DFCC (Western Corridor, Phase-2) EXPRESS FREIGHT CONSORTIUM

Civil, Building and Track works in Vaitarana – Sachin Section

Package: CT P12 QUALITY ASSURANCE PLAN

Project Quality Assurance Plan

Table of Contents

1 Scope
1.1 General
1.2 Application
2 Normative References
3 Terms and Conditions
4 Quality Management System
4.1 General Requirements
4.2 Documents
4.3 Control of Documents
4.4 Control of Records
5 Management Responsibility
5.1 Management Commitment
5.2 Customer Focus
5.3 Quality Policy
5.4 Quality Management System Planning
5.5 Responsibility and Authority
5.6 Management Review
6 Resource Management
6.1 Provision of Resources
6.2 Human Resources
6.2 Resources Monitoring
7 Product Realisation
7.1 Proposed Quality System for Vendor & Sub Contractor Inspection
7.2 Proposed Material Management System
7.3 Inspection and Verification at Project site
8 Measurement, Analysis and Improvement
8.1 General
8.2 Performance Measurement
8.3 Non Conformance Control
8.4 Data Analyses
8.5 Improvement

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Scope (ISO Clause 1.0)

1.1 General
This Quality Assurance Plan (QAP) is developed on the basis of
requirements of Employer’s Requirements (ER) contained in Vol. – II of
Tender Papers and local conditions so as to provide adequate guidelines
for all parties involved to carry the works specified in the contract in a
planned and controlled manner that satisfies contractual and
Consortium requirements. The project quality assurance plan also
provides a system for managing, monitoring and recording of the
performance of the quality system.

1.2 Application
This Quality Assurance Plan (QAP) describes how M/s Express Freight
Consortium intends to manage the Quality Management System of
Desi gn an d Built Contra ct CT P 12 , for Vaitarana - Sachin Section, a
part of Western Dedicated Freight Corridor Project of DFCCIL.

This Quality Assurance Plan is based upon the guidelines and clauses of
ISO: 9001 -2008 Standards. The relevant Clause of ISO : 9001 – 2008
standards is written in parenthesis.
The Sr. Quality Manager is responsible to ensure all planned quality
assurance and control activities are implemented and completed by the
relevant Project team members.

2 Normative References (ISO Clause 2)

This QAP is developed based upon the following documents:
1. ISO:9000 -2005 Quality Management System – Fundamentals and
vocabulary.
2 . IS/ ISO : 9001 – 2008 – Quality Management System Requirements.
3 . Contract Documents – Vol- II, Appendix 7 of ER

3 Terms and Conditions (ISO Clause 3)

T h i s P r oj e c t Q u a l i t y A s su r a n ce P l a n i s d e v el op e d t o e n su re th e
f u l f i lm en t of Qu a l i t y S t a n d a r d s a s p er V ol - I I , A p p en d i x – 7 a n d
ot h er E mp l o ye r’ s Re q u i re men t s m e n ti o n ed i n T en d er P a p e rs .

4 Quality Management System (ISO Clause 4)

4.1 General Requirements
The System for managing quality on this Project is a part of the Project
Management System. The Project Management System interfaces
closely with the other functional systems on the Project and runs as a
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single integrated system.

The effect of this integrated approach is that there are many functions of
management with impact on quality that are covered in other and more
appropriate Project Plan and not duplicated in this Plan (e.g., for
procurement activities, it is more appropriate to document in the
Project Procurement Plan).

This Project Quality Plan is important but one of the suites of Project
Plans that covers all aspects of quality management on the Project and
the requirements of ISO 9001:2008.
Terms/Abbreviations used in this Plan
Env Environmental
ER Employer’s Requirements
ITP Inspection and Test Plan
Consortium Express Freight Consortium
MTC Manufacturer’s Test Certificate
NCR Non Conformance Report
OHS Occupational Health and Safety
PD Position Description
PDP Performance Development Planning
PMP Project Management Plan (this Plan)
QA Quality Assurance
QC Quality Control
SOP Standard Operating Procedures
TPI Third Party Inspection
WMS Work Method Statement

4.2 Documents
The quality management documents shall include:
a) Quality Policy and Quality Objectives
b) Project Quality Manual
c) Project Procedure Manual
d) Documents and Records required as per ISO: 9001 -2008.
e) MTCs, Lab. Reports, Test Results and MSDS.

4.3 Control of Documents

Documents required by the quality management system shall be controlled.
Records are a special type of document and shall be controlled according to the
requirements given in 4.4 of this QAP.

A Documented procedure shall be established to define the controls needed.

a) to approve documents for adequacy prior to issue,

b) to review and update as necessary and re-approve documents,

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c) to ensure that changes and the current revision status of documents are
identified,
d) to ensure that relevant versions of applicable documents are available at
points of use,
e) to ensure that documents are available remain legible and readily
identifiable.
f) to ensure that documents of external origin determined by the organization
to be necessary for the planning and operation of the quality management
system are identified and their distribution controlled, and
g) to prevent the unintended use of obsolete documents, and to apply suitable
identification to them if they are retained for any purpose.

Other specific procedure for this project as mentioned below shall be adopted:
(i) Holders of registered copies receive revisions to this document,
should they occur, with a request that the superseded copy be
destroyed. Registration of copies ceases once the final stage of the
project has reached PRACTICAL ACCEPTANCE. The revision
number is included at the end of the document number, which is
noted in the centre of the bottom of each page. When amendments
occur, the relevant section of the document is reissued with the
revision number updated accordingly.

(ii) Revisions are identified with a vertical “revisions’ line to the

right of the revised text.
Additions are shown in italics; deletions are hidden. Earlier additions
revert to normal text in subsequent amendments.

(iii) The Project Manager approves amendments by signature on the cover

sheet to the plan.

(iv) The System Administrator maintains a Register of the holders of this

Plan.
(v) Amendments to the Plan are distributed according to (i) above and
this is reflected in the Register.

(vi) The Project Manager keeps the original of the latest version of this
Plan.

4.4 Control of Records

Records established to provide evidence of conformity to requirements and of the

effective operation of the quality management system shall be controlled.

The organization shall establish a documented procedure to define the controls

needed for the identification, storage protection, retrieval, retention and
disposition of records.
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Records shall remain legible, readily identifiable and retrievable.

5.0 Management Responsibility

5.1 Management Commitment

Top management shall provide evidence of its commitment to the development

and implementation of the quality management system and continually
improving its effectiveness by

a) communicating to the organization the importance of meeting customer

as well as statutory and regulatory requirements,
b) establishing the quality policy,
c) ensuring that quality objectives are established
d) conducting management reviews, and
e) ensuring the availability of resources

The monthly meetings shall be held by Project Head with Quality Team and also
involving Construction Team to ensure the compliance of above said points

Top management shall ensure that

a) the planning of the quality management system is carried out in order to

meet the requirements given in 4.1, as well as the quality objectives, and
b) the integrity of the quality management system is maintained when
changes to the quality management system are planned and implemented.

5.2 Customer Focus

Top management shall ensure that customer requirements are determined and
are met with the aim of enhancing customer satisfaction (as mentioned elsewhere
in this Doc.)

5.3 Quality Policy

T h e Q ua l i t y P ol i c y of th e C on s o rt i u m P a rt n er M / s I R C ON
I N T E RN A T I O NA L L T D. ( An In d ia n P S U u nd er th e Mi n i st r y of
R a i l w a y s) i s p l a ce d a t A tt a c h m e n t No : 1 . T h e C on s o rt i u m i s
r es o l ved t o f ol l ow th i s Qu a l i t y P ol i c y.

I R CO N I NT E R N A T I ON A L L T D . – a p a r t n er of Ex p re s s F r ei g ht
C on s o rt i u m i s Q MS c er ti f i ed or g a n i sa ti on si n ce 1 9 9 6 a n d M / s
M/ s T ÜV S ÜD A s i a P a ci f i c i s ou r ce rt i f i ca t i on b od y a g a i n s i n c e
b e gi n n i n g.
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5.4 Quality Management System Planning(ISO Clause 5.4.)

5.4.1. Quality Planning
The Project Management System is developed specifically to
meet the Client’s expectations, based on the requirements of the
Contract. Such requirements also include identification and analysis of
risks and constraints.

Quality Planning focus on:

(i) Quality objectives and targets
(ii) Resources requirements
(iii) Develop and implement Quality Plans, ITP, WMS as required
(iv) Competency and training needs
(v) Inspection test plans and Work conformance/non Conformance
report during construction / installation activities
(vi) Maintaining Calibration register for measuring equipment
(vii) Site plant & equipment maintenance, damage investigation
(viii) Material Controls
(ix) Identify constraints and risks
(x) Meeting with Engineers / Sub-Contractors
(xi) Maintaining daily inspection progress reports
(xii) Quality toolbox induction and on job training for QA/ QC
personnel
(xiii) Internal Audit to check compliance with Project Quality system
(xiv) Continual improvement

5.4.2 Objectives and Targets

The Project Quality Team adopts the following for this Project:

Objective Strategy Measures

Ensure Use Internal quality audit Level 2 audit score >
Consortium process as a management tool 80%.
management to monitor the project
100% level 2 audit
systems are management system compliance
findings are closed out
consistently against Corporate requirements.
prior to the
implemented
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Objective Strategy Measures

across the Track the status of closing out subsequent audits.
business audit findings.
Focus on Manage Customer 100% Customer
customer complaints/ feedbacks Complaints/ feedbacks
satisfaction. through the Customer to be closed out within
time allotted.
Feedbacks Register.
Customer satisfaction
Implement customer survey to be completed
satisfaction survey on projects. at 50% and 100% of
project completion.
Ensure Control operational works Outstanding NCR’s
operational through approved plans, SOP’s, rate <
works are WMS’s, ITP’s, etc. 25% of total NCR’s
carried out in an Conduct Quality Talk and raised at the end of
efficient and implement each month.
effective manner. Quality Pocket Card System
Monitor the Complete Pre- qualification 100% pre
Subcontractors/ Process for all new major assessments carried
Suppliers subcontractors/ Suppliers out for new major
performance to which are not included in
subcontractors/
ensure their Consortium Master Preferred
services meet Vendor Register. Suppliers.
Consortium Carry out the quality 100% quality
quality standard inspections for Subcontractors/ inspections carried
and contractor suppliers. out as per project
Conduct the performance inspection schedule/
evaluation for major Quality assurance
Subcontractors/suppliers. plan / ITP.
100% performance
evaluation is conducted
for major
subcontractors/
suppliers at the time of
contract completion.
Progress of the above targets and measures are reported monthly in the
Quality section of the Monthly Project Reports.

5.4.3 Quality Team

The Quality Team on this Project is set-up in the overall organisation
structure for the Project. Only key positions are indicated. In general, the
Sr. Quality Manager is responsible for quality management of the Project.

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The positions may change throughout the life of the Project based on
situation and work requirements as determined by the Project Manager.
Such changes are reflected in a detailed organisation chart which is
produced and updated monthly for inclusion into the Monthly Project
Progress Reports.
The Origination Chart of Quality Deptt. is placed at Attachment No: 2

5.4.4 Project Constraints and Risks

5.4.4.1 Project Constraints
Constraints Controls

Control and supervision of sub- - Periodic Review and auditing

contractors work processes of sub- contractors
services/works/processes,
- Supervision of sub-
contracting personnel by
Consortium Supervisors and
Quality personnel

Supply and control of project - Materials inspections by

procured materials Consortium Quality personnel
or appointed TPI At supplier
Concrete ingredients premises
arrangements - On-site testing of supplied
materials.

Prevailing attitude & culture of Robust inspection and testing

subcontractors / suppliers regime.
towards quality - Extend awareness and
education programmes to
subcontractors / suppliers.

Limited coverage of QA / QC - Section Managers to be

Engineers responsible for quality in their
own Packages.
- Implement monthly audits andITP
verifications on all Sections
Heavy reliance on Construction - Robust inspection and testing
Team to conduct day-to-day regime.
- awareness & education
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Constraints Controls

inspections & testing programme to Construction team

Length of site allowing too many - Project Instruction on access &

access /egress points for material material control specific to
deliveries. individual Sections by Section
Managers

Interfaces with the Client’s / Identify on ITP & implement

Employer’s site representatives

5.4.4.2 Project Risks

Risks related to Quality management of this project have been identified in
the Project Risk Identification matrices. Controls to manage the identified
risks are documented in various sections in this and other related
Project Plans and System documents. These are referenced in the Project
Risk Identification matrices.
The Project Risk Identification matrices are restricted documents and for
internal use only. Copies are held by the Project department managers.
No copies are to be issued to any external parties without prior
permission from the Project Manager.
These matrices are reviewed and updated by the Project Manager monthly
in conjunction with the relevant Manager and included in the Monthly
Project Progress Report.

5.5. Responsibility and Authority (ISO Clause 5.5.)

The responsibility and authority assigned to each member of the Project
Quality Team by their respective superior is documented in their Position
Descriptions.
The Sr. Quality Manager is the Quality Management Representative for
the Project as defined in clause 5.5.2 ISO 9001:2008.
Assist the Project Manager in determining the quality Management
objectives and targets for the project. Liaising with the representative
of the client with respect to quality acceptance criteria. Establishing
and maintaining a system for the storage/retrieval of quality
assurance & control records and the associated updating of registers.

The Sr. Quality Manager is responsible to assign tasks to each member of

the Project Quality Team and the limits of the area to be covered by each
member. These may change from time to time as decided by the Sr. Quality
Manager as the Project progress. These assignments are reviewed and
handed out to the team by the Project Quality Manager during the
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monthly meetings.

