QAP-New Bridge Project - DRAFT

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-
17) at Km. 91+000 God River, Km. 94+400 Kal River, and Km. 161+400 Choradi River in Raigad
District in the State of Maharashtra on EPC Mode.
QUALITY ASSURANCE MANUAL
ABBREVIATION
CPM Critical Path Method

EOT Extension of Time
IRC Indian Roads Congress
ISO International Organization for Standardization

MoRTH Ministry of Road Transport and Highways
PWD (NH DIVISON) National Highways Authority of India
NH National Highway
PERT Programme Evaluation & Review Technique
Supervision Consultant Project Management Consultants
QA Quality Assurance
QC Quality Control
QAP QA Plan
QAM QA Manual
SE Senior Engineer
SOP Setting out Point
PM Project Manager
TOR Terms of Reference
Abbreviation & TOC i

TABLE OF CONTENTS
1.0 INTRODUCTION..........................................................................................................................................1
1.1 General................................................................................................................................1
1.2 Objective..............................................................................................................................1
1.3 Need for Guidelines on Quality Systems..............................................................................2
1.4 Need for Quality Control.....................................................................................................2
1.5 Pre-requisites for Quality Control........................................................................................2
1.6 Types of Quality Control......................................................................................................3
1.7 Quality Assurance and Quality Assurance Manual.............................................................3
2.0 QUALITY ASSURANCE REQUIREMENTS............................................................................................4
2.1 Classes of Quality Assurance for Roads and Road Bridges................................................4

2.2 Guidelines for selection of QA class for Highway/Road bridge projects............................4
2.3 Specifications for Work........................................................................................................4
2.4 Quality Assurance requirement for the above chosen class is given below under the
following heads....................................................................................................................4
3.0 QUALITY ASSURANCE PLAN FOR DESIGN AND CONSTRUCTION...........................................18
3.1 Introduction........................................................................................................................18
3.2 Outline of Quality Plan......................................................................................................18
3.3 Distribution of Quality Manual.........................................................................................19
4.0 PROJECT ORGANISATION.....................................................................................................................22
4.1 General..............................................................................................................................22
4.2 Inter-relationship...............................................................................................................22
4.3 Engineers Organization.....................................................................................................22
4.4 Task Assignment................................................................................................................24
4.4.1 Monitor Site Establishment.......................................................................................24
4.5 Job Descriptions................................................................................................................24
4.5.1 Site Engineers (Structures / Highways).....................................................................25
4.5.2 Senior Engineers (Structures / Highways)................................................................26
4.5.3 Material Engineer.....................................................................................................28
4.5.4 The Project Manager (PM).......................................................................................29
5.0 CONTROL OF DATA AND DOCUMENTATION..................................................................................30
5.1 Drawing Registers.............................................................................................................30

5.2 Road related documents.....................................................................................................30
5.3 Quality related records and documents.............................................................................30
5.4 Correspondence.................................................................................................................31
5.5 Progress Reports................................................................................................................32
5.6 Final Report.......................................................................................................................32
5.7 Other Records....................................................................................................................33
5.8 Maintenance of Drawing Registers...................................................................................33
5.9 Management of Drawing Registers...................................................................................33
6.0 PROJECT MONITORING.........................................................................................................................34
6.1 Contract Monitoring..........................................................................................................34

6.2 Material Procurement Monitoring....................................................................................35
6.3 Equipment Monitoring.......................................................................................................35
6.4 Progress Monitoring..........................................................................................................36
Abbreviation & TOC ii

7.0 SURVEY CONTROL AND SETTING OUT.............................................................................................38
7.1 Survey Control Stations.....................................................................................................38

7.2 Setting Out Points (S.O.P.'s)..............................................................................................38
7.3 Schedules of Control Stations & S.O.P.'s..........................................................................39
7.4 Control & Checking of Stations & S.O.P's........................................................................39
7.5 Approval of Control Stations & S.O.P.'s...........................................................................39
7.6 Setting Out of Works..........................................................................................................39
8.0 TEMPORARY WORKS..............................................................................................................................40
8.1 Temporary Works Procedure.............................................................................................40

8.2 Design of Temporary Works..............................................................................................40
8.3 Checking & Approval of Proposals...................................................................................40
8.4 Erection of Temporary Works............................................................................................41
8.5 Checking of Temporary Works Erection............................................................................41
8.6 Certification of Temporary Works.....................................................................................41
8.7 Monitoring during Loading...............................................................................................41
8.8 Dismantling of Temporary Works......................................................................................41
9.0 METHOD STATEMENTS..........................................................................................................................43
9.1 Method Statement Procedures...........................................................................................43

9.2 Submission of Method Statements......................................................................................43
9.3 Checking & Approval of Method Statement......................................................................44
9.4 Trials, Assessment, Work Samples.....................................................................................44
9.5 Permanent Works, Review of Methods..............................................................................45
10.0 MATERIALS................................................................................................................................................46
10.1 Outline of Materials Procedures.......................................................................................46

10.1.1 Testing of Materials...................................................................................................46
10.1.2 Inspection and Certification of Materials on Receipt...............................................46
10.1.3 Testing of Materials going into Construction...........................................................46
10.1.4 Test Records..............................................................................................................46
10.1.5 Assessment & Analysis..............................................................................................46
10.1.6 Structure Logs...........................................................................................................46
10.1.7 Summaries.................................................................................................................47
10.1.8 Quality Assurance Procedures..................................................................................47
10.2 Materials Testing...............................................................................................................47
10.2.1 Materials List.............................................................................................................47
10.2.2 Tests...........................................................................................................................47
10.2.3 Test Procedures.........................................................................................................47
10.2.4 Test Frequencies and Calibration Schedule..............................................................47
10.2.5 Variation of Test Frequencies...................................................................................47
10.2.6 Equipment for Field Testing, Laboratory and Surveys.............................................48
10.3 Control of Materials..........................................................................................................48
10.3.1 Delivery.....................................................................................................................48
10.3.2 Packaging & Transport.............................................................................................48
10.3.3 Marking.....................................................................................................................48
10.3.4 Storage and Inventory of Materials...........................................................................48
10.3.5 Non-Compliance........................................................................................................49
10.3.6 Control Documents....................................................................................................49
10.4 Test Records.......................................................................................................................49
10.4.1 Tests...........................................................................................................................49
10.4.2 Sampling....................................................................................................................49
10.4.3 Test Results................................................................................................................49
10.4.4 Transfer to Record Sheets and Summaries................................................................49
10.4.5 Records of Test Frequencies.....................................................................................49
10.4.6 Non-Compliance........................................................................................................50
Abbreviation & TOC ii
10.5 Results Analysis and Assessment.......................................................................................50
10.5.1 Data Summaries........................................................................................................50
10.5.2 Analysis of Data........................................................................................................50
10.5.3 Non-Compliance........................................................................................................50
10.5.4 Proformas..................................................................................................................50
10.5.5 Check upon Analysis..................................................................................................51
10.6 Pour Inspection / Records..................................................................................................51
10.6.1 Procedure..................................................................................................................51
10.6.2 Actions Pre-Pour.......................................................................................................51
10.6.3 Actions During Pour..................................................................................................51
10.6.4 Actions after Pours....................................................................................................51
10.6.5 Check on Actions.......................................................................................................51
11.0 WORKMANSHIP........................................................................................................................................52
11.1 Inspection of Work.............................................................................................................52

11.2 Written Inspection Requests & Approvals/Rejections.......................................................52
11.3 Inspection Proformae.........................................................................................................53
11.4 Authority Levels for Inspections/Approvals.......................................................................53
11.5 Records of Inspection.........................................................................................................53
11.6 Inspection Procedures.......................................................................................................53
11.6.1 Foundations...............................................................................................................54
11.6.2 Formwork..................................................................................................................54
11.6.3 Reinforcement............................................................................................................54
11.6.4 Concreting.................................................................................................................55
11.6.5 Underwater Concreting.............................................................................................58
12.0 PROTECTION DURING CONSTRUCTION STAGE............................................................................59
13.0 MEETINGS / SITE VISITS........................................................................................................................60
14.0 QUALITY CONTROL STANDARDS AND REFERENCES.................................................................61
15.0 NON-COMPLIANCE PROCEDURES......................................................................................................83
15.1 General..............................................................................................................................83
15.2 Works other than Concrete................................................................................................83
15.2.1 Procedures.................................................................................................................83
15.2.2 Records......................................................................................................................83
15.2.3 Analysis......................................................................................................................84
15.3 Concrete Works..................................................................................................................84
15.3.1 Non-Compliance Other Than Strength or Finish......................................................84
15.3.2 Non-Compliance with Strength Requirements..........................................................84
15.3.3 Non-Compliance with Finish Requirements..............................................................85
16.0 QUALITY AUDIT........................................................................................................................................86
16.1 Programme........................................................................................................................86
16.2 Quality Audit Report..........................................................................................................86
17.0 PROFORMAE OF QUALITY RECORDS...............................................................................................87
Abbreviation & TOC i

v
LIST OF TABLE
Table 1 – Tolerances in Surface Levels.......................................................................................................61

Table 2 - Maximum permitted number of Surface Irregularities.................................................................61
Table 3 - Quality Control Program (for Soil & Material)............................................................................63
Table 4 - Quality Control Program (for Subbase & Base)...........................................................................66
Table 5 - Quality Control Program (for Bituminous Pavement)..................................................................67
Table 6 - Bituminous Pavement Work Inspection Guideline.......................................................................71
Table 7 - Quality Control Program (Concrete Pavement)............................................................................74
Table 8 – Quality Control Program (Structural Concrete) ..........................................................................76
vi
1.0 INTRODUCTION
1.1 General
The last decade, the construction technology has developed rapidly especially in the field of Roads
and Highways. High performance modem machinery and new technology materials have enabled
construction industry to carryout works with great speed and precision. Keeping in pace with this
development the quality control procedures have evolved which are essential to monitor, test and
check the works so that the works are executed as per the contract specifications. The design and
construction operations of many activities require proper coordination and checking, and fool
proof documentation and auditing.
The Quality Assurance Plan (QAP) is for “Construction of Major High – Level Bridges across
Panvel – Mahad – Panjim Road NH-66 (Old-NH-17) at Km. 91+000 God River, Km. 94+400 Kal
River, and Km. 161+400 Choradi River in Raigad District in the State of Maharashtra on EPC
Mode.” is essentially intended to assist the project team to carry out the various project related
activities in conformity with the contractual and technical requirements as per IRC Standards,
MoR&TH Specifications and the Terms of Reference (TOR) as given in the Contract Agreement.
The overall aim of the QAP is to eliminate errors rather than detect errors so that deliverables are
of required quality and can be submitted within the agreed time frame. The QAP is in
conformation with quality standards and the declared quality policy of “Shinde Developers Pvt
Ltd”. All the activities of the project to be carried out shall be based on the quality assurance
system / procedures set out on the basis of the IRC Standards, BIS Specifications, MoRTH
Specifications and Circulars, sound engineering practices and as approved by the Public Works
Department – NH Division.
1.2 Objective
The project of Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road
NH-66 (Old-NH-17) at Km. 91+000 God River, Km. 94+400 Kal River, and Km. 161+400
Choradi River in Raigad District in the State of Maharashtra consists of providing Flexable
payment main carriage way, Paved shoulders, Major Bridges provisions as per agreed contract.
The objective of this quality manual is to execute this project with high quality materials and
workmanship as prescribed in the contract Technical Specifications and various relevant
publications of Indian Standard Code of Practices and Indian Roads Congress. This document will
help the site staff responsible for construction supervision to ensure that the contract
specifications and various test procedures prescribed for each and every item of work are carried
out at the prescribed frequency and compared with the acceptable limits / results specified. This
will ensure a high degree of workmanship for the project since quality of work is of paramount
importance for this project. It may be stressed here that the quality of work should not be
sacrificed for the sake of speedier completion of work. It is essential that all the materials used in
the work should be of superior quality conforming to the contract specifications and the degree of
workmanship should be of high order so that the end product is more durable and maintenance
free.
Consistent and comprehensive methods of checking and approval of works are achieved by
establishing step by step procedures. These procedures reduce human errors, omission and
difference of approach between individuals. The day-to-day supervision and quality control of
materials and works would be carried out by the Consultants as per Quality Assurance Manual in
conjunction with Contract Documents and under the guide lines of Authority engineer and
Client’s technicians in this regard to ensure the quality of works conforming to standards and
specifications.
Quality Assurance Manual 1

1.3 Need for Guidelines on Quality Systems
In order to achieve the aim of building safe, serviceable, durable and economic highways and
bridges, roads and bridge structures should meet certain requirements. The characteristics that a
structure should possess to fulfill these requirements have to be specified. The codes of practice
and the contract documents strive to achieve this by way of defining design criteria, practical
rules, technical specifications, testing and acceptance criteria and workmanship. All these
strategies implicitly depend upon human skills for their successful and reliable application, which,
eventually, determines the quality and performance of highways/bridges. The basic desire to
produce quality work is essential in the minds of all those connected with highways and bridges
projects.
In order to achieve the required level of quality of the final product, as specified by engineering
schemes, it is necessary to have a strategy for management of human skills by way of Quality
System defining quality policy, quality assurance plan and quality audit. Apart from this, it is also
necessary to explicitly define Quality itself, which is expected to be achieved through the Quality
System. These guidelines have, therefore, been evolved to facilitate preparation of appropriate
Quality System for the project of Construction of Major High – Level Bridges across Panvel –
Mahad – Panjim Road NH-66 (Old-NH-17) at Km. 91+000 God River, Km. 94+400 Kal River, and
Km. 161+400 Choradi River in Raigad District in the State of Maharashtra on EPC Mode Use and
application of these guidelines will inculcate, in all those involved in building this activity, an
ability to provide the product or services expected of them consistently, thereby, assuring the
users and instilling confidence in the users.
1.4 Need for Quality Control
Quality control is an important requirement for highway and bridge construction for ensuring
quality and for creating durable national assets. The need for quality control on these
constructions has increased considerably in recent times due to a significant increase in traffic
intensities, and the level of service expected of highway facilities. Improved level of service of the
highways will result in considerable savings in vehicle operating cost and in favorable road user
reaction and public opinion. Quality control in the form of sensory checks which are intrinsically
subjective and qualitative are grossly inadequate for present-day needs and must instead be based
on proper objective and quantitative measurements.
1.5 Pre-requisites for Quality Control
The pre-requisites for effective control of highway and bridge constructions are:
 Construction specifications and estimates should provide for effective quality control
 Adequately trained staff and equipped agency for exercising quality control should be set up.
 Periodic appraisal of the quality control data should be made not only for implementation
during construction but also for effecting possible improvements in quality control and
construction techniques themselves. Updating of knowledge by on job training.

1.6 Types of Quality Control
Over the years, two types of methods have emerged for exercising quality control during the
construction of works. One is generally known as Process control and the other as End result type
of control. In the former, the designer makes the decisions regarding the type of equipment, the
procedure of construction and the amount of work required to obtain the desired result. In the End
result' type of control, the construction agency, which may be a private Contractor, has a free hand
in the selection of construction methods and equipment to achieve the desired end product.
The choice of either type of control is largely a matter of judgment, depending on the magnitude
of the job, different environmental factors involved, and the available facilities. In India, gradually
the trend is towards End result type of working on highway pavement and embankment
construction jobs. But in several situations, for example on small jobs, or where input type of tests
like material gradation and purity of lime are to be carried out, expediency would be in adopting
Process type of control. Because of circumstances, a combination of the Process and End result
types of control will continue to be adopted in India, depending on the nature and size of the job.
In the End result type of specification, the field engineering personnel carry out tests on finished
work at regular intervals to evaluate whether it meets the specification requirements or not. On the
other hand, in Process type control, the responsibility of field personnel is to make sure that the
work in its different phases is executed in the manner predetermined and laid down in
specifications.
1.7 Quality Assurance and Quality Assurance Manual
Quality Assurance (QA) is defined as all the planned and systematic activities implemented
within the Quality System and demonstrated as needed, to provide adequate confidence that an
entity will fulfill the requirements. A Quality Assurance Manual (QAM) provides a base
document outlining policy, procedures, responsibilities, compliance, acceptance criteria and
documentation. It should be prepared and accepted by all parties concerned before start of project.
It should generally cover the following:
a) Identification of all parties involved in QA and their inter-relationship.

b) Internal QA system of each party.
c) Levels of cross-checking/verification in case of multiple verifications/controls, including
systems of inspection and audit, wherever applicable.
d) Organization of personnel, responsibilities and lines of reporting for QA purposes.
e) Criteria for acceptance/rejection, including identification of proper authorities for such
decisions.
f) Inspection at the end of defect liability period.
g) Items to be covered in maintenance manual.
h) All formats for documentation.

2.0 QUALITY ASSURANCE REQUIREMENTS

2.1 Classes of Quality Assurance for Roads and Road Bridges
Depending upon the levels of checking/cross-checking and controls, required to provide adequate
confidence, four classes of quality assurance are mentioned below.
Classes of Quality Assurance Class Nomenclature

(1) Nominal QA Q-1
(2) Normal QA Q–2
(3) High OA Q–3
(4) Extra High QA Q–4
There will be four classes of QA for Highway/Road construction.
Since the degree of requirement of confidence for bridge construction is very high, nominal QA
i.e. Class Q-1 is not permitted in bridge construction. Thus there will be only three classes of QA
for bridge construction, namely Q-2, Q-3 and Q-4.
2.2 Guidelines for selection of QA class for Highway/Road bridge projects
Prior to project preparation stage, one of the four classes for the highway projects and one of the
three classes for road bridges for QA should be chosen. This classification should be reviewed
depending on site specific problems and types of solutions involved. As the project is upgradation
of the important National Highway No.17, QA Class chosen for the road and bridges is class
‘High QA-Q-3’.
2.3 Specifications for Work
Specifications for Road and Bridge works published in 2013 (Fifth Revision) by IRC for Ministry
of Road Transport & Highways and other related Indian Road Congress publications by way of
abstracting essential requirements of construction of various items of work.
2.4 Quality Assurance requirement for the above chosen class is given below under the
following heads
A) Road Works
B) Bridge Works
A. Road Works
Sl. No. Item High QA (Q – 3)

1 Road Project Preparation
1.1 Adequacy and reliability of Data collection through specialized agencies,
Data cross checking through in-house agencies.
1.2 QA Systems and Authority Engineer checking and reviews through
Documentation a separate in-house unit.
1.3 Topographical Survey Mapping and drawing preparation by specialized
agency.

1.4 Survey equipment Electronic distance measuring equipment, auto

levels and high precision alignments etc. suitably
calibrated. Use of computer aided drafting
recommended.
2 Design and Drawings

2.1 Organization External organization with approved QA systems
for checking and review.
2.2 a) Drawings (Longitudinal Project specific drawings made at pre-execution
Profiles, cross sections) stage by the Consultants.
b) Cross drainage and other Project specific drawings made at pre-execution

services stage by the Consultants.
c) Road furniture Project specific drawings made at pre-execution

stage by the Consultants.
2.3 Design modifications due to By agency employed to do the design
site variations or substitute
materials or other reasons
2.6 Mock-up tests for various Required in case of use of new materials /
pavement layers innovative items.
3 Contractual Aspects (Contract Document)

3.1 a) Suppliers/Sub-Contractor Pre-qualification prior to engaging the sub-
Contractor.
b) Nominated Sub- Where required, to be specified in tender

Contractor / agency
3.2 a) Specification and contract Complete contract documents with full
documents specifications including all relevant codes should
be available at site. Specifications for non-
standard items to be detailed finalized and
approved at appropriate level of responsibility.
b) Prebid meeting Preferable

3.3 QA Manual Contractor to submit and get approved the QA
manual defining all activities with minimum two
levels of controls. Each of the controlling
authority to have their own QA manual covering
their responsibilities and procedure details
regarding inter discipline activities.
3.4 Defect liability period As per contract.
(Responsibilities of owner and
Contractor should be defined in For manufactured items appropriate defect
the tender liability period to be specified
document)
4 Construction Organizations
4.1 Organization of Contractors execution staff responsible for


Contractor supervision and surveillance of quality and with
second level surveillance by the Consultants.
4.2 Organization of owner/project Authority Engineer quality assurance team of the
management consultant Consultants in addition to PWD (NH DIVISON).
4.3 Organization for planning of Construction activities planned in details,
construction activities. including material sourcing, sequencing work,
resource planning, method of quality control, use
of networks review at regular intervals and
resource leveling.
4.4 Supervision Full time supervision for all Construction,
periodic visits by designer/client with additional
full time supervision by the Consultant.
4.5 Quality surveillance Quality surveillance by Contractors Authority
Engineer team in addition to consultant and
with random Audit by special agencies.
5 Materials
5.1 General Purchased from large and established suppliers /
a) Materials from natural traders and/or with own source of supply.
sources. Authority Engineer testing and acceptance by
Contractors/owner’s QA and documented Testing
and acceptance at start of project and at specified
intervals.
Manufacture’s tests sample checks for initial

b) Factory manufactured acceptance only
items including cement, Regular testing at specified frequencies during
steel, bitumen construction based on mutually agreed QA
procedures
ISO-9000 Certification preferable, Manufacturer
with ISO certification may be given preference.
Record purchase dates, retain manufacturer’s test

c) Records for all materials certificates and record locations of use and issue
date.
Physical testing facilities at site, Special tests to

d) Testing facilities be done at Authority Engineer laboratories and
Audit on the site laboratory by Authority
Engineer agency.
5.2 a) Coarse aggregates – Sampling and testing daily at production facility.
Grading Conduct routine tests as per specifications.
- Other physical tests At the beginning for mix design, and every
(crushing value, abrasion, change of source/codal stipulations
flakiness index, stripping,
moisture, etc.
- Deleterious contents Mandatory for selection of source and whenever

there is change in source of supply as per codal
stipulations.
- Aggregate reactivity Mandatory for selection of source and whenever

there is change in source of supply

b) Fine aggregate At the time mix of design, stack change and at

(Sand/crusher run) increased frequency at site laboratory as per
specifications.
c) Borrow Materials
- Grading Every 3000 Cum. of borrow operation-2 tests.
- Physical tests Every 3000 Cum. of borrow operation-2 tests.
- Deleterious materials At time of selection and once weekly
5.3 Water Suitability At beginning and at increased frequencies in site
lab after every monsoon.
Chemical analysis Mandatory at beginning and at start of working

season.
5.4 Cement-Normal physical and Additional to manufacturer’s tests; sample and
Chemical tests. test random deliveries.
Form of purchase, storage, Directly from factory to site godown or silos.

transportation and use within Transportation supervised and documented.
acceptable time limit Encourage bulk cement containers.
5.5 Admixtures
a) Approval Independently carried out acceptance; testing
after field trials for each source. Spectrographic
tests for each batch of supply.
Retrials with change in source of cement, routine
checking by testing for every batch of admixture.
b) Dosage dispensing and Manufacturer’s data/certificate acceptable as

production controls at basis of comparison for production lot.
site. - Automatic dispensing required.
- Specific gravity checks to be frequent
- Continuous workability monitoring required
- Visual inspection of concrete after striking
forms for local defects (delayed setting)
c) Training of site staff by Training of site staff in use as well as quality

manufacturer control, plus periodic visits by manufacturer’s
experts.
5.6 Reinforcing steel Normal For each consignment starting from the beginning
physical tests. and for every change in source in addition to
manufacturers test certificates.
Chemical composition Once at beginning and if in doubt for every

source change.
5.7 Bitumen and Bitumen Test every consignment prior to receipt at site.
Products
Normal physical tests Test in the beginning and for every change in
Chemical tests source additional to manufacturers test.
5.8 Road Marking Normal Paints Apart from Manufacturer’s test certificates test
Physical tests. independently and additionally test random
batches.
5.9 Road Signs Manufacturer’s test certificates additional witness
test at Manufacturer’s works.


