED STEEL TRUSSES: +/-10MM C) PERMISSIBLE TOLERANCES IN CRANE GIRDER AND RAILS : +/-5MM. D) VERTICALITY OF COLUMN : 1MM PER METER (MAX. 10MM) ALL TOLERANCES FOR ABOVE SHELL BE AS PER APPROVED DRG/ IS -12843 Thickness of thickest part at the point of Welding using other than low hydrogen | Welding using low hydrogen welding elec-_ welding electrodes welding electrodes IS -2062 trodes or sub- merged arc welding (IS -2062) Upto 20 mm (Including) None None Over 20mm to 40mm (including) 66°C 20°C Over 40mm to 63mm (including) Not allowed 66°c Over 63mm Not allowed 110°C PREPARED BY REVIEW BY APPROVED BY Name Singnature wee uy Jo UORIUaLIa|duty 30} Yooqpuryy s:00U/3uy 5 ereANNEXURE-IL Contractor's Name FIELD QUALITY PLAN ITEM : STRUCTURAL STEEL SUB-ITEM : FABRICATION & ERECTION DOC NO. REV. NO. SHEET NO. ACCEPTED DEVIATIONS IN FABRICATED STEEL STRUCTURES a Characteristics Deviation / Tolerance 1.0 | COLUMNS a) Deviation in length ‘L? measured from bottom surface of the column footings. to the group of holes for trusses, fasteners, collarbeams, purlins and other elements to be connected to column. When Lis under 10m 5] 2 Ton When L is over 10m + /- 15mm b) Deviation in distance ‘L ‘ from bottom surface of the column fotting to the top of crane brackets, When L is under 10 m + /- 5mm When L is over 10m + /- 10mm ©) Deviation in distance from bearing surface of the bracket to the first| + /~ Imm fastener of the element to the connected to column, 4) Deviation in distance between any group of holes for connection of |+ /-2mm bracings to column, ©) Sag of column element (curvanure) 1/1000 of length of element but not moze f)_ Difference in web depth of column i) Atsplice joint +7 22mm if) Atany other location + [10mm 2) Deviation in distance from supporting surface of milled end of the [+ /-3mm dispatch element of column to the cleat or seating plate for fastening of collar beams, purlins, girders. Etc(Fish plates, brackets) Si. Characteristics Deviation / Tolerance No. 2. | TRUSSES a) Deviation in span “L of the truss between end erection holes in gussets of supporting units or between external planes of supporting, gussets or angles when trusses are resting on brackets or supports: ‘When Lis under 25 m + 7mm ‘When Lis over 25m 1/2500 of leagth but not more than 10mm. b) Deviation in distance between the centres of holes or webs of angles | 3mm for fastening bracing & purlins, monitors, etc. ©) Deviation in distance between the first row of erection holes and the | 1mm bearing surface at cleat or seating plate. 4) Distance between holes for fasteners to top and bottom chords of | 3mm trusses on supports. ©) Sag of separate elements between node points, 1/1500 of length of element but not more than 10mm. 3. | BEAMS a) Deviation in span L of beams between end erection holes. Outer Surfaces of end plates: When L is under 25m = 10mm When T is over 25m £ 1/2500 of length but not more than 15mm. 'b) Deviation in the height of beam as measured from the bearing 3mm surface to the top of upper flange. ©) Deviation in distance between the group of holes for fastening of | £ 3mm purlings monitors, bracings, bracing girders ete. a) Sag (Curvature) of the grider dispatch member. 1/1000 of length but not more then 15mm 4, [ELEMENTS OF FRAME WORK BRACINGS, PURLINS ETC. a) Deviation in distance between end erection holes, determining the span_of elements. 3mm b) Sag of dispatch members 1/1000 of length but not more than 15mm. ©) Deviation in distance between the groups of erection holes of the | + 3mm element. @) GratingsStair / Railings , ladders ete. = 12mm ee msnpuy Jo vontiwewua/dusy 20} yooqpuesy sx99UBUs FP & TL amxouuy:SI. Characteristics Deviation / Tolerance No. 5._| SHOP ASSEMBLY (BEFORE DESPATCH FOR ERECTION) a) Columns weighing more than 20T Every first and further every tenth set of identical structure to be put fo b) Roof trusses of 30 M or more span coatrol assembly. ©) Crane girders with span more than 18M Number of erection bolts shall be at least 30% of the total No. of holes d) Bunkers ACCEPTED DEVIATIONS IN HOLES FOR BOLTS Si. Characteristic Deviation Tolerance of Deviation in each group No. 1. |) Deviation of dia holes for rivet and bolts ) Upto 16mm +imm No limit i) Over 16mm + 15mm b) Deviations of dia of turned and fitted bolts: Upper limit : +0.125mm No limit Nominal dia of bolts and holes Lower limit : 0.00 2. | Ovalness @ifference the greatest and lesser dia) i)_Up to 16mm hole dia +imm No limit ii) Over 16mm hole dia +1.5mm 3. | Deformity in size greater then 1.5mm and cracks in the Not permitted edge of holes. 