Final Chambal Pressure Vol - IV QC Manual

VOLUME-IV QUALITY ASSURANCE/CONTROL MANUAL CHAMBAL MICRO IRRIGATION PROJECT SHEOPUR
GOVERNMENT OF MADHYA PRADESH

Water Resources Department
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CHAMBAL MICRO IRRIGATION PROJECT

VOLUME-IV
QUALITY CONTROL MANUAL

WATER RESOURCES DEPARTMENT
BHOPAL (M.P.)
TENDER DOCUMENT
TURN KEY TENDER
NIT NO 02/G/CE/2012-13 Bhopal, dated : 27/8/2012
MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 1

VOLUME-IV
ﾧ Introduction
This section of the Quality Assurance/Quality Control Manual presents the Project’s
background, defines quality-related terms, and gives an outline of the Manual. The
importance of quality control of construction of works on Irrigation projects needs no
emphasis. Irrigation projects involve heavy expenditure and contribute to the prosperity of
the state. There may be loss of human life and life of structures may also get reduced if
projects are not executed properly. For above reason construction projects should proceed
with diligence as per prescribed specifications. To ensure execution of works as per standard,
constant control on quality is very necessary. This manual is brought out to guide field staff,
construction agency and supervisory staff of WRD to control and maintain quality as per
prescribed standard.
1.1 Background
GENERAL
Madhya Pradesh (MP) is the State of India having a geographical area of 30.8 million
hectares. The state is predominantly agriculture-oriented as 80% of its population is
dependent on agriculture. The net shown area of the state is 14.96 million hectares.
1.2 Objective of quality control manual
The Project is unique in its nature and complexity. In view of this complexity, it is essential
and important to put in place a comprehensive, consistent, and common system for quality
assurance and control during construction of Project. Generally the quality control manual is
based on the practices prescribed by Indian Standards and specification of the Department,
when any specifications are not provided in this manual the standard practices prescribed by
B.I.S. shall prevail.
1.3 Quality Definitions
Quality is the totality of features and characteristics of a product or service that bear on its
ability to satisfy a given need. The term 'given need', in case of project works, can be
interpreted as the functional requirements. The quality of outputs is always agreed upon
between the supplier and the client (in project works, contractor and the Employer), and the
quality objective must be to achieve zero defects. It can be made possible only by ensuring
the quality at all stages of project works.
The following are some definitions pertaining to quality and how to achieve it:
Quality: Conformance to requirements.

Quality Control (QC): The operational techniques and activities (such as reviewing, checking,
inspecting, testing, etc.) that are used to fulfill requirements for quality.
Quality Assurance (QA): The planned and systematic actions necessary to provide adequate
confidence that the work will satisfy quality requirements.
Quality System (QS): A set of documented processes, which seek to provide confidence that
the project outputs will fulfill the functional requirements. The Quality System should
encompass the organization, responsibilities, human resources, materials, equipment,
processes, inspections, testing and other parameters of the project. A key element of QS is the
QA/QC Manual.
Quality Surveillance: This normally covers two aspects:
At the project level, a review to ensure that the quality practices are implemented and
documented in relation to the quality system; and
At the contract package level, inspection and testing to ensure that the works executed meet
the required quality standards.
1.4 QA/QC Manual

This QA/QC Manual focuses on the implementation activities of the project following
contract award, and primarily on supervision and quality control of construction works. The
QA/QC Manual is intended to be used primarily by the project staff of the Engineer’s
Representative and the Supervision Consultants.
The QA/QC Manual for the Project does not attempt to suggest technical
specifications, since these are stated in the contract documents. Its aim is to ensure that the
works are executed as per specifications. Quality control and test results shall be interpreted
as applicable for Contract Package, in accordance with the contract conditions.
2.0 GENERAL - construction quality control –
This section provides an overview of construction quality control activities, including testing
and site inspection.
2.1 Introduction
Construction quality control (CQC) is intended to provide a comprehensive, common and
consistent framework for the project. CQC comprises two main elements of quality control:
Testing
Inspections
Testing control covers the type of tests to be carried out, frequency of testing and g.
Inspection control covers the timing of inspections, what has to be inspected and the
inspection procedures.
CQC should be affected at five stages:
Input Materials and Equipment Components
In-process Activities
Stage Completion
Interfacing
Final Completion
2.2 Testing
Various site tests on materials and works are required to be carried out by the Contractor
during construction. A well equipped and properly operating site test laboratory is an
important element of the quality assurance plan. A checklist showing typical testing
equipment to be provided in the contractor’s site laboratory as indicated in Table 2.1.
The contractor shall set-up the site laboratory at the start of his project and informs the
Engineer-in-Charge and the Consultant for conducting inspections. Laboratory equipment
shall be properly calibrated, and calibration certificates should be kept at the laboratory for
review by Engineer-in-Charge and Consultant, as necessary. Specialized tests at outside
laboratories shall only be undertaken with the prior approval of the Engineer-in-Charge at
Contractor’s cost.
Tests should be performed in accordance with the contract documents, as described in this
Manual. All test samples should be preserved, with proper identification numbers and other
applicable information. These samples must be stored on site by the contractor.
In addition to the site laboratory the Contractor shall have mobile laboratories to collect
samples and carry out tests of various sites as the work is scattered and spread in wide area.

Table 2.1
Checklist of Site Testing Laboratory Equipment
Contract No: ______Name of Work:___________ Contractor Name:____________
Testing Equipment
Type of Test
Yes
(1)
No
(1)
Balance (2 type) volume measuring apparatus & hand tools etc.