5.10 Road furniture Accept Manufacturer’s QA systems and audit
regularly.
6 Workmanship
6.1 General - controls direct and
indirect
a) Working and supervision Skilled workers having special training to be
insisted
Full time supervision from Contractor and
Consultant.
Periodic check by designer with predetermined
frequency
Documentation of inspection and certification of
compliance by designer’s representative
b) Use of mock-ups Required for certain elements of works (if)

specified in tender documents to be carried out in
presence of designer, QA team of owner
To simulate actual site conditions.
No work on site to be permitted prior to
successful demonstrative mock-up
6.2 Mix designs sub base, base Mix design performed at beginning of work or for
and pavement courses new source of materials with subsequent QC as
per code and by experienced supervisors with
minimum of two levels of control
6.3 Fabrication and fixing of Site bending by skilled workers with regular
Reinforcement checking by supervisors.
Bar schedules are made and checked before use.
Placement of reinforcement checked
independently and also checked by QA team
before concreting.
6.4 Form Work
a) Materials System form work or as specified in the contract
b) Design checks Design checked approved independently
c) Tolerances, geometry Checks for all members by supervisory staff.
tightness
d) Verticality
6.5 Earth Works
a) Tests for density As per MoRT&H specifications, each compacted
layer
b) Geometry check All layers
c) Equipment Vibratory rollers mandatory and other equipment
as specified in the contract.
6.6 Granular Sub-Bases
a) Material Premixed to suitable grading as per Mix Design
required.
b) Laboratory tests Each layer to be sampled from location and tested
all as per MoRT&H
c) Geometry checks All layers.
6.7 Granular Bases/Binder Coarse
Bases Materials
a. Aggregate Crushed and screened mandatory


b. Binder quality Qualify source- test every consignment at
arrival
Workmanship
a) Paving Sensor paver mandatory
b) Compaction Vibratory equipment mandatory
c) Geometry checks All layers
6.8 Wearing Coarse -
Asphalt/Concrete
a) Material/Aggregates Crushed/Screened aggregates mandatory
b) Mixing Plant mixing mandatory
c) Paving Sensor Paver mandatory
d) Compaction Vibratory equipment mandatory
e) Geometry checks All layers
B. Bridge Works
Sl. No. Item High QA ( Q- 3)

1 Road Bridge Project Preparation
1.1 Adequacy and reliability of Data collection from primary local sources and
data cross checking by other methods either in-house
or through specialized survey and investigation
agencies.
1.2 Q.A. Systems & In-house checking and verification, in-dependent
documentation checking and review through a separate in-house
unit, or through external organization.
2 Design and Drawings

2.1 Organization Owner's in-house/consultants/Contractors design
offices with established internal QA procedures,
in-dependent checking and review
through an in-house unit
2.2 a) Drawings Project specific drawings made at pre-execution
stage indication limits of validity of details given
on the drawing.
b) Bar Bending Bar Bending Schedules shall be prepared at site

Schedules, Cable layout by the Contractor & got approved by the Engineer
and stressing schedule at site prior to execution, full details of cable
layout and stressing schedule to be given by
designer and implemented at site by
Contractor.
2.3 Design Review & Proof Designs checking by in-house but Authority
Checking Engineer design unit and review through an in-
house unit or
through external organization.
2.4 Design Modifications due to Design notes should clearly state the limits of
site variations or substitute validity of drawings, Reference should be made to
materials and other reasons design office for changes and all changes
incorporated in revised drawings and re-issued
within reasonable period.


2.5 As built drawings As built drawings essential with changes
incorporated in revised drawings shall be prepared
by the Contractor and submitted to the Engineer.
2.6 Maintenance of As-built To be maintained by owner, and maintenance

Drawings, Designs, agency with full record to be maintained in
Specification & Construction addition at central office for Govt. agencies.
information.
2.7 Model Tests/Prototype Test
a) River hydrology If necessary should be carried out before
finalization of design.
b) Structural model test If necessary should be carried out before

finalization of design.
c) Non-destructive testing ND testing on sample basis by owner/appointed

(ultrasonic, radiography, etc.) agency for checking, achievement of quality is to
be encouraged.
3 Contractual Aspects (Contract Document)

3.1 Suppliers/Sub-Contractor Pre-qualification prior to engaging the Sub-
Contractor.
3.2 Specifications and Contract Complete contract document should be easily
Documents accessible. Complete contract documents with full
specifications including all relevant codes should
be available at site at all times. Specifications for
non-standard items to be detailed finalized and
cleared at appropriate level of responsibility.
3.3 QA Manual Contractor to submit and get approved the QA
manual defining all activities with minimum two
levels of controls. Each of the controlling
authority to have their own QA manual covering
their responsibilities.
3.4 Defect liability period. As per contract.
(Responsibilities of owner &
Contractor should be defined For manufactured items like bearing, expansion
in the tender joint etc. appropriate defect liability period to be
document). specified.
4 Construction Organizations
4.1 Organization of Contractor Contractors execution staff responsible for both
supervision and surveillance of quality, with
external agency/owner for audit of quality plan
and its operation. With separately set up QA
group for operation of quality plan.
4.2 Project Management Supervision Consultant should have specially set-
Consultant (Supervision up QA group for operation of quality plan.
Consultant)
4.3 Planning of Construction Broad planning made by Contractor and got
activities approved form owner/Supervision Consultant
with construction activities planned in details
including material planning, sequencing of work,


identifying requirement of skilled labour,
supervisory staff and methods of quality control.
Deployment of skilled labour
Execution of work only after prior intimation to

owner's supervisory representative as per
procedures.
Use of bar chart and PERT/CPM techniques and

regular review as a part of monitoring and
replanning activity to meet the targets.
4.4 Supervision Full time supervisors of the Contractors for all
construction activities and additional full time
supervision by Supervision Consultant.
Periodic visits by designer/owner.
4.5 Quality Surveillance and Quality surveillance by constructors' qualified
Audit engineers, and owners' supervisory representative.
Separate QA cells of constructor and
owner/Supervision Consultant (two levels QA)
following format and documented quality plan.
Regular surveillance and audit are essential.
5 Materials
5.1 General
a) Materials from Natural Small or medium scale purchases from large &
Sources established suppliers/traders. Also bulk purchase
from source.
Sources mutually agreed to between Contractor
and owners' project teams and documented.
Authority Engineer testing/acceptance by
Contractors & owner’s Q.A. teams and
documented.
Testing/acceptance at the start of the project as
well as at specified frequency.
b) Factory manufactured
items including cement, steel Manufacturer's test certificates with sample
bearings, expansion joints etc. checks for initial acceptance only.
Regular testing at specified sampling frequency
during construction.
Set up mutually agreed Q.A. methods at two
levels for inspection/testing to cover the specific
purchase order.
ISO:9000 certificate not essential for
manufactured items. In case the manufacturer has
ISO:9000 certification, he may be given
preference.
c) Records for all materials Record of sources and purchase dates for all
items. For manufactured items record of
manufacturers' test certificate. Also record of


issue of manufactured materials and location of
use.
d) Testing facilities Physical testing facilities at site. For Chemical &
Special tests from nearby established test
laboratories Use of chemical testing kits for quick
checks at site are to be preferred.
5.2 a) Aggregates Coarse
Aggregates
- Grading At the beginning for mix design and for every
changes of source/stack and for every major
structural element.
- Other Physical tests At the beginning for mix design and for every
(crushing value abrasion change of source.
moisture contents etc.)
- Deleterious Contents Mandatory for selection of source and whenever
there is change in source of supply.
- Aggregate Reactivity Mandatory for selection of source and whenever
there is change in source of supply.
b) Fine Aggregate (Sand)

Grading At the beginning for mix design and for every
stack, change of source/for every major structural
element mix.
Other Physical Tests At the beginning for mix design and for every
(crushing value, abrasion, change of source.
moisture contents etc.)
Deleterious Contents Mandatory selection of source and whenever there

is change in source of supply.
For Control of Chlorides etc. Simple but frequent chemical checks at site for
effectiveness.
External laboratory checks/control (two level
control).
5.3 Water
- Suitability At the beginning
- Chemical Analysis Mandatory at the beginning of project and
repeated (for chlorides and sulphates) in between
if any change is perceived / suspected in water
quality (including seasonal changes).
5.4 Cement
Normal Physical and Manufacture’s certificate acceptable & testing in
Chemical Tests case of doubt or not-availability of certificate. At
frequency of each new consignment and
documented. Special tests will be required for
special cements.
Form of purchase stage, Supply from factory with direct transportation

Transportation, and use from factory to site go down/silos. Transportation
within acceptable time limit and transshipment supervised and documented.
5.5 Admixtures
a) Approval Independently carried out acceptance testing after


field trials for each sources.
Re-trials with change in source of Cement.
Routine checking by testing for every batch of
admixture.
Manufacturer’s date/certificate acceptable as basis
of comparison for production lot.
b) Dosage Dispensing and Dosage to be finalized after field trial mixes,
Production Controls at special mechanical devices to be used for
Site. dispensing.
Frequent checks for specific gravity and solid
contents.
Continuous monitoring of workability of concrete.
Visual inspection of concrete after striking forms
for local defects (including delayed setting).
c) Training of Site Staff by Proper training of site staff in use as well as

Manufacturer quality control, plus periodic visits by
manufacturer’s expert.
5.6 Reinforcing Steel
- Normal Physical Tests Once at beginning and for every change in source
in addition to manufacturer's certificate for each
consignment.
- Chemical Composition Once at beginning and if in doubt for any source.

5.7 Prestressing Steels /
Anchorage Systems and
Cable-anchorage assembly.
a) General (for all items of In a sealed and moisture proof go down with
prestressing including minimum openings store, above ground level on
equipment). raised supports or in racks.
- Storage Such go down will have humidity control. In

addition, vapor face inhibitors and/or water-
soluble oils to protect steel.
- Compatibility of Various Suitability of anchorages for use with

Components. wires/strands (meeting relevant specifications) to
be certified by the manufacturer of anchorages.
Also compatibility of all other materials and
equipment to be thus certified/cleared after
inspection.
- Methods of Handling & Also the manufacturer to supply special assistance

Care taking. at site, if required, to train and supervise personnel
at work.
b) HT Wires/Strands
- Mechanical Properties In addition to manufacturer's certificate, tests done
(Tensile Strength, Proof on random samples for a lot of 50 tonne, or part
Stress). thereof and witnessed by Authority Engineer QA
team at random.

- Modulus of Elasticity Insist for manufacturer's certificate giving

stress/strain curve and modulus of elasticity.
Sample testing witnessed by Authority Engineer
QA team.
Modulus established initially (acceptance test).
- Relaxation Tests. Testing & Certification essential for 1000 hours
test by Authority Engineer test house.
- Chemical Composition Manufacturer’s Certificate can be accepted with

special testing, if in doubt Plus testing by
Authority Engineer agency on random sample
basis.
- Packing
Packing with two layer for waterproofing and
mechanical protection.
- Transportation
Transport vehicle check.
Protection from environmental or physical
damage.
Suitability of Coil Size /
Weight for use at Site Coils handled by mechanical devices prohibiting
movement by rolling.
The wire/strand should be free of kinks or
deformations and straight.
Contact with contaminated surfaces avoided.
c) Anchorages System
(Chemical Composition Permitted using anchorage of established
Geometry & Heat manufacturers of long standing based on
Treatments, Supplementary certification of suitability & quality by
Tests). manufacturer supported by manufacturer’s
detailed QA plan (which can be verified by
purchaser if necessary).
d) Cable anchorage Assembly
(Acceptance Testing).
- Static Tensile test & load
transfer test. Manufacturer’s certificate & inspection as per QA
plan.
May additionally require testing at site or at
Authority Engineer laboratory as per FIP
Guidelines to qualify the material.
Dynamic Test for Cable /
Anchorage Assembly Manufacturer’s certificate of testing.
Also Authority Engineer laboratory testing for
new system of anchorages/cables.
e) Sheathing/Cable Duct
– Supply Purchase from manufacturer with metallic
sheathings coated with water soluble rust-
preventive oil.
Workability and Transverse
bending Tests as per IRC:18. Test certificate by the manufacturer for each lot to
be furnished. Additional Authority Engineer test
to be done on random samples.
5.8 Any other materials (like Manufacturer’s Certificate supported by sample


expansion joints, bearings, testing and with higher frequency of testing.
railing etc.) QA plan of manufacturer to be initially approved.
5.9 New Materials Normally not to be used. May be accepted by
competent technical authority for use after full
testing at laboratory/and field trials.
Special specifications for properties, testing and

acceptance criteria to be evolved and laid down
for use at site.
5.10 Bearings and Expansion The bearings and Expansion Joints shall be
Joints purchased from the party approved by MoRTH/
PWD (NH DIVISON). The name of the supplier /
Manufacturer
shall be got approved from Engineer. Testing shall
be carried out by DGST authorities.
6 Workmanship
6.1 General (Direct & Indirect)
a) Working and Supervision. Skilled workers having special training and
working under experienced supervisors. (Where
trade qualifications exist should be insisted upon).
Full time supervision from Contractor as well as
from owner or his agent.
Periodic check by designer during site visit and
also at predetermined stages and frequency.
Documented inspection and certification of
compliance by designer’s representative.
b) Use of Mock-ups* Quality mock-ups are required only for certain

elements (typical slice and difficult zones), which
should be specified in tender document. Mock-ups
to be carried out in presence of designer and QA
team of owner.
Mock-up should use actual proposed methods of
construction, including plant and equipment.
No work on structure should be permitted before
demonstrative mock-up.
* Notes: Full scale mock-ups of part of structure are made for various purposes as follows:
1. Verification of proper detailing and choice of concrete mix and making modification in
either or both to achieve satisfactory concreting.
2. To establish effective methods of transporting, placing and compacting.
3. Training of workers for operation in (2) above.
4. To demonstrate efficacy of the overall construction operations in achieving its aim.
6.2 Concrete Mix Design Mix design performed at beginning of work or for
new source of materials with subsequent QC as
per code and by experienced supervisors with
minimum two levels controls.
6.3 Fabrication and Fixing of Site bending by skilled workers with regular
Reinforcement checking by qualified supervisor.
Bar bending schedules are made and checked
before use.
Correct placement of reinforcement and provision
of proper cover checked independently before
concreting with checked and documented by QA


team.
6.4 Fabrication & Fixing of
Prestressing Cables.
a) Clearing Should be free of rust, Light rust on wires (not
strands) can be removed, wires cleaned and used.
b) Preparation of steel/cables Pre-fabricated and sheathed cable can be

permitted.
However, post-threaded wires/strands just before
stressing are be preferred.
Cables strictly prepared on raised/clean benches
and kept free from dust at all times.
c) Laying & Supporting Cable layout prepared giving coordinates at close

intervals as needed by fixing requirements (and
not by theoretical curves or equations alone), and
supported firmly in place, Post threaded cable
ducts should be held against floatation during
concreting to ensure cable profile.
Layout and leak tightness of sheathing to be
independently checked and documented by
owner's Q.A. Team of his agent.
6.5 Formwork
a) Materials Any suitable material meeting codal requirements
and capable of giving specified form finish.
b) Design Check Formwork / design made and approved

independently.
c) Specialist Systems Specialized formwork systems need not be

insisted upon. Specialized formwork systems, to
be preferred with properly trained carpenters /
fitters.
d) Experienced Carpenters / Skilled carpenters / fitters under supervisory staff

Fitters. with the work supervised additionally by owner’s
supervisors or agents.
e) Tolerance, Geometry and Checks for all members by supervisory staff.

Leak tightness checks.
f) Deshuttering. Under supervisory staff for important members.

The system should provide for gradual, uniform
and shock-free DE shuttering arrangements.
g) Formwork for Special As per design requirement under control of

Structures. qualified staff, with additional supervision by
owner’s supervisors or agents. Checks by QA
team till procedures at site are established.
6.6 Mixing / Conveying / Placing Batching plant is mandatory.
/ Curing of Concrete. Use specialized equipment for transportation. The
adverse effects of the methods of conveyance


(segregation, delays, stiffening of mix etc.), should
be regularly monitored, controlled and
documented.
Experienced concreting gangs under supervisory
staff with two level controls. Also, regular control
by qualified staff. Method of control by pour card
recommended.
Placing concrete and compacting under
supervisory staff. Also, regular control by
qualified staff. Surveillance by QA team.
Proper curing under frequent checks by Authority
Engineer supervisors and documentation.
6.7 Stressing of Cables
- Stressing equipment Stressing equipment calibrated, tested and
certified by manufacturer / supplier
Checking and re-calibration at site at regular pre-
determined frequency by qualified staff under
supervision of owner and his agent.
- Stressing Operations Only under strict supervision of stressing

supervisor and site engineer. The manufacturer to
supply special assistance at site to train personnel
and supervise work.
Sample basis check for elongation/pull in of all
wires/strands in the cable assembly (uniformity of
stressing).
Check of friction and wobble In-situ check on losses by stressing from one side
losses jack using as active jack and other as a passive
jack on a sample basis.
(For long cables and high total deviation, the
passive jack may not register pressures within
stroke length of active jack. For such cases special
tests or provision of shorts cables may be
required.)
6.8 Grout & Grouting
a) Grouting of Prestressing At the beginning of work for designing suitable
Cable grouts.
- Composition and Physical Physical properties to be verified once in a week
Properties or with change of batch of cement or admixture.
- Fluidity Test, Bleeding By visual inspection.

Characteristics During Testing at frequency of one a week or with change
working. of batch or cement/admixture.
Equipment Equipment tested and passed for satisfactory

performance regularly.
Workers / Supervisors Trained staff under qualified supervision

Surveillance by QA team.
Admixtures Where used, as per item 5.5


b) Grouting with
non- cementitious /
special materials Use of special pre-packaged high strength non-
c) Cement Grouting for bolts shrink grouts preferred. Methods to be established
and Fixing apparatus. on mock-up with regular sample checks for
efficiency.
3.0 QUALITY ASSURANCE PLAN FOR DESIGN AND CONSTRUCTION

3.1 Introduction
Quality planning to assure quality of product has been adopted over the last few decades for
special and complex projects. However, in case of highway engineering and construction, efforts
in this regard are visible only in the recent years. As a result of continuing efforts, it has become
possible to evolve appropriate methods and level of documentation for Quality Assurance plan for
highway projects.
Surveillance of project implementation, if well organized into a quality assurance plan,

contributes towards quality. For this, step by step procedures which would help in achieving
consistent and comprehensive methods of checking and approval of works at every staged, need to
be established and documented. These procedures should be reviewed periodically, amended, as
found necessary, and revised documents prepared.
All parties involved in the QA plan should have their internal QA systems clearly defined in form
of a specific Quality Assurance Manual (QAM) for the respective purposes, such as, QAM for
manufactured products (by the manufacturers or suppliers). It is also necessary for
owner/purchaser to have his own internal QA plan. QA for highway project as a whole integrating
all these plans shall be prepared/or approved by the owner and/or approving authority, if any.
Each vendor (i.e., supplier, designer, Contractor, and manufacturer) will thus, have his own
internal QA procedures, which are required to be agreed upon, in advance, with the purchaser of
the respective activity. As highway building in India is mostly undertaken by Govt. agencies, it is
necessary that the Contractor/designer obtains concurrence of their QAM from the concerned
Government agency. The Guidelines provided in Chapter 2 should be used by the respective
parties in evolving of the operational QAM to be agreed between the Contractor and the
Department for adoption at site.
3.2 Outline of Quality Plan
The major elements mentioned below are the main headings that comprise the Quality System.
 Project organization and implementation.

 Drawings and Documents
 Project Monitoring
 Survey Control & Setting Out
 Temporary Works
 Method Statements
 Materials
 Workmanship
 Protection during construction stage
 Meetings / Site Visits
 Quality Audit
 Quality Control Standards and Reference

 Proforma of Quality Records
Subsequent chapters describe the procedures to be followed for each of the main headings above.
Every Supervision Consultant / Contractor shall be, in the final eventuality, responsible for
establishing its own quality assurance procedures. Various elements of the Quality Manual should
be prepared and revised by the respective Supervision Consultant because of their greater
knowledge of the local conditions, specifications etc. for their respective packages. The Quality
Manual should not be thought of as a static document. It should be frequently reviewed, and
where procedures are found to be unsatisfactory for some reason they should be amended.
This manual is not intended to be a contractual document, nor is it to take precedence over the
specifications. Rather it is merely a guide and reference to the various site staff in the supervision
of project in discharging their duties in a smooth and systematic manner. It can be updated on
periodic manner.
3.3 Distribution of Quality Manual
The master copy should be held by the Project Manager, Supervision Consultant, together with a
record of the issue of copies and revisions.
Copies should be issued to all Resident Engineers and access to it should be freely available to all
consultant’s personnel. Extra copies may be required to facilitate this.
Master copies of all revisions should be held separately for back reference.
All Manuals should be checked periodically for completeness.
Superseded sheets whenever held should be clearly indicated by a diagonal red stripe.

