Quality Assurance Plan for Kerala State Transport Project-II

TP-II RKI Package IV / 3- QUALITY ASSURANCE PLAN
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NAME OF THE PROJECT

KERALA STATE TRANSPORT PROJECT-II
RKI-IV/3- Rehabilitation and Upgradation of Pathanamthitta- Ayroor,
Muttukudukka-Illathupady, Muttukudukka-Prakkanam, Prakkanam-
Elavumthitta, Kulanada- Ramanchira, Thannikuzhy-Thonniamala Roads in
Pathanamthitta District ( Length 28.204 km)
DETAILS OF PROJECT
Client KSTP
Sai Consulting Engineers Pvt. Ltd.
Consultant In Association with
Orion Infra Consulting Pvt. Ltd.
Contractor THERUVATH PRL JV
Project Duration 18 months
Submitted By Approved By
For Theruvath PRL JV
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CONTENTS
CHAPTER DESCRIPTION PAGE NO
1. INTRODUCTION 04
2. QUALITY SYSTEM 08
3. QUALITY MANAGEMENT IN CONSTRUCTION AND REPORTING 10
4. CONSTRUCTION SCHEDULING 14
5. QUALITY CONTROL AND ASSURANCE IN CONSTRUCTION 16
6. QUALITY CONTROL OF ROAD WORKS 18
8. DOCUMENTATIONS, RECORDS, CONTROL & INTERNAL AUDIT 24
9. CONTRACT MANAGEMENT FRAMEWORK 27
Appendix
A PROJECT ORGANISATION CHART 29
B METHOD STATEMENTS 30
B1 SURVEY WORK 31
B2 CLEARING & GRUBBING 34
B3 DISMANTLING OF FLEXIBLE PAVEMENT 37
B4 ROADWAY EXCAVATION 39
B5 EMBANKMENT CONSTRUCTION 45
B6 SUBGRADE CONSTRUCTION 50
B7 GSB 54
B8 WMM 58
B9 PRIME COAT 62
B10 DBM 63
B11 RECYCLING OF BITUMINOUS PAVEMENT 69
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B12 TACK COAT 74
B13 BITUMINOUS CONCRETE 75
B16 SLAB /BOX CULVERT 81
B17 PIPE CULVERT 86
B18 CONCRETE WORKS 89
B19 GUNITING /SHOTCRETING WORKS 93
B20 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN & CEMENT 96

GROUTING
B21 PITCHING/ REVETMENT OF SLOPE 100
B22 LAYING CEMENT CONCRETE KERB 103
B23 CONSTRUCTION OF FOOTPATH 105
C QUALITY CONTROL TEST FREQUENCIES 107
D QUALITY ASSURANCE FORMATS 131
E CHECK LISTS 133
F FORMAT REGISTERS 146
G FLOW CHARTS 157
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CHAPTER 01
1.1 Introduction
This document describes the planned quality assurance goals, practices, tools, and scheduling for the
Rehabilitation and Upgradation of Pathanamthitta-Ayroor, Muttukudukka-Illathupady, Muttukudukka-
Prakkanam, Prakkanam-Elavumthitta, Kulanada-Ramanchira, Thannikuzhy-Thonniamala Roads in
Pathanamthitta District.
Quality Assurance measures will provide consistent & comprehensive methods of checking & approval
of the work for correct executing of a particular job. This can be achieved by establishing step by step
procedure that will reduce/ eliminate human errors if any.
1.2 Project Summary
Pathanamthitta-Ayroor Road (3.1)
Road section starts from Thiruvalla – Kumbazh Highway (Juma Masjid junction) and ends at
Vazhakunnam junction, Ayroor on Melukara Ranni road with a total length of 12.3 Km. Land use
pattern along road section is mix type; built up and agriculture (rubber plantation). The carriageway
in this section is generally intermediate lane configuration with varying BT width between 4.99 m to
5.11 m. ROW generally varies from 10 to 15m, except at 1.3 km of road section at start up to ring
road crossing which falls in Pathanamthitta city. Entire project road passes through plain / rolling
terrain with poor geometry and observed with moderate traffic. Six major junctions observed on this
road.
Muttukudukka-IllathupadiRoad (3.2)
Road section starts from Elanthoor - Santhosh Jn road (Muttukudukka Jn.) and ends at Illathupadi on
Elanthoor market – Palachuvadu road with a total length of 3.6km. Land use pattern along road
section is agriculture (rubber plantation) with scattered built up. The carriageway in this section is
generally single lane configuration with varying BT width between 3.5 to 3.6m.ROW generally
varies from 8 to 10m. Project road passes through rolling terrain with fair to poor geometry and
observed with low traffic.
Muttukudukka – Prakkanam Road (3.3)
Road section starts from Muttukudukka – Illathupadi road and ends at Prakkanam Jn. On Omalloor
– Paiyaram road with a total length of 2.2Km. Land use pattern along road section is agriculture
(rubber plantation) with scattered built up. The carriageway in this section is generally intermediate
lane configuration with varying BT width between 5.1 m to 5.5 m. ROW generally varies from 10
to 12 m. Project road passes through rolling terrain with fair geometry and observed with low traffic.
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Prakkanam – Elavumthitta Road (3.4)
Road section starts from Omalloor – Paiyaram at Prakkanam Jn . (end of road no.3.3)and ends at
Elavumthitta on Manjinikara - Elavumthitta road with a total length of 2.9Km. Land use pattern
along road section is agriculture (rubber plantation) with scattered built up. The carriageway in this
section is generally intermediate lane configuration with varying BT width of 5.5m. ROW is
generally 10m. Project road passes through rolling terrain with fair geometry and observed with low
traffic.
Kulanada - Ramanchira Road (3.5)
Road section starts from Kulanada – Omalloor road at Kulanada and ends at Ramanchira on
Thumpamon – Paryaram road with a total length of 4.8Km. Land use pattern along road section is
agriculture (rubber plantation) with scattered built up. The carriageway in this section is generally
intermediate lane configuration with varying BT width between 4 .99 m to 5.11 m. ROW is
generally 10-12m. Project road passes through rolling terrain with poor geometry and observed with
low to moderate traffic.
Thannikkuzhy - Thonniamala Road (3.6)
Road section starts from Pathanamthitta – Ayroor road (2.5Km from start of road no.3.1) ends at
Thonniamala road with a total length of 2.4Km. Land use pattern along road section is forest /
rubber plantation with scattered built up. The carriageway in this section is generally single lane
configuration with varying BT width between 3.2m to 3.5m. ROW is generally 10m. Project road
passes through rolling/hilly terrain with poor geometry and observed with low traffic. This road is
damaged due to flood and drainage issues observed at many locations. Requirement of retaining wall
/ protection is observed at many locations.
1.3 Project Quality Statement
Manage and deliver sustainable quality elements by providing standards set and maintain
commitment by maximising the level of service and satisfaction, and thereby enhancing the
competitiveness of the company.
1.4 Revision / Amendments
The project quality manual contains issue number, revision number and revision date on each relevant
page. In case of any amendment required, the revised sub-section will be reissued and its revision number
and date shall be changed accordingly.
Amendments shall be approved by the Head of QA at site office. The Revision Status Sheet detailing the
amendment, date and approval will be issued with each amendment by the Quality Control / Assurance
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Engineer. Each new revision will be distributed as per the original with a request that the revised sub-
sections be destroyed. After ten (10) revisions a new issue will be introduced superseding all previous
revisions. A register will be maintained to record the distribution of the Project Quality Manual as below:
Copy No Doc No/ Issue Issued to Issued Date
1
2
3
4
1.5 Definitions & Terminology

: All the operations for the purpose of determining the values of the errors of
Calibration
measuring instruments, material measures, and measurement standards
Controlled : An original numbered copy of a document for which amendments will be
Document automatically advised
: An activity the intention of which is to return a non-conforming item or action to a
Corrective
state or conformity. It also covers action taken to prevent further recurrence s of
Action
non-conformity.
: An action to be taken concerning material components or products which a decision
Disposition
has been made.
Any written or printed manual, procedure or format that is a part of the quality
Document
system. The term includes documents & data that can be read by people or machines
: The careful examination, measurement and testing of the characteristics of products
Inspection
and services to ensure they meet regulatory and contractual requirements.
: A location or stage in the manufacturing, production or construction cycle where
inspection and inspection and testing are performed by personnel whose responsibility is to
test point determine the acceptability of products or services and to record inspection and test
data.
Non- : A deficiency in characteristic, documentation, or procedure which renders the
conformance quality of a product or service unacceptable or indeterminate or not according to
/nonconformity specified requirements
: A document that specifies, as applicable, the purpose and scope of an activity; what
Procedure shall be done and by whom; when, where and how it shall be done; what materials,
equipment, and documentations shall be used; and how it is all controlled.
: Inspection of the product at a lesser frequency than the inspection carried out for
Product
normal quality control purpose as an aid to assessing the effectiveness of quality
Quality Audit
control
Quality : All those planned and systematic actions necessary to provide confidence that
Assurance products or services will satisfy given requirements
Quality Audit : A systematic and independent examination to determine whether quality activities
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and related results comply with planned arrangements and whether these
arrangements are implemented effectively and are suitable to achieve objective.
Quality System : The independent examination of an organizations quality assurance system carried
Audit out by an auditing team from within or outside the organization.
: Those actions which provide a means to measure and regulate the characteristics of
Quality a product or service to establish requirements.
Control Operational techniques or activities (e.g. inspection or test) used to verify technical
and quality requirements for services and or products.
: The overall quality intentions and directions of an organization as regards quality, as
Qualify Policy
formally expressed by top management.
: A document setting out the specific quality practices, resources, activities and
Quality Plan
responsibilities relevant to a particular contract or project.
Remedial : An action to be taken concerning material, components or products about which a
Action decision has been made
: The process of restoring a non-conforming characteristic to a condition such that the
Repair item conforms to the original specified requirements, where such a repair or
restoration is acceptable
The continuing evaluation of the status of procedures, methods, conditions,
Surveillance products, process and services and analysis of records to assure that quality
requirements will be met.
Verification : Conforming that an activity or condition conforms to specified requirement.
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CHAPTER 2
QUALITY SYSTEM
2.1 Introduction
The achievement of Quality through compliance with Contract agreement, codes requirements and tender
specifications implicitly depends upon the "systemized human skill" for the successful and reliable
applications.
Quality Assurance (QA) is essentially the system of planning, organizing, executing and controlling the
"human skills "to assure the compliance towards quality.
QA activity is an integral part of every work function. Quality link starts with the contractor and finally
extends up to the employer and approving authority, who have responsibility by the way of supervision
and technical auditing which ascertains the compliance independently.
The total system of planning of internal and external controls, testing and quality control, acceptance
criteria and documentation is covered in the Quality Assurance System.
2.2 Planning
This project Quality Manual lists the documents which details the Quality System to be planned,
established, implemented and maintained as part of the contractor for the road work for the project.
The Project Quality Plan consists of the following:
i. The project Quality Manual Statement of the company
ii. Project specific details including Organization and System Element Description
iii. Inspection and test plans (including Construction Process Flow Charts and Quality
Verification Checklists)
iv. Project specific Procedures as required by the contract specification / contract agreement
The Project Quality Manual describes the managerial and technical systems which will be implemented to
achieve conformance to specified requirements. The systems will cover all on site work under the
contract. Where necessary the systems will be extended to include offsite activities as well.
The inspection and test plan will identify necessary processes to verify conformance of the work during
performance of the identified project tasks. It will include acceptance criteria and details for performance
of inspection and test activities, as applicable.
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2.3 Control
Control will be achieved by implementing the requirements of the Project Quality Manual including
construction process controls, inspection and test plan and audit requirements. Continuous monitoring and
the investigation of timely corrective action will form the basis of control. System Element Descriptions
will detail the methods by which the quality system is controlled. The agreed Inspection and Test Plans
will be used for controlling the work and detecting non-conformance.
2.4 Verification
Verification processes shall be established to ensure that the planning and controls have been effective
and the Quality System and constructed works conform to the specified requirements. The outcome of all
verification activities shall be documented and maintained as quality records. Records of conformance
shall be available for inspection by the Contractor's Representative upon request to provide evidence of
the outcome of activities undertaken to achieve conformance.
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CHAPTER 3
QUALITY MANAGEMENT IN CONSTRUCTION AND REPORTING
3.1 Responsibilities of Management
The Project manager has the overall responsibility for construction of the project with ensuring best of
quality for satisfaction of client. The Head of the Quality Assurance Group will report to the Project
Manager and will act independently to implement QA policy of the company. He has the responsibility
for formulating, implementing, reviewing, monitoring, verifying and assessing the effectiveness of
Quality Assurance program. He has also been delegated the authority to take corrective measures in case
of any significant quality related problems are noticed, with the intimation to the Project Manager. Quality
Assurance plans will be implemented by the site QA/QC team. Project Manager will interact with,
QA/QC Engineer of Supervision Consultant for review of material tests, mix designs and various QA/QC
procedures.
3.2 Organization set up of the Project
The Organization chart is presented in Appendix A.
3.3 Responsibilities of Key staff at Site
3.3.1 Project Manager
The Project Manager for the project has the following responsibilities.
a) Overall management of the project. He will have the authority and responsibility for time,
cost, safety and quality aspects of the project
b) Approving the project Quality Plan including System Element Description and Inspection
and Test Plan and Project Specific Procedures.
c) Approving the disposition of Non-conformance report issued by the authorized

representative nominated by him.
d) Communication and interface between Sub- contractors and the Project team.
e) Responsible for the planning, implementation, control and maintenance of the Project
Quality Plan.
f) Review of design documents to ensure they provide satisfactory standards against which
quality can be measured.
g) Issue all the relevant documentation and amendments to the project team.
h) Guide and instruct others in the essential aspects of quality management
i) Verification of inspection and test activities

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j) Apply acceptance criteria and classify work as conforming or non-conforming. Issue non-
conformance reports where necessary.
k) Recommend remedial actions and re inspect to close the issue
l) Recommend corrective action in case of recurring non-conformance
3.3.2 Material Engineer
The Material Engineer for the project has the following responsibilities.
a) Responsibilities for the planning, implementation, control and maintenance of the Project Quality
Plan.
b) Guide and instruct others in the essential aspects of quality management.
c) Ensure that the quality of construction satisfies the standards.
d) Ensure that suitable measuring and testing equipment is available and calibration of same is
monitored regularly.
e) Verification of inspection and test activities.
f) Recommend remedial action and re inspect to close out.
g) Recommend corrective action in case of recurring non-conformance.
h) Responsible for preparing Monthly Quality Management Report.
3.3.3 Dy. Project manager
3.3.4 The DPM for the project has the following responsibilities:
a) Responsible for overall execution and inspection of works on site as per specifications and
standards.
b) Guide, supervise, co-ordinate and monitor the work of the Contractor's project team
c) Responsible for implementation of standards and procedures as per the Quality Plan and Contract
agreement
d) Responsible for complete adherence to maintenance standards during construction and operation
3.4 Functions of QA / QC system
(i) For each major activity of work, method statement will be prepared indicating the quality
checks for incorporated materials and stage of construction. The method statements are
incorporated in Appendix B
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(ii) Ensure that equipment and testing instruments are calibrated properly and adjusted to
maintain their accuracy within the acceptable limits.
(iii) Provide day to day routine / sudden spot checks on materials and finished products.
(iv) Identify problems and initiate action, which results in solution.
(v) Verify implementation of solutions / corrections
(vi) Report regularly on effectiveness of the system
(vii) All the test reports have to be certified by the representative
(viii) All records of qualifying and routine tests / checks will be jointly maintained at the PM (QC)
office. The Quality control tests shall be carried out as per the frequencies mentioned in
Appendix C
(ix) Internal project QA report will be prepared by project ME (QC) summarizing the activities of
QA department.
(x) ME/QA/IQC In-charge through his representative at site will point out the non-conformity of
standards if any, to the contractor's authorized representative in writing and a copy of the
same to be sent to the Project Manager for getting the work done as per quality standard
required as specified in contract agreement, quality specifications or drawings.
The Client, contractor, Supervision Consultant, Material supplier and Manufacturer, each form a link of
the quality chain. The strength of this chain is dependent on each and every link. The ME (QC) is to keep
a continuous watch on this chain and spot the weak link before it snapped.
3.5 Quality Management Reports
The QA/QC in-charge at site shall prepare a monthly Quality Management Report for review by the
Project Manager. The Quality Report shall be subdivided into the following headings.
Summary of Inspection and Test Activities.
Registers of non-conformance & Corrective Action
Outstanding approvals by the Supervision Consultant
Items of specific concern.
General Notes
Distribution of the Quality Management Report shall be as follows:
Sector Head (Roads)
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Project Manager
Material Engineer
The Quality Management Report will be submitted to the Project Manager within one week of the close
of the monthly reporting period and in turn Site shall forward this to Supervision Consultant for record
and action required if any.
3.6 Management Reviews
The operation and effectiveness of the Project Quality Plan shall be regularly reviewed by Management
Review meetings periodically for the duration of the project. The Quality Management Report together
with Audit Reports shall form the basis of the review. The Management Review meetings will be attended
by the Head of QA at head office, Branch QA Coordinator, Project Manager and the QA/QC in-charge of
respective site. Minutes of the management review meeting will be taken by the ME (QC). He shall be
responsible to prepare and distribute minutes to the members of the review team for their information and
action.
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CHAPTER 4
CONSTRUCTION SCHEDULING
This section of the Manual out-lines requirements and procedures for construction scheduling and control
of work progress.
4.1 Construction Work Program
The Contractor will submit a detailed work program for execution of the works. This program will show
the following, as a minimum,
(i) Itemized work activities to be executed, based on the Contract's Bill of Quantities, indicating
start and finish dates and scheduled achievement (progress) each month
(ii) Sequencing of work and activity interdependence
(iii) Calendar dates for achievement of various milestones, and for completion of works by section
and of the project as a whole, within the time periods provided for in the Contract.
The Contractor's program has to be reviewed and approved by the Supervision Consultant as stipulated in
the Contract agreement. Once approved, the program will not be modified except with the prior approval
of the Engineer.
4.2 Progress control
The contractor is required to undertake its activities in accordance with the approved work program. Each
month the Contractor shall indicate the actual work completed as compared to work scheduled. In the
event portions of the work are in danger of being delayed, or actually are delayed, the Contractor will
determine plan for remedial action.
Various circumstances may justify the changing of Contract requirements for completion of the project on
a specific date. Among these circumstances are items not within the control, such as: changes to Contract
requirements (modification of Contract); suspensions of work; delays in providing access; etc. Generally,
such occurrences will justify a delay in completion if they affect activities on the critical path of the
program. However, each instance must be carefully evaluated and fully documented before a decision can
be made.
The following are guidelines for controlling work progress:
(i) There should always be a baseline program.If changes to the baseline program are required, an
updated baseline program (baseline program no. 2, etc.) should be created.
(ii) Unauthorized changes to completion milestones should not be allowed, unless authorized by a
Contract modification
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(iii) The Supervision Consultant will monitor the progress of works, and the Supervision Consultant
and the contractor will update their completion percentages using mutually agreed-upon
information
(iv) The Contractor should maintain accurate as-built information for scheduled activities. The
Supervision Consultant’s daily inspection report should have space for inspectors to note the
actual start and finish of activities. Additionally, actual starts and completions should be written
on a copy of the schedule to provide information for an 'as-built' schedule.
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CHAPTER 5
QUALITY CONTROL AND ASSURANCE IN CONSTRUCTION
Flow chart for the quality control team at site, functioning and responsibilities are given below.
Flow chart for Functioning of site QC Team
QUALITY MATERIAL
CONTROL ME APPROVAL DETAILS
SME BYCONTRACTOR
MATERIAL TESTING Consultant
ACCEPTED FAIL
INCORPORATE TO WORKS
CONTRACTOR
RFI Consultant
TESTING OF WORS BY QC TEAM
ACCEPTED NOT ACCEPTED
ME NCPN/ CAR /CONFORMITY TEST
CONTRACTOR
REMOVAL/ ACCEPTED
DEMOLITION
REDO WORK
Flow chart for day to day functioning with Responsibilities

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ACTIVITY RESPONSIBILITY
INSPECTION REQUEST OFFICE ASSISTANT /

OFFICE MANAGER
MARKEDTO CONCERNED QME

MARKED TO MATERIAL ENGINEER FOR
CONCERNED SECTIONS MATERIAL RELATED
/ STRETCH INCHARGE INSPECTION /TEST
FOR INSPECTION
Sr.MANAGER
TESTS / SAMPLING
INSPECTION ALONG WITH AS REQUIRED QME
CHECKLIST & PRODUCE
DAILY REPORT
HIGHWAY / BRIDGE
ENGINEER
ACCEPTED NOT ACCEPTED
MARKED APPROVED & Sr.MANAGER &

