APCO INFRATECH PVT. LTD.

QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

METHODOLOGY OF PAVEMENT QUALITY

CONCRETE

For APCO Name Designation Sign

Prepared By Sr. Manager (QC)

Asst. Manager
Reviewed By
(Planning)

Approved By Project Manager

For CLIENT Name Designation Sign

Reviewed By

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

History of Revisions

Chapter/clause no. & text

Revision No. Revision date Reason for revision
affected

00 15 December First Issue

2018

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

TABLE OF CONTENTS

S. No. Description of Title Page No.

1.0 Purpose 4

2.0 Scope 4

3.0 Definitions 4

4.0 Cross References 4

5.0 Responsibilities 5

6.0 Procedure 6-15

6.1 Construction Materials for PQC 6-7
6.2 Design of Mixes for PQC, Trials 7-8
6.3 Details of Plant, Equipment and Machinery 8-9
6.4 Survey and Setting out Works 9-10
6.5 Laying Pavement Quality Concrete ( PQC ) 10-14
6.6 Quality Assurance and Control Checks 14
6.7 Safety and Environmental requirements 14-15

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

1.0 PURPOSE:

The purpose of this Segment Quality Plan for Construction of Pavement Quality Concrete
( PQC ) is to provide detailed Construction Methodology, Materials used, Resources deployed
and also Quality Assurance & Control System/Procedures APCO and its
Sub-contractor’s/Supplier’s etc. in execution of PQC under the said Contract.

2.0 SCOPE:
The Scope of this Segmental Quality Plan shall cover the following activities:
 Selection, Testing and Acceptance of all incorporated Materials for PQC.
 Design of Mixes for PQC and Trials, Acceptance etc.
 Details of Plant, Equipment/Machinery as required in execution of PQC.
 Batching, Mixing, Transporting, Placing, Finishing and Curing of Concrete for PQC.
 Mechanized Texturing and Curing operation by using curing compound for PQC.
 Joint Cutting and application of Joint Sealing compound as approved.
 Quality Assurance and Control Checks during operation and post concreting.

3.0 DEFINITIONS:
The words like Contract, Contractor, Engineer (Synonymous to Engineer’s representative),
Drawing, Employer, Government, Works, Worksite used in this Quality Plan shall be
considered to have the meaning as understood from the definitions of these terms given in the
General conditions of the contract. For other general definitions pertaining to APCO Quality
Management System, refer Project Quality Plan.

4.0 CROSS REFERENCES:

This Segment Quality Plan shall be read in conjunction with the following documents:
(i) Specifications for Road & Bridge works, Ministry of Road Transport & Highways
(MORTH) – 5TH Revision.
(ii) Guidelines for Expressway (2010).
(iii) Manual of Specifications and Standards for Expressways (IRC:SP:99- 2013)
published by IRC, Government of India

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

5.0 RESPONSIBILITIES:

Responsible personnel for execution and quality control activities in construction of PQC are as per
the Responsibility Matrix under mentioned:

S. Activity Description Execution Checking / Approving

No Q. Control Authority
.
01 Preparation of Quality Plan Section-in- Highway Project Manager /
for PQC. charge Manager & QC Engineer
Manager
02 Selection and Testing of Section-in- QC Manager Project Manager /
various materials for PQC, charge & QC Engineer
Mix Design & Trials etc. Engineer/ Lab
prior to start of PQC Technician
activities.
03 Establishment of C/way Surveyor Survey in- Engineer/
centerline with Total station charge Designated
as per coordinate. Representative
04 Survey, Setting out and Surveyor Section-in- Engineer/
fixing of string lines prior to charge/Site Designated
start of PQC. Engineer Representative
05 PQC Paver deployment at Section-in- Highway Project
various locations and other charge / Site Manager Manager in
logistics, management etc. Engineer consultation
with Engineer
06 Batching and Mixing of Batching Plant Q.C. Engineer/
Concrete as per approved In-charge Engineer/Lab Designated
Design Mix. Technician Representative
07 Control on movement of Paver Engineer/ Paver In- Manager (P&M)
Paver and maintenance Supervisor charge for effective
checks/control during control of Paving
operation. Operation.
08 Transportation, Placing, Section-in- Q.C.Engineer/ Engineer/
Compaction and finishing of charge / Site Technician Designated
PQC Layer. Engineer Representative
09 Texturing, Curing Joint Section-in- Q.C.Engineer/ Engineer/
Cutting and Sealing charge / Site Technician Designated
operations for PQC. Engineer Representative
10 Inspection & Testing PQC as QC QC Manager / Engineer/
per approved ITP and Engineer/Lab QC Engineer Residence
maintaining all formats. Technician Engineer/Material

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

Engineer

6.0 PROCEDURE:

The detailed Construction Methodology involved in execution of PQC including Quality Assurance &
Control etc. has been described in the following sub-chapters:

6.1 Selection, Testing and Acceptance of Construction Materials for PQC:

6.1.1 Cement: As per the Technical specifications – MoRT&H Cl. 602.2.2, Ordinary Portland
Cement of 43 grade conforming to IS: 8112 shall be given preference to MTC/Lab test certificate
shall be maintained for each and every week of Cement received and Cement shall be stored as per
MoRT&H Cl. 1014.4.

6.1.2 Fly Ash: As per the Technical specifications – MoRT&H Cl. 602.2.2, Fly ash upto 20% by
weight of Cementitious material may be used in Ordinary Portland Cement 43 grade as part of
replacement of cement provided uniform blending with cement is ensured. The fly ash shall
conform to IS: 3812 (Part-1)

6.1.3 Coarse Aggregate: Aggregate’s to be used in the construction of PQC concrete shall be of
natural material complying with IS: 383. Aggregate shall not be Alkali reactive. Coarse aggregate
shall consist of clean, hard, strong, dense, &durable pieces of crushed stone & shall comply with
clause 602.2.6.2 of MoRT&H. Aggregate of only approved source shall be used. Maximum size of
Aggregate used shall be 31.5mm for PQC. Aggregate for PQC, Los Angeles Abrasion Value
should not be more than 35 percent. Water absorption of aggregate shall not be more than 2%.The
aggregate shall be tested for soundness in accordance with IS : 2386.

6.1.4 Fine Aggregate: The Fine aggregate shall consist of clean, natural sand or crushed stone
sand or a combination of the two and shall conform to IS: 383. Fine Aggregates shall be free from
soft particles, clay, shale, loam, cemented particles, mica, organic and other foreign matter & shall
comply with clause 602.2.6.3 of MoRT&H.

The coarse and fine aggregate shall be obtained Separately as 20 mm nominal single size, 10 mm
nominal size graded aggregates and fine aggregates of crushed dust or sand or a combination of
these two.

For Aggregates of Pavement Quality Concrete, Continuously graded or gap graded aggregates may
be used, depending on the grading of the Fine Aggregates.

6.1.5 Water: Water to be used for mixing & curing of concrete shall meet the requirements
stipulated in Clause1010 of Section 1000 of MoRT&H specifications. and approval for the same
shall be taken from the Engineer before use in mix.

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

6.1.6 Admixtures: Admixtures conforming to IS: 6925 and IS: 9103 shall be used to improve
workability of the concrete for PQC. Prior approval from Engineer shall be obtained for use and
particular type of Admixture in PQC. Trial Mix will be carried out to assess its performance .It
will comply with clause 602.2.3 of MoRT&H.

6.1.7 MS Bars for Dowels in Joints: MS bars confirming to Clause 602.2.8/ IS: 432 shall be used
for Dowels in Joints. Size of bars shall be with details/dimensions as indicated in the drawings and
free from oil, dirt, loose rust or scale. They shall be straight, free of irregularities and burring
restricting slippage in the concrete. Dowel bars shall conform to IS: 432 of Grade 1.

6.1.8 Tie bars in Joints: Tie bars in longitudinal joints shall be deformed steel bars of strength
500 Mpa conforming to Clause 602.2.8/ IS: 1786. The bars shall be free from oil, dirt, loose rust
and scale. Tie bars shall conform to IS.: 1786.

6.1.9 Pre molded Joint filler: It will comply with sub clause 602.2.9 of Technical Specification
prior approval from Engineer shall be obtained before finalization of the same.

6.1.10 Joint sealing Compound : As per Supplementary Technical Specification, for hot applied
electrometric type, complying with AASHTO M 282 for joints in asphalt pavements or joints
between asphalt and concrete pavements and cold applied polyurethane or polysulphide type
complying with BS 5212(Part 2) for joints in concrete pavements. Suitable primers as
recommended by the manufacturers of each type of joint sealant shall be used. It will comply with
sub-clause 602.2.10 of MoRT&H.

6.1.11 Curing compound: Curing Compound conforming to MoRT&H clause 601.6.7 c) shall be
used. The curing compound shall have a water efficiency index of 90% in accordance with BS
Specification no.7542.

6.1.12 Separation Membrane: Separation membrane shall be white impermeable plastic sheeting
of 125 micron thick. It will comply with sub-clauses 602.5 of MoRT&H

6.2 Design of Mixes for PQC and trials :

6.2.1 Mix proportions for Pavement Quality Concrete (PQC) :

Concrete Mix design for PQC shall be done as per IS: 10262 or any other rational method and
MoRT&H Cl. 602.3. The mix design shall be based on the flexural strength of concrete.

The minimum cement content shall not be less than 360 kg per cum. of Concrete. The Pavement
concrete shall have a minimum flexural characteristic strength of 4.5 Mpa.at 28 days. The maximum
free water-cement ratio shall be 0.45.

Or In case of Fly ash use, minimum cement content shall not be less than 310 kg per cum of concrete,
the fly ash shall be used up to 20% of cementitious materials.

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

A slump value in the range of 30 +/- 15 mm is reasonable for paving works but the actual slump
maintained shall be decided as per site requirement and got approved by the Engineer.

Design Features:
1. Target Mean Strength at 28 days : 5.80 Mpa
2. Characteristic Flexural Strength at 28 days: 4 .5Mpa.
3. Maximum size of Aggregate : 28 mm
4. Degree of Workability: Slump as per IS : 1199 : 30+15 mm.
5. Min. Cement Content: 360 Kgs.
6. Maximum Water-Cement Ratio : 0.45
7. Degree of Quality Control : Very Good
8. Type of exposure : Normal

6.3 Details of Plant, Equipment and Machinery :

The following Plant, Equipment and Machinery shall be deployed for PQC execution and shall be
maintained as per manufacturers operations /maintenance guidelines:

Batching Plant :

Batching Plants of suitable capacity will be installed to cater the needs of Concrete for DLC and PQC
uninterruptedly and these Plants are fully automatic in operation to produce Concrete of consistence
proportions /quality & quantity at desired rate of 1 meter /minute shall be maintained.
Batching Plants shall be maintained as per manufacturer’s instructions and also as per APCO standard
Equipment Maintenance Manual/Service charts etc. The Plant shall be calibrated every month as per
established procedure and necessary records maintained by Quality control department.

PQC Paver (Slip Form type ) :

Slip form Paver which will meet all the requirements specified in Clause no. 602.9.6 of MORT&H
shall be used for laying PQC. The main components of the Paver are spreading augur, vibrators,
finishing beam and super-smoother. This slip form paver is capable of receiving Concrete dumped
without segregation at its front end, spreading, compacting with in-built internal needle vibrators and
finishing with super-smoother. This paver has been equipped with auto dowel bar inserter (DBI) and
auto Tie rod inserter (TRI) which will automatically insert the Dowel bars and Tie rods at pre-set/
desired locations inside the concrete with vibration to ensure proper finishing of concrete after
insertion of Dowel and Tie bars.
Paver movement and alignment of finished PQC shall be controlled by Sensors fixed to the Paver
which in turn shall be guided by string wire installed as per Clause 602.8 aligned as per
level/alignment shown in the drawing.
Slip form Paver shall be maintained as manufacturer’s instructions and daily checks shall be carried
out to ensure proper and uninterrupted functioning of the machine.

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

Texture-Curing Machine :
Texture Curing Machine (TCM) which will meet the requirements specified in Sub Clause no.
602.9.11 of MoRT&H shall be used for Texturing and subsequent Curing operations for PQC This
machine is capable of forming desired surface-texture to compacted and finished Concrete layer with
in-built brushes and subsequent curing compound arrangement with desired rate of application to form
a uniform impervious membrane.
Texturing and Curing Machine shall be maintained as manufacturer’s instructions and daily checks
shall be carried out to ensure proper and uninterrupted functioning of the machine.
Texturing shall be done parallel to the alignment as mentioned in contract specification vide
Cl.no.602.9.11.1 b).
In addition to the above Major Plant and Equipment the following Machinery shall also be used for
laying PQC :

 Concrete transporting tippers – The concrete shall be transported by tipping trucks , sufficient in
numbers to ensure a continuous supply of material to feed the laying equipment to work at a
specified uniform speed 1m per minute and in an uninterrupted manner.
 Concrete Saw cutting Machines/tools – as required
 Total Station, Level instruments, string wires & pegs etc.
 Water tanker with sprinkling bars, gunny bags etc. – as required
 Q.C. Machinery/tools, Slump Cone, Cube/Beam moulds, Core cutting machine needle vibrators
etc. as required at field and a full-fledged Material Testing Laboratory has already been established
for performing various laboratory tests on DLC and PQC as per relevant ITP’s.

 Lighting Towers /Illumination as per requirements.- Lux level

 Joint Sealing Equipment

 Air Compressor /Blower, Mechanical Brooms as required

6.4 Survey and Setting out for PQC :

Survey and setting out of String line is a very important crucial activity to be completed and
thoroughly checked prior to start of PQC Laying. The following steps are involved in Setting out of
string wire before laying PQC.
1) Centre line of carriageway will be marked at every 5m & 10 m interval on DLC surface in
curves & straight road respectively by using Total station/Theodolite. Pre decided location of
Dwell joints will be marked on DLC.

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

2) String line of 3mm dia wire rope will be fixed on both sides of proposed PQC edges at a
constant height approximately 100 mm and offset 1.0 – 1.5 M away from the Pavement. This
string line will be supported/ anchored by stakes at every 10 M intervals on both sides in
straight location & 5m in horizontal curve location.
3) The string wire shall be tensioned on the stakes so that a 500 gms. weight shall produce a
deflection of not more than 20mm when suspended at the mid-point between any pair of
stakes. To ensure the required tension of string wire, hand winches will be used to tighten the
string line to avoid any sagging. These winches will be placed at maximum 300 M intervals.
4) The stakes shall be positioned and the string wire maintained/tensioned at their correct
level/height and alignment as per relevant section drawings before concreting takes place.

5) It shall be ensured that the stakes and guide wires are not affected by the construction
equipment when concreting is in progress.

6) Detailed Survey Check sheet shall be maintained incorporating all survey and setting out
details relevant to PQC to be executed.

6.5 Laying of Pavement Quality Concrete ( PQC ) :

Prior to start of Pavement Quality Concrete, Trial patch of at least 100m long will be laid which shall
be laid over a period of two days. The objective of laying a trial patch is to see the performance of mix
i.e., whether proportioned and mixed as per approved design mix, minimum mixing time and to set the
right procedure of laying, optimization of Slip form Paver output and other resources and also to
establish required inspection checks for effective laying of PQC at pavement. Approval of trial patch
will be obtained from the Engineer. The methodology of laying trial patch is being submitted
separately for approval.

6.5.1 Laying of Separation Membrane:

A separation membrane shall be laid on DLC surface prior to PQC laying. Separation membrane shall
be impermeable white plastic sheeting of 125 microns thick laid flat without creases. Before placing
the separation membrane, the DLC surface shall be swept clean of all the extraneous materials using
air compressors. Overlap of membrane shall be at least 300mm and any damaged sheet shall be
replaced immediately.

6.5.2 Concrete Production:

Concrete shall be produced in the Batching Plant, having capacity at least 20% more than output
required to meet the paving speed of 1m per minute. The no. of plant will be limited to two which is
capable proportioning the material by weight, with each type of material being weighed separately.
The Batching Plant and mixing shall be carried out in a forced action central batching and mixing

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

plant, which has automatic control. The controls are fully computerized so as to ensure accurate
proportioning and mixing. The accuracy of weighing scales of the batching plant will be within +/- 2
percent in the case of the aggregate and +/- 1 percent in the case of cement and water. Approved
admixtures will be added in to the mix in liquid form. Loaders will be used to load aggregate from
stacks of approved material in to conveyor hopper.

Following measures to control temperature of produced concrete within 30 deg centigrade will be
adopted.

i) Mechanically water will be sprinkled to cool the aggregate if required.

ii) Chilled water will be used for preparation of concrete. For this purpose water chilling plant will
be used at batching plant if required.
6.5.3 Transportation of concrete:

Plant mix concrete shall be discharged immediately from the mixer, transported directly to the point
where it is to be laid and protect from the weather by covering the tippers/dumpers. The concrete will
be transported by sufficient number of tippers/dumpers. The number of the tippers/dumpers will be
adequate in number so as to feed the Paver to work at a specified uniform speed and in an
uninterrupted manner.

6.5.4 Laying procedure of PQC:

(i) String line shall be fixed at both sides of proposed PQC layer as per the procedure
described in clause no. 6.4 and Survey check record shall be maintained.

(ii) Slip Form Paver shall be positioned in place and thoroughly checked in all respects as per
maintenance checklist.
The approved PQC Mix shall be Batched & Mixed in a fully automatic
Centralized batching plant as per the approved design mix and to the specified workability
finalized during trials. Q. C. Engineer /Technician at Batching Plant shall ensure that the
right proportion/quantity of various ingredients of Mix being fed in to the mixer and
properly mixed as recommended by the manufacturer and the Technical Specification prior
to discharge in to the truck.

(iii) Before sending the Concrete to pour site its properties i.e., temp., slump etc. shall be
checked at plant and recorded. Slump tests, temp etc will be recorded at laying site also .

(iv) Concrete mix shall be transported to the paver site by means of tippers/dumpers of
sufficient capacity in sufficient numbers to ensure a constant supply of concrete so as to
achieve more than the min. specified paving rate. Covers shall be used for protection of
concrete against the weather.

(v) The sufficient nos. of dumpers carrying PQC shall reach in front of paver to dump the
concrete on DLC surface. Any damages of separation membrane due to dumpers

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

movement shall be replaced by providing 280mm overlap. The freshly mixed Concrete
shall be unloaded in the front of slip form paving train of required capacity having
Electronic sensor device. The Paver shall be equipped with Dowel bar inserter.

(vi) The laid concrete shall be leveled, compacted by the high frequency vibrators fitted in the
paver & shape it through moulding plate between the side forms and finishing beam.
(vii) The level of the paver mould & oscillating beam shall be controlled automatically from the
string wires installed by sensors attached at the four corners of the slip form paving
machine.
(viii) Dowel bars of specified size as per drawings shall be automatically inserted by the Slip
Form Paver Auto Dowel Inserter inside the Pavement Quality Concrete at required level &
position as per drawings. Dowel bars shall be covered by a thin plastic sheath for at least
two thirds of the length from one end of dowel bars in contraction joints or half the length
plus 50mm for expansion joints as per Cl.no.602.6.5.5. It shall be ensured that sufficient
nos. of Dowel bars are stacked at Paver Cartridge and any defective bars found, it shall be
immediately replaced.

(ix) Tie bars of specified size as per drawings shall be automatically inserted by the Slip form
Paver Auto Tie Bar inserter inside the PQC. at required level & position as per approved
drawing. It shall be ensured that sufficient nos. of Tie Bars are stacked at Paver Cartridge
and any defective bars found, it shall be immediately replaced. Dowel bars & tie bars
should be free from rust etc. Details of dowel joints at the junction of all structures shall be
incorporated in a separate sketch and approval taken.

(x) After final finishing of the slab and before the application of curing compound, the surface
of PQC layer shall be tined/brush-textured.

(xi) The surface shall be tined/ brush-textured, while the concrete is still plastic and the
optimum time gap in between final finishing of concrete surface and start of brush-
texturing longitudinal shall be maintained to achieve the required texture depth .
Sufficient nos. of movable tents/ trusses along with tarpaulin will be provided to cover the
green/freshly paved slab to protect from adverse conditions arises if any.

(xii) Immediately after the surface texturing, the surface & sides of the PQC slab shall be
Initially Cured by the application of approved curing compound by means of a Mechanical
sprayer in built with Texture-Curing Machine. This auto spraying machine is capable of
spraying required quantity of liquid curing compound recommended by manufacturer to
ensure proper and effective application of curing compound on entire pavement surface.

(xiii) Application rate of Curing Compound will be established by analyzing its effectiveness to
retain the water inside the concrete. In addition to the application of curing compound the
pavement shall be covered with moist Hessian Cloth & same shall be kept damp for a
period of 14 days.

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

The surface regularity, level, & strength shall be tested to conform to the requirement of
technical specifications. Refer attached Inspection & Test Plans for the various inspection
checks/tests to be conducted on the concrete during operation and post-concrete checks.

(xiv) Initial Joint Cutting: Marking of exact location of transverse and L- Joints with paint shall
be done. Joint cutting at relevant Transverse i.e., expansion/contraction and Longitudinal
/other construction joints etc. as per relevant drawings shall be carried out using Concrete
Saw Cutters. The size of groove to form joints shall be as per approved drawings. The
initial joint cutting will be taken as soon as concrete harden to take the load of Joint Cutting
Machine and no significant damage to edges of groove occurs. Time lapse required to start
joint cutting after finishing of concrete surface shall vary with climatic condition and other
factors. The initial joint cutting shall be demonstrated in the trial length.
After the joint cutting, the joint shall be washed/ cleaned with high pressure jet and hooks
to remove the slurry and broken stone chips.

(xv) Widening of Joint & Filling :

Widening of the initial cut to the size mentioned in the approved drawing with the help of
concrete saw cutting machine.
Widened joint shall be washed off the slurry by using the pressure jet of water.
Sealant shall then be filled specified depth and finished by tooling specified shape as per
manufacturer’s specification.

(xvi) Surface Tolerance: Surface Tolerance shall be within the limits of +6/-6 mm tolerance
limit as per MoRT&H Clause 902.3, Surface levels shall be checked on a grid of points
spaced at 6.25 m along the length and 3.5m transversely between 0.5 m from the edges and
at the center of the pavement.
(xvii) Various Quality Control Inspection and Tests for various activities in laying of PQC until its
final acceptance are described in subsequent sub-chapter/ Inspection and Test Plan.

6.5.5 Opening to traffic :

No vehicular traffic shall be allowed on the finished surface until a field flexural strength of minimum
4.50 MPa has been achieved as per Sub clause no 602.13 of Technical Specification. Each series of
test specimens shall be cured at condition similar to the field conditions. The method of curing and
storing of test specimens in order to intimate field conditions shall be approved by the Engineer.

6.6 Quality Assurance and Control Checks :

As part of Quality Assurance this Segment Quality Plan for PQC has been prepared in line with the
specifications provided in relevant MoRT&H clauses, Contract Supplementary Technical
Specifications and other Codes/Standards/Specifications etc. elsewhere mentioned in this Plan. This
Plan has been distributed to all concerned personnel who are involved in overall execution of PQC in

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 APCO INFRATECH PVT. LTD. QUALITY MANAGEMENT SYSTEM

DOC. NO.: APCO/MSRDCL//QC/04

Construction of Nagpur – Mumbai Super
Communication Expressway (Package – REV. No.:00
05) from Km.217+023 to Km. 259+900
on EPC mode REV. DATE: 26 NOVEMBER, 2018

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

order to ensure that work shall be performed as per the procedures furnished in this Quality Plan and
also to achieve consistency in execution at various locations.
As a part of Quality Control all the Inspection and Testing requirements for various activities involved
in laying of PQC shall be carried out as per relevant MoRT&H Specifications & Contract Technical
Specifications etc including as described in Inspection and Test Plans attached to this Segment Quality
Plan for PQC.
These Inspection and Test Plans shall consists of type of Inspection and name of the Test to be
conducted for Product Realization, frequency of testing, acceptance criteria and category of Inspection
as mentioned in ITP.
Inspection and Test Plans shall be revised whenever there is any change in methodology and
specifications etc. Various Field and Laboratory Test Formats referred in Inspection and Test Plans
shall be maintained as per the frequency mentioned in respective ITP’s for various activities.

The document and records shall be maintained to demonstrate the compliance to established APCO
Quality Management System in execution of present Methodology and also to meet the Contract
Technical Specifications requirements.

All the Inspection and Testing of Field Inspection and Testing Formats shall be maintained.

Frequency of Inspection and Testing shall be as mentioned in relevant Inspection and Test Plans.

6.7 Safety & Environmental Requirements :

Hazard Identification, Risk assessment and Risk control measures for each and every activities and
sub-activities involved in the present Segment shall be identified and necessary action plan shall be
initiated.

Refer the following Documents for details about the Site Safety Management system:

Project Occupational Health and Safety Management Plan

Environmental Aspects and Impacts associated with various activities and sub-activities involved in
the present segment and their mitigation/control measures shall be identified and necessary measures
shall be initiated.

Refer the following Documents for details about the Site Environmental Management Plan: Project
Environmental Management Plan.

“EMP mentioned in Contract Specification in relation to all Constituent materials, activities/ sub-
activities forming part of PQC and its laying shall be strictly adhered to.”

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