Objective Strategy Measures

Maintain • Maintain ISO 9001 • No major NC
Management Certificate. raised by
System Certification. Certification Body.
• Identify root causes of
the NC’s and take • 100% close out of
actions to rectify the identified NC’s
issues while prevent within time frame.
them from recurring.
Enhance the Improve the 100% project
document control functionality and documents, identified
management process implementation level in Project Master
to ensure project key Documents Register,
of EDMS at projects.
documents are are upload
properly retained. Provide training to Project
Document Controllers to
enhance their skills and
knowledge
Capture and share Projects hold Lesson Projects hold Lessons
Company workshops to capture Learnt workshops at
experience/ good practices as well as 50% and 100% of
issues encountered during project completion.
knowledge to
the execution stage.
- Promote the
Projects send the complete
recurring of project lesson learnt
successful Registers and Project End
outcomes of Reports to Corporate at
the time of Project
completion.
- Preclude the Corporate Systems Team
repetition of to upload Project lesson
unsuccessful learnt Register and End of
events Project Report into
Knowledge Data Centre on
Consortium or IRCON
INTRANET.

1. PROJECT MANAGER
• Reports to Operation Director and intimating project progress timely
basis

• Full and final responsibility for the delivery of the Project in

accordance with the Consortium's Performance guidelines and the
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State Department expectations

• Liaise with the designated liaison manager to ensure they are kept up
to date on the issues and progress of the site.

• To identify appropriate resources (people, equipment, procedure and

processes) in order to provide the facility to implement the works.

• To establish and maintain the physical environment for HSSEC

(Health, Safety, Security, Environment and Community) in order to
meet specific group policies.

• To manage relationship with client and other key stakeholders in

order to foster a
Positive image and potential repeat business

• To manage the implementation of the works in order to meet the

budgetary and time
Expectations of the joint venture

• To foster an environment that provides opportunities and enables

development, Progression and succession internally, and have an
understanding of external (competitors) in order to provide sustainability
of the human resource assets in the Consortium

• Act decisively in emergency situations

• Overall responsibility for the execution of the project in

accordance with the requirements of the contract

• Responsibility to implement and maintain the Project Management

Plan for the processes Under his responsibility

• Conducts the project meeting as and when required.

• Promote an interest and enthusiasm within your required work for

health, safety and environment. Self-promote and lead on best practice
and act in accordance with the prescribed management system and
procedures in fulfilling an injury and incident free working environment

2. PROJECT CONSTRUCTION MANAGER

To be responsible for;

• Sub contractors overall performance and progress.

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• Keeping within budgeted costs

• The adequacy of resources employed

• Construction planning and working methods.

• Site safety and compliance with Project Safety Plan and all local
regulations

• Quality of works in accordance with the Design and Project Quality

Plan and to record non-compliance.

• Identification and reporting of design changes and modification

• All construction records, returns and forecasting.

• To ensure:

• Technology transfer is carried out effectively within local staff.

• The design of all temporary works is carried out and approved by

the Engineering Manager.

• Subcontracts are comprehensive in scope and detail and to ensure

consultation with QS staff in their preparation and negotiation.

• The costing of the construction is monitored at all times and

reported in line with Contract Policy and that all opportunities are
taken to minimize cost.

• All relevant notifications to the client are delivered in the current form
and within the necessary time frame.

• Acquaint construction staff with their duties, responsibilities and

what is expected of them.

• To monitor performance, identify deficiencies and initiate both training

on and off site for the development of junior staff employed in consultant
with the Project Manager.

• Ensure close liaison with Section Managers at all times to optimize

use of plant and labour resource.

• Maintaining professional relationships with clients and engineers.

• Prepare/ Produce End of Contract Report or other reports as required.

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• Other duties as directed.

3. DIRECTOR / SHE

• Advise the Project management team on:

• Preventing injury to personnel and damage to plant and equipment.

• Further improvement in existing sound working methods.

• Legal requirements affecting safety, health, welfare and environmental.

• Provision and use of protective clothing and equipment.

• Potential hazards on new contracts before work starts and on

the site safety organization.
• New developments in methods of safe working.
• Carry out site surveys in association with the project management
team to ensure that only safe methods of working are in operation
and that all regulations are being observed.
• Determine the cause of any accident or dangerous occurrence and
recommend means of preventing recurrence.
• Conduct safety induction for all Project and subcontractors’ employees
on the Project’s
• OH&S requirements.
• Manage/carry out the safety training of all levels of employees on the
Project.
• Promote awareness of injury prevention and damage control to all levels
of employees.
• Provide feedback on new policies or procedures adopted.
• Keep up-to-date with recommended codes of practices and new safety
literature and circulate information applicable to each level of staff.
• Functional reporting to the Regional Quality and Safety
Manager on Safety
• Performance of the Project to comply with Regional Procedures.
• Fulfill the role of Safety Officer required in the OH&S Act.
• Supervise the recording and analysis of information on injuries,
damage and loss, assess accident trends and review overall safety
performance of the project.

• Assist the Project QA/E Manager in carrying out environmental

inspections and monitoring.
• Maintain contact and relationship with officials and professional
bodies.
• Supervise the work and performance of the Safety Officers and other
subordinates, as designated.
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• Assist in the development and maintenance of Consortium systems.

• Other duties as directed.

4. SENIOR QUALITY MANAGER

To liaise with construction management to ensure all inspection and

testing requirements are well planned and implemented at site to meet the
Quality Standards so that completed work quality is achieved in order to
meet client’s requirement as per the contract.
• To liaise with client’s representative to ensure all inspection and testing
requirements are fulfilled and complete work quality is achieved in
order to meet client’s requirement as per the contract

• To ensure all records are completed and compiled for submission to

client with regards to completed work quality in order to meet client’s
requirement as per the contract.

• To liaise with construction team to ensure quality of

products/supplies/services by sub- contractors meet the specified
requirement at source with regard to completed work quality in order
to meet client’s requirement as per the contract

• To coordinate the implementation of the Consortium Management

System through the implementation of the project quality plan in
order to meet the Consortium’s internal policies and certification to
international standards.

• To liaise with construction team to ensure all inspection and testing

requirements are fulfilled and completed work quality is achieved in
order to meet client’s requirement as per the contract.

• To liaise with client’s representative to ensure all inspection and testing

requirements are fulfilled and complete work quality is achieved in
order to meet client’s requirement as per the contract.

• Ensure that the quality system is fully established, implemented and

maintained at all levels in line with the requirements of the Project
Quality Plan

• Implement and maintain a Management Information System

that measures the effectiveness of the quality plan

• Maintain a quality audit programme and carry out internal and external
quality audits

• Report the performance of the quality system to the Project Director for
review
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• Ensure that the quality plan is promptly amended when

improved practices are identified

• Coordinate activities of the Construction Quality Control and Design

Quality Assurance Teams

• Ensure that the materials quality control programme is carried out as

required in the
Specifications and Project Quality Plan

• Verify, confirm and certify conformance of the materials, finished

product and testing requirements of the contract and the Project Quality
Plan

5. QA and QC MANAGERS

• Quality Assurance Manager responsible for Process Related Quality

Assurance and In-charge of Site Testing Laboratory. To ensure
preparation of all the work methods as required by the contract and
corresponding inspection & test plans and formats. To ensure all the
tests are conducted in laboratories (internal & external) as per
standards and integrity of results is maintained. Also to conduct
required surveillance audits and periodical internal quality audits.

• Quality Control Manager responsible to ensure quality in ‘Product

Related’ activities at Site. To supervise and manage the material (raw
materials only) acceptance, handling, storage, material & constructions
and fabricated items testing as per frequency mentioned in QAP, and
ensuring conformity with specification regularity standards and
inspection test plans. To ensure proper workmanship in construction
various processes. Also to conduct required surveillance audits and
periodical internal quality audits, at Sites.

Both Quality Assurance Manager and Quality Control Manager will

report to Senior Quality Manager.

6. QA MANAGER

• QA Manager to be responsible to control, review and maintain quality

system documents within the Management System a n d i n L a b . Also
acts as controller for the distribution of all controlled documents
associated with the Project Management and Material Testing System.

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• Assists Project Management, Sr. Quality Manager and Sr. Q/A

Engineers in developing and implementing quality assurance system
and matters relating to the quality assurance, method statements, work
procedures and testing of materials.

• Monitors the implementation of the quality systems and facilitates

continual improvement initiatives to the systems.

• Ensures all lab. employees are aware of the quality requirements in

their designated duties.

• Facilitates training and development of staff in quality assurance

management related fields.

• Liaise with Design Consultants Project Team to ensure all works are
certified as accepted.

• Reports to Sr. Quality Manager on quality assurance management

performance and material testing reports.

7. QC MANAGER

• QC Manager to be responsible to control, review and maintain

quality system documents within the Management System at
Project level and at Site.

• Assists Construction Management, Sr. Quality Manager and Sr. QC

Engineers in developing and implementing quality control system
and matters relating to the quality control, method statements, work
procedures and routine testing at site.

• Monitors the implementation of the quality systems and facilitates

continual improvement initiatives to the systems.

• Ensures all employees at site are aware of the quality requirements in

their designated duties.

• Facilitates training and development of site staff in quality

management related fields.

• Liaise with QC Engineers of Sub-cons and their staff to ensure all

works are carried out as per quality control procedures.

• Reports to Sr. Quality Manager on quality control management

performance and frequency and results of field testing.

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8. PROJECT LOGISTICS MANAGER

• Reports to the Project Manager

• Implement Project Logistics Plan for all logistics requirement

• To assist to order reoccurring consumables at minimum stock level in

order to maintain consumable stock and ensure consumable stock is
in working condition. Also ensure hindrance free availability of PPE
and other safety gadgets.

• Responsibility for the timely and orderly execution of all plant and
materials on site as required under the contract

• Manage sub-cons and supply contracts for plant supervise and

coordinate activities of subcontractors and suppliers for such works

• Ensure all work being undertaken is conducted in a safe manner.

• Drive daily work production on assigned work front.

• Ensure all Store & Plant personnel are working in accordance to the
correct logistics documentation for the project.

• Coordinate with Area Managers with their daily material requirements

• Train the local work force with a view of improving its skill levels by:
increasing efficiency, its ability to undertake work safety, and raise the
standard of quality of the finished work produced.

• Ensure all work being undertaken is to high standard of finish

9. INTERFACE MANAGER

• Management of permanent Mechanical & Electrical works

design consultant(s) to ensure permanent works deliverables
complies with project requirements and with technical &
commercial contractual requirements.

• Expedite authority approval of permanent works MEP design.

• To liaise with procurement and engineering staff to ensure the

selection of material that meet budget and specification in order to
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ensure approvals are obtained from client

• To manage engineering team in the production of shop

drawings and installation method statements in order to meet
the project program with regards to installation works

• To manage engineering staff in the selection of subcontractors

that meet budget and specification in order to obtain pre-
qualification from the client

• To check parameters such as scope of works and material quantities

for the permanent works to ensure both contractual
requirements and estimated quantities are not exceeded.

• Liaison with Section Managers to ensure efficient communication,

immediate response to design/construction related queries and
timely transfer of drawings/documents.

• Ensure design changes are effectively coordinated.

• Solution of design problems relating to permanent MEP works design

elements.

• Liaison with Design Consultant(s), Subcontractors and Vendors

and participation in design coordination meetings and design
review meetings.

• Arrange for the necessary approval of permanent MEP works

materials by the appropriate design consultant(s) and Client.

• Monitoring of costs associated with permanent MEP works designs.

• Preparation of biweekly and monthly progress report documentation.

• Liaison with in-house planning section regarding monitoring of

the progress of the design relating to the contract programme.

• Participate in Value Engineering in accordance with project

procedures.

• Review and verification of permanent works deliverables in

accordance with project procedures.

• Adherence to design programme.

• Participate in auditing of design Consultants.

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• Comply with all Project Management Plan requirements applicable

to this position description.

10. PROJECT SENIOR ENGINEER

• To plan, supervise; coordinate all temporary and permanent works

design and Design Consultant activities in order to ensure compliance
with relevant engineering requirements and also with technical and
commercial contractual obligations

• To coordinate and ensure the quality of the works including

procurement of material (permanent and temporary works) in a
timely manner in order to ensure construction continues as
scheduled.

• Preparation of Bill of material, Purchase Requisition etc.

• To ensure project program is updated on a regular basis IN ORDER

TO update master program.

• To obtain approval for statutory authorities, clients, technical

representatives from other organization on the project site (design
consultant) in order to ensure approvals are obtained in a timely
manner.

• To provide system installation at site & commissioning

• Vendor Management

5.6 Management Reviews (ISO Clause 5.6)

As the Project runs on an integrated system, review of the quality
system is carried out as part of the review of the overall Project
Management System.

Other reviews are also carried in the monthly quality meeting with the
Project Quality Team

Reporting and Meetings

All Project Quality M a n a g e r s ( b o t h Q A a n d Q C ) , a l l q u a l i t y

Engineers submits a weekly report to the Sr. Quality Manager. The format
of these weekly reports is determined by the Sr. Quality Manager based on
the data required to enable him to analyses the performance of the
quality system on the field and to compile his report for inclusion into the
Monthly Project Report.

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The required information of Quality section s h a l l b e s u b m i t t e d f o r

Management Review, monthly. However, Sr. Quality Manager may include
additional information as he sees fit or required by the Engineer. This
report is submitted to the Project Manager.
The Sr. Quality Manager calls for meetings at least once a month with his
team as a forum to discuss problems encountered/anticipated and to
disseminate critical information. This Meeting minutes are distributed
to all concerned departments and quality team members for necessary
action.