Quality Assurance Flow Chart for Quality Control of Earthwork
Earthwork
Backfill
Sub-grade
Sub-grade Course
Material Test before the Work
Change of Material Unsuitable

Source Material Properties
Compacting Test in field

- Spreading Thickness
- Number of Roller Passes
Decide Actual Working Method
Under Construction
Quality Control
Process Quality Control Work Quality Control
Checking character of Material Measurement of Degree of

- Standard Density Compaction in the Filed
- Optimum Moisture
Judgement No Remedial
Compare with the Percent MDD
Obtain Density for measurement
Result of Material Check
Quality Control & rolling
Test Before the
Work Unacceptable
Yes
On Going

Quality Assurance Flow Chart for Quality Control for Concrete Work
Concrete Work
Drainage
Structural
Cube Concrete
Other Nominal Mix

Work
Material Test before the Work
Change of Material Unsuitable

Source Material Properties
Trial Mixing (Specified Mix)

Develop Mix Design
No Judgement Slump, Strength,

Try Again
Workability W/C etc.
Yes
Decide Job Mix Proportion
Under Construction
Quality Control
Investigate /
Reject
Process Quality Control Work Quality Control
Checking Material Properties Measurement of Slump & Strength, Test Cubes

- Cement Workability & Taking Cubes 7 Days /
- Admixture 28 Days
- Aggregate
Judgement No Return to Plant

Compare with the
New Job Stump, / Reject
Result of Material
Mix Workability
Test before the
Proportion Work
Yes
Yes On Going

4.0 PROJECT ORGANISATION

4.1 General
Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-
NH-17) at Km. 91+000 God River, Km. 94+400 Kal River, and Km. 161+400 Choradi River in
Raigad essentially consists of construction of road with flexible pavement with shoulders, major
bridges. Thus, the total task assignment calls for coordinated action from personnel having
experience of various streams who have to work in tandem for successful timely completion of
the project. This manual broadly outlines a general guidance for proper supervision during
construction stage and is essentially intended to assist the project field personnel in carrying out
the contract work in an orderly, procedural and efficient manner.
In the project
The Authority is the Chief Engineer (National Highways), Public Works Department Mumbai.
Trigidhe Contractor is the firm/company who has been assigned by the Authority for under taking
the actual construction work, here it is Reliance – CAI joint Venture and Subcontractor is Shinde
Developers Pvt Ltd.
4.2 Inter-relationship
It is pertinent that the services of the - Client-Authority Engineer and Contractor - should be
aimed at only one goal of completing the project in accordance with technical specifications and
contract documents. Hence to achieve the desired quality of work within the scheduled time frame
as well as a pragmatic approach in rendering the services in a most effective manner, an
interaction between them is of absolute necessity. They should assist each other for the greater
interest of the project. Mutual understanding and equanimity is required when dealing with
problems of conflicts, difference in opinion in any contractual matter. Attempt should be made to
arrive at a mutually acceptable decision if not unanimous which will bring the three parties to
work as a close-knit team with high degree of understanding and co-operation among themselves
for the success of the project. This can only be achieved through meetings and discussions, which
will bridge the communication gap between them.
4.3 Engineers Organization
The Engineer is Senior Resident Engineer (SRE) usually operates and carries out his duties
through his Resident Engineer, Site Engineers and Supervisor who will carry out all field duties
on behalf of the Engineer and exercise authority as delegated to each one of them. For fulfilling
the above stated objectives, Engineer will be assisted by a team of qualified, experienced and
professional staff at the site of work.
A chart showing Engineers' establishment at the project site is shown in below Figure.

Flow Chart
Project Manager
1 No.
Project Co-ordinator (HO)

1 No.
Material Engineer Highway Engineer Structure Engineer

3 No. 3 No. 3 Nos.
Surveyor
Laboratory Technician 3 Nos.
6 Nos.
Note: Additional supporting Staff include Computer operator, Secretary, Accountant, and
Messenger.

4.4 Task Assignment
Scope of services, as stated in Contractor Agreement is fairly comprehensive and need not be
reproduced here except for highlighting some salient points with clear understanding of task
assignment throughout the stages of pretender, during execution of work, post completion and
other special tasks if any.
Work will be carried out by a team of Senior Engineers and field staff, under the leadership of
Engineer, with reasonable and pragmatic approach where compliance with contract documents
specifications is essential.
Supervision Consultant with suitably qualified and experience staff has been appointed to assist
the Contractor in the implementation of Project as per the Contactors Agreement.
General approach would be to adopt a well thought out strategy that will ensure time bound
deliverables, acceptable progress of the project with quality work and above all the final product
i.e. completion & handing over of project with satisfaction of Authority meeting the requirement
in Agreement.
4.4.1 Monitor Site Establishment
Engineers office to co-ordinate all activities on rendering services in a most effective

manner
Field Office to operate and control all field activities and to maintain liaison with
Contractor or his representative
Field Laboratory to control over acceptability of material for use in permanent work or
intended to be used in permanent work
Contractor’s safety & comply with provisions of contract, subsequent legislation &
establishment law of land in respect of labour, safety, insurance, medical and other
welfare aspects.
Construction Resource deployment, matching with work programme, uninterrupted

methodology traffic flow, safety of personnel, works & environmental aspect,
protective work, compliance to contract documents.
Contractor’s Review and keeping a track on the capability of Contractor

superintendence superintending and key personnel in the context of this particular
project.
4.5 Job Descriptions
Descriptions of jobs issued to Supervision contractors staff shall include the duties listed below.
These duties relate primarily to supervision of construction as it relates to Quality Assurance of
construction. They do not cover contractual matters and measurement which should be added as
appropriate by the Project Manager/Senior Engineer to individual descriptions.

The job descriptions for each individual shall be issued by the Project Manager/Senior Engineer and
shall include the following:
a) Name
b) Position or title
c) Name of immediate superior
d) Extent of responsibilities (physical location and scope of work)
e) Conditions of employment
f) Duties as described below
g) Duties additional to those described below
4.5.1 Site Engineers (Structures / Highways)

Field Engineers shall: -
a) Act under the direction of the Senior Engineer (Structures / Highways) to whom they are
assigned.
b) Familiarize themselves with the Drawings, Specification and Conditions of Contract.
c) Familiarize themselves with and follow Quality Assurance procedures described in the Q.A.
Manual
d) Carryout field setting out checks
e) Carry out field inspections for road and bridge works as per QAP and Contract Technical
Specifications in approved proforma.
f) Liaise with Contractors / Supervision Consultant staff responsible for materials and
workmanship to ensure:
i. Materials in use are approved
ii. Testing is carried out as required
g) Maintain daily records of:
i. Contractors activities
ii. Plant working/standing times on each activity
iii. Labour working/standing times on each activity
iv. Progress made
v. Inspections carried out
vi. Works approved/not approved
vii. Duties carried out by himself
viii. Instructions received
ix. Verbal communications with Contractor
h) Submit a daily report to the Senior Engineer
i) Carry out checks as directed by their Senior Engineer for:

i. Contractors’ temporary works
ii. Contractors’ method statements
iii. Contractors’ sketches and drawings
j) Prepare drawings and sketches as directed by their Senior Engineer.

Approval of Work
In carrying out field checks, Field Engineer shall:

 complete the relevant check list proforma for the works being checked
 report their findings to the Senior Engineer (Structures / Highways)
Field Engineers shall sign Request for Inspection Forms and checks the work. Approval for the
work shall be given by Project Manager/Senior Engineer.
Field Engineers shall not issue instructions to the Contractor unless specifically directed to do so
by the Senior Engineer (Structures / Highways).
4.5.2 Senior Engineers (Structures / Highways)

Senior Engineers shall:
a) Act under the direction of Project Manager.
b) Familiarize themselves with the Drawings, Specification and Conditions of Contract.
c) Familiarize themselves and follow Quality Assurance procedures described in the QA

Manual.
d) Be responsible for day to day supervision of construction works allocated to them.
e) Carryout field directions and direct Site Engineers on these tasks.
f) Maintain daily records of:
i. Inspections carried out.

ii. Works approved/not approved
iii. Instructions received
iv. Instructions issued to Contractor
v. Instructions issued to subordinate staff
vi. Verbal communications with Contractor
vii. Verbal reports received from subordinate staff
viii. Verbal reports to the PROJECT MANAGER
ix. Duties carried out by RE
g) Be responsible for checks of:

i. Contractor’s temporary works
ii. Contractors’ method statements
iii. Contractor’s s sketches and drawings
h) Submit a monthly report to the PROJECT MANAGER regarding:

i. Summary of Contractor’s progress
ii. Summary of duties carried out by his division
iii. Summary of works approved / not approved
iv. Summary of instructions issued to Contractor’s
v. Summary of problems, areas of concern, action taken and action required,
drawings awaited for construction etc.

i) Draft correspondence to Contractor’s for signature by the Project Manager.
j) Ensure that Field Engineers carry out their duties correctly.
k) Direct clerical staff assigned to his division and ensures that filing of correspondence and site
records is maintained in an orderly manner.
Instructions to Contractor’s
Senior Engineers shall only issue instructions to the Contractor’s with regard to compliance or
non-compliance with the Contract requirements. Such instructions shall be maintained in a field
register in mutually agreed format.
Senior Engineer shall not instruct additional work beyond the scope of the Contract.

4.5.3 Material Engineer

Material Engineer shall:
a) Act under the direction of the Project Manager.
b) Familiarize himself with the Drawings, Specification and Conditions of contract.
c) Familiarize himself with the specified Codes of Practice and Standards relating to materials
quality control and workmanship.
d) Familiarize himself with and follow the Quality Assurance procedures described in the QA
Manual.
e) Carryout and direct Site Engineers on the field sampling, testing and inspection of materials
and workmanship.
f) Liaise with the Supervision Consultant /Contractor staff responsible for works construction.
g) Maintain daily records of

i. Materials or workmanship testing duties carried out, test results
ii. Materials or workmanship testing carried out by the Contractor and witnessed,
test results
iii. Materials and workmanship approved/not approved.
iv. Instructions received.
v. Instructions issued to Contractor.
vi. Instructions issued to subordinate staff.
vii. Verbal communication with Contractor.
viii. Verbal reports received from subordinate staff.
ix. Verbal reports to the Project Manager.
x. Duties carried out by Material Engineer.
h) Be responsible for reviewing Contractor’s material and workmanship proposals and method
statements.
i) Submit a monthly report to the Project Manager recording:

i. Summary of materials and workmanship testing and inspections.
ii. Summary of materials on site.
iii. Summary of approvals, rejections.
iv. Summary of instructions to the Contractor.
v. Summary of problems, areas of concern, action taken, action required.
j) Draft correspondence to Contractor’s for signature by Project Manager.
k) Ensure Field Engineers carry out their duties correctly.
l) Direct clerical staff assigned to his division and ensure that filing of correspondence and site
records is maintained in an orderly manner.
Instructions to Contractor

Material Engineers shall only issue instructions to the Contractor’s with regard to compliance
or non-compliance with the Contract requirements. Such instructions shall be maintained in a
field register in mutually agreed format.
Material Engineer shall not instruct work additional to the Contract scope.
4.5.4 The Project Manager (PM)

The PM have overall responsibility for the supervision of construction and administration of the
Contract. His duties and responsibilities are wide-ranging.
However, so far as it related to Quality Assurance, the PM’s duties shall include the following:
a) Organization and structure of Supervision Consultant site staff.
b) Issue of written job descriptions to individuals. These shall include the duties listed in sections
above with or without appropriate modifications.
c) Ensuring satisfactory execution of the works in accordance with the Specification.
d) Ensuring the correct and efficient execution of duties by individual staff members. This shall
include:
i. Regular objective assessment of individual job performance.
ii. Guidance and direction in areas of shortcomings.
iii. Overall staff organization for maximum efficiency taking account of individual
strengths and weaknesses.
e) Read reports of subordinate staff and take appropriate action.
f) Submit a monthly report to the PWD (NH DIVISON) recording:

i. Summary of Contractor’s progress.
ii. Notes of meetings held with Contractor’s
iii. Summary of problems, areas of concern, action taken, and action required.
g) Approval of work. He shall ensure the correct levels of approval authority are maintained.
In all cases the PM is finally responsible for work approval irrespective of approvals or
rejections by subordinate staff.
h) Holding weekly meetings with the Contractor’s to ensure proper superintendence of work by
the Contractor’s. Matters relating to construction problems, materials and workmanship,
method statements, trials etc. should be discussed.
i) Correspondence and Records. The PM shall ensure that all facts and salient points relating to
execution of the works are comprehensively recorded in written correspondence and records.

5.0 CONTROL OF DATA AND DOCUMENTATION

Proper documentation and record keeping is of vital importance for a fruitful project
implementation. It is also required to keep the documents, events, which occurred during the
whole of the contract period, for future references.
5.1 Drawing Registers
Registers of drawings shall be kept as detailed in this document to ensure that the latest approved
drawings only are used for the construction of each part of the works. The registers shall include
all drawings of both permanent and temporary works.
All the organizations connected with the project shall keep registers of drawings, these
organization being:
a) Project Management Consultants - the authority responsible for ensuring correct execution of
the Works and approval of temporary works drawings.
b) Contractor’s responsible for the execution of the Works and preparation of temporary works
drawings.
c) PWD (NH DIVISON) - The Client
5.2 Road related documents
Drawings, specifications, work instructions and other road related documents shall be maintained
as described below to ensure that only the latest approved documents are used for the construction
of each part of the work, which covers both the temporary and the permanent works:
a) The issuing authority should maintain the registers of drawings/documents giving information
about reference number, revision reference, title/date of issue, to whom issued, number of
copies issued, status of issue, date of approval, purpose of issue, etc. (Superseded
drawings/documents shall be so super scribed boldly across the heading block).
b) Receiving officer to whom documents are issued at site should maintain similar record.
c) Maintenance and accessibility of site instruction book/order with both issuing party and to
whom issued.
d) Maintenance and accessibility of registers of correspondence files.
e) Daily diary of work
f) List of registers on site.
5.3 Quality related records and documents.
For quality assurance of work, it is essential to document each and every operation and activity
connected with the work and maintain the record of inspections, approvals/non-approvals and
other statistical day-to-day information about the progress of work. These are normally recorded
in the standard forms (to be specially evolved for each activity) and they constitute an important
component of the Quality Assurance Manual. Each activity or operation could be broadly
categorized as under.
a) Method Statement
The method statements give detailed proposals of the constructing agency which are approved
by the 'Engineer'. These method statements are written in form of various steps in a particular

sequence supplemented by suitable sketches to be self-explanatory. No change shall be carried

out from the procedures prescribed in the method statements without first obtaining approvals
to such change from the 'Engineer'.
b) Inspection Performa
These are used for the purpose of seeking approvals from the 'Engineer' or his representative
before commencing every operation, such as, pour cards for concrete, approval to
reinforcement, approval to formwork, approval to setting out, approval to prestressing,
approval to grouting, approval to earthworks, approval to asphalting, etc. These are usually
supplemented by standard check-list which have to be verified by the 'Engineer' and after he
is satisfied about the various points the approval is then accorded on that form.
c) Test Results
This set of Performa is meant for recording the results of day-to-day tests carried out in
accordance with the requirements or specifications. The Performa are usually maintained in
two forms; one is loose leaf system for recording the various observations during each test
and second is for recording the summary of test results in a register form to facilitate analysis
later.
d) Daily Diary of Work and Quantity Records

Elaborate registers are required to be maintained at site to record the day-today operations,
activities and events taking place at the site of work, such as, equipment deployed, manpower
deployed, activities carried out, different types of materials consumed, detailed observations
of the activities at site (foundation strata, tilts, shifts, etc.), visits by senior level engineers and
follow-up of their instructions. These records will enable preparation of the completion report
as well as investigating any unusual observations, which come to notice afterwards. In case
any site order is required to be issued and empowered to do so that should be maintained in
"Works Site Order Book" duly signed by Contractor & issuing officer. A copy to be given to
the Contractor for compliance which also to be confirmed by the officer giving order.
e) Non-conforming Products
Detailed statements have to be prepared describing the procedures to be followed as soon as
any result not conforming to the requirements (or unusually better results) is obtained. Such
statements deal with the (i) procedures to be adopted for rectification of the particular
component where such result have been noticed, (ii) the long-term corrective action, and
(iii) immediate preventive actions in other similarly affected activities till the long-term
corrective actions are implemented.
f) Quality Audit
A separate set of proformae with detailed instructions are laid down for facilitating the audit
of the quality assurance by an Authority Engineer unit at periodical intervals.
5.4 Correspondence
On a major contract such as this a large quantity of documents are used and records and
correspondence generated. It is essential that a comprehensive filing system exists and a register
of document files kept to enable quick recovery of documents. This is necessary if valuable time
is not to be wasted carrying out searches or particular documents.

5.5 Progress Reports
For monitoring the progress, a report containing progress as well as other information is to be
prepared every month or on a time basis as per Contract. Progress Report should contain various
happenings at site but not limited to
a) Executive Summary showing physical progress, up-to-date expenditure, project assessment
and any significant events
b) Project Data depicting Loan No, Funding Agency (if any), Original Sanctioned Cost,
Estimated Project Cost, Tender Amount, Civil Contract Details, Consultancy Contract details
etc.
c) Project "S" curve
d) Preconstruction Activity
e) Major Road Works item, Bridge & Culvert Items
f) Variation Order, Claim
g) Quality Control Certification
h) Construction Constraints (both for Contractor and Authority)
i) Substantial Completion, Liquidated Damage
j) Financial - IPC, Advance, Current Contract Amount, Escalation, Value of Taking Over
Certificate
k) Project Staffing - Authority, Consultant, Contractor - any change to be intimated
l) Other matters of interest like stages of construction with respect to milestones. The work plan
for the next month.
m) Charts, figures, photographs.
n) Equipment and machinery status
5.6 Final Report
After completion of project a Final Report on Construction Supervision is required to be

submitted which should inter-alia include the following:
 Back Ground Information

 Engineering detail of the Project
 Description of the project execution
 Sources of material used for various elements of the Project
 Compendium of tests on quality of materials and work
 Data on modification / adjustment / alternatives to the original design of road element
 Contract changes and variation
 As built drawing
 Project cost
 Supervision organization and their performances
 Methodology of construction adopted
 Any critical study of important Technical Problem
 Problems encountered, Constraints and their solutions
 Hold ups and solutions
 Important events
 Suggestions for future improvements
 Comments on Specification and Conditions of Contract
 Chronology of actions such as contract award, commencement of work, completion of various
sections, issue of taking over certificate, defect liability certificate, Final Statement.

5.7 Other Records
It is essential for the project to prepare procedure for proper documentation of various important
events during the implementation of project. Before the actual execution starts i.e. just before
issue of NTP, the status and condition of existing road also to be documented which when
improved will give a better idea about the nature of improvement done and functional efficiency
of the improved road which then be compared with the old existing one. Important activities are
also to be documented when necessary. These documents are to be photographed or video-filmed
properly referred with respect to location and time of picturization.
5.8 Maintenance of Drawing Registers
In each organization connected with the project one person shall be appointed to maintain
registers of drawings as described above. This shall normally be the CAD operators in the
organization. He shall answer to the engineer responsible for design or construction as
appropriate.
Summaries - The person identified as above shall prepare each month a summary of drawings
issued or received. The purpose of the summaries is to identify potential delays in drawing
production or approval to prevent delays to construction. The summaries should enable the
engineer in charge to compare data with target programmed figures and to take action to prevent
delays. This will help in identifying drawings awaited for execution.
5.9 Management of Drawing Registers
In each organization connected with the project one engineer shall be appointed to manage the
production, receipt allocation of drawings, etc. He shall ensure that the register is properly
maintained as described above and shall carry out the following duties:
a) Give directions on the issue of drawings i.e. to whom, number of copies, etc.
b) Allocate duties of reviewing, checking and commenting to individual engineers and
technicians.
c) Ensure that the register is properly maintained.
d) Ensure that production / review of drawings is carried out as per programmed to prevent
construction delays.
e) Review periodic summaries of drawings status, identify potential areas of delay and take
action to prevent delay.
f) Inspect the registers regularly.
g) Liaise with other organizations and hold meetings to establish drawing preparation and
approval priorities.

