GOVERNMENT OF TELANGANA

ROADS AND BUILDINGS DEPARTNENT

Office of the Engineer-In-Chief(R&B)

Administration& euality Control,
Errum Manzil, Hyderabad,
Telangana State.

Sub:-(R&B) Department- Quality Control wing- Assurance and Management of

Quality
of works- Quality Assurance and Management Plan-Implementation-
Instructions-Issued -Regarding.

Ref : - 1) sE/Qc/Hydera bad Lr. No. SEec/HyD/eA&M p AEE3 201 5, Dt. 23-09-20 1
I / 5.
2) T'O. Lr. No. 2609 1 50009/ ENC/Adm n&QC/ DEEI AEE2 120 1 5, Dt: 29-09-20 15 to a | |
the HODs of (R&B)Department.
3) T.O. Lr' No. 2609 1 50009/ ENC/Adm n&QC/ DEEI AEE2 120 1 5, Dt: 16- 1 1-20 1 5 to a | |
the HODs of (R&B)Department.
*******

The department has taken up large scale/road development programme in the

state. A need is felt for executing the above works to the required quality to ensure
longevity of road works undertaken by the department. Hence, the
euality Assurance
and Management Plan for (R&B) Depaftment is here with communicated to all the
Superintending Engineers (R&B) with a request to adopt the same in execution of works
in order to perform the construction tasks in a systematic way within the quality system
to achieve proper quality assurance and quality control during the execution phase.
Fufther, the SEs are directed to furnish a copy of the same to all field officers up
to the
AEE/AE cadre for effective implementation during executing works. The
euality
Assurance and Management Plan is also placed in the (R&B) Department website.

Encl: Quality Assurance and Management plan

is mailed to the SEs to their e-mail IDs.
L
'i>-;au^-/-2.
/
/z/tz4az-
For Engin6er-in-ChieflR&e;
gdministration &QC

To ffit''
> The Superintending Engineers (R&B) i.e, 1) Rural Circle, Hyderabad 2) Head
euarter
circle, Hyderabad 3) Karimnagar 4) warangal 5) Medak 6) Nalgonda 7)Khammam
8) Nizambad 9) Mahabubnagar 10) Adilabadll) NH Circle, Hyderabad 12) Etectrical
Circle, Hyderabad 13) D&p wing, Hyderabad.
(Contd.,)
F Copy to
information and
1) The Engineer-in-Chief(R&B) State Roads &CRN, Hyderabad for
necessary action.
for information and
2) The chief Enginee(R&B) NH, CRF, LWE&PPP, Hyderabad
necessary action.
for information
3) The Chief Engineer(R&B) Buildings, NABARD & HUDCO, Hyderabad
and necessary action'
4) The Engineer-in-Chief(R&B) ,Cl-E & Member of CoT, Hyderabad for information
and necessary action.

> Copy to
1) The Superintending Enginee(R&B)I&QC Circle, Hyderabad
for information and
necessary action.
and
2) The Executive Engineer(R&B),QC Division, Hyderabad for information
necessary action.
3) The Executive Engineer(R&B)QC Division, warangal for
information and necessary
action.

r Copy to
Tab|e.
1) The Dy' Engineer-in-Chief(R&B) Admn. &QC, Hyderabad

2) The Dy. Executive Engineer(R&B),E-Governance, olo Engineer-in-chief(R&B),

' Hydeiabad to place in website roadbuild.telangana.qov.in
 1

Government of Telangana
Roads and Buildings Department

Quality Assurance and

Management Plan

“Prepared By” “Approved By”

Sri M.Krishna Murthy,M.E
Superintending Engineer(R&B)
I&QC Circle, Hyderabad.
with assistance of
Smt.G.Jaya Laxmi, AEE(R&B)
Sri K.Bikshapathi, M.E
Engineer-in-Chief(R&B),
Administration & QC,
Hyderabad, Telangana.
 2

QUALITY ASSURANCE AND MANAGEMENT PLAN FOR R&B

DEPATRMENT: GOVT. OF TELANGANA STATE

Preface: The importance of transportation system in development of any country/state is

realised in all contries. Out of all available transportation systems road transport system is
very important and vital one. This is more so in case of Telangana state as it is a land locked
state and the other major transport system i.e., Railways has meager presence in the State.

In this Scenario, it is imperative that the roads are built and maintained to the
standards as specified in the respective contracts. With a view to achieve the required
standards in road construction and maintenance, uniformly and consistently, it is necessary
to have all the required standards, construction methods, quality control procedures and
tests at one place in the form of a document. Therefore all the relevant information is
compiled and put in this document.

This quality Assurance/Management plan is developed with an intention to aid the

personnel responsible/involved in construction and maintenance to achieve the required
standards.

Definition of Q-A/M Plan: it is defined as all the planned and systematic activities
implemented within the quality system and demonstrated as needed to provide adequate
confidence that it will fulfill all the requirements.

It is a tool aimed at achieving the required standards and specifications in a

particular work. It outlines the general procedures and guidelines to be followed in the
activities involved in a project.

The QA/M Plan consists of two main parts i.e., (i) Quality Control and (ii) Quality
Audit. The first part is very important one where in it helps in achieving a specified quality
product. The second part evaluates quality standards of the final product. This plan is
developed with main focus on Road and Bridge Projects. This plan, once implemented will
help in achieving uniform and consistent standards in all projects across the state.

This plan envisages the following steps.

 3

(i) a) Selection/Approval of the specified materials proposed to be used in the

project.

b) Design of mix wherever necessary.

(ii) Demonstration of the specified machinery to be used in the project.

(iii) Proper methodology of construction to be adopted in the project.
(iv) Testing and passing of final product.
(v) Final quality audit.

The design of mix / job mix formula is to be got approved by the Engineer-in-charge
before starting of the work/According permission to start the work.

All agreements specify that the tenderer shall inspect and select the quarries of his
own choice (cl. 9 of preamble to BOQ and Cl.10.1 of conditions of contract). Cl.25.1 specifies
that the contractor shall furnish within one month from work order, a work program.

The Superintending Engineer/ Executive Engineer shall ensure that the work
program includes the source of (i) all quarried materials like (a) earth (b) aggregates (c) sand
etc.,

(ii) All manufactured materials like (a) cement, (b) Bitumen, (c) Steel etc.,

(iii) List of equipment in accordance with requirement of work program like (a)HMP
(b) Concrete Batching plant (c) Pavers (d) PTR etc.,

The Superintending Engineer/Executive Engineer shall ensure that the materials

proposed satisfy all the required standards and shall not allow collection of material which is
not in accordance with the specifications.

The Executive Engineer shall ensure that the field laboratory is established for works
costing more than Rs.2.00 Crores.

The quality assurance and quality control in work execution is best achieved by
adopting.

(i) Correct work methodology

(ii) Selection of specified material based on initial material testing.
(iii) Use of right plant and machinery during the construction.
(iv) RFI and OK card system.
 4

(v) Testing of materials during construction to satisfy the material requirements.

(vi) Testing and approving final product
(vii) Proper documentation/recording of the above activities.
Quality assurance and quality control is achieved in three stages

1) Material selection stage

2) Processing stage
3) Finished stage

The field engineers shall conduct the tests as required as per the frequency specified
for each items of work. The items of work which are not within the specified limits shall be
rejected or rectified /redone as specified in the departmental circulars.