General laboratory test
Electronic Balance
For general measurement purpose
Oven
Drying and moisture content determination
Sieves, sieve shaker and hydrometer

Grain size analysis and classification of soil and aggregates
Atterberg limit apparatus

Plasticity of Soil
Procter/modified proctor (IS heavy) density equipment

Soil compaction test
Sand replacement cylinder and core cutter

In-situ density test for field compaction control

Compression testing machine 100 MT and 5 MT capacity

Compressive strength of cement, concrete, brick, etc.
Cylinder and cube moulds

Concrete sampling
Slump test
Workability and control of water in concrete casting
Vicat apparatus
Setting time determination of cement
SPT equipment and hand auger

Boring, sampling and soil strength test
Unconfined compression testing machine

Determination of shear strength of cohesive soil
Direct shear equipment

Determination of angle of internal friction of soil
Consolidation test equipment

Determination of settlement /compressibility of soil
Los Angles Abrasion test/ Impact Testing Machine

Los Angeles Abrasion test/ Impact Test
Core drilling equipment

In-situ sampling

Measuring instruments
Measurement of sizes
Marshal stability test equipment

Road works. To be available at Hot Mix Plant site.
Leveling instruments
Tolerances of roads surfaces
Permeability testing Instrument
Swelling Pressure Test Instrument
Tests for rising main pipes & pipe joints
Note: 1. Yes or No to be tick marked by Engineer-in-Charge to indicate the equipment

at the site laboratory)
In addition to tests performed on site, the contractor is responsible for specialized tests which
are performed at approved laboratories, and for factory inspections.
2.3 Site Inspections

Site inspections shall be carried out to ensure that the materials and construction activities
conform to the prescribed standards. Site inspections can be divided into day-to-day
supervision and periodic quality inspection. The suggestions in respect of these two have
been elaborated herein.
2.3.1 Day-to-day supervision
The Employer’s Representatives, Consultant appointed by the Department, Department
Officers shall carry out the day-to-day site supervision of construction activities. This
includes checking of lines, levels and layouts.
2.3.2 Periodic quality inspections

The Consultant appointed by the department & Engineer in Charge shall carry out
periodic quality inspections during in-process, stage completion, interfacing and final
completion, and during all critical activities as per the following examples:
excavation
placing of reinforcing steel
concrete batching and pouring
Pipe laying & associated works
2.3.3 Squad checks
The concept of Squad Checks has been adopted to have an external review of quality
of works executed. For squad checking Employer may appoint teams to inspect the work
from time to time. The tentative agenda for squad checking is described as below:
physical inspection of the works under execution and inspection of quality of workmanship;
review of site documentation and contractor compliance;
sample verification of test reports and quality certificates;
review of issues, constraints and lacunae in quality system implementation;
preparing of action plans for improving the quality; and
performance appraisal of the contractors.
3.0 Control of Materials Components
This section provides an overview of control requirements for materials, including site testing
and manufacturers’ certification.
3.1 General
Control and approval of construction materials and equipment components to be incorporated
in the works shall be based on the following:
Test reports for materials tested at site, such as soil, cement, sand, water and aggregates,
rising main etc. the contractor will perform all tests. The Employer’s
Representatives/Consultant appointed by the Department/Department Officers shall
witness/carry out necessary test on the material.
Manufacturer’s certificates and IS mark for manufactured items indicated in table 3.2 or as
stipulated in the contract.
Reference IS code for testing of material is list down in the table 3.3.
3.2. Materials Tested on Site
The materials to be tested on site include cement, water, aggregates for concrete, soil for
embankments, and materials for road works. For aggregates and soil, the contractor shall
obtain the approval of the borrow source or quarry from the Engineer-in-Charge before
extracting material. The list of materials to be tested on site is given in Table 3.1 below. The
reports are to be maintained in a bound register.
Table 3.1
List of Materials Tested on Site
Sl. No.
Material

Cement
Sand
Water for Construction Works
Coarse Aggregate for Concrete Work
1. Granular Sub-base (GSB) Material

2. Material for WBM
3. Metal for BM
4. Binder for WBM
5. Rising main Pipe & Pipe joints
3.3 Materials and Equipment Certified By Manufacturer
Acceptance of certain manufactured materials and equipments, components, as
stipulated in the contract, shall be based on test certificate(s) from the manufacturer
conforming to IS and on visual inspection. These items shall bear the IS mark.
Materials and equipment subject to manufacturer’s certification are listed in Table 3.2.
Table 3.2
List of Materials and Equipments Certified by Manufacturer
 Reinforcement Steel
 Paint, Primers and Protective Coatings
 Water Proofing Compound
 Metal Works such as MS ladder, footrest etc.
 Flow Measuring Devices – General
 Level Indicator & Controllers
 Laboratory Equipment
 All other items as specified in the contract documents
 Steel plates for pipe fabrication.
 Pumps
 Transformers
 SCADA equipment, control equipment,
 All electro-mechanical & hydro-mechanical components/equipment.
 Epoxy coatings
3.4 Details of reference Indian Standard for testing of material
Table 3.3
Details of reference Indian Standard for testing of material
Sr. Test Reference Indian Standard
No.
1. Water
.pH value IS IS-3025
Coarse Aggregate
Sieve analysis IS 2386 (Part 1): 1963
Unit Weight IS 2386 (Part 3): 1963
Sr. Test Reference Indian Standard

No.
Water absorption IS 2386 (Part 3): 1963
Specific gravity IS 2386 (Part 3): 1963
Impact value IS 2386 (Part 4): 1963
Abrasion value IS 2386 (Part 4): 1963
Crushing value IS 2386 (Part 4): 1963
Soundness IS 2386 (Part 5): 1963
Surface moisture IS 2386 (Part 3): 1963
2. Sand
Fineness modulus IS 2386 (Part 1): 1963
Unit weight IS 2386 (Part 3): 1963
Silt and Clay IS 2386 (Part 2): 1963
Bulking IS 2386 (Part 3): 1963
Moisture Content IS 2386 (Part 2): 1963
Water absorption IS 2386 (Part 3): 1963
3. Cement
Consistency IS 4031 (Part 4): 1988
Initial and final setting time IS 4031 (Part 5): 1988
Compressive strength IS 4031 (Part 7): 1988
Adulteration of cement IS 4031 (Part 6): 1988
Chemical test IS 4035: 1985
Specific surface IS 4031 (Part 2): 1988
4. Concrete
Compressive strength IS 516: 1959
Slump IS 1199: 1959
Permeability IS 3085: 1965
5. Soil
Standard Compaction test IS 2720 (Part 7): 1980
Atterberg’s limits IS 2720 (Part 5): 1985
Grain size analysis IS 2720 (Part 4): 1985
Shear strength (triaxial shear test) IS 2720 (Part 11): 1971
Permeability tests IS 2720 (Part 17): 1986
Swelling pressure IS 2720 (Part 41): 1977
Total soluble solids IS: 2720 (Part 21)
6.0 M.S. Pipe