ISSUE OF NCPN/CAR
RETURN QME
RECORDS/CONCERNED FILE
RFI
SQME FOR RECORD

ADMINISTRAION RECTIFICATION / RE DO WORK
RECORDED IN REGISTER/ CONTRACTOR FOR NEXT

COMPUTER IN M.S EXCEL STAGE / LAYER
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CHAPTER6
QUALITY CONTROL OF ROAD WORKS
6.1 General
Quality control of materials forms an integral part of the overall construction and supervision function.
Taken properly into account, it provides the link between the design and the finished works.
Testing of construction materials is carried out for a variety of reasons and purposes including.
(i) Screening Tests (e.g. Choosing a borrow source, an aggregate supplier, a manufacturer/ supplier
of cement etc.)
(ii) Control Tests (e.g. sampling and testing of cement material delivered to site to confirm
adherence to project specifications and to conform manufacturers Test certificate)
(iii) Trial mixes (selection of appropriate concrete mix design, design of bituminous mixtures etc.)
(iv) Acceptance Tests (e.g. testing of cubes cast of produced concrete to confirm that required
strength is achieved and is consistent)
Suppliers of manufactured materials such as Cement, Steel, Bitumen, Bearings, Expansion Joints, Road
furniture etc. shall be screened based on submissions, review of sample Manufacturer' s Test
Certificates and experience on previous projects of the manufacturer. Independent testing by third party
in the presence of Contractor's / Supervision Consultant may also be required. Control and approval of
construction materials shall he based on the following:
 Test reports for materials tested, such as cement, sand, water, soil, aggregates and bitumen; and
 Manufacturer's certificates for materials such as steel, cement, admixtures etc.
The details of input materials should be recorded in a Materials Register (See Appendix F).
All test results shall be entered into a testing register maintained at site laboratory, with an indication of
conformance/non-conformance. A format for testing register is given in Appendix F. This section
hereinafter provides an overview or control requirements for materials, including site testing and
manufacturers' certification.
All materials to be incorporated and all works performed shall be strictly in conformity with the
Contract agreement and Specification requirements. The laboratory will be equipped with sufficient
number of modern and efficient equipment suitable to carry out the tests prescribed for different
materials and work according to the contract agreement and specifications. The equipment’s shall be
procured to conduct the specified test as per MoRTH and facilities to be provided
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 The laboratory will be manned by a qualified Material Engineer assisted by experienced

Engineers Technicians, Laboratory helpers and the set-up will be got approved by the Contractor's
representative.
 Quality Controls tests on the materials and work shall be carried out to the frequency mentioned
in the Appendix C. in the absence of clear indications about method and or frequency of tests for
any item, the direction of the Contractor's representative and AE shall be followed.
 For satisfying the Quality of the materials and work, Quality Control tests will also be conducted
by the Contractor's / Supervision Consultant, (by himself, by his Quality Control units or by any
other agencies deemed fit by him), generally to the frequency set forth herein under. Additional
tests may also be conducted where in the opinion of the Contractor's representative / Authority
Engineer need for such tests exists.
 Provision of necessary cooperation and assistance in obtaining the samples for test and carrying
out the field test as required by the Contractor's representative, Supervision Consultant from time
to time. This may include provision of labours, attendance, assistance in packing and dispatching
any other assistance considered necessary in connection with the test.
 For the work of embankment, subgrade and pavement, construction of subsequent layer of some
or other material over the finished layer will be done after obtaining approval from the
Contractor's representative. Similar approval from the Contractor's representative will be obtained
in respect of all other items of works to proceeding with the next stage of construction.
 The entire test to be conducted at laboratory and at site shall be documented as per the specified
manner. Usually the documentation shall be maintained in such a fashion that it shall be very
easily traceable with a specific RFI No. mentioned with date in schematic diagram for each
Structure and layer chart for Roads and in turn this shall be filed in Km basis for Roads with
bituminous and Non-Bituminous in a separate file / volume as a lot. For structures each structure
shall be defined as a single lot. For all routine tests for Roads and structures, borrow areas results,
bought out items shall be maintained in a separate lot irrespective or Km/ Structure.
6.1.1Construction Sequence and Control Flow Charts
Flow charts indicating the construction sequence and control points for road works are shown in
Appendix H
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6.2 Material Testing
6.2.1 List of equipment at site testing laboratory
Equipment at site testing laboratory shall be as per list provided in MoRTH clause 121.3. Other
materials if any required shall be tested at approved third party laboratory.
6.2.2List of materials to be tested on site
All the materials except bought out materials shall be tested at site laboratory. Any special test if
required for any material shall be conducted at outside approved laboratory.
 Cement
 Water
 Coarse aggregates
 Fine aggregates
 Cut soil/Borrow soil for Embankment and Subgrade
 GSA material
 Bitumen
6.3 List of materials to be certified by manufacturer
 Reinforcement / pre stressing Steel

 Cement
 Bitumen
 Paints
 PVC Pipes
 Reinforced Concrete Pipes
 Joint Filler Material
 Anti-stripping Compounds
 Concrete Admixtures
 Bitumen Modifiers
 Traffic Signs
 Laboratory Equipment
 Bearings
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6.4 Handling and Storage of Material
Proper care will be taken while handling and storage of all incoming materials as well as materials at in-
process stage up to the completion of the project to protect their quality from deterioration and prevent
damage. Only experienced and qualified personnel will be involved in these processes.
6.4.1 Handling of Materials
(i) As and when the materials are received and routed through inward section of stores and
issued for actual use, necessary precautions will be taken for safe handling.
(ii) Cement bag will be unloaded manually without using hooks. Cement bags will be stored at
the work-site in storage sheds with proper care.
(iii) Concrete mix will be shifted to work place through transit mixer.
(iv) All other materials will be handled manually and / or using appropriate equipment taking
necessary precautions to prevent damage.
6.5 Storage of Materials
Following aspects will be taken into consideration for storage:
(i) Access to storage area for stacking and retrieval

(ii) Cleanliness and good house-keeping practices
(iii) Fire protection
(iv) Identification and marking
(v) Corrosion protection
(vi) Prevention of physical damage
(vii) Protective cover and seals
(viii) Periodic inspection to ensure that the specified storage conditions are maintained
(ix) Steel of different classifications and sizes will be stored separately
(x) The expiry date of consumables will be clearly displayed and the items reaching expiry date
will be promptly intimated to the concerned agencies.
(xi) Bitumen in barrels will be stacked vertically. Leaky barrel will be segregated out
(xii) for Admixtures, sealants or other chemicals, manufactures test certificate will be obtained
and the same will he checked for meeting the specifications laid down in the contract
agreement, if required by testing in an independent laboratory
(xiii) Other materials such as electrical fittings, paints etc. will be kept in suitable and properly
protected storerooms.
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6.6 Identifications of Non- conforming Product and Management
6.6.1 Non-conformance Product Notification (NCPN)
Contractor will implement a system to identify and provide a disposition for all non-
conformances associated with the works. The authorized representative of Contractor shall be
responsible for recording of non-conformances by issuing a Non-Conformance Product
Notification (NCPN) to contractor. All NCPN shall be forwarded to the Chief Project Manager
for the determination of a disposition with concurrence by the Project Manager of contractor.
Outline of Activities
Non-conformances identified during inspection, testing and verification activities shall be

addressed to the workforce by issue of an Inspection note by the respective section and the same
will be forwarded to the Project Manager. Based on that NCPN (Non Conformance Product
Notification) shall be issued.
All NCPN shall be reviewed by the Project Manager and assigned a disposition as follows, either
repair, rework, use-as-it-is.
All NCPN shall be submitted to the contractor for their concurrence.
The non-conformances Product Notification shall detail the following:
 A unique identification number based on inspection report.

 Reference to the drawings/ specification.
 Location within the Works.
 Description of the non-conformance.
 Authorized representative signature and date.
 Chief Project Manager’s approval of action with respect to disposition.
 Re-inspection acceptance signature and date by the authorized representative or his
representative.
 Contractor authorized person's approval/disapproval.
The ME shall maintain Non-conformance Product Register to monitor the sign-off of the
assigned disposition. The Register shall be reviewed on a monthly basis and a report provided to
the Project Manager.
6.7 Corrective Action Request
Contractor shall promptly implement corrective action to address conditions identified as adverse
to quality ensuring that the actions arc effective and that their effectiveness continues. The
Project Manager (with consultation from all responsible parties) shall be responsible for approval
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of the proposed corrective action. The Highway / Bridge / Material Engineer shall be responsible
for identifying the need for, proposing and assessing the effectiveness of corrective action. Where
conditions adverse to quality are identified the concerned Engineer shall complete the proposed
Corrective Action Report. The Project Manager shall approve the proposed Corrective Action.
The concerned section in-charge shall monitor the implementation and effectiveness of the
Corrective Action.
Outline of Activities
The ME shall monitor implementation of Corrective Action using the Corrective Action Report
Register (Proforma in Appendix F). The Register shall be reviewed at the regular meetings on a
fortnightly / monthly basis anda report provided to the Project Manager. The ME shall also
implement a corrective action request register for CARs issued by the contractor and a register of
nonconforming product / service notification - correction action request. The following things
shall be as part of attachment,
 Corrective Action Report

 Corrective Action Register
 Corrective Action Request Register
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CHAPTER 7
DOCUMENTATIONS, RECORDS, CONTROL& INTERNAL AUDIT
7.1 General
This part of the document mentions the procedures maintained for identification, collection, indexing,
filing, storage, maintenance and disposition of Quality records.
The following Quality records will be maintained.
 Inspection and test reports
 Validation report
 Audit report
 Material review report
 Calibration data
Procedures will be carried out in accordance with the following:
a) Identification: All documentation covered will bear distinct identification.
b) Collection and Retrieval: If any record pulled out from the filling system for any reference and
site use will be noted as "Issued Particulars, and to be returned immediately after use”. All records
will be kept in such a position that these will be easily accessible and retrievable as and when
needed.
c) Drawings/Documents:
 All Good for Construction drawings and documents will be entered in the register indicating
number of copies received and distribution trade-off.
 The revision of Drawings/Documents whenever received will be entered in the register.
 The distribution of revised copies will be done with issue note and the previous copies will be
retrieved for availing any reference/misuse for actual execution.
d) Indexing: All filing system will be having indexing of all contents. Each Quality Record., will be
marked Volume I, Volume II, etc. for reports, forms, etc.
e) Filing and Storage: Hard copies will be kept in files, and files will be kept in racks /cabinets /CD /
Floppies will be stored in suitable cabinet only.
f) Retention: Quality Control records will be maintained up to Contract Period and then handed over
to the KSTP.
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7.2 Internal Quality Audit
The purpose is to establish a system for verification of the implementation and effectiveness of a quality
system by means of a uniform and controlled method for planning, scheduling, coordinating and
performing quality audits and to assign responsibility for these activities.
Objective
 That the quality system is effective.
 It is being implemented / complied with.
Internal Quality Audit will be carried out to verify whether quality activities and related results comply
with planned arrangements as laid down in the Quality Assurance Manual and whether these
arrangements are implemented effectively and desired objectives are achieved.
The audit will be carried out by staff not having direct responsibility for actual execution work on the
project, and also not reporting to the Project Manager.
The Internal Quality Audit will be normally carried out once in a month or at a lesser frequency than
carried out for normal quality control purpose as an aid to assessing the effectiveness of quality control
and also on the basis of the following factors on demand.
 Complaints regarding QA/QC implementation
 Discrepancy in records
 Contractual requirements
 Changes in Quality Assurance System itself
 Results of previous Internal Quality Audit
Audit findings, conclusions and recommendations will be submitted in documentary form for
consideration by designated member of the management.
The following points will be covered in the reporting and follow-up of audit findings
 Specific examples of non-compliance/non-conformity or deficiencies will be documented in the

audit report and possible reasons for such deficiencies, where evident, may be included.
 Appropriate corrective actions may be suggested.
 Implementation and effectiveness of corrective actions suggested in previous audit will be

assessed.
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7.3 Training in Quality Assurance
The training'/awareness program is prepared to ensure that the skill, aptitude, knowledge required by the
personnel in meeting Quality requirements for installation is to be maintained at adequate level.
Training procedures will be initiated by developing job descriptions and job profiles for all employees.
The information will be maintained in Quality Assurance Manual.
Consideration will be given for providing training to the personnel of all levels within the Company.
7.3.1 Management Personnel
Provision for training will be considered to provide Executives and Managers with an
understanding of the quality system together with the tools and techniques needed for full
participation in the operation of the system. They will also understand the criteria available to
evaluate the effectiveness of the system.
7.3.2 Technical Personnel
Training will include primary quality assignments, marketing, procurement, process engineering,
and product engineering. Particular attention will be given to training in statistical techniques
such as data collection and analysis, statistical sampling, process capability studies, problem
identification, problem analysis and corrective actions.
7.4 List of Test & Frequency to be conducted at site
The Quality Control tests shall be carried out as per the frequencies set forth in Appendix C. The
specifications are also mentioned in the Appendix C
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CHAPTER 8
CONTRACT MANAGEMENT FRAMEWORK
8.1 Contract Management Framework

There are three key players in the Contract Management Framework
 Employer/Granting Agency (KSTP)
 Consultants (SAI – Orion JV )
 Contractor (THERUVATH PRL JV)
Appendix A Project Organisation Chart
Appendix B Method Statements
Appendix C Quality Control Test Frequencies
Appendix D Quality Assurance Formats
Appendix E Check Lists
Appendix F Format Registers
Appendix G Flow Charts
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APPENDIX A
PROJECT ORGANIZATION CHART
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Organization & Management Responsibility
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bv
Chief Executive Officer

( C.E.O)
Sr. Project Manager
Finance
Project Manager
manager
Construction Plant Engineer Safety

Logistics Accountants
Manager (CM) (PE) Engineer
Project Quality Quantity Project Co-

Draftsman Surveyors
Engineer (PE) Controller (QC) Surveyor (QS) ordinator (PC)
Site Engineers Supervisor
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APPENDIX B
METHOD STATEMENTS
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B1 METHOD STATEMENT FOR SURVEY WORKS

B1.1 Objective
This section provides setting out-survey works methodology adopted by THERUVATH-PRL JV in

the project
B1.2 Scope of Work
This scope of work Includes traversing, fixing of control station points, horizontal and vertical
alignment as per designed co-ordinates and levels.
B1.3 Reference Documents
• Specification for Road & Bridge works, (fifth Revision) Published by Indian Roads Congress
New Delhi.
• Contract documents Volume-I Technical Specifications.
• MoRTH.
B1.4 Man Power
• Senior Surveyor
• Junior Surveyor
• Survey Supervisors
B1.5 Equipment/Instruments
• Global Positioning System (G.P.S.)
• Total Station (Electronic distometer)
• Prism Stand
• Auto Level
• Levelling Staff
• Measuring Tape
• Nails, Hammers, Marking Paint, Chalk piece, Brushes (White, Yellow & Red)
• Ranging rods (50mm dia -3m long)
• Field umbrellas
• Safety Jackets (Reflective)
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B1.6 Construction Method
B1.6.1 Alignment Fixing
• The control point of GPS (Global Positioning System) pillar is fixed at every 2 km interval for
execution of survey works. The same GPS pillars are also having the value of coordinate and
levels.
• Keeping the same GPS pillars as a reference, traversing of coordinate has been fixed between
GPS pillar to GPS pillar (i.e. every 2 km interval). Closing error of traverse has been adjusted by
bow-ditch method in between two GPS pillars. The traverse closure is less than 1:20000
• Horizontal angle is observed by taking minimum of two sets of rounds from different locations.
All the observations are logged and the spread between observed rounds of horizontal angles did
not exceed 2 seconds (Two sets of angles agreed within 5 seconds)
• In between GPS pillars at every 250meter interval, along the road alignment, the sub control
pillar [Bench Mark Pillar (BMP)] is fixed at the end of ROW (Right Of Way). The location of
benchmark pillar is marked at site by paint identifying location. Benchmark pillars are concrete
pillars. Size of concrete pillar is 150X150X450 mm. 10 mm rod is embedded inside and projected
15mm above the concrete pillar. During the time of traversing the bearing was recorded on the
punch point of rod projected over the benchmark pillar. The coordinate value of each benchmark
pillar was arrived after traverse adjustment by bow-ditch method.
The project-alignment coordinate given by client – KSTP is fixed over the existing road by 1-
second accuracy of total station.The alignment point is marked at every 20m interval on the
straight portion and 10m interval on the curve portion by round head nail. The same point is
marked with yellow point and location (chainage) written on the road for quick reference. For
fixing this alignment for total length, the traversed coordinate of benchmark pillar, fixed at every
250mtr interval along the project alignment, are used. Detailed copy of coordinate value of
benchmark pillar (BMP) along-with chainage and location will be given to clients and site
engineers for their reference.
B1.6.2 Bench Mark Fixing
For every 250m interval and near all structures the concrete bench mark pillar is fixed along the
project alignment at the end of ROW. Location and chainage is marked at site with paint. The
pillar is used for fixing the benchmark.
GPS pillar to GPS pillar (every 2 km interval) the level traversing has been done retaining the RL
(Reduced Level) of GPS pillar. During the time of traversing the level, the levels are transferred
over every 250mtr interval benchmark control pillars also. During benchmark level transferring
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maximum observing distance were 100mtr, keeping the fore sight and back sight distance equal.
The spread between observed ranges of vertical angles did not exceed 2 seconds. The closing
error on a level circuit did not exceed 12 root of K in mm 12√K (where K is distance in
Km.).The closing error has been distributed to all the bench mark in network in between GPS to
GPS. The benchmark pillar (BMP) levels will be checked by client. Detailed benchmark list
mentioning level Location and chainage will be issued to client and site engineers for their
reference.
B1.6.3 Toe Line Fixing
The toe line is fixed for every layer by means of calculating the thickness of pavement layer
multiplied by percentage of given formation slope. The toe distance will be measured from given
alignment nail. The cross-section drawings also can be followed for toe line marking. In order to
facilitate the setting out of the works the centre line of the carriageway must be accurately
established and get it approved by the engineer. It must be referenced in a manner satisfactory to
engineer, every 50m intervals in plane and20m in Hills terrain.
B1.7 Controls
• Every month temporary bench marks (TBM) are checked and get it approved by Engineer.
• Care shall be taken against control station points and temporary bench mark pillars to not to be
disturbed or damaged by any lateral loads
• Maximum allowable error between any adjacent bench mark pillars shall not be more than 2mm
when it is closed.
B1.8 Site Records to maintain
• Centre line co-ordinates
• OGL Field books
• TBM list for all site engineers i.e.(Highway, Survey, Bridge)
B1.9 Management of the method statement
The senior Surveyor will plan and execute the traversing, alignment fixing, bench mark fixing, towline
fixing with help of the junior surveyors and survey supervisors up to the accuracy of the works as per
the requirements and the same will be checked and get it approved by Engineer.
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B2 METHOD STATEMENT FOR CLEARING & GRUBBING CONSTRUCTION

B2.1 Objective
This method statement provides Clearing & Grubbing methodology adopted by THERUVATH PRL
JV in the package.
B2.2 Scope of Work
This work will consist of cutting, removing and disposing of all unsuitable materials such as trees of
girth <300mm, bushes, shrubs, stumps of girth <300mm, roots, grass, weeds, top organic soil etc., not
exceeding 150mm in thickness, beyond toe edge of formation. It will include necessary excavation by
excavator or any other suitable equipment, back filling the excavated area up to a maximum depth of
150mm and also complete filling of the pits resulting from uprooting of trees & stumps by suitable
soil and making the surface in proper grade by suitable/approved soil and making the surface in proper
grade by suitable equipment Motor grader and compacted by power roller to required compaction
95% as per Section 300.Clearing and grubbing will be performed in advance of earthwork operations
as per Clause 201 of MoRTH and Technical specification.
• Specification for Road & Bridge works (Fifth Revision), Published by Indian Roads
Congress New Delhi.
• Contract documents Volume-II Technical Specifications.
B2.4 Man Power
• Senior Engineer
• Junior Engineer
• Supervisors
• Labour
B2.5 Equipment
• Excavator
• Dumpers
• Dozer
• Water Tanker
• Vibratory roller
•
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B2.6 Material
Material from approved suitable Granular fill/sand is used for filling of Pits resulting from uprooting
of trees & stumps. Specifications for the materials is given below.
Maximum Particle Size Shall not be more than 75 mm
Free Swell Index Max 50 %
Plasticity Index Non Plastic
B2.7 Construction Methods
B2.7.1 Setting out
The limits of ROW will be set out on either side from proposed centre line.The material which is
unsuitable for construction of road such as trees, bushes, stumps, roots, grass, weeds, top organic
soil will be disposed off by using excavator and end dumpers. Boulders, stones, and other
materials usable in road constructions shall be neatly stacked at approved locations.
All Excavation below original ground level arising out of the clearing and grubbing and also after
removal of trees, stumps, etc., will be filled with suitable material and compacted thoroughly so
as to make the surface fit for the next layers in accordance with the section 300 of specifications.
The compaction will be done with the help of vibratory roller of 8 to 10 tonne static weight.
B2.7.2 Stripping and storing top soil
100 to 150 mm topsoil existing over the sites of excavation will be stripped and stock piled at
designated locations for re-use in covering embankment slopes, cut slopes, berms and other
disturbed areas where re-vegetation is desired. Prior to stripping the topsoil, all trees, shrubs etc.
will be removed along with their roots.
B2.7.3 Preservation of Property / Amenities
Items adjacent to or with in the construction works which are not to be disturbed will be protected
from injury damage.
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B2.7.4 Disposal of Materials.
All materials arising from clearing and grubbing operation shall be the property of Government
and shall be disposed by the contractor as hereinafter provided or directed by the Engineer, as per
Sub Clause 201.4 & EMP Norms and clause 301.3.11.
Boulders, stones and other materials usable in road construction will be neatly stacked as directed
by the Engineer. Stacking of stumps, boulders, stones etc., will be done at specified spots with all
leads.
B2.7.5 Traffic safety
Traffic safety will be taken care along the stretches where Clearing & Grubbing activities are in
progress. Barricades erected on either side of the carriageway/portion of the carriage way shall be
of strong design to resist violation. White and block bands and with reflective bands in between
will be fixed, for demarcating the area of proposed carriageway from the existing carriageway
during the course of work. All the vehicles will have a red flags and reflective bands on the rear.
Flag men will be deployed where crossing of the existing road in unsafe.
The senior Engineer will plan and execute the construction of Clearing & Grubbing with help of the
Junior Engineers and site Supervisors up to the accuracy of the works as per the requirements and the
same will be checked and get it approved by Engineer.
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B3 METHOD STATEMENT FOR DISMANTLING OF FLEXIBLE PAVEMENT

B3.1 Objective
This method statement provides bituminous / Granular pavement dismantling methodology adopted
by THERUVATH PRL JV in the package.
B3.2 Scope of Work
This scope of work deals with dismantling and disposal of dismantled material, stacking serviceable
and unserviceable materials separately with all lead and lift as per the clause 202 of MoRTH,
Technical specifications.