6.0 PROJECT MONITORING

Programmed should be reviewed and checked for
 their correctness
 detail and logical sequence of operation
 capability with agreed workable machinery & equipment
 compatibility with output of machineries vis-a-vis time period
 anticipated monthly turn over dependent on financial progress
 back up support of cash flow schedule
Depending on the progress of work not conforming to the approved work program or any change
in operation due to various reasons, the program will call for revising schedule to ensure
completion of the works within the Time for Completion.
For the interest of Project, it may be necessary to assist the Contractor in advising him on up- to-
date technique for project control, construction method, sequence, scheduling and organizational
setup. The Engineer would interact closely with the agency while reviewing and approving
Contractor’s work program.
Program should include inter-alia the following
a) A bar chart showing different activities under the various principal (Milestone) tasks, their
relationship and criticality along with likely deviation and time limit of each activity within
the total time frame of project based on available equipment, and production rate.
b) A detailed network programme encompassing detailed break up of tasks, resource allocation
of tasks based on their maximum availability parallel activities, scheduling of resources,
establishment of milestone and critical path from the date of commencement of work to its
completion.
Programme should be verified critically with proper analysis, evaluation and monitoring progress
of work. The consultant shall uphold the spirit of contract bearing in mind that time is the essence
of Contract.
Having identified the bottleneck and problems appropriate solution to be suggested based on
which rescheduling of work programme wherever necessary to be done for completion of project
within the period prescribed in the contract.
Cash flow generally becomes a big hurdle in running the project site, which ultimately hampers
the progress. So a realist’s cash flow estimate based on payments to which the Contractor will be
entitled under the contract or from Contractors other sources, should be prepared which will be
compatible with work programme.
6.1 Contract Monitoring
The Engineer will interact with Contractor for proper interpretation of contract condition,
Technical Specification and above all Contractors obligation for executing and completing the
work with due care and diligence including remedying any defects. If any ambiguity and
inconsistency exists in the contract documents, consultant will work with Authority to clarity
these aspects.
Original contract amount may undergo changes due to quantity overrun, quantity under un with
respect to provisions in bills of quantity or for any other reasons. Accordingly, contract amount

need to be revised frequently preferably every month based on variations which will be effected
during that particular month. These variations may arise as a result of change or unforeseen
conditions, changed scope of work, un priced work, nonscheduled work, modification of original
plan and specification due to change in character of work or alteration in character of work
resulting in increased / reduced quantity. All these changes in contract amount will be notified to
the Contractor through variation orders. Fixation of rates and their application on condition of
contract, proper justification necessitating variation and financial implication therefore will be
properly drafted and approved by the Authority. This variation order then will become a legally
binding part of the contract.
In case of subletting a part of work, when requested by Contractor and provided in the contract,
necessary advice will be given to Authority in respect of necessity of subletting, suitability of
Sub-Contractor, impact of sub-contract on the main contract and finished work, degree of
sensitivity of work assigned under the subcontract and general advisability or otherwise subletting
in a particular situation.
6.2 Material Procurement Monitoring
Timely procurement and processing of material are of vital importance in accelerating progress.
Hence a procurement program of material with a pragmatic approach towards specialized sub-
contracted / manufactured items should be prepared commensurate with requirement. Programme
should be sufficiently in advance with proposed planning of its timely requirement as well as total
requirement for the project It is always better to keep a buffer stock of one month's requirement
not only for smooth running of project but also for offsetting unforeseen circumstances. Seasonal
hindrances for borrow pits when the soil is neither borrowable nor compatible due to presence of
excessive moisture will be taken care of by timely precautionary measures. Stock piling during
dry season on highlands in the vicinity of project road for shorter haulage will be more effective to
avoid delay and consequently delay in construction of further layers. Accordingly, a material
inventory will be maintained for monitoring continuous supply, advance procurement, provision
& storage of approved quality construction material in sufficient quantity along with their
incorporation in works so as to ensure unobstructed progress of works in line with construction
programme.
6.3 Equipment Monitoring
Deployment and utilization of proper equipment matching with time schedule besides
procurement of material plays a most vital role for the progress of project. Technical Specification
has been prepared to suit equipment-oriented method of construction. For the mechanized
construction activities, the Contractor should have adequate and right type of equipment for
various construction activities. Hence during construction, the deployment of standard and
specialized equipment including their suitability, efficacy, condition, age, workability proposed
by the Contractor’s shall be examined.
Although the Contractor is entitled to schedule his work as he sees fit, the Supervision Consultant
shall prefer and recommend a balanced schedule for consistent output reflecting optimum
utilisation & equipment requirements. Starting of too many different items in a particular time
makes the program optimistic or perhaps a little unrealistic. Due consideration should be given for
some lead time for aggregate production required for different pavement layers after setting up
and commissioning of plant.
The Contractor’s arrived at his equipment needs based on total quantities. This may be very
misleading in case where more than two operations proposed to be carried on simultaneously.
Equipment may be adequate to carry out the total quantity over the contract period but may be

totally inadequate to carryout simultaneous operations that may have been scheduled over specific
periods. The Contractors estimated production rates for equipment should be reasonable. In any
event a major break down of key machinery will have a serious effect on progress and it would be
prudent that requirement of additional equipment should be looked into. Contractor’s should plan
his activities in such a way that
 Equipment’s will work in tandem close together to reinforce each rather in the case of break-
down and that maintenance aspects, spare-parts etc. are fully implemented.
 Scheduled monthly production should be more uniform, consistent unless the Contractor has
some particular reason to have them fluctuate.
 Actual anticipated quantities are used for deployment of machineries in place of quantities
shown in the Bill of Quantities, if they are significantly different.
 The implementation of proper maintenance programme can be assured for all major
equipment to minimize down time. This would include routine and preventative maintenance
including stocking of adequate spare-parts.
In order to have an acceptable equipment production rate, the same shall be arrived at following
discussion with consultant's staff, Project Manager, Contractor’s representative based on actual
observation of some activities on site and theoretical rates in other instances.
A table of major equipment based on total quantities will be prepared which should be updated at
suitable interval depending on the performance and progress.
A Bar type chart summarizing the major road activities, the months when the activities are to take
place and the quantity to be performed each month will also be prepared for reflecting an uniform
and consistent output.
Based on requirement for each individual item of work, total requirement equipment wise will
then be evaluated for comparing with contract and the Contractor’s may be informed accordingly
for enhancement in deployment of machinery which was deficient in original contract, increase in
quantity or balance time vis-a-vis balance quantity.
Supervisory staff shall monitor the deployment of machinery and their actual utilisation vis-a-vis
total requirement of equipment proposed.
6.4 Progress Monitoring
The progress of works should be compared with respect to the programme already approved and
agreed by the Contractor’s Any shortfall or lag behind the schedule should be brought to the
notice of Contractor’s for taking necessary steps to compensate the same so that the progress can
be accelerated for completing the project within the contract period. Monitoring and updating
activities will extend over the entire duration of construction period at regular interval. Consultant
will provide necessary assistance in adopting the most appropriate technique satisfying the
requirement of client, funding agency, Contractor’s and above all for the interest of the project.
Depending on the observance, analysis of performance and variance against the scheduled
programme, cash flow projection, delays (non-compensable delays, compensable delays) will be
reviewed. These would be updated periodically to minimize the effect of such variance on the
project implementation process.
If the shifting of target date for final completion or part completion appears unavoidable due to
delays, consultant will prepare a revised schedule based on time loss due to various reasons for
advance information to Authority. Total loss of time not necessarily be the addition of all losses

because of overlapping or simultaneous happenings of two or more events. A bar diagram also to
be prepared.
Considering the convenience, methodology & sequence of construction commensurate with site
condition the Contractor’s may propose to carry out the activities which may be, staggered both
vertically & horizontally in scattered stretches within the selected length in different layers on
each side of proposed road centerline. To monitor the progress and also for check/balance of any
particular layer, consultant suggest for maintaining
 a comprehensive table showing the performance of Contractor’s vis-a-vis future required

performance to complete the work within time frame.
 a consolidated bar chart depicting all the activities of construction.
 'S' Curve depicting the progress pattern which was scheduled on monthly basis vis-a-vis the
progress pattern based on actual work done and their cumulative effect commensurate with
the approved work programme along with illustration of anticipated monthly as well as
cumulative turnover.

7.0 SURVEY CONTROL AND SETTING OUT

The Quality Assurance of surveying and setting out shall be the responsibility of the Contractor’s
and the same be verified / checked by Supervision Consultant.
Each organization shall appoint a professional qualified land surveyor to be responsible for this
work. The setting out data for the work including lines, levels and layouts as available from the
contract documents would be checked by the Consultants prior to handing over to the Contractor’s
for setting-out works. The Bench Marks and HIPs including reference points would be shown and
handed over to the Contractor’s
All surveys, measurements, etc. will be permanently recorded on field books or drawings. These
will be properly indexed, numbered and presented to form the permanent record of the job. In
addition, periodic check surveys will be made to ensure that the line, levels and permanent and
temporary bench marks are properly maintained with respect to the survey monuments. Any
discrepancies or anomalies will be reported to the Contractor’s under intimation to PWD (NH
DIVISON) along with suggested rectification measures.
The check survey would, inter-alia, include, the following:
 Permanent and temporary Bench Mark Pillars

 Survey control points (survey monuments)
 Reference pillars for curves
 Levels of excavation and fills for roads and structures
 Setting out of stakes for highway alignment
 Setting out of culvert works
 Depth of construction layers for the pavement works
 Cross-sectional geometry
 Other miscellaneous works as necessary
7.1 Survey Control Stations
The setting out of the Works shall be controlled by the establishment of approved Survey Control
Stations. These stations shall be related to the National or Local Grid as directed by the
Supervision Consultant. The stations shall be defined by three co-ordinates, these being Easting,
Northing, and Level in metres above datum and a Station Number.
The control stations shall be of robust construction located on firm standings and protected by
suitable barricades from disturbance by outside agents, site traffic and the like.
7.2 Setting Out Points (S.O.P.'s)
Setting Out Points, S.O.P.'s shall be established from the survey control stations and shall be
defined by three co-ordinates - Easting, Northing and Level. These points shall be used for the
setting out of the works. They shall be of robust construction, located on firm standings and
protected by suitable barricading from disturbance.

7.3 Schedules of Control Stations & S.O.P.'s
Schedules of Control Stations and S.O.P.'s shall be prepared by the Contractor’s for approval by
the Supervision Consultant. These schedules shall contain the following information:
a) Control Station and S.O.P. number
b) Co-ordinates - Easting, Northing, Level
c) Date Approved for each marker
d) Revision Date
e) Distribution record
The schedules shall be regularly updated. The Supervision Consultant shall ensure that only the
latest revised approved schedule of markers or stations is used for setting out purposes and shall
arrange for the withdrawal from use of superseded schedules. Accordingly, records of distribution
of schedules shall be kept.
7.4 Control & Checking of Stations & S.O. P’s
The Contractor’s Surveyor shall maintain a programme of regular checking of Survey Control
Stations and S.O.P.'s at monthly or weekly intervals as agreed with the Supervision Consultant.
Where it is suspected that disturbance may have occurred to a particular station or point it shall be
immediately withdrawn from the approved list and its co-ordinate values shall be re-established.
On every occasion that the Contractor’s re-establishes co-ordinate values for a station or marker
he shall submit these for approval by the Supervision Consultant. This shall be done irrespective
of whether or not the values have been altered since the previous establishment.
The Supervision Consultant Surveyor shall maintain a programme of periodic checking of control
stations and S.O.P.'s and shall check all establishment or re-establishment of co-ordinates
submitted for approval by the Contractor’s. Where co-ordinate values are not agreed the
Supervision, Consultant shall immediately notify the Contractor that the Station and S.O.P. in
question is not approved.
On the occasion of non-approval of a station or marker, revised schedules shall immediately be

issued by the Contractor’s with the date clearly marked and the works "not approved" written
against the station or marker in question. The Contractor’s surveyor shall re-establish co-
ordinates and re-submit them for approval by the Supervision Consultant surveyor.
7.5 Approval of Control Stations & S.O.P.'s
All requests for approval of survey stations and S.O.P.'s shall be made by the Contractor’s in
writing accompanied by suitable plans or sketches. This written request shall be made on a
Request for Inspection.
Approval or non-approval shall be notified in writing by the Supervision Consultant's Surveyor by

returning the request form signed accordingly.
7.6 Setting Out of Works
The Contractor’s shall set out the Works using only approved Survey Control Stations and Setting
Out Points and shall submit the setting out for approval by the Supervision Consultant.

No permanent works shall be approved without the prior approval of the setting out by the
Supervision Consultant.
The Supervision Consultant shall check the setting out for correctness of the plan alignment,
levels and dimensions in accordance with the approved drawings for construction.
8.0 TEMPORARY WORKS

8.1 Temporary Works Procedure
The importance of temporary works cannot be over emphasized for the attainment of safety and
good workmanship and a sound durable structure. Temporary works are often structurally
complex and cover a wide variety of structural materials and loading conditions. It is therefore
essential that these works are overseen by competent experienced qualified engineers.
It should be borne in mind that Contractual responsibility & liability for temporary works lies
with the Contractor’s and therefore the role of the Supervision Consultant under the Contract is
one of approval or non-approval of Contractor’s temporary works. Care shall be taken by the
Supervision Consultant that no specific instructions are issued which can be construed to relieve
the Contractors of or prevent him from carrying out his contractual obligations.
Temporary works are generally as under:
a) Centering and formwork

b) Temporary structures built to enable / house operating plant/machinery
c) Diversions of temporary nature for traffic
d) Services detour
The temporary works procedure shall be in the following stages:
a) Design, drawings and method statement.

b) Checking and approval of proposals.
c) Erection procedures.
d) Checking & approval of erection.
e) Certification.
f) Monitoring during loading.
g) Dismantling of the temporary works.
8.2 Design of Temporary Works
Temporary works shall be designed in accordance with specified codes of practice or as per
contract specifications. Calculations shall be produced by the Contractor’s along with drawings
and method statement. The design shall consider all the loads mentioned in the codes including
accidental and wind loads. Consideration shall be given to deflections to ensure specified finished
work tolerances.
8.3 Checking & Approval of Proposals
Although the contractual responsibility for temporary works lies with the Contractor’s, checking
of proposals is an essential part of the Quality Assurance of the permanent works.

Contractor’s shall furnish the design and drawings of all temporary works such as formwork
including their supports for approval of the Consultants before any section is taken up. Therefore,
the Supervision Consultant’s Engineer shall check that proposals are in accordance with the
design codes. Notwithstanding any approval or review of drawings and design of the Consultants,
the Contractor shall be entirely responsible for the adequacy and safety for temporary works.
It is necessary to consider all details including strengths of connections, adequacy of bracing, load
bearing stiffeners & other vital components.
8.4 Erection of Temporary Works
Erection of temporary works should not proceed without approved drawings except for minor
temporary works where failure will not jeopardize site safety. Erection shall be strictly in
accordance with the approved drawings. Where it is necessary due to unforeseen circumstances to
depart from the approved drawings, approval shall first be obtained from the Supervision
Consultant's Engineer and drawings amended accordingly.
8.5 Checking of Temporary Works Erection
During the erection of temporary works, checking shall be carried out by the Supervision
Consultant staff to ensure compliance with the approved drawings. Any departures from this shall
be reported to Supervision Consultant’s Engineer.
On completion of erection, the Contractor’s shall submit a written request for inspection to the
Supervision Consultant whose staff shall then complete detailed checking of the works.
8.6 Certification of Temporary Works
Once both the Contractor’s and the Supervision Consultant’s Engineers are satisfied with the
temporary works, a Temporary Works Approval Certificate shall be jointly signed prior to loading
the works.
After due consideration of Safety, size, importance and the possible consequences of failure of
any particular temporary works, Supervision Consultant shall designate whether or not
Certification is required. Usually minor formwork shall not require a certificate.
8.7 Monitoring during Loading
Care shall be taken to ensure loading is carried out in accordance with the sequence envisaged in
the design and described in the approved method statement. Where possible deflections shall be
measured and compared to anticipated values.
8.8 Dismantling of Temporary Works
The timing of dismantling of temporary works shall be as specified. The Contractor’s shall obtain
written approval from the Supervision Consultant to dismantle temporary works to ensure no
damage results to the permanent works.

The sequence of dismantling is often overlooked with consequent accident. Therefore the
dismantling of temporary works shall be included in the approved method statement. Checking
shall be carried out to ensure that approved procedures are followed.

9.0 METHOD STATEMENTS

This section covers method statements for execution of the permanent works as distinct from
temporary works described elsewhere. These method statements are required for major items of
work like Bituminous works etc. They give elaborate description of construction procedure, plants
and machinery that will be deployed, Design mix / Job mix details and field / lab testing of the
works to be carried out.
9.1 Method Statement Procedures
Where specified or where considered necessary by the Supervision Consultant, the Contractor’s
shall submit method statements for the execution of the permanent work to specification. The
procedure for method statement shall generally be as follows: -
a) Submission of method statement to 'Engineer'.

b) Checking and approval of proposals.
c) Trials of method away from permanent works
d) Assessment of trial, review of method statement.
e) Second trail if necessary etc.
f) Work sample on the permanent works.
g) Execution of permanent works.
h) Ongoing review of method.
9.2 Submission of Method Statements
The Contractor’s shall submit written method statements clearly detailing each step of the
proposed method of execution of the particular part of the works concerned. The statement shall
cover the following aspects: -
a) Materials : Where alternative options, sources or types of material are

permitted the Contractor’s shall state his proposals & obtain
approval of materials as described elsewhere in this document.
b) Plant & equipment : The Contractor’s shall submit proposals for plant &
equipment / machinery including manufacture's details and
performance specifications.
c) Labour The Contractor’s shall describe the categories & numbers of

skilled & unskilled personnel, foremen & engineers he proposes
to carry out the works.
d) Method description The stage by stage method description shall be fully detailed in
sequential order.
e) Testing a) the method shall allow for testing at intervals or key stages
and the times for this shall be taken into account.
b) the Contractor’s shall submit the complete list of testing
equipment and proposed location of field laboratory.
f) Approval of works The Contractor’s shall state at what stages or intervals he

proposes checking & part approval of works by the Supervision

Consultant
g) Trials details of trials proposed shall be submitted as described in para

9.4
9.3 Checking & Approval of Method Statement
The Supervision Consultant shall scrutinize the points described above to ensure compliance with
the Specification and satisfy himself on the provision made for trials, testing & stage approval of
works. He shall check that the proposed plant, equipment & human resources appear realistic to
carry out the works to programme. He shall make written comment to the Contractor on points
with which he is not satisfied until acceptable proposals are received and can be approved. The
adequacy of resources allocated to the work can be determined during trials as described below at
para 9.4. The Consultants will examine the job-mix and associated details submitted by the
Contractor in respect of sub-base, base course, asphalt concrete mixes and cement concrete mixes
and approve these, based on his Authority Engineer review and testing. Any modification
/ re-testing required will be promptly communicated to the Contractor.
Laboratory and field test result will be recorded on standard format established in QA Manual.
The Consultants, if necessary, will instruct the Contractor to carry out special tests on materials in
accordance with IRC guidelines / MoRT&H or other International specifications conforming to
contract provisions to ensure specified quality control standards.
Guidelines regarding safety of operations and environmental protection, will be checked and
verified by the Consultants in consideration of the contract provisions, the relevant local laws and
regulations also conforming to regulated standards.
Particular attention will be paid to the following:
 interference with existing traffic

 public safety
 accident potential of construction operations
 borrowing and spoiling operations
 air pollution
 noise pollution
It will be ensured that the Contractor’s adopts suitable preventive and corrective measures to
minimize the risks from the above-mentioned causes and avoid any damages to life or property or
existing services resulting from the operations or activities.
Once approved, the written method statement shall be issued to Contractor’s personnel
responsible for execution of the work and the Supervision Consultant staff responsible for
supervision. The concerned staff shall make themselves familiar with the proposed method. No
departure from the method statement shall be made unless resubmission of a revised statement is
made and re-approval obtained.
9.4 Trials, Assessment, Work Samples
For all work items, at the commencement, as required by the specification, Trial Stretches will be
made to demonstrate the construction norms for quality work as is expected of the Contractor’s.
These trial stretches will also identify the skill and training requirement of

operators, the requirement of the equipment, training of Contractor’s inspectors and

superintendents.
Trials, although sometimes costly & cause initial delay, frequently benefit the Contractor’s in the
longer term by resulting in establishment of efficient practice & first-time approval of works.
They are of obvious advantage to the Authority in reducing faulty execution of permanent work
and establishing confidence in the execution of critical works. Trials can sometimes be
economically carried out by taking advantage of temporary works execution to try out permanent
works e.g. concrete for temporary cofferdams using proposed permanent works trials mixes.
Where appropriate, work trials away from the permanent works shall be carried out. This is
particularly necessary where the following circumstances: -
a) Work is of complex specialist nature.

b) Where execution of faulty permanent work results in difficult remedial work or removal e.g.
concrete special finishes, grouting prestressing ducts, underwater concreting etc.
c) Where traffic has disturbed for longer period.
During trials, careful monitoring, measurement & testing shall be carried out and the results
documented for assessment and comparison to specification requirements. The results shall be
reviewed & discussions held between the Supervision Consultant and the Contractor’s. At this
stage minor or major changes can be made to the proposals and re-trials ordered as necessary.
Where the nature of the work permits, trial samples of work can be carried out on the permanent
work. This will usually be restricted to cases where faulty work can more easily be rectified or
removal is less costly. This will apply to more routine non-complex work.
9.5 Permanent Works, Review of Methods
It is frequently the case that trials cannot truly represent the real site conditions and methods
which were satisfactory in the trial require modification & re-appraisal. Therefore, special
vigilance shall be exercised both by the Contractor’s superintending personnel and the
Supervision Consultant’s supervising staff when a particular category of permanent work starts or
circumstances change. If necessary re-trials shall be carried out where the first trials were clearly
unrepresentative of the existing conditions.

10.0 MATERIALS
10.1 Outline of Materials Procedures
The Contractor’s is primarily responsible to carry out tests on naturally occurring materials and
manufactured materials and works in accordance with Contract provisions, IRC / MoRT&H
specifications and sound engineering practices. The Consultant shall assess and review all tests
and in case found necessary, will carry out Authority Engineer tests in field laboratory.
The main elements of the procedures for Materials Quality Assurance are as follows:
10.1.1 Testing of Materials

All materials shall be tested as specified before their incorporation in the Works to ensure
compliance with the Specification. Stock-piles & stores shall be controlled to ensure all materials
are subject to testing & inspection.
10.1.2 Inspection and Certification of Materials on Receipt

In addition to testing and in some cases as specified in place of testing, certificates will be
provided by manufacturers of materials and products. These test certificates shall be inspected,
monitored and compared to other test data and relevant specifications as appropriate to ensure
compliance & for approval.
10.1.3 Testing of Materials going into Construction

Not only shall the individual component materials be tested but tests shall be taken as specified of
materials in their initial and final stages when fabricated, constructed or processed in the specified
manner.
10.1.4 Test Records

As part of the Quality Control procedure all tests shall be logged on appropriate proformas given
in the relevant IRC & IS Codes and record books. These shall include all the details required to be
tested as specified.
10.1.5 Assessment & Analysis

All data, test & inspection results shall be analyzed as required and compared to the specified
values to ensure compliance, as part of the Quality Control procedures. Records of compliance
and non-compliance shall be kept.
10.1.6 Structure Logs

Test data, results & compliance shall be related to the part of the structure, in which the materials
are used. This will enable Structure Logs to be prepared which will show materials compliance
for all elements.

10.1.7 Summaries
Summaries of test data, results & compliance shall be prepared at intervals as specified or directed
by the Engineer or Material Engineer.
10.1.8 Quality Assurance Procedures

The following sections state the procedures which shall be followed to give assurance that Quality
Control is being carried out as specified. It must be understood that the procedures described are
not themselves the Quality Control procedures which are described in the Specification & the
Codes of Practice or Standards specified.
10.2 Materials Testing
10.2.1 Materials List

To ensure that no materials are omitted from consideration, a full list of all the materials specified
in the project shall be drawn up. The quality control tests on materials are intended essentially to
be carried out on the material brought to site. However, at times, from practical and other
considerations, some testing could be done advantageously at the material source. In these
circumstances, the Senior Engineer may do additional testing at sites as may be found necessary to
ensure that the materials being used in the construction are of specified quality.
10.2.2 Tests
The tests required are all those detailed in the Contract Technical Specification or in the Standard
Specifications (IRC & IS) referred to by the above documents. A full list of all the required tests
shall be drawn up by the Material Engineer for Materials.
10.2.3 Test Procedures

Care shall be taken to ensure that tests are carried out in accordance with the procedures described
in the relevant Specification, Code or Standard. Guidance notes shall be prepared as necessary by
the Material Engineer for Materials to ensure consistent, correct practice by laboratory staff.
10.2.4 Test Frequencies and Calibration Schedule

Frequencies for the main tests have been suggested in the section 900 of MoRT&H Specifications.
A full list shall be drawn up by the Material Engineer for Materials showing the specified test
frequencies or where these are not specified the intended test frequency.
Testing equipment shall be calibrated and serviced periodically as per manufacturer's

specifications.
10.2.5 Variation of Test Frequencies

The frequency of testing shall be based on the following considerations: -
a) Specified frequency - this minimum frequency shall be followed.

b) Test results to date. When results show good compliance and consistency of quality then the
frequency of tests can be reduced (but not less than specified). When results show poor
compliance & inconsistency then the frequency of tests must be maintained or increased.

c) Criticality of the material to the structural overall. For the main materials in structurally
critical areas no reductions in test frequency should be contemplated which might give rise to
doubts on assurance of quality control. For all materials, careful consideration must be given
before reductions are made. All changes to the frequency of testing must be approved by the
Material Engineer.
d) The use of certificated data. Where the Material Engineer is satisfied that Authority Engineer
& reliable test certificates exist, a reduction in test frequency may be authorized.
10.2.6 Equipment for Field Testing, Laboratory and Surveys

The relevant equipment necessary for carrying out testing and survey works will be procured by
the Contractor’s including establishment of laboratory. The laboratory equipment available with
the Contractor’s will be reviewed by Material Engineer regarding their usefulness for the project
and accordingly recommendations will be made.
10.3 Control of Materials
10.3.1 Delivery
A log of material deliveries to site shall be maintained and all materials shall be inspected on
arrival. The Material Engineer shall initiate a system of notification by the Contractor of expected
deliveries.
10.3.2 Packaging & Transport

Inspection of packing and transport shall be made and the findings logged to ensure compliance
with the Specification or the manufacturer’s instructions and recommendations. Where incorrect
packing and transport is found, special inspections shall be made for signs of deterioration of the
material quality.
10.3.3 Marking
The Contractor’s shall be required where specified to clearly mark materials to identify their
origin, grade and constituent.
10.3.4 Storage and Inventory of Materials

Materials must be stored as specified or in accordance with manufacturer’s instructions and
recommendations. Materials for which approval is pending must be stored separately from
materials already approved. The Contractor’s shall be requested (or instructed if specified) to
submit his method statement for storage and handling of materials to ensure separation. An
inventory record of materials stock shall be maintained for the project.
All the materials brought to the site shall be stacked and stored as specified so as to prevent
deterioration or intrusion by foreign matter and to ensure the preservation of their quality and
fitness for work. Materials which have been improperly stored or have been stored for long
periods shall be re-tested where their suitability for incorporation in the work is in doubt.

10.3.5 Non-Compliance
Where the Contractor fails to control materials then approval shall be withheld or withdrawn as
appropriate.
10.3.6 Control Documents
The Material Engineer shall initiate logs and record proformas which list deliveries and record
satisfactory or unsatisfactory packaging, transport, marking and storage.
10.4 Test Records
10.4.1 Tests
Laboratory and field tests will be performed on materials and works at the frequencies laid down
in the Contract Specification by Contractor’s under direct supervision of the Consultants. All
these tests will be authenticated by the Consultant’s Material Engineer that these tests have been
done in their presence. The records of all tests performed on materials and works will be
maintained by Consultants with a copy of test results furnished to the Contractor.
10.4.2 Sampling
The following procedure shall be followed:
a) Details of sampling shall be logged in a sample record sheet for each sample taken.
b) This record sheet shall be returned with the sample to the laboratory.
c) Details shall be transferred from the record sheet & entered in the appropriate test data record
book.
d) Any necessary future test dates shall be logged in the Laboratory Schedule / Diary to ensure
testing at the correct date.
The Material Engineer shall prepare the necessary proformas for sample record sheets for the
different materials and shall initiate and maintain Laboratory Record Books and Laboratory
Schedules.
10.4.3 Test Results

The full test data and results shall be recorded in the Laboratory Record Book for the particular
material. This shall include the reference number of the sample and reference number and Code or
Standard of the test carried out.
10.4.4 Transfer to Record Sheets and Summaries

Test results relating to acceptance criteria as detailed in the particular test procedure shall be
transferred to record sheets, summaries, analysis sheets or structure logs as appropriate. These
shall show compliance or non-compliance.
10.4.5 Records of Test Frequencies

To ensure compliance with the specified or required test frequency, the numbers of each test
carried out for the different materials shall be logged. This log shall include:
a) the test name or reference number

b) the required test frequency

c) the actual test frequency
The Material Engineer shall examine this log and take appropriate action where the test frequency
is less than required.
All test result record sheets shall be submitted to and examined by the Material Engineer. He shall
ensure that the correct procedure for non-complying materials are followed. This shall be as
specified i.e. rejection, retesting followed by rejection / acceptance etc.
10.5 Results Analysis and Assessment
10.5.1 Data Summaries

Summary sheets, analysis sheets and structure logs shall be produced from the test records. The
summaries shall include:
a) sample reference numbers

b) dates taken
c) location of material
d) key results
e) analysis of results
f) compliance or non-compliance
The completed summaries serve also as a status check on Quality Assurance i.e. they show
whether or not the necessary testing has in fact been done.
10.5.2 Analysis of Data

As specified or as appropriate the data shall be analysed by one or more of the statistical methods
given below, as per relevant codes and specification.
a) mean of results
b) S.D. of results
c) range of results
d) maximum and minimum values
e) number of non-compliances
f) correlation between properties
g) deviations from range
h) running totals
i) others
Any non-compliance must be detailed and actions taken reported. A daily register of non-
compliance shall be prepared and actions signed off by the Material Engineer as required.
10.5.4 Proformas
Example proformas are provided for cement data and concrete test data in Chapter 19.
Appropriate proformas shall be prepared by the Supervision Consultant for all materials.

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-17) at Km. 91+000
God River, Km. 94+400 Kal River, and Km. 161+400 Choradi River in Raigad District in the State of Maharashtra on
EPC Mode.
10.5.5 Check upon Analysis

The Supervision Consultant shall carry out spot checks on analysis of results by laboratory staff.
Where these checks show incorrect procedures or analysis by any individual the following action
shall be taken:
a) further checking of procedures carried out by the individual concerned.
b) assessment whether error isolated or not.
c) correction of erroneous results.
d) guidance to individual on correct procedures as necessary.
10.6 Pour Inspection / Records
10.6.1 Procedure
For each concrete pour a full record shall be kept of details of the pour. These shall include: -
a) times of batching and placing

b) Admixture’s
c) slump test results at the batching plant & at the placing point
d) cube test results
e) curing record
f) post concreting inspections, cracks etc.
g) analysis of results.
10.6.2 Actions Pre-Pour

The inspection check list before pour approval (see Workmanship) shall be completed by the Site
Engineer's responsible for that part of the bridge construction and Filed Engineer as appropriate.
10.6.3 Actions During Pour

Inspection of batching, slump testing, recording times and quantities shall be carried out as
specified and logged on record sheets - see proforma in Chapter 19. In addition, each batch of
concrete shall be visually examined and if this shows any possibility of non-compliance then
additional slumps and cubes/beams shall be taken. These special tests shall be recorded but not
used as part of routine Q.C. record analysis.
Any non-complying concrete shall be rejected.
10.6.4 Actions after Pours

Records of curing inspections, cube results and slumps tests with means, standard deviations,
maximum and minimum shall be kept. Results of inspections for cracking, unsound concrete and
poor-quality finish shall also be record. Proformas for those records shall be prepared by the
Supervision Consultant and shall record compliance or noncompliance as the case may be.
10.6.5 Check on Actions

The Supervision Consultant shall ensure that the record keeping described above is maintained.

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-17) at Km. 91+000
God River, Km. 94+400 Kal River, and Km. 161+400 Choradi River in Raigad District in the State of Maharashtra on
EPC Mode.
11.0 WORKMANSHIP
11.1 Inspection of Work
The primary means by which quality of work in the field can be assured is by inspection in a
regular and systematic manner. The staff of the Supervision Consultant shall routinely inspect
work. Inspections shall be made irrespective of whether or not a Request for Inspection has been
made by the Contractor’s
Procedures & preformat shall be written for inspection of each category of the work. Staff of the
Supervision Consultant shall familiarize themselves with these procedures and carry out
inspections accordingly.
It is beneficial to the works if faults are identified early before rectification becomes difficult,
costly & delays progress. Therefore, irrespective of whether a Request for Inspection has been
submitted faulty work shall be notified as soon as possible to the Contractor. Written confirmation
should follow if no action is taken.
It is the Contractor’s s responsibility to ensure correct construction of the Works & he should
provide sufficient competent superintendence to achieve this. Care should be taken by the
Supervision Consultant’s staff not to communicate instructions or directives to the Contractor’s
operatives. Liaison should be maintained through the Contractors superintending staff.
11.2 Written Inspection Requests & Approvals/Rejections
For Quality Assurance to be achieved it shall be mandatory that Requests for Inspection and
Approval or Non-Approval of works are made in writing. This is the only way in which confusion
& dispute on these matters can be avoided and a smooth-running professional relationship can be
maintained between Contractor’s and Supervision Consultant’s personnel.
The use of written requests for inspection also provides an historical record of construction
sequence & events.
Requests for Inspection shall include the following information.
a) the part of the works required to be inspected

b) the category of works for which inspection is requested
c) the time the works shall be ready for inspection
d) the signature of the Contractor’s 's engineer making the request
e) the time of submission of the Request form
f) the signature of the Supervision Consultant’s staff member who receives the request (this
signature is for RECEIPT ONLY of the request
g) the time the inspection is completed
h) whether or not the works are approved
i) the reasons why work is not approved
j) the signature of the Supervision Consultant’s member of staff responsible for the inspection
k) the time of return of the Request form
l) the signature of the Contractor’s staff member who receives the Request form
The Request forms shall be submitted in quadruplicate, preferably colour coded, as follows: -

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-17) at Km.
91+000 God River, Km. 94+400 Kal River, and Km. 161+400 Choradi River in Raigad District in the State of
Maharashtra on EPC Mode.
Top copy, white - returned to Contractor’s after completion of inspection &

signatures
Second copy, yellow - retained by Field Engineer (Structures or Highways) of
Supervision Consultant
after completion of inspection & signatures
Third copy, blue - retained by Material Engineer of Supervision Consultant after
completion of inspection & signatures
11.3 Inspection Proformae
It is necessary for Quality Assurance to ensure that no aspects of workmanship are omitted from
an inspection. Therefore, proformas shall be produced for each category of work or stage of
construction.
These proformas may be linked to specific Requests for Inspection or simply used for routine
inspection. Proformas should be carried on site and completed during the inspection. For formal
inspections, the proformas shall be attached to the Request for Inspection for information of the
engineer authorized to sign the Request form.
11.4 Authority Levels for Inspections/Approvals
It is necessary that approval of permanent work is given only by engineers sufficiently

experienced in the relevant aspect of the work. Approvals by junior inexperienced staff shall not
be permitted until they are judged competent at that level by the Supervision Consultant.
The Supervision Consultant shall designate in writing to each member of staff his level of
authority with respect to approval of works. It is important to have sufficient suitably experienced
& authorized staff on the site so that formal approval is not delayed due to absence of particular
individuals.
Each member of the Supervision Consultants staff shall make himself familiar with his permitted
lavel of authority & where this is unclear shall seek clarification from his immediate superior or
the Supervision Consultant.
11.5 Records of Inspection
A very large number of Requests for inspection are normally generated in any large project. It is
necessary to establish and maintain a system of filling so that the records of inspection are easily
recoverable. Of the two copies of Requests for Inspection retained by the Supervision Consultant
one shall be filled in simple chronological order and the other under the heading of the relevant
part of the work.
11.6 Inspection Procedures
The inspections may be preliminary, periodic or on completion of work. These will have to be
carried out during various stages of construction. Check lists shall be followed to systemize the
inspection procedures. The inspection procedures of some categories of work are described in this
section. The Supervision Consultant’s staff carrying out inspections shall follow the procedures
described below.

11.6.1 Foundations
The preliminary, periodic & completion checks shall be made as described below and recorded on
proforma record sheets. Examples of record sheet are shown in Chapter 19. These examples do
not cover all the checks & records for which further proformas shall be prepared by the Senior
Engineer (Quality Assurance).
11.6.2 Formwork
Apart from considerations of site safety, properly designed and erected formwork is essential for
durability, serviceability and aesthetics of the permanent works. Failure are costly. Grout loss
creates unsound concrete. Excessive deflections lead to incorrect dimensions and poor
appearance. Poor quality formwork materials and workmanship cause unsightly finishes.
For Quality Assurance, the procedures described below shall be followed when checking and
approving formwork. The checks shall be carried out using the check list proforma given in
Chapter 19 on which the results of the inspection shall be recorded.
Formwork Drawings
Except for minor works as agreed by the Supervision Consultant formwork should be properly
designed, timber/metal stresses and deflections calculated and details shown on scale drawings or
sketches for the carpenters/joiners. These should be prepared by the Contractor’s and checked and
approved by the Supervision Consultant.
Formwork Erection
This should be checked against the approved sketches or drawings for correctness of line, level,
member sizes, spacing, grout tightness, tie rods, fillets, chamfers, cast in items (ducts, box-outs
etc) and material quality.
The check shall ensure that the form work will carry the imposed loads, form the concrete to the
desired shape and dimensions without loss of any constitute concrete material and produce the
specified finish.
Trial Panels
Where specified, trial panels shall be constructed to achieve specified finishes using the proposed
permanent work formwork. The trial panels must represent as closely as possible the real
permanent works, using approved mixes etc. The trials should be used to check such items as joint
details.
11.6.3 Reinforcement
Quality Assurance of reinforcement fixing is only achieved by methodical thorough checking.
Arrangements of reinforcement can be complex and concentration is necessary to ensure
comprehensive checking. Reference must be made to approved working drawings to prevent
omissions.
The checklist proforma shown in Chapter 19 shall be used and each item considered before
approval of works.

Reinforcing Bars Stockpiles
The stockpile of bars shall be organised in such a manner that separate deliveries are distinctly
labelled. Approved stock shall be kept separately from stock awaiting approval.
Drawing and Bar Schedules
Errors on drawings and schedules can be a major source of steel fixing problems. This can be
minimized by careful drawing and schedule preparation and checking.
Cutting and Bending
The bar bending and cutting equipment shall be checked to ensure correct radii of bends and no
damage to bars. It is essential to check that correct bending wheels are used to prevent overtight
radii and 'necking' of bars.
Bar Corrosion Treatment
If specified in the Contract Specifications, this shall be applied and checked after cutting and
bending and rechecked after fixing to identify and rectify handling damage. Checks shall be made
to ensure correct handling practices to minimize damage to protective coats i.e. non-metal slings
for lifting, careful stacking etc.
Bar Fixing
Size and spacing of bars, lap lengths, position of laps, provision of correct cover, sufficiency of
cover blocks shall all be carefully checked. The completed assembly shall be rigidly supported on
'chairs' and tied as specified. This shall be adequate to prevent deflections of the assembly under
action of the concrete gang live load, skip/pump discharge and so on. Flexible assemblies are
detrimental when deflections of reinforcement are transmitted to previously placed concrete in the
initial stages of setting.
11.6.4 Concreting
The procedures and preparation of concreting are complex with several elements all having to be
satisfactory at the same time. There is potential for mishaps and delay with consequent
detrimental effects on the permanent works. Thus, it is essential that all aspects are considered
carefully and all component activities are separately and collectively approved before concreting
begins.
Pre-Concreting Checks
a) Materials shall be approved; trial mixes carried out and approved mixes established.
b) Method statement - the Contractor’s should submit a detailed method statement for concreting
procedures. This should cover the following points:
o Batching plant, type and capacity

o Standby batching plant, type and capacity
o Truck mixers, numbers capacity
o Planned rates of pour and times from batching to placement
o Method of placing, crane and skip, pump etc.
o Standby crane, pump
o Concreting gang, standby steel fixers

o Carpenters, fitters, relief gang for long pour etc.

o Compaction/vibration equipment
o Sequence of pour to meet time constraints, prevent cold joints.
c) Checks at batching plant shall be made to ensure that sufficient stocks exist of approved
materials, that both the batching plant and standby batching plant are in full working order
and that the correct number of truck mixers in good working order are present.
d) Checks at the site shall include that falsework, formwork and steel fixing are approved, that
all concreting labour plant and equipment are ready, that standby plant and labour are present,
that access is arranged for trucks, that lighting arrangements have been made when necessary
and that curing arrangements are ready.
e) Before approval to concrete is given the checks described above shall be carried out and
recorded on the check list proforma example shown in Chapter 19.
Checks during Concreting
a) Batching and transport of concrete
In order to ensure that specified time constraints are met for placing batched concrete it is
essential to have a concreting record system whereby tickets are issued with each truck load
of concrete. These should record the following information:
o Ticket No.
o Truck No.
o Time of start of batching
o Time of completion of batching
o Quantity of water added
o Quantity & Type of admixture added if any
o Quantity of concrete batched
o Time of arrival of truck at site
o Slump test result both at batching plant & placement point
o Time of start of placement
o Time of finish of placement
o Whether cubes taken
The information shall be transferred onto pour summary sheets which shall thus show the full
concreting history of the pour.
Examples of proformas for concrete delivery tickets and pour summary sheets are shown in
Chapter 19.
b) Placing of Concrete
Inspection shall ensure that specified procedures are followed with respect to:
o depositing concrete i.e. not dropping more than height specified

o movement of skip to prevent high build up and segregation of concrete
o maximum layer thicknesses of deposited concrete
o not pushing concrete with vibrators
o correct vibration/compaction to remove entrapped air
o finishing /grooving
o curing

Inspection of shutters shall be made during concreting for grout loss and excessive deflection.
Checks After Concreting
a) Curing
It is most important for Quality Assurance of durability of the finished product after
placement that the concrete is cured properly. The purpose of curing is to prevent water loss
by evaporation from the wet concrete thus causing shrinkage cracking with consequent
detriment to durability and concrete cover protection to reinforcement.
Curing should be applied as soon as possible after finishing the concrete top surface. It should
be applied piecemeal to prevent areas being left exposed and drying out. The most rigorous
inspection of this item is required to instill correct curing practices.
Point to be ensured are :

o that curing arrangements are adequate before the pour is allowed to start that these
arrangements are made to cover 24 hours per day until the specified period (usually 7
days) has elapsed.
o that spot checks at all times of day and night are carried out.
o that if curing is not maintained, all further concreting approval is withheld until the
Supervision Consultant is satisfied with revised arrangements.
It should be noted that adequate curing is most difficult in hot, dry, windy conditions.
Alternate wetting and drying out of fresh concrete is severely damaging and must not be
allowed. If specified, concreting shall not be allowed when the calculated rate of evaporation
exceeds the specified limits.
Curing compounds are not to be trusted to ensure adequate curing. For these to work properly
all factors must be 100% satisfactory and this is very difficult to achieve. Problems result
from old stock, poor storage, mixing difficulties, loss of pigments on transfer from barrels to
dispensers, faulty sprays/dispensers, blocked jets and so on. Even in favorable conditions,
there can be wide range of performance of curing compounds.
The recommended curing practice is hessian covers constantly wetted with potable water,
aided by plastic / polythene sheeting to reduce the rate of evaporation. Timber battens to
secure covering are essential, especially in windy conditions.
Inspections shall be made frequently in the first 24 hours concreting for early shrinkage
cracking. This is evidence that curing is inadequate. Thereafter daily checks shall be made for
evidence of cracking.
An example of post concreting check proforma is shown in Chapter 19.
b) Finish
The standard of finish shall be inspected for compliance with the Specification.
c) Monitoring of Test Results
In order to prevent strength failures, the following procedure shall be followed:
1. The standard deviation, mean values, minimum strengths shall be plotted for the specified
numbers of results/time intervals against minimum specified values.

2. Trends shall be observed. Where a decrease in quality giving cause for concern but still
within specification becomes apparent the following action shall be taken:
o The Contractor’s shall be notified in writing of the facts and requested to investigate
the reasons for deterioration.
o The quality control of all the parts, placement times, methods etc. shall be examined
and possible causes of deterioration identified.
o The number of tests and inspections shall be increased.
o Appropriate measures shall be taken to restore the quality.
3. Where the strength fails to comply then the non-compliance procedure described in
Section 17.3 shall be observed.
11.6.5 Underwater Concreting
Method for concreting under water is well known and shall not be repeated here. Reference should
be made to specialist literature on this subject. For Quality Assurance of concrete placed
underwater the following procedures shall be followed.
Method Statement
The Contractor’s shall present a detailed method statement covering the following points:
a) Mix design
b) Method of placement
c) Sequence of placing with sketches
d) Verification.
Trials
The method of concreting underwater shall be the subject of a full-scale trial away from the
permanent works. This should entail two or more separate concrete deliveries to the point of
placement to simulate real delay time between batching. The trial shall be carried out so that
complete exposure of the pour is possible to allow close inspection in the dry of the finished work.
This should be broken up and the concrete examined for soundness and extent of cement washout.
Only on completion of satisfactory trials shall the method statement be approved.
Execution of Permanent Work
Care shall be taken to ensure that the approved method statement is followed exactly. On
exposure, careful inspection shall be made for soundness and extent of cement washing out. Any
areas of leakage indicate unsound concrete and consideration should be given to breaking out and
re-execution of this work.
Concrete batching, placing and slump records shall be kept as for normal concreting operations.

12.0 PROTECTION DURING CONSTRUCTION STAGE
In order to produce a quality end product, it is necessary to lay down procedures for preventing
any damage or deterioration of the various materials brought to site as well as the works partially
completed or fully completed till the completion of the entire job.
There procedures will have to be laid down in respect of the following:
a) Storage of materials, like, cement, rebars, aggregates, bitumen, emulsion, inflammable

solvents, etc.
b) Protection of the partially completed components of the road, both from the point of view of
structural stability and from the adverse effects of the environment, and temporary or early
opening.
c) Prevention of accidents to the structure as well as all personnel working on the project due to
incomplete work or works in progress and due to existing traffic.
If any deterioration is noticed in spite of protective measures, the same is to be certified before
taking up subsequent operations.

13.0 MEETINGS / SITE VISITS
Site review meetings are important events and of absolute necessity during project execution. The
meeting gives an opportunity to both the Contractor’s and Engineer/Engineers Representative to
meet each other in order to discuss various issues and to exchange view on the project
implementation for resolving the same in a mutually acceptable manner. It is also desirable that
the Authoritys Representative attends these meetings.
Meeting should be held periodically, preferably on a specific day of month and at a place based on
mutual agreement between the Authority/Project Director, Engineer/Engineers Representative and
the Contractor’s – Authority Engineer Consultant to discuss about project related issues but not
limited to the following salient points.
 Progress monitoring on total project - schedule V/s actual

 Quantity achievement of individual item of work - target V/s executed quantity Reason for
shortfall
 Constraints of Contractor’s
 Constraints of Engineer/Authority
 Outstanding issues arising from previous meeting
Immediate action shall be taken by the concerned parties with assistance from Authority wherever
necessary for resolving the issues which may have been the subjects in the meetings.
The minutes of review meeting shall be taken by Project Manager. The minutes of meeting shall
enlist the decisions taken and the actions required to be taken by respective personnel along with
the proposed date for action completion. It should be distributed to all the function participating in
the meeting and nominated ones for any specifications. The status of minutes of previous meeting
shall be taken up during the next subsequent meeting and the progress or delays to be assessed
and remedial suggestions taken.
During the project implementation stage site visits of dignitaries’ high officials of Government,
representative from funding agency etc generally takes place to review the progress, status,
bottlenecks, remedial measures, and action to be taken for the better interest of project.

14.0 QUALITY CONTROL STANDARDS AND REFERENCES
The detailed technical specifications, which are part of contract document, describes elaborately
the method of carrying out the works, material & quality requirements and the tests, if any, that
are to be carried out (with reference to appropriate MoRT&H, IS or IRC codes), and also specify
the tolerances and standards for acceptance / measurement of work. The following tables attempt
to present the gist of the above.
Table 1 – Tolerances in Surface Levels
+ 20mm
1. Subgrade -20mm
2. Sub-base
+ 10 mm
(a) Flexible pavement - 10 mm
3. Base-course for flexible pavement

+ 6mm
(a) Bituminous course - 6 mm
(b) Other than bituminous + 10 mm
Machine laid - 10 mm
Wearing course for flexible pavement + 6mm

4.
Machine laid - 6 mm
*This may not exceed 8 mm at 0-30 cms from the edges.
Table 2 - Maximum permitted number of Surface Irregularities
Surfaces of carriageways and Surfaces of laybys, service areas

paved shoulders and all bituminous base courses
Irregularity 4mm 7mm 4mm 7mm
Length (m) 300 75 300 75 300 75 300 75
National Highway 15 9 2 1 40 18 4 2
The maximum allowable difference between the road surface and underside of a 3 m straight-edge
when placed parallel with, or at right angles to the center line of the road at points decided by the
Engineer shall be
for pavement surface (bituminous and cement concrete) 3 mm

for bituminous base courses 6 mm
for granular sub-base/base courses 8 mm

for subgrade 15mm

Table 3 - Quality Control Program (for Soil & Material)
Item Construction Type of Test Frequency of Test Application Quality Standard Remarks
Item Standard
Initial Test  Embankment MDD / lab Sample low Low embankment less than 3 m
for approval  Subgrade Density (incorporated) - compaction height MDD = 15.2 kN/cum (min)
(borrow/cut  Backfill No. of samples as 1S:2720 (Part
soil) directedby - 7) Year
Engineer 1980
Heavy High embankment more than 3 m

compaction height MDD = 16.0 kN/cum (min)
1S:2720
(Part- 8) Year
1983
Subgrade MDD = 17.5 kN/cum (min)

Moisture Sample (incorporated) IS:2720 (Part
Content – No. of samples as – 2) Year
directed by Engineer 1973
CBR (only Sample IS:2720 (Part
subgrade) (incorporated) – No. – 16) Year
of samples as directed 1987
by Engineer
Sieve Analysis Sample IS:2720 (Part
(sand/grain (incorporated) – No. – 4) Year
context) of samples as directed 1985
by Engineer
Liquid Limit & Sample IS:2720 (Part
Plasticity Limits (incorporated) – No. – 5) Year
of samples as directed 1985
by Engineer

Item Standard
lab Quality  Embankment MDD / lab 2 per 3000m3 / Each low Low
Control:  Subgrade Density type to be tested,2 compaction embankment
Routine test  Backfill tests. 1S:2720 (Part height less than 3 m MDD = 15.2
during - 7) Year kN/cum (min)
construction 1980
Heavy High
compaction Embankment height more than 3 m
1S:2720 MDD = 16.0
(Part- 8) Year kN/cum (min)
1983
Moisture 2 per 3000m3 / 2 IS:2720 (Part
Content tests. – 2) Year
1973
CBR (only 1 per 3000m3/One IS:2720 (Part
subgrade) CBR test (average of – 16) Year
three specimens) 1987
Sieve Analysis 2 per 3000m3 / Each IS:2720 (Part
(sand/grain type to be tested,2 – 4) Year
context) tests. 1985
Liquid Limit & 2 per 3000m3 / Each IS:2720 (Part LL = 50 Max. PI = 25 Max.
Plasticity Limits type to be tested,2 – 5) Year
tests. 1985
Quality  Embankment  Field dry Embankment: Min 10 i) low i) Compacted to 95% of MDD / lab Acceptance
Control (in  Subgrade Destiny (FDD) pits / 3000 m² for compaction density (min) criteria:
field) during  Backfill  Core cutting each layer 1S:2720 (Part Mean value
construction method Subgrade: Min. 10 - 7) Year ii) Subgrade: Compacted to 97% of is not less
 Sand pits / 2000 m² (one 1980 MDD/lab density (min) than
replacement set) for specified

Item Standard
method each layer ii) Heavy iii) Backfill: Compacted to 90% of value plus:
 Nuclear Backfill: Min 10 pits / compaction MDD/lab density (min) [1.65 –
3000 m² for 1S:2720 (1.65/no. of
each layer (Part- 8) Year samples)
1983 (Latest ½)] times of
method) standard
deviation.
Moisture 1 no./ 250 m³ IS:2720 (Part
Content (Natural – 2) Year
moisture content) 1973
CBR (only for If required site CBR IS:2720 (Part Equal (or) more than Lab CBR By mobile
subgrade) carried out – 16) Year CBR
1987 equipment
Rockfill Gradation 1 no./ single layer of - - To confirm
embankment 500 mm thick the size of
rock material
to class 313.1

Table 4 - Quality Control Program (for Subbase & Base)
Item Construction Type of Test Frequency of Application Quality Standard Remarks

Item Test Standard
Initial Test Subbase / base Sieve Analysis IS : 2720 (Part - 4) Design Mix
for approval Liquid Limit IS : 2720 (Part – 5) Design Mix
Plastic Limit IS : 2720 (Part – 5) Design Mix
Moisture Control IS : 2720 (Part – 2) Max. 2.45 % Design Mix
Water Absorption IS : 2720 (Part – 3) Max. 2 % Design Mix
Soundness of Aggregate IS : 2720 (Part – 5) Max. 10 % Design Mix
California Bearing Ratio IS : 2720 (Part – 16) Max. 30 % Design Mix
Compaction Test IS : 2720 (Part - 8) Max. Dry Density Design Mix
Modified lab density)
lab Quality Subbase / base Compaction Test As Required. IS : 2720 (Part – 8)
Control: (Modified) lab density
Routine test Moisture Content 1 no./ 400 sq.m. IS : 2720 (Part – 3) Near optimum
during Moisture Content
construction Sieve Analysis 1 no./ 400 sq.m. IS : 2720 (Part – 4)
Liquid Limit 1 no./ 400 sq.m. IS : 2720 (Part – 5) LL = 25% Max. PI
6% Max. of material
passing 425 micron
sieve
Plastic Limit
California Bearing Ratio As required IS : 2720 (Part – 16) Min. 30%
Field Quality Subbase / base Field Dry Density 1 no./ every IS : 2720 (Part – 28) Compacted to 98%
Control Layer per 1000 of maximum dry
sq.m. density (as per IS:
2720 – Part 8)

Item Construction Type of Test Frequency of Application Quality Standard Remarks
Item Test Standard
WMM Base Agg. Imp. Value 1 no./ 1000 m³
Sieve Analysis 1 no./ 200 m³
Flakiness / Elongation 1 no./ 500 m³
Atterberg Limits 1 no./ 200 m³
Density of 1 no./ 1000 m2
compacted layer
Table 5 - Quality Control Program (for Bituminous Pavement)
Item Kind of Kind of Type of Test Frequency of Application Quality Standard

Material Material Test Standard
Material Bituminous Bitumen Quality of Two samples IS:73 Penetration Quality Certification from factory
Examination Wearing Bitumen per lot Grade S 65 or A 65
before the Course (60/70) or as per
work contract
Fine Aggregate Sieve Analysis IS: 2386 (Part-1)
Specific Gravity IS: 2386 (Part-3) Minimum 2.45% (Crushed Stone)
Water absorption 1 Number / 25 IS: 2386 (Part-3) Minimum 2% (Crushed Stone)
cu.m
Sodium Sulphate IS: 2386 (Part-5) Maximum 12%
Soundness Loss
Course Sieve Analysis IS: 2386 (Part-1)
Aggregate Specific Gravity IS: 2386 (Part-3) Minimum 2.45% (Crushed Stone)
Water absorption 1 Number / 50 IS: 2386 (Part-3) Minimum 2% (Crushed Stone)
cu.m
Abrasion Loss 1 Number / 50 IS: 2386 (Part-4) Maximum 30%
cu.m
Sodium Sulphate 1 Number / 50 IS: 2386 (Part-5) Maximum 12%

Soundness Loss cu.m
Job Mix formula Sieve Analysis 1 Number / IS: 2386 (Part-1) As per IRC para 507.3 Table 500-
(Mix Grading) 400 T 13
Minimum 2
Test per plant
per day
Bituminous Marshall 1 Number / Asphalt Institute As per IRC table 500-11 or 500 19,
Mix stability 400 T Manual MS-2 whichever is applicable
Minimum 2
Test per plant
per day
Bituminous Fine Sieve Analysis IS: 2386 (Part-1)
Base Coarse Aggregate Specific Gravity IS: 2386 (Part-3) Minimum 2.45% (Crushed Stone)
Water absorption IS: 2386 (Part-3) Minimum 2% (Crushed Stone)
Soundness Loss
Regular Bituminous Coarse Sieve Analysis IS: 2386 (Part-1)
Quality Wearing Aggregate Specific Gravity IS: 2386 (Part-3) Minimum 2.45% (Crushed Stone)
Control Course Water absorption IS: 2386 (Part-3) Minimum 2% (Crushed Stone)
Abrasion Loss IS: 2386 (Part-4) BM DBM BC
Los Angles 40 35 30
Abrasion value
Aggregate Impact 30 27 24
Value
Soundness Loss
Job Mix formula Sieve Analysis 1 Number / IS: 2386 (Part-1) As per IRC para 507.3 Table 500-
(Mix Grading) 400 T 13
Minimum 2

Test per plant
per day
Bituminous Marshall 1 Number / Asphalt Institute As per IRC table 500-11 or 500 19,
Mix stability 400 T Manual MS-2 whichever is applicable
Minimum 2
Test per plant
per day
Ordinary Wearing Asphalt Mixture Temperature Any Time Spreading Temp. Min. 110˚ C:
Quality Coarse and required Mixing Temp. 160˚ C, Rolling
Control Binder Temp. 80-100˚ C
Asphalt content 1 to 2 AASHTO T 170 Asphalt content (+/-) 0.3%
times/day
Gradation 1 to 2 IS: 2386 (Part-3)
times/day
Density Every 1,000 IS: 2386 (Part-3) Degree of Compaction 95%
sq.m.
Asphalt Asphalt Mixture Temperature Any Time Spreading Temp. (110˚ C)
Treated required Compaction Temp. (110˚- 160˚
Base Course C)
Asphalt content 1 to 2 AASHTO T 170 Asphalt content (+/-) 0.3%
times/day
Gradation 1 to 2 IS: 2386 (Part-1)
times/day
Density Every 500 IS: 2386 (Part-3) Degree of Compaction 95%
sq.m.

Table 6 - Bituminous Pavement Work Inspection Guideline
Item Inspection Items Remarks

Before Priming Check Compaction of Base Location,
Length,
Check for Preparation Works Lane,
Degree of Compaction,
Brooming of loose Materials
Confirm Elevation / Levelling of Base Variation from Design level of Surface,
Variation from Design Thickness of Base,
Surface Irregularity of 3m Straight edge,
Variation from Design Crossfall or camber,
Variation from longitudinal grade over 25 m length
During Application of Prime Check Tachometer Speed of Bituminous Distributor to be used during spraying of Prime
Coat Coat
Check Spray Bars Check Nozzles,
Check Bituminous Distributor Check Spray Width,
Check Hand Sprayer Attachment
Check Heating Device Check temperature of Bituminous materials
Check Flow Indicator Rate of Application of Prime Coat
Determine Quantity of Bituminous Material Rate of Prime Coat applied per unit area
Used
Check Weather Conditions Rate of Prime Coat applied per unit area
Before mixing and spreading Check Prime Coat Correct disturbed section
bituminous concrete Check Equipment’s Conditions Bituminous paver steel wheeled tandem roller pneumatic tired roller.
Plate compactor / hand tamper for small area
When batched bituminous Check Job-Mix Formula Grading (before Mixing & after mixing) at plant & site,
concrete arrives at the paving site Stability,
Flow,
Air Voids,
Aggregate voids fills with bitumen
Check Bituminous Batching Plant Weight / Hoppers / Scales,

Heating tanks for bituminous cement,
Aggregate dryers,
Conveyors,
Aggregate storage bins,
Temperature gauges,
Heating temperature of bituminous concrete and aggregate during
Mixing
Check Weather Condition No batching will be allowed during inclement weather,
No spreading of bituminous during rains
Check Temperature Bituminous concrete shall not be laid when it is too hot or too cold
Check Quality of Mix Homogeneity of Mix,

Luster,
Segregation,
Take samples of Marshall Stability Tests and specific gravity and
bitumen content
Check Surface to be Paved Surfaces should be thoroughly cleaned
Check Bituminous Paver Paver must be self-propelled mechanical spreading and finishing
equipment,
Adjustable screed,
Provided with full width roller / tamper,
Pavers should not leave ridges/indentation on the spread bituminous
concrete mix.
During spreading / paving with Check laying of material Laying bituminous concrete shall commence on lower side of roadway,
bituminous Edges of previously laid surface course shall be cut vertical and painted
with bituminous before laying the adjacent course,
During paving check Joints on upper layers shall be laterally displaced from the joint of the
compacion lower layer,
Correct course/segregated sections by blending with finer materials.
Check compaction of laid surfacing Compaction shall immediately follow after placing and from lower edge
to ridge laterally,
Initial rolling shall follow paver as close as possible,
Final rolling shall eliminate marks from previous rolling,

Rolling shall continue until minimum specified compaction is attained
and all surface movement has ceased,
Wherever newly laid surface is to be opened for traffic immediately,
ramps shall be provided at all the edges with slope not less than 1 in 10.
Checks to be done after Check elevation/levelling of laid surface Variation from design thickness of layer,
spreading and compacting course Variation from design level or surface,
the laid bituminous concrete Permitted surface irregularity,
Variation from cross-fall or camber.
Check Quality of laid surfacing Check Surface Texture Check segregated sections and course textured surfaces
Check thickness and density of laid Cut core samples on laid bituminous concrete to check thickness and
bituminous concrete density of laid bituminous concrete.
Application of tack coat Please follow item 2 – Application of Prime Please follow item 2 – Application of Prime Coat
(emulsified bituminous) prior to Coat
overlay of newly laid bituminous Check Weather Condition Tack coat shall never be applied when weather is foggy or rainy.
concrete
Laying of the second layer of Please follow item-4 - as Spreading /
bituminous concrete wearing Paving with bituminous concrete up to item-5
course - Checks to be done after spreading and
compacting the laid bituminous concrete.

3. Coarse Aggregate (i) Los Angeles Once for each source of supply and
Abrasion value or IS: 2386 Subsequently on monthly basis.
Aggregate Impact test (Pt.4)
(ii) Soundness IS: 2386 Before approving the aggregates and

(Pt.5) every month subsequently.
(iii) Alkali aggregate IS: 2386 - do -
reactivity (Pt.7)
Once for approval of source
4. Water Chemical Tests IS: 456 of supply, subsequently only
in case of doubt.
5. Concrete (i) Strength of concrete 2 cubes and 2 beams per 150m3 or part
IS: 516 thereof (one for 7day and other for
28day strength) or minimum 6 cubes
and 6 beams per day’s work
whichever is more.
(ii) Core strength on IS: 516 As per the requirement of the
hardened concrete Engineer; only in case of doubt.
(iii) Workability of fresh One test for each dumper load at both
concrete-Slump Test Batching plant site and paving site
IS: 1199 initially when work starts.
Subsequently sampling may be done
from alternate dumper.
(iv) Thickness From the level data of concrete
determination Pavement surface and sub-base at grid
points of 5/6.25 m x 3.5 m
(v) Thickness 3 cores per trial length.
measurement for trial
length
(vi) Verification of level String line or steel forms shall be
of string line in the case of slip checked for level at an interval of 5.0
form paving and steel forms in m or 6.25m. The level tolerance
the case of fixed form paving. allowed shall be +2mm. These shall
be got approved 1-2 hours before the
commencement of the concreting
activity.

Table 8 - Quality Control Program (for Structural Concrete)
Item Class of Kind of Type of Test Frequency of Test Application Quality Standard
Concrete Material Standard
Material M15, M20, Cement Quality of Cement 1 Number for each IS:269, IS:455, Quality Certification
examination M25, M30, source of supply IS:1489, IS:8112 from Production
before the work M35, M40 and IS:12269
and M45 Admixture Quality of Admixture Not contain calcium
chloride
Water Quality of Water IS:456 Not including salt,
acid, alkali, sugar, Veg.
Fine aggregate Sieve analysis IS:2386 (Part 1)
Specific gravity (bulk) IS:2386 (Part 3) Minimum 2.50
Soundness IS:2386 (Part 5)
Water absorption IS:2386 (Part 2)
Deleterious materials and IS:2386 (Part 2)
organic impurities
Coarse Sieve analysis IS:2386 (Part 1)
Aggregate Specific gravity (bulk) IS:2386 (Part 3) Minimum 2.50
Abrasion loss IS:2386 (Part 4) Maximum 30%
Soundness IS:2386 (Part 5)
Alkali aggregate IS:2386 (Part 7)
reactivity
organic impurities
Water absorption IS:2386 (Part 3)
Quality Control M15, M20, Cement Quality of Cement 1 Number for each IS:269, IS:455,
for field sample M25, M30, Admixture Quality of Admixture source of supply IS:1489, IS:8112 Quality Certification
M35, M40 and IS:12269 from Production
and M45

Quality Control M15, M20, Fine aggregate Sieve analysis IS:2386 (Part 1)
Source / Stack M25, M30, Specific gravity (bulk) IS:2386 (Part 3) Minimum 2.50
Yard M35, M40 Water absorption IS:2386 (Part 3) Maximum 2.0 %
and M45 Deleterious materials and IS:2386 (Part 2)
organic impurities
Quality Control M15, M20, Coarse Sieve analysis IS:2386 (Part 1)
Source / Stockyard M25, M30, Aggregate Specific gravity (bulk) IS:2386 (Part 3) Minimum 2.50
M35 and Abrasion loss IS:2386 (Part 4) Maximum 30%
M40 Water absorption IS:2386 (Part 3)
organic impurities
Alkali aggregate IS:2386 (Part 7)
reactivity
Field Quality M15, M20, Mix concrete Slump Upto 50 cu.m 1 IS:1199
Control M25, M30, Number / Every 10
M35 and cu.m. Above 50
M40 cu.m. 1Number
/ Every 50 cu. in.

CONTRACT NO:
NAME OF LABORATORY:
SUMMARY OF TESTS FOR CEMENT (CHEMICAL COMPOSITION)

(AS PER IS- 8112 / 1989)
Supplier /Manufacturer: Date of Sampling:

Source: Date of Testing:
Quantity (M. Tonne): Sampling By:
To be used in structure (name): Tested By:
Sl. Test Result Acceptable Limit

No.
1 Ration of percentage of lime to that of silica Not greater than 1.02 and not
alumina and iron oxide less than 0.66
2 Ratio of % of alumina to that of % Iron Not less than 0.66

oxide
3 Insoluble residue, %by mass Not more than 2
4 Magnesia, % by mass Not more than 6
5 Sulphur content, calculated as SO3, %by Not more than 2.75 When C3A
mass not more than 7%.
Not more than 3.0 When C3A is

greater than 7%.
6 Total loss on ignition Not more than 5%.
7 Total chloride content, % of mass of cement Not more than 0.05

(to be treated as per IS:12423-1988)
CONFORMS TO SPECIFICATION DOES NOT CONFORM
CONTRACTOR EPC CONTRACTOR AUTHORITY ENGINEER

CONTRACT NO:
NAME OF LABORATORY:
SUMMARY OF TESTS FOR HIGH ORDINARY PORTLAND CEMENT

(AS PER IS: 8112 – 1989)


No.
1 Fineness by BLAINE’S air permeability Not less than 3500
method as per IS: 4031 (Part 2), m²/ Kg.
2 Compressive strength as per IS:4031 (Part

6), Mpa :
a. 72 ± 1 hour Not less than 230

b. 168 ± 2 hours Not less than 330
c. 672 ± 4 hours Not less than 430
3 Setting time as per IS :4031 (Part 5),

minutes:
a. Initial Not less than 30

b. Final Not more than 600
4 Soundness (as per IS: 4031 (Part 3)):
a. Lechatelier method, mm 10 unaerated & 5 aerated

b. Autoclave method, percent 0.8
5 Total Chloride content % by mass of Not more than 0.05

Cement, as per IS: 12423 - 1988
CONFORMS TO SPECIFICATION DOES NOT CONFORM

CONTRACT NO:
NAME OF LABORATORY:
SUMMARY OF TEST RESULTS OF COARSE AGGREGATE

CONCRETE WORKS AS PER (PART – I) IS: 1963


No. (Maximum)
1 Grading
a) Individual aggregate sizes, 40/20/10 mm
b) After mixing as per Design mix formula graded aggregate
2 Coal and lignite (% by wt.) Max 1.0

3 Clay lumps (% by wt) Max 1.0
4 Material finer than 75 micron IS sieve (% by wt) Max 3.0
5 Soft flagments (Crushed aggregate) Nil **
6 Aggregate Impact (%)
Or
Aggregate crushing value (%) 30 for wearing surfaces &
45 for others
7 Aggregate Abrasion value (%) 30 for wearing surfaces &
50 for others
8 Soundness 12% in sodium sulphate
18% in magnesium
sulphate
9 Flakiness Index (%) As per specifications
10 Angularity Number As per specifications
11 bulk density/voids As per specifications
12 Specific gravity As per specifications
** 3% for uncrushed aggregate.

CONTRACT NO:
NAME OF LABORATORY:
SUMMARY OF TEST RESULTS OF SAND

FOR CONCRETE WORKS
(AS PER IS : 383/1970 AND IS : 2386/1963)
Sample No.: Date of Sampling:

Quantity of Aggregate (m³): Date of Testing:
Name of Quarry: Sampling By:

Sl. Test Result Acceptable Range

No.
1 Grading (zone) zone I, II, III
2 Bulk Density (Kg/m³)
3 Moisture content (%)
4 Percentage of bulking
5 Coal & lignite (% by weight) Max 1.0
6 Clay lump (% by wt.) Max 1.0
7 Material finer than 75 micron Max 3.0*
IS sieve (% by wt)
8 Shale (% BY WT.)
9 Soundness Max 1.0
10% in sodium sulphate.
15% in magnesium sulphate
10 Chloride content as CI (%)
11 Sulphate as SO 4 (%)
* 15% for crushed fine aggregate Remarks:

CONTRACT NO:
PLACE OF TESTS:
INSPECTION & TESTING BY:
SUMMARY OF TEST RESULTS FOR R.C. PIPES

(AS PER IS: 458 -1991 & IS: 3597 -1985)
Supplier/Manufacturers: Date of Tests:
Class of Pipe: NP 4
Sl. Tests/Checks Test Method Results Acceptable Range

No.
1 Dimensional Tolerances IS : 458-1991 As per Clause 7.2
a) Internal Diameter
b) Wall thickness
2 Water Absorption Tests IS: 3597 i) 2.5% for first 10 minutes

immersion
ii) 6.5% for 20 hrs immersion
3 3-edge bearing tests (load IS: 3597 As per Table-4 of

to produce 0.25 mm crack) IS:458-1988
4 Ultimate Load IS: 3597 As per Table-4 of

IS:458-1988
5 Hydrostatic Pressure Tests IS: 3597

6 Concrete Cube compressive IS: 516 20 N/mm² for 28 days
strength strength & 35 N/mm² for 28
days strength for pipe dia
above 1800 mm

CONTRACT NO:
NAME OF LABORATORY:
SUMMARY OF TEST RESULTS OF WATER

(AS PER IS: 3025 and IS 456)
Source/Location: Date of Sampling:

Date of Testing:
To Be Used In Structure No: ............... Sampling By:
Tested By:
Sl. Tests Results Permissible Limit (Maximum)

No.
1 pH Value Greater than 6
2 Chlorides, mg/1 2000 (PCC)

1000 (RCC) – for
structures of lengths 30
m & below
500 (PSC & RCC)
3 Sulphates, mg/1 500
4 Organic solid, mg/1 200
5 Inorganic Solid, mg/1 3000
6 Suspended Solid, mg/1 2000
7 Qty. of 0.1 normal NaOH to neutralize 200 2 ml

ml sample of water
8 Qty. of 0.1 normal NC1 to neutralize 200 10 ml
ml sample of water
CONFORMS OF SPECIFICATION DOES NOT CONFORM

CONTRACT NO:
NAME OF LABORATORY:
SUMMARY OF TEST RESULTS OF REINFORCEMENT HYSD BARS

(AS PER IS: 1786 (GRADE 415)
Supplier/Manufacturer: Date of Sampling:

DIA of BAR, mm: Date of Testing
Sampling By:
Quantity (M. Tonne): Tested By:
To be used in Structure (Name):
Sl. Tests Results Permissible Limit (Maximum)

No.
1 Weight in Kg/m As per IS: 1786
2 0.2% Proof stress/Yield stress, N/mm² 415 (min.)
3 Tensile strength, N/mm² 10% more than actual 0.2%

proof stress but not less than
485 N/mm²
4 Elongation, %, on gauge length 5.65 √A, 14.5 (min)

where A = Sectional area of test piece
5 Bend Test as per IS:1599 -1974
6 Rebend Test as per 1786
7 Deformations and Surface Characteristics as per IS: 1786
8 Chemical Composition as per IS: 1786
CONFORMS OF SPECIFICATION DOES NOT CONFORM

15.0 NON-COMPLIANCE PROCEDURES
15.1 General
In broad terms, for the Quality Assurance of the finished work it is necessary for the materials and
workmanship to comply with the Contract requirements. Non-complying work shall be rejected.
Strict vigilance will be provided by the Consultants on the quality of materials to be used for the
work and also on adequate measures to be adopted to avoid delivery of unsuitable materials. The
Consultants will order for removal or replacement of the unsuitable material brought to site by the
Contractor. The Consultants will perform work-tests regularly to ensure Quality and workmanship
during the process of construction of various items of work both in-situ and in the laboratory in
accordance with IRC/MoRT&H guidelines and Specifications and Contract provision and, if
found any part of work defective or substantial, will instruct the Contractor to rectify or dismantle.
The statement above is true in general terms but special difficulties arise in the case of concrete,
where the non-compliance may only be known after 28-day cube results. In these cases, removal,
re-execution or rectification of the work is usually difficult. Therefore, separate procedures are
laid out below for non-complying concretes.
For quality assurance of the finished work, it is necessary for the materials and workmanship to
fully comply with the work requirement. Non-conforming work has to be dealt with as per
procedures for dealing with non-conformities as per performa F1 of IRC: SP-57 -2000.
15.2 Works other than Concrete
15.2.1 Procedures
The procedure for acceptance of finished work for earthworks, formwork, reinforcement,
materials for concrete, pre-stressing and bridge finishing works are straightforward and shall be as
follows:
a) Regular and special testing, logging of results and inspections shall determine compliance or
non-compliance.
b) Any non-compliance shall without delay be notified to the Contractor. This shall be done both
verbally and in writing by the following means:
 Return of the Request for Inspection form signed "not approved" with the reasons for
rejection stated.
 Issue of a Site Instruction or Site Works Order or letter stating the facts and confirming
that the works are not acceptable for inclusion in the permanent works.
c) The Contractor shall be asked to state his exact proposals for rectification and it shall be
ensured that the faulty work is made good and retested or inspected.
15.2.2 Records
It is mandatory that all instances of work outside the Specification are recorded in writing to the
Contractor. This ensures that:
a) The Contractor is irrefutably informed.

b) A record of non-compliance is built up to give a general guide to the Contractors
performance.

15.2.3 Analysis
The Quality Assurance Manager shall summarise the following information for each category of
work:
a) The total number of inspections and tests.

b) The number of "first time" approvals i.e. the number of times the material or workmanship is
approved on the first test or inspection.
c) The number of second, third, fourth etc. inspections or tests of the same work required before
final approval.
d) The percentage of first time approvals, second, third etc. over suitable time intervals.
From the above information, the Supervision Consultant shall review the Contractors
superintendence and take action where necessary to improve matters.
From increases or decreases in the number of first time approvals, the improvement or
deterioration in Contractors performance can be monitored.
15.3 Concrete Works
The primary means by which Quality Assurance shall be achieved is by the procedures described
in Section 11.6.4 of Chapter 11.
15.3.1 Non-Compliance Other Than Strength or Finish

In the event that any requirement other than strength and standard of finish is not met then the
following procedure shall be followed:
a) The Contractor shall be notified without delay verbally and in writing by the following
means:
 Return of the Request for Inspection signed "not approved" with the reasons for rejection
stated.
 Issue of a Site Instruction or Site Works Order or letter stating the facts and confirming
that the works are not approved.
b) Approval to carry out concreting of a similar nature shall be withheld.
c) The Contractor shall be asked for his proposals to rectify the non-compliance which may
involve re-submission of materials, new trial mixes, revised method statement.
d) The acceptance or rejection of any unapproved concrete work shall be referred to the
Supervision Consultant.
e) When satisfied with the measures taken to ensure future compliance the Supervision
Consultant shall confirm approval to continue concrete for permanent works.
15.3.2 Non-Compliance with Strength Requirements

The Specification for concrete recognizes the statistical possibility of cube failures and thus limits
of means, standard deviations, minimum values of strength are specified. A single isolated
unsatisfactory cube result is not usually cause for rejection.
In order to provide assurance against strength failures the procedures described in Section 12.6.4
of Chapter 12 shall be observed. In the event of cube failures, the non-compliance procedures
described in the Specification shall be followed. Special situations, however, arise, such as,
strength of concrete, where non-conformance may only be known after sometime, e.g., after 28

days. Therefore, separate detailed procedures should be laid out for dealing with such non-
conforming concretes (Refer Proforma F-1 of IRC:SP-57-2000 for further guidance)
In addition the following procedures shall be followed:
a) Approval of concreting of similar works shall be withheld.

b) All aspects of concreting shall be reviewed.
c) The cause of failure shall be identified and measures taken to remedy the problem.
15.3.3 Non-Compliance with Finish Requirements

In order to prevent occurrence of unacceptable standard of finish the procedures for formwork and
trial panels described in Section 12.6.2 of Chapter 12 shall be followed.
Where the required finish is not attained then the non-compliance procedure described in the
Specification shall be followed.
In addition, the following procedures shall be followed:
a) Approval of similar formwork shall be withheld.

b) All aspects of formwork shall be reviewed.
c) The cause of poor finish shall be identified.
d) The procedures described in Section 12.6.2 of Chapter 12 shall be followed to establish
satisfactory finished.

16.0 QUALITY AUDIT
The Quality Assurance Manager of constructor and RE(QA) of Consultant shall objectively
evaluate the extent of compliance with the quality systems and their effectiveness. The audit shall
include the process and product quality audit as well as the assessment of adequacy of systems as
laid out in QA Manual.
The audit program shall assign qualified personnel to perform such audits and define the
procedures and frequency of audits, the method of reporting the findings and recommendations
and the means for corrective actions and their re-audit.
16.1 Programme
The Senior Engineer (Quality Assurance) shall establish, document and implement a programme
for audits which shall objectively evaluate the adequacy of the functions, systems and procedures
as referenced in this Manual.
The audit programme shall define:
1. the functions, systems and procedures to be audited

2. those personnel qualified to perform audits
3. frequency of audits
4. method of reporting findings and recommendations
5. the means for having corrective actions agreed upon and implemented
Audits shall include an evaluation of:
1. quality practices, systems, procedures and instructions

2. certification, documents and records
Audits shall be carried out by appropriately trained personnel who are not directly responsible for
the area being audited
Audits shall be performed in accordance with documented audit procedures and/or checklists
which identify essential characteristics.
Management responsible for the area audited shall review, agree, and correct deficiencies
revealed in the documented audited results. All actions taken to correct deficiencies shall be re-
audited to verify compliance and a close-out report issued.
16.2 Quality Audit Report
The scope and depth of the Quality Audits shall be determined by the Project Manager and Senior
Engineer (Quality Assurance).

17.0 PROFORMAE OF QUALITY RECORDS
The proformae are divided into different categories for Road Project and road bridges.
For Road Project
Category A: Planning Proformae

Category B: Inspection Proformae
Category C: Calibration Proformae
Category D: Surveillance Proformae
Category E: Proformae for Registers and Records
Category F: Proformae for Procedural Guidelines of QA System
For Road Bridge Project
Category A: Planning Proformae

Category B: Inspection Proformae
Category C: Surveillance Proformae
Category E: Proformae for Registers and Records
Category F: Proformae for Procedural Guidelines of QA System
Note: Different proformae according to the various categories mentioned above have been
referred from IRC Special Publication. These typical proformae have been adopted on some of the
work sites in India to have an idea of the format. The proformae are indicative and may be
modified, augmented or supplemented according to the needs of particular work. The typical
proformae for the road projects will be as per formats given on pages 53 to 100 of IRC: SP-57-
2000 whereas typical proformae for the road bridge projects will be as per formats given on pages
from 47 to 81 of IRC: SP-47-1998.
Some sample proformae is enclosed for ready reference.

FORM – 1
EXAMPLE OF TYPICAL REGISTER OF ISSUE OF DRAWINGS
Drawing Rev. Title Date Issued to No. of Status of Date

Number copies Issue Superseded

FORM - 2
EXAMPLE OF TYPICAL REGISTER OF RECEIPT OF DRAWINGS
Drawing Rev. Title Drawn Date No. of Status of For Date action Status of Date
Number By Received copies Drawings action Completed Drawing Superseded
Issue By

FORM - 3
DRAWING REGISTER/ISSUE RECORD
Project: Job No: Register Page: Sheet:
Drawing number prefix: Date From: Date To:
Drg. Title Size Revisions

No.
Issued to
Issue Date
Issue Codes
1 = Preliminary
2 = for Information Issued By:
3 = for Comment
4 = for Approval Date:
5 = Tender Drawing
6 = Construction Drawing Comments:

FORM -4
REVISION DETAIL FORMAT
Ref. SI No. Detailed Description of Revision Related Page No. Appd. Date
of Document Requirement Document
(Provide extra sheet if required)

FORM - 5
EXAMPLE OF TYPICAL REQUEST FOR INSPECTION FORM
Location:
Part of Works:
Category of Work:
Time Works ready for Inspection:
Remarks:
Signed: Request received:
Name: Name:
Time: Hrs. Date:
THE WORKS DESCRIBED ABOVE HAVE BEEN INSPECTED AND APPROVAL OF THE
WORK IS HEREBY GRANTED* / WITHHELD FOR THE FOLLOWING REASONS* :
(* Delete as applicable)
Received: Signed:
Name: Name:
Time: Hrs. Date:

FORM - 6
REQUEST FOR INSPECTION OF WORKS
Sr. No.
Sub Location:
Location:
Part of Works:
Category of Work:
Works ready for Inspection:
Remarks
Contractor Consultant
Request sent by: Request received by:
Time: Time:
Date: Date:
Signature: Signature:
THE WORKS DESCRIBED ABOVE HAVE BEEN INSPECTED AND APPROVAL OF

WORK HIS HEREBY GRANTED / WITH HELD FOR THE FOLLOWING REASONS:
Received Signed

FORM – 7
DESIGN & SUPERVISION CONSULTANT
SITE INSPECTION REPORT
To: Date:
Project Manager:
Package No.:
Item of Work:
Location:
Observation of Consultant:
Comments & Suggestion:
(if approval is asked for, write clearly approved or not approved showing reason)
(if used for any other purpose write Not Applicable, NA)
Signed: Signed:

FORM - 8
CHECKLIST FOR
SURVEILLANCE TO QUALITY
Sl. Description Views Remarks Action

No. taken date
A Embankment Fill / Subgrade
1 Checking receiving bed Ok Not Ok
Length Ok Not Ok
Width Ok Not Ok
Compaction Ok Not Ok
Clean Ok Not Ok
2 Approved material used on bed Yes No
3 Attained Specified Compaction Yes No
4 Line, Level, Grade Ok Not Ok
5 Physical Appearance of bed S NS
B Sub Base
1 Underlying bed ready for receiving sub Yes No
base material
2 Approved material used on bed Yes No
3 Blending of different ingredients Ok Not Ok
5 Layer Depth Ok Not Ok
6 Compaction Ok Not Ok
C Wet Mix Macadam

1 Sub base top ready for receiving WMM Yes No
Material
2 Approved mix material from plant supplied Yes No
3 General appearance of mix S NS
4 Homogeneity of mix S NS
5 Laying / Spreading mix on bed S NS
7 All ingredient present in mix Yes No
8 Layer depth Ok Not Ok
9 Compaction Ok Not Ok
10 Segregated patches present Yes No
11 Surface finish S NS
D Asphalt Paving Work

Before Priming
1 Check receiving bed
Length Ok Not Ok
Width Ok Not Ok
Base Compaction Ok Not Ok
2 Brooming loose material Yes No

No. taken date
3 Spray width Ok Not Ok
4 Cut back proportion Ok Not Ok
5 Weather S/H/W/CL
During Priming
1 Spray bar Ok Not Ok
2 Nozzle clear Yes No
3 Nozzle inclination Ok Not Ok
4 Heating device of distributor Ok Not Ok
5 Speed of distributor Ok Not Ok
6 Flow indicator Ok Not Ok
7 Rate of spray Ok Not Ok
8 Uniformity of Spray S NS
Before mixing ingredients
1 Check, plant, hopper, weight & scales,
heating tank, dryer, conveyor, storage,
tank, temp gauge
2 Temperature of aggregate, binder Ok Not Ok
3 Weather: Inclement – No batching
Ram - No spreading
During Laying
1 Check primed surface, equipment fleet
2 Correct disturbed section
3 Check Homogeneity of mix
4 Homogeneity of mix Yes No
5 Rolling operation, temperature S NS
6 Movement of matrix during rolling Yes No
8 Long & transverse joint cutting Yes No
9 Surface Texture S NS
10 Surface regularity S NS
11 Rolling continued till arrest of movement Yes No
12 Thickness Ok Not Ok
E Pre-Concreting Stage
1 Name of Structure
2 Structural Element
3 Concrete Grade
4 Proportion
5 Concrete Quantity (theoretical)
6 Cement Bag No.
Form Work
7 Type
8 Period of Retention
9 Line, Squareness Ok Not Ok
10 Level, Slope Ok Not Ok

No. taken date
11 Joints, Water tightness Ok Not Ok
12 Rigidity of Supports / Bracing Ok Not Ok
13 Surface Condition Ok Not Ok
14 Verticality  5 mm for 1.5 m ht
15 Substructure  20 mm for entire ht Ok Not Ok
16 Width in solid member (  + 5 mm) Ok Not Ok
17 Dia. In circular member (  - 3 mm) Ok Not Ok
18 Transverse Deck width (  ± 10 mm) Ok Not Ok
19 Overall Depth (  + 5 mm) Ok Not Ok
20 Thickness of Web, Bottom, Flange & Deck Ok Not Ok
Slab (  + 3 mm)
Concreting Stage
1 Starting time
2 Finishing time
3 Pouring time
4 Weather
5 Slump (Batch No.)
6 Cube (Batch No.) S/H/W/CI
7 Concrete Quantity (Actual)
8 Cement bag
9 Aggregate (Coarse / Fine)
10 Reinforcement
Post Concreting Stage
1 Pouring date / Shutter stripping date
2 Curing method / curing time
3 Class of finish S NS
4 Surface defect S/M/MJ
5 Cracks
6 Nature of Crack Yes No
7 Hair Line Crack (thickness) <0.2 mm >0.2 mm
8 Spalling Yes No
9 Alignment S NS
10 Level S NS
11 Dimension S NS
Descriptive answer enters in Remarks column
S = Satisfactory H= Humid W = Windy

CL = Cloudy M = Major NS = Not Satisfactory

FORM – 9
FORMWORK INSPECTION CHECK LIST
Location:
Contractors Inspection Request N˚
Contractors Drawing or Sketch N˚
1. Formwork drawing / Sketch approved

2. Trial panel approved (if required)
3. Shutter alignment correct
4. Shutter level correct, including screeds
5. Shutter dimensions correct
6. Primary formwork member sizes correct
7. Primary formwork member spacing correct
8. Primary formwork member material quality acceptable
9. Secondary formwork member sizes correct
10. Secondary formwork member spacing correct
11. Secondary formwork member material quality acceptable
12. Gaps between primary & Secondary members closed / wedged
13. Face boarding/plywood/metal thickness correct
14. Joints between panels closed (no gaps)
15. Joints between panels flush (no steps/lips)
16. Panels flatness acceptable
17. Gaps between secondary members & face panels closed
18. Tie rod material & sizes correct
19. Tie rod spacing correct
20. Tie rods tight, face cones flush
21. Box-outs, case-in items, ducts fixed correctly, securely
22. Prestressing ducts & vents, alignments & fixing acceptable
23. Prestressing anchorage positions, fixing acceptable
24. Chamfers/fillets sizes, straightness, fixing acceptable
25. Shutters clean
26. Shutter release oil material approved
27. Shutter release oil applied correctly
28. Construction joint preparation satisfactory
29. Contraction/expansion joint preparation satisfactory
30. Safe access constructed
31. Adequate work space provided for labour, equipment

FORM – 10
FORMWORK INSPECTION CHECK LIST
Location:
Contractors Inspection Request N˚ Dated

Reference Drawing Nos. Yes No N.A.
1 Working drawing checked and approved

2 Latest revision being used
3 Bar schedules approved
4 Reinforcing steel material approved
5 Bar bending & cutting satisfactory
6 Corrosion treatment of bars satisfactory
7 Bar size correct
8 Bar spacing correct
9 Bar lap lengths correct
10 Bar laps at correct locations
11 Bars tied as specified
12 Bar assembly rigid
13 Cover to bottom bars correct
14 Cover to side bars correct
15 Cover to top bars correct
16 Cover blocks approved

FORM – 11
REINFORCEMENT INSPECTION CHECKLIST
Location:
Contractors inspection Request No. Dated:

Ref. Drawing No. Yes No N.A.
1 Working drawing checked and approved

2 Latest Revision being used
3 Bar schedules approved
4 Reinforcing steel material approved
5 Bar bending & cutting material approved
6 Corrosion treatment of bars, if required, satisfactory
7 Bar sizes correct
8 Bar spacing correct
9 Bar lap length correct
10 Bar laps at correct locations
11 Bars tied as specified
12 Bar assembly rigid and adequately supported
(including spacers / chair supports)
13 Cover to bottom bars correct
14 Cover to side bars correct
15 Cover to top bars correct
16 Cover block approved including fixing
Inspected By: Name Signed Date

(for Contractor)
Approved By: Name Signed Date

(for Department)

FORM – 12
INSPECTION CHECKLIST BEFORE APPROVAL TO CONCRETE
Location:
Contractors inspection Request N˚ Yes/No or Checker

N.A. Initials
1 Method statement approved

2 Batching plant in working order
3 Standby batcher in working order
4 Water, sand, aggregate, cement approved
5 Water, sand, aggregate, cement stock sufficient
6 Truck mixers – number, working under satisfactory
7 Temporary falsework approved
8 Formwork approved (incl. prestressing ducts)
9 Reinforcement approved
10 Concreting plant & equipment in working order
11 Standby crane, vibrators present
12 Concrete gang present, incl. carpenter, steel fixer,
mechanics & electricians
13 Access provided
14 Lighting provided
15 Curing arrangements made
16 Laboratory notified

FORM – 13
CONTRACTOR
CHECKLIST
PRE-CONCRETING CHECK LIST
Sr. No.: Date:
Location:
Component of Structure:
Particulars Remarks
Yes No
Materials
1 Sufficient material available at actual position of concreting as
per requirement for the concerned quantity of concrete.
2 Material is to be used for concreting are tested and found
satisfactory as per following tests.
Water & Admixture:
a) pH
b) Chloride
c) Sulphate
Sand:
a) Gradation / silt content
b) Water absorption / Moisture content
Coarse Aggregate:
a) Gradation
b) % of water absorption
c) Mix design adjusted for actual values of moisture content &
water absorption & gradation.
Checked By: Approved By:

FORM – 14
CONCRETE BATCHING DELIVERY TICKET NO.
Date:
Location of Pour:
Class of Concrete: Truck No.:
Batching started: hrs. Batching Finished: Hrs.
Quality Batched: m³
Quality Water: lintre (gross)
Signed: Signed:
Name: Name:
CONTRACTOR EPC CONTRACTOR
Truck arrived on site: hrs

Slump test result(s): mm at hrs
Discharge Started: hrs
Placement Completed: hrs
No. of cubes taken:
Signed: Signed:
Name: Name:
CONTRACTOR EPC CONTRACTOR
Note: Tickets in quadruplicate:

Top copy - retained by Supervision Consultant after
placement 2nd copy - retained by Contractor after placement
3rd copy - retained by Supervision Consultant after batching
4th copy - retained by Contractor after batching

FORM -15
CONCRETE POUR RECORD SHEET
Date:
Start Time: Batching Plant: Pour Locations:
Lorry Number
Ticket Number
Grade of Concrete
Time Batched
Quantity Batched
Cumulative
Total Batched
Water Content
Slump/mm
(time tested)
Quantity Placed
Time Placed
Cumulative Total
Quantity Rejected
Reason Rejected
Cubes Taken
Concrete Temp
Remarks: Signed:
(Delays, Weather etc) Name:
Date:

FORM -16
CONCRETE WORK POUR CARD
1. STRUCTURE :
2. OCA TION :
3. GRADE OF CONCRETE :
4. QUANTITY OF POUR :
5. CEMENT REQUIRED :
6. WATER CEMENT RATIO :
7. FORM WORK :
8. REINFORCEMENT :
9. ADDITIONAL REINFORCEMENT IF ANY :
10. EMEDDED FIXTURES :

FORM -17
POST CONCRETING INSPECTION
Location:
Date of pour:
Date side shutter stripped:

Date soffit shutter stripped:
Curing: Method
Start Date: Finish Date :
Checks:
Date
S or NS
Whether
S= Satisfactory, NS=Not Satisfactory, D= Dry, R=Rain. H=Humid. W=Windy
Surface Defects : No defects Class of Finish:
Minor defects
Major defects
Non conformance report No.: Dated :
Cracks : No cracks:
Cracks: Date observed
Nature of cracks: hair1ine/<0.25mm/>0.25mm
Spalling : No spalling:
Spalling:
Cracking/Spalling Report No. Date:
Position/Dimensions: Alignment S or NS Non-conformance

Levels S or NS Report No.
Dimensions S or NS Dated:
Remarks:
Signed: Name: Date:

FORM -17
CRACKING / SPALLING REPORT
Location
Nature of the deficiency: Crack Spalling (Tick)
Sketch: (Indicate position/dimensions)
Inspected By: Date: Signature:
DEPUTY ENGINEER EVALUATION (Tick as applicable)
Not significant (use as is)
Structural or indeterminable origin - NCR to be raised
Date: Name: Signature:
QUALITY FOLLOW-UP
Non-Conformance Report No.: Name: Signature:

FORM -17
TEST RESULTS SUMMARY
Test No.: Mean: SD: Max: Min: Compliance

(Yes / No)
Slump (mm)
7 day (kg/cm²)
28 day (kg/ cm²)
Any non-compliance: Yes/No: Appr.
If yes - actions taken.
Signed
Name
Date
DATA TRANSFER
Data passed to structure record - Yes/No Date
Signed
Name

FORM -18
EXAMPLE OF TYPICAL TEMPORARY WORKS CERTIFICATE
Project:
Location:
Temporary Works for:
Temporary Works Drawing Nos:
(incl. Method statement)
It is confirmed that the temporary works shown on the drawings listed above have:
1. Been designed with the professional care by a qualified engineer in accordance with BS 5975
2. Erected in accordance with drawings listed above and approved method statement.
I am satisfied that the temporary works can now be loaded with a view to ensuring safety of personnel and
the well being of the permanent works.
Signed:
Name: (Contractors Temp. Works Engineer)
It is confirmed that the design, drawings, method statement and erection of the temporary works shown on
the drawings listed above have been checked with due professional care by a qualified engineer with a
view to ensuring safety of personnel and the wellbeing of the permanent works. Consent is given to load
the said temporary works.
Signed:
Name:
For EPC CONTRACTOR

FORM -19
QUALITY ASSURANCE MANUAL
FOUNDATIONS
Excavation
1. Required depth in metres

2. Shoring done
3. Dewatering required and pump capacity required
4. Availability of pumps Available / Not Available
5. Location of dewatering point
6. Dumping place for excavated material Fixed / Not Fixed
Formwork for Foundation
1 Materials required and position of availability Checked / Not Checked

2 Check formwork for dimensions, rigidity and accessibility for
foundations Satisfactory / Not Satisfactory
3 Check availability of required quantities of aggregates, Available / Not Available

cement, water for construction of foundations as per required
specifications
4 Check the quality of sand, coarse aggregates and cement as per Checked / Not Checked
specifications
5 Check that reinforcement is as per drawings and specifications Yes / No

6 Check concrete mix specified and design mix results Checked / Not Checked
7 Check concreting is as per specifications Yes / No
8 Check availability of concrete mixers of adequate capacity
9 Check availability of Vibrators Nos.
10 Check required no. of cubes for 7 days and 28 days tests are
taken Yes / No
11 Record any deviations and observations

FORM - 20
REQUEST FOR APPROVAL
Name of work: Embankment / Subgrade / GSB / WMM / BM / DBM / BC
Chainage: From To R.L.: From To:

Layer No. :
The above work has been executed as per laid down specifications of the contract & may be inspected and
approved. Supporting documents are enclosed.
Engineer
In-charge
Date: Contractor
Received by Supervision Consultant on
Engineer-in-charge
Consultant
The above work has been checked & found as under:
1. Quality of materials used in the work: ok / not ok

2. Horizontal alignment: ok / not ok
3. Longitudinal / transverse profile: ok / not ok
4. Surface evenness: ok / not ok
5. % Relative compaction achieved:
6. Remarks / discrepancy, if any:
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
7. Start of the next stage of construction: Yes / No
Engineer-in-charge
Consultant
Returned to the Contractor on

FORM - 21
CLEARANCE CARD FOR EMBANKMENT / SUBGRADE
Chainage: From To
Straight / Curve
Testing Carried out on Date:
Field dry density for Layer No: Panel Size

From To
1. Soil/ Murrum from approved borrow area : Yes / No

2. Existing G.L./ Embankment level recorded : Yes / No
3. Natural moisture content of the soil spread : %
(As against OMC = %)
4. Line, Grade, Profile, Thickness of Compacted
Embankment Layers (Indicate - Levels)
Chainage
Left Toe
Right Toe
5. Field - dry density determination: (lab MDD) = (gm /cc)

Average of tests : (gm /cc)
Compaction as per Specification : %
Relative Compaction Achieved :
6. Results: Satisfactory / Unsatisfactory
Communication to Contractor :
Start of next layer : Yes / No
Action taken by Contractor :

FORM - 22
CLEARANCE CARD FOR GSB / WET-MIX MACADAM
Chainage: From To Carriageway: Left / Right Date:
1. Moisture Content of the Mix: Optimum Moisture Content Layer No:
2. Whether Line Grade & Profile Checked: Yes / No
Chainage Top Width (m) R.L. at Left Toe R.L. at Centre R.L. at Right Toe
(m) Required Actual Required Actual Required Actual Required Actual
L.S. R.L. L.S. R.L. L.S. R.L.
3. Field Dry Density Determination Maximum Dry Density (gm/cc) Mean Field Dry Density (gmlcc)
Compaction Specified: Relative Compaction Achieved:
Communication to Contractor: Test Results: OK / NOT OK Start of Next Layer: Yes/ No
Whether the Service Crossing is checked: YES/NO
1. Telephone
2. Power
3. Effluent Line
4. Storm Water Drain
5. Others

FORM - 23
QUALITY ASSURANCE / QUALITY CONTROL LAB
DAILY PROGRESS REPORT
Chainage: Date:
Soil:
I] Field Test Report:

Field Density & Degree of Compaction Achieved (Emb > 95%, Subgrade > 97%, GSB > 98%)
Chainag Foundation / Layer Qty. MDD OMC Field Degree of Remarks

Embankment in for for M/C Compaction
/ Subgrade / Cu. M Borrow Borrow Achieved
GSB /WMM Soil Soil
Total Qty
for Day
Summary Embankment Sub- GSB WMM
grade
Qty. till
Yesterday
Total Qty
for Day
Qty upto
date
II] Lab Soil Test Report
Sample Near by Gravel Sand Silt LL PI MDD OMC CBR FSI Remar
Detail Chainage & ks
Clay
III] Weather Report:
Temperature Max: °C Min. °C Rainfall for Today mm
Cumulative Rainfall mm

FORM - 24
CLEARANCE CARD FOR DENSE BITUMINOUS MACADAM / ASPHALT CONCRETE
Date:
Chainage: From To Carriageway: Left / Right
Whether the mix is as per specification: Yes / No
Whether line grade & profile checked: Yes / No
Bench Mark R.L. Backsight H.L.:
Chainage Top Width (m) R.L. at Left Toe R.L. at Centre R.L. at Right Toe
(m) Required Actual Required Actual Required Actual Required Actual
L.S. R.L. L.S. R.L. L.S. R.L.
Whether the layer is approved: Yes / No
Instructions to the Contractor if any:

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-17) at Km. 91+000 God River, Km. 94+400 Kal River, and
Km. 161+400 Choradi River in Raigad District in the State of Maharashtra on EPC Mode.
FORM - 26
AGGREGATE CONSUMPTION REPORT
PLANT AND MACHINERY

Receipt Consumption Stock
Description W Hrs Hrs B/D Idle Hrs Production
For the Cumulative For the Cumulative (MT)
day day
River Sand
Cement
Admixture Dry
Rheobuild
CICO
300 R
Rheobuild 8501
SIKA - 286

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-17) at
Km. 91+000 God River, Km. 94+400 Kal River, and Km. 161+400 Choradi River in Raigad District in the
State of Maharashtra on EPC Mode.
FORM - 27
DAILY REPORT
Date:
Time:
Working Hours
Name of Plant
Sl. Remarks
/ Machinery Nos Run Break Down Idle Total Conc. Metal
Plant
1 ORU B.P. - I
2 ORU B.P. - II
3 Liebherr
4 PUG Mill
Machinery
1 WL Loader (H)
2 WL Loader
(ECC)
3 Dozer
4 L & T 580
Case
5 Transit Mixer
6 Dumper
7 Tatra

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-17) at Km. 91+000 God River, Km. 94+400 Kal
River, and Km. 161+400 Choradi River in Raigad District in the State of Maharashtra on EPC Mode.
FORM - 28
BATCHING PLANT - DAILY PROGRESS REPORT
THRU:- Date:- / /
Consumption of Materials in Kg
Completion
Description
Admixture
per m³
Metal Kgs
Unit Nos.
Concrete
Rate, of
Pour m³
Starting
Qty. m³
Average
Card
Concret
Time
Time
Sand
Lts.
Grade
Cement
No.
Cement
SI
/ hrs.
10mm 20mm 40mm
Pour
in kg
of
down down down C.S. R.S.
Cement stock inSilo unit No. A M.T.: This month total Qty. : M³
Silo unit No. B M.T.: This week total Qty. : M³
Total Cement Stock M. T. as on SECTION INCHARGE

Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-17)
at Km. 91+000 God River, Km. 94+400 Kal River, and Km. 161+400 Choradi River in Raigad District in
the State of Maharashtra on EPC Mode.
FORM - 29
CONSTRUCTION DETAILS
MATERIALS - LABORATORY TESTS
Results
No. of
Sr. Type of Test Failed &
Tests done Passed
rectified
1 Aggregate G-I
15 2389 (I) Grading
15 2380 (V) Flakiness
A.I.V.
2 Aggregate G-II Grading
15 2380 (I) Flakiness
A.I.V.
3 Aggregate G-III
15 2380 (I) Grading
Flakiness
A.I.V.
4 Sub-grade FDD
OMC & MDD /
sacked CBR
5 Inverted Choke - Grading
6 Binding Material - LL & PI
7 Excavated Soil- MDD / OMC /
FDD
Excavated soil CBR Shoulder
8 SDBC Grading
Flakiness
A.I.V.
Water Absorption
Bitumen Content
Stripping
Stability Flow
Quality binder
Rel compaction
9 Diversion Embankment Soil- FDD
10 Borrow Area LL/PI
OMC + CBR
N.M.C.
11 BUSG (Course key aggregate) Grading
Flakiness
A.I.V.
Sand Content
12 LBM & BM Grading
Flakiness
A.I.V.
B.C.

Results
No. of
Sr. Type of Test Failed &
Tests done Passed rectified
Stripping
Water absorption
Relative compactions
13 DBM Grading
Flakiness
A.I.V.
ECD.
Water absorption
Stripping
Stability Flow
Bitumen Content
Quality binder
Relative compaction
14 Embankment Shoulder / FDD
15 Raising FDD
16 Bricks Water absorption /
comp.
17 Aggregate Gradation (10 mm +
20 mm)
18 Sand Gradation
Finess modulus

FORM - 30
LAB AND FIELD TESTS
Laboratory and Field tests taken in the month of
Type of Test No. of Tests Corrective or Remedial Action

Pass Fail taken on failed tests
EarthWork Embankment
N.M.C.
Sieve Analysis
Proctor test
Field Density
LL / PL
C.B.R.
Earthwork Subgrade
N.M.C.
Sieve Analysis
Proctor test
Field Density
LL / PL
C.B.R.
Sub-Base
Gradation
C.B.R.
Field Density
LL / PL
Sieve Analysis
Proctor test
WMM
Gradation
PI of Binding Material
Flakiness Index
Concrete
Cube-Strength (28 days)
Agg. Gradation
Workability
Aggregates
Flakiness Index
A.I.V.
Water Absorption
Cement
Consistency
Initial Setting time
Final Setting time
Cube Strength (28 days)

FORM - 31
CALIBRATION REPORTS OF MAJOR TESTING INSTRUMENTS AND EQUIPMENTS
Sr. Description Accuracy Periodicity of Calibration Done by Date of Last

No. Calibration Calibration
1 Concrete compression ± 2 tons 12 months

testing machine.
Sr. No. 594
2 Electronic Weighing 1 Gm 12 months

Balance.
MIC No. 634
Capacity 5 kg
3 Wet Mix Plant 2% 6 months or as

Made by Condequip (I) required
Ltd.
4 Hot Mix Plant 1% 6 months or as

Made by Condequip (I) required
Ltd.
5 Measuring Tape 1 mm Before initial

use and every
12 months
6 Paint Thickness Gauge Before each

use
7 Pressure Gauge Every 2

months
8 Cube Testing Machine 6 months or as

required

FORM - 32
CALIBRATION OF SAND (As per IS 2720 Part 28)
Sample No: Date of Sampling:
Source of Sample: Sampled By:
Location: Date of Testing:
Lab Job No.:
OBSERVATION TABLE
Determination No.
S. No. Description
1 2 3
1 Weight of sand in cone
(of pouring cylinder) W2gm
2 Volume of calibrating container (V) cc
3 Weight of sand (+ cylinder) before pouring

W1 gm
4 Weight of sand (+ cylinder) after pouring
W3 gm
5 Weight of sand fill calibrating container
Wa = (W1-W3-W2) gm
6 Bulk Density of Sand Ss=Wa/V gm/cc
7 Average Bulk Density of Sand gm/cc

FORM - 33
Messrs
Site Testing Services
Date
Ref
TESTING REPORT
Materials for Concrete Page of
Contract Month
Fine Aggregate Type Source
Activity / Test Frequency Observations
Sampling
Sieve Analysis
Clay / Silt / Fine Dust
Clay / Silt / Fine Dust

(Field Settling)
Organic Impurities
Moisture Content
Storage Bins

FORM - 34
Messrs
Site Testing Services
Date
Ref
TESTING REPORT
Materials for Concrete Page of
Contract Month
Fine Aggregate Type Source
Activity / Test Frequency Observations
Sampling
Sieve Analysis
Organic Impurities
Flakiness Index
Moisture Content
Storage Bins

FORM - 35
PERMIT TO WORK ON
PLANT MACHINERY & OTHER POWER DRIVEN EQUIPMENT
Name of the equipment :
Area / Location :
Clearance required for : (Time) to on (Date)
Nature of the job to be done :
Requested by Approved by
Name Name
Designation Designation
Date & Time Date & Time
Equipment de-energized at (Time) (Date)
Fuses removed Yes / No

Circuit Breaker Lowered / Removed Yes / No
Danger Tag provided Yes / No
Earthling lead No Provided
Authorised Signature
Name:
Designation:
Time: Date:
--------------------------------------------------------------------------------------------------------------------------------
We have completed job on the above equipment and we certify that
1. The equipment is clear of all the men doing the job.

2. All tools and tackles have been removed.
3. Whole of the area has been cleared.
4. The equipment can be energized.
Name:
Designation:
Time: Date:
--------------------------------------------------------------------------------------------------------------------------------
Equipment Energised at (Time) (Date)
Earthing Lead No. Provided Yes/No
Name:
Designation:
Time: Date:

QAP-New Bridge Project - DRAFT

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Construction of Major High – Level Bridges across Panvel – Mahad – Panjim Road NH-66 (Old-NH-

QUALITY ASSURANCE MANUAL

CPM Critical Path Method

ISO International Organization for Standardization

Abbreviation & TOC i

2.1 Classes of Quality Assurance for Roads and Road Bridges................................................4

5.1 Drawing Registers.............................................................................................................30

6.1 Contract Monitoring..........................................................................................................34

Abbreviation & TOC ii

7.1 Survey Control Stations.....................................................................................................38

8.1 Temporary Works Procedure.............................................................................................40

9.1 Method Statement Procedures...........................................................................................43

10.1 Outline of Materials Procedures.......................................................................................46

11.1 Inspection of Work.............................................................................................................52

13.0 MEETINGS / SITE VISITS........................................................................................................................60

14.0 QUALITY CONTROL STANDARDS AND REFERENCES.................................................................61

15.0 NON-COMPLIANCE PROCEDURES......................................................................................................83

Abbreviation & TOC i

Table 1 – Tolerances in Surface Levels.......................................................................................................61

Quality Assurance Manual 1

1.3 Need for Guidelines on Quality Systems

1.4 Need for Quality Control

1.5 Pre-requisites for Quality Control

Quality Assurance Manual 2

1.6 Types of Quality Control

1.7 Quality Assurance and Quality Assurance Manual

It should generally cover the following:

a) Identification of all parties involved in QA and their inter-relationship.

Quality Assurance Manual 3

2.0 QUALITY ASSURANCE REQUIREMENTS

Classes of Quality Assurance Class Nomenclature

There will be four classes of QA for Highway/Road construction.

2.2 Guidelines for selection of QA class for Highway/Road bridge projects

2.3 Specifications for Work

Sl. No. Item High QA (Q – 3)

Quality Assurance Manual 4

Sl. No. Item High QA (Q – 3)

1.4 Survey equipment Electronic distance measuring equipment, auto

2 Design and Drawings

b) Cross drainage and other Project specific drawings made at pre-execution

c) Road furniture Project specific drawings made at pre-execution

3 Contractual Aspects (Contract Document)

b) Nominated Sub- Where required, to be specified in tender

b) Prebid meeting Preferable

Quality Assurance Manual 5

Sl. No. Item High QA (Q – 3)

Manufacture’s tests sample checks for initial

Record purchase dates, retain manufacturer’s test

Physical testing facilities at site, Special tests to

- Deleterious contents Mandatory for selection of source and whenever

- Aggregate reactivity Mandatory for selection of source and whenever

Quality Assurance Manual 6

Sl. No. Item High QA (Q – 3)

b) Fine aggregate At the time mix of design, stack change and at

Chemical analysis Mandatory at beginning and at start of working

Form of purchase, storage, Directly from factory to site godown or silos.

b) Dosage dispensing and Manufacturer’s data/certificate acceptable as

c) Training of site staff by Training of site staff in use as well as quality

Chemical composition Once at beginning and if in doubt for every

Quality Assurance Manual 7

Sl. No. Item High QA (Q – 3)

b) Use of mock-ups Required for certain elements of works (if)

Quality Assurance Manual 8