`Seamless / electrically welded steel pipes for water, gas, IS 3589
Sewage - specification.
Recommended practice for Radiographic inspection of fusion IS: 4853

welded butt joints in steel pipes.
Recommended practice for ultrasonic butt weld in ferric steel.

IS:4260

Methods of testing fusion welded joints and weld mains in steel:

IS:3600 (Part – I)
part 1 cruciform fillet weld tensile test
Sampling of pipe for various tests and criteria for conformity. IS : 4711
Methods of tensile testing of steel tubes. IS:1894
Hot - Rolled Steel Strip for Welded Tubes and Pipes

-Specifications IS:10748
Dimensions for Steel Plates, Sheets, Strips and Flats for

General Engineer-in-Charge Purpose
IS:1730
7.0 DI pipes
A. Ductile Iron is made by a metallurgical process which I S 8329-1994
involves the addition of magnesium in to molten iron of ( ISO: 2531-1998 EN-
low sulfer content. It is 30% lighter than C I pipes. 545-1994)
B. Ductile Iron fittings.
C. DI pipe joints (use rubber gasket confirming to) IS 9523-1980
IS 5389
Note : All the latest & relevant ISI codes and references for all materials to be used are to be followed & will
be applicable.
4.0 Control of General Earth works in WORKS :
This section of the QA/QC manual cover the testing of works and the inspection of workmanship for
general earthworks in balancing reservoir.
4.1 Soil identification and description

Before testing a soil, the sample has to be examined and data obtained from visual inspection is to be
noted. This includes noting of colour, odour, presence of minerals, presence of organic and foreign
matter and geological history as may be often evident from visual inspection. The visual inspection aids
the development of a feel soil behavior and it helps in interpretation of the results, obtained. A possible
error in sample numbering will also be detected in case the visual inspection does not tally with actual
results in the laboratories. An experienced technician can even predict the behavior of a soil with
sufficient accuracy by working it in his hand and inspecting it carefully. At the conclusion of a test, the
laboratory technician should check to see that the results are in agreement with what was expected
from his visual classification.
4.2 Testing of Works
The soil sample have to be inspected and tested as soon as after their arrival at the laboratory. The soil
proposed to be used in these works must have been tested by the contractor and approved by
Employer’s Representatives/Consultant appointed by the Department/Department Officers. The
contractor shall submit the soil testing report to the Engineer-in-Charge.
Tests and frequency of test for general earth works in Work are listed in Table 4.1. Test report formats
are included in Appendix A. The contractor shall conduct tests as stipulated. The Representative of
Consultant and Engineer-in-Charge will witness the test conducted.

Table 4.1
Statement showing test and frequencies of various tests for earthwork
Sr. Name of Test Investigation Design Construction Record Test Remarks
No.
1. MOISTURE CONTENT Before the commencement
of day’s work/shift, one
sample shall be tested for
each of the construction
soils separately. Sample is
to be collected from the
spot where the material is
proposed to be brought on
embankment.
2. SPECIFIC GRAVITY For each 0.75 Mm3 of soil For each 0.15 Mm3 of
explored 3 tests for every zone each soil type
separately including filter 3 tests investigated, 5 tests
minimum for each quarry. for each of the zone
including filter, 5 tests
minimum for each
quarry.
3. GRAIN SIZE ANALYSIS For every 1 Mm3 or less soil For every 0.15 Mm3 or Two samples for 150m x The frequency for each
explored, 6 tests for material to less of each soil type 150m borrow areas test is as below
be used in each of the zone of the investigated for each proposed to be utilized. For
embankment separately, 12 tests zone 5 tests for each any change of material
for filter zones, 3 tests minimum zone and 20 tests for minimum 2 samples shall
for each quarry filter, 5 tests minimum tested. Total Earth Frequency
for each quarry. work (for each
work for
each zone)
Below 0.5 1 per
Mm3 10,000 m3
0.5 Mm3 to 1 per

1.5 Mm3 15,000 m3
1.5 Mm3 to 1 per

3 Mm3 20,000 m3
Above 3 1 per
Mm3 40,000 m3
5. ATTERBERG LIMITS Same as above, no tests for filter Same as above, no As per record tests Separate tests are to be
material. tests for filter material. conducted for each zone.
Samples to be collected
from different locations
and elevations so as to be
truly representative.
6. SHRINKAGE LIMIT Not required Not required As per record tests In addition to the above, a
set of record tests are to be
taken at instrument
installation. One
undisturbed sample shall
be taken at each
embankment piezometer
immediately prior to the
excavation of offset side
trench
7. COMPACTION For each 0.75 Mm3 soil explored, For each 0.15 Mm3 of For Total progress up to In case of vertical
12 tests for each zone separately; each soil type 1,500 m3 per day, one settlement gauge,
minimum 3 tests for each quarry. investigated 5 tests for test/day shall be conducted installation, two samples
each zone separately; i.e., one day on Hearting shall be taken for each
minimum 5 tests for soil, next day on Casing cross arm installation, one
each quarry. soil, third day on Random at the bottom of trench
fill and so on. If there be excavated for cross arm
any change in soil, and the other in the
additional one test/day shall tamped back fill of the
be conducted. For total trench after it has been
progress beyond, 1500 m3 brought up to the adjacent
per day, daily one test for embankment level.
each of the construction
soils shall be conducted.
8. TRIAXIAL SHEAR For each 0.75 Mm3 soil explored, For each 0.15 Mm3 of