Facilities: The Project Manager in conjunction with the Sr. Quality

Manager ensures the Project Quality Team is provided with adequate
facilities to perform their assigned tasks properly. Such facilities include
the temporary site facilities mentioned in Project Construction Plan.

Where provision of such facilities is not possible or impractical, the Sr.

Quality Manager out-sources the required services (e.g., laboratory)
in conjunction with the Project Manager.

Monitoring of Inspection and Measuring Equipment: The Sr. Quality

Manager identifies all monitoring and measuring equipment required
by the Project Quality Engineers and Surveyors for verifying conformity
of the Works to the specifications and arranges for them to be procured as
required.

These equipment are not included in those mentioned in Project

Construction Plan.

6. Resource Management (ISO Clause 6)

6.1 Provision of Resources

For timely completion of project with desired Quality Standards the required
resources shall be arranged by the Project Head including
a) to implement and maintain the quality management system and continually
improve its effectiveness.

6.2 Human Resources

For assuring and controlling the quality of works, documentation, process control
and product control and realisation the required manpower shall be engaged.

The organisation chart showing the deployment of Key Official pf

a) Design Team is placed at Attachment No: 3.
b) Construction Organisation
(during Design Stage) is placed at Attachment No: 4.
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c) Construction Organisation
(after Design Stage) is placed at Attachment No: 5.

6.2.1 Resources Monitoring

Should at any time during the project, the Sr. Quality Manager consider
resources inadequate for the work to be done, the perceived inadequacy is
discussed with the Project Manager to determine a solution.

6.2.2 Competency, Training & Awareness

In addition to the formal performance appraisal system and subsequent

training needs identification, the Sr. Quality Manager also assess on-the-
job the competency of his team members. The Sr. Quality Manager
determines the type of training required and arranges for the training as
and when planned by HR section. Such training can be in the form
of external, internal or on-the-job courses.

As minimum, the following types of training must be completed.

Topics Type of training

(as a minimum)
Project Management System Induction

Usage of Inspection & Test Plans Briefing

Daily work briefing Briefing/Toolbox meeting

Safe work practices Briefing/Toolbox meeting

Welding & Rigging –Safe & Good
Briefing/Toolbox meeting
Practices
Material Handling and Installation
Briefing/Toolbox meeting
– Good Practices
Awareness of ISO 9001:2008
Internal/External course
requirements

Writing procedures Internal/External course

Internal Quality Auditing Internal/External course

Lead Auditor (optional) External course (IRCA-

approved)

All trainings are managed according to Project Procedure o n

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Training

The first 6 training topics listed above are also extended to the
subcontractors responsible for the various trades identified. The Project
Quality Manager in conjunction with the Project Manager ensures the
subcontractors attend these trainings.

7.1 Proposed Quality System for Vendor & Sub Contractor Inspection (ISO
Clause 7.4.1)

Pre-Contract Evaluation
i. Non-preferred Subcontractors or Suppliers shall complete Pre-
qualification Questionnaire. The prequalification questionnaire will be
reviewed by commercial manager and concerned managers (i.e.
Operations Manager, Quality Manager & SHE Manager etc.).

ii. The Subcontractors/Suppliers will submit their quotations after their

Pre-qualification Questionnaire are approved by Commercial Manager.

Performance Evaluation
Quality Manager in consultation with Procurement Manager shall develop
and maintain the Subcontractors / Suppliers Audit Plan to review
subcontractors / Supplier performance.

The audit / Inspection frequency is defined as below:

Major Contract with the duration more than 6 months
 15% of work completion
 50% of work completion
 100% of work completion (Final Evaluation)

Major Contract with the duration less than 6 months

 50% of work completion
 100% of work completion (Final Evaluation)

Minor Contract
 100% of work completion (Final Evaluation)

Final Evaluation shall be conducted once the subcontractors/Suppliers

complete their work prior to settlement of Final payment.
Proposed Quality System for interfaces with the monitoring of external
inspection agencies will be accordance with proposed procedure for
interfaces with and monitoring of external inspection agencies.

7.2 Proposed Material Management System (ISO Clause 7.4.3)

Consortium adopts QMS (Material Management System) to Control project
materials from procurement process till the materials issued to site.
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QA software’s Materials Management System is a fully integrated system for

managing all phases of the material management process, from Bill of
Material through to receipt in store and issues to the field. It is designed to
handle large volumes of data and enable the management of change to be
carried out quickly and effectively.

QMS uses a Stock Code library to define a catalogue of stock codes used on
a project. Uses of a stock code library minimize one of the main sources of
error in the material control process. The QMS system is made up of a
number of elements, each of which addresses a particular area of the
material control process.

Stock Code Library

Bill of Materials (BOM).

Inquires (Requisitions)

Bid Documents

Purchase Orders

Shipping

Expediting

Material Deliveries

Material Movements

Material issues

Materials Availability Analysis

Stock control.

7.3 Inspection and Verification at Project site (ISO Clause 7.5)

In order to complete the project successfully meeting the Client’s

requirements, it is necessary to map out the process or task and identify
the inspection or test point, the responsible person, and the record to
demonstrate compliance.

i. Inspection and Test Plans (ISO Clause 7.5.1)

Inspection and Test Plans serve as a checklist specifying at what

point of the process certain inspection or/and test would be
required, the frequency and the person responsible for the inspection
and testing, acceptance criteria and type of records required.

All these planned inspection and testing are derived by correlating

requirements from the Construction Programme, Contract
specifications, Work Method Statements, construction/shop
drawings and industrial standards.

Inspection and Test Plans (ITP) shall be developed and

controlled a n d d o c u m e n t e d . In-Process Inspection and
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Testing. It is required that all Supervisors responsible for the

activities as per ITP to sign on the ITP to indicate having read and
understood the requirements.

Appointed subcontractors are requested to submit their own ITP or

QA Plan for review by the Construction Team and the Project
Quality Manager. Where the subcontractor is unable to produce
ITP or where submitted ITP does not meet the requirements, the Sr.
Quality Manager decides whether to assists the subcontractor in
amending the ITP or issue Consortium-produced ITP for their use.

Any interfaces with the Client/PMC/TPI representatives with

regard to joint and/or acceptance inspection must be included in
the ITP to ensure these are carried out. HOLD points are included
into the ITP only when it is required contractually. Additional hold
points requested by the Client/PMC/TPI must be agreed with the
Project Manager.

A briefing is held whenever an ITP is issued for all

engineers, supervisors and subcontractors involved to explain the
usage of the ITP as well as to highlight any issues identified. This
briefing is called by the Project Quality Manager and conducted
by the originator of the ITP or other nominated person by the Project
Quality Manager.

ii. ITP Verifications (ISO Clause 7.5.2)

To ensure a most robust inspection and testing regime, verification is

carried out to ensure the personnel responsible are implementing
the planned inspection and testing so effectively and in timely
manner.

The Project Quality Manager is responsible to identify the area

and activity, plan, and assign personnel to carry out the
verification activity. The frequency depends on the criticality of the
activity, but generally, this is carried at least once a month for all
Packages.

Site Quality Engineer/Inspectors are nominated to undertake the

verification activities as per approved ITP by client. Further hold or
witness point activity related to Client TPI/PMC shall be intimated
or notified prior to the activity commencement and to ensure
their presence is there for necessary witness/hold point clearance as
per approved ITP. The verifying site Quality Engineer/Inspector is also
rotated with regards to the assigned activity or area.

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Conformance Reports are completed and submitted to the Project

Quality Manager for review and coordinate any further action
required.

iii. Laboratory Testing (ISO Clause 7.6)

As the testing frequency is very minimal and impractical, the tests

will be conducted in an approved independent third party laboratory.
All test results from the laboratory testing are kept with Sr. Quality
Manager who then forward them to the relevant manager for any
action necessary.

The Sr. Quality Manager is also responsible for ensuring that all
equipment or external laboratories used for testing are calibrated and
adequate. Verification visits are also carried out on any appointed
external laboratories on a regular basis to provide continuous
confidence in the reports submitted by these laboratories.

8. Measurement, Analysis and Improvement

8.1 General

The organization shall plan and implement the monitoring, measurement

analysis and improvement processes needed.

a) to demonstrate conformity to product requirements,

b) to ensure conformity of the quality management system, and
c) to continually improve the effectiveness of the quality management system.

This shall include determination of applicable methods, including statistical

techniques, and the extent of their use

8.2 Performance Measurement (ISO Clause 8.2)

Auditing (ISO Clause 8.2.2)

The implementation and effectiveness of the Project Management
System is verified by conducting periodic audits.

Level 1 – Project or Site Quality Audit (Self Audit)

Sr. Quality Manager is responsible to conduct the QMS Level 1 Audit

at-least once per month. Standard Level 1 Audit Checklist is to be
used as a basis to conduct the audit.

Records of the Quality Audit are to be submitted to the Project

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Manager and Construction

Manager. Project Level 1 Audit Scores are reported in Quality Monthly
Report.

Level 2 – Cross Audit against Project Management Systems and ISO 9001
requirements. These Audits focus on compliance of the Project /
Business Unit Management System with ISO 9001 and Consortium
requirements. Internal Audits are categorized to 2 levels shall be
conducted by HQ Quality Team.
The CVs. of HQ Audit team including their experience, authority and
methods of audit shall be submitted to the Engineer for review before
carrying out quality audits.

The programme of HQ team shall be informed to the Engineer so that

the Engineer’s representative may witness the audit.

The Internal Quality and SHE Audits shall be conducted at maximum

six months intervals. The HQ Quality Team shall prepare a QMS
Audit Programme for the project – main offices, branch offices and
site offices and sites Following each audit a final report shall be
prepared within 7 days, by the Lead Auditor and distributed to
Project Manager, Dy Project Manager and Sr. Quality Manager and
Director / SHE.

Audits are conducted & reported. Quality Audits and subsequent

improvement actions addressed for necessary action. The Quality
Manager nominates the auditor(s) for those audits be scheduled for
the Project.

Level 3 - In case, Engineer requires quality audits on the Consortium or

it’s any Sub-con / Vendor to be carried out by his representative or
the Employer’s staff, then the Consortium shall afford to such
auditors all necessary facilities and access to the activities and
records to permit this function to be performed.

Upon receipt of corrective action request (CAR) or similar document

issued by the Engineer as a result of quality audits, the Consortium
shall promptly investigate the matter and submit the proposed
corrective and preventive actions within 14 days to the Engineer for
review. The Consortium shall take timely corrective and preventive
actions to rectify the matter and to prevent re-occurrence. Evidence to
demonstrate effective implementation of corrective and preventive
actions shall be submitted by the Consortium to the Engineer for
review.

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8.3 Non Conformance Control (ISO Clause 8.3)

If the Engineer issues any nonconformity report or similar documents to

notify the Consortium of any item of the Works which does not conform
to the requirements of the Contract, then the Consortium shall promptly
investigate the matter and, within 14 days of notification by the
Engineer, submit to the Engineer for review the remedial measures and
necessary actions to be taken to rectify the item and to prevent re-
occurrence.
Also the Non-conformance s h a l l b e identified, reported by Quality
Team and the Construction Team shall rectify according to
Project P rocedure and Conformance Reports.

Coordination and maintaining an actual potential quality non-

conformance control system including the issuing of NCR reports to
the Project Manager and ensure corrective and preventive actions are
implemented effectively. Raising Non Conformance Reports (NCR) is
not solely by the Project Quality Team. The Project Construction
Team is also responsible to raise NCR according to Project
Construction Plan.

The Consortium shall maintain and update a nonconformity register to

indicate the status of all nonconformities which are identified by the
Engineer / and or our Quality Team. This Register shall be submitted
for review upon request by the Engineer.

The Sr. Quality Manager is responsible to perform the analysis of non-

conformances and Conformance Reports and include the analysis
into his Monthly Project Report.

8.4 Data Analyses (ISO Clause 8.4)

Various data are collected and analysed as indicators of the

performance of the quality management system. Such data includes
the following.

• Objectives and targets for the Project Quality Dept.

• Audit findings

• Non Conformance

The Sr. Quality Manager collates the data collected from the various
sources as set out in the procedures and coordinates with the
department as action arising from these analyses. These are
reported in the Monthly Project Report.
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The above list does not include technical data for measuring quality
level of finished work; like concrete cube results, soil compaction
results, material testing, etc. These are tracked and compiled
separately as per the relevant ITP.

8.5 Improvement (ISO Clause 8.5)

8.5.1 Continual Improvement

The Consortium shall continually improve the effectiveness of the quality

management system through the use of the quality policy, quality
objectives, audit results, analysis of data, corrective and preventive actions
and management review.

8.5.2 Corrective Action

The Consortium shall take action to eliminate the causes of

nonconformities in order to prevent recurrence. Corrective actions shall be
appropriate to the effects of the nonconformities encountered.

A documented procedure shall be established to define requirements for:

a) reviewing nonconformities (including customer complaints)

b) determining the causes of nonconformities,
c) evaluating the need for action to ensure that nonconformities do not
recur,
d) determining and implementing action needed,
e) records of the results of action taken (see 4.3 & 4.4), and
f) reviewing the effectiveness of the corrective action taken.

8.5.3 Preventive Action

The Consortium shall determine action to eliminate the causes of potential

nonconformities in order to prevent their occurrence. Preventive actions
shall be appropriate to the effects of the potential problems.