4. | Misalignment of holes in separate plates in the joints: ) Uptoimm Upto 50% ii) From 1 to 1.5mm Up to 10% NOTE : Burrs in holes shall be removed, the depth and width of countersunk hole shall not deviate from the standard by more than 1.5mm. PERMISSIBLE FABRICATION DEVIATION OF STEEL STRUCTURES Si. ‘Types of Structures and Tolerance No. Constructions 1 COLUMN a) ‘Assembly Fits O.imm Base plate and column ») Frame joints 2.0mm, ° Web and flange 13mm ¢) Web and stiffeners 1.5mm } Flange & Stiffeners, Intermediate stiffeners & Bearing stiffeners: 1.5mm 8 Cap plate & column O.imm 2 Crane girder seat O.imm, ») ‘Beam brackets 2.0mm, 2. BEAMS a) Web and flange 15mm ») Web and Stiffeners 1.5mm } Flange & Stiffeners, Intermediate stiffeners & Bearing stiffeners 15mm 3. CRANE GIRDER 5 Web and flange O.imm, ») Web and Stiffeners Oimm, 2 Flange & Stiffeners, Intermediate stiffeners & bearing stiffeners. O.imm, 4. BUNKERS & HOPPERS a) Ring beam and Wall 15mm, ») Stiffeners and Walls 15mm °° Stiffeners and Ring beams 1.5mm 4) Deflection of straight section of compression chord from the 1/500 of span but plane of truss, collar beam or girder not more than 10mm 5. PURLIN Deviation in distance between puslins. 5mm ore saoouug, sioelorg jemsnpuy jo wonwusua}duiy 103 jooqpuy qromxouuy: LeTOLERANESS IN ERECTED STEEL STRUCTURS SI. Description “Tolerance No. 1.0 [ERECTED STEEL COLUMNS i) Deviation of column axis at foundation top level with respect to true axis ) In longitudinal direction + 5mm b) In lateral direction + 5mm ii) Deviation in the level of bearing surface of columns at foundation top with respect to true level| + 5mm ii) Out of plumb ness (verticality) of columa axis from true vertical axis, as measured at column top. a) For columns without any special requirements. 1) up to and including 30m height £ H/1000 or = 25mm whichever is less 2) over 30m height £ 1/1200 or £ 35mm whichever is less b) For column with special requirements like cranes or such similar requirements, 1) Up to and including 30m height = H/1000 or + 20mm whichever is less 2) Over 30 m height = H/1500 or + 25mm whichever is less iv)_Deviation in straightness in longitudinal and transverse of column at any point along the height.| + H/1500 or + 10 mm whichever is less v) Difference in the erected positions of adjacent pairs of columas along length or across width of) 5mm building prior to connecting trusses / beams with respect to true distance. vi) Deviation in any bearing or seating level with respect to true level. = 5mm vil) Deviation in difference in beating levels of a member on adjacent pair of columns both across | + 5mm and along the building, 2.0 [ERECTED STEEL TRUSSES 1) Shiftat the centre of span top chord member with respect to the vertical plane passing through] + 1/250 of height of truss in mm at the centre of bottom chord. centre of span or + 15mm whichever is less i) Lateral shift of top chord truss at the centre of span from the vertical plane passing through the| + 1/1500 of span of truss in mm or centre of supports of the truss whichever is less ii) Lateral shift in location of truss from its true axis in plan 10mm iv) Lateral shift in location of purlin from true position = 5mm ¥) Deviation in difference or bearing levels of trusses from the true £ 1/200 of span truss in mm or + 20mm whichever is less si. Description Tolerance No. 3. [ERECTED CRANE GIRDER AND RAILS. D)_ Shift in the centre line of crane rail with respect to centre line of web crane girder. = {(web thk in mm)+2mm}/2 ii) Shift in plan of alignment of crane sail with respect to true axis of crane rail at any point. 5mm| iii) Deviation in crane tack gauge with respect to the gauges 2) For track gauge up to and including 15mm 5mm b) For track gauge more than 15m £ [5 +0.256-15)}mm subject to a maximum of + 10mm where S in meters is true track gauge. iv)_Deviation in the crane rail level at any point from true level =10mm v) Difference in levels between crane track rails at. a) Supports of crane girders 15mm b) Mid span of crane girders 20mm Wi) Relative shift of crane rail surface at a joint in plan and elevation. 2mm subject to grinding of surfaces for smooth transition PREPARED BY REVIEW BY APPROVED BY, Name Singnature Bre sioolosg jomsnpuy Jo voRMLaW[dwy 10} yoogpuryy ss90uKFUg, Tramssuuy 6beANNEXURE-II PROJECT STRUCTURAL STE! . PACKAGE. : STRUCTURAL S' Contractor's Name DOCNG : AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECK Classification of Checks Class of Check Inspection agency ‘Accepting Agency Disposition Authority Critical Exection Engineer & QA/QC | bend of QA/ QC CLIENT Bagineer Major Erection Engineer + Task Head of Execution dept. CLIENT performer Minor Task performer Erection Engineer CLIENT ost ‘Types of Check : (@)_R ~ Record Verification (b) V—Visual Check (Q P=Physical Check (@ M-—Measurement ( T-Test Critical: A, Major: B, Minor: C NOTE: 1. Quantum of check shall be 100% for all characteristics unless otherwise mentioned in reference documents/ Quality Plan. 2. QA is also authorized to carry out surveillance in any of the “B” and “C” Category of checks & Erection Engineer is authorized to carry out sur- veillance in any of the ‘C’ category checks at his discretion. In case of non-conformity, accepting authority shall ensure disposition of non-conformity. Before acceptance, the same shall be reflected in log sheet / protocol. ‘N category checks are Customer hold points (CHP). All Instruments used for Checking should have valid Calibration Certificate. aR saoforg [emsnpuy jo uonLIuaLua|dusy 404 Yooqpuryy §.x99uiSus