Each activity of construction shall be associated with RFI and OK card system i.e right from
setting out to final completion. The contractor shall first establish TBMs. Raise an RFI for
verification of TBMs. The Engineer-in-charge shall verify & approve the TBMs if correct. If
TBMs are not correct then redirect to establish them afresh. This methodology shall be
continued for each item like setting out, C&G, Formation, layer wise approval, wherever
construction of a particular item involves construction in layers and for Inspection of
specified plant & Machinery etc., RFIs shall be accompanied by the abstract of test results,
levels etc.,

Quality Control for Road works:

1) Setting out & levels at different stages:

Working BMs/TBM shall be established one per KM and at each culvert/bridge etc.
center lines, toe lines etc., shall be staked carefully. The surface of road way construction
shall be controlled carefully so as to achieve the designed profile/level. The tolerances with
reference to various stages of construction shall be as indicated.

Control of Alignment Level and Surface Regularity (Clause 902)

All work done shall confirm to the lines, grades, cross sections and dimensions as shown on the
drawing or as directed Engineer subject to the permitted tolerances described below:
 5

Sl. No Item Clause Tolerance

(mm)
Horizontal alignment as reckoned with the reference to the center line
1 of the carriage way and as shown on drawing

(I) edges of the carriage way 902.2 ± 10

(II) edges of the roadway and lower layers of pavement ± 25

2 Surface Levels 902.3

Levels of sub grade and different pavement courses (with reference to
the longitudinal and cross profile to the road shown on the drawings)
I Sub grade ±20
II Sub base(GSB) ±10
Pavement Quality Concrete ±5
Dry lean Concrete ±6
III Base Course for Flexible Pavement

Bituminous Layers ±6
Over – machine laid WMM ±10

IV Wearing Course (MSS & BC)

Machine laid ±6

Provided that the negative tolerance for wearing course shall not be permitted in conjunction with
the positive tolerance for base Course if the thickness of the former is thereby reduced by more than
the following limits.

4 mm for bituminous wearing course of thickness 40 mm or more.

3mm for bituminous wearing course of thickness less than 40 mm

5mm for concrete pavement slab.

Surface Regularity of Sub grade and Pavement Courses (Clause 902.4)

The longitudinal profile shall be checked with a three meter long straight edge at the middle of
each traffic lane along a line parallel to the centre line of the road. The cross profile shall be checked
with a set of three camber boards at intervals of 10 meter.
 6

Permitted tolerance of surface regularity are as fallows.

Type of Construction Surface of Surface of Lay byes,

Sl. Carriageways Service areas and all
No and paved shoulders Bituminous base sources

1 Irregularity 4mm 7mm 4mm 7mm

2
Length(Meters) 300 75 300 75 300 75 300 75

No.of irregularities in
3
National Highways 15 9 2 1 40 18 4 2
No.of irregularities in
4 Road of lower category 40 18 4 2 60 27 6 3

The maximum allowable difference between the road surface and underside of 3m straight edge
when Placed parallel or right angles to the centre line of the road at points decided by Engineer shall be:

 For paved bituminous surface: 3mm

 For bituminous base courses: 6mm
 Granular base/sub bases: 8mm
 Sub base under concrete pavement:10mm
 For subgrade 15mm

Rectification, in case surface irregularity exceeds (Clause 902.4)

In cases where requirements of surface irregularity are not satisfied and the tolerance limits given
above are exceeded in respect of sub grade and various pavement courses, work of rectification shall
be carried out in the following manner:

A) SUBGRADE: Where the surface is high, it shall be trimmed and suitably compacting shall correct
the deficiency. Where the surface is low, adding fresh material and suitably
compacting shall correct the deficiency.

B) GRANULAR SUB-BASE: Same as at (A) above but the degree of compacting and the type of material
shall confirm to Clause 401.

C) WMM: Where the surface is high or low, the top 75 mm shall be scarified reshaped with added
material wherever necessary and re compacted as per requirement.

D) BITUMINOUS Construction:

I) Other than wearing course: where the surface is low, the deficiency shall be corrected by
adding fresh material and re-compacting to specifications. Where the surface is high, the extra
thickness in the effected layer shall be removed and replaced with fresh material and compacted to
specifications.
 7

ii) Wearing Course: Where the surface is high or low, the full depth of the layer shall be
removed and replaced with fresh material and compacted to specifications.

In all cases of bituminous construction, where the removal and replacement of a bituminous
layer is involved, the area treated shall not be less than 3.5 m in width and not less than 5 meters in
length.

2) C & G Stage: (i) In this stage it requires to ensure that the C&G is done up to the widths
as specified or up to toe line/edge of excavation. (ii) Pre-levels i.e. levels prior to
commencement of C&G and after C & G are taken & verified.

3) Embankment construction/formation stage: The material used for embankment shall

confirm to the specifications of cl. 305; soil with Liquid limit (LL)> 50 & PI > 25 shall not
be used for embankment. Soils with Free swelling index (FSI) > 50 shall not be used.

Lumps/coarse material of size > 75mm shall not be allowed in embankment and >
50mm shall not be allowed in sub grade.

Soil shall be such that the Max. Dry Densities are

1. Embankment up to 3 mtrs. height MDD ≥ 15.2 KN/cum

2. Embankment ht. > 3m MDD ≥ 16 KN/cum
3. Sub grade/earth shoulders/verges/ back fill MDD ≥ 17.5 KN/cum

Embankment / sub grade shall be compacted in layers of 250mm compacted thickness,

if vibratory rollers / vibratory earth compactors are used. It shall be 200mm if static
rollers are used.

Quality control test for embankment/sub grade.

 8
ITEM CLAUSE TEST RQUIRED FREQUENCY RELEVANT I.S LIMITS
(Min) CODE

EMBAN 305
KMENT Plasticity 2 tests per 3000 IS:2720(pt-V) LL≤50,PI ≤25
cum
MDD and OMC --do— IS:2720(pt-VIII) Up to 3
M≥1.52kN/cum
Above
3m,≥1.6kN/cum
Free Swelling
Index --do— IS:2720(pt-40) ≤50

Natural do IS:2720(pt-II)
moisture
content

Moisture 2-3 test for every IS:2720(pt-II) -2 to +1% of

content just 250 cum of loose OMC
before soil
compaction

Field density 1 test for IS:2720(pt-28) ≥95% MDD of

1000sqm heavy compaction
for embankment

Subgrade ≥97%of MDD of

heavy compaction
for sub grade&
earthen shoulders

Control of Compaction: Control of compaction of embankment shall be exercised by taking at least

one set of ten measurements of density for each 3000 sq.m of compacted area of each layer. Test
location shall be chosen only through random sampling techniques. If non destructive tests are
conducted the number of tests shall be doubled. If considerable variations are observed between
the individual density results, the minimum number of tests in one set shall be increased. The
acceptance criteria shall be subject to condition that the mean density is not less than the specified
density plus (1.65 – 1.65/√n)*σ.

For earth work in shoulders and sub grade at least one set of ten density measurements shall be
taken for each 2000 sq. m of compacted area.

‘n’ is number of samples.

‘σ’ is standard deviation .