A documented procedure shall be established to define requirement for:

a) determining potential nonconformities and their causes.

b) evaluating the need for action to prevent occurrence of nonconformities.
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c) determining and implementing action needed,

d) records of results of action taken (see 4.3 & 4.4) and,
e) reviewing the effectiveness of the preventive action taken

8.6 Lesson Learnt

The Lesson Learned provides the instructions for how actions

arising from the reviews to be dispositional.

The Sr. Quality Manager is responsible to coordinate with the relevant

Manager(s) to ensure the action are closed and documented. Such
documented corrective and preventive actions are included into the End
of Project Report for the benefit of future projects.

*** END OF MAIN DOC. ***

9.0 ATTACHMENT & ANNEXURE

9.1 Attachments to this QAP

1. Attachment No: 1 Quality Policy Page 1
2. Attachment No: 2 Origination Chart of Quality Deptt. Page 1
3 Attachment No: 2.1 Origination Chart of HQ Audit Team and
CVs of Team Members Page 5
4. Attachment No: 3 Origination Chart of Design Team Page 1
5. Attachment No: 4 Construction Organisation
(during Design Stage) Page 1
6. Attachment No: 5 Construction Organisation
(after Design Stage) Page 1
7. Attachment No: 6 Flow Charts for Earthwork, Blanketing,
RMC and Rebar Works Page 4

9.2 Annexure with this QAP

1. Material Inspection and Test Plan Page 26

2. Manufacturing Quality Assurance Plan Page 7
3. Site Quality Assurance Plan_and_
On Site_Off Site Testing Arrangement Page 19
4. Site Testing procedures and Site Quality Control Formats Page 85

SP://Project Quality Assurance Plan _ Rev R2 Page 29 of 29

 ORGANISATION CHART FOR QUALITY MANAGEMENT, CONTRACT CT P12 ATTACHMENT No: 2
PROJECT HEAD
Overall In-charge

Director / SHE Project Quality Interface Manager Project Logistic Manager

Deptt.

Sr. Manager/
Quality

Vaitarana - Vapi Sec. Vapi - Sachin Sec.

Lab at PALGHAR Lab at ANCHELI

QA Manager QC Manager QA Manager QC Manager

{Process {Product Related {Process {Product Related
Related and and at Site} Related and and at Site}
at Lab} at Lab}

Sr QA Engr-I Sr QA Engr-II Sr QC Engr-I Sr QC Engr-II Sr QA Engr-I Sr QA Engr-II Sr QC Engr-I Sr QC Engr-II

Lab Staff Lab Staff

QC Engr- I QC Engr- II QC Engr- I QC Engr- II QC Engr- I QC Engr- II QC Engr- I QC Engr- II

LEGEND
Name of Post
Name / Name of Employee.
Type of
Designation in Parent Company

Status
R2 Mar 07, 16First Issue after Inception
 ATTACHMENT No: 6

Flow Chart of Earth Work

Activity Sequence of Control Documentation

Input Work Points

Selection of B/A Selection of Borrow Area Borrow area chart

Testing
No. of blows Lab density & OMC
MDD,
Lab test Not Ok & MC
OMC

OK
Dumping of Soil & Dozing Layer Thickness Layer chart
Dumping of soil in layers

Watering up to +/- OMC

Sprinkling water OMC Moisture content register

Compaction Compaction No. of passes

Field testing Not Ok

Checking of
Test Format
layer

Scrap up to 15 cm
Scraping

Re-grading &
Watering

Compaction
Ok

Checking of Test Format

layer

Out put Go for next activity

 Flow Chart of Blanket Material

Activity Sequence of Control Documentation

Input Work Points

Selection of B/A Selection of Blanket Material Borrow area chart

Testing
No. of blows Lab density & OMC
MDD, PI,
Lab test Not Ok & PI
LL,

OK
Dumping of Blanketing Thickness
Dumping of material material & Dozing

Watering up to +/- OMC

Sprinkling water OMC Moisture content register

Compaction Compaction No. of passes

Field testing Not Ok Checking of

layer & GV2 Test Format
test
Scrap up to 15 cm
Scraping

Re-grading &
Watering

Compaction
Ok

Checking of Test Format

layer

Out put Go for next activity

 Flow Chart of RMC

Activity Sequence of Control Documentation

Input Work Points

Preparation of Mix design Approved Mix design & Borrow area chart
working drawing

Selection & collection of

materials Quality of Agg.
& cement type

Lab test Not Ok Check Grading Lab test Report

Quality of Type of cement MTC of cement
materials Admixture MTC of Admixture

OK
Calibrate Plant &
Calibration of Plant correction of moisture Computerized report from plant

Preparation of mix as per mix Mix design

Mixing of material design & discharge in TM

Casting of cubes at plant

Casting cubes at plant No. of cubes Cube register

Transportation of concrete Temp.

Timing Pour Card

Pouring Pouring of concrete & cast

cubes as per code No. of cubes Cube register

Compaction Compaction of concrete & curing

Checking
Not Ok Cube register
Strength of
Lab test
cubes
Corrective action as
required
Ok

Deshuttering of sides Deshuttering & curing

 Flow Chart of Rebar

Activity Sequence of Control Documentation

Input Work Points

Issue of approved drawing Working drawing

Preparation of Bar Bending

Preparation Schedule Bend & L BBS

Not Ok
Checking of Length
Checking BBS

OK
Cutting, Bending &
Cutting & Placing Placement of bars as per Spacing
drawing with proper cover

Checking of
Checking bars & Nos., Spacing Pour Card
cover & Cover

Out Put
Reinforcement
ready for concreting
Compaction

Cube register
Lab test

Deshuttering of sides Deshuttering & curing

 ANNEXURE - 1

DFCC Project, Contract CT P-12 MATERIAL INSPECTION AND TEST PLAN

Inspection by and Type of

Remarks
Inspection
Sr. Inspection, measuring and Records to be
Material / Activity Frequency of Testing Reference Standard Specification limit for acceptance Responsibility
No. test equipment maintained
Consortium Engineer

A FORMATION WORKS

I Existing Ground Test

1 Ev2 Values 1 test per KM Stretch DIN : 18134 - 2001 > 20MPa Plate Load Test Setup Site In charge Lab test result W R

2 Undrained Cohesion Test (Cu) 1 test per KM Stretch IS: 2720 - 1993 Part X > 25 KPa Triaxial Test Site In charge Lab test result W R

N-Value
3 1 test per KM Stretch IS: 2131 -1981 >5 SPT Apparatus Site In charge Lab test result W R
(Standard Penetration Test)

II Soil Embankment - Material (borrow area)

5000 m³ or change of strata which

1 Natural Moisture Content IS:2720-1973 Part - II As per code Rapid Moisture Meter Site In charge Lab test result W W
ever is earlier

5000 m³ or change of strata which

2 Sieve Analysis/ Gradation IS:2720-1985 Part - IV As per code IS Sieve Set Site In charge Lab test result W W
ever is earlier

5000 m³ or change of strata which

3 Atterberg Limit IS:2720-1985 Part - IV As per code Casagranda apparatus Site In charge Lab test result W W
ever is earlier
Every six month or change of
4 Swelling Index strata which ever is earlier, As and IS:2720-1977 Part - XL As per code Measuring cylinder Site In charge Authorised lab result W R
when decided by E-IC
Modified Proctor Value (Heavy 5000 m³ or change of strata which
5 IS:2720-1983 Part - VIII As per code Proctor Apparatus Site In charge Lab test result W R
Compaction) ever is earlier

III Soil Field Compaction Test

Layer Thickness
1 (Under use of 10T Vibro Soil Every layer IRC Specs 200 - 250mm By scaling during compaction Site In charge Site Records W W
Compactors)

2 Calibration of Sand Density Monthly IS:2720-1983 Part - XXVIII As per code Calibrating cylinder Site In charge Site Records W W

Sand Replacement method as per Min. 97% of MDD for embankment & Sand Replacement/ Core
3 Field Density Test Site In charge Site Records W R
200 m² in top 1m of sub grade & IS: 2720 (Part XXVIII), Min. 98% of MDD for Sub-grade Cutter Method
500m² in below top 1m sub grade. Core Cutter Method as per
Moisture Content IS: 2720 (Part XXIX) As per code Rapid moisture meter/oven Site In charge Site Records W R

4 Ev2 Values 1 Test / KM at top of Sub-grade DIN : 18134 - 2001 > 60MPa Plate Load Test Setup Site In charge Lab test result W R

5 Finished Top Levels of Sub-grade At every 200M Tender Paper Clause 5.9.10 ± 30mm w.r.t Design RL Auto Level Site In charge Survey Sheet W R

SP// Inspection and Test Plan_Rev R2 Page 1 of 26

 ANNEXURE – 2

DFCC (Western Corridor, Phase-2) EXPRESS FREIGHT CONSORTIUM

Civil, Building and Track works in Vaitarana – Sachin Section
Package: CT P12 QUALITY ASSURANCE PLAN

MANUFACTURING QUALITY ASSURANCE PLAN

1.0 INTRODUCTION

The works of Design, Construction and Commissioning of Double Line

Railway Track in Vaitarana - Sachin Section of Western Dedicated Freight
Corridor (Phase-2) of DFCC {CONTRACT CT P 12} have been secured by M/s
Express Freight Consortium ( Mitsui, IRCON & TATA Consortium) on Lump
Sum price basis. The works involves Construction of Formation in
Embankment / Cutting, Construction of Cross Drainage Structures and other
Minor Bridges, Construction of Buildings for Railway Operations and other
Ancillary use, Supply of Power (Other than TSS & OHE), Construction of
Track, Diversion of Utilities etc.

This document sets out the Manufacturing Management and quality

assurance plan.

2.0 REFERENCES

The following documents/drawings have been referred for the preparation of

this plan ;

• Project Quality assurance Plan

• Contract Document Volume II
• Contract Document Volume III
• Various IS, IRS and IRC Codes and Specifications

3.0 RESPONSIBILITY AND AUTHORITY

The Responsibilities of the team members are given below:

3.1 Project Manager:- To organize & manage all resources and office & field
activities to achieve an efficient and effective job completion.

3.2 Sr. Quality Manager:- Sr. Quality Manager shall be the overall In-charge of
Project Quality aspects. He will be responsible to ensure that quality of all
activities is of required standards and meet the requirements of Contract
Documents and Quality Assurance Plan. He will plan, execute, evaluate and
audit all the quality aspects of the project. He shall always remain in touch
with Project Manager of the Consortium and regularly interact with Quality
Head and Senior Executives of the Engineer / Client.

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3.3 Quality Assurance Manager (QA Manager):- The duty of QA Manager is to

ensure quality in ‘Process Related’ activities and also ‘Testing in Laboratory’.
To ensure preparation of all the work methods as required by the contract
and corresponding inspection & test plans and formats. To ensure all the
tests are conducted in laboratories (internal & external) as per standards and
integrity of results is maintained. Also to conduct required surveillance
audits and periodical internal quality audits.

3.4 Sr. QA Engineer:- To develop the required Method Statements / Work

Procedures and ITP formats. To supervise the laboratory tests. Sr. QA
Engineer will report to QA Manager.

3.5 Quality Control Manager (QC Manager):- The duty of QC Manager is to

ensure quality in ‘Product Related’ activities at Site. To supervise and manage
the material (raw materials only) acceptance, handling, storage, material &
constructions and fabricated items testing as per frequency mentioned in
QAP, and ensuring conformity with specification regularity standards and
inspection test plans. To ensure proper workmanship in construction various
processes. Also to conduct required surveillance audits and periodical
internal quality audits, at Sites.

3.6 Sr. QC Engineer:- To conduct regular, surveillance verifies in-process

inspection by QC Engineers and Jr. QC Engineers and test on the materials
and workmanship in accordance with contract requirement & ITP.

3.7 Section in-charge - To ensure activity is in accordance with work method

requirements, regularity standard and shall complete in timely manner and
with the high quality standards as per QAP. To ensure deployment of required
type and quantity of resources – materials, machinery & men. All PPE and
Environment protection gadgets are available at site of work.

3.8 Site in-charge – To ensure all structures are built in accordance with the
approved Working Drawings. All equipment are properly maintained and are
capable of working with full efficiency. To ensure the required safety,
environment protection measures are in place.

3.9 Site Engineer – Ensure the construction activity as per Working Drawings,
approved work procedure, correct quality and safety & without any
appreciable effect on environment.

3.10 Supervisor – Front line supervision of the working labour and to ensure strict
conformance to methods, quality and safety.

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3.11 Director / SHE:- To review Method Statements/ Work Procedure, Mitigation

of Hazards and to carry out SHE inspection of construction area, resources
(Men, Machine & Materials), P&M, Cranes & Lifting Devices, Scaffoldings &
Working platforms and other tools and tackles. (for details please refer SHE
Section)

4.0 MANUFACTURING QUALITY MANAGEMENT

Construction of Formation (Embankment or Cutting), Blanketing, Laying of

Track, RCC Construction and Building Works are the most important and
critical component of this Contract. Following shall be ensured in manufacturing
quality assurance.

4.1 Construction of Formation

• The alignment and profile of the section shall be freezed before

commencement of earthwork. And Working Drawings shall be made available
at site.

• Soil for embankment fill shall be ensured from suitable borrow area after
intensive checking of the borrow area soil properties.

• The soil/ rock from the cutting stretches shall be used in fill area if found
suitable and economically viable.

• The load carrying capacity of existing ground in track alignment shall be

ascertained and loose or unsuitable soil shall be removed.

• Survey Posts and Reference Pillars with values of Easting & Northing and
Elevation written on Steel Plate fixed to the Post/ Pillar shall be installed at
suitable intervals and kept with utmost care for all future works.

• The compaction of the embankment fill shall be carried out mechanically

using Vibro Soil Compactor and the Density of compacted layer shall be
checked regularly.

• In borrow area, top soil be reserved separately and then the borrow area shall
be re-developed, to the extent possible.

• The suitable blanketing materials shall be selected by extensive testing.

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• Mechanised methods shall be used to achieve the full compaction of

blanketing layer/s and strict quality controls shall be exercised.

• The top surface of Sub-grade and Blanketing shall be compacted to minimum

surface tolerances and the required Second Deformation Modulus Tests shall
be conducted

4.2 RCC Works

• For RCC works, the raw materials e.g., Aggregates, Sand, Cement,
Admixtures etc. shall be procured as per Quality Standards mentioned in
QAP and Contract Documents and elsewhere.

• Rebars manufactured by integrated plants shall be used. The delivery of

rebars in straight position shall be ensured by transporting in flat bed
trailers.

• The cutting and bending of rebars shall be carried out mechanically.

• The rebar cages shall be prepared by tying the rebars properly so that they
don’t get disturbed during concreting.

• The Batching Plant/s shall be calibrated regularly to ensure quality

production.

• After every pour, TMs shall be cleaned properly.

• Proper compaction of concrete shall be ensured, at site.

• Proper curing of RCC structures shall be ensured.

4.3 Structural Steel

• Finished rolled material shall be procured from primary manufacturers and
free from cracks, flaws, injurious seams, laps, blisters, ragged and imperfect
edges and other defects. They shall also be free from loose mill scale, rust,
pits or other defects affecting its strength and durability.

• Raw materials such as structural steel, nut, bolts washers etc. are from
RDSO approved vendors, inspected and confirming to specifications.

• Qualified manpower shall be made available and deployed in manufacturing

and fabrication process.

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• Approved Technical Drawings and Shop Drawings shall be available.

• Approved equipment for the Manufacturing and fabrication is available.

• General requirements relating to the supply of material shall conform to the

specifications of IS:1387

• All materials shall be stored as to prevent deterioration, and to ensure the

preservation of their quality and fitness for the work. The materials shall be
stored under cover.

• The steel to be used in fabrication shall be stored in separate stack clear of

the ground section-wise and lengthwise.

• The storage area shall be kept clean and properly drained. Structural steel
shall be so stored and handled in such a manner that members are not
subjected to excessive stresses and damage.

• We shall have a storage yard for storing the fabricated steel structures and
other materials which will be delivered to site.

• The yard shall have proper facilities such as drainage and lighting including
access for cranes, trailers and other heavy equipment.

• All Shop / field connection materials, shop paint etc. shall be stored on racks
and platforms, off the ground in a properly covered condition.

• All tests shall be ensured as per approved ITP for fabrication.

• The consortium representative shall be present during all these shop

assembly (wherever fabrication is done), it’s dismantling and marking
operations.

• Fabricated structural steel materials shall be delivered to site, with all

necessary field connection materials, in such sequence as will permit the
most efficient and economical performance of the erection work.

• Fabricated parts shall be handled and stacked in such a way-that no damage

is caused to the components.

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• Measures shall be taken to minimize damage to the protective treatment on

the steelwork. All work shall be protected from damage in transit.

• Particular care shall be taken to stiffen free ends, prevent permanent

distortion and adequately protect all machined surfaces.

• All bolts, nuts, washers, screws, small plates and articles generally shall be
suitably packed and identified.

4.4 PSC Sleeper

• The raw materials e.g. Aggregates, Sand, HTS Strands shall be checked as per
QAP before acceptance.

• For casting of sleepers fresh cement of grade 53-S shall be used. The cement
shall be stored in air tight storage.

• HTS stands shall be delivered properly wrapped with protective coverings like
bituminous crepe-paper covering to prevent hydrogen embrittlement, and
covered with tarpaulin etc. to prevent ingress of moisture and dirt in a humid
or corrosive atmosphere. They should be stored at an elevated platform to
prevent them from rising moisture if any, from the humid/ wet ground
condition. The Storage area shall also have an adequate ventilation, to
prevent condensation. Particular care shall be taken to stiffen free ends,
prevent permanent distortion and adequately protect all machined surfaces.

• Proper care shall be exercised to carry out the stressing of strands. The jacks
shall be calibrated, regularly.

• After every casting, the moulds shall be cleaned properly and the dimensions
shall be checked to ensure correct dimensions.

• The steam curing shall be intensively supervised and steam temperature shall
not be allowed to increase above 65°C and humidity shall kept at 100%.

• The sleepers shall be handled properly after demoulding, and during

stacking, loading, transportation, unloading and during fixing at site so that
no damage occur to the sleepers.

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5.0 Manufactured Items

• The following manufactured items shall be used for this project

i) Head Hardened UIC 60Rails

ii) Track Fastenings
iii) Rebars (HYSD, HTS Strands)
iv) Bearings
v) Bolts Nuts and Washers
vi) Paints

The Head Hardened Rails of Grade 1080 shall be procured from Japanese Company
(may be any one or all from Nippon Steel, Sumitomo Metal Corporation, JFE Steel
Corporation). The various track fastenings, bearings, bolts & nuts and paints shall
be procured from RDSO approved vendors as per relevant RDSO / Indian Railway
Standards. The detailed QAP as per IRS and Contract Specifications shall be
adhered.

The details of ITPs are attached. However, any other test required as per
codes/manual and or instructions of Engineer / Client shall be ensured.

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SITE QUALITY ASSURANCE PLAN

AND
ON SITE & OFF SITE TESTING ARRANGEMENTS

1.0 INTRODUCTION

The works of Design, Construction and Commissioning of Double Line

Railway Track in Vaitarana - Sachin Section of Western Dedicated
Freight Corridor (Phase-2) of DFCC {CONTRACT CT P 12} have been
secured by M/s Express Freight Consortium ( Mitsui, IRCON & TATA
Consortium) on Lump Sum price basis. The works involves Construction
of Formation in Embankment / Cutting, Construction of Cross Drainage
Structures and other Minor Bridges, Construction of Buildings for
Railway Operations and other Ancillary use, Supply of Power (Other than
TSS & OHE), Construction of Track, Diversion of Utilities etc.

This document sets out the Manufacturing Management and quality

assurance plan.

2.0 REFERENCES

The following documents/drawings have been referred for the

preparation of this plan ;

• Project Quality Assurance Plan

• Contract Document Volume II
• Contract Document Volume III
• Various IS, IRS and IRC Codes and Specifications

3.0 HIERARCHY OF CODES AND DOCUMENTS

For managing and controlling the whole system in this Project, the
following hierarchy in the increasing order for the Quality Management
System documentation shall be followed:-

DIN Standards, BS Codes, IRC Specs., IS Codes, IR Unified Standard

Specs. (2010), IRS Codes, Contract Conditions, Project Quality
Assurance Plan, Approved Drawings

4.0 RESPONSIBILITY AND AUTHORITY

The Responsibilities of the team members are given below:

4.1 Project Manager:- To organize & manage all resources and office
& field activities to achieve an efficient and effective job completion.

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4.2 Sr. Quality Manager:- Sr. Quality Manager shall be the overall In-
charge of Project Quality aspects. He will be responsible to ensure
that quality of all activities is of required standards and meet the
requirements of Contract Documents and Quality Assurance Plan.
He will plan, execute, evaluate and audit all the quality aspects of
the project. He shall always remain in touch with Project Manager
of the Consortium and regularly interact with Quality Head and
Senior Executives of the Engineer / Client.

4.3 Quality Assurance Manager (QA Manager):- The duty of QA

Manager is to ensure quality in ‘Process Related’ activities and also
‘Testing in Laboratory’. To ensure preparation of all the work
methods as required by the contract and corresponding inspection
& test plans and formats. To ensure all the tests are conducted in
laboratories (internal & external) as per standards and integrity of
results is maintained. Also to conduct required surveillance audits
and periodical internal quality audits.

4.4 Sr. QA Engineer:- To develop the required Method Statements /

Work Procedures and ITP formats. To supervise the laboratory
tests. Sr. QA Engineer will report to QA Manager.

4.5 Quality Control Manager (QC Manager):- The duty of QC

Manager is to ensure quality in ‘Product Related’ activities at Site.
To supervise and manage the material (raw materials only)
acceptance, handling, storage, material & constructions and
fabricated items testing as per frequency mentioned in QAP, and
ensuring conformity with specification regularity standards and
inspection test plans. To ensure proper workmanship in
construction various processes. Also to conduct required
surveillance audits and periodical internal quality audits, at Sites.

4.6 Sr. QC Engineer:- To conduct regular, surveillance verifies in-

process inspection by QC Engineers and Jr. QC Engineers and test
on the materials and workmanship in accordance with contract
requirement & ITP.

4.7 Section in-charge - To ensure activity is in accordance with work

method requirements, regularity standard and shall complete in
timely manner and with the high quality standards as per QAP. To
ensure deployment of required type and quantity of resources –
materials, machinery & men. All PPE and Environment protection
gadgets are available at site of work.

4.8 Site in-charge – To ensure all structures are built in accordance

with the approved Working Drawings. All equipment are properly
maintained and are capable of working with full efficiency. To
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ensure the required safety, environment protection measures are

in place.

4.9 Site Engineer – Ensure the construction activity as per Working

Drawings, approved work procedure, correct quality and safety &
without any appreciable effect on environment.
4.10 Supervisor – Front line supervision of the working labour and to
ensure strict conformance to methods, quality and safety.

4.11 Director / SHE:- To review Method Statements/ Work Procedure,

Mitigation of Hazards and to carry out SHE inspection of
construction area, resources (Men, Machine & Materials), P&M,
Cranes & Lifting Devices, Scaffoldings & Working platforms and
other tools and tackles. (for details please refer SHE Section)

5.0 PROPOSED ‘ON SITE’ TESTING ARRANGEMENTS

The Consortium shall establish two laboratories one at Palghar and second at
Ancheli. Both these labs shall be well equipped and headed by experienced
Quality Assurance Manager and his team/s. The timely calibration of various
Lab equipments shall be ensured and shall be monitored by Senior Quality
Manager – Head of Project Quality Team

The test frequency for carrying out various tests both in house and external
have been clearly identified in respective quality assurance plans, which shall
be confirming to relevant codes and specification.

5.1 LIST OF PROPOSED ‘ON SITE’ TESTS

S. No. Test (Name in Short)

A Tests on Existing Ground
1 Second Deformation Modulus (EV2 Test)
2 Standard Penetration Test
B Embankment Fill Material and Laying of Fills at Site
1 Grain Size Analysis
2 Soil Classification
3 Atterberg’s Limits
4 MDD and OMC
5 CBR Value Test
6 Second Deformation Modulus (EV2 Test)
7 Compaction Density Test (Modified Proctor Test)
C Blanket Materials and laying of Blanket at Site
1 Grain Size Analysis
2 MDD and OMC

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S. No. Test (Name in Short)

3 Los Angles Abrasion Test
4 CBR Value Test
5 Second Deformation Modulus (EV2 Test)
6 Compaction Density Test (Modified Proctor Test)
D Cement
1 Normal Consistency
2 Initial and Final Setting Time
3 Soundness Test
4 Fineness
E Fine Aggregate
1 Grading Analysis
2 Silt content
3 Moisture Content
4 Specific Gravity
5 Bulk density
6 Fineness
7 Water Absorption test
F Coarse Aggregate
1 Grading Analysis
2 Moisture Content
3 Specific Gravity
4 Water Absorption test
5 Aggregate Impact Value/ Crushing Value
6 Bulk Density
7 Flakiness and Elongation Index
G Concrete
1 Design Mix
2 Workability
3 Temperature
4 Air Content
5 Compressive Strength
6 NDT of Concrete
H Batching Plant
1 Calibration of Plant
2 Calibration of Electronic Probes
I Bentonite
1 Viscosity
2 pH value
3 Density of Bentonite Suspension in bore hole

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S. No. Test (Name in Short)

J Water
1 Temperature
2 pH value
K Concrete Admixture
1 Specific Gravity
L Structural Steel
1 Straightness of members/ Flatness of plates
2 Visual Check for rusting, if any
M Fabrication Works
1 Weld Sizes/ Soundness of Rivets / Tightening of Bolts
2 DPT Tests on Fillet Welds
3 Paint Thickness
N Brick Works
1 Brick Size
2 Water Absorption Test
3 Efflorescence Test
4 Compressive Strength Test
O ELECTRICAL WORKS
I Power Supply and Lighting Works
1 Tests of Transformer prior to commissioning
2 Site performance test for electrical system work
II Cable-tray
1 Installation of cable tray
III Diesel Generator
1 Site performance test for the DG
IV High Mast lighting
1 Site performance test for the High Mast
P Other Ancillary Works
I Fire Detection Works
1 Site performance test for the fire detection system
II Fire Protection System
1 Site performance test for Gas suppression System
III Solar Power Battery Back-ups
1 Site performance test for the Solar Power Batteries
IV HVAC System
1 Window AC/ Split AC
2 Desert Coolers
3 Exhaust Fans
4 Ceiling Fans

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S. No. Test (Name in Short)

V SCADA for Auxiliary Power Supply
1 Site performance test for the SCADA system
VI Plumbing and Drainage
1 Instant Geysers
2 Site performance test for Instant Geysers
3 Solar Geysers
4 Site performance test for Solar Geysers
Q ROAD WORKS
I Earthwork
1 Grain size analysis
2 Liquid Limit Index and Plasticity Index
3 Free Swelling index
4 Laboratory Compaction
6 CBR of borrow area
7 MDD & OMC (in Lab)
8 Max. Particle Size
9 Compaction Density Test (Modified Proctor Test)
10 Moisture Content
11 Compacted Layer Thickness
12 Surface irregularity
II Granular Sub-Base
1 Grain size analysis
2 Aggregate Impact Value
3 Liquid Limit Index and Plasticity Index
4 Moisture Content Prior to Compaction
5 MDD
6 CBR – at 98% dry density
7 Compaction Density Test (Modified Proctor Test)
8 Layer Thickness
9 Level Tolerance
10 Surface irregularity
III Wet Mix Macadam
1 Gradation
2 Aggregate Impact Value
3 Aggregate Los Angles Abrasion value
4 Plasticity Index
5 Combined Flakiness Index & Elongation Index
6 Moisture Content Prior to Compaction
7 MDD
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S. No. Test (Name in Short)

8 CBR
9 Compaction Density Test (Modified Proctor Test)
10 Mixing Method
11 Laying
12 Compacted Layer Thickness
13 Level Tolerance
14 Surface irregularity
IV Prime Coat
1 Rate of Spray
1.1 Bitumen Emulsion on Granular Surface
1.2 Cutback Bitumen on Granular Surface
2 Temperature at Time of Application
3 Temp. of Spray
V Tack Coat
1 Rate of Spray
1.1 Bituminous Surface
1.2 Granular Surface treated with Primer
1.3 Cement Concrete Pavement
2 Temperature at Time of Application
3 Temp. of Spray
VI Bituminous Construction for DBM & BC
1 Softening Point of Modifier Binder
2 Penetration at 25 °C and 4 °C of Modified Binder
3 Aggregate Impact Values of Aggregates (either AIV Test
or LAA Test)
4 Los Angeles Abrasion value of Aggregates (either AIV
Test or LAA Test)
5 Flakiness and Elongation index of Aggregates
6 Water Absorption of Aggregates
7 Grading of Aggregates
8 Plasticity Index
9 Sand Equivalent Test
10 Aggregate grading for Dense Bituminous
Macadam/ Semi-dense Bituminous Concrete and
Bituminous Concrete
11 Control on temperature of Binder, aggregates for mixing,
of Mix while laying & rolling
12 Binder content of mix and aggregate grading for
Dense Bituminous Macadam/Semi-dense Bituminous
Concrete and Bituminous concrete
13 Rate of spread of mixed material
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S. No. Test (Name in Short)

14 Stability of Mix
15 Density of compacted Mix
16 Level Tolerance
R TRACK WORKS
I PSC Sleepers
1 Dimensions
2 Length
3 Width at Top
4 Width at Base
5 Height at Centre of Rail Seat
6 Track Gauge
7 Rail Cant
8 Rail Seat Plane
9 Differential Tilt of rail seats
10 Stacking of Sleepers at depots/ Site
11 Laying of Sleepers in Track
12 Checking of Sleeper Moulds
II Ballast (Machine Crushed Only)
1 Sieve Analysis
2 Aggregate Abrasion Value (Los Angles)
3 Aggregate Impact Value
4 Water Absorption
II RAILS
1 Dimensions
2 Toe Load Test
S OTHER ITEMS
I Compression Testing Machine
1 General Conditions of CTM
2 Inspection of the loading platens
II Sheathing Ducts
1 Water Tightness
III Bearings
1 Inspection and testing of finished bearings.
1.1 Visual inspection
1.2 Plan dimension of assembled bearing
1.3 Overall height of assembled bearing
Parallelism of top surface of assembled bearing w. r. t.
1.4
the bottom surface as datum
Height of confined elastomeric pressure pad/ Thickness
1.5
of Rubber Bearing
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S. No. Test (Name in Short)

1.6 Thickness of any machined steel component
Overall dimensions of any unmachined cast steel
1.7
component
2 Installation of Bearings at Site
2.1 Bedding
2.2 Tightening of fastenings/ Use of Adhesive
2.3 Bearing Position Tolerances

The list if required shall be reviewed and modified as required in consultation

with the Engineer.

5.2 PROVISIONAL LIST OF EQUIPMENT USED FOR ‘ON SITE’ LAB (each)

Sr. No. Item Description Qty./Lab

1 Compression Testing Machine – 1
2000kN
2 Aggregate Impact Testing Machine 1
3 Los Angels Abrasion Test Machine 1
4 Le-Chatilier for cement soundness 1
testing
5 VICAT apparatus with needle 1
6 Blaine’s Air Permeability 1
7 Casagrande Test Kit 1
8 Shrinkage limit apparatus 1
9 Vee Bee Apparatus 1
10 SET OF BRASS SIEVES 200 mm
dia
A 20 mm 1
B 19 mm 1
C 10 mm 1
D 4.75 mm 1
E 2.36 mm 1
F 1.18 mm 1
G 600 µ 1
H 300 µ 1
I 150 µ 1
J 75 µ 1
K 90 µ 1
L 45 µ 1
11 SET OF GI SIEVES 450 mm dia
A 63 mm 1
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Sr. No. Item Description Qty./Lab

B 40 mm 1
C 25 mm 1
D 20 mm 2
E 16 mm 1
F 12.5 mm 2
G 10 mm 2
12 Slump cone with base plate 6
13 Electric Hot Air Oven (50 to 300 C) 1
14 Deisccators 2
15 Concrete cube mould (150x150x 100
150mm)
16 Lab Concrete Trial mixer – pan type 1
17 Concrete cube mould 30
(100x100x100mm)
18 Concrete cube mould (70.6 x 70.6 x 21
70.6 mm)
19 150 dia sand pouring cylinder with 1
conical funnel set
20 Mortar Cube Vibrator 1
21 Concrete Cube Vibrating Table 2
22 Core cutter with collar 2
23 Digital Rebound Hammer 1
24 CBR Apparatus full set 1
24A Weight for CBR mould (2.5 kg) 32
24B Soaking tank for 24 CBR mould 1
25 Modified heavy proctor density 1
apparatus full unit
26 Dial gauges 0-25 (50 mm Dia) with 15
Magnetic Stand
27 Modulus of Sub-grade Reaction Test 2
Set up Complete including reaction
frame & 30cm, 45cm and 75cm
Circular Plates.
Or

Electronic Plate Bearing Device Model

AX® 01a of ‘The Anix GmbH’ or
equivalent to conduct test as per DIN:
18134.
28 Bulk Density Cylinder (3L, 15L, 20L) 2 each
29 Rapid Moisture Meter Box Set – 25% 2
30 Rapid Moisture Meter Box Set – 50% 2
31 Sand replacement (Field density 1
apparatus)
32 Elongation gauge 2
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Sr. No. Item Description Qty./Lab

33 Flakiness gauge 2
34 Pycno meter with glass plate 1000 ml 1
35 100 dia sand pouring cylinder with 1
conical funnel set
36 200 dia sand pouring cylinder with 1
conical funnel set
37 Electronic Balance Digital 10kg (1gm) 2
38 Electronic Weigh Balance 50 kg 1
(1 gm)
39 Electronic Weigh Balance 5kg 1
(0.1 gm)
40 Hand auger with extension rod 1
41 25 Nos. Weights each of 20Kg 1
42 Digital Stop Watch 2
43 Hydrometer (Range 0 to 100%) 4
44 Digital Hydrometer (Range 0 to 100%) 2
45 Water Testing Kit 2
46 Thermometer 0 to 300 C 2
47 Digital pH meter 2
50 Digital Vernier caliper 300 mm 2
51 Micrometer (0-25) 1
52 Weld Gauge Sets 4
53 Digital Paint Thickness Gauge 1
(Elcometer)
54 Portable Digital Hardness tester 1
55 Miscellaneous Items
A Gl Tray (45 x 45 cm) 4
B Gl Tray (45 x 30 cm) 4
C Enamel Tray (60cm x 60 cm) 5
D Enamel Tray (60cm x 45 cm) 5
E Glass Measuring Jar 1000 ml 2
F Glass Measuring Jar 500 ml 2
G Glass Measuring Jar 250 ml 2
H Glass Measuring Jar 100 ml 2
I PVC Measuring Jar 1000 ml 3
J PVC Measuring Jar 500 ml 3
K PVC Measuring Jar 250 ml 3
L PVC Measuring Jar 100 ml 3
M Aluminium dish with lid 5 cm 4
N Glass 10 mm x 500 x 500 mm 1

6.0 PROPOSED OFF SITE TESTING ARRANGEMENT

As far as off-site testing facility is concerned, the Consortium has identify
adequate number of external material testing facility in order to send test
samples for carrying out various tests for which testing facility is not
SP::// Site Quality Assurance Plan _and _On Site_ Off Site Testing Page 11 of 19
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available at site. NABL accredited laboratory shall only be engaged for

off-site.

NDT tests on hardened concrete and structural steel, bricks, sleepers,

rails, electrical cables, electrical panels, and other ancillary system
equipments/ materials if required shall also be conducted by external
agency.

The test frequency for carrying out various tests both in house and
external have been clearly identified in respective quality assurance
plans, which shall be confirming to relevant codes and specification.

6.1 Provisional List of ‘OFF SITE’ Tests

S. No. Test (Name in Short)
A Tests on Existing Ground
1 Undrained Cohesion Test (Cu)
B Embankment Fill Material and Laying of Fills
at Site
1 Triaxial compression testing, UU, CU, CD test
2 Direct Shear Test
3 Consolidation Test
C Blanket Materials and laying of Blanket at Site
1 Coefficient of Uniformity Test
2 Coefficient of curvature (Cc) Test
D Cement
1 Chemical Tests on cement
2 Fineness Test – Third Party Test
E Fine Aggregate
1 Deleterious Material
2 Soundness
3 Alkali-Aggregate Reactivity
F Coarse Aggregate
1 Soundness
2 Alkali-Aggregate Reactivity
3 Petrographic Analysis
G Concrete
1 Chloride Content
2 Sulphuric Anhydride content
3 Water Permeability Test
H Batching Plant
1 Computer Programming of Plant
2 Calibration of Electronic Probes and Water And
Chemical Dosing System
I Bentonite
1 Swelling Index
2 Liquid Limit
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S. No. Test (Name in Short)

3 Sand Content in Bentonite Powder
J Water
1 Physical and Chemical Tests
K Concrete Admixture
1 Uniformity / Physical Tests
L Structural Steel
1 Physical and Chemical Properties
2 Rolling and Cutting tolerances
M Fabrication Works
1 UST Test on Highly Loaded Butt Welded Joints
N Brick Works
1 Efflorescence Test – Third Party Test
2 Compressive Strength Test – Third Party Test
O ELECTRICAL WORKS
I Power Supply and Lighting Works
1 Factory acceptance test for transformer
Factory acceptance test for switch boards ( HT &
2
MV main board)
3 Factory acceptance Test certificate for cable
II Cable-tray
1 Factory acceptance test for Cable Trays
III Diesel Generator
1 Factory acceptance test for DG
IV High Mast lighting
1 Factory acceptance test for High Mast
P Other Ancillary Works
I Fire Detection Works
1 Type test certificate for cable & fire alarm panels
II Fire Protection System
1 Test Certificate for Fire Extinguisher
Factory acceptance test for Gas Suppression
2
System
III Solar Power Battery Back-ups
1 Factory acceptance test for Solar Power Batteries
IV HVAC System
1 Window AC/ Split AC
2 Desert Coolers
3 Exhaust Fans
4 Ceiling Fans
V SCADA for Auxiliary Power Supply
1 Factory acceptance test for SCADA
VI Plumbing and Drainage
1 Instant Geysers
2 Site performance test for Instant Geysers

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S. No. Test (Name in Short)

3 Solar Geysers
4 Site performance test for Solar Geysers
Q ROAD WORKS
I Earthwork
Deleterious Content
1 • Organic matter
• Soluble matter
II Granular Sub-Base
1 Deleterious Content
2 Soundness, if Water Absorption is > 2%
3 Roller Type
III Wet Mix Macadam
1 Water Absorption
2 Roller Type
IV Prime Coat
1 Quality of Binder
V Tack Coat
1 Quality of Binder
VI Bituminous Construction for DBM & BC
1 Quality of Binder
2 Elastic Recovery of Modifie Binder
3 Ductility of Modified Binder
4 Flash Point of Modified Binder
5 Fraass breaking of Modified Binder
6 Viscosity at 150 °C of Modified Binder
7 Thin film Oven Test, Penetration, Softening
Point, Elastic Recovery of Residue and Loss on
Heating of Modified Binder
8 Stripping value of Aggregates
9 Polished Stone value of Aggregates
10 Percentage of fractured faces
11 Soundness of aggregates
12 Water sensitivity
R TRACK WORKS
I PSC Sleepers
1 Fastener Repeated Load Test
2 Lateral Restraint Test
3 Longitudinal Restraint Test
Bond Development or Tendon Anchorage Ultimate
4
Load Test
5 Rail Pad Test
6 Load Test on Sleepers
A Load for Centre Top
B Centre bottom,
C Rails Seat Bottom Cracking
SP::// Site Quality Assurance Plan _and _On Site_ Off Site Testing Page 14 of 19
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S. No. Test (Name in Short)