6 tests for each of the zones, each soil type

separately, minimum 3 tests for investigated 5 tests for
each of quarry. each of zones;
minimum 5 tests for
each quarry.
9. RELATIVE DENSITY Not required If directed specifically One test per 1,500 Mm3 of Not required
material
10. PERMEABILITY 5 tests on each type of soil 2 tests for each zone As per record tests Test mentioned at S. Nos.
separately including (1) to (7) of this annexure
filter, minimum 5 tests are to be conducted as
for each quarry Record Tests.
11. FIELD DENSITY (SAND Per day two tests per first Test mentioned at S. Nos.
REPLACEMENT 300 cum, Earth work and (1) to (7) of this annexure
METHOD) then one test per every are to be conducted as
additional 300 cum. Record Tests.
Separately, separate tests
shall be conducted for each
zone
12. FIELD DENSITY TEST Per day two tests per first Test mentioned at S. Nos.
FOR SOIL (CORE 300 cum, Earth work and (1) to (7) of this annexure
CUTTER METHOD) then one test per every are to be conducted as
additional 300 cum. Record Tests
Separately, separate tests
shall be conducted for each
zone
13. PLACEMENT One test per 20 sqm of the Not required
MOISTURE placed material before
(PENETROMETER rolling. Minimum 3 tests
METHOD) shall be performed on the
placement.
14. NEEDLE DENSITY The penetration resistance Not required.
(PENETROMETER shall be observed at 20 m
METHOD) along length and breadth of
area under compaction and
also at places of doubtful
compaction.
15. RISING MAINS Relevant Electrical &
(Pipe, Pipe joints and mechanical work testing as
pumps, transformers, applicable.
SCADA etc)

1.0 Control of General Civil and Structural works
This section of the QA/QC Manual covers the testing of works and the inspection of workmanship for general
civil and structural works. The key elements to be inspected in these works are concreting, and finish. The
requirements for testing and control of materials for these works are outlined in Section 3.
5.1 Construction Sequence and Control Flow Charts

Flow charts indicating the construction sequence and control points for cement concrete is shown in Figure
5.1.

All the materials proposed to be used in cement concrete works must have been tested by the contractor and
approved by the Employer’s Representatives/Consultant appointed by the Department/Department Officers
well in advance of these works. The contractor shall submit the concrete pouring report to the Engineer-in-
Charge and Consultant as and when concreting is done.
Tests and frequency of test for cement concrete works are listed in Table 5.1. Test report formats are included
in Appendix A. The contractor shall conduct tests as stipulated. The Representative of Consultant and
Engineer-in-Charge will witness the test conducted.
5.3 Inspection Checklists
Inspection checklists for concreting and finishes, and building services and finishes are presented in Appendix
A.
5.4 O.K. CARDS AND TEST RESULTS FORMATS :
O.K. Cards and test results formats are given for general guidance. These may be suitably modified by
Engineer-in-Charge in consultation with Employer(s) consultant and contractor to meet with requirements of
works.

5.1

Table 5.1
List of Tests and frequency of test for concrete work
Sr. Name of test Frequency of test Remarks

No Mass concrete Small concrete jobs and
RCC Works
1. Adulteration of cement One per every 50 tonnes One per every 50 tonnes of
of cement cement
2. Fineness by dry sieving One per every 50 tonnes One per every 50 tonnes of
of cement cement
3. Setting time One per every 50 tonnes One per every 50 tonnes of
of cement cement
4. Soundness (Le-Chatellier’s One per every 50 tonnes One per every 50 tonnes of
method) of cement cement
5. Determination of Consistency of One per every 50 tonnes One per every 50 tonnes of
standard cement paste of cement cement
6. Particle size analysis of Once a week, additional if Once a fortnight, additional if

aggregate source is changed. source is changed
7. Flakiness Index of coarse Once a week, additional if Once a fortnight, additional if

aggregates source is changed. source is changed
8. Silt test on fine aggregate Once a week, additional if Once a week, additional if
source is changed source is changed
9. Clay, fine silt and fine dust in Once a week

aggregate (sedimentation
method)
10. Surface moisture content in fine One per shift per stock Once a fortnight
aggregate (Hot plate method) pile
11. Surface moisture content in fine Once a week One per shift of stock pile
aggregate (laboratory method)
12. Bulking of fine aggregate One per shift per stock Once a fortnight
pile
13. Specific gravity and water Once a week One per shift per stock pile
absorption for aggregates (up to
10 mm size)
14. Specific gravity and water Once a week Once a fortnight
absorption for aggregates (above
10 mm sieve)
15. Slump of cement concrete One per every two hours One per every two hours
working per mixer working per mixer
16. Density and air contents of fresh One per week, additional One per mixer per month,
concrete if source of aggregate is additional if source of
changed aggregate is changed.
17. Compressive strength of Up to 100 cum work per One per shift per mixer
moulded cement concrete day one per shift per mixer (separately for each
specimen proportion)
18. Alkalinity and acidity test for Once per source of supply Once per source of supply
water to be used in concreting

6.0 Control of Road Works

This section of the QA/QC Manual covers the testing of works and the inspection of workmanship for road
works, including earthworks, placement of sub-base and WBM layers, application of prime and tack coats, and
placement of bituminous layers. The requirements for testing and control of materials for road works are
outlined in Section 3.
All the materials proposed to be used in road works must have been tested by the contractor and approved by
the Employer’s Representatives/Consultant appointed by the Department/Department Officers well in advance
of these works.
Tests and frequency of test for road works are listed in Table 6.1. Test report formats are included in Appendix
A. The contractor shall conduct tests as stipulated. The Representative of Consultant and Engineer-in-Charge
will witness the test conducted.
6.2 Inspection Checklists

An inspection checklist for road works is presented in Appendix A.
Table 6.1
List of Tests and frequency of test for Road Work
Sl. No. Type of Test Frequency of Test
1. Moisture content as per IS-2270 1 test per 250 m3 or part thereof
2. Gradation by wet sieve analysis 1 test per 200 m3 or part thereof
3. Atterberg limits --- do ---
4. Deleterious constituents --- do ---
5. OMC and MDD --- do ---
6 Aggregate Impact Value One test for 200 m3
7 Grading by wet sieve analysis One test for 100 m3
8 Flakiness Index and Elongation Index One test for 200 m3 of aggregate
9 Atterberg limits of binding material One test for 25m3 of binding material
(Only for WBM)


O.K. CARD
FOR
LAYOUT OF STRUCTURES
For use by construction Engineers
o. k. card no.______________ date,____________
1. Name of structure :
2. Location : R.D./C.H.___________to_________
Village________________________
3. Alignment of Gond Dam Project to be

walked over by and approved by officer in-
charge(Department)
Reference to GTS B.M.

4. Location:
Value:
5. Surveyed by Contractor. :
:
6. Checked by Sub Engineer or AE.
:
7. Approved by S.E.
CONTRACTOR CONSULTANT/DEPARTMENT
S/E (WORKS) A.E. (WORKS) E.E. (WORKS)


O.K. CARD
FOR
FOR CONCRETE WORK IN FOUNDATION & PLINTH
O.K. Card No. ______________ Date _____________ Shift__________

1. Name of Work :
2. Location of work :
(i) Block Bo. : ______________ to ______________
(ii) R.D./C.H. : ______________ to ______________
(iii) Offset : ______________ to ______________
(iv) Lift R.L. : ______________ to R.L. ___________
3. Name of Agency :
4. Method of concrete mixing :
(i) Mixer vol./wt. :
(ii) Batching vol./wt. :
5. Method of Placing (i) Dropping from top (ii) Dropping by Bucket
(iii) Hand Placing.
6. Method of Consolidation :
(i) Mech. Vibrator
(ii) Hand keeping by trowel
(iii) Hand tamping by rod
7. (i) Grade of mix
(ii) Proportion (designed)
(iii) Slump required
(iv) Max size of aggregate required to be used
(v) Designed strength.. ………………….. kg / sq. cm.
8. Date and Time (i) Starting __________ (ii) Finishing________

CONTRACTOR CONSULTANT/DEPTT. S/E/ A.E./E.E. (WORKS)
2/2
S. Date For use by QC personal Cube Mix W/C F.M. Max. size Unit wt. Remark
No. of Location of test No. portion of ratio of of Of agg.
test Blo Off RL concrete sand aggregate
ck RD set
1 2 3 4 5 6 7 8 9 10
Remarks (i) General Quantity of Material

(ii) Oversize/Under size
(iii) Segregation/bleeding
(iv) Surface cleaning
(v) Workmanship
(vi) Others


O.K. CARD
FOR CONCRETE WORK IN SUPERSTRUCTURE
O.K. Card No. _________________ Date ___________ Shift____________

1. Name of Work :
2. Location of work :
(i) Block Bo. : ______________ to ______________
(ii) R.D./C.H. : ______________ to ______________
(iii) Offset : ______________ to ______________
(iv) Lift R.L. : ______________ to R.L. ___________
3. Name of Agency :
4. Method of concrete mixing :

(I) Hand vol./wt.
(ii) Mixer vol./wt. :
(iii) Batching vol./wt. :
5. Method of Placing (i) Dropping from top (ii) Dropping by Bucket

(iii) Hand Placing.
6. Method of Consolidation :
(i) Mech. Vibrator
(ii) Hand keeping by trowel
(iii) Hand tamping by rod
7. (i) Grade of mix

(ii) Proportion (designed)
(iii) Slump required
(iv) Max size of aggregate required to be used
(v) Designed strength.. ………………….. kg / sq. cm.

8. Date and Time (i) Starting __________ (ii) Finishing________
2/2
S date For use by Q.C. Personnel Cube Mix W/C F.M. Max. size Unit wt. Remark
N of test Location of test No. portion of ratio of of Of agg.
o Block Off RL concrete sand aggregate
. RD set
CH
1 2 3 4 5 6 7 8 9 10
Remarks (i) General Quantity of Material
(vii) Oversize/Under size
(viii) Segregation/bleeding
(ix) Surface cleaning
(x) Workmanship
(xi) Others


O.K. CARD
FOR
FOR EARTH WORK
O. K. Card No.______________ Date,__________ Shift____________
1. Name of Work :
2. Location of work
(i) R.D. / C.H. : _____________to______________
3. Depth of filling :
R.L. of the previous layer :
RL of the present layer :
4. Type of roller used____________No. of passes______________
5. Surface preparation
(i) Stripping :
(ii) Narrowing :
(iii) Removal of vegetation :
(iv) Watering :
6. Date and Time start of rolling :
7. Date and Time of completion of rolling :
8. Any other information or reference :
2/2
(For use of Q/C Personnel)
S. Particulars Results Remarks (State short coming or O.K. for fresh layer)
No.
1 2 3 4 5
1. Date of test
2. Surface preparation
3. Field classification of soil
4. Borrow area grid No. __________pit No._____________
5. Location of test
(i) R.D.
(ii) Offset
(iii) R.L. __________________________

6. Thickness of layer.
7. Wet density Of rolled fill
8. Moisture content of rolled fill
9. Dry density of rolled fill
10 Laboratory data
(i) OMC
(ii) MDD.
11 Compaction efficiency
12 Trimming and finishing of side slopes


Test results of Post-checking of Rolled fill of ______________ embankment at RD __________for compaction

efficiency.
S. No. Date of Laboratory Location Fill Embankment

Sampling Sample No. Ch. Offset RL M/C % Dry
Density
1 2 3 4 5 6 7 8
1.
2.
3.
4.
5.
Contd.
Proctor’s Compaction Compaction eff. % Deviation in Remarks
OMC MDD kg/cm3 (%) M. C. C. E.
9 10 11 12 13 14
Note: -
1. % deviation in MC = (OMC - Embankment M. C. x 100)
O. M. C.
2 % deviation in C. E. = (Prescribed C. E. - C. E. Attained)
Prescribed Comp. Efficiency
Negative sign shows results on higher side which, is desirable for (2) but undesirable for (1)
Laboratory in Charge (Contractor)
CONSULTANT/DEPTT. S/E/ A.E./E.E. (WORKS)


Test results of Post-checking of Rolled fill of ________________________ embankment at RD __________for

permeability.
S. No. Date of Laboratory Location Rolled filled dry

Sampling Sample No. density
Ch. Offset RL Dry Density
1 2 3 4 5 6 7
Contd.
% MC of the fill Permeability of U/D sample Test not performed as per Remarks
(n/year) Frequency
8 9 10 11
Laboratory in Charge (Contractor) Consultant/DEPTT. Supervisor/Officer from

Department
No ___________/ Date_____________
Forwarded to the EE, Consultant/DEPTT. S.E. for necessary action


Test results of soil sample of Borrow area/embankment at RD __________ Ref.__________(if any)
S. No. Laboratory Location of Natural Specific Total Grain size analysis (IS 2720 (Part 4)
Sample No. Borrow Pit dry Gravity gravel IS Sand 2.02 Silt 0.02 Clay
No. of RL/ density No 480 mm% to 0.002 0.002 mm
Ch. off kg/m3 mm% %
1 3 4 5 6 7 8 9 10

Department
No ___________/ Date_____________
Forwarded to the EE, Consultant/DEPTT., S.E. for necessary action


Test results of sand samples Conducted at Central Laboratory / Field Laboratory
Location: Quarry/Stack __________________Reference

1. SIEVE ANALYSIS (IS-2386)
Sieve Sieve Size Retained on Cumulative Passing Grading Limits/Remarks
No. (mm) Each Sieve (% Percentage Through
Wt) Retained (%Wt)
2. FINENESS MODULUS: _________________

Department
No ___________/ Date_____________


Test results of Coarse aggregate samples Conducted at Central Laboratory / Field Laboratory

GRADATION/SIEVE ANALYSIS
Sieve Sieve Size Wt. Of Retained on Cumulative Passing Grading
No. (mm) material Each Sieve (% Percentage Through Limits/Remarks
retained (g) Wt) Retained (%Wt)
Comments of Laboratory In-Charge ________________________________________

________________________________________

Department
No ___________/ Date_____________


Test results of coarse aggregate samples Conducted at Central Laboratory /Field Laboratory
Water Absorption test

Sl.No Wt. of Oven Wt. of Wet Wt. of Water % of Water Remarks
Dried Material Material Absorbed Absorbed
(gms) (gms) (gms)
Water Absorption of Material :______________

Comments of Laboratory Assistant _______________________________________
________________________________________
Laboratory In-Charge (Contractor) Consultant/DEPTT. Supervisor/Officer from

Department
No ___________/ Date_____________
Forwarded to the EE, Consultant/DEPTT. SE for necessary action



Test results of coarse aggregate samples Conducted at Central Laboratory / Field Laboratory

AGGREGATE IMPACT VALUE TEST
No. Detail Unit Trial
1 2 3 4 5
1 Wt. of dry aggregate passing 12.5 Gms
mm and retained on 10 mm sieve +
cylinder measure
2 Wt. of cylindrical measure Gms
3 Wt. of dry aggregate taken (1)-(2) Gms
4 Wt. of crushed aggregate passing Gms

2.36 mm sieve after subjecting the
test specimen to 15 blows
5 Aggregate Impact Value %
100*(4)/(3)
Average Value : ____________
________________________________________

Department
No ___________/ Date_____________


Test results of Coarse aggregate samples conducted at central laboratory/field laboratory

FLAKINESS AND ELONGATION INDEX TEST
Sieve Range Total Wt. Wt. Of Flakiness Wt. Of Wt. Of Elongation

(mm) of Aggregate Index Non-flaky Aggregate Index
Aggregate Passing Sample Passing
(gms) Thickness Elongation
Gauge Gauge
63-50
50-40
40-31.5
31.5-25
25-20
20-16
16-12.5
12.5-10
10-6.3
Flakiness Index ___________
Elongation Index ___________
Comments of Laboratory In-Charge_______________________________________
______________________________________

Department
No ___________/ Date_____________



Test results of coarse aggregate samples Conduct at Central Laboratory / Field Laboratory
SOUNDNESS TEST
No. Detail Unit Number of Cycle
1 2 3 4 5 6 7 8 9 10
1 Wt. Of clean dry aggregate of Gms
specified size range
2 Wt. of dry aggregate dried in oven Gms
after each cycle
3 Loss of aggregate after 10 number of Gms
cycles subject to immersion and oven
drying after each cycle
=(1)-(2)
4 Soundness Value
=100*(3) / (1)
Average Value : _____________

________________________________________

Department
No ___________/ Date_____________


Test results of Water samples conducted at central laboratory.
Sl. No Color pH Value Organic Inorganic Sulphates Chlorides (as Suspended

Solids Solids (as SO4) Cl) Matter
(mg/l) (mg/l) (mg/l) (mg/l) (mg/l)
Limits >6 <200 <3000 <500 PCC <2000 <2000
RCC <1000
Traces of Oil & Grease ____________________________
Average Hardness as CaCO3 ____________________________________________
Comments of Laboratory In-Charge ______________________________________

________________________________________
Department
No ___________/ Date_____________


Test results of soil sample of Borrow area/embankment at RD __________ Ref.__________(if any) Central Laboratory
MOISTURE CONTENT TEST (FIELD)

Test No. 1 2 3 4 5
Container No.
Wt. Of wet soil taken (Sw)
Wt. Of dry soil in pan (Sd)
Wt. Of water (W=Sw-Sd)
Moisture content
= 100* W/Sd
Comments of the Laboratory In-charge
Laboratory In-Charge Consultant/DEPTT. Supervisor/Officer from Department
No ___________/ Date_____________
Laboratory in Charge


FIELD DENSITY TEST BY SAND REPLACEMENT METHOD

Daily Log Ref.________ No. of Samples Tested:____ Date Sample Collected : _____
Date __________ Tested as per IS-______ Tested : _______
I. Determination of Bulk Density of Sand
Sl.No Particulars Unit Trial No
1 2 3
1 Inside dia. Of calibrating container Cm
2 Inside height of calibrating container Cm
3 Volume of calibrating container CC
4 Wt. of sand + cylinder before pouring Gm
5 Wt. Of sand in the cone Gm
6 Wt. Of sand + cylinder after pouring in calibrating container Gm
7 Wt. Of sand filling with calibrating container Gm
8 Bulk density of sand Gm/cc
II. Determination of Bulk Density of Soil In-situ
1 2 3
1 Wt. Of wet soil from hole Gm
2 Wt. Of sand + cylinder after pouring into the hole Gm
3 Wt. Of sand in the soil Gm
4 Volume of the hole CC
5 Bulk density of soil in-situ Gm/cc
III. Determination of Dry Density of Soil In-situ
1 2 3
1 Container No.
2 Wt. Of container Gm
3 Wt. Of container + wet soil Gm
4 Wt. Of container + dry soil Gm
5 Wt. Of dry soil Gm
6 Wt. Of water Gm
7 Water content % %
8 Dry density Gm/cc

Forwarded to the EE, Consultant, SE for necessary action


FREE SWELL INDEX TEST FOR SOILS
Source Of Supply: Quantity: _____ T/M3

Consignment No.: _____ No. of Samples Tested:_____ Date Sample Collected: ______
Stores Entry No.:______ Tested as per IS-_____ Tested: ______
Oven Dry Soil Passing Through Glass Graduated Cylinders
WEIGHT OF EACH SAMPLE
425-micron IS Sieve _____ ml size
____ gms
1. Volume of Soil Specimen read from the Graduated Cylinder

Containing Distilled Water (Vd) ______ ml
2. Volume of Soil Specimen read from the Graduated Cylinder

Containing Kerosene (Vk) ______ ml
3. Free Swell Index .. 100 x (Vd-Vk)/Vk ______ %

________________________________________

Department
No ___________/ Date_____________


_________________
LIQUID LIMIT AND PLASTICITY INDEX (Atterberg limits)
Sr. Particular Unit Liquid Limit Plastic limit

No. 1 2 3 4 5 1 2 3
1. No. of blows No
2. Cup No.
3. Wt. of cup+wet soil (W1) g
4. Wt. of cup+dry soil (W2) g
5. Wt. of water = W3=(W1-W2) g
6. Wt. of cup = W4 g
7. Wt. of dry soil W5=W2-W4 g
8. Moisture content W=W3/W5x100 %
Liquid limit WL : %
Plastic limit, Wp : %
Plasticity index, Ip = WL - Wp = %

________________________________________

Department
No ___________/ Date_____________


OMC & MDD TEST

No. of Samples Tested:_____ Date Sample Collected : ______
Tested as per IS-_________ Tested : ________
a) Bulk density
Sr. Particular Unit Test no.
No. 1 2 3 4 5 6 7 8
Wt. of mould + compacted soil
(W1)
Wt. of mould (W2) g
Wt. of compacted soil (W1 - W2) g
Volume of mould (V) cc
Wet density (rb) (W1-W2)/V g/cc
b) Dry density
Sr. Particular Unit Test no.
No. 1 2 3 4 5 6 7 8
1. Wt. of cup + wet soil (W3) g
2. Wt. of cup + dry soil (W4) g
3. Wt. of water = W5=(W3-W4) g
4. Wt. of cup (W6) g
5. Wt. of dry soil, W7=W4-W6 g
6. Moisture content %
=W=(W5/W7)x100
7. Dry density = rd=rb(1+W/100) g/cc
Maximum dry density

Mean MDD : g/cc _____________
Mean OMC : % _____________

________________________________________

Department
No ___________/ Date_____________


Test results at RD __________ Ref.__________(if any) Central Laboratory

CONCRETE COMPRESSIVE STRENGTH TEST
Pour Card No: Pour Card Date: Quantity : _____ T/M3
Daily Log Ref.________ No. of Samples Tested:_____ Date Sample Collected : ______
Date __________ Tested as per IS-_________ Tested : ________
Sr. Particulars Unit Test no.

No.
1 2 3
1. Identification mark/Sample No.
2. Wt. of specimen kg
3. Length of specimen cm
4. Breadth of specimen cm
5. Height of specimen cm
6. Cross sectional area of the specimen cm2
7. Crushing load kg
8. Compressive strength kg/cm2
Average compressive strength of concrete = _______ kg/cm2

________________________________________
Department
No ___________/ Date_____________


Test results at RD __________ Ref.__________(if any) Central Laboratory

CONCRETE SLUMP TEST
Pour Card No: Pour Card Date: Quantity : _____ T/M3
Daily Log Ref.________ No. of Samples Tested:_____ Date Sample Collected : ______
Date __________ Tested as per IS-_________ Tested : ________
Sr. Particulars Unit Test no.