(Acceptance criteria as above may be fallowed instead of as given in circular dt.17-10-2006)

 9

4) Non-Bituminous sub bases/Bases

4(i) GSB: - The grading shall be as per table 400-1 of MORTH for the grade of GSB specified in
the contract. The compacted individual layer thickness of GSB shall not be more than 200mm.
Grading for Granular Sub-base Materials

Percentage by Weight Passing the IS sieve

IS Sieve
Designation Grading I Grading II Grading III Grading IV Grading V Grading VI
75.0 mm 100 - - - 100 -
53.0 mm 80 – 100 100 100 100 80-100 100
26.5 mm 55 – 90 70- 100 55 – 75 50 – 80 55 – 90 75 – 100
9.50 mm 35 – 65 50 – 80 - - 35 -65 55 – 75
4.75 mm 25 – 55 40 - 65 10 – 30 15 – 35 25 – 50 30 – 55
2.36 mm 20 – 40 30 – 50 - - 10 – 20 10 – 25
0.85 mm - - - - 2 -10 -
0.425 mm 10 – 15 10 – 15 - - 0–5 0 -8
0.075 mm <5 <5 <5 <5 - 0-3

The limits of various quality aspects of GSB shall be as fallows.

FREQUENCY RELEVANT
ITEM CLAUSE TEST REQUIRED LIMITS
(Min) IS CODE

(1) Granular 401 Gradation 1 test per IS 2386(pt-IV) As per table

Sub-base 400cum 401-1 of
(Maximum MORTH
compacted Atterberg limits of
thickness of aggregates passing --do -- IS 2720 (pt-V) LL≤ 25, PI≤6
layer to be 425 micron sieve
≤200 mm)
Field density test 1 test per IS 2720 (pt-28) ≥98% of
1000sqm MDD(Heavy
IS 2720 (pt- II) compaction)
Moisture content 1 test per -1to-2 of
prior to compaction 400sqm OMC
IS 2720 (pt-
Deleterious As required XXVIII)
constituents

CBR As required IS 2720 (pt-XVI) ≥30

Water absorption As required IS 2386 (pt – III) ≤2%

 10

The acceptance criteria shall be subject to condition that the mean density is not less than the
specified density plus (1.65 – 1.65/√n)*σ.

‘n’ is number of samples.

‘σ’ is standard deviation

4(ii) Wet Mix Macadam sub base: Compacted thickness of a single layer shall not be less than
75mm nor more than 200mm. The material shall be graded aggregate and granular material. The
aggregate shall confirm to the limits specified in table 400-13. Which is extracted hereunder

Grading requirements of Aggregates for Wet Mix Macadam

IS Sieve Designation Percentage by weight passing the IS Sieve

53.00 mm 100
45.00 mm 95-100
26.50 mm -
22.40 mm 60 - 80
11.20 mm 40 – 60
4.75 mm 25 – 40
2.36 mm 15 – 40
600.00 micron 8 – 22
75.00 micron 0-5

The grading shall not vary from low limit on one sieve to the high sieve on the adjacent
sieve. Mixing, laying and compacting shall be as per the specifications in a particular contract like use
of pug mill, paver, and vibratory roller etc., without exception where ever they are provided for in
the agreement.

Lateral confinement of aggregates shall be achieved by simultaneous building of

shoulders/berms.
Rolling shall be done to achieve at least 98% of MDD(Heavy compaction).

After final compaction WMM surface shall be allowed to dry for 24 hours.
No vehicular traffic shall be allowed on WMM surface.

Where the surface irregularity exceeds the permissible tolerance limits, or defective, the full
thickness of the layer shall be scarified over the affected area, re-shaped with added premixed
material or removed and replaced with fresh material and compacted to required density. Various
limits of quality control tests on WMM surface are as follows:
 11

ITEM CLAUSE TESTS REQUIRED FREQUENCY RELEVANT I.S. LIMITS

(Min) CODE
Wet Mix 406 Aggregate Impact 1 test per IS 2386 (pt-IV) ≤ 30
Macadam value 1000cum.
IS 2720 (pt-IV)
Grading 1 test per 200 As per table
cum. IS 2386 (pt-I) 400-13 of
MORTH
Flakiness and 1 test per 500 ≤35%
Elongation Index cum. IS 2720 (pt-V)

P.I limits (on material 1 test per 200 ≤6

finer than 425μ) cum. IS 2720 (pt-
VIII)

Field Dry Density IS 2720 (pt-II)

1 set of 3tests ≥98% of
per 1000 sqm. MDD(Heavy
Water absorption compaction)
As required ≤2%

The acceptance criteria shall be subject to condition that the mean density is not less than
the specified density plus (1.65 – 1.65/√n)*σ.

‘n’ is number of samples.

‘σ’ is standard deviation

5 Bituminous Bases/W.C.

Binder shall confirm to grades mentioned in I.S. 73 and modified binders shall confirm to
specification as IRC SP53 and IS 15462

5(i) Prime coat: Prime coat is applied on a prepared granular surface on which a bituminous layer in
going to be laid.

The characteristics of prime coat and frequency for tests shall be as follows.

ITEM CLAUSE TESTS FREQUENCY (Min) RELEVANT LIMITS

REQUIRED I.S. CODE
Prime coat 502 Rate of 3 test per day IS 8887
spread of
binder
Quality of Depending on the lot size, the no.of
Binder representative containers are selected.
Samples are drawn from each of such selected
container. On each of these samples viscosity,
flash point and ductility tests are conducted.
Remaining tests are done on samples obtained
by mixing together of bitumen from all
individual samples proportionately.
 12

5(ii) Tack coat: It is applied on a primed granular surface or on a bituminous surface which
is going to receive next layer of bituminous surface. The material shall be as specified in
agreement i.e., VG 10 or bitumen emulsion etc. The required properties, tests to be
conducted are as follows.

ITEM CLAUSE TESTS FREQUENCY (Min) RELEVANT I.S. LIMITS

REQUIRED CODE
Tack coat 503 & table Quality of Depending on the lot size, the no.of IS : 73- 1992
900 – 4 binder as representative containers are selected. IS : 217- 1988
specified in Samples are drawn from each of such IS : 8887- 1995
relevant IS selected container. On each of these
samples viscosity, flash point and
ductility tests are conducted.
Remaining tests are done on samples
obtained by mixing together of
bitumen from all individual samples
proportionately.
Binder At regular close intervals 20o C to 70o C
temperature
Rate of spread 3 tests per day As per Tables
of binder 500-5

PROCEDURE FOR MIXING, LAYING AND COMPACTING FOR BM/DBM/BC.

Mixing:

The ingredients of BM i.e. (i) Bitumen, (ii) Coarse aggregate and (iii)Fine aggregates
shall be as per relevant MORTH classes which are compiled in this QAP at relevant pages.

The mix of aggregate and binder shall be prepared in Hot Mix Plant of specified type
and capacity. The mix shall be uniform and mixed at specified temperatures as indicated in
respective clauses and extracted here in QAP.

The difference in temperature between the binder and aggregate shall not exceed
140 C. The Hot Mix Plant shall be calibrated from time to time to produce the desired mix.

Transporting:

Mix shall be transported in clean, insulated and covered vehicles. Asphalt release
agent like soap or lime water may be applied to interiors to facilitate discharge of material.
 13

Laying:
Spreading/laying mix shall be avoided (i) when standing water is present (ii) when rain is
imminent, (iii) when the course on which the mix is going to be laid is damp, (iv)when the course on
which the mix is going to be laid is having temperature < 100 C for conventional bitumen and < 150 C
for modified bitumen. (v) when wind speed exceeds 40 kmph at 2m height. Spreading shall be by
specified type of paving machine. Mix soon after arrival at the site shall be supplied continuously to
the paver and laid without delay. Paver speed shall be adjusted to ensure even and uniform flow,
free from dragging, tearing and segregation. Where paver can’t reach, the material shall be spread,
raked and levelled with suitable hand tools. The bitumen mix shall be spread on surface cleaned of
all loose and extraneous matter by means of a mechanical broom and air jet. The equipment for
applying a high pressure air jet shall be available full time at the site.

Compaction:
Compaction shall commence as soon as possible after laying. Rolling shall be completed
before the temperature falls below specified temperature. Rolling of the longitudinal joints shall be
done immediately behind the paving operation. After rolling of longitudinal joint, rolling shall
commence from edges and shall progress towards centre. In super elevated or unidirectional
camber rolling shall progress from lower edge to upper edge. Rolling shall continue until all roller
makes have been removed from the surface. Rolling shall be in three stages: (i) The initial or break
down rolling with 8-10 t static weight smooth wheeled rollers (ii) The intermediate rolling with 8 -
10 t static weight or vibratory roller or with 12 to 15 t PTR with a tyre pressure of at least 0.56MPa,
(iii)Finish rolling shall be with 6 – 8 t smooth wheel tandem rollers. Each pass of roller shall overlap
with the previous pass by 1/3rd of the roller width and in case of PTR by 300mm. Roller speed shall
not be more than 5 Kmph.

Joints:
All joints shall be cut vertical to the full thickness of the previously laid mix. All loosened
material shall be discarded and the vertical face coated with a suitable viscosity grade hot bitumen.
The material/mix shall be spread along the joint with a overlap of 25mm to 50mm. The thickness of
the loose overlap shall be ~ ¼ of final compacted thickness. The overlap shall be dragged back to
hot lane and rolled to give a high density joint. Longitudinal joints shall not be in wheel tract zones.

Transverse joints in successive layers shall be with a minimum off set of 2m.
 14

All joints shall be made flush.

The requirements of grading, binder content, mix for BM, DBM & BC shall be as
detailed below.

5(iii) Bituminous Macadam: compacted thickness of single layer- 50mm to 100mm

Bitumen- As per contract specifications.

The grading requirement and content of bitumen shall be as given below.

Grading 1 2
Nominal Maximum aggregate Size* 40mm 19mm
Layer thickness 80 -100mm 50-75mm
IS Sieve size (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4 – 19 4 – 19
0.3 2 – 10 2 – 10
0.075 0–8 0–8
Bitumen content ** percent by mass 3.3** 3.4**
of total mix
* Nominal maximum aggregate size is the largest specified sieve size upon which any of the
aggregate material is retained.

** Corresponding to specific gravity of the aggregate 2.7.

The required physical properties of aggregate shall be as specified below.

Property Test Requirement Test method

Cleanliness(dust) Grain size analysis Max. 5% passing 0.075 IS: 2386 Part I
micron
Particle shape Combined Flakiness and Max. 35% IS: 2386 Part I
Elongation indices
Strength Los Angeles Abrasion Value Max. 40% IS: 2386 IV
or
Aggregate Impact value Max. 30% IS: 2386 IV
Durability Soundness (Sodium or 5 Cycles
Magnesium)
Sodium Sulphate Max. 12% IS: 2386 Part V
Magnesium Sulphate Max. 18% IS: 2386 Part V
Water absorption Water absorption Max. 2% IS: 2386 Part III
Stripping Coating and Stripping of Min. Retained coating IS: 6241
Bitumen Aggregate 95%
Water sensitivity Retained Tensile Strength* Min. 80% AASHTO 283
* If the minimum retained tensile strength falls below 80 percent, use of anti stripping agent is
recommended to meet the minimum requirements.
 15
The other tests to be conducted on B.M are as follows.
Bituminous Macadam i) Quality of binder
ii) Aggregate Impact value or Los
Angeles Abrasion Value
iii) Combined Flakiness and
Elongation indices
iv) Stripping value
v) Water absorption of aggregates
vi) Water sensitivity of mix
vii) Grading of aggregates
viii)Soundness (Magnesium
sulphate/Sodium sulphate)
ix)Percentage of fractured faces
x) Binder content
xi) Control of temperature of
binder and aggregate for mix
and of the mix at the time of
laying and rolling
xii)Density of compacted layer
xiii)Rate of spread of Mixed
material
The B.M layer shall be protected with next layer of pavement course or W.C within a
maximum period of forty eight hours. If there is any delay, it shall be covered by seal coat.
Depending on the lot size, the
no.of representative containers are
selected. Samples are drawn from
each of such selected container. On
each of these samples viscosity,
flash point and ductility tests are
conducted.
Remaining tests are done on
samples obtained by mixing
together of bitumen from all
individual samples proportionately.
One test per 200 cu.m. of each
source and whenever there is
change in the quality of aggregate.
One test per 350 cu.m for each
source
One test of each source and
whenever there is change in the
quality of aggregate
- do -
- do -
2 tests per day
One test of each source and
whenever there is change in the
quality of aggregate
1 test per 100cum of aggregate
Two tests per day per plant
At regular intervals
One test per 700 sq.marea
At regular intervals.
 16

5(iv) DENSE GRADED BITUMINOUS MACADAM

The thickness of single layer shall be from 50mm to 100mm. The combined grading and
bitumen content of DBM shall be as fallows.

Grading 1 2
Nominal aggregate Size* 37.5mm 26.5 mm
Layer thickness 75 -100mm 50-75 mm
IS Sieve size (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 95-100 100
26.5 63- 93 90 – 100
19 - 71 – 95
13.2 55- 75 56 – 80
9.5 - -
4.75 38 – 54 38 – 54
2.36 28 – 42 28 – 42
1.18 - -
0.6 - -
0.3 7 – 21 7 – 21
0.15 - -
0.075 2–8 2–8
Bitumen content % by mass of Min. 4.0** Min. 4.5**
total mix

 The nominal maximum particle size is the largest specified sieve size upon which any of the
aggregate is retained.

** Corresponds to specific gravity of aggregates being 2.7. In case aggregate have specific gravity
more than 2.7, the minimum bitumen content can be reduced proportionately. Further the
region wherein highest daily mean air temperature is 300 C or lower and lowest daily air
temperature is - 100 C or lower, the bitumen content may be increased by 0.5 percent.
 17

The physical properties of aggregates shall be as follows.

Property Test Specification Method of Test

Cleanliness (dust) Grain size analysis Max. 5% passing IS: 2386 Part I
0.075mm sieve
Particle shape Combined Flakiness and Max. 35% IS: 2386 Part I
Elongation indices*
Strength Los Angeles Abrasion Value Max. 35% IS: 2386 IV
or
Aggregate Impact value Max. 27%
Durability Soundness either: Sodium IS: 2386 Part V
Sulphate or Max. 12%
Magnesium Sulphate
Max. 18%
Water absorption Water absorption Max. 2% IS: 2386 Part III
Stripping Coating and Stripping of Minimum retained IS: 6241
Bitumen Aggregate Mix coating 95%

Water sensitivity Retained Tensile Strength* Min. 80% AASHTO 283

 To determine this combined proportion, the flaky stone from a representative sample should
first be separated out. Flakiness index is weight of flaky stone metal divided by weight of
stone sample. Only the elongated particles be separated out from the remaining (non-flaky)
stone metal. Elongation Index is weight or elongated particles divided by total non-flaky
particles. The values of flakiness index and elongation index so found are added up.

** If the minimum retained tensile test strength falls below 80 percent, use of anti stripping agent
is recommended to meet the requirement.

Apart from grading and quality of individual ingredients, the mix of DBM shall satisfy the
following requirements.

Properties Viscosity Modified bitumen Test Method

Grade paving
Bitumen Hot climate Cold climate
Compaction level 75 blows on each face of the specimen
Minimum stability (kN 9.0 12.0 10.0 AASHTO T245
at 600 C)
Marshall flow (mm) 2–4 2.5 – 4 3.5 – 5 AASHTO T245
Marshall Quotient 2–5 2.5 - 5 MS-2 and ASTM
Stability D2041
Flow
% Air Voids 3.5
% Voids Filled with 65 – 75
Bitumen (VFB)
Coating of aggregate 95% minimum IS: 6241
particle
Tensile Strength ratio 80% Minimum AASHTO T 283
 18

Opening to the traffic shall be after the DBM layer is cooled to ambient temperature.

ITEM CLAU TESTS REQUIRED FREQUENCY (Min) RELEVANT I.S. LIMITS

SE CODE
Dense 505 Density of 1 test per 700sq.m area 92% of Gmm
Graded compacted layer
Bitumino Quality of Binder Depending on the lot size, the IS:1203-1220 As per IS 73
us no.of representative containers
Macadam are selected. Samples are drawn
from each of such selected
container. On each of these
samples viscosity, flash point
and ductility tests are
conducted.
Remaining tests are done on
samples obtained by mixing
together of bitumen from all
individual samples
proportionately.
Plasticity Index As required IS: 2720 part 5 ≤4%

Combined 1 set of test per 400 tons IS:2386,part-II As per MOST table
gradation subjected to a minimum of
two test per plant per day

Bitumen content One test for 400 tonnes of ASTM D-2172 Min 4%by weight
mix subject min of two tests of total mix for
per plant per day Grd-1

Min 4.5%for Grd-II

Temperature of At regular close intervals 150oC to 1650C
Bitumen
Temperature of --do-- 1500C to 1700C
Aggregate
Temperature of 150oC to 1650C
mixed material
Temperature of At regular close intervals VG.30=140
laying VG.20=135
Temperature of --do-- VG.30=90
Rolling VG.20=85

Stability at 600C One set of test per 400 tons ASTM D1559 <9 KN
subjected to a minimum of
two test per plant per day

Flow 2-4mm

Percent Air Voids 3-5

Percent Voids in As per the table

mineral
aggregates
Percent Voids 65-75
filled with
Bitumen

Temperature of At regular close intervals

Mix
 19

MINIMUM PERCENT VOIDS IN MINERAL AGGREGATE

Nominal Maximum Minimum VMA, percent related to design air voids present
Particle size(mm) 3.0 4.0 5.0
26.5 11.0 12.0 13.0

37.5 10.0 11.0 12.0

PERMISSIBLE VARIATIONS IN THE JOB MIX FORMULA

Subjected to the condition that final gradation shall remain within respective gradation band

DESCRIPTION BASE / BINDER COURSE WEARING COURSE

Aggregate passing 19mm sieve or larger ±8% ±7%

Aggregate passing 13.2, 9.5 mm sieve ±7% ±6%
Aggregate passing 4.75mm sieve ±6% ±5%
Aggregate passing 2.36,1.18,0.6mm sieve ±5% ±4%
Aggregate passing 0.3,0.15mm sieve ±4% ±3%
Aggregate passing 0.075mm sieve ±2% ±1.5%
Binder content ±0.3% ±0.3%
Mixing Temperature ±100C ±100C

5(v) Bituminous concrete

Bituminous concrete is laid in single layer of 30mm/40mm/50mm.

Physical requirements for Coarse Aggregate for Bituminous Concrete

Property Test Specification Method of test

Cleanliness(dust) Grain size analysis Max 5% passing I.S 2386PartI
0.0075mm sieve
Particle shape Combined Flakiness and Max 35% I.S 2386PartI
Elongation indices
Strength Los Angeles Abrasion Value Max30% I.S 2386PartIV
or Aggregate Impact Value Max24%
Durability Soundness either: Sodium Max12% I.S 2386PartV
sulphate or
Magnesium Sulphate Max18%
Polishing Polished stone Value Min 55 BS:812-114
Water absorption Water Absorption Max2% I.S 2386Part III
Stripping Coating and Stripping of Minimum retained IS:6241
Bitumen Aggregate Mix coating 95%
Water Sensitivity Retained Tensile Strength Min 80% AASHTO 283
Plasticity Index Max 4%
If the minimum retained tensile test strength falls below 80 percent, use of anti stripping
agent is recommended to meet the requirement.
 20

Composition of Bituminous Concrete Pavement Layer

Grading 1 2
Nominal aggregate size 19mm 13.2mm
Layer thickness 50mm 30-40mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45
37.5
26.5 100
19 90-100 100
13.2 59-79 90-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content % by mass of total Min 5.2* Min 5.4**
mix

Note:
 The nominal maximum particle size is the largest specified sieve size up on which any of
the aggregate is retained

** Corresponding to specific gravity of aggregate being 2.7 .In case aggregate have specific
gravity more than 2.7, the minimum bitumen content can be reduced
proportionately. Further the region where highest daily mean air temperature is 300
C or lower and lowest daily air temperature is – 100 C or lower, the bitumen content
may be increased by 0.5 percent.
 21

Other Quality Control Tests on B.C are as fallows.

TESTS RELEVANT I.S.

ITEM CLAUSE FREQUENCY (Min) LIMITS
REQUIRED CODE
Bituminous 507 Quality of Depending on the lot size, the no.
Concrete Binder of representative containers are As per IS 73
selected. Samples are drawn from
each of such selected container. On
each of these samples viscosity,
flash point and ductility tests are
conducted.

Remaining tests are done on

samples obtained by mixing
together of bitumen from all
individual samples proportionately.
Binder One set of test per 400 tons
Content subjected to a minimum of two
test per plant per day

Combined One set of test per 400 tons IS:2386,part-II As per MOST
gradation/mix subjected to a minimum of two table
grading test per plant per day

Density of One test per 700 sq.m area 92% of Gmm

compacted
layer
Soundness One test for each source and
test whenever there is change
quality of aggregate
Plasticity Index One test for each source and
whenever there is change
quality of aggregate
Temperature At regular close intervals IS:1203 150oC to
of Bitumen 1650C
mix
Aggregate One test for350 cum of
impact aggregate for each source and
value/los whenever there is change in
angeles quality of aggregate.
abraison

Temperature --do-- 1500C to

of Aggregate 1700C
Mix
Temperature At regular close intervals VG 30 = 140
of laying VG 20 = 135
Temperature --do-- VG 30 = 90
of Rolling VG 20 = 85
Flakiness and One test for350 cum of
Elongation aggregate for each source and
index whenever there is change in
quality of aggregate.
Permissible variations from JMF shall be as indicated under DBM for wear course.
B.C. layer is opened to traffic after 48hours.
 22

For all bituminous layers the acceptance criteria with regard to density is that the mean density is
not less than the specified density plus (1.65 – 1.65/√n)*σ.

‘n’ is number of samples.

‘σ’ is standard deviation.

6. Concrete pavements/Rigid pavements

Rigid pavements are usually constructed on a sub base consisting of (a) Granular material
OR (b) stabilized soil OR(c) Semi Rigid material, usually DLC.

Below this sub base, the sub grade shall have the following properties.

