Name of work : Construction of the RCC Box of NHRB @ 341.

160 km of Kachchh Branch Canal (NH-

41 @ Ch.117/500) including Earthwork, Lining, Structure, Service Road, Diversion Road and
Approach Road and O and M work for five year (Remaining work of IR-19-20-21)
Brief Note on Quality Assurance Progremme
As stipulated under the contract agreement, the contractor has to submit Quality
Assurance Programme (QAP) to be followed during Construction of the RCC Box of
NHRB @ 341.160 km of Kachchh Branch Canal (NH-41 @ Ch.117/500) including
Earthwork, Lining, Structure, Service Road, Diversion Road and Approach Road and
O and M work for five year (Remaining work of IR-19-20-21)

(i) Excavation for canal, gutter, foundation of structures & Earthwork 23036
for embankment of canal, road etc. m3
(ii) Various Grades of Concrete for the structural works including 1833.5
concrete lining. m3
(iii) Steel Reinforcement for the structures. 208 MT
The QAP shall be divided in following various operations.

(A) Quality Assurance Organization :

All sampling & testing accordance with the relevant Indian Standard and/or International
standard as stipulated in the contract shall be carry out in the laboratory established by M/S
MARUTI FOUNDATION AND CONSTRUCTION CO on site. Where no specific testing
procedure in mentioned, the test shall be carried out as per procedure accepted Engineering
practice and direction of Engineer-in-charge.
(B) Procurement of various construction materials and their testing:
Following construction materials for various item of work will be required. All
required tests for such materials/ products will be carried out in the laboratories
as mentioned in Annex-I to VII.
(a) Soil:-
(i) Canal Excavation.
(ii) Borrow area.
(iii) Structure foundation excavation (FRL).
(b) Concrete for the canal structures and lining:-
(i) Cement
(ii) Sand
(iii) Course Aggregate
 (iv) Water (Plant site/Structure FRL)
(v) PVC Water Stop
(vi) Pre-molded Asphalt Pads
(vii) Anchor Bolts for embedded parts
(viii) Curing Compound
(ix) AEA/ Anti corrosion admixture.
(c) Steel Reinforcement:-
(i) Steel
(d) Road work:-
(i) Road Metals
(ii) Bitumen
(iii) Mix Design for Carpet/ Wet Mix.
(e) Other miscellaneous materials:-
RCC Spun Pipes, Asbestos Pipes, PVC Pipes, CI Pipes, GI Pipes,
stoneware pipe etc.

Procurement and Utilization of materials:

(1) Earthwork:
Suitable excavated soil available from canal and foundation excavation will be
utilized in various zones of canal banks and refilling foundations. The surplus
and unusable excavated stuff will be deposited in spoil bank. The balance
quantity, if required, will be brought from designated borrow area.

(2) Concrete:
The concrete required for the canal structures and lining will be manufactured
in batching and mixing plant installed at the site of work. The same will be
transported by transit mixers and placed in the locations by chute of transit
mixer.

Cement for manufacture of concrete will be procured along with

necessary test certificates from the manufactures of approved cement plants.
The samples of cement so procured will also be supplied to SSNNL approved
laboratory for the testing as stipulated in the contract specifications.
 The Crushed Aggregate & Fine Aggregate required for concrete will be
procured from the approved quarries or other suitable source. The sand will be
procured from approved River or suitable source tested at establish laboratory
as per tender specification.

Water available from the approved source will be used in concrete and curing.
The same will be tested at establish laboratory as per tender specification.

If required, Approved quality of admixture will be used in concrete. The mix

design for the different grade of cement will be get approved from competent
authority before start execution.

3) Reinforcement:
The Steel for reinforcement will be procured from the BIS primary manufactures
or their authorized dealers only. BIS manufacture's test certificate along with
test results will be furnished to SSNNL. The mechanical and chemical testing
will be carried out in SSNNL approved lab before using in work.
(4) Road work:
The required crushed metal for the road will be obtained from the approved
quarries site & testing will be carry out as per tender specification. The bitumen
and other asphalt material required for road work will be obtained from
approved sources & test result. They will be maintaining as per tender
specification.

(5) Other Materials:

Other materials required in construction viz. copper plate, PVC Water
Stop, bituminous, Asphalt Pads etc. will be procured from approved
manufactures along with (MTC) test certificates. Testing will be carried
out in SSNNL approved laboratory & Q.C records will be maintain as per
tender specification.

 Storage and delivery of materials :

The materials such as Sand, Crushed metals and steel will be transported in
open trucks and delivered at site either at Batching and Mixing Plant or
stockyard.
Aggregate will be stacked in such a way as to prevent the admixture of foreign
materials such as soil, vegetable matter etc. Heaps of fine and coarse
aggregates will be kept separate. When different sizes of fine or coarse
aggregate are procured separately, they will be stored in separate stockpiles,
sufficiently away from each other to prevent the materials at the edge of the
piles for getting intermixed.

The aggregate will be stockpiled adjacent to the Batching and Mixing Plant so
as to require minimum rehandling and labour when conveyed to the mixer.

The aggregate will be placed on dry hard patch of ground. The stockpiles of the
aggregate will be kept free of dirt, rubbish, papers, vegetable matter etc.

Cement will be carted in truck covered with trapolenes and will be properly
stored in dry watertight and properly ventilated store.

For other material such as Curing Compound, PVC Water Stop, Asphalt Pads,
Anchor Bolts, PVC Strip and various pipes will be transported in open trucks
and will be stacked separately in store building constructed at work site.

Laboratory facilities at work site:

A laboratory building will be constructed at suitable location at camp site at
Motalayja. All day to day testing of materials and finished work will be carried
out in agency laboratory at site. As stipulated in contract specifications,
necessary samples along with labour will be provided to agency for testing in
our laboratory.
As required we will also establish our own laboratory facilities at site with
following required instruments for carrying necessary test for soils, cement,
sand, aggregate and concrete etc.

(A) For earthwork :

 Set of fine sieves with F.M. Assembly 01 Set
 Proctor Mould 100 mm dia with 2.6 Km. Rammer 01 No.
 Core Cutter with dolley 09 Nos.
  Rammer for Core Cutter 01 No.
 Weight Box 01 No.
(B) For Concrete :
 Compression Testing Machine 01 No.
 Cube Moulds 15 x 15 x 15 cm 24 Nos.
 Slump Test Apparatus 02 Nos.
 Set of Coarse sieves 01 No.
 Elongation Gauge 01 No.
 Flakiness Gauge 01 No.
 Electronic Balance of Capacity 200 gm x 0.1 gm. 01 No.
 G.I. Tray 18" x 12" x 12" x 12" 06 Nos.
 Two pan balance 20 kg. capacity with set of wts 01 No.
 Two pan balance 5 kg. capacity with set of wts 01 No.
 Measuring Cylinder 250 ml & 100 ml (Glass) 03 Nos.
 Thermometer 01 Nos.
 Digital Stopwatch 01 No
 Penetration test equipment 01 No.
The stipulated tests of different material/ products will be carried out as
listed in Annex. I to VIII.
 Preparation and maintenance of test records :
Our representative will remain present at the time of collecting samples and
testing in laboratory and the test records will be jointly maintained by us and
SSNNL in Performa prescribed by SSNNL for quality control. The O.K. Cards
as required will be filled up and got signed by the competent authority of
SSNNL.

Following records will be maintained and kept by us.

LABORATORY :
The Laboratory will maintain the following records :-
 Q.C. Procedures documents.
 Technical records- Relevant Specification, Contract Documents., Test
Procedures, relevant codes of practices.
 Records of calibrations of measuring and testing equipments.
 Material procurement consumption & testing record.
 Material test report - Printed forms, tests registers etc.
 Embankment, Lining, Concrete register.
 Miscellaneous record.

The documents of testing generally comprise of the following:-

 Date of test, Performa of incoming samples, types of tests to be
performed and acceptance criteria, if any.
 Location where the material is used.
 Method of testing and relevant prescribed Performa with reference to
Standards, to be filled up during testing.
 Test results will be recorded in the concerned test registers.

Field :
 As per the provisions of testing covered under different items of the
specification, the records of field tests are to be maintained as under :-

Earthwork :
 Bank seat approval register.
 Moisture control registers.
 Field moisture control testing by core cutter.
Concrete for Structure & Lining :
 Mix design for the different grades of concrete.
 Register for gradation of coarse aggregates for different M.S.A.
 Finesses modulus, silt content and free moisture content of sand.
 Concrete batch weight register.
 Concrete cube casting and slump.
 Concrete cube compressive test register.
 Cement temperature & TSD/PH of water register.
 Centering, shuttering, reinforcement & water stop register.
 Curing Compound & AEA, PVC, Copper plate, bituminous silent
compound etc…
 Register of sample of curing compound collected and test results,
coverage and their actual consumption.

 Quality Assurance of work :-

Field tests during the construction of work as per frequency prescribed in
tender specification will be performed and reported to the inspecting officers’s
of SSNNL.

Quality Control of Earthwork :

Following factors will be considered for assuring quality of earthwork.
 Testing of various materials such as soil available from canal and
foundation / gutter excavation or borrow area for embankment.
 Preparation of seat of Embankment after removal of grass, roots and
organic material by stripping the seat to a required depth as prescribed
in the specifications.
 Over excavation should not be permitted because back filled material
cannot achieve required degree of compaction. However over excavated
portion shall be filled up with suitable material, moistened and
compacted to the required density.
 Estimation of Natural Moisture Content (NMC) of Borrow area material
or the material available form canal/ foundation/ gutter excavation.
 Determination of proctor values i.e. Maximum Dry Density (MDD) &
Optimum Moisture Content (OMC)
 Determination of moisture to be added to the soil as per OMC and NMC
of soil. Sometime, if the NMC is more, soil is required to be dried.
 Placing of uniform layers of specified thickness (normally 15 cm to 23
cm) for embankment.
 Watering and compaction.
 Testing for moisture content and FDD to know the degree of compaction
to be achieved with respect to proctor MDD & OMC. Additional rolling
and watering if required to be carried out with respect to density tests.

Quality Control of Concrete for the Canal Structures :

Following factors will be locked into for ensuring quality of concrete for the
Canal Structures.
 To carry out necessary tests for determining the suitability of materials to
be used. The materials are coarse aggregates, fine aggregate, water,
cement, steel reinforcement, PVC water stop, curing compound and
admixtures.
 To get assurance of the suitable mix designs for different grades of
concrete based on the materials to be utilized.
 To give the batch weight based on the mix design and applying
necessary correction for over/ under size and also moisture content of
sand/ aggregate.
 To check line and level for the shuttering and arrangement for placement
of concrete.
 To check reinforcement.
 To check the workability of concrete, compaction etc.
 To carry out necessary tests for concrete, such as slump, casting of
required sets of cubes for compressive strength, mixer efficiency tests
and calibration of batching and mixing plant.
 To ensure proper curing arrangement for the prescribed curing period
including use of curing compound and it's testing in laboratory prior to
use.
 To carry out non- destructive testing (if required).

Quality Control of Lining

Following aspects will be looked into for ensuring the quality of Concrete Lining.
 Points related to concrete manufacture as described in concrete for
structure will also be applicable. Necessary approval of sub grade, i.e.
degree of compaction and moisture content.
 Testing of construction materials i.e. coarse aggregates, fine aggregate,
cement, Water AEA and curing compound.
 Checking of Paver's Jack Level, Grider's alignment, Roller movement
etc.
 To undertake necessary tests for concrete such as slump for workability,
casting of required sets of cubes for compressive strength, mixture
efficiency test etc.
 Placement of concrete by paver machine.
 To ensure proper curing arrangement, including curing compound, its
testing and coverage.
 Proper insertion of joints in transverse and longitudinal direction.
 To ensure specified thickness of cement concrete lining by taking cores.
 Testing of hardened concrete for density, compressive strength, water
absorption etc. by taking cores after completion of curing period.
 To undertake screening of green concrete for examining consistency of
concrete (occasionally).
 Under drainage & PRV.

Quality Control of Construction Materials :

Following tests will be carried out for the quality control of construction
materials.
 COARES AGGREGATES (Crushed)
 Appearance test, i.e. clean hard, dense, free from vegetation,
durable etc.
 Specific gravity.
 Gradation.
 Water Absorption
 Impact
 Soundness
  Flakiness and elongation indices.
 Petrography.

 FINE AGGREGATE (Sand)

 Size and appearance
 Gradation for deciding zone
 Specific gravity
 Water absorption
 Moisture control i.e. free moisture available
 Fineness modulus
 Soundness
 Deleterious constituents.
 Silt content
 Petrography

 CEMENT
 Grade of cement (i.e. 43 or 53)
 Type of cement i.e. OPC
 Brand of cement various manufacture brands approved by
SSNNL.
 Date/ Week of Manufacturing, Batch number and Lot number.
 Consistency
 Setting time, initial and Final
 Fineness
 Soundless
 Compressive strength

 WATER
 Free from injurious amount of deleterious material.
 Potable or not
 Chemical analysis : Acids and alkalies, Salt contents etc.
  Organic, Inorganic, Sulphate, Chloride contents etc.
 PH Value
 Other test as stipulated in IS 456 to compare with the test result
of distilled water.

 ADMIXTURE : AIR ENTRAINING AGENT (AEA)

 Proportion of caustic soda to Resin depending upon the grade of
Resin.
 Specific Gravity
 Solid content
 PH value
 Doses to be fixed

 CURING COMPOUND
 Appearance test
 Water retention test
 Daylight reflectance
 Dry to touch i.e. drying time
 Coverage

 PVC WATER STOP

 Tensile Strength
 Ultimate elongation
 Tear resistance
 Stiffness in extraction
 Accelerated extraction
 Alkali test
 Cold bend test
 Impact resistance

 MISCELLANEOUS MATERIALS
 Anchor Bolts : (As per IS 2062- 1984 or IS 226-1975)
  Asphalt Pads : (As per IS 1838 - 1983)

 TMT/CRS STEEL BARS

 Diameter to be verified
 Ultimate Tensile Strength
 Yield Strength
 Elongation

 SOIL
 Classification
1. Grain size analysis
2. Atterberg Limits.

 Proctor Test for MDD at OMC

 Permeability test
 Consolidation
 Specific Gravity test

 METHOD OF SAMPLES
 Soils
 Disturbed Samples :
 From trial pits from individual stratum by cutting a
notch in the side.

 From bore holes :

 Auger samples
 Samples from S.P.T.
 Wash samples in case of granular soils or bailer
samples.

 Undisturbed samples :
 From Trail pits.
  Chunk samples
 Core cutter samples
 From bore holes.
 Shelly tubes
 Piston tube samples

 Cement :
15 Kg. one sample of bags in a consignment of up to 100 tones, 2
upto 200 tones, 3 upto 300 tones, 4 upto 500 tones, 5 upto 1000
tones, 6 upto 2000 tones, 7 and larger consignments.

 Sand :
10 Kg per sample

 Metal / Gravel :
100 Kg. per sample

 Rubble :
25 Kg. per sample

 Cement Concrete :
6 Nos. of cube samples (15 x 15 x 15 cm size)

 Steel :
1mt. long sample

CONCLUSION :-
The Q.A.P. as mentioned in foregoing paras will be followed scrupulously. It will be
seen that the materials as per standards laid down in technical specifications will be
used in the work. The finished work of earthwork, lining and structures will be true to
line and levels and will comply the testing procedure laid down in technical
specifications.
 ANNEXURE - I

GENERAL TEST FOR EARTHWORK / BORROW AREA

Sr. Particulars of test Relevant Frequency Equipments Where
No. IS No. Tested
1. Grain size analysis IS : 2720 One per Balance, set of coarse and fine Field
source sieves, hydrometer with jars, stirrer, Laboratory
stopwatch

2. Atterberg's Limits
(a) Plastic Limit IS : 2720 One per Flat Glass Plate, spatula or plate Approved
(Part-5) source knives, grand glass plate, container Laboratory
1985 balance and oven.

(b) Liquid Limit IS : 2720 One per Mechanical device, Grooving tool, Approved
(Part-5) source evaporating dish, flat glass plate Laboratory
1985 spatula, plate knives, balance, oven,
wash bottle container etc.

(c)Cone Preparation IS : 2720 One per Cone penetrometer, balance, Approved

method (Part-5) source containers oven etc. Laboratory
1985

(d) Plasticity Index IS : 2720 One per From Above Approved

(Part-5) source Laboratory
1985

2. Standard Proctor IS : 2720 One per Standard compaction mould, Field

(Part - 7) source spatula, metal rammer, balance, Laboratory
1987 oven, extractor container etc.

3. Field Density and

moisture content
(a) Core cutter IS : 2720 2/15000 Cylindrical core cutter, steel dolley, Field
method (Part -29) M3 or per steel rammer, balance plate knife, Laboratory
1988 zone per steel rule, extractor, stove, container
reach etc.
 (b) Sand replacement IS : 2720 2/15000 Small sand pouring cylinder, tools Field
method (Part -28) M3 or per for excavating holes, cylindrical Laboratory
1988 zone per calibration, container balance etc.
reach

(c) Water replacement IS : 2720 2/15000 Container etc. Field

method (Part -33) M3 or per Laboratory
zone per
reach

(d) Box Shear One per Box shear machine with mould Field
source Laboratory

ANNEXURE - II

GENERAL TESTS FOR CEMENT CONCRETE

[As per IS : 456-1978, IS : 1959 and IS : 1199-1959]

Sr. Particulars of test Relevant Frequency Equipments Where

No. IS No. Tested
1. Mixer efficiency Twice in a Container, mixer, weighting. Field
Season Laboratory

2. Workability IS : One/ Slump cone, Tamping, Road, Steel Field

1199 Session/ tape etc. Laboratory
1959 Grade

3. Compressive strength As per 200 T compression testing machine, Field

clause 15 cm size cube mould etc. Laboratory
3.7 at page
no.
TS-84 of
Vol. II
 ANNEXURE - III
PORTLAND CEMENT
[As per IS : 269-1976, IS: 8112 and IS : 12269-1987]

Sr. Particulars of test Relevant Frequency Equipments Where

No. IS No. Tested
1. Consistency --- One per 50 or Vicat needle apparatus with Approved
Ton part there Plunger 10 mm dia ('G' type), Laboratory

of brand/ grade balance etc.

2. Setting Time
Approved
Initial setting time --- One per 50 or
Laboratory
Ton part there
of brand/ grade

One per 50 or Approved

3. Fineness by sieving --- Ton part there Laboratory
of brand/ grade

One per 50 or Cube Mould (7.07 cm) 50 M2 Field

4. Compressive strength --- Ton part there face area, body vibrator, Laboratory
of brand/ grade compression testing machine,
curing, tank etc.

Twice in a
5. Chemical Testing --- Season/
Branch/ grade Approved
or as decided Laboratory
by Engineer-
in-charge
 ANNEXURE - IV
GENERAL TEST FOR FINE AGGREGATES (Sand)
[As per IS : 2386-P-I,P-III, P-VII, P-VIII-1963 & IS : 383-1970]

Sr. Particulars of test Relevant Frequency Equipments Where

No. IS No. Tested
1. Gradation fineness IS : 383 As per day Set of fine sieves 4.75 mm to Field
module (FM) 1970 (2000 gm 75 mic balance Laboratory
& IS : 2386 sample)
(P-I) 1963

2. Specific gravity and water IS : 2386 Twice in a Pycnometer bottle, balance, Field
absorption (P-III) 1963 season (500 oven etc. Laboratory
gm sample)

3. Silt content IS : 2386 One per day 75 mic. Sieve, container, Field
(P-III) 1963 (500 gm balance, oven etc. Laboratory
sample)

4. Petrographic analysis and --- One Time in a --- Approved

Alkali Reactivity season Laboratory

ANNEXURE - V

GENERAL TEST FOR COARSE AGGREGATES (Metal, Gravel etc.)

[As per IS : 2386-P-I,P-III, P-VII, P-VIII-1963 & IS : 383-1970]
Sr. Particulars of test Relevant Frequency Equipments Where
No. IS No. Tested
1. Gradation IS : 383 One per day Set of coarse of sieves 80 mm Field
1970 to 4.75 mm Laboratory
& IS : 2386
(P-I) 1963

2. Specific gravity and water IS : 2386 One Time in a Wire basket, balance, oven etc. Approved
absorption (P-III) 1963 season Laboratory

Approved
3. Flakiness & elongation IS : 2386 One Time in a Balance, Metal, Gauge, Sieves Laboratory
(P-III) 1963 season .

Approved
4. Petrographic analysis and --- One Time in a --- Laboratory
Alkali Reactivity season

ANNEXURE - VI

GENERAL TEST FOR STEEL REINFORCEMENT

Sr. Particulars of test Relevant Frequency Equipments Where
No. IS No. Tested
1. Yield Strength --- As per clause --- One Time
5.4.1 on page in a season
TS-197 Vol-II

2. Ultimate tensile strength --- --- do --- ---

--- do ---
3. Elongation --- --- do --- ---
--- do ---
4. Bend/ Rebend --- --- do --- ---
--- do ---
5. Chemical Testing --- One Time in ---
season --- do ---

ANNEXURE - VII

GENERAL TEST FOR PVC WATER STOP

Sr. Particulars of test Relevant Frequency Equipments Where
No. IS No. Tested
1. Tensile Strength minimum --- As per clause --- In
8.9 on page Approved
TS 330 Vol. II Laboratory

--- do ---
2. Ultimate Elongation --- --- --- do ---
minimum
--- do ---
3. Tear resistance minimum --- --- --- do ---

--- do ---
4. Stiffness in flexture --- --- --- do ---
minimum
5. Accelerated extraction Twice in a
(a) Tensile strength --- season --- --- do ---
minimum

(b) Ultimate elongation

minimum

ANNEXURE - VIII

GENERAL TEST FOR BI\TUMIN

Sr. Particulars of test Relevant Frequency Equipments Where
No. IS No. Tested
1. Binder temp for IS:15462 Two samples per lot to be --- In
application. subjected to all or some Approved
test as directed by the Laboratory
Engineer-in-charge

2. Rate of spread binder. --- --- do --- --- --- do ---

of bitumen

3. viscosity --- --- do --- --- --- do ---

4. Specific Gravity --- --- do --- --- --- do ---

5. Penetration test --- --- do --- --- Field

Laboratory