No. 1 2 3
1. Wt. of cement kg
2. Wt. of fine aggregate kg
3. Wt. of coarse aggregate kg
4. Water/cement ratio
5. Wt. of water kg
6. Slump mm
Average Slump of concrete = _______ mm

Department
No ___________/ Date_____________


DAILY CONCRETE REPORT
Test results at RD __________ Ref.__________(if any)

Where the concrete used:
Supervised By: Quantity : _____ T/M3
Daily Log Ref.________ Mix Grade: _______ Date Sample Collected : ______
Date __________ Time Start _____ Finish ____ Tested : ________
Concrete materials per bag of cement
Material Size TC Fineness Specific Impact Water Dry batch
Ref module gravity value absorption weight
Cement
Coarse Aggregate 1 CA1
Coarse Aggregate 2 CA2
Fine Aggregate
Water
Sieve Size Gradation % Finer No. of Concrete Cubes for Testing
CA1 CA2 FA
mm
40 Cube No
20
4.75 Time
2.36
1.18 Cube No
0.60
0.30 Time
0.15
Slump Test Temperature Test
Sl.No Time Value Sl.No Time Value Time Air Temperature Concrete Temperature
1 5
2 6
3 7
4 8
Forwarded to the EE, Consultant, SE for necessary action
Contractor Consultant/DEPTT. S/E/A.E./E.E. (Works)









VOL-II
ENGINEER-IN-CHIEF
BHOPAL M.P 2


QUALITY CONTROL INDEX PAGE
MANUAL VOLUME – II S.No
(1) Details of Field/Laboratory Annexure No.1
test and reference to ISI
(2) Statement showing the Annexure No.2
frequencies of various test
for earth work and
concrete/masonry
(i) Existing Quality control Annexure No.2-A
Laboratories
(3) PROCEDURE FOR DIFFERENT SOIL TESTS
(i) Grain size Analysis Annexure No.3/1
(ii) Consistency Limits (Liquid Annexure No.3/2
and plastic limits)
(iii) Shrinkage of Limit Annexure No.3/3
(iv) Engineering test for earth Annexure No.3/4
Dam, Design, (Compaction
Test)
(v) Permeability of soil Annexure No.3/5
(vi) Swell Pressure Test Annexure No.3/6
(vii) Shear strength (Triaxial Annexure No.3/7
Shear test)
(4) TESTING OF MATERIALS
(i) Testing Aggregate Annexure No.4/1
(ii) Determination of Annexure No.4/2
soundness of coarse and
Fine aggregate
(iii) Testing of Cement Annexure No.4/3
(iv) Testing of bricks Annexure No.4/4
(v) Testing of Hydrated Lime Annexure No.4/5
(vi) Testing of Pozzolana Annexure No.4/6
MADHYA PRADESH WATER RESOURCES DEPARTMENT, BHOPAL PAGE 51

Final Chambal Pressure Vol - IV QC Manual

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VOLUME-IV QUALITY ASSURANCE/CONTROL MANUAL CHAMBAL MICRO IRRIGATION PROJECT SHEOPUR

GOVERNMENT OF MADHYA PRADESH

CHAMBAL MICRO IRRIGATION PROJECT

GOVERNMENT OF MADHYA PRADESH

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 1

Quality: Conformance to requirements.

1.4 QA/QC Manual

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 3

Contract No: ______Name of Work:___________ Contractor Name:____________

Balance (2 type) volume measuring apparatus & hand tools etc.

Sieves, sieve shaker and hydrometer

Atterberg limit apparatus

Procter/modified proctor (IS heavy) density equipment

Sand replacement cylinder and core cutter

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 4

Compression testing machine 100 MT and 5 MT capacity

Cylinder and cube moulds

SPT equipment and hand auger

Unconfined compression testing machine

Direct shear equipment

Consolidation test equipment

Los Angles Abrasion test/ Impact Testing Machine

Core drilling equipment

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 5

Marshal stability test equipment

Permeability testing Instrument

Swelling Pressure Test Instrument

Tests for rising main pipes & pipe joints

Note: 1. Yes or No to be tick marked by Engineer-in-Charge to indicate the equipment

2.3 Site Inspections

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 6

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 7

Water for Construction Works

Coarse Aggregate for Concrete Work

1. Granular Sub-base (GSB) Material

Sr. Test Reference Indian Standard

6.0 M.S. Pipe

Recommended practice for Radiographic inspection of fusion IS: 4853

Recommended practice for ultrasonic butt weld in ferric steel.

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 9

Methods of testing fusion welded joints and weld mains in steel:

Methods of tensile testing of steel tubes. IS:1894

Hot - Rolled Steel Strip for Welded Tubes and Pipes

Dimensions for Steel Plates, Sheets, Strips and Flats for

4.0 Control of General Earth works in WORKS :

4.1 Soil identification and description

4.2 Testing of Works

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 10

0.5 Mm3 to 1 per

1.5 Mm3 to 1 per

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 11

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 12

6 tests for each of the zones, each soil type

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 14

1.0 Control of General Civil and Structural works

5.1 Construction Sequence and Control Flow Charts

5.2 Testing of Works

5.3 Inspection Checklists

5.4 O.K. CARDS AND TEST RESULTS FORMATS :

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 15

MADHYA PRDESH WATER RESOURCES DEPARTMENT,BHOPAL Page 16

Sr. Name of test Frequency of test Remarks

6. Particle size analysis of Once a week, additional if Once a fortnight, additional if

Contract No: Name of Work:_ Contractor Name:________

o. k. card no.__ date,

O.K. Card No. ________ Date _ Shift____

O.K. Card No. ___________ Date _ Shift________

8. Date and Time (i) Starting __ (ii) Finishing

O. K. Card No. Date, Shift

4. Type of roller usedNo. of passes__

Test results of Post-checking of Rolled fill of ____ embankment at RD for compaction

Test results of Post-checking of Rolled fill of ______________ embankment at RD for

Test results of soil sample of Borrow area/embankment at RD Ref.(if any)