(i) No soft spots are present in the sub grade

(ii) It shall be coarse grained material
(iii) The top 150mm thick layer of sub grade shall have drainage property.

When the DLC is used it shall be for 100mm thickness.

The grading of aggregate (combined grading of fine and coarse aggregates) shall be as
follows

Aggregate Gradation for Dry Lean Concrete

Sieve designation Percentage by weight passing the sieve

26.50mm 100
19.0mm 75-95
9.50mm 50-70
4.75mm 30-55
2.36mm 17-42
600µ 8-22
300µ 7-17
150µ 2-12
75µ 0-10

The maximum aggregate cementitious material shall be 15:1.

The field density achieved at edges i.e 0.5m from edges shall not be less than 96% maximum
density that is achieved during trial construction.

The minimum dry density shall not be less than 98% of maximum dry density obtained
during trial length construction.

The average compressive strength of each consecutive group of cubes shall not be less than
10mpa at 7days. The minimum individual cube strength shall not be less than 7.5mpa at
7days. OR
 23

As per the strength requirements as per designs.

While laying the DLC, the concrete shall have the moisture content between OMC and OMC
+2%.

Time from mixing of concrete and the final finishing in any transverse section shall not be
more than 90mts if temperature is 250c to 300c and 120 minutes if temperature is < 250c (of
concrete).

DLC shall be of zero slump.

No heavy commercial vehicles shall be allowed on DLC.

Pavement Quality Concrete:

Aggregate shall satisfy the requirements as indicated below.

Permissible Limits of Deleterious sub grade in Fine and Coarse Aggregates

Fine Aggregate Coarse Aggregate

Deleterious Method of
S.No Percentage by Percentage by
Substance Test
Weight,(Max) Weight(Max)
Uncrushed Crushed* Uncrushed Crushed*
(1) (2) (3) (4) (5) (6) (7)
i) Coal and IS:2386 1.0 1.0 1.0 1.0
lignite (part ii)
ii) Clay lumps Do 1.0 1.0 1.0 1.0
iii) Materials IS:2386 3.0 8.0 3.0 3.0
finer than (part i)
75µ IS Sieve
iv) Soft IS:2386 - - 3.0 -
fragments (part ii)
v) Shale IS:2386 1.0 - - -
(Part II)-1963
vi) Total of 5.0 2.0 5.0 5.0
percentages
of all
deleterious
materials
(except
mica)
including SL.
No.(i) to (v)
for col.4,6
and 7 and Sl.
(i) and (ii) for
Col.5 only
* Crushed aggregate at least one face is fractured.
 24

The combined grading of Fine and Coarse aggregates for PQC shall be as fallows.

Sieve Designation Percent by weight passing the sieve

31.5mm 100
26.5mm 85-95
19.0mm 68-88
9.5mm 45-65
4.75mm 30-55
600 microns 8-30
150microns 5-15
75 microns 0-5

Water absorption ≤ 2%

Concreting shall not be done when concrete temperature is > 300c

When the ambient temperature is more than 350c concrete shall not be done.
No traffic shall be allowed on concrete pavement with in a period of 28days from its
construction.

Material Test Test Method Minimum desirable frequencies

Cement Physical and IS: 269/445/1489 Once for each source of supply and
Chemical test occasionally when called for in case
IS: 8112,
of long and or improper storage
IS: 12269

Aggregate 1. Gradation IS 2386 Part 1 One test for every day’s work of
each fraction of coarse aggregate
and fine aggregate.
IS 2386 Part 2
- do -
2. Deleterious
IS 2386 part 3 Regularly as required , subject to a
3. Water absorption
minimum of 1 test / day for coarse
aggregate and two test /day for
fine aggregate.

4. Bulking of fine IS: 2386 part 3 Once for each source for moisture
aggregate content for deriving the moisture
content and bulking relationship.
 25

Coarse aggregate 1. Los Angels IS 2386 Part 4 Once for each source of supply and
abrasion Value/AIV subsequently when warranted by
changes in the quality of
aggregate/monthly basis

2.Soundness IS 2386 Part 5 As required/before approving of

source of supply.
3. Alkali aggregate IS 2386 Part 6 - do -
reactivity

Water Chemical test IS : 456 One for approval of source of

supply subsequently only in case of
doubt.

Concrete i) Strength of IS:516 2 cubes and 2 beams per 150cu.m.

concrete or part thereof (one for 7 day and
other for 28 day strength) or
minimum 6 cubes and 6 beams per
day’s work which every is more.

ii) Core strength on IS:516 As per the requirement of the

hardened concrete Engineer, only in case of doubt.

iii) Workability of IS:1199 One test per each dumper load at

fresh concrete-slump both batching plant site and paving
test site initially when work starts.
Subsequently sampling may be
done from alternate dumper.

iv)Thickness From the level data of concrete

determination pavement surface and sub-base at
grid points of 5/6.25 m x 3.5m

v)Thickness 3 cores per trial length

measurement for
trial length

vi) Verification of String line or steel forms shall be

level of string line in checked for level at an interval of
the case of slip form 5.0 m or 6.25m. The level
paving and steel tolerance allowed shall be + 2 mm.
forms in the case of These shall be got approved 1-2
fixed form paving hours before the commencement
of the concreting activity.
 26

BRIDGES
Bridge is one of the most important inventions of the human history. Bridges are not only
most difficult structures to be constructed but also the most expensive part of highway
projects.

Therefore it is all the more important that these structures are built with a proper and
detailed QAP in place.

QAP for bridges/ C.D works shall start with planning and investigation stage.

Planning stage: Planning of bridges influences the overall cost of the bridge. Hence it is
utmost important to have proper planning.

(i) For bridges up to 60m length the siting of bridges shall generally governed by the
approach alignment (straight, minimum shifting etc.)
(ii) For bridges from 60 to 300mm. The site selection shall be suitability of bridges
site and proper alignment of approaches.
(iii) For bridges of length > 300m, suitability of bridge site shall have the overriding
consideration.

Investigation stage:
(1) Hydraulic investigation: The cost of bridge and /or safety of the bridge is influenced by
this aspect to a large extent. Under estimation of maximum discharge will endanger the
bridge safety whereas over estimation of maximum discharge will increase the cost of
bridges. Hence max discharge shall be properly estimated by (i) Correctly assessing the HFL,
(ii) Selection of proper cross sections (Always at right angle to the direction of flow).(iii)
Correct estimation of bed slope.(iv) correct estimation of catchment area.(v) Adoption of
correct formula for assessing ‘Q’ i.e., max discharge. For all major bridges, it is always
advisable to obtain HFL and ‘Q’ from CWC for the site selected. Correct estimation of silt
factor which influences the type, and depth of foundations.

(2) Geological/Subsurface investigation: This investigation will greatly influence the safety
and cost of the bridges.

The required aspects will be as follows.

The subsurface investigation for bridges shall be carried out in the following three
zones:

i) Between bed level and up to anticipated maximum scour depth (below H.F.L)

ii) From the maximum scour depth to the founding level.

iii) From founding level to a depth of about 1 ½ times the width of the foundation.
 27

The data required to be obtained from each zone will cover soil classification,
particle size distribution, shear strength characteristics, compressibility and permeability as
detailed in Table 1 of Annex 2 of IRC:78 . In all cases, samples of soils shall be collected at
every 1 m to 1.5 m depth or at change of strata.

The sub soil investigation shall cover the following aspects.

For bridge works, the investigations shall be comprehensive enough to give the following
information to the designer:

i) The engineering properties of the soil/rock,

ii) The location and extent of soft layers, cavities and gas pockets, if
any, under the hard founding strata.

iii)The geological condition like type of rock, faults, fissures or

subsidence due to mining, cavities, hollows, porosity etc.

iv) Ground water level.

v) Artesian conditions, if any.

vi)Quality of water in contact with the foundation.

vii) The depth and extent of scour

viii) Suitable depth of foundation.

ix) Bearing capacity of the stratum

x) Probable settlement and differential settlement of the

foundations.

xi) Likely sinking or driving effort, and

xii) Likely construction difficulties.

Structural concrete: The requirement of concrete for different exposure conditions with
20mm aggregate are as follows.

Requirement of concrete for different exposure condition using 20mm Aggregate

Exposure condition Maximum Water Minimum Minimum Grade

Cement Ratio Cement content, of Concrete
kg/m3
Moderate 0.45 340 M25
Severe 0.45 360 M30
Very Severe 0.40 380 M40
 28

Note:

i) All three provisions given in the above table for a particular exposure condition, shall be
satisfied.
ii) The term cement for maximum w/c ratio and minimum cement content shown in Table
includes all cementitious materials mentioned in Clause 1715.2. The maximum limit of
fly ash and ground granulated blast furnace slag in the blended cement shall be as
specified in IS:1489 (Part-I) and IS: 455 respectively.
iii) For plain cement concrete, with or without surface reinforcement, the minimum grade
of concrete can be lowered by 5 MPa and maximum water/cement ratio exceeded by
0.05.

Cement content shown in the above table shall be increased by 40 kg/m3 for use of 40mm
nominal size aggregates.

The grading requirement of coarse aggregate shall be as follows.

Grading Requirement of Coarse Aggregate

IS Sieve Size Percentage Passing for Graded Aggregate of Nominal size

40mm 20mm 12.5mm
63mm -- -- --
40mm 95 – 100 100 --
20mm 30 – 70 95 – 100 100
12.5mm -- -- 90 – 100
10mm 10 – 35 25 – 55 40 – 85
4.75mm 0–5 0 – 10 0 - 10

Grading Requirements of Fine Aggregates

IS Sieve Size Percentage Passing for

Grading Zone-I Grading Zone II Grading Zone III
10 mm 100 100 100
4.75 mm 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100
1.18 mm 30-70 55-90 75-100
600 micron 15-34 35-59 60-79
300 micron 5-20 8-30 12-40
150 micron 0-10 0-10 0-10

Note: When the grading falls outside the limits of any particular grading zone of sieves other than 600 –
micron IS Sieve by a total amount not exceeding 5 percent, it shall be regarded as falling within that
grading zone. However for crushed stone sand, the permissible limit on 150-micron IS Sieve is
increased to 20 percent. Reference shall be made to clause: 4.3 of IS: 383.

The Flakiness index for coarse aggregate shall not be more than 35.
The Fineness modulus of Fine Aggregate shall be≥ 2 and ≤ 3.5.
 29

The consistency limits of concrete shall be as follows.

Requirements of Consistency

Slump (mm) (at the Time

Type
of Placing of Concrete)
1) a) Structure with exposed inclined surface requiring low 25
slump concrete to allow proper compaction
b) Plain cement concrete 25
2) RCC structure with widely spaced reinforcement; e.g. solid 40 – 50
columns, piers, abutments, footings, well steining.
3) RCC structure with fair degree of congestion of 50 – 75
reinforcement; e.g. pier and abutment caps, box culverts,
well curb, well cap, walls with thickness greater than
300mm
4) RCC and PSC structure with highly congested 75 – 125
reinforcements e.g. deck slab girders, box girders, walls
with thickness less than 300mm
5) Under water concreting through tremie e.g. bottom plug, 150 – 200
cast in-situ piling.

Notwithstanding the optimum consistency indicated against Sl. No.1 to 3, the situation
should be property assessed to arrive at the desired workability with the adjustment of
admixture in each case, where the concrete is to be transported through transit mixer and
placed using concrete pump. Under these circumstances, the optimum consistency during
placement for the items of work of Sl. No.1 to 3, can be considered ranging from 75mm to
150mm. This is, however, subject to satisfying the other essential criteria of strength,
durability etc. and approval of the Engineer.

The requirement of nominal mix shall be as follows.

Requirements for Nominal Mix Concrete

Concrete Total Quantity of Dry Proportion of Fine Maximum Quantity of

Aggregate by Mass per 50 to Coarse Water for 50 Kg of
Kg of Cement to be taken Aggregate (by Cement (Litres)
as the sum of individual Mass) PCC RCC
Masses of Fine and Coarse
Aggregate(kg)

M 15 350 Generally 1:2, 25

subject to upper
M 20 250 25 22
limit 1:1.5 and
lower limit of 1:2.5
 30

The nominal size of coarse aggregate shall be as follows.

Maximum Nominal size of Coarse Aggregate

Maximum Nominal
Components Size of Coarse
Aggregate (mm)
i) RCC well curb 20
ii) RCC/PCC well steining 40
iii)Well cap or Pile Cap Solid type piers and abutments 40
iv) RCC work in girder, slabs wearing coat, kerb, approach slab, 20
hollow piers and abutments, pier/abutment caps, piles
v) PSC work 20
vi) Any other item As specified by the
Engineer

Maximum nominal size of aggregates shall also be restricted to the smaller of the following
values:

a) 10mm less than the minimum lateral clear distance between individual
reinforcements.
b) 10mm less than the minimum clear cover to the reinforcement
c) One quarter of minimum thickness of member.

The proportions of the various individual sizes of aggregates shall be so adjusted that
the grading produces the densest mix and the grading curve corresponds to the maximum
nominal size adopted for the concrete mix.

EQUIPMENT

Unless specified otherwise, equipment for production, transportation and compaction of

concrete shall be as under:

a) Production of Concrete:
i) For overall bridge length of less than 200 m – batch type concrete
mixer, diesel or electric operated, with a minimum size of 200
litres automatic water measuring system and integral weigher
(hydraulic/pneumatic type)

ii) For overall bridge length of 200 m or more – concrete batching

and mixing plant fully automatic, with minimum capacity of 15
cum per hour.
 31

Accuracy of measurement

The accuracy of the measuring devices shall fall within the following limits:

Measurement of Cement : + 3 percent of the quantity of cement in each batch

Measurement of Water : + 3 percent of the quantity of water in each batch
Measurement of Aggregate : + 3 percent of the quantity of aggregate in each batch
Measurement of Admixture : + 3 percent of the quantity of admixture in each batch

b) For Compaction of Concrete:

i) Internal vibrators size 25mm to 70mm
ii) Form vibrators minimum 500 watts
iii) Screed vibrators full width of carriageway (upto two lanes)

Sampling and Testing

Concrete for preparing 3 test cubes shall be taken from a batch of concrete at point of
delivery for construction, according to procedure laid down in IS:1199.

A random sampling procedure shall be adopted which ensures that each of the concrete
batches forming the lot under acceptance inspection has equal chance of being chosen for
taking cubes.

150mm cubes shall be made, cured and tested at the age of 28 days for compressive
strength in accordance with the IS:516. The 28 day test strength result for each cube shall
form an item of the sample. Tests at other age shall also be performed, if specified.

Where automated batching plant/Ready Mixed Concrete Plant is located away from the
place of use and the time gap between production and placement is more than the initial
setting time or where any ingredients are added subsequent to mixing, separate sets of
samples shall be collected and tested at batching plant and at location of placement. The
results shall be compared and used to make suitable adjustment at batching plants so that
properties of concrete at placement are as per the requirements.

Test specimen and sample strength

Three test specimens shall be made from each sample for testing at 28 days. Additional
cubes may be required for various purposes such as to determine the strength of concrete
at 7 days or for any other purpose.

The test strength of the sample shall be the average of the strength of 3 cubes. The
individual variation should not be more than + 15 percent of the average. If variation is
more, the test results of the sample are invalid.

Frequency
 32

Minimum Frequency of sampling

Quantity of Concrete in Work, M3 No. of Samples

1–5 1
6 – 15 2
16 – 30 3
31 – 50 4
51 and above 4 plus one additional sample for each
additional 50 m3 or part thereof

At least one sample shall be taken from each shift of work.

Acceptance criteria
Cubes

The concrete shall be taken as having the specified compressive strength when
both the following conditions are met:

a) The mean strength determined from any group of four consecutive non-
overlapping samples exceed
b) s the specified characteristic compressive strength by 3 MPa.
c) Strength of any sample is not less than the specified characteristic compressive
strength minus 3 MPa.

The quantity of concrete represented by the test results include the batches from
which the first and last samples were taken, together with all intervening batches.

PILE FOUNDATIONS
The requirement of concrete in piles shall be as follows.

Requirements for Concrete in Piles

Cast in-situ Precast Concrete

Concrete by Tremie
Grade of concrete M 35 M 35
Minimum cement content 400 kg/m3 400 kg/m3
Minimum water cement ratio 0.4 0.40
Slump (mm) as measured at the 150-200 50 – 75
time of placement
 33

The terms ‘minimum cement content’ and ‘minimum water cement’ ratio mentioned are to
based on total cementitious material (inclusive of all mineral admixtures called additives)
mentioned in Clause 1007 of these specifications. Maximum limits for such additives shall
be as specified in Clause 1716.2 of these specifications.

The tolerances for piles are as follows.

Permissible Tolerances of Piles

i) Precast Concrete Piles:

a) Variation in cross-sectional dimensions : + 5mm

b) Variation in length : + 25mm

c) Surface irregularities measured with 3 m straight edge : 5 mm

d) Bow for total length of pile in mm : 1 mm/m length of pile

Limited to 20mm

ii) Driven Piles:

a) Variation in cross-sectional dimensions : + 50 mm, - 10 mm

b) Variation from vertical for vertical piles : 1 in 150

c) For vertical piles deviation at piling platform level : 75 mm

d) Variation of level of top of piles : + 25mm

iii) Bored Piles:

a) Variation in cross-sectional dimensions : + 50 mm, - 10 mm

b) Variation from vertical for vertical piles : 1 in 150

c) For vertical piles deviation at piling platform level : 75 mm

d) Variation of level of top of piles : + 25mm

iv) For raker piles from specified rake : 1 in 25

Permissible Tolerances of Piles Caps

a) Variation in dimensions : + 50 mm, - 10 mm

b) Misplacement from specified position in plan : 15 mm

c) Surface irregularities measured : 5 mm with 3 straight edge

d) Variation of level of top of piles : + 25mm

 34

Well Foundations:
Most commonly used deep foundations. These may be in brick masonry, PCC or RCC.
The tolerances are

TOLERANCES

The permissible tilt and shift shall not exceed 1 (horizontal) in 80 (vertical) and the shift at
the well base shall not be more than 150mm in any resultant direction.

For the well steining and well cap, the permissible tolerances shall be as follows:

a) Variation in dimensions : + 50 mm, - 10 mm

b) Misplacement from specified position in plan : 15 mm
c) Surface unevenness measured with 3 m straight edge : 5 mm
d) Variation of level of top : + 25mm

Reduction in Rate of sinking as penalty is as follows.

If any well with tilt and/or shift exceeding the permissible values is accepted by the Engineer
the contractor shall be subjected to a reduction in the rates for the sinking of well as
follows:

S. Amount of Tilt and/or Shift Percent Reduction on

No. the Rate(s) for Sinking
of whole Well
1) Tilt exceeding the specified permissible value but equal 5 percent
to or within 1 in 60
2) Tilt exceeding 1 in 60 but equal to or within 1 in 50 10 percent
3) Tilt exceeding 1 in 50 20 percent
4) Shift exceeding the specified permissible value but equal 2 percent
to or within 200 mm
5) Shift exceeding 200 mm but equal to or within 300 mm 5 percent
6) Shift exceeding 300 mm 10 percent

For excessive tilt and shift, the reduction in rates shall be decided separately by the
Engineer.
Open foundations: The Open foundation shall be executed as per specifications
indicated in the drawing to the dimensions indicated there on.

The tolerance limits are as follows.

TOLERANCES

a) Variation in dimensions : + 50 mm, - 10 mm

b) Misplacement from specified position in plan : 15 mm
c) Surface unevenness measured with 3 m straight edge : 5 mm
d) Variation of level of top : + 25mm
 35

Substructure: The substructure shall be as per specifications and dimensions as indicated

in the drawings. The tolerances shall be as follows.

TOLERANCES IN CONCRETE ELEMENTS

a) Variation in cross-sectional dimensions : + 10 mm, - 5 mm
b) Misplacement from specified position in plan : 10 mm
c) Variation of level at top : + 10 mm
d) Variations of reduced levels of bearing areas : + 5 mm
e) Variations from plumb over full height : + 10 mm
f) Surface unevenness measured with 3 m straight edge
All surfaces except bearing areas : 5 mm
Bearing areas : 3 mm

Concrete superstructure: The superstructure shall be as per specifications and

dimensions as indicated in the drawings. The tolerances shall be as follows.

Precast/cast in situ Concrete Superstructure

a) Variations in thickness of top and
bottom slab for box girders, top and - 5 mm to + 10 mm
bottom flange for T-girders and slabs
b) Variations in web thickness -5 mm to + 10 mm
c) Variations in overall depth or width + 5 mm
d) Variation in length overall and length shall not exceed + 10 mm or
between bearings. + 0.1 percent of the span length, whichever is less.
e) Permissible surface unevenness in 5 mm
deck slab when measured with a 3
m straight edge or template.
To achieve required quality it is essential that each activity of construction shall be preceded
by approval of previous construction activity through an RFI. Starting of C&G shall be
preceded by approval of pre levels. Starting of embankment shall be preceded by approval
of levels after C&G. Starting of Sub grade shall be preceded by approval of embankment
etc., This process will ensure implementation of quality control in the projects.

Note: 1. Where ever the limits as specified above are over ruled through Government
orders/concerned HOD orders they shall be fallowed.
Enls.1. Copy of circular no.12582/Vig.I/1/2005-1 dt.17-10-2006.
2. List of Equipment for various activities communicated through circular .no.
711/ENC-QC/TS/DEE/AEE1/2014 Dt. 24-11-2014
 1

FLOW CHART FOR QA/MP

for Road works – Flexible payments

START

AGREEMENT CONCLUDED

SUBMISSION OF WORK PROGRAMME BY THE

CONTRACTOR

NO
IS THE WORK PROGRAMME
PROPER AND APPROVED

YES

EACH OF THE FOLLOWING ACTIVITIES SHALL BE

ASSOCIATED WITH SUBMISSION OF RFI FOR
INSPECTION AND CHECKING. APPROVