HEGCPL, Mumbai Technical Specification - Site Enabling Bid Issue

166893.71.0004 Work - Off Site Drainage, North East. March 30, 2010

APPENDIX 1E

FIELD QUALITY PLAN (FQP)

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APPENDIX 1 E FIELD QUALITY PLAN

TABLE OF CONTENTS

Sr. No. Description

1.0 SETTING UP OF FQA LAB
2.0 PLANT & MACHINERY
3.0 EARTHWORK
4.0 CEMENT
5.0 COARSE AGGREGATE
6.0 FINE AGGREGATE
7.0 REINFORCEMENT STEEL
8.0 WATER
9.0 STAGING AND FORM WORK
10.0 EMBEDDED PARTS
11.0 CONCRETING
12.0 CONCRETE TESTING
13.0 JOINTS IN CONCRETE MATERIALS
14.0 DRAINAGE
15.0 PLASTERING
16.0 PAINTING
17.0 BOUGHT-OUT ITEMS

ANNEXURE I: SUGGESTIVE LIST OF LAB EQUIPMENTS

ANNEXURE II: LOG SHEETS OF FIELD TESTS

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AUTHORISATION FOR CHECKS

CLASS OF CHECK LEGEND INSPECTION AUTHORITY ACCEPTING AGENCY

CRITICAL A Engineer - HEGCPL Engineer-in-Charge (EIC) - HEGCPL

MAJOR B Engineer - HEGCPL Engineer-in-Charge (EIC) - HEGCPL

MINOR C Engineer - HEGCPL Engineer-in-Charge (EIC) - HEGCPL

LEGENDS USED FOR TYPE OF CHECKS

R:REVIEW OF RECORD, V: VERIFICATION, M: MEASUREMENT, P:PHYSICAL CHECK, T: TESTING.

ABBREVIATIONS I ACRONYMS
OMC: Optimum Moisture Content GI: Galvanized Iron
MOD: Maximum Dry Density CA: Course Aggregate
WBM: Water Bound Macadam FA: Fine Aggregate
PCC: Plain cement concreting CI: Cast Iron
RCC: Reinforced Cement Concreting MS: Mild Steel
CNS: Cohesive Non Shrinking Soil TC: Test Certificate
IRC: Indian Road Congress

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QUANTUM I
TYPE OF REFERENCE DOCUMENTI FORMAT OF
SL.NO. CHARACTERISTICS liTEM INSTRUMENT CLASS FREQUENCY OF REMARKS
CHECK ACCETANCESTANDARD RECORD
CHECK
1.0 SETTING UP OF FQA LAB:
Ensure that laboratory is established at site Equipments List as per
V - B 100% Logbook
before commencinq of work. Annexure-I

2.0 PLANT & MACHINERY:

Ensure availability of the following: Concrete
VIP -- C 100% Logbook
mixers & Concrete placers
Vibrators of adequate capacity
Weigh batchers & batching plants I measuring
boxes in exceptional cases.
Concrete pump
Air compressor
Pumps, check for type and ratinq
Jack hammer
Transit mixer
Generator
Winches, Cranes
Excavator, power roller, plate compactor

3.0 EARTHWORK:
3.1 Excavation: (Refer Table 1 of Technical Specifications on Earthwork)
Check preliminary Survey and layout of Layout I Foundation
3.2 M Total Station B 100% L6
foundations, includinq initial qround level. Drawinqs
3.3 Review of soil I rock test report. R -- B 100% Soil/Rock test report Test Report
Soil I rocks are striped & removed up to the Maintain
identified level. Record dimension & final pit/bed -Compressor I Identified level based on appropriate side
3.1 P/M B 100% L6
level. Note: Any extra excavation carried, should Drilling Machine soil report. slope during
be filled with PCC. excavation.

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4.0 CEMENT:
Test Certificates as per
4.1 - Review of Manufacturer's Test Cert R B 100% Reviewed TC
IS: 1489 Part-I
- Check cement for Type, Consistency, Initial and
final setting time, Compressive strength Compressive L-01
Sample as per IS :
(3 days & 7 days), and C3A Content. T Strength Testing B L-02
1489 Part-I
Note: For critical items of work, ordinary MIC Mould L-05
Portland cement may have to be used.
To avoid deterioration from moisture, One sample from
4.2 VIP - C IS: 4082 Logbook
contamination, and mix up, ensure followinq: each lot received.

- Storage in Covered sheds on raised platforms.

- Not more than 10 bags are stacked on one

heap in order to have proper access for
inspection.
- Stacking of bags consignment wise, type and
qrade wise for clear identification
- Different types of material are stored
separately

5.0 COARSE AGGREGATE:

5.1 Conduct followinq tests for mix desiqn:

Sieve Set, weigh IS 383, IS 2386 & Approved L-04

- Sieve analysis for shape & particle Size M B -
balance, Oven, Jar Technical Specifications. Test Report

- Moisture content
Quantum: One per 100 M3 or part
thereof, or on change of source,
whichever is earlier?
Sieve Set, weigh Each type & source IS 383, IS 2386 & Approved
- Specific gravity -Bulk density MIT B Test Report
balance, Oven, Jar of supply/lS codes Technical Specifications.

- Bulk density
- Voids
- absorption value
- Soundness
- Reaction with Alkali
- Flakiness Index
- Petroqraphv examination

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- Deleterious materials, MICA content

- Mechanical properties; crushing strength,
Abrasion strenqth & impact value
- Elonqation index

6.0 FINE AGGREGATE:

Ensure, following tests are conducted for each
6.1
source of material supply (for mix design):
- Particle size and shape bv Sieve analvsis T Sieve set B -- IS Code L-03
Quantum: One per 100 M3 or part thereof, or
Test Report
chanae of source, whichever is earlier?
- Moisture content T B IS Code
Measuring Jar, -Every day IS
- Specific gravity, density, voids T/M Weigh Balance, B Code/ Approved Test Certificates Test Report
Oven Tech. Spec
- Soundness & absorption IS 383
- Reaction with Alkali IS 515
- Deleterious materials, MICA, Silt, & Clay
IS 2386
content, and Oraanic Impurities
- Mortar makina properties
- Petrooranhv examination
- Bulkina of sand

Before use at site check for Silt & Clay content, IS Code/ Approved IS Code/Approved Tech. L-03
6.2 T/M Sieve set B
Sieve analysis & Bulking of sand. Tech. Spec. Spec. Test Report

Concrete Admixture: Review of manufacturer's Manufacturer Catalogue /

Approved Tech.
6.3 test certificates to ensure conformance to R - C IS Code / ASTM Code / -
Spec.
specifications. Approved Tech. Spec.

7.0 REINFORCEMENT STEEL:

7.1 During storage, check visually and verify records. VIR - C Periodical IS 4082 Protocol

In absence of
test certificates /
test to be
Verified Test
7.2 Review of test certificate for following: V - A IS 1786 performed
Certificate
randomly to
confirm the
properties.

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- Chemical analysis. IS432

- Mechanical Properties like Tensile Strength,

IS 1566
Elongation, Yield Stress, Bend Test.

- Grade of Steel.
- Dimensions.
7.3 Verify the followinq:
- Surface characteristics like free from cracks,
Surface flaws, imperfect edge, and rough V - B Random -- Protocol
locoed.
- Dimensions
- Identification for different type and M Screw qauqe B Random
qrade of steel V - B Random
Ensure that reinforcement bars interfering with
7.4 Measuring Bar Bending Schedules,
pockets, pipes, sleeves, openings etc are not cut M B 100% Protocol
Tape Drawings
but suitably adjusted.

Ensure that the joints and crossing bars are tied IS 2502,Bar Bending
7.5 P - C 100% -
properly with correct size & type of binding wire. Schedules, Drawings

Measuring IS 456, Bar bending

7.6 Ensure lapping of bars, wherever necessary C 100% -
Tape Schedules, Drawinqs
Measuring Bar Bending Schedules,
7.7 Check for placement of reinforcement bar. P C 100% -
Tape Drawinqs

8.0 WATER:
Before use, ensure that water from all Source is Once in a month
8.1 T - B Test Certificate IS 456 Logbook
potable. per source
8.2 Conduct test for neutralization factor M Indicator B -00- IS 3025 & IS 456 Loqbook
8.3 Check and ascertain limits of solids. M B -00- IS 3025 & IS 456 Loqbook
8.4 Conduct Test for pH value. M pH Meter B -00- IS 456 Loqbook

9.0 STAGING AND FORM WORK:

Ensure the form works are carried out as per
Approved Tech. Spec. /
9.1 contract specifications, drawings, and layout PN - B 100% L6
Drawing
checked.

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9.2 Check for followinq:

Drawings I Approved Tech.

a. Cleanliness, damage, war-page etc. V Water level C 100% Logbook
Spec. I Procedure for
alignment checking of form
works I Approved Staging
Ensure internal dimension of box form and
Design
b. distances between internal surfaces of shuttering M Measuring Tape C 100%
of walls from desiqn dimensions.
Ensure horizontality I verticality before and after Sprit level Plumb
c. M C 100% -- -Do-
placement of reinforcement. bob
d. Staqinq if any, as per desiqn. VIP - C 100% -- -Do-

e. Form work materials are as per the specification. PN - C 100% -- -Do-

9.3 Ensure the followinq:

Hammer Plumb bob
- Strength & soundness of material P/TNIM C 100% Drawings Logbook
Water level
- Proper [oininq I bracinq
- Verticality of side shuttering before and after
Measuring tape C 100%
reinforcement
- Specified level & Dimensions
- Proper Supports
- Use of Form release aqents
9.4 Ensure for no loss of liquid thro' [oints. PN - C 100% - -

10.0 EMBEDDED PARTS:

10.1 Ensure for followinq:
Dumpy level,
a. Position and leveling of embedded parts M B 100% Drawings Protocol
Measurinq tape

b. Position and level of critical embedded parts. M Leveling Instrument B 100% Drawings Protocol

c. Position, depth and size of holes for bolts. M Measurinq tape B 100% Drawinqs Protocol
Suitable pipe sleeves have been provided in
d. M Measuring tape B 100% Drawings -
holes before concretinq.

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All necessary steps like welding of lugs to

reinforcement, Jigs, fixtures and templates are
e. P - C 100% Drawings -
completed to keep the embedded parts
undisturbed durinq the process of concretinq.
Ensure length, diameter and verticality of Plumb bob,
10.2 M B 100% Drawings Protocol
embedded bolts. Measurinq tape
Ensure that sufficient length of bolts protruding
10.3 above finished floor level to accommodate M Measuring tape B 100% Drawings Protocol
equipment (base frame)
Ensure that threads of foundation bolts are
10.4 protected by PVC tape after application of V - B 100% Drawings -
qrease.

11.0 CONCRETING:
Drawing & technical
11.1 Checking of Layout and program of concreting. V Leveling Instrument B Drawing L6,L7
specification
11.2 Ensure followinq before concretinq:
Approved
Preliminary Tests are conducted for determining Compressive
a. T A Technical Test Certificate IS 456 L05 Protocol
design mix for required strength. Testing M/c
Specification
Cement water and aggregate content as per mix Weigh Batcher, IS 456
b. - B L18
desiqn. Measurinq Jar IS 10262
11.3 Check concrete for followinq:
The moisture content in both fine and coarse Measuring Jar Approved IS 456
L5,L8,
a. aggregates before use and correct water cement M Oven, weigh B Technical IS 2386 Part III
L18
ratio wherever necessary. Balance Specification IS 1199 & Annexure II
Slump conel Approved IS 456
Workability of the concrete checked at frequent L5,L8,
b. compaction factor B Technical IS 2386 Part III
intervals by slump cone Test I compaction factor. L19
apparatus Specification IS 1199 & Annexure II
Ensure for continuous concreting and adequate
11.4 P - B 100% IS456 -
quantity of constituents.

Ensure that all measuring equipments are

maintained in clean & serviceable condition, and
11.5 - - C 100% Test Certificate -
their accuracy is checked periodically &
corrected by recalibration wherever necessary.

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11.6 Ensure reinforcement for followinq:

The reinforcement rods are clean, and free from
V - C Random -- -
paint, oil and other coatinqs.
The reinforcement rods are placed correctly in
position with adequate separators before pouring P - B 100% Drawings -
concrete.
11.7 Check and ensure the followinq:

Area to be concreted is clean and free from

a. V - B 100% -- -
debris any extraneous matter of water logging.

Water stopper or seals are introduced wherever

b. P - C 100% Drawings -
required.
Adequate cover is provided between
c. P - C 100% -- -
reinforcement and shutterinq.
Old concrete surfaces are chipped, cleaned with
d. wire brush, wetted and a coat of cement slurry P C 100% -- -
applied before lavinq new concrete.

The temperature of concrete should not exceed

e. 25deg C for major specified equipment M Thermometer B 100% IS 456 Logbook
foundation. Use ice proportionally, if required.

Temperature is above
Stripping time of formwork is strictly regulated as
f. P - B 1 IS 456 Logbook 200 C and ordinary
follows in normal circumstances: cement is used

1. Wall columns & vertical sides of beams: 24 to

48 hours
2. Slab (props left under): 3 days.
3. Beam soffits (props left under): 7 days
4. Removal of props to Slabs span less than 4.5
M: 7 days
5. Removal of props to Slabs span more than 4.5
M: 14 days

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6. Removal of props to beams and arches

spanning up to 6 M: 14 day
7. Removal of props to beams and arches
spanning over 6 M: 21 days
Note: Where rapid hardening cement is used,
the stripping time in respect of items 2 and 4 of
above, be regulated at 3/7 of the corresponding
periods stated for ordinary cement.
11.8 Ensure for followina:
Concrete is transported I placed and
compacted before expiry of initial setting time
a. P - C 100% Logbook
of cement and not disturbed subsequently.

Concrete is placed in even layers in quick

b. succession, each of which is compacted before P - C 100%
placing next layer and no cold joints are formed.

Curing of concrete is carried out for a minimum

period of 7 days from the date of placing of
concrete. Curing is started not later than 10 to 12
c. P - B 100%
hours after termination of concreting in normal
weather, and in hot and windy weather within 2
to 3 hours.

12.0 CONCRETE TESTING:

Adequate number of specimen cubes for Testing
are taken from mixed concrete, identified IS 456, 2911 & Approved
12.1 T Steel Moulds A IS 456 In case test results of
properly, and kept 3 nos. (Minimum) for 7 days & Technical Specifications. load test / core test
3 nos. for 28 days. are not satisfactory,
further test to be
Concrete cubes are Tested at specified period Compressive Test
12.2 T A 100% IS 516 IS 2911 L05 conducted to assess
and recorded. Machine the quality of
Test results of concrete cubes are examined to concrete.
Laboratory Test Results Reviewed
12.3 verify the specified grade of concrete as R - A 100%
IS 516 IS 2911 Test Report
required.
Visual, dimensional, and core test on finished
12.4 VIT Test Set Up A 100% Approved Tech Spec Protocol
structures.

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13.0 JOINTS IN CONCRETE MATERIALS:

Tech. Spec.! Manufacturer's Review of Mfr's
13.1 Check following materials for grade, brand, etc.: R - B Once per lot Reviewed TC
TC TC
- Bitumen Impreqnated Board
- PVC Water Stops
- Bitumen Sealinq Compound
- Two Part Poly-Sulphide Sealant
- Expanded Polystyrene Board
13.2 Installation & fixinq, as and wherever required P - C As required Tech Spec.! Orawinq -

14.0 DRAINAGE:
Ensure that all pipes, fittings & fixtures are as per
14.1 V - B 100% -00- Logbook
relevant code.

Check for proper alignment, level, and slope of Measuring Tape,

14.2 M B 100% -00- Protocol
each laid length Leveling Instrument

Ensure proper jointing of each laid length of

14.3 V - C 100% -00- -
pipes
Ensure proper curing of joints on RCC pipelines,
14.4 V - C 100% -00- Logbook
minimum for 10 days.

15 PLASTERING:
Check for proper Cement -Mortar proportion, Drawings, IRC Technical
16.1 VIM - C 100%
cleaninq, hackinq, etc. Specifications
Ensure that the plastering of brick walls shall be
16.2 of min. 18mm thick for outside and 12mm for VIM Steel tape C 100% -00- Protocol
inside
Ensure that the plastering of concrete ceiling is
16.3 VIM -Do- C 100% -00-
6mm thick (min) mortar.
Check for grooves, openings, rounding of
16.4 VIM - C 100% -00-
corners hollows in plaster.
Curing of plastering surfaces is carried out for 7
16.5 VIM - C 100% -00-
days minimum.
16.6 Check Verticality of Plasterinq. VIM Plumb Bob B 100% -00-

Drawing I Technical
16 PAINTING: VIM Elkometer B 100% Protocol
Specification.
16.1 Check for followinq:
- Color, Shade I Brand
- Surface Preparation
- Number of coats
- Curinq if any
- Final finish (OFT)

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Approved Tech. Spec / Test Verification of

17 BOUGHT·OUT ITEMS: R ..- B 100%
Relevant IS Codes Certificate TC.
17.1 Review the Manufacturer's Test
Certificates for conformity of brand, type,
17.2 technical specifications etc. Make & brand to be
approved by

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