• Specification for Road & Bridge works (FIFTH Revision), published by Indian Roads
Congress New Delhi.
• Contract documents.
• Construction Drawings.
• MoRTH
B3.4 Man Power
• Senior Engineer
• Junior Engineer
• Supervisors
• Labour
B3.5 Equipment
• Excavator
• Dumpers
• Dozer
• Backhoe loader
• Water tanker with sprinklers
B3.6 Procedure
Pavement is dismantled carefully using machineries like JCB/ Excavator etc. and the resulting
materials removed without causing any damage to the part of the structure to be retained and any
other properties or structures nearby. Flexible pavements & disposal of dismantled materials up
to a lead of 1000 meters, stacking serviceable materials separately by mechanical means. All
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base courses in the carriage way and shoulders etc. designated for removal are broken into pieces
whose volume do not exceeding 0.02 cum.
B3.7 Backfilling
Holes and depressions caused by dismantling operations are backfilled with excavated or other
approved materials and compacted to required density as directed by the Engineer in Charge.
B3.8 Disposal of material
All surplus materials is disposed with all leads and lifts
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B4 METHOD STATEMENT FOR ROADWAY EXCAVATION

B4.1 Objective
This method statement provides Roadway Excavation methodology adopted by THERUVATH PRL
JV in the package.
B4.2 Scope of Work
This scope of work deals with excavation removal and satisfactory disposal of materials necessary for
construction of Roadway, Road shoulder, verge, drains and waterways as per the clause 301 of
MoRTH Technical specifications.
 IRC SP 84 :2014 and Specification for Road & Bridge works (Fifth Revision), Published by
Indian Roads Congress New Delhi.
 Contract documents Volume-II Technical Specifications.
 Construction Drawings
B4.4 Man Power
• Senior Engineer
• Junior Engineer
• Supervisors
• Labour
B4.5Equipment
• Excavator
• Dumpers
• Measuring Tape
• Dozer
B4.6Material
Classification of Excavated Material
a. Soil: This will comprise top soil, turf, sand, silt, loam, clay, peat, black cotton soil, soft
shale and loose moorum and a mixture of these.
b. Ordinary Rock (not requiring blasting): Any rock such as laterites, shale and
conglomerates, varieties of limestone and sandstone, macadam surface such as water
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bound and bitumen / tar bound, soling of roads, paths and hard core, lime concrete, stone
masonry in lime mortar and brick work in lime / cement mortar below ground level, RCC,
boulders which do not require blasting more than 300mm found lying loose on the surface.
c. Hard Rock (requiring blasting): Any rock or cement concrete for the excavation of
which the use of mechanical plant and/or blasting is required. RCC below ground level,
boulders required. RCC below ground level, boulders require blasting. Blasting operation
is subject to Engineer's approval.
d. Hard Rock (Blasting Prohibited):Hard Rock requiring blasting as described under (c) but
where blasting is prohibited for an reason and excavation has to be carried out by
chiselling, wedging or any other agreed method
e. Marshy soil:This shall include soils like soft clays and peat's excavated below the original
ground level of marshes and swamps and soils excavated from other areas requiring
continuous pumping or bailing out of water
f. Hard Rock (requiring Controlled Blasting):Hard Rock requiring blasting as described

under (c) but where blasting would damage abutting structures like building, bridge
foundation, etc., and excavation has to be carried out by controlled blasting without
causing any detrimental damage to nearby structures.
B4.7ConstructionMethod
B4.7.1 Setting out
After the site is cleared as per Section-200 of MoRTH, the limits of excavation will be set out
true to lines, curves, slopes, grades and sections as shown in the drawings of cross sections.
B4.7.2 General Excavation
The excavation work will be carried out such that any suitable materials available from
excavation will be used for filling up road way embankment as decided by the Engineer.While
executing excavation, adequate precaution will be taken against soil erosion, water pollution.
The surface area of erodible earth material exposed by clearing and grubbing, excavation, borrow
and fill operations shall be limited to the extent practicable. The Contractor will provide
immediate permanent or temporary erosion and sedimentation control measures to prevent soil
erosion and sedimentation that will adversely affect construction operations, damage adjacent
properties, or cause contamination of nearby streams or other water courses, lakes, reservoirs etc.
Such work may involve the construction of temporary berms, dikes, sediment basins, slope drains
and use of temporary mulches, fabrics, mats, seeding, or other control devices or methods as
necessary to control erosion and sedimentation. Cut and fill slopes shall be seeded and turfed as
required on the plans.
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B4.7.3 Rock Excavation
Where rock is encountered in road excavation it will be removed up to the formation level or as
indicated on drawings
B4.7.4 Marsh Excavation & Unsuitable Material
Where unstable shale's or other unsuitable materials are encountered at the formation level, these
will be excavated to the extent of 500 mm below formation level.
Excavation of marshes will begin at one end and proceed in one direction across the entire marsh
immediately ahead of backfilling. The method and sequence of excavating and backfilling shall
be such as to ensure, to the extent practicable, the complete removal or displacement of all muck
from, within the lateral limits as per the drawings, and to the bottom of the marsh, firm support or
levels indicated or by Engineer's instruction
B4.7.5 Excavation of Road Shoulders/Verge/Median for Widening of Pavement or
Providing Treated Shoulders
In works involving widening of existing pavement, the existing paved shoulders/hard

shoulder/earthen shoulders/verge/median shall be removed to its full width and depth up to the
Sub grade bottom level shown on drawings or as indicated by the Engineer, preparation of cut
formation as per clause 305 supporting subgrade /embankment. Method of benching will be
followed with each successive to layer of existing pavement layer cut at least 250mm wider than
bottom layer. While doing so care shall be taken to see that no portion of the existing pavement
designated for retention is loosened or disturbed. If the existing pavement gets disturbed or
loosened, it shall be dismantled and cut to a regular shape with side vertical and the
disturbed/loosened portion to be removed completely and re-laid as directed by the Engineer, at
the cost of the Contractor.
If the existing material below the sub base level up to depth of 500mm or more is suitable for
Subgrade (with soaked CBR not less than 10%) shall be retained. The cut formation shall be
prepared to support the sub-base as per Clause 305. Any unsuitable material encountered in this
portion of subgrade shall be removed and replaced with suitable material and compacted in
accordance with clause 305.
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B4.7.6 Excavation for Surface /sub -surface drains
Where the Contract provides for construction of Surface/sub-surface drains to Clause 309,
excavation for these shall be carried out in proper sequence with other works as approved by the
Engineer. Specific trapezoidal bucket should be used.
Slides
If slips, slide over-breaks or subsidence occur in cutting during the process of construction they
shall be removed at the cost of the Contractor as ordered by the Engineer. Adequate, precautions
shall be taken to ensure that during construction; the slopes are not rendered unstable or give rise
to recurrent slides after construction.
Dewatering
If water is met with in the excavations due to springs, seepage, rain or other causes, it shall be
removed by suitable diversions, pumping or bailing out and the excavation kept dry whenever so
required or directed by the Engineer. In case of presence springs or seepage the Contractor will
apply for Engineers decision.
B4.8 Disposal of Excavated Material
All the excavated materials shall be the property of the Employer, Suitable material obtained
from the excavation of the roadway, shoulders,verges,drains, cross drainage works etc. will be
used for
 Filling road way embankment with all lifts and leads
 Filling existing pits/ponds in the 1igllt of way d directed by the Engineer, including
levelling and spreading, with all lifts and leads.
 For landscaping of the road as directed by the Engineer, including levelling and
spreading,with all lifts and leads.
Unsuitable and surplus material, which in the opinion of the Engineer cannot be used in the
works, shall be removed from site by the Contractor and disposed of at the nearest dip or other
approved location with all lifts and leads in accordance with all statutory requirements.
B4.9 Back Filling
Back filling of masonry/concrete/hume pipe drain excavation will be done with approved
material after concrete/masonry/hume pipe is fully set and carried out in such a way as not to
cause undue thrust on any part of the structure and /or not to cause differential settlement. All
space between the drain walls and the side of the excavation shall be refilled to the original
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surface making due allowance for settlement in layers generally not exceeding150mm compacted
thickness to the required density, using suitable compaction equipment such as mechanical
tamper, rammer or plate compactor as directed by the Engineer.
B4.10 Plying of Construction Traffic
Construction traffic shall not use the cut formation and finished subgrade without the prior
pem1ission of the Engineer. Any damage arising out of such use shall be made good by the
Contractor as his own expense.
B4.11 Preservation of Property
The Contractor shall undertake all reasonable precautions for the protection and preservation of
any or all existing road side trees drain. Sewers or other sub-surface drains, pipes, conduits and
any other structures under or above ground, which may be affected by construction operations
and which, in the opinion of the Engineer, shall be continued in use without any change.
B4.12 Preparation of Cut Formation
The Cut formation, which serves as a subgrade, shall be prepared to receive the sub- base/base
course as directed by the Engineer, Where the material in the Subgrade (that is within 500mm
from the lowest level of the pavement) has a density less than 97% the same shall be loosened to
a depth of 500mm and compacted in layers in accordance with the requirements of clause
305.Any unsuitable material encountered in the subgrade level shall be removed as directed by
the Engineer compacted in accordance with clause305.
In rocky formations, the surface irregularities shall be corrected and the levels brought up to the
specified elevation with granular base material as directed by the Engineer, laid and compacted in
accordance with the respective specifications for these materials. The unsuitable material shall be
disposed of at the nearest dip or other approved location with all lifts and leads in accordance
with all statutory requirements in accordance with clause301.3.11. After satisfying the density
requirements the cut formation shall be prepared to receive the sub base /base course in
accordance with clauses 310 and 311 to receive the sub- base/base course.
B4.13 Finishing Operations
Finishing operations shall include the work of property shaping and dressing all excavated
surfaces.When completed, no point on the slopes shall vary from the designated slopes by more
than 150mm measured at right angles to the slopes, except where excavation is in rock (hard or
soft) where no point shall any portion of the slope encroach on the roadway. The finished cut
formation shall satisfy the surface tolerances described in Clause 902.All preventive measures
against erosion sliding shall be completed prior any laying of the sub base.
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B4.14 Traffic Safety
Traffic safety shall be taken care of the along the stretches where earthwork activities are in progress.
Bamboos with alternative white and block bands and with reflective bands in between shall be fixed,
for demarcating the area of proposed carriageway from the existing carriageway during the course of
work. All the vehicles shall have a red flag and reflective bands on the rear. Flag men shall be
deployed where crossing of the existing road is unsafe. In case of blasting the traffic shall be closed
during blasting operation and removal of any debris shall be done before opening to traffic.
The senior Engineer will plan and execute the construction of embankment with help of the Junior
Engineers and site Supervisors up to the accuracy of the works as per the requirements.
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B5 METHOD STATEMENT FOR EMBANKMENT CONSTRUCTION

B5.1 Objective
This method statement provides Embankment construction methodology adopted by THERUVATH
PRL JV in the package.
B5.2 Scope of Work
This scope of work deals with laying, spreading, and compacting embankment layer with approved
materials obtained from approved sources, including material from roadway and drain excavation,
borrow pits or other sources as per the clause 305 & 900 of MoRTH, Technical specifications.
• Specification for Road & Bridge works (FIFTH Revision), published by Indian Roads
Congress New Delhi.
• Construction Drawings.
• IRC 36.1970 Recommended practice for the construction of earth embankments for road
works.
B5.4 Man Power
• Senior Engineer
• Junior Engineer
• Supervisors
• Labour
B5.5 Equipment
• Excavator
• Dumpers
• Dozer
• Auto Level
• Levelling Staff
• Measuring Tape
• Motor Grader
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B5.6 Materials
The materials used in embankments, subgrade, earthen shoulders and miscellaneous backfills are soil
free from logs, stumps, roots, rubbish or any other ingredients likely to deteriorate or affect the
stability of the embankment. The size of coarse material in the mixture of earth do not exceed 75 mm
when placed in embankment and 50 mm when placed in subgrade. As per MoRTH clause 305.2.1.2
& 305.2.1.3 ,
Max Particle Size Shall not be more than 75 mm or should not be

more than 2/3 rd of compacted layer thickness
whichever is minimum
Free swelling index for expansive clay Max 50 %
Liquid limit Max 70 %
Plasticity index Max 45
B5.6.1 Borrow materials

The arrangement of the source of supply of the materials for embankment will be as per the
guidelines and environmental requirements, in respect of excavation and borrow areas as stipulated,
from time to time by the Ministry of Environment and Forests, Govt. of India and local bodies.
Borrow pits along the roads shall be discouraged. Ridges of not less than 8 m width will be left at
intervals not exceeding 300 m. Small drains will be cut through the ridges to facilitate drainage. The
depth of the pits will be regulated such that, their bottom doesnot cut an imaginary line having a
slope of 1 vertical to 4 horizontal projected from the edges of final section of the bank, the
maximum depth in any case being limited to 1.5 m.Also no pit will be dug within the offset width of
a minimum of 10 m.
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B5.6.2 Density Requirements of Embankment – MoRTH Table 300-1

Maximum Laboratory dry unit
Type of Work weight when tested as per IS
2720(Part 8)
Embankments up to 3m height not
Not less than 15.2 kN/calm.
subjected to extensive flooding
Embankment exceeding 3m height or
embankment of any height subject to long Not less than 16.0 kN/cu.m
periods of inundation
Sub grade and earthen shoulders/ backfill Not less than 17.5 KN/cum
B5.6.3Compaction Requirement for Embankment- MoRTH Table 300-2

Relative compaction as % of maximum
Type of work/Material laboratory dry density as per IS:
2720(Part8)
Embankments
a. Up to 6rn height Not less than 95
b. High Embankment (exceeding 6m
Not less than 97
height)
Such material is not allowed in

Expansive clays
construction
B5.7.1 Setting out
After the site has been cleared as per clause 201, the work will be set out true to lines, grades,
slopes, curves and sections shown on drawing.
B5.7.2 Compacting ground supporting embankment
The original ground will be levelled to facilitate placement of first layer of embankment,
scarified, mixed with water and then compacted by rolling so as to achieve minimum dry density
95% as given in table 300-2.
Where the ground supporting embankment is found to be unsuitable (material mentioned in

clause 305.2.1.1) or the original ground material is having free swell index greater than 50% the
same will be removed up to 500mm and will be replaced with approved material as per clause
305.3.4.
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B5.7.3 Transporting of Material
The approved material from barrow area will be transported by means of end dumpers and
dumped in the form of heaps as per 305.2.2.2.
B5.7.4 Spreading material in Layers and bringing to appropriate moisture content
The embankment material will be spread in layers of uniform thickness not exceeding 200 mm
compacted thickness over the entire width of embankment finished by motor grader and
compacted to 95% as in the table 300-2. Each compacted layer will be finish parallel to the final
cross-section of the embankment.
Moisture content of the material will be checked and extra moisture content required will be
added before rolling.
The moisture content of each layer will be checked and it should be within the range of OMC
+1% to OMC -2 percent. If moisture content is found out of these limits the same will be brought
within limits by addition of water or by aeration as the case may be.
B5.7.5 Compaction
The compaction will be done with the help of vibratory roller of 8 to 10 tonne static weight. Each
layer will be thoroughly compacted to the densities specified in the specifications which are
mentioned at the beginning of this document for reference. The rolling pattern will be finalized in
trial stretch. Compaction will be carried out from lower edge to upper edge with 8-10 T rollers till
to achieve the required compaction and no tyre or drum impression on the surface and
compaction requirement as per 302. MoRTH and compaction procedure 305.3.6.
Field density tests will be carried out as per the frequency as specified in the specifications.If the
required field density is not achieved, compaction will be continued till required density is
achieved. Loose pockets if any will be removed and replaced with approved material before
Compaction. Drainage and others as per MoRTH section 300
B5.8 Embankment around Structures
The material used for backfill will be Granular material, Sand, stone, dust etc. Around the structures it
may be impracticable to use conventional rollers. The compaction will be carried out by small
vibratory roller, Plate compactor or Power rammer.
The filling around culverts, bridges and other structures up to a distance of twice the height of the road
from the bottom of the abutment will be carried out independent of the work on the main
embankment. The fill material will not be placed against any abutment or wing wall, until the concrete
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or masonry has been in position for 14 days. The fill material will be deposited in horizontal layers in
loose thickness and compacted thoroughly to not less than 97 % MDD.
B5.9 Traffic Safety
Traffic safety will be taken care along the stretches where earthwork activities are in progress.
Bamboos with alternative white and block bands and with reflective bands in between will be fixed,
work. All the vehicles will have a red flags and reflective bands on the rear. Flag men will be
deployed where crossing of the existing road is unsafe.
B5.10 Surface Finish and Quality Control of Work
Quality control of the above work will be as per table 900-3of MoRTH
• The top levels will be checked and shall be within +20mm and -25mm of designed level.
• The compacted surface will be checked for field density at the frequency of 1
• Test for 1000 sqm.The degree of compaction will not be less than 95%
• Moisture content will be checked before compaction for preceding the work.
B5.11 Management of the Method Statement
The senior Engineer will plan and execute the construction of embankment with help of the Junior
Engineers and site Supervisors up to the accuracy of the works as per the requirements and the same
will be checked and get it approved by Engineer.
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B6 METHOD STATEMENT FOR SUBGRADE CONSTRUCTION

B6.1 Objective
This method statement provides Subgrade construction methodology adopted by THERUVATH PRL
JV in the package.
B6.2 Scope of Work
This scope of work deals with laying, spreading, and compacting embankment layer with approved
materials as per the clause 305 & 900 of MoRTH, Technical specifications.
• Specification for Road & Bridge works (Fifth Revision), published by Indian Roads
Congress New Delhi.
• Contract documents, MoRTH
B6.4 Man Power
• Senior Engineer
• Junior Engineer
• Supervisors
• Labour
B6.5 Equipment
• Excavator
• Dumpers
• Dozer
• Auto Level
• Levelling Staff
• Measuring Tape
• Motor Grader
• Vibratory roller ,Water Tanker
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B6.6 Borrow Material
The material to be used in Subgrade should satisfy the requirement or the 4-day soaked design
CBRof10% when tested as per IS: 2720 (Part 16) at 97% maximum dry density (IS: 2720 (Part 8)).
Specifications for the materials is given below.
Shall not be more than 50 mm or should not be more than 2/3 rd of

Max Particle Size
compacted layer thickness whichever is minimum
Free swelling index
Max 50 %
of expansive clay
Liquid limit Max 45 %
Plasticity index Max 18
CBR(4 days
Min 10%@97%MDD
soaked)
B6.6.1 Density Requirements of Embankment- MoRTH Table 300-1

Maximum Laboratory dry unit weight when tested
Type of Work
as per IS 2720(Part 8)
Sub grade and earthen shoulders
Not less than 17.5 kN/cu.m
/backfill
B6.6.2 Compaction Requirement for Embankment- MoRTH Table 300-2

Relative compaction as % of maximum
Type of work/Material laboratory dry density as per IS:IS
2720(Part8)
Subgrade Not less than 97
B6.7.1 Setting out
After the proper approval for Embankment top before dumping of Sub grade material giving base
water. The site has been cleared as per clause 201, the work will be set out true to lines, grades,
slopes, curves and sections shown on drawing.
B6.7.2 Compacting ground supporting embankment
In case where the difference between the subgrade level (top of the subgrade on which pavement
rests) and ground level is less than 0.5 m and the ground does not have 97percent relative
compaction with respect to the dry density as given in Table 300-2, the ground will be loosened
up to a level 0.5m below the subgrade level, watered and compacted in layers in accordance with
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Clauses 305.3.5 and 305.3.6 to not less than 97 percent of dry density as given in Table 300-2 of
MoRTH.
The approved material from barrow area will be transported by means of end dumpers and
dumped in the form of heaps.
B6.7.4 Spreading material in Layers and bringing to appropriate moisture content
The subgrade material will be spread in layers of uniform thickness not exceeding 200 mm
compacted thickness over the entire width of subgrade finished by motor grader and compacted
to the specified requirements as in the table 300-2. Each compacted layer will be finish parallel to
the final cross-section of the subgrade.Moisture content of the material will be checked and extra
moisture content required will be added.
The moisture content of each layer will be checked and it should be within the range of OMC
+1% to OMC -2 percent.If moisture content is found out of these limits the same will be brought
within limits by addition of water or by aeration as the case may be.
B6.7.5 Compaction
The compaction will be done with the help of vibratory roller of 8 to 10 tonne static weight. Each
layer will be thoroughly compacted to the densities specified in the specifications which are
mentioned at the end of this document for reference. The rolling pattern will be finalized in trial
stretch. Compaction will be carried out from lower edge to upper edge with 8-10 T roller till to
achieve the required compaction and no tyre or drum impression on the surface.
On completion of compaction of the particular stretch the RFI is raised for inspection to the
Engineer to conduct FOO test & levels. Field density will be done in the manner and frequency
as specified in the specifications.
Loose pockets or surface foliation will be removed by mechanical means only. To avoid any
loose pockets or foliation the final level will be reached by cutting in excess and never by adding
layer less than 100mm. In case material is missing the layer will beloosen by scarifying,
moisturizing prior to dumping or new malarial.
B6.8 Subgrade Around Structures
The filling around culverts, bridges and other structures up to a distance of twice the height of the road
from the back of the abutment will be carried out independent of the work on the main subgrade. The
fill material will not be placed against any abutment or wing wall, until the concrete or masonry has
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been in position for 14 days. The fill material will be deposited in horizontal layers in loose thickness
and compacted thoroughly to not less than 97 % MDD.
B6.9 Traffic Safety
Quality control of the above work will be as per table 900-3of MoRTH
• The top levels will be checked and shall be within +20mm and -25mm of designed level.
• Test for 500 sqm. The degree of compaction will not be less than 97%
• No site traffic will be allowed except for GSB purpose
The senior Engineer will plan and execute the construction of subgrade with help of the Junior
Engineers and site Supervisors up to the accuracy of the works as per the requirements and the same
will be checked and get it approved by Engineer
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B7 METHOD STATEMENT FOR GRANULAR SUB BASE

B7.1 Objective
This method statement provides Granular Sub Base construction methodology adopted by
THERUVATH PRL JV in the package.
B7.2 Scope of Work
This scope of work deals with mixing, laying, spreading, compacting Granular Sub Base layer with
approved materials as per the clause 401 of MoRTH, Technical specifications.

• Specification for Road & Bridge works (Fifth Revision), published by Indian Roads
Congress New Delhi.
• IRC 36-1976
• Hand book of Quality control for construction or Roads & Runways (fourth revision)
B7.4 Man Power
• Senior Engineer (Highways)
• Junior Engineer (Highways)
• Mobile screening plant operator
• Mobile screening plant Helper
• Supervisors
• Labour
B7.5 Equipment
• Front Loader
• Excavator
• Dumpers
• Auto Level
• Levelling Staff
• Measuring Tape
• Motor Grader
• Water tanker
B7.6 Material
The Material to be used for work will be combination of gravel, sand, coarse aggregate and crusher
dust depending upon the grading required. The material will be free from organic or other deleterious
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constituents and conform to the Grading V given in table 400-1. Specifications for the materials is
given below.
Percent by weight passing the IS sieve

IS Sieve Designation
Grading V
75.0mm 100
53.0 mm 80-100
26.5 mm 55-90
9.5 mm 35-65
4.75 mm 25-50
2.36 mm 10-20
0.85 mm 2-10
0.425 mm 0-5
0.075 mm -
CBR Value (Minimum) 30%
Compaction Requirement for Embankment

Relative compaction as % of maximum laboratory
Type of work/Material
dry density as per IS:IS 2720(part8)
Granular Subgrade Not less than 98%
Liquid limit Max 25%
Plasticity index Max 6%
Aggregate Impact value Max 40
B7.7.1 Preparation of Sub – Base
Immediately prior to the laying of Sub material, the sub grade already finished shall be prepared
by removing any extraneous matter, and if any damage to the surface shall be rectified and lightly
sprinkled with water and shall be rolled with 8- 10 Ton capacity soil compactor.
B7.7.2 Preparation of Mix
The gravel or coarse aggregate of different fractions and stone dust will be stacked separately and
mixed by taking the required proportions with the help of Excavators or loaders till it satisfies the
grading requirements.
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The approved material from mixing site will be transported by means of end dumpers
B7.7.4 Spreading Material in Layers and Bringing to Appropriate Moisture Content
Granular Sub Base material will be spread in layers of uniform thickness over the entire width.
The motor grader shall be capable of spreading a material uniformly all over the surface, its blade
shall have hydraulic control suitable for initial adjustments and maintaining the same so as to
achieve the specified slope and grade. Moisture content of the material will be checked and extra
moisture content required will be added. The moisture content of each layer will be checked and
it should be within the range of OMC +1% to OMC -2 percent.If moisture content is found out of
these limits the same will be brought within limits by addition of water or by aeration as the case
may be.
B7.7.5 Compaction
The compaction will be done with the help or vibratory roller of 8 to 10 tonne static weight. Each
layer will be thoroughly compacted to the 98 % of maximum dry density. The rolling pattern will
be finalized in trial stretch. Compact ion shall be carried out from lower edge to upper edge with
8-10 T roller our till to achieve the required compaction and no tyre or drum impression on the
surface. The speed of roller shall not exceed 5 km/h. Where ever the roller is not accessible, the
mixture will be thoroughly compacted with the help of plate compactor or small roller.On
completion of compaction the stretch will be checked for FDD and levels. Field density will be
done in the manner and frequency as specified in the specifications.
Loose pockets or surface foliation will be removed by mechanical means only to avoid any loose
pockets or foliation the final level shall be reached by culling in excess and never by adding layer
less than 100mm. In case material is missing the layer shall be loosen by scarifying, moistening
prior any dumping or new material. All loose, segregated or otherwise defective areas will be
made good to the full thickness of the layer and re--compacted.
B7.7.6 Setting,Drying& opening to traffic
After final compaction of sub base course, the road shall be allowed to dry.No vehicular traffic of
any kind should be allowed on the finished sub-base surface till it has dried and covered with
next item layers up to the 2nd layer of DBM.
B7.8 Traffic Safety
Bamboos with alternative white and block bands and with reflective bands in between will be
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fixed, for demarcating the area of proposed carriageway from the existing carriageway during the
course of work. All the vehicles will have a red flags and reflective bands on the rear. Flag men
will be deployed where crossing of the existing road is unsafe.
Quality control of the above work will be as per table 900-1 and 900-3of MoRTH.
• The top levels will be checked and shall be within +20mm and -25mm of designed level. If
irregularities developed during rolling which exceed 12mm when tested 3-meter straight edge,
the surface will be loosened and premixed material added or removed as required before
rolling so as to achieve a uniform surface conforming to the desired grade and cross fall.
• Test for 500 sqm. The degree of compaction will not be less than 98%
The senior Engineer (Highways) will plan and execute the construction of granular Sub Base with
help of the Junior Engineers and site Supervisors up to the accuracy of the works as per the
requirements and the same will be checked and get it approved by Engineer.
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B8 METHOD STATEMENT FOR WET MIX MACADAM

B8.1 Objective
This method statement provides Wet Mix Macadam construction methodology adopted by
B8.2 Scope of Work
This scope of work deals with mixing, laying, spreading, and compacting Wet Mix Macadam layer
with approved materials as per the clause of406 MoRTH, Technical specifications.

• Specification for Road & Bridge works (Fourth Revision), Published by Indian Roads
Congress New Delhi.
• IRC 109.1997
B8.4 Man Power
• Junior Engineer (Highways)
• Wet mix plant operator
• Wet mix paver operator
• Supervisors
• Un skilled workers
• Lab staff
• Survey staff
• Quality Technician
B8.5 Equipment
• WMM Mixing plant
• Paver
• Dumpers
• Auto Level
• Levelling Staff
• Measuring Tape
• Motor Grader
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B8.6 Specification- As per MoRTH Table 400-12

Los Angeles Abrasion Value Max 40 %
Aggregate Impact Value Max 30%
Combined Flakiness and Elongation Index Max 35%
Plasticity Index Max 6
Percent by weight passing the IS sieve

IS Sieve Designation
Grading 1
53.0 mm 100
45.0 mm 95-100
26.5 mm -
22.4 mm 60-80
11.2 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
0.6 mm 8-22
0.075 mm 0-5
B8.7 Material
Coarse aggregates shall be crushed stone. If crushed gravel/ shingle is used, not less than 90 % by
weight of gravel pieces retained on 4.75 mm sieve shall have atleast two fractured faces. The
aggregates shall satisfy either Los Angles Abrasion value or Aggregate Impact value.
Compaction Requirement for Wet Mix Macadam

Relative compaction as % of maximum laboratory
Type of work/Material
dry density as per IS:IS 2720(Part8)
Wet Mix Macadam Not less than 98 %
B8.8.1 Preparation of WMM- Base
Prior to the laying of WMM-Base material, the Granular sub base already finished will be
prepared by removing any extraneous matter, and if any damage to the surface will be rectified
and lightly sprinkled with water and will be rolled with 8-10 Ton capacity Compactor.
B8.8.2 Provision of Lateral Confinement of Wet Mix
While constructing WMM, arrangement will made for the lateral confinement of wet mix.This
will be done by laying materials adjoining shoulders along with that of wet mix layer.The
sequence of operations will be such that the construction of the shoulder is done in layers each
matching the thickness of the adjoining pavement layer.Only after a layer of pavement and
corresponding layers in shoulder have laid and compacted. The construction of the next layer of
pavement and shoulder will be taken up.
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B8.8.3 Preparation of Mix
In the wet mix plant, the required material will be transported to 4 bins.The plant is calibrated and
adjusted as per the JMF.The bin opening and speed of feeder belt will be adjusted to achieve the
required gradation. It will be mixed in a mixing plant of 200 T /hour having provision for control
addition of water to maintain the required OMC and forced / positive mixing arrangement mixer
of concrete batching plant. For small quantity of wet mix work concrete mixers will be used after
getting prior approval Engineer.
The approved material from mixing plant will be transported by means of end dumpers. Dumpers
will be arranged in such a way that the paver will have enough material to feed continuously.
B8.8.5 Spreading of mix
The wet Mix Macadam material will be spread by paver with guide wire arrangement in full
width of the pavement.The moisture content of each layer will be checked and it should be within
the range of OMC +1% to OMC -2 percent.If moisture content is found out of these limits the
same will be brought within limits by addition of water or by aeration as the case may be.
B8.8.6 Compaction
The compaction will be done with the help or vibratory roller of 8 to 10 tonne static weight. Each
layer will be thoroughly compacted tothe 98% of maximum dry density. The rolling pattern and
loose thickness will be finalized in Trial stretch. Compaction will be carried out from lower edge
to upper edge with 8-10 T roller our till to achieve the required compaction and no tyre or drum
impression on the surface. The speed of roller shall not exceed 5 km/h., along forms kerbs, walls
or other places not accessible to the roller, the mixture will be thoroughly compacted with the
help of plate compactor.On completion of compaction, FDD tests will be carried out and levels
will be checked. Minimum frequency for FDD of WMM is one test for 500 m2·
Loose pockets or surface foliation will be removed by mechanical means only to avoid any loose
pockets or foliation the final level shall be reached by culling in excess and never by adding layer
less than 75mm. In case material is missing the layer shall be loosen by scarifying, moistening
prior any dumping or new material. All loose, segregated or otherwise defective areas will be
made good to the full thickness of the layer and re-compacted.
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B8.8.7 Setting, drying& opening to traffic
After final compaction of wet mix macadam course, the road shall be allowed to dry. Prime coat
will be applied when the surface layer is slightly moist.No vehicular traffic of any kind should be
allowed on the finished sub-base surface till it has dried and covered with next item layers up to
the 2nd layer of DBM. Special care will be taken to close the section to all traffic before DBM by
keeping boulders over the finished surfaced.
B8.9 Traffic safety
Bamboos with alternative white and block bands and with reflective bands in between will be
fixed, for demarcating the area of proposed carriageway from the existing carriageway during the
course of work. All the vehicles will have a red flags and reflective bands on the rear. Flag men
will be deployed where crossing of the existing road is unsafe.
Quality control of the above work will be as per table 900-1 and 900-3 of MoRTH.
• The top levels will be checked and shall be within +10mm and -10mm of designed level. If
irregularities develop during rolling which exceed 8 mm when tested 3-meter straight edge,
the surface will be loosened and premixed material added or removed as required before
rolling again so as to achieve a uniform surface conforming to the desired grade and cross fall
• The compacted surface will be checked for field density at the frequency of Test for 500 sqm.
The degree of compaction will not be less than 98%.Moisture content will be checked before
compaction for preceding the work.
The senior engineer will plan and execute the construction of embankment with help of the Junior
Engineers and site Supervisors up to the accuracy of the works as per the requirements.
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B9 METHOD STATEMENT FOR PRIME COAT

B9.1 Objective
This method statement provides application of Prime Coat methodology adopted by THERUVATH
PRL JV in the package.
B9.2 Scope of Work
This work consists of the application of a single coat slow setting cationic emulsion to a porous
granular surface preparatory to the superimposition of bituminous treatment of mix.
B9.3 Material
As per Clause 502.2.3 technical specification the Primer will be slow setting cationic emulsion
Complying with IS: 8887.
B9.4 Staff
• Compressor operator)
• Supervisors
• Sprayer operator
• Lab Engineers
B9.5 Machinery
• Compressor
• Primer sprayer
• Mechanical boomer
B9.6 Preparation of Road Surface
Prior to applying the primer, the surface will be carefully swept clean of dust and loose particles, care
will be taken not to disturb the interlocked aggregate. This will be done when the surface layer is
slightly moist and the surface will be kept moist until the primer is applied.
B9.7 Rate of Spray
A.s per table 500-3 of MoRTH, the rate of spray of prime coat is 0.7 to 1 kg /sq.m and it will be
sprayed uniformly.
B9.8 Curing of Primer and Opening to Traffic
A Primed surface will be allowed to cure for at least 24 hours or such other period as is found to be
necessary to allow all the volatiles to evaporate before any sub request treatment or mix is laid. Any
unabsorbed primer will be blotted with an application of sand, using the minimum quantity. A primed
surface willnow be opened to traffic, other than that necessary to lay the next course.
B9.9 Protection for Kerb
A rubber pad will be hanged al the end of spray bar to avoid spillage of emulsion over the kerb.
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B10 Method statement for Dense Bituminous Macadam

B10.1 Objective
This method statement provides for Dense Bituminous Macadam methodology adopted by SPL - RM
JV in the package.
B10.2 Scope of Work
This scope of work deals with mixing, laying, spreading, and compacting the approved Bituminous
mix in accordance with clause 507 of MoRTH.

• Specification for Road & Bridge works (Fourth Revision), published by Indian Roads
Congress New Delhi.
• IRC 109-1997
B10.4 Man Power
• Senior Engineer
• Junior Engineer
• Hot mix plant operator
• Electronic sensor paver operator
• Supervisor
• Lab staff
• Survey staff
B10.5 Equipment
• Hot Mixing plant
• Electronic sensor Paver
• Dumpers
• Auto Level
• Levelling Staff
• Measuring Tape
• Smooth -W heeled Roller
• Pneumatic tired Roller
• Bitumen sprayer
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• Air compressor
• Thermometers
• 150mm core cutter
• Compressor/Mechanical broom for prime coat and tack coal
• 3-meter-long Straight edge
• Camber board
B10.6 Material
The Material to be used for construction of dense bituminous macadam should satisfy the following
requirements.
• Paving bitumen of grade VG-30 will be used.
• Coarse aggregates will be of clean, strong, durable, cubical shape and free from other
deleterious matter and adherent coating.
• Los Angeles Abrasion value will not be more than 35 % when tested as per IS: 2386 (Part
-4).
• Aggregate impact value will not be more than 27% when tested as per IS: 2386 (Part -4).
• Flakiness and Elongation indices will not be more than 35 % when tested as per IS: 2335
(Part -1).
• Stripping value of bitumen aggregate mixtures will be of minimum retained coating 95%
when tested as per IS 6241.
• Water absorption of the aggregate will not be more than 2% when tested as per IS: 2386
(Part-3).
• The filler will be graded within the following limits.
IS Sieve Percent passing
600 microns 100
300 microns 95-100
75 microns 85-100
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• Grading of DBM is as follows- (For Grade 2)
Grade II
Sieve Designation
Percent passing
45 mm 100
37.5 mm 100
26.5 mm 90-100
19.0 mm 71-95
13.2 mm 56-80
4.75 mm 38-54
2.36 mm 28-42
300 microns 7-21
75 microns 2-8
B10.7 Methodology
• Before starting the production, the condition of weather (i.e. atmosphere temperature&
rain fall will be checked and recorded in a register
• Laying of bituminous mixtures will not be carried out when the air temperature at the site
is below 10°C or when the wind speed exceeds 40Km/hr at 2m height.
• The base will be thoroughly swept clean free from dust and foreign matter by means of
compressed air or mechanical brooms before applying prime coat & tack coat
• Marking will be done by adjusting paver sensor to its lines, grades and cross-sections.
String rods will be placed at 10 m interval on both sides
• RS-1 emulsion will be applied as Tack coat over the prepared base to the required
quantity
• The temperature of the bitumen will be 150-160°C. The temperature of the coarse
aggregate will be 150-165°C. The difference of the temperature between the binder &
aggregate should not more than 14°C
• Mix produced from the hot mix plant will be transported to the site by means of end
dumpers and the dumpers will be covered properly (when the atmosphere temperature is
< 25 °C).
• The mix will be unloaded gently into the paver hoper and paving will be started
uniformly. The temperature of the mix will be checked at weigh bridge and before
unloading in to the paver hoper by the lab technicians and the mix will be rejected by
them and send back if the temperature is found <125°C (As per table 500-5 of MoRTH).
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• The same will be informed to HMP operator, if any discrepancy found in HMP, the plant
will be shut down immediately and called for service engineer.
• The levels will be checked before paving and after compaction with respect to the
FRL.FRL levels will be given to the site engineer separately.
• Initial or break down rolling will be carried out immediately following closeto the paver
in longitudinal direction from lower edge to upper edge with 80-100 KN static weight of
smooth wheeler roller. Over lapping on successive passes by at least one half of the width
of rear roll. The speed of the roller will be maintained not more than 5Km/hr
• Intermediate rolling will be done with 80-100 KN static weight of vibratory roller
followed by pneumatic tired roller of 12-lSKN weight having tyre pressure of at leasts.6
kg/sq.m and it will be continued till the compaction achieved is at least 98% of lab
modified Marshall density. Finishing rolling will be done with smooth wheeled roller on
the layered surface
• If the density is not satisfactory, the layer will be removed up to full depth and freshly
laid and compacted
B10.8 Quality Control
• The prime coat will be slow setting emulsion will be applied at a rate of 0.7-1 Kg/sqm
after cleaning the WMM surface with the help of compressed air and mechanical
broomer.
• The tack coat is not necessary, when the material to receive an over lay is a freshly laid
bituminous layer that has not been subjected traffic or contaminated by dust, where the
overlay is completed within two days.
The following tests will be conducted in the laboratory

Sl No. Name of Test Specifications Frequency
1 Aggregate Impact Value 27% Maximum One test per 50Cum of aggregate
Los Angeles Abrasion
2 35% Maximum One test per 50Cum of aggregate
value
3 Flakiness and Elongation 35% Maximum One test per 50Cum of aggregate
Minimum
One set of three representative
4 Stripping value retained coating
specimens for each source
95%
5 Water sensitivity of mix Minimum 80%
6 Water absorption of 2%Maximum One set of three representative
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aggregates specimens for each source
7 Grading of aggregates - One test per 25Cum of aggregate
Soundness
One determination for each source
• Magnesium 18%
8 of supply then as warranted by
sulphate
change in the quality of aggregates
• Sodium sulphate 12%
One set of tests on individual
constituents and mixed aggregate
9 Mixing Grading from the dyer for each 400tones of
the mix subject a minimum of two
tests from plant per day
Min 2025 kg for
Stability of mix flow, air
grade I AND For each 400 tons of mix product, a
voids, voids in mineral
900 kg for grade set of 3 Marshall specimens to be
aggregate (VMA)(%)
10 II 2-4MM 3-6% prepared and tested subject to a
Minimum II minimum of two sets being tested
Voids filled in Bitumen per plant per day.
related to design
(VFB)
air voids 65-75%
Control of temperature of
binder in boiler, aggregate
11 - At regular close intervals
in the dyer and mix at the
time of laying and rolling
One test per 400 tons of mix subject
Minimum 4.5 %
12 Control of binder content to a minimum of two tests per plant
for grade II
per day
One test per 400 tons of mix subject
13 Grading of mix to a minimum of two tests per plant
per day
Regular control through checks on
Rate of spread of mixed
14 - the weight of the mixed material and
material
layer thickness.
Density of compacted
15 - One test per 250 m2Area
layer
Should not
For each finished lane before
16 Roughness Index exceed 2000
allowing for traffic.
mm/ Km

17 Polished stone value -
specimens for each source of supply
Surface regularity of As given in

18 At regular close intervals
DBM below table
• The application of track coat will be checked as per the following table.
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Type of surface Quantity/sq.m
Normal bituminous surface 0.2-0.3
Granular surface treated with primer 0.25-0.3
• The graduation of the mix will be controlled as per the approved designed mix.
• Mix temperature will be controlled at plant within the range of 150-163°C and the
temperature less than 125°C will not be used for paving.
• The compacted surface will be checked for field density by taking cores at the frequency
of 1test for250 sq.m. The degree of compaction should not be less than 98% of lab
Marshall Density.
• The surface will be checked for levels at 5m intervals longitudinally and transversely and
the same will be within +/- 6mm
• By engaging sufficient no. of dumpers (i.e. 7 to 0), the paving will be continued without
any stop on that day.
• Before starting the paving, the end of the DBM layer which has paved on previous day
will be cut to a straight line. After applying tack coat on cut area, paving will be start just
before from the cut portion. The mix over the previous day layer will be removed
manually.
• Paving will be stopped 300mm before expansion joint and will be commenced after
300mm from expansion joint. Where ever the approach slab is to be providing, 3.5m
length from the abutment will be left for the same.
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B11 Method statement for Recycling of Bituminous pavement

B11.1 Objective
This method statement provides the methodology for recycling of bituminous pavement adopted by
B11.2 Scope of Work
This scope of work deals with recycling of existing bituminous pavement materials to upgrade an
existing bituminous pavement which has served its initially intended purpose. The work consist of
pavement removal, stockpiling of material from the old pavement, addition of new bitumen and
untreated aggregates in the requisite proportions, mixing, spreading and compaction of the blended
materials in accordance with clause 519 of MoRTH.

• Specification for Road & Bridge works (Fourth Revision), published by Indian Roads
Congress New Delhi.
• IRC 120-2015
B11.4 Man Power
• Senior Engineer
• Junior Engineer
• Supervisor
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• Lab staff
• Survey staff
B11.5 Equipment
• Electronic sensor Paver
• Dumpers
• Auto Level
• Levelling Staff
• Measuring Tape
• Smooth -W heeled Roller
• Pneumatic tired Roller
• Bitumen sprayer
• Air compressor
• Thermometers
• 3-meter-long Straight edge
• Camber board
B11.6 Reclaimed Bituminous materials for Central Plant Recycling
B11.6.1 Materials for recycled pavement
The recycled materials are a blend of reclaimed and new materials proportioned to achieve a paving
mixture with the specified engineering properties. The reclaimed materials are tested and evaluated to
find the optimum blend meeting the mixture requirements. Such tests are carried out on representative
sample, either core sampled from the carriageway or samples taken from the stockpiles. As an absolute
minimum, one sample to represent 500 m two lane carriageway will be taken.
B11.6.2 Bitumen Extraction
The procedure described in ASTM D-2172 and IRC SP11-1988 (Appendix 5) will be used to
quantitatively separate aggregates and bitumen from any representative sample of reclaimed bituminous
pavement.
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B11.6.3 Aggregate Evaluation
Mechanical sieve analysis (IS : 2386, Part I, Wet sieving method) will be performed on the aggregate
portion of the reclaimed bituminous pavement sample to determine the grading. It is essential that the
reclaimed materials to be recycled are consistent, as variable materials will cause problems with the
control of quality and impede the efficiency of the recycling operation. After selecting the proportion of
the reclaimed materials to be recycled, the grading of the mixture will be adjusted to meet the
specification requirements, by the addition of selected aggregate sizes.
B11.6.4 Evaluation of Bitumen
When the amount of reclaimed bituminous materials to be used in the mixture exceeds 10 %, the
penetration value of the recovered binder from the reclaimed bituminous material, before mixing, shall
exceed 15 pen, after recovery of binder in accordance with the requirements of BS 2000: Part 397, when
tested in accordance with IS : 1203. Provided the above requirement is met, hardening of the old binder,
during the original mixing process or through ageing, can be compensated for by adding softer bitumen,
to obtain the appropriate final grade of binder. After mixing with the recycled, the binder recovered from
the mixture shall have a recovered penetration value not less than the value specified in MoRTH Table
500-48.
Minimum recovered penetration value of binder after mixing- As per MoRTH Table 500-48
Specified Grade of Binder Viscosity Grade Minimum recovered penetration value of binder
after mixing
40 (45 pen) 27
30 (65 pen) 39
10 (90 pen) 54
B11.6.5 Combined Aggregate Grading
Blend reclaimed and new aggregate shall meet the grading criteria specified in clauses 505 or 506 of
MoRTH
B11.6.6 Mixture Design
The combined aggregate grading & binder content shall meet the requirements as per clauses 504 or 505
of MoRTH. The mix design shall also comply with the requirement of Table 500-10 of MoRTH. The
variation in three or four sieves with respect to percentage passing shall not exceed 3 to 4 % per sieve.
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B11.7Procedure
This consist of 2 steps:
a) Reclaiming Old Pavement Materials/ Cold Removal Process
b) Hot in Plant Recycling (HIP)
a) Reclaiming Old Pavement Materials/ Cold Removal Process
Removal of pavement materials to the required depth can be accomplished at ambient temperature (cold
process) by milling. Milling is the control removal of an existing pavement to a desired depth, using
specially designed equipment having replaceable tungsten carbide cutting teeth mounted on a rotor drum
driven by the power supplied by the milling machine. It is the most common way of reclaiming the
bituminous pavement material. It is mostly used following a cold process, and hence commonly known as
cold milling. In the cold process, the ripping and crushing operations will be carried out using scarifiers,
grid rollers, or rippers or by any other means as directed by the Engineer. The removed materials will be
loaded and hauled for crushing to the required size. Alternatively, cold milling or planning machines can
be used to reclaim bituminous pavement to controlled depths. Milling machines transfers maximum
energy on to milling drum in removing pavement layers by impacting the pavement with milling teeth
mounted on a drum rotating at about 200 rpm. The impacts break up the pavement by ripping through the
mastic and aggregate particles. Crushing of aggregate particles causes the gradation of the millings to be
finer than the gradation of the pavement layers in place. The final gradation required of the reclaimed
bituminous materials (RBM) by milling can be obtained by controlling depth of milling cut, and speed of
machine .Also Gradation bar on milling machine helps to control the cut size. Thereafter the bituminous
layers are removed, any remaining aggregate materials that are to be incorporated in the recycled hot mix
will be scarified and removed. When the pavement material removal is completed, any drainage
deficiencies occurring will be corrected. After that, the base/sub base, as the case may be, will be cut,
graded and compacted to the required profile and density.
In the cold process, the reclaimed bituminous pavement material stockpiled with height of stockpiles not
exceeding 3 m. The reclaimed untreated aggregate base /sub base material also will be stock piled in the
same manner as new aggregate.
b) Hot in Plant Recycling (HIP)
Hot mix recycling is a method in which the old Asphalt is combined with new aggregate and an asphalt
cement or recycling agent to produce hot mix asphalt (HMA). Both batch and drum type hot mix plants
are used to produce recycled mix. Hot in-plant recycling involves the usual Hot mix production process
with two main differences, viz (i) instead of all fresh aggregates and bitumen in the usual Hot Mix
production, HIP uses RBM to the extent of 30 %, (ii) rejuvenators are required to soften the oxidized
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binder in RBM. The Asphalt is obtained from pavement milling with a rotary drum cold planning
machine and may be further processed by ripping and crushing operations, if needed. The mix lay down
and compaction equipment and procedures are same as for conventional HMA. The ratio of old Asphalt
to new aggregates depends on the mix design, on the type of hot mix asphalt plants, and on the quality of
stack emission generated. The use of microwave technology has allowed the use of a higher amount of
Asphalt, because the Asphalt can be preheated
B11.9 Opening to Traffic
For recycled material forming the base or binder course layer, Clause 504.5 or 505.5 shall apply as
appropriate. For recycled material forming the wearing course layer, Clause 508.4 shall apply.
B11.10 Surface Finish and Quality Control
The surface finish of the completed construction shall conform to the requirements of Clause 902. For
control of the quality of materials and the works carried out the relevant provisions of Section 900 shall
apply.
B11.11 Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with the
provisions of Clause 112 of MoRTH.
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B12 METHOD STATEMENT FOR TACK COAT

B12.1 Objective
This method statement provides laying of Tack coat methodology adopted by THERUVATH PRL JV
in the package
B12.2 Scope of Work
This work consists of the application of a single coat Rapid setting cationic emulsion to an existing
bituminous road surface or on primed surface.
B12.3 Material
As per Clause 502.2.3 technical specification the Primer will be slow setting cationic emulsion
complying with IS: 8887.
B12.4 Staff
• Senior Engineer
• Compressor operator
• Supervisors
• Sprayer operator
• Lab Engineers
B12.5 Machinery
• Compressor
• Primer sprayer
• Mechanical broomer
B12.6 Preparation of Road Surface
Immediately before the application of tack coat, the surface will be swept clean with a mechanical
broom or high-pressure air jet.
B12.7 Rate of spray
As per table 500-2 of MoRTH, the rate of spray of tack coat is 0.25 to 0.3 kg/sq.m on granular
surfaces treated with primer and hungry bituminous surface and 0.2 -0.3 kg/sqm on normal bitumen
surfaces
B12.8 Curing of primer and opening to traffic.
The Tack coat will be left to cure until all the volatiles have evaporated before any subsequent
construction is started
B12.9 Protection for kerb
A rubber pad will be hanged al the end of spray bar to avoid spillage of emulsion over the kerb.
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B13 Method statement for Bituminous Concrete
B13.1 Objective
This method statement provides Bituminous Concrete methodology adopted by THERUVATH PRL
JV in the package.
B13.2 Scope of Work
This scope of work deals with laying, spreading, and Compacting the approved Bituminous mix in
accordance with clause 507 of MoRTH.

• Specification for Road & Bridge works (Fifth Revision), Published by Indian Roads
Congress New Delhi.
• IRC 109-1997
B13.4 Man Power
• Senior Engineer
• Junior Engineer
• Supervisor
• Lab staff
• Survey staff with levelling instrument
B13.5 Equipment
• Electronic sensorPaver
• Dumpers
• Auto level
• Levelling Staff
• Measuring Tape
• Smooth -Wheeled Roller
• Pneumatic tyred Roller
• Bitumen sprayer
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• Air compressor
• Thermometers
• Towed fifth wheel bump integrator (Calibrated one)
• 3 meter long Straight edge
• Camber board
• Water tanker
B13.6 Material
The Material to be used for construction of dense Bituminous Course should satisfy the following
requirements.
• Paving bitumen of grade VG-30 will be used.
• Coarse aggregates will be of clean, strong, durable, cubical shape and
• Free from other deleterious matter and adherent coating.
• Los Angeles Abrasion value will not be more than 30% when tested as per IS: 2386 (Part
-4).
• Aggregate impact value will not be more than 24% when tested as per IS: 2386 (Part -4).
• Flakiness and Elongation indices will not be more than 35% when tested as per IS: 2335
(Part -1).
• Stripping value of bitumen aggregate mixtures will be of minimum retained coating 95%
when tested as per IS 6241.
• Water absorption of the aggregate will not be more than 2% when tested as per IS: 2386
(Part-3).
• Polished stone value of the aggregate min 55 when tested as per BS 812 part 114.
• The filler will be graded within the following limits.
IS Sieve Percent passing

600 microns 100
300 microns 95-100
75 microns 85-100
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Grading of BC is as follows (for Grade II)

Grade II
Sieve Designation
Percent Passing
19.0 mm 100
13.2 mm 90-100
9.5 mm 70-88
4.75 mm 53-71
2.36 mm 42-58
1.18 mm 34-48
0.6 mm 26-38
0.3 mm 18-28
0.15 mm 12-20
0.075 mm 4-10
B13.7 Methodology
• Before starting the production, the condition of weather (i.e. atmosphere temperature &
rain fall will be checked and recorded in a register
• Laying of bituminous mixtures will not be carried out when the air temperature at the site
is below 10°C or when the wind speed exceeds 40Km/hr at 2m height.
• The base will be thoroughly swept clean free from dust and foreign matter by means of
compressed air or mechanical brooms before applying prime coat & tack coat
• Marking will be done by adjusting paver sensor to its lines, grades and cross-sections.
String rods will be placed at 10 m interval on both sides
• RS-1 emulsion will be applied as Tack coat over the prepared base to the required
quantity
• The temperature of the bitumen will be 150-160°C. The temperature of the coarse
aggregate will be 150-165°C. The difference of the temperature between the binder &
aggregate should not more than 14°C
• Mix produced from the hot mix plant will be transported to the site by means of end
dumpers and the dumpers will be covered properly (when the atmosphere temperature is
< 25 °C).
• The mix will be unloaded gently into the paver hoper and paving will be started
uniformly. The temperature of the mix will be checked at weigh bridge and before
unloading in to the paver hoper by the lab technicians and the mix will be rejected by
them and send back if the temperature is found <125°C (As per table 500-5 of MORTH).
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The same will be informed to HMP operator, if any discrepancy found in HMP, the plant
will be shut down immediately and called for service engineer.
• The levels will be checked before paving and after compaction with respect to the
FRL.FRL levels will be given to the site engineer separately.
• Initial or break down rolling will be carried out immediately following closeto the paver
in longitudinal direction from lower edge to upper edge with 80-100 KN static weight of
smooth wheeler roller. Over lapping on successive passes by at least one half of the width
of rear roll. The speed of the roller will be maintained not more than 5Km/hr
• Intermediate rolling will be done with 80-100 KN static weight of vibratory roller
followed by pneumatic tired roller of 12-l5KN weight having tyre pressure of at least 5.6
kg/sq.m and it will be continued till the compaction achieved is at least 98% of lab
modified Marshall density. Finishing rolling will be done with smooth wheeled roller on
the layered surface
• If the density is not satisfactory, the layer will be removed up to full depth and freshly
laid and compacted
• The Traffic will be opened on BC after24hrs and mix has cooled down to the surrounding
temperature.
B13.8 Quality Control
• The prime coat will be slow setting emulsion will be applied at a rate of 0.7 to 1 Kg/sqm
after cleaning the WMM surface with the help of compressed air and mechanical
broomer.
• The tack coat is not necessary, when the material to receive an over lay is a freshly laid
bituminous layer that has not been subjected traffic or contaminated by dust, where the
overlay is completed within two days.
The following tests will be conducted in the laboratory

1 Aggregate Impact Value 24% Maximum One test per 50Cum of aggregate
Los Angeles Abrasion
value
Flakiness and
Elongation
Minimum retained One set of three representative
4 Stripping value
coating 95% specimens for each source
5 Water sensitivity of mix Minimum 80%
6 Water absorption of 2%Maximum One set of three representative
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aggregates specimens for each source
7 Grading of aggregates - One test per 25Cum of aggregate
Soundness One determination for each source
8 • Magnesium sulphate 18% of supply then as warranted by
• Sodium sulphate 12% change in the quality of aggregates
One set of tests on individual
constituents and mixed aggregate
9 Mixing Grading from the dyer for each 400tones of
the mix subject a minimum of two
tests from plant per day
Stability of mix flow, air
voids, voids in mineral
Min 900 kg for
aggregate (VMA)(%)
grade I and grade II For each 400 tons of mix product,
2-4mm 3-6% a set of 3 Marshall specimens to
10 Minimum 12 related be prepared and tested subject to a
to design air voids minimum of two sets being tested
per plant per day.
Voids filled in
65-75%
Bitumen(VFB)
Control of temperature
of binder in boiler,
11 aggregate in the dyer - At regular close intervals
and mix at the time of
laying and rolling
Minimum 5.0 % for One test per 400 tons of mix
Control of binder
12 grade II and for subject to a minimum of two tests
content
grade-I respectively per plant per day
One test per 400 tons of mix
13 Grading of mix subject to a minimum of two tests
per plant per day
Regular control through checks on
Rate of spread of mixed
14 - the weight of the mixed material
material
and layer thickness.
Density of compacted
15 - One test per 250 m2 Area
layer
Should not exceed For each finished lane before
16 Roughness Index
2000 mm/ Km allowing for traffic.
17 Polished stone value Minimum 55 specimens for each source of
supply
• The application of track coat will be checked as per the following table.
Type of surface Quantity/sq.m

Normal bituminous surface 0.25-0.3
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Granular surface treated with primer 0.2-0.3
• The graduation of the mix will be controlled as per the approved designed mix.
• Mix temperature will be controlled at plant within the range of 150-163°C and the
temperature less than 125°C will not be used for paving.
• The compacted surface will be checked for field density by taking cores at the frequency
of 1test for 250 sq.m. The degree of compaction should not be less than 98% of lab
Marshall Density.
• The surface will be checked for levels at 5m intervals longitudinally and transversely and
the same will be within +/- 6mm
• By engaging sufficient no. of dumpers (i.e. 7 to 0), the paving will be continued without
any stop on that day.
• Before starting the paving, the end of the DBM layer which has paved on previous day
will be cut to a straight line. After applying tack coat on cut area, paving will be start just
before from the cut portion. The mix over the previous day layer will be removed
manually.
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B14 METHOD STATEMENT FOR SLAB / BOX CULVERTS

B14.1 Scope
The following types of culvert construction are involved in our scope of work.
a) Reconstruction of culvert
b) Widening of slab culvert
B14.2 Reference
 Ministry of Road Transport & Highway Specification.
 Relevant Drawings
 IRC: SP-13
B14.3 Working Drawing
Working drawings and bar bending schedule will be submitted to the engineer prior to start of work at
site. The drawing of complete form work will be submitted to the engineer before any erection is
taken up. After approval of the above from the engineer, the setting out will be started. Construction
of slab/ box culvert will be completed on one side and passage of traffic opened and then another side
will be taken up.
B14.4 Sources of Material
 Coarse Aggregate: Maximum nominal size of coarse aggregate for various structural
components in PCC & RCC shall conform to section 1700
 Sand / Fine Aggregate: All the fine aggregates shall conform to IS:383 and test for
conformity shall be carried out as per IS:2386 and section -1008 of tile technical
specifications
 Cement: Ordinary Portland cement - 53 grade conforming to IS: 12269 and section 1006 of
the technical specifications
 Steel: Steel shall conform to IS: 1786 and as per section 1600 of MoRTH
 Water: As per Section -1010 of MoRTH.
 Admixture: As per Section -1012 of MoRTH
 Formwork: As per Section -1500 of MoRTH
B14.5 Production,Transportation, laying and curing of concrete
 Concrete from the batching plant will be transported by the Transit Mixer to the placement
site. Placing of concrete will be done by chute & head load and concrete shall not be freely
dropped in to place form a height exceeding 1.5 m. Slump test will be performed to
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confirm the required slump and proper record will be maintained at batching plant and
placing site.
 After checking of steel reinforcement and shuttering by the Engineer's representative, the
request for concreting will be produced. If concreters not started within 24 hours of the
approval being given, it shall be obtained again from the Engineer. Concreting will always
be planned to proceed continuously to complete up to construction joint as shown in the
approved drawing. When concrete is conveyed by chute, slope of the chute shall be so
adjusted that the concrete flows without the use of excessive quantity of water and without
any segregation of its ingredients. The delivery end of the chute shall be as close as
possible to the point of deposit the chute shall be thoroughly flushed •with water before
and after each working period and the water used for this purpose shall be discharged
outside the formwork.
 All formwork and reinforcement contained is; it shall be. Cleaned and made free from
standing water & dust, immediately before placing of concrete. When deposited shall have
a temperature of not less than 5 degree Celsius and not more than 40 degree Celsius. It
shall be compacted in its final position within 30 minutes of it; discharge from the transit
mixer. When this time shall be within 1hour of the addition of cement to the mix. Finishing
and top and bottom slab will be as per required levels as specified in the drawing concrete
shall be thoroughly compacted by vibration and over vibration shall be avoided to
minimize the risk of forming a weak surface layer. Additional vibrators in serviceable
condition shall be kept at site so that they can be used in the event of break down. Fresh
concrete shall not be placed against concrete, which has been in position for more 30
minutes unless proper construction joint is formed. The concrete shall be deposited in
horizontal layer to a compacted depth not exceed 300 mm.
 As per section 1713.1of MoRTH the exposed surface of concrete shall be kept
continuously in a damp or wet condition by pending or by covering with a layer of jacks,
canvas, Hessian cloth or similar materials and shall be kept constantly wet for a period of
not be less than 14 days from the date of placing of concrete.
B14.6 Test and sampling procedures
 The material will be tested as per MoRTH specification and relevant IS and IRC codes will
be followed for the testing procedures. Concrete produced will be sampled and tested as
per IS:516 and IS:1199 respectively. Concrete cubes shall be cast in the batching plant area
and site on regular basis. The number of cubes & its testing shall conform to clause no.
1700 of MoRTH.
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 Random sampling and lot-by-lot or acceptance inspection shall be made for the 28 days
cube strength of concrete. Concrete under acceptance shall be rationally divided into lost
for the purpose of sampling before commencement of work.
 Concrete for making 3 test cubes shall be taken from a batch of concrete at point of
delivery in to construction according to procedure laid down in IS: 199.Three test
specimens shall be made from each sample for testing 28 days. Additional cubes will be
taken to determine the strength of concrete at 7 days.
 The minimum frequency of sampling of concrete of each grade shall be in

accordance with following.
Quantity of Concrete Nos. of Samples

1- 5 1
6-15 2
16-30 3
31-50 4
4 plus one additional sample part for each
51 and above
additional50 m3 or part thereof
 At least one sample shall be taken from each Lift of work immediately after the removal of
forms, exposed bars or bolts if any shall cut inside the concrete member to a depth of at
least 50 mm below the surface of concrete and resulting holes filled with cement mortar.
 All construction and expansion joints in the completed work shall be left carefully tooled
and free from any mortar and concrete. Expansion joint filler shall be left exposed forits
full length with clean and true edges
B14.7 Grade of Concrete

 M-15 = For P.C.C (Levelling Course)
 M-20 = For P.C.C of abutment, wing wall,return wall etc
 M-30 = For R.C.C Slab
 Mix of Concrete: As per approved mix design.
B14.8 Construction Operations
a) Setting out
 After the site has been surveyed, the limits of excavation shall be set out to true lines,
curves and slope as per the MoRTH specifications.
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b) Dismantling of Existing Structure
 Structure shall be dismantled carefully and the resulting material so removed as not to
cause any damage to the serviceable material to be salvaged. In case of reconstruction the
existing structure will be dismantled after taking the joint measurement of existing up to
OGL. Measurement for balance part of structure will be taken in due course while
dismantling. Then final sketch of the. structure will be prepared and submitted to
Engineer
c) Excavation
 The excavation for foundation bed shall be done true to the lines and grades shown on the
drawing or as directed by Engineer in accordance with the Technical Specifications
 If bedrock or boulder strata are encountered excavation shall be taken down to at least
200 mm below the bottom level of the foundation with prior permission of the Engineer.
 Excavation consist of the removal of the material for the construction of foundation for
raft, wing wall and other similar structure, and additional(as per contract) specification
and the lines and dimensions shown on the drawing or as indicated by the Engineer. The
work shall include draining and pumping. The removal of all longs, stumps, grubs and
other deleterious matter and obstruction, necessary for placing the foundations trimming
of excavation, back filling and cleaning up the site and disposal of all surplus material
 Excavation will be taken to the width of the lowest step of the footing and shall be left
plumb where the nature of soil allows it. Where the nature soil or the depth of the trench
and the season of the year do not permit vertical sides, we shall put up the necessary
shoring, strutting and planking or cut slope to a safer angle or both with due regard to
safety of personnel and works and up to the satisfaction of the Engineer.
d) Preparation of Foundations
The bottom of the foundation shall be levelled both longitudinally and transversely or as
directed by the Engineer.
e) Back filling:
Backing shall be done with approved material after concrete is fully set and carried out in
such a way as not cause under thrust on any part of the structure
i. Inside Foundation
All space between foundation concrete and the sides of excavation shall be refilled to the
original surface in layers not exceeding 150 mm compacted thicknesses.
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ii. End wall and wing wall

The filled material shall not be placed against end wall and wing walls; unless permission
has been given by the Engineer but in no case until the concrete has been in position for
14 days. The material for backfill shall not be having plasticity index and liquid limits
more than 20 and 40 respectively. Filling behind end walls and wing walls for all
structures will confirm to the general guidelines given in appendix 6 of IRC:78. The
filled material shall be deposited in horizontal layer in loose thickness and compacted to
the requirement of table 300-2 of MoRTH
B14.9 Construction Joints
Construction Joints shall be avoided as for as possible and in no case the locations of such joints shall
be changed or increased from the shown on the drawing except with express approval of the Engineer
the joints shall be provided in a direction perpendicular to the member axis
B14.10 Safety
During construction of slab culvert adequate safety & traffic sign shall be installed as per safety plan
management and clause 100 of MoRTH standards.
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B15 METHOD STATEMENT FOR PIPE CULVERT CONSTRUCTION

B15.1 Objective
This method statement provides Pipe culvert construction methodology adopted by SPL-RM JV in the
package.
B15.2 Scope of Work
The work shall consist of furnishing and installing reinforced cement concrete Pipes, of the type,
diameter and length required at the locations shown in the drawing in accordance with clause 2900 of
MoRTH, Technical specification.

 Specification for Road & Bridge works (Fourth Revision), published by Indian Roads
Congress New Delhi.
 Contract documents. Volume-II Technical Specifications
 Construction Drawings.
 IS 458.2003 Pre cast concrete pipes
B15.4 Man Power
 Senior Engineer
 Junior Engineer
 Supervisors
 Labour
B15.5 Equipment
 Excavator
 Trippers
 Concrete batching plant
 Transit mixers
 Measuring tapes
 Water Tanker
 Shuttering plates
 Cranes with rope
 Plate and needle vibrators
 Survey kits etc.
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B15.6 Material
All materials used in the construction of Pipes shall be inspected, tested and approved by the
concessionaire either at the place of manufacture or at the site before their incorporation in the works.
B15.7.1 Setting out
 The place where the culvert exists will be located and the centreline shall be located
with the help of total station. The culvert so located either perpendicular or with some
skew to the road alignment according to the flow direction
 Reference points shall be fixed on both s des of the culvert in both traffic direction
and normal to the traffic direction.
 Temporary benchmark shall be established near the culvert and it should be checked
regularity with respect to the permanent benchmark. The limits of excavation shall be
marked on original ground to the line and length as per the drawing.
 The original ground levels shall be taken on center line and either side of the
centerline of the culvert location to the required width and length as per the drawing.
 The number of rows to be taken is depending on width of the culvert, OGL's shall be
taken throughout the length of the culvert including flexible apron. The length of the
culvert is varied from culvert to culvert depending on proposed road levels and bed
levels of the channel
 Working drawing shall be submitted for Engineer's approval
B15.7.2 Excavation
 Excavation will be carried out by means of excavator to the required level, length and
width and the excavated soil shall be removed by loading in to the end dumpers.
Excavation shall be including apron and temporary put let, the excess material shall be
removed from the site, at the same time, in order not to block the outlet. All temporary
mud mitigation measures to protect adjacent land shall be taken immediately.
 The excavated portion shall be cleaned off if any slush, and it should be dressed
properly
B15.7.3 Bedding for pipe -First class Bedding
The pipe will be bedded on a continuous layer of well compacted approved granular
material, shaped concentrically to fit the lower part the pipe exterior for at least 10% of its
overall height or otherwise shown in Drawing. The bedding material is well graded sand or
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another granular material passing 5.6 mm sieve suitably compacted. The compacted
thickness of the bedding layer in no case will be less than 75 mm.
B15.7.4 Pipe Laying and Jointing
The laying of pipes shall be done on prepared foundation. The laying shall start from the
outlet and proceed towards the inlet and shall be done to the specified levels and
grades.The pipes shall be fitted and matched in such a way that they form a Culvert with a
smooth invert. The jointing shall be done in such a way it is smooth and consistent Joint
with the interior surface of the pipe.
B15.7.5 Back Filling
The backfilling shall be done after the jointing material has hardened. The backfill will be
with selected granular material Sand/Stone dust of approved quality. Back filling shall be
carried in layers not exceeding 150mrn to the level 300mm above the top of the pipe shall
be done as per the drawing and technical specification clause 305 and clause 710.1.4 of
IRC. 78. Sand as a backfill material will be compacted with water. Sand will be filled and
confined. Water is poured up to saturation condition to get compaction.Compaction shall
proceed with light equipment such as small vibrating roller or vibrating plate
B15.7.6 Head Wall
Specified concrete should be laid for the remaining head wall portion after aligning
shuttering with proper compaction in layers, shuttering shall be good enough conditions to
avoid any loss of mortar and honeycomb
B15.7.7 Opening to Traffic:
No traffic shall be permitted to cross the pipeline until filling over the Lop of pipe is
600mm.
B15.8 Traffic Safety
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B16 METHOD STATEMENT FOR CONCRETE WORKS

B16.1 Scope & of Works
The work shall consist of producing and placing the concrete of grade M-40, M- 30, and M-20& M-15
by weight batching in accordance with the specifications conforming to MoRTH specifications, IRC-
21-2000 and the work specifications stipulated in the contract document.
B16.2 Reference
 Ministry of Road Transport & Highway Specifications.
 Technical Specifications
 Relevant drawings
B16.3 Setting Out
After completion of site preparation, alignment of structure of culverts is marked on the ground with
lime and /or string. With reference to its alignment other points of structures like wing wall, abutment
wall are pegged. For construction purpose temporary bench marks (TBM} should be established at
nearby location of structure. The place of TBM shall be chosen in a such a way that it will not be
disturbed by the construction activities and it shall remain in position until all the works are completed
in that location
B16.4 Material
Cement
Cement confirming to IS: 12269will be used only after ensuring the minimum required design
strength. Manufacturer's test certificate have be submitted to the Engineer for every consignment of
cement. The certificate covers all the tests for chemical requirements, physical requirements and
chloride content. Independent tests of samples drawn from the consignment will be carried out at the
site laboratory or in an independent laboratory approved by the Engineer, immediately after delivery.
Coarse Aggregate
Coarse aggregate will be produced from approved quarry in required sizes. It consists of
clean,hard,strong,dense, non-porous and durable pieces of crushed stone or a suitable combination
thereof as specified.Maximum nominal size of aggregate for various structural components conform to
the Table 1700-7 MORTH Specifications.
Fine Aggregate
Fine aggregate for structural concrete is clean, hard,Strong and durable pieces of crushed stone or
suitable combination of natural sand. They do not contain, lumps, soft or flaky, materials, mica or
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other deleterious materials in such a quantity to reduce the durability and strength of concrete.
Gradation of fine aggregate conform to Table 1000-2 of MORTH specifications.
Water
Water conform to section 1010 of MORTH Specifications. Water is free from injurious materials like
oils, acids, alkaline. Salts, sugar, organic materials or other substances that may be deleterious to the
concrete or steel. Potable water is generally considered satisfactory for construction purpose. Mixing
and curing with seawater shall not be permitted.
Reinforcement Steel
Reinforcement steel conforms to section 1009.3 of MORTH specifications. Reinforcement will be

thermo-mechanically treated (TMT} deformed bars of grade Fe500 confirming to IS code 1786. Only
uncoated steel will be used as per shape and size shown on the drawing.
B16.5 Placing of reinforcement
 Reinforcement will be placed in accordance with the drawing and shall be inspected and
approved by Engineer. After getting approval from Engineer, immediately pouring of concrete
can be allowed.
 Reinforcement shall be tied with binding wire (1 mm dia.) in such a way that it shouldn't be
displaced while pouring the concrete on it.
 Cover blocks made of cement mortar with the same durability of surrounding concrete will be
used.
 Layers of bar is separated by spacer bars kept at approximately m interval and minimum size of
spacer bar shall be 12mm, or equal to maximum size of main reinforcement or maximum size of
aggregate whichever is greater. Horizontal reinforcement shall not be allowed to sag between
supports.
 Necessary auxiliary bars like spacer, chairs, and blocks shall be provided to fix the reinforcement
in it; correct position.
B16.6 Proportioning Concrete
The concreting will be done on mix design. All measuring equipments are clean and in serviceable
condition; their accuracy will be periodically checked. Water cement ratio is maintained constant to its
connecting value taking in to account of moisture content of aggregates. The amount of water to be
added will be adjusted to compensate the variation in moisture content due to weather condition.
Proportioning of concrete will be as per approved design mix by weigh batching.
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B16.7 Equipment
Equipment required to carry out construction work are as under:
 Batching plant
 Mixer trucks
 Vibrator
 Wheel loader
 Excavator
 Shutter material
 Bar bending & cutting machine
 Concrete pump
B16.8 Transporting, pacing & Compaction concrete
Transportation of concrete is carried by transit mixer or pumps. Hose pipe from the pump to the
placing area should be laid out with minimum bends. Concrete at the time of pouring should have
temperature in between 5 to 40 degree Celsius. It shall be compacted to its final position within 30
minutes of its discharge from the mixer. Concrete will be poured in horizontal layer of compacted
thickness of 300mm. fresh concrete shall not be placed against concrete which has been in position for
30 minutes or as fixed by mix design unless appropriate construction joints are provided.
Placement of concrete will not be carried out when the day temperature exceeds 40 deg Celsius.
B16.9 Formwork
Formwork conforms to section 1500 of MORTH specifications. Material and components used for
formwork will be examined for damage or excessive deterioration before use/reuse and shall be used
only if found suitable after necessary repairs.Only steel formwork will be used. The steel used for
forms shall be of such thickness that the forms remain true to shape. All bolts should be countersunk.
The use of approved internal steel ties or plastic spacers shall be permitted. Structural steel tube used
as support for forms shall have a minimum wall thickness of 4mm.
B16.10 Construction Joints
Construction joints will be provided as minimum as possible and shall be per drawings. Laitance shall
be removed before fresh concrete is cast. The surface shall be roughened enough not to dislodge the
coarse aggregate. Concrete may be brushed with stiff brush in green stage at the location of
construction joint, fully hardened concrete shall be treated with mechanical tools to remove the
laitance.
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B16.11 Curing
Water curing shall be done with specified in section 1000of MORTH specifications. Exposed surface
of concrete will be kept continuously in a damp or wet condition by containing water or by covering
with a layer of sacks, canvas, hessian or similar materials and shall be kept constantly wet for a period
of minimum 14 days from the date of placing the concrete.
B16.12 Plants Equipment

 Batching plant
 Transit mixer
 Vibrator rod type
 Water tanker
 Diesel generator set
B16.13 Work safety
Traffic shall be maintained over a reasonably smooth travelled way which shall be so marked by
signs, delineators, guiding device and other methods that a person who has no knowledge of
conditions may safety and with a minimum of discomfort and inconvenience ride, drive or walk, day
or night, overall or any portion of the highway and/ or structure under construction where traffic is to
be maintained. It should be noticed that maintenance and protection of traffic over a highway during
construction is considered as important as the construction itself.
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B17 METHOD STATEMENT FOR GUNITING/SHOTCRETING WORKS

This work consist of Guniting the damaged part of slab after removing the damaged part of defective
concrete
B17.2 Reference
B17.3 General
The gunite is a mixture of cement, sand and water. It comprises 100 parts by weight of cement, 300
parts by weight of quartz sand, 35-50 parts by weight of water and 2 parts by weight of approved
quick setting compound. In general dry mix shortcrete can be used.
B17.4 Material
Cement
Ordinary Portland Cement conforming to IS 269 is used in guniting
Sand
Sand for guniting comply with the requirements stipulated in IS 383. In general, sand should neither
be too coarse to increase the rebound nor too fine to increase the slump. It should preferably have a
moisture content between 3 to 6 percent.
The grading of sand lie within the limits given below : MoRTH Clause 2807.3
IS Sieve Designation Percentage passing the sieve

4.75 mm 95-100
2.36 mm 65-90
1.18mm 45-75
600 micron 30-50
300 micron 10-22
150 micron 2-8
For thick sections it is advantageous to incorporate coarse aggregate in the mix provided adequate
guniting equipment is available. Coarse aggregate, when used, would conform to grading given in Table I
of IS:9012. The percentage of coarse aggregate is normally kept as 20 to 40 percent of the total aggregate
and the mix shall be suitably designed
Water
Water/cement ratio for guniting fall within the range 0.35 to 0.50 by mass, wet enough to reduce the
rebound. Drying shrinkage is between percent to 0.10 percent. The quick setting compound will be added
at the nozzle with water just before guniting.
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B17.5 Procedure
 The cement and sand will be batched and mixed and conveyed through a hose pipe with
the help of compressed air.
 A separate line will bring the water under pressure. The cement, sand and water mix will
be passed through and intimately mixed in a special manifold and then projected at high
velocity to the surface being repaired.
 The density of gunite cannot be less than 2000 kg/cu.m. The strength of gunite can not be
less than 25 MPa. For effective guniting, the nozzle will be kept 60 to 150 cm away from
the surface, preferably normal to that surface. While enclosing reinforcement bars during
repairs, the nozzle will be held closer at a slight angle and the mix will be wetter than the
normal.
 Test panels simulating actual field conditions will be fabricated for conducting
preconstruction testing. The procedure for testing the cubes or cylinders taken from the
panels stipulated in clause 6 of IS:9012 will be followed.It should be ensured from tests
that a strength of about 25 MPa at 28 days is available for the mortar/concrete mix.
 The defective concrete will be cut out to the full depth till sound concrete surface is
reached. Under no circumstances should the thickness of concrete to be removed be less
than clear cover to the main reinforcement. No square shoulders will be left at the
perimeter of the cut-off portion and all edges will be tapered.
 Thereafter, all loose and foreign materials will be removed and the surface be
sandblasted to make it rough to receive shotcrete after applying a coat of bonding epoxy
as per recommendation of the manufacturer @ 0.67 kg/ sq.m of surface area.
 The exposed reinforcement will be thoroughly cleaned free of rust, scales etc. by wire
brushing. Wherever the reinforcements have been corroded, the same will be removed
and replaced by additional reinforcement. Before application of gunite, a coat of neat
cement slurry will be applied on the surface of the reinforcement.
 Sufficient clearance will be provided around the reinforcement to permit encashment

with sound gunite. Care will be taken to avoid sand pockets behind the reinforcement.
 A thickness of 25 to 40 mm of gunite can normally be deposited in one operation. If, for

some reason, the total thickness is to be built up in successive operations, the previous
layer will be allowed to set but not become hard before the application of the subsequent
layer. It would always be necessary to apply guniting on a damp concrete surface.
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 Where required, welded wire fabrics 5 cm x 5 cm x No. 10 gauge will be provided in the
first layer of guniting. In case the damage to the concrete member is too deep, the
specifications for guniting as well as requirement of placement of wire mesh has to be
decided as per field conditions.
 The stipulations given in IS:9012 regarding application of gunite will be followed so as

to keep the rebound to the minimum. The quality of guniting and workmanship will be
such that the percentage of rebound mentioned in IS:9012 can be adhered to. In no
circumstances the rebound material be re-used in the work.
 It is desirable that green gunite is moistened for at least 7 days. Guniting work will not
be done during windy or rainy conditions.
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B18 METHOD STATEMENT FOR SEALING OF CRACKS BY INJECTION OF

EPOXY RESIN & CEMENT GROUTING
This work consist of sealing of crack by injecting grout (Epoxy grouting & Cement grouting)
B18.2 Reference
B18.3 Material
The material for injection is suitable two-component low viscosity epoxy resin, having the
required characteristics of bonding with concrete and resistance to moisture penetration. Epoxy
mortar or polysulphide resin may be used for sealing the surface.
The material for epoxy injection shall conform to the following :
 The mixing ratio of resin and hardener shall generally be between1 to 1 and 2 to 1 by
volume subject to manufacturer’s recommendation.
 Neither the mixed epoxy adhesives nor their individual component shall contain solvents and
thickners.
 The components shall be free of lumps or foreign material. The viscosity of the individual
components shall not change more than +/- 15 percent when kept in closed containers at
25°C after two weeks.
 Consistency of mixed adhesive shall satisfy the requirements given in MoRTH Table 2800-1
Standard Version (cps) Low Viscosity version (cps)

Viscosity of mixed adhesive (200-300) (100-190)
@ 25°C
Pot Life of mixed adhesive 1 hour +15 minutes
at 25°C
Set time of mixed adhesive 3 - 6 hours
at 25°C
In the case of two component injection system where resin and hardener get mixed at point
of injection pot life at 25°C shall be not greater than 15 min + 10 minutes.
B18.3.1 Equipment for Injection

The equipment is portable, positive displacement type pump with interlock to provide positive
ratio control of exact proportion of the two components at nozzle. The pumps shall be generally
electrically powered and shall provide in-time metering and mixing. The tolerance on mix ratio
shall be 5% by volume. The injection equipment shall have automatic pressure control capable of
discharging mixed adhesive at any pre-set pressure within the prescribed limits and shall be
additionally equipped with a manual pressure control. The injection equipment shall be equipped
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with sensors on both the components A and B reservoirs that will automatically stop the machine
when only one component is being pumped to the mixing head.
B18.4 Procedure
a) Preparation of surface
 Surfaces adjacent to cracks or other areas of application is be cleaned of dirt, dust, grease, oil
efflorescence or other foreign matter by brushing/water jetting/sand blasting. Acids and
corrosives are not permitted for cleaning.
 Entry ports will be provided along the crack at intervals of not more than the thickness of
concrete at the location.
 Surface seal material can be applied to the face of the crack between the entry ports. For through
cracks, surface seal shall be applied to both faces.
 Before proceeding with the injection, the surface seal material must gain adequate strength with
respect to concrete strength of the member/injection pressure.
b) Epoxy Injection
 Injection of epoxy adhesive begin at lowest entry port and continue until there is an appearance
of epoxy adhesive at the next entry port adjacent to the entry port being pumped.
 When epoxy adhesive travel is indicated by appearance at the next adjacent port, injection will be
discontinued on the entry port being pumped and entry port will be sealed. Thereafter, epoxy
injection will be transferred to next adjacent port where epoxy adhesive has appeared.Epoxy
adhesive injection shall be performed continuously until cracks are completely filled.
 If port to port travel of epoxy adhesive is not indicated, the work shall immediately be stopped. In
case the volume of the injected material exceeds 2 litres for a particular entry port, the work shall
be stopped and the specifications may be reviewed.
B18.4.1 Precautions for Application
a) Unless otherwise specified, components A and B, i.e., resin and hardener, is at a temperature
between 10°C and 35°C at the time of mixing.
b) Temperature of structural member during epoxy injection shall be between 10°C and 35°C
unless otherwise specified.
c) Immediately prior to use, each component shall be thoroughly mixed with a clean paddle. The
paddle shall be of a type that does not induce air into the material. Separate clean paddle must be
used for each component.
d) Any heating of the adhesive components shall be done by application of indirect heat in case
the work is to be done in cold climate.
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e) Just before use, the two components shall be thoroughly mixed in the ratios specified by the
manufacturer. The length of mixing time shall be in strict accordance with manufacturer’s
recommendations. When mixed, all adhesives with different coloured components shall have a
uniform colour without streaks.
f) The use of solvents and thinners will not be permitted except for cleaning of equipment.
Testing
B18.4.2 Material Testing :
Prior to approval of the material, the following tests are carried out at site or in an authorized laboratory
for each batch of resin and hardener and each combination thereof at the cost of the Contractor.
i) Viscosity test for resin and hardener and the mix – three specimens each.
ii) Pot life test - three specimens each.
iii) Bond test – three specimens each.
iv) Shear test – six specimens each, 3 after 24 hours and the other three after 72 hours of
curing.
B18.5 CEMENT GROUTING
Grouting is normally performed with a mixture of neat Portland Cement and water. Other additives and
admixtures may be added to improve the impermeability, strength, etc. on the approval of the Engineer.
The size of the particles and the consistency of the grout must be suited to the passageways it must
follow. Neat grout will not flow freely into holes smaller than about three times the largest cement
particle. Except in large cavities where thick mortar can be placed, the sand should all pass the 28-mesh
sieve and have a large portion passing the 50 and the 100 mesh sieves. The proportions of Ordinary
Portland Cement to sand will depend upon the size of the spaces to be filled and will vary from a neat
grout to about 1:1 mix. The amount of water to be added depends upon the consistency required. Grouts
with as little as 16 litres of water per bag of cement could be handled and it should seldom be necessary
to use more than 35 to 40 litres of water per bag of cement.Where necessary and approved by the
Engineer, admixtures to Portland Cement grout mixtures may be added for delaying the setting time,
increasing flow ability, minimizing segregation and shrinkage.
B18.5.1 Preparation
The surface have to be cleaned with wire brush and compressed air, 15 m dia and 150 to 200 mm deep
holes along the length of the cracks at a spacing of 500 mm may be drilled by wet drilling using rotary
percussion drills and nipples inserted in these holes.
B18.5.2 Proportioning, Mixing and Equipment for Grouting

 The cement grout can be mechanically mixed using a system of power-driven paddles of high
speed centrifugal pump. The grout pump to be used shall permit close control of pressures to
allow a flexible rate of injection with minimum clogging of valves and ports. The most
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satisfactory equipment for injecting grout is a pump of the double-acting flexible reciprocating
type giving a steady flow.
 The grout pump shall be so placed as to reduce the waste in cleaning lines. It is preferable to add
50 percent or more of the mixing water into the mixer before adding the dry ingredients and then
the remaining water. A continuous supply of grout is preferable to an intermittent one.
 Consistency of the grout may be determined by trials starting with thin grout i.e. about 40 litres
of water per bag of cement and progressively decreasing the water content to about 15 litres per
bag of cement.
 Where the mixer and pump are combined in one unit, the dry material shall be screened before
mixing. If the mixer and pump are in separate units, the grout shall pass through a screen before
it enters the pump.
B18.5.3 Application
Highest practical pressure within the limits 100-400 kPa have be used in order to force the surplus water
from the grout. As the pressure may be distributed hydraulically over considerable areas, vigilance must
be exercised to prevent damage or needless waste of grout. Grouting is to be done by attaching a packer
(consisting of expansible tube of rubber) to the end of the grout supply pump through the holes and
nipples. Pressure have be steady to ensure a continuous flow of grout. Grouting shall not be continued till
the hole consumes mix at the rate of not less than 30 litres in 20 minutes or until refusal at the grouting
pressure of 400 kPa at any hole until refusal. Should the grout escape from an adjacent nipple, it should
be plugged or capped. Any seam, crack or joint through which grout escapes shall be caulked with epoxy
mortar as soon as thick grout appears.
B18.5.4 Cleaning of Equipment
After completion of each grouting operation or temporary shutdown, it is advisable to force clear water
through the pump until the discharge line shows no colour, after which the pump covers shall be removed
and the valve chambers thoroughly cleaned.
B18.5.5 Testing
Percolation test done at the end of grouting operation shall give a value of less than 2 lugions.
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B19 METHOD STATEMENT FOR PITCHING/ REVETMENT ON SLOPES

This work consist of covering the slopes of guide bunds, training works and road embankments
with stone, boulders, cement concrete blocks or stones in wire crates over a layer of granular
material called filter. While river side slopes are given this protection against river action, the rear
slopes, not subjected to direct attack of the river, may be protected against ordinary wave
splashing by 0.3-0.6 metre thick cover of clayey or silty earth and turfed
B19.2 Reference
B19.3 Pitching/Filter media
Pitching : The pitching is provided with stones of thickness& shape as indicated in the drawings.The
stone have be sound, hard, durable and fairly regular in shape. Quarry stone should be used. Round
boulders arel not be allowed. The stones subject to marked deterioration by water or weather can not be
accepted.
The size and weight of stone conform to clause 5.3.5.1 of IRC:89. No stone, weighing less than 40 kg
cannot be used. The sizes of spalls is a minimum of 25 mm and be suitable to fill the voids in the
pitching. Where the required size stones are not economically available, cement concrete blocks in
minimum M15 grade conforming to Section 1700 or stones in wire crates can be used in place of isolated
stones of equivalent weight.
Filter Media:The material for the filter consist of sand, gravel, stone or coarse sand. To prevent escape of
the embankment material through the voids of the stone pitching / cement concrete blocks as well as to
allow free movement of water without creating any uplift head on the pitching, one or more layers of
graded materials, commonly known as a filter medium, shall be provided underneath the pitching.
The gradation of the filter material have to satisfy the following requirements:
D 15 (Filter)< 5
D 85 (Base)
D 15 (Filter)< 20
4<
D 15 (Base)
D 50 (Filter)< 25
D 50 (Base)
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B19.4 Construction Operations
 Before laying the pitching, the side of banks have be trimmed to the required slope and profiles
put up by means of line and pegs at intervals of 3 metres to ensure regular straight work and a
uniform slope throughout. Depressions shall be filled and thoroughly compacted.
 The filter granular material will be laid over the prepared base and suitably compacted to the
thickness specified on the drawings.
 The lowest course of pitching will be started from the toe wall and built up in courses upwards.
The toe wall have to be in dry rubble masonry (uncoursed) conforming to Clause 1405.3, in case
of dry rubble pitching and shall be in nominal mix cement concrete (M 15) conforming to Clause
1704.3 in case of cement concrete block pitching.
 The stone pitching will commence in a trench below the toe of the slope. Stone will be placed by
derrick or by hand to the required length, thickness and depth conforming to the drawings.
Stones will be set normal to the slope, and placed so that the largest dimension is perpendicular
to the face of the slope, unless such dimension is greater than the specified thickness of pitching.
 The largest stones will be placed in the bottom courses and for use as headers for subsequent
courses.
 In hand placed pitching, the stone of flat stratified nature should be placed with the principal
bedding plane normal to the slope. The pattern of laying shall be such that the joints are broken
and voids are minimum by packing with spalls, wherever necessary, and the top surface is as
smooth as possible.
 When full depth of pitching can be formed with a single stone, the stones shall be laid breaking
joints and all interstices between adjacent stones shall be filled in with spalls of the proper size
and wedged in with hammers to ensure tight packing.
 When two or more layers of stones must be laid to obtain the design thickness of pitching, dry
masonry can be used and stones shall be well bonded.
 To ensure regular and orderly disposition of the full intended quantity of stone as shown,
template cross walls in dry masonry will be built about a metre wide and to the full height of the
specified thickness at suitable intervals and all along the length and width of the pitching. Within
these walls the stones shall be hand packed as specified.
B19.5 Toe Protection

In conformity with clause 5.3.7. of IRC:89, a toe wall have to be provided at the junction of slope pitching
and launching apron of a guide bund so as to protect the slope pitchingfrom falling even when the apron is
not laid at low water level. The toe wall will be in dry rubble masonry (uncoursed) conforming to Clause
1400 of specification or in cement concrete of M15 grade.Pitching/revetment have to be with stones in wire
crates and in nominal mix cement concrete (M 15. For protection of ties of bank slopes terminating either in
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short aprons at bed levels or anchored in flooring/ rocky bed, the provision of clause 8.2.2 of IRC:89 can be
complied with.
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B20 METHOD STATEMENT FOR LAYING OF CEMENT CONCRETE KERB

This work shall consist of constructing cement concrete kerbs in the central median and/or along
the foot paths or separators in conformity with lines, levels and dimensions as specified in the
drawings.
B20.2 Reference
B20.3 Materials
The following construction materials shall be used for the activity:
Cement:
Ordinary Portland Cement of 43 and 53 Grades conforming to IS:8112 and IS:12269 codes
respectively and shall meet all physical specification.
Coarse and Fine Aggregate:
Coarse and fine aggregate conforming to IS: 383 shall be used. Gradation of combined
aggregates of different sizes shall be following IS 383 and MORTH sec. 1000. Different
mechanical properties of coarse aggregates and properties of fine aggregate are to be conformed
to IS: 383 and the tests shall be conducted as per relevant test codes.
Water:
Potable water shall be used for concreting and shall be conforming to MORTH Specification.
Concrete :
The concrete of grade M 20 to be used for the kerb shall be produced at the batching plant as per
the approved mix design. The concrete shall be loaded on to the transit mixer directly from the
batching plant and transported to the laying location.
B20.4 Procedure:
 Mark the lines, level, and adjust the sensor of the kerb casting machine
accordingly. Put the pegs at every 5-meter interval and mark the levels on it.
These pegs are then joined with metal wire.
 The concrete shall be produced in the batching plant as per the approved mix
formula.
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 The concrete shall be loaded onto the transit mixers directly from the Batching
plants for transporting to the kerb location.
 The kerb shall be laid on a firm foundation of 100mm thick grade M10
concrete cast-in-situ and extending 50mm beyond the kerbstone.
 The cast-in-situ kerb shall be constructed with kerb casting machine in all
situation except at location where continuous casting with equipment is not
practicable. In those situations, precast concrete blocks shall be used.
 kerb casting machine is capable of laying the kerbs in required cross-section
and producing a well compacted mass of concrete free of voids and
honeycombs.
 In the portions where the footpath is provided, and if the slope of the
carriageway is towards the median, there shall be sufficient gap/recess left in
the kerb to facilitate drainage opening.
 After laying the kerbs and just prior to hardening of the concrete, saw cut
grooves shall be provided at 5m interval.
 Vertical and horizontal tolerance with respect to true line and level shall be +/-
6 mm.
 Curing of kerb shall be done by brushing it with curing compound and spread
the hessian cloth over it and keeping it moist for five days.
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B21 METHOD STATEMENT FOR THE CONSTRUCTION OF FOOTPATH

This work shall consist of constructing Footpaths in conformity with lines, levels and dimensions
as specified in the drawings.
B21.2 Reference
B21.3 Materials
The footpaths are constructed with any of the following types:
a) Cast-in-situ cement concrete of Grade M 20 as per Section 1700 of the Specifications.
The minimum size of the panels shall be as specified in the drawings.
b) Precast cement concrete blocks and interlocking blocks/tiles of grade not less than M 30
as per Section 1700 of the Specifications. The thickness and size of the cement concrete
blocks or interlocking blocks/ tiles will be as specified in the drawings.
The precast concrete blocks and interlocking concrete block pavement shall be laid on a bedding
of sand of thickness specified in the drawing. The grading of the sand layer shall be as in Table
400-16 o MoRTH
ISSieveSize PercentPassing
9.52mm 100
4.75mm 95—100
2.36mm 80—100
1.18mm 50—95
600micron 25—60
300 micron 10—30
150micron 0—15
0—10
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The joints shall be filled with sand passing a 2.35 mm size with the grading as in Table 400-17of
MoRTH..
IS Sieve Size Percent Passing

2.36mm 100
1.18mm 90—100
600micron 60—90
300 micron 30—60
150 micron 15—30
75 micron 0—10
The bedding sand slightly moist, the moisture content being about 4 percent. The bedding sand
shall be compacted by vibratory plate compactor.The blocks shall be laid to the levels indicated
on the drawings and to the pattern directed by the Engineer. The surface tolerance shall be +/-10
mm with respect to the design level. The blocks shall be embedded using a hammer.
B21.4 Procedure
 Drainage pipes below the footpath originating from the kerbs shall be first laid in the required
slope and connected to the drains/sumps/storm water drain/drainage chutes as per provisions of
the drawings, or as specified.
 Portion on back side of kerbs have to be filled and compacted with granular sub-base material as
per Clause 401 of the Specifications in specified thickness.
 Over the prepared base, precast concrete interlocking blocks/tiles/natural stone slabs and/or cast-
in- situ slab shall be set/laid as described in Clauses 410.3.4 and 410.3.5.
 The blocks/tiles will be set on a layer of average 12 mm thick cement-sand mortar (1:3) laid on
prepared base in such a way that there is no rocking. The gaps between the blocks/tiles/slabs shall
not be more than 12 mm and shall be filled with cement-sand mortar (1:3).
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APPENDIX C
QUALITY CONTROL TESTS
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Product Test Stage Characteristic Acceptance Criteria Inspection Frequency Sample Performance Reference Clause from
Size Standard MOSRT&H/
Supplementary Technical
Specifications
Embankmen Gradation Lab Grain size Should not be OL, 1) At the beginning for 4.75m IS : 2720 (Part MOSRT&H specifications
t test Analysis OI, OH approval of each source m to 75 4)1985 for Roads & bridges
and change of source mic Section -305/ /clause—305-
2) 2 Tests per 3000m3 2
Section -900/ clause -903.2
MDD Lab Embankment 1.52 g/cc Minimum 1) At the beginning for 19 mm IS : 2720 (Part MOSRT&H specifications
test up to 3m height approval of each source Passing 8)1983 for Roads & bridges
Lab Embankment 1.60 g/cc Minimum and change of source Section -305/ /clause—305-
test exceeding 3m 2) 2 Tests per 3000m3 2
height Section -900/ clause -903.2
Liquid Limit Lab LL value 70% Maximum 1) At the beginning for 425 IS : 2720 (Part MOSRT&H specifications
test approval of each source mic 5)1985 for Roads & bridges
and change of source passing Section -305/ /clause—305-
Plasticity Index Lab PI value 45% Maximum 2) 2 Tests per 3000m3 2
test Section -900/ clause -903.2
Free Swell Index Lab Free swell Not more than 50% As required by the 425 IS : 2720 (Part MOSRT&H specifications
test Index Engineer mic 40) for Roads & bridges
passing Section -305/ /clause—305-
2
Deleterious Lab Sulphate Not more than 0.5% As required by the IS : 2720 (Part MOSRT&H specifications
Content test Content (SO3) by mass Engineer 27)1977 for Roads & bridges
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Section -305/ /clause—305-
2
Moisture Content Field Moisture -2, +1 of OMC 1 Tests per 250m2 IS : 2720 (Part MOSRT&H specifications
Prior to test Content test 2)1973 for Roads & bridges
Compaction Section -305/ /clause—305-
2
Field Dry density Field Degree of Field density shall 1set per 1000m2 of each IS : 2720 (Part MOSRT&H specifications
of Embankment test compaction not be less than compacted area with 8)1974 for Roads & bridges
Layers up to 6m 95%. The minimum number of 6 Section -900/ clause -903.2
height acceptance criteria tests in one set of & Contract Specifications
shall be the Mean measurements
Field Density is not
less than the 95%
plus (1.65- 1.65/No.
of samples0.50) times
the standard
deviation
Field Dry density Field Degree of Field density shall 1set per 1000m2 of each
of Embankment test compaction not be less than compacted area with
Layers up to 6m 97%. The minimum number of 6
height acceptance criteria tests in one set of
shall be the Mean measurements
Field Density is not
less than the 97%
plus (1.65- 1.65/No.
of samples0.50) times
the standard
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deviation
Subgrade Gradation Lab Grain size Should not be OL, 1) 1) At the beginning for 4.75m IS : 2720 (Part MOSRT&H specifications
and Shoulder test Analysis OI, OH approval of each source m to 75 4)1985 for Roads & bridges
(Earthen) and change of source mic Section -305/ /clause—305-
2) 2 Tests per 3000m3 2
MDD Lab MDD 1.75 g/cc Minimum 1) At the beginning for 19 mm IS : 2720 (Part MOSRT&H specifications
test approval of each source Passing 8)1983 for Roads & bridges
and change of source Section -305/ /clause—305-
2) 2 Tests per 3000m3 2
Plasticity Index Lab PI value 45% Maximum and change of source passing Section -305/ /clause—305-
test 2) 2 Tests per 3000m3 2
Free Swell Index Lab Free swell Not more than 50% As required by the 425 IS : 2720 (Part MOSRT&H specifications
test Index Engineer mic 40) for Roads & bridges
passing Section -305/ /clause—305-
2
CBR Lab CBR value 8 % Minimum 1) At the beginning for 19 mm IS : 2720 (Part
test approval of each source passing 16)1979
and change of source
2) 1 Tests per 3000m3
Deleterious Lab Sulphate Not more than 0.5% As required by the IS : 2720 (Part MOSRT&H specifications
Content test Content (SO3) by mass Engineer 27)1977 for Roads & bridges
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Section -305/ /clause—305-
2
Moisture Content Field Moisture -2, +1 of OMC 1 Tests per 250m2 IS : 2720 (Part MOSRT&H specifications
Compaction Section -305/ /clause—305-
2
Field Dry density Field Degree of Field density shall 1set per 1000m2 of each IS : 2720 (Part MOSRT&H specifications
test compaction not be less than compacted area with 28)1974 for Roads & bridges
97%. minimum number of 6 Section -900/ clause -903.2
tests in one set of & Contract Specifications
measurements
GSB Gradation Lab Grain size IS Sieve % 1) At the beginning for 75mm IS : 2386 (Part MOSRT&H specifications
test Analysis (mm) Passing approval of each source to 425 1a)1963 for Roads & bridges
by and change of source mic Section -400/ /clause—401
weight 2) 1 Tests per 400 cum (Table 400-1)
75 100 Section -900/ clause -
53 80-100 903.3/Table 900-3
26.50 55-90 &Contract specifications
9.50 35-65
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4.75 25-50
2.36 10-20
0.85 2-10
0.425 0-5
0.075 -
Plasticity Index Lab PI value 6% Maximum and change of source passing Section -400/ /clause—401
test 2) 1 Tests per 400 cum Section -900/ clause -
903.3/Table 900-3
Water Absorption Lab WA 2 % Maximum As required by the IS : 2386 (Part 3) MOSRT&H specifications
test Engineer for Roads & bridges
Section -400/ /clause—401
Aggregate Impact Lab AIV value 40 Maximum As required by the IS : 2386 (Part 4) MOSRT&H specifications
Value test Engineer or IS : 5640 for Roads & bridges
Section -400/ /clause—401
CBR @ 98% dry Lab CBR value 30 Minimum 1) At the beginning for 37.5m IS : 2720 (Part MOSRT&H specifications
density test approval of each source m 16)1979 for Roads & bridges
and change of source passing Section -400/ /clause—401
Moisture Content Field Moisture -2, +1 of OMC 1 Tests per 400 cum IS : 2720 (Part MOSRT&H specifications
Compaction Section -900/ clause -903.2
Field Dry density Field Degree of Field density shall 1set per 1000m2 of each IS : 2720 (Part 8) /Table 900-3
test compaction not be less than compacted area
98%.
WMM Gradation Lab Grain Size IS Sieve % 1) At the beginning for 53mm IS : 2386 (Part MOSRT&H specifications
test analysis (mm) Passing approval of each source to 75 1a)1963 for Roads & bridges
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by and change of source mic Section -400/ /clause—401
weight 2) 1 Tests per 200 cum (Table 400-1)
53 100 Section -900/ clause -
45 95-100 903.3/Table 900-3
22.4 60-80 &Contract specifications
11.2 40-60
4.75 25-40
2.36 15-30
0.600 8-22
0.075 0-5
Aggregate Impact Lab Impact value 30 % Maximum 1) At the beginning for 12.5 IS : 2386 (Part MOSRT&H specifications
value test approval of each source mm to 4)1963 for Roads & bridges
and change of source 10 mm Section -400/ /clause—401
2) 1 Tests per 1000 cum Section -900/ clause -
903.3/Table 900-3
Flakiness & Lab Fl OR El Value 35 % Maximum 1) At the beginning for IS : 2386 (Part MOSRT&H specifications
Elongation test approval of each source 1)1963 for Roads & bridges
and change of source Section -400/ /clause—401
2) 1 Tests per 500 cum Section -900/ clause -
903.3/Table 900-3
Specific Gravity Lab WA 2 % Maximum for At the beginning for IS : 2386 (Part MOSRT&H specifications
and Water test water absorption approval of each source 1)1963 for Roads & bridges
absorption and change of source Section -400/ /clause—401
Section -900/ clause -
903.3/Table 900-3
Field Dry Density Field Degree of Field density shall 1set of 3 tests per 1000m2 IS : 2720 (Part MOSRT&H specifications
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of compacted test Compaction not be less than 8)1974 for Roads & bridges
98%. Section -900/ clause -903.2
/Table 900-3
Prime Coat Quality of Binder Lab Binder Quality 20-100 seconds at 1) At the beginning for IS 1206-1978 IS: 8887
(Viscosity) test 25°C approval of each source MOSRT&H specifications
and change of source for Roads & bridges
2) 1 Tests per Lot Section -500/ clause -502 &
Section -900/ Table 900-4
Rate of Spread of Field Quality of 0.7 -1 Kg/ Sqm 3 tests per day - MOSRT&H specifications
Binder test Binder for Roads & bridges
Section -900/ /Table 900-4
Tack coat Quality of Binder Lab Binder Quality 20-100 seconds at 1) At the beginning for IS 1206-1978 MOSRT&H specifications
( Viscosity) test 50°C approval of each source for Roads & bridges
and change of source Section -500/ clause -502 &
2) 1 Tests per Lot Section -900/ Table 900-4
Rate of Spread of Field Quality of 0.3 to 0.35 kg/ m2 1 Tests per 500m2 and MOSRT&H specifications
Binder test Binder over concrete 3Tests per day for Roads & bridges
surface Section -900/ Table 900-4
0.25 to 0.3 kg/ m2
over granular
surface treated with
primer
0.2 to 0.3 kg/ m2
over bituminous
surface
Aggregates Cleanliness(Dust) Lab Grain size Max 5% passing At the beginning for IS:2386 MOSRT&H specifications
test Analysis 0.075 mm sieve approval of each source (Part1) for Roads & bridges
and change of source Section -500/ clause -507 /
Table-500.8 & Table-
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500.17 Section -900/ Table
900-4
Aggregate Impact Lab Impact value For DBM -27 % 1) At the beginning for 12.5m IS:2386 MOSRT&H specifications
value test Maximum approval of each source m to (Part4) 1963 for Roads & bridges
For BC – 24% and change of sour 100 Section -500/ clause -507 /
Maximum mm Table-500.8 & Table-
900-4
Flakiness and Lab Fl and El Value 35 % Maximum 1) At the beginning for IS:2386 MOSRT&H specifications
Elongation test approval of each source (Part1) 1963 for Roads & bridges
and change of sou Section -500/ clause -507 /
900-4
Specific Gravity Lab WA 2 % Maximum At the beginning for IS:2386 MOSRT&H specifications
and Water test approval of each source (Part3) 1963 for Roads & bridges
absorption and change of source Section -500/ clause -507 /
900-4
Bitumen Penetration Lab Penetration Min 45 for VG 30 1) At the beginning for IS: 1203-1978 IS:73
test approval of each source
2) 2 Tests per lot
Ductility Lab Ductility 40 Minimum for 1) At the beginning for IS: 1208-1978 IS:73
test VG 30 approval of each source
2) 2 Tests per lot
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Softening Point Lab Softening Point 47°C Minimum for 1) At the beginning for IS: 1205-1978 IS:73
test VG 30 approval of each source
2) 2 Tests per lot
Specific Gravity Lab Specific 0.99 Minimum 1) At the beginning for IS: 1202-1978 MOSRT&H specifications
test Gravity approval of each source for Roads & bridges
and change of source Section -500/ clause -
2) 2 Tests per lot 507.2.1 & IS:73
Flash Point Lab Flash point 220°C minimum 1) At the beginning for IS: 1209-1978 IS:73
test approval of each source
2) 2 Tests per lot
Dense Gradation Lab Grain size Nominal Aggregate 1) At the beginning for MOSRT&H specifications
Bituminous test analysis size 26.5mm approval of each source for Roads & bridges
Macadam Grading-I1 Layer and change of source Section -500/ clause -507
thickness 50-75mm 2) One set for each 400 &Table 500-10
tons of mix subject to a
minimum of 2 tests per
plant per day
IS Sieve %
(mm) Passing
by
weight
45.00 -
37.50 100
26.50 90-100
19 71-95
13.20 56-80
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4.75 38-54
2.36 28-42
0.300 7-21
0.075 2-8
Marshall Stability Lab Stability Modified Marshall 1) At the beginning for ASTM D MOSRT&H specifications
test Method approval of each source 2726/1188 for Roads & bridges
@600 c 9 kN Minimum and change of source Section -500/ clause -507 &
2) 3 tests of stability, flow Table 500-11
Flow Lab Flow 2- 4 mm
value, density and void
test
contents for one set for
Air Voids Lab Voids 3% -5 %
each 400 tons of mix
test
subject to a minimum of
Voids in mineral Lab VMA 11% Minimum
2 tests per plant per day
aggregate test
Voids filled with Lab VFB 65% - 75 %
bitumen test
Extraction and Lab Binder content ± 0.30% of OBC IRC SP 11-
Sieve Analysis test and Grain size 1988(APP-5)
Flakiness and Lab Fl and El Value 27% Maximum 1 Test per 350m3 IS:2386 Part-
Elongation test 1(1963)
Aggregate Impact Lab Impact Value 30 % Maximum 1 Test per 350m3 IS:2386 Part-
value test 4(1963)
Stripping value Lab Percentage of Minimum retained At the beginning for IS:6241-1971 MOSRT&H specifications
test Coating coating should be approval of each source for Roads & bridges
95% and change of source Section -500/ clause -507 /
900-4
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Bitumen Mixing Field 150°C to 165°C MoRTH Table 500-2
Test
Aggregate Mixing Field 150°C to 170°C MoRTH Table 500-2
Test
Mixed Material Field 150 to 165 °C MoRTH Table 500-2
Test
Control of mix Field 140°C minimum 1 Test per every load of MOSRT&H specifications
temp. at the time Test mix for Roads & bridges
of Laying Section -500/ clause -507
Section -900/ clause-903
Rolling Field 90°C minimum MoRTH Table 500-2
Test
Bituminous Gradation Lab Grain Size Nominal aggregate

concrete Test analysis Size 13.2 mm
Grading-II
IS Sieve % 1) At the beginning
(mm) Passing for approval of each source
by and change of source
weight 2) One set for each
26.50 - 400 tons of mix subject to
19.00 100 a minimum of 2 tests per
13.20 90-100 plant per day
9.50 70-88
4.75 53-71
2.36 42-58
1.18 34-48
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0.600 26-38
0.300 18-28
0.150 12-20
0.075 4-10
Marshall Stability Lab 9 KN Minimum 1) At the beginning for ASTM D IRC SP:53
test approval of each source 2726/1188
Flow Lab 2 mm -4 mm 2) One set for each 400
test tons of mix subject to a
Air Voids Lab 3% -5% minimum of 2 tests per
test plant per day
Extraction and Lab Binder content ± 0.30% of OBC IRC SP 11-
Sieve Analysis test and Grain size 1988(APP-5)
Stripping value Lab Percentage of 95% At the beginning for AASHTO T 182 IRC SP :53
test Coating approval of each source
Bitumen Mixing Field 150°C minimum 150°C to 165 °C MoRTH Table 500-2
Test
Aggregate Mixing Field 150°C to 170°C
Test
Mixed Material Field 150 to 165 °C
Test
Control of mix Field 140°C minimum 1 Test per every load of MOSRT&H specifications
temp. at the time Test mix for Roads & bridges
of Laying Section -500/ clause -507
Section -900/ clause-903
Rolling Field 90°C minimum

Test
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Field Density of Field Degree of 98% Minimum 1 Test per 700m2 AASHTMO:DT MOSRT&H specifications
Asphalt layers Test compaction 230-68 for Roads & bridges
Section -500/ clause -509
Section -900/ clause-903.4 /
Table 900-4
Cement Physical Tests
Standard Lab Not specified 1) At the beginning for IS : 4031 MOSRT&H specifications
Consistency Test approval of each source (Part4)1988 for Roads & bridges
and change of source Section -1000/ clause -1006
2) One test per lot subject
to maximum 0f 500
Tonnes
Initial Setting Lab 30 minutes 1) At the beginning for IS : 4031 MOSRT&H specifications
Time Test Minimum approval of each source (Part5)1988 for Roads & bridges
to maximum 0f 500
Tonnes
Final Setting Lab 600 minutes 1) At the beginning for IS : 4031 MOSRT&H specifications
Time Test Maximum approval of each source (Part5)1988 for Roads & bridges
to maximum 0f 500
Tonnes
Compressive Lab Not less than 16 1) At the beginning for IS : 4031 MOSRT&H specifications
Strength Test MPa for 33 grade approval of each source (Part6)1988 for Roads & bridges
1) At 3 days and change of source Section -1000/ clause -1006
Not less than 23 2) One test per lot subject
MPa for 43 grade to maximum 0f 500
Tonnes
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Not less than 27
MPa for 53 grade
2) At 7 days Lab Not less than 22 1) At the beginning for IS : 4031 MOSRT&H specifications
Test MPa for 33 grade approval of each source (Part6)1988 for Roads & bridges
Tonnes
Not less than 27
MPa for 53 grade
3) At 28 days Lab Not less than 33 1) At the beginning for IS : 4031 MOSRT&H specifications
Test MPa for 33 grade approval of each source (Part6)1988 for Roads & bridges
Tonnes
Not less than 53
MPa for 53 grade
Specific Gravity Lab 3.15 for Portland 1) At the beginning for IS : 4031 MOSRT&H specifications
Test cement (generally approval of each source (Part11)1988 for Roads & bridges
3.1 to 3.16 g/cc) and change of source Section -1000/ clause -1006
to maximum 0f 500
Tonnes
Fineness of Lab 10 % Maximum 1) At the beginning for IS : 4031 MOSRT&H specifications
cement Test approval of each source (Part1)1988 for Roads & bridges
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___________________________________________________________________________
to maximum 0f 500
Tonnes
Soundness (Le – Lab 10 mm Maximum 1) At the beginning for IS : 4031 MOSRT&H specifications
Chatlier method) Test approval of each source (Part3)1988 for Roads & bridges
to maximum 0f 500
Tonnes
Concrete Coarse Aggregate
works Sieve analysis or Lab 20mm 1) At the beginning for IS : 2386 IS:383-1970
all in aggregate Test nominal Size approval of each source (Part1a)1963
2) One test for every days
work of each fraction of
coarse aggregate
IS % 3)
Sieve(m Passing
m) by
weight
40 100
20 95-100
10 25-55
4.75 0-10
Flakiness index Lab 35% Maximum 1) At the beginning for IS : 2386 MOSRT&H specifications
Test approval of each source (Part1)1963 for Roads & bridges
2) Once in a month
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Specific Gravity Lab - At the beginning for IS : 2386 MOSRT&H specifications
an Water Test approval of each source (Part3)1963 for Roads & bridges
absorption and change of source Section -1000/ clause -1007
Aggregate Impact Lab 27 % Maximum 1) At the beginning for 80 MOSRT&H specifications

Value Test approval of each source for Roads & bridges
2) Once in a month
Fine Aggregates
Sieve analysis for Lab Grain size IS Sieve % At the beginning for IS : 2386 MOSRT&H specifications
fine aggregate Test analysis (mm) Passing approval of each source (Part1a)1963 for Roads & bridges
zone –I by and change of source Section -1000/ clause -1008
weight &
10 100 Table -1000-2 & IS: 383-
4.75 90-100 1970
2.36 60-95
1.18 30-70
0.600 15-34
0.300 5-20
0.150 0-10
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zone –II by and change of source Section -1000/ clause -1008
weight &
10 100 Table -1000-2 & IS: 383-
4.75 90-100 1970
2.36 75-100
1.18 55-90
0.600 35-59
0.300 8-30
0.150 0-10
zone –III by and change of source Section -1000/ clause -1008
weight &
10 100 Table -1000-2 & IS: 383-
4.75 90-100 1970
2.36 85-100
1.18 75-100
0.600 60-79
0.300 12-40
0.150 0-10
Material finer Lab Silt content 3 % Maximum At the beginning for IS:383-1970
than 75 micron Test approval of each source
sieve and change of source
Specific Gravity Lab At the beginning for IS : 2386 MOSRT&H specifications
and Water test approval of each source (Part3)1963 for Roads & bridges
absorption and change of source Section -1000/ clause -1008
Water Chemical Tests
PH Value Lab 6 Minimum At the beginning for IS:3025 MOSRT&H specifications
test approval of each source for Roads & bridges
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Sulphates(SO3) Lab 400 mg/ litre At the beginning for IS:3025(Part 32) MOSRT&H specifications
test Maximum approval of each source for Roads & bridges
Chlorides (Cl) Lab 500 mg/ litre At the beginning for IS:3025(Part 24) MOSRT&H specifications
Test Maximum approval of each source for Roads & bridges
Lab 2000mg/ litre for for and change of source Section -1000/ clause -1010
Test concrete not
containing
embedded steel, 500
mg/l for reinforced
work - maximum
Physical Tests
Suspended Matter Lab 2000 mg/ Litre At the beginning for IS:3025(Part 17) MOSRT&H specifications
Organic matter Lab 200 mg/ Litre At the beginning for IS:3025(Part 18) MOSRT&H specifications
In organic matter Lab 3000 mg/ Litre At the beginning for IS:3025(Part 18) MOSRT&H specifications
Steel Chemical Tests
Carbon Lab 0.30 Maximum for At the beginning for IS: 1786-1985 MOSRT&H specifications
Test Fe 415 approval of each source for Roads & bridges
0.30 Maximum for and change of source Section -1000/ clause -
Fe 500 1009.3
Sulphur Lab 0.06 Maximum for At the beginning for IS: 1786-1985 MOSRT&H specifications
Fe 500 1009.3
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Phosphorous Lab 0.06Maximum for At the beginning for IS: 1786-1985 MOSRT&H specifications
Fe 500 1009.3
Sulphur Lab 0.11 Maximum for At the beginning for IS: 1786-1985 MOSRT&H specifications
+Phosphorous Test Fe 415 approval of each source for Roads & bridges
Fe 500 1009.3
Physical Tests
Ultimate Tensile Lab 10% more than the IS: 1786-1985 MOSRT&H specifications
Strength Test actual 0.2% proof for Roads & bridges
stress but not less Section -1000/ clause -
than 485 MPa for Fe 1009.3
415
8% more than the
actual 0.2% proof
stress but not less
than 545 MPa for Fe
500
0.2 % Proof Stress Lab 415N/mm2 IS: 1786-1985 MOSRT&H specifications

Test Minimum for Fe 415 for Roads & bridges
500 N/mm2 Section -1000/ clause -
Minimum for Fe 500 1009.3
Elongation Lab 14.50 % Minimum IS: 1786-1985 MOSRT&H specifications
percentage Test for Fe 415 for Roads & bridges
12.0 % Minimum Section -1000/ clause -
for Fe 500 1009.3
Bend Test Lab Bent to inclined IS: 1786-1985 MOSRT&H specifications

Test angle of 135°C for Roads & bridges
Page 128 of 173
___________________________________________________________________________
1009.3
Re-bend Test Lab Bent to inclined IS: 1786-1985 MOSRT&H specifications
Test angle of 157.5°C for Roads & bridges
1009.3
Mass per meter/ Lab 6.310±3% for 32 1) At the beginning for IS: 1786-1985 MOSRT&H specifications
Rolling margin Test mm dia approval of each source for Roads & bridges
3.850±3% for 25 and change of source Section -1000/ clause -
mm dia 2) 1 Test per Consignment 1009.3
2.470±3% for 20
mm dia
1.580±5% for 16
mm dia
0.888±5% for 12
mm dia
0.617±3% for 10
mm dia
0.395±3% for 8 mm
dia
concrete Workability of Field PCC 50 ±25 mm One test per each transit IS : 1199-1959 MOSRT&H specifications
fresh concrete test RCC 100 ±25 mm mixer at both batching for Roads & bridges
plant and site initially Section -1700/ clause -1716
when work starts.
Subsequently sampling
may be done alternate
transit mixers
Compressive Lab M10-10 MPa Qnty of No.of IS : 516-1959 MOSRT&H specifications
Strength of Test M20-20 MPa concrete samples for Roads & bridges
Concrete M25-25 MPa (m3) Section -1700/ clause -1716
Page 129 of 173

___________________________________________________________________________
M30-30 MPa 1-5 1
M35-35 MPa 6-15 2
M40-40 MPa
16-30 3
M45-45 MPa
31-50 4
51 and 4 plus one
above additional
sample for
each
additional
50 m3 or
part thereof
Hume Pipes Tolerances in Field Over 95 mm + 7mm, 1) At the beginning for IS : 3597-1985 IS:458-2003
(HP-4) dimensions for test -3.5mm approval of each source
wall thickness and change of source
Tolerance in Field Upto & including 2) As per IS:458-2003 IS : 3597-1985 IS:458-2003
dimensions for test 300 mm-±3 mm Table -22
internal dia. of Over 300mm and
pipe upto and including
600mm= ±5 mm
Over 600±10mm
Tolerance in Field ±1% of standard IS : 3597-1985 IS:458-2003
dimensions for test length
overall length
Three edges Field Workin 46.30kN 1) At the beginning for IS : 3597-1985 IS:458-2003
Bearing test g load approval of each source
Test(Load to and change of source
produce 0.25mm 2) As per IS:458-2003
crack) Table -22
600mm dia
Page 130 of 173

___________________________________________________________________________
Three edges Field Workin 72.60kN 1) At the beginning for IS : 3597-1985 IS:458-2003
crack) Table -22
1000mm dia
Three edges Field Workin 88.30 kN 1) At the beginning for IS : 3597-1985 IS:458-2003
crack) Table -22
1200mm dia
Hydrostatic Field pressure 1.50N/m 1) At the beginning for IS : 3597-1985 IS:458-2003
pressure Test test m2 approval of each source
2) As per IS:458-2003
Table -22
Compressive Field Minimum 35 MPa 1) At the beginning for IS : 3597-1985 IS:458-2003

strength of test @ 28 days approval of each source
concrete and change of source
2) As per IS:458-2003
Table -22
Thermoplasti Binder Content Lab 18% Minimum by Once at the beginning for BS:3262 part I MOSRT&H specifications
c Road Test weight approval of each source for Roads & bridges
Material and change of source Section -800/ clause -803
Glass Beads Lab 30 % Once at the beginning for BS:3262 part I MOSRT&H specifications
Test approval of each source for Roads & bridges
Titanium Dioxide Lab 10% Minimum Once at the beginning for BS:3262 part I MOSRT&H specifications
Page 131 of 173

___________________________________________________________________________
content Test approval of each source for Roads & bridges
Calcium Lab 42% Maximum Once at the beginning for BS:3262 part I MOSRT&H specifications
carbonate and Test approval of each source for Roads & bridges
inert fillers and change of source Section -800/ clause -803
Day light Lab 65% Minimum (for Once at the beginning for AASHTO M 249 MOSRT&H specifications
luminance at 45° Test white colour) approval of each source for Roads & bridges
Drying time Lab Once at the beginning for - MOSRT&H specifications
Test 15 minutes approval of each source for Roads & bridges
Maximum and change of source Section -800/ clause -803
Skid resistance Lab 42% Minimum Once at the beginning for BS:6044 MOSRT&H specifications
Softening point Lab 102.5 ±9.5°C Once at the beginning for ASTM D 36 MOSRT&H specifications
Flowness Index Lab 25% Maximum Once at the beginning for AASHTO M 249 MOSRT&H specifications
Page 132 of 173

_________________________________________________________________________
__
APPENDIX D
REQUEST FOR INSPECTION (RFI)
REQUEST FOR INSPECTION (RFI)
Page 133 of 173

REQUEST FOR INSPECTION

: RKI Package IV - Road 3 - Rehabilitation and Up gradation of Pathanamthitta Ayroor
Name of Work –Muttukudukka Illathupadi – Muttukudukka Prakkanam – Prakkanam Elavumthitta –
Kulanada Ramanchira – Tbannikkuzhy Thonniamala Road (Length 28.204 KM)
Client : Project Director, Kerala State Transport Project
Consultant Engineer : Sai Consulting Engineers Pvt Ltd JV Orion Infra Consulting Pvt.Ltd.
Contractor : M/s Theruvath - PRL (JV)

Inspection Date & Time : RFI No.
Highway Structure Materials Survey ESHS miscellaneous
Activity List
Survey C&G Electrical Work Excavation Embankment
SG GSB WMM Prime Coat Tack Coat
DBM BC Reinforcement Lab Form Work
L/T Drain Concrete RCC Drain Safety (ESHS) RW/TW/BW
Foot Path Paver Block U- Drain Crash Barrier Other Works
Work Particulars
Chainage : Side:
Description of Work :
Layer/Lift :
For Contractor Requested By For Consultant Engineer/Received By

Chainage : Chainage :
Name : Name :
Date & Time : Date & Time :
Comments/Observation/ Recommendations
For Contractor For Consultant Engineer
Name : DRE /ME /BE /Surveyor /LT /Road safety Expert / Experts
(Env/H&S/Social) :-
Designation :
Satisfactory/ Non-Compliance
Signature :
Signature:
Approved /Not Approved
TL/Resident Engineer
Date /Time ;
Contractor Representative Received
Copies 3:- White-For Billing/Pink-For AE /Yellow For EPC Contractor Sign/Date
Page 134 of 173

Quality Assurance Plan for Kerala State Transport Project-II

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Quality Assurance Plan for Kerala State Transport Project-II

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TP-II RKI Package IV / 3- QUALITY ASSURANCE PLAN

NAME OF THE PROJECT

CHAPTER DESCRIPTION PAGE NO

3. QUALITY MANAGEMENT IN CONSTRUCTION AND REPORTING 10

5. QUALITY CONTROL AND ASSURANCE IN CONSTRUCTION 16

6. QUALITY CONTROL OF ROAD WORKS 18

8. DOCUMENTATIONS, RECORDS, CONTROL & INTERNAL AUDIT 24

9. CONTRACT MANAGEMENT FRAMEWORK 27

A PROJECT ORGANISATION CHART 29

B2 CLEARING & GRUBBING 34

B3 DISMANTLING OF FLEXIBLE PAVEMENT 37

B11 RECYCLING OF BITUMINOUS PAVEMENT 69

B13 BITUMINOUS CONCRETE 75

B16 SLAB /BOX CULVERT 81

B17 PIPE CULVERT 86

B18 CONCRETE WORKS 89

B19 GUNITING /SHOTCRETING WORKS 93

B20 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN & CEMENT 96

B21 PITCHING/ REVETMENT OF SLOPE 100

B22 LAYING CEMENT CONCRETE KERB 103

B23 CONSTRUCTION OF FOOTPATH 105

C QUALITY CONTROL TEST FREQUENCIES 107

D QUALITY ASSURANCE FORMATS 131

E CHECK LISTS 133

F FORMAT REGISTERS 146

G FLOW CHARTS 157

1.2 Project Summary

Pathanamthitta-Ayroor Road (3.1)

Muttukudukka – Prakkanam Road (3.3)

Prakkanam – Elavumthitta Road (3.4)

Kulanada - Ramanchira Road (3.5)

Thannikkuzhy - Thonniamala Road (3.6)

1.3 Project Quality Statement

1.4 Revision / Amendments

Copy No Doc No/ Issue Issued to Issued Date

1.5 Definitions & Terminology

i. The project Quality Manual Statement of the company

3.2 Organization set up of the Project

The Organization chart is presented in Appendix A.

3.3 Responsibilities of Key staff at Site

3.3.1 Project Manager

c) Approving the disposition of Non-conformance report issued by the authorized

h) Guide and instruct others in the essential aspects of quality management

i) Verification of inspection and test activities

k) Recommend remedial actions and re inspect to close the issue

l) Recommend corrective action in case of recurring non-conformance

3.3.2 Material Engineer

b) Guide and instruct others in the essential aspects of quality management.

c) Ensure that the quality of construction satisfies the standards.

e) Verification of inspection and test activities.

f) Recommend remedial action and re inspect to close out.

g) Recommend corrective action in case of recurring non-conformance.

h) Responsible for preparing Monthly Quality Management Report.

3.3.3 Dy. Project manager

3.4 Functions of QA / QC system

(iv) Identify problems and initiate action, which results in solution.

(v) Verify implementation of solutions / corrections

(vi) Report regularly on effectiveness of the system

(vii) All the test reports have to be certified by the representative

3.5 Quality Management Reports

Summary of Inspection and Test Activities.

Registers of non-conformance & Corrective Action