D Rails Seat Bottom Failure
E Bond Development or Tendon Anchorage
II Ballast (Machine Crushed Only)
Aggregate Abrasion Value (Los Angles) – Third
1
Party Test
2 Aggregate Impact Value – Third Party Test
II RAILS
1 Rails – Qualifying Criteria
1.1 Residual Stress
1.2 Fracture Toughness
1.3 Fatigue Test
1.4 Steel Making
2 Finished Rail Inspection
2.1 Dimensional Verification
A Overall Height
B Width of Head
C Width of flange
D Thickness of Web
E Verticality / Asymmetry
F Flanges
G Fishing Surface
H Surface Flatness
2.2 Other Protrusions etc.
A End Squareness
B End Straightness
2.3 Chemical Analysis
2.4 Mechanical Properties
A Tensile Test
B Sulphur Print Test
C Brinall hardness test
D Falling Weight Test
E Hydrogen content
Finished rail Surface -
F
Rail profile
2.5 Ultrasonic Testing
III Elastic Rail Clips
1 After raw material received at work premises
1.1 Chemical analysis,
Grain size, inclusion
rating, hardness,
1.2
depth of decarb,
freedom from surface defects
1.3 Dimensions
2 Manufacturing

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S. No. Test (Name in Short)

2.1 Shearing
2.2 After ERC formation & Quenching
A Dimensions
B Die Marks
C Quench Hardness
3 After Tempering
3.1 Hardness of ERC
4 Finished ERC Before offering for inspection
Inclusion rating, depth of decarb, freedom from
4.1
surface defects
IV Grooved Rubber Sole Plates (6mm Th)
1 Hardness
2 Tensile Strength
2.1 Before ageing
2.2 After ageing at 100 ± 1 °C for 96 + 0/ - 2 Hours
3 Retention after aging
3.1 Before ageing
3.2 After ageing at 100 ± 1 °C for 96 + 0/ - 2 Hours
3.3 Retention after aging
4 Relaxed Modulus at 100% elongation
4.1 Before ageing
Change after ageing at 100 ± 1 °C for 96 + 0/ - 2
4.2
Hours
Compression Set subject to 50% compression at
5
100 ± 1 °C for 24 + 0/ - 2 Hours
Tension Set subject to 50% stretch at 100 ± 1 °C
6
for 24 + 0/ - 2 Hours
7 Load Compression Test
8 Electrical Resistance
9 Ash Content
10 Specific Gravity
V Glass Filed Nylon Liners - 66
1 Raw Materials
1.1 Melting Point
1.2 Specific Gravity
1.3 Glass Filler
2 GFN Liner - 66
2.1 Cross Breaking Load
2.2 Water Absorption
2.3 Hardness – Rockwell
2.4 Tensile Strength
2.5 Elongation at Break
2.3 Dielectric Strength
2.7 Volume Resistivity

SP::// Site Quality Assurance Plan _and _On Site_ Off Site Testing Page 16 of 19
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S. No. Test (Name in Short)

VI Metal Liners
1 Material
1.1 Designation
1.2 UTS
1.3 Yield Strength
1.4 Elongation
1.5 Hardness
1.6 Bend Test
1.7 Chemical Analysis
VII Glued Joint
1 Glass Cloth carrier Reinforcement
2 Insulation Resistance
3 Vertical Profile
4 Lateral Alignment
5 Shear Strength of Glue
S OTHER ITEMS
I Compression Testing Machine
1 Calibration of Dial Gauge
II Sheathing Ducts
Physical Dimensions: a) Length
1
b) Thickness v/s dia.
Physical Dimensions: a) Length
2
b) Thickness v/s dia.
3 Duct Class
III Bearings
Raw materials for POT, POT cum-PTFE
III-A
Bearings
UTS, YS, % elongation, Ultrasonic Test (Level - 3)
1 and
Chemical Analysis of Cast Steel
UTS, YS, % elongation, and Chemical Analysis of
2
Mild Steel
UTS, YS, % elongation, and Chemical Analysis of
3
Forged Steel
4 Chemical Tests of Stainless Steel
5 PTFE
5.1 Hardness
5.2 Min. Tensile Strength
5.3 Minimum elongation at break
5.4 Maximum compression set
5.5 Accelerated ageing
Physical and chemical tests of Bolts and Nuts for
6
Bearing
7 Stainless steel sliding surface
7.1 Flatness
SP::// Site Quality Assurance Plan _and _On Site_ Off Site Testing Page 17 of 19
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S. No. Test (Name in Short)

7.2 Surface finish
8 Process inspection
8.1 Test of welds
8.2 Hardness Test
8.3 Ultrasonic Test
STEEL REINFORCED RUBBER BEARINGS for
III-B
RAILWAY BRIDGES
9.1 Mechanical properties of rubber
9.2 Shore Hardness
9.3 Shear Modulus
9.4 Breaking strength in Compression
9.5 Bond Between Rubber and Steel
9.6 Fatigue Test
9.7 Mechanical properties of steel plates
9.8 Yield Strength
9.9 Tensile Strength
9.10 Thickness

6.2 Provisional List of ISO/IEC/17025 – 2005 accredited labs (In India

generally known as NABL Accredited) for ‘OFF SITE’ Testing

Sr. Name of Address

No. Laboratory
1 Alok Industries Survey No. 261.268, Village- Balitha,
Ltd. Taluka Pardi, P.O. Box No.43, Vapi-
396191 District Valsad (Gujarat) Tel:
0260- 3089100, 3089371
2 Bureau Veritas Construction Services Laboratory, Plot
India Private No.B3/B$, Off Thane-Belapur Road in
Limited front of Sandoz, MIDC Digha, Navi
Mumbai – 400708, Maharashtra, Phone
No.022-67859100 Fax- 02267859199
3 Ecube 18 Vardhman Industrial
Consultants Pvt. Premises, Gokul Nagar, L.B.S. MArg,
Ltd. Thane (W) 400601, India Tel : 022-
21720333/444 Fax : 022-21720222
4 Elca Laboratories Plot No.A-444, Road No.37 (Off Road
No.28), Near Rubber Products, Wagle
Estate, Thane – 400604, Unit-II, W-361,
TTC Industrial Area, MIDC, Rabale, Navi
Mumbai – 400604
022-25824499, 258823142,
5 Essar Steel 27, Km, Surat- Hazira Road, Hazira, Dist.
Limited - Surat, Gujarat Ph:02616683885
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Sr. Name of Address

No. Laboratory
Transformer Oil
Testing
Laboratory
6 International C-101-104, Diamond World, 1st Floor,
Gemological Mangadh Chowk, Varachha Road, Surat-
Institute (India) 395006 Tel: 0261- 4020550,
Private Limited 09820620630 Fax: 0261- 4020551
7 L&T Heavy Larsen & Toubro Limited, Technology
Engineering Block, Hazira Manufacturing Complex,
Calibration and Post: Bhatha, Dist: Surat, Gujarat-
Testing 394510. Phone-0261-2805242, Fax No.-
Laboratory 0261-2805050
8 L&T Special Hazira Manufacturing Complex, PO:
Steels and Heavy Bhatha, District Surat Gujarat-394510 Ph
Forgins No-0261-2203337.
Laboratory.
9 Metallurgical Mehta House, Ashok Silk Mill Lane,
Services Private Off. L.B.S. Marg, Ghatkpar (W),
Limited Mumbai, Maharashtra, Location 1, Mehta
House, Ashok Silk Mill, Lane, Off. L.B.S.
Marg, Ghatkopat (W), Mumbai,
Maharashtra, Phone 022-2500 0240, 0241
10 Reliance Hazira Manufacturing Division, Vil. Mora,
Industries Ltd. - P.O. Bhatha, Surat-Hazira Road, Surat –
QA/QC Lab, 394510 Tel.: 0261 – 2835384
11 Structural Structwel, Plot No.15, Sector24, Off: Sion-
Designers & Panvel Highway, Turbhe, Navi Mumbai –
Consultants Pvt. 400705, Phone : 91-22-27841010
Ltd.
12 TCR Engineering Plot No.EL-182, MIDC, TTC Industrial
Services Private Area, Electronic Zone Mahape, Navi
Limited Mumbai, Maharashtra – 400 011, Tel:
3097921, 3097923, 98210 16949
13 Unique 216, Road No. 6-F, New Estate,
Engineering Udhyognagar, Udhna, Surat– 394 210. Ph:
Testing & 0261- 2278205, Fax: 0261-2277213
Advisory Services
14 Welspun India Survey No. 76, Vill- Morai Vapi, Dist –
Ltd. Valsad Gujarat - 396191 Tel : 0260 –
2437437 Fax : 0260 - 22437088

SP::// Site Quality Assurance Plan _and _On Site_ Off Site Testing Page 19 of 19
 ANNEXURE – 4
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SITE TESTING PROCEDURES AND

SITE QUALITY CONTROL FORMATS
1.0 TESTING OF AGGREGATES

1.1 Gradation of aggregates

1.0 Objective

1.1 To determine the gradation of aggregate.

2.0 Reference

2.1 IS : 2386 (Part1)-1963

3.0 Responsibility

3.1 As per Organisation Chart

4.0 Apparatus

4.1 Sieves used shall conform to IS 460-1992

a. IS sieve : 80 mm, 63 mm, 50 mm, 20 mm, 10 mm, 4.75 mm, 2.36

mm, 1.18 mm, 600 microns 425 microns, 150 microns, 75 microns.
b. Balance: sufficient capacity and having accuracy 1 g.

5.0 Procedure

5.1 Sample:

The minimum weight of sample to be taken for sieve analysis should be as

below:

Max size of aggregate in mm Min. wt. of sample to be taken for

sieving in kg.
63 50
50 35
40 15
20 2
12.5 1
10 0.5
4.75 0.2
2.36 0.1

5.2 The minimum sample to be taken for sieving is obtained by quartering or by

means of a sample divider or by any suitable means.
5.3 Take the sample of aggregate and weight to the nearest gm.

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5.4 Take the sieves for gradation analysis and place it on one over another i.e.
large size sieves on the top.
5.5 Care should be taken that the sieves are clean before use.
5.6 If sieving is carried out by hand then each sieve should be taken separately
over a clean tray and sieving carried out for a period of not less than 2
minutes.
5.7 The shaking should be done with a varied motion backwards and forwards left
to right circular clockwise and anti-clockwise and with frequent jerking, so
that the material is kept moving over the sieve surface in frequently changing
directions.
5.8 Material smaller than 20 mm should not be helped through the sieve by hand
or by brushing.
5.9 If lumps of line materials present, it may be broken by gentle pressure with
fingers against the side of the sieve.
5.10 If sieving is carried out by mechanical sieve shaker then it shall be carried out
for a period of not less than 10 minutes.
5.11 On completion of sieving the material retained on each sieve shall be weighed
to the nearest g.
5.12 Result :
From the observations the cumulative percentage passing by weight of the
total sample shall be calculated and reported to the nearest whole number.

6.0 Documentation

6.1 Format No. 1

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1.2 Aggregate Impact value

1.0 Objective

1.1 The aggregate impact value gives a relative measure of the resistance of an
aggregate to sudden shock or impact.

2.0 Reference

2.1 IS : 2386(Part-4)-1963

3.0 Responsibility

3.1 As per Organisation Chart

4.0 Apparatus

4.1 Impact testing machine, consists of hammer weight 13.5 to 14.0 kg with the
lower end of hammer is cylindrical is shape, metal base, means for raising
hammer up to 380 + or – 5 mm.
4.2 Cylindrical cup ( internal dimensions )
diameter 103 mm,
depth 50 mm,
> 6.3 mm thick

4.3 Cylindrical measure cup ( internal dimensions )

diameter 75 mm,
depth 50 mm

4.4 Sieves : 12.5 mm, 10 mm and 2.36 mm IS sieves

4.5 Tamping Rod : 10 mm dia and 230 mm long metal rod rounded at one end.

4.6 Balance : Electronic balance, capacity not less than 500 g accurate to 0.1 g.

4.7 Oven.

5.0 Procedure

5.1 Preparation of test sample :

1.1.1 The material for test consists of aggregate which passage 12.5
mm and retained on 10 mm IS sieve.

5.1.2 The aggregate is oven dried for 4 hours and cooled.

5.1.3 Then it is filled in measuring cylinder in 3 layers, each layer tamped with 25
strokes by tamping rod. The surplus aggregate overflowing stuck off using the
tamping road as straight edge.

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5.1.4 The net weight of aggregate in the measuring cylinder is determined to the
nearest gram and the weight of aggregate shall be used for the duplicate test
on the same material.
5.2 The cup shall be fixed in position on the base of impact testing machine. The
test sample (the quantity of aggregate filled in measuring cylinder) is placed
in it and compacted by a single tamping of 25 strocks of the tamping rod.
5.3 The hammer shall be raised until its lower face is 38 cm above on the upper
surface of the aggregate in the cup, and allowed to fall freely on the
aggregate. The test sample shall be subjected to a total 15 such blows each
being delivered at an interval of not less than one second.
5.4 The crushed aggregate shall then be removed from the cup and the whole of
it sieved on the 2.36 mm IS sieve until no further significant amount passes
in one minute. The fraction passing the sieve shall be weighed to an accuracy
to 0.1 g.
5.5 The fraction retained on the sieve shall also be weighed.
5.6 If the total weight is less than the initial weight by more than one gram, the
result shall be discarded and a fresh test made.
5.7 Two tests shall be made.

5.8 Calculation :

As per format No. 2

5.9 Result

The mean of the two results shall be reported to the nearest whole number as
the aggregate impact value of the tested material.

6.0 Documentation

6.1 Format No. 2

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1.3 Flakiness & Elongation Index value

1.0 Objective

1.1 To determine flakiness and elongation index.

2.0 Reference

2.1 IS 2386(Part 1) - 1963

3.0 Responsibility

3.1 As per Organisation Chart

4.0 Apparatus

4.1 Balance : sufficient capacity and accuracy of 0.1% of the weight of the test
sample.
4.2 Metal guage : Flakiness guage , Elongation gauge.

4.3 Sieves : 63 mm, 50 mm, 40 mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5
mm, 10 mm & 6.3 mm.

5.0 Procedure

5.1 Sample

The coarse aggregate shall be screened through set of sieves specified in

Table as below :

Passing through IS Retained on IS Thickness gauge = Length gauge =

sieve (mm) sieve (mm) 0.6 x (I+II)/2 1.8 x (I+II)/2
I II (mm) (mm)
63 50 33.9 -
50 40 27.0 81.0
40 31.5 19.5 58.5
31.5 25 16.95 -
25 20 13.5 40.5
20 16 10.8 32.4
16 12.5 8.55 25.6
12.5 10 6.75 20.2
10 6.3 4.89 14.7

200 pieces of aggregate retained on particular sieve shall be chosen

arbitrarily to form the test sample.
5.2 The sample as obtained above shall be weighed nearest to the gram.
5.3 Each fraction shall be tried to pass through the thickness gauge (flakiness
gauge). The aggregate passing the flakiness gauge shall be weighed and

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recorded. The aggregate retained on the flakiness gauge shall also be
weighed and recorded.
5.4 Now the aggregate retained on the flakiness gauge shall be tried to pass
through in length guage (elongation guage). The aggregate retained is
weighed and recorded.
5.5 The flakiness index of aggregate is the percentage by weight of particles
whose least dimension (thickness) is less than 3/5th of the mean dimension.
The test is not applicable to size smaller than 6.3 mm.
5.6 The elongation index of an aggregate is the % by weight of particles whose
greatest dimension (length) is greater than 1.8 times their mean dimension.
The elongation index is not applicable to size smaller than 6.3 mm.

5.7 Result

Report the flakiness index and elongation in percentage, nearest to the whole
number.

6.0 Documentation

6.1 Format No.3

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1.4 Specific gravity & water absorption

1.0 Objective

1.1 To determine the specific gravity and water absorption of aggregates.

Note : Determination of water absorption by this method is not always be

producible with aggregates of high porosity.

2.0 Reference

2.1 IS 2386(Part 3)-1963

3.0 Responsibility

3.1 As per Organisation Chart

A) For aggregate larger than 10 mm

4A.0 Apparatus

4A.1 Balance – A balance or scale of capacity not less than 3 kg, readable and
accurate to 0.5 g and of such a type and shape as to permit the basket
containing the sample to be suspended from the beam and weighed in water.
4A.2 Oven – A well ventilated over, thermostatically controlled, to maintain a
temperature of 100 to 110° C.

4A.3 A wire basket of not more than 6.3 mm mesh or a perforated container of
convenient size, preferably chromium plated and polished, with hire hangers
not thicker than one millimeter for suspending it from the balance

4A.4 A stout watertight container in which the basket may be freely suspended.

4A.5 Two dry soft absorbent cloths each not less than 75 x 45 cm.

4A.6. A shallow tray of area not less than 650 cm².

4A.7 An airtight container of capacity similar to that of the basket.

5A.0 Procedure

5A.1 Sample

A sample of not less than 2000 g of the aggregate shall be tested. Aggregates
which have been artificially heated shall not normally be used. If such
material is used the fact shall be stated in the report. Two tests shall be
made, and it is recommended that the two samples should be tested
concurrently.

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5A.2 The sample shall be thoroughly washed to remove finer particles and dust,
drained and then placed in the wire basket and immersed in distilled water at
a temperature between 22º C to 32º C with a cover of atleast 5 cm of water
above the top of basket.

5A.3 Immediately after immersion the entrapped air shall be removed from the
sample by lifting the basked containing it 25 mm above the base of the tank
and allowing it to drop 25 times at the rate of about one drop per second. The
basket and aggregate shall remain completely immersed during the operation
and for a period of 24 ± ½ hours afterwards.
5A.4 The basket and the sample shall than be jolted and weighed in water at a
temperature of 22º C to 32º C. If it is necessary for them to be transferred to
a different tank for weighing, they shall be jolted 25 times as described above
in the new tank before weighing.

5A.5 The basket and aggregate shall then be removed from the water and allowed
to drain for a few minutes, after which the aggregate shall be gently empted
from the basket on to one of the dry clothes, and the empty basket shall be
returned to the water, jolted 25 times and weighed in water.

5A.6 The aggregate placed on the dry clot shall be gently surface dried with the
cloth, transferring it to the second dry cloth when the first will remove no
further moisture.

5A.7 It shall then be spread out not more than one stone deep on the second cloth,
and left exposed to the atmosphere away from direct sunlight or any other
source of heat for not less than 10 minutes, or until it appears to be
completely surface dry (which with some aggregate may taken an hour or
more).

5A.8 The aggregate shall be turned over at least one during this period and a
gentle current of unheated air may be used after the first ten minutes to
accelerate the drying of difficult aggregates.
5A.9 The aggregates then shall be weighed.

5A.10 The aggregate shall then be placed in the oven in the shallow tray, at a
temperature of 100 to 110º C and maintained at this temperature for 24 ± ½
hours. It shall then be removed from the oven, cooled in airtight container
and weighed.
5A.11 Calculation :

As per format No. 4

5A.12 Result

The individual and mean results shall be reported. The size of the aggregate
tested shall be stated, and whether it has been artificially heated.

B) Aggregate smaller than 10 mm

4B.0 Apparatus

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4B.1 Balance

4B.2 Oven

4B.3 Vessel : Any form vessel capable of holding 0.5 to 1 kg of material upto 10
mm in size and capable of being filled with water to a constant volume with
an accuracy of ± 0.5 ml. Either of the two following vessels is suitable :

4B.3a A glass vessel (pycnometer) of about 1 liter capacity having a metal conical
screw top with a 6 mm diameter hole at its apex. The screw top shall be
watertight when it is screwed on to the jar, and if necessary, a rubber or fiber
washer shall be inserted in the joint. If such a washer is used, a mark shall be
made on the jar to correspond with a mark on the screw top so that the screw
is tightened to the same position every time and the volume contained by the
air is constant throughout the test.

4B.3b A wide mouthed glass vessel, such as a gas jar, of about 1.25 liters capacity
with a flat ground lip and a plane ground disc of plate glass to cover it, giving
a virtually watertight fit.
4B.4 A means of supplying of current and warm air, such as a hair drier.
4B.5 A tray of area not less than 325 cm².
4B.6 An airtight container large enough to take the sample
4B.7 Filter papers and funnel.

5B.0 Procedure

By using pycnometer

5B.1 A sample of about 1 kg for 10 mm to 4.75 mm or 500 g if finer than 4.75

mm, shall be placed in the tray and covered with distilled water at a
temperature of 22º C to 32º C. Soon after immersion, air entrapped in or
doubles on the surface of the aggregate shall be removed by a gentle
agitation with a rod. The sample shall remain immersed for 24± ½ hours.

5B.2 The water shall then be carefully drained from the sample, by decantation
through a filter paper, any material being returned to the sample. The
aggregate including any solid matter retained on the filter paper shall be
exposed to a gentle current of warm air to evaporate surface moisture and
shall be stirred at frequent intervals to ensure uniform drying until no free
surface moisture can be seen and the material just attains a ‘free-curing’
condition. Care shall be taken to ensure that this stage is not passed. The
saturated and surface-dry sample shall be weighed.

5B.3. The aggregate shall then be placed in the pycnometer which shall be filled
with distilled water. Any trapped air shall be eliminated by rotating the
pycnometer on its side, the hole in the apex of the cone being covered with
finger. The pycnometer shall be topped up with distilled water to remove any
forth from the surface and so that the surface of the water in the hole is flat.
The pycnometer shall be dried on the outside and weighed.

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5B.4 The contents of the pycnometer shall be emptied into the tray, care being
taken to ensure that all the aggregate is transferred. The pycnometer shall be
refilled with distilled water to the same level as before, dried on the outside
and weighed. The difference in the temperature of the water in the
pycnometer during the first and second weighing shall not exceed 2º C.
5B.5 The water shall then be carefully drained from the sample by decantation
through a filter paper and any material retained returned to the sample. The
sample shall be cooled in the air-tight container and weighed.
5B.6 Two tests shall be made.

By using jar

5B.7 The procedure shall be the sample except that in filling the jar with water it
shall be filled just to overflowing and the glass plate slid over it to exclude
any air bubbles.

5B.8 Calculation

As per format No. 7

5B.9 Result
The individual and mean results shall be reported and the grading of the
aggregate shall be stated.

6.0 Documentation

6.1 Format No.4

6.2 Format No.7

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1.5 Water absorption of aggregate

1.0 Objective

1.1 Determination of water absorption of by aggregates by oven dry method.

2.0 Reference

2.1 IS : 2386(part 3)-1963

3.0 Responsibility

3.1 As per Organisation Chart

4.0 Apparatus

4.1 Balance : Sensitive to 0.5% of the weight of the sample to be weighed.

4.2 Oven
4.3 Container

5.0 Procedure

5.1 Clean the container thoroughly

5.2 Dry it and determine its empty weight with lid.
5.3 Take the required quantity of the aggregate in the container and kept soaking
in water for about 24 hours.
5.4 The saturated aggregate is taken out and wiped with dry cloth.
5.5 The saturated surface dry aggregate is weighed and noted .
5.6 The aggregate is dried in oven for 24 hours or up to consent weight is
obtained.
5.7 The dried aggregate is weighed.
5.8 Calculation

As per test format No. 5

5.9 Result

The water content of the soil shall be reported to two significant figures.

6.0 Documentation

6.1 Format No.5

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1.6 Silt content in sand

1.0 Objective

1.1 Determination of silt contents in sand. This method is rough indication of

material finer than 75 micron sieve.

2.0 Reference

2.1 IS : 383-1970 ( Reaffirmed 1997 )

3.0 Responsibility

3.1 As per Organisation Chart

4.0 Apparatus

4.1 Graduated glass cylinder of 1 liter capacity.

4.2 Balance

5.0 Procedure

5.1 Take about 200 g of sand.

5.2 Pour the sand in glass cylinder
5.3 Pour the water in glass cylinder upto 1000 ml.
5.4 Note the level of the sand (V1)
5.5 Mix the sand and water with stirring
5.6 The suspension shall be allowed to settle for one hour and the thickness of
the turbid suspension layer shall be measure (V2)
5.7 The ratio of turbid layer suspension (V2) to the sand (v1) multiply by 100
shall give the silt content in the sand.

6.0 Documentation

6.1 As per Format No.8

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1.7 Organic impurities in sand

1.0 Objective

1.1 Estimation of organic impurities in sand :

This method of test covers an approximate method of estimating whether
organic compounds are present in natural sand in sufficient quantities to be
harmful, and hence intends to show whether further tests are necessary or
desirable.

2.0 Reference

2.1 IS 2386(Part 2)-1963

3.0 Responsibility

3.1 As per Organisation Chart

4.0 Apparatus

4.1 350 ml Graduated jar.

4.2 Sodium hydroxide
4.3 Tannic acid
4.4 Alcohol
4.5 Colored acetate sheets

5.0 Reference

5.1 The sand shall be tested as delivered and without drying. A 350ml graduated
clear glass medicine bottle shall be filled to the 75 ml mark with 3% solution
of sodium hydroxide in water. The sand shall be added gradually until the
volume measured by the sand layer is 125 ml. The volume shall then be
made up to 200 ml by adding more solution. The bottle shall be stoppered
and shaken vigorously and then allowed to stand for 24 hours.
5.2 Other tests shall be made if the color of the liquid above the sand is darker
than a standard solution freshly prepared as follows :
5.3 Add 2.5 ml of 2% solution of tannic acid in 10% alcohol, to 97.5 ml of a 3%
sodium hydroxide solution. Place in a 350 ml bottle, stopper, shaker
vigorously and allow to stand for 24 hours before comparison with the
solution above the sand. Alternatively, an instrument or colored a acetate
sheets for making the comparison can be obtained but it is desirable that
these should be verified on receipt by comparison with the standard solution.

6.0 Documentation
6.1 Format No.9

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2.0 CEMENT

2.1 Normal Consistency of Cement

1.0 Objective

1.1 Determination of Normal consistency of cement

2.0 Reference

2.1 IS 4031(Part 4)-1988 (Reaffirmed 1995)

3.0 Responsibility

3.1 As per Organisation Chart

4.0 Apparatus

4.1 Vicat`s apparatus

4.2 Balance & weights
4.3 Graduated glass cylinder
4.4 Stop watch
4.5 Gauging trowel

5.0 Procedure

5.1 The temperature of the room and materials shall be maintained at 27º C + or
-2º C. The relative humidity of the laboratory shall be 65+ or – percent.
5.2 Take 400 g of cement sample and add weighed quantity of potable water (say
24% by weight of the cement for first trial).
5.3 Mi9x with help of a spatula for about 30 seconds. Then mix with hand for
about a minute. Prepare a ball of the paste & toss it from one hand to another
at least six times and then fill into the mould, cre should be taken to see that
it is filled from large end and towards short end and no pressure is used in
filling.
5.4 After completely filling the mould, smoothen the surface of the paste, making
it level with to top of the mould. The mould may be slightly shaken to expel
the air.
5.5 Place the larger end of the mould and the glass plate and whole assembly
under the rod bearing the plunger.
5.6 A standard plunger, 10 mm dia, 50 mm long is attached and brought down to
touch the surface of the paste, in the mould and quickly released allowing it
to sink into the paste by its own weight. This operation shall be carried out
immediately after filling the mould.
5.7 Take the reading by nothing the depth of penetration of plunger.
5.8 The whole process of adding water to penetration should finish within 3 to 5
minutes from the moment water added to the cement and these should be no
vibration of any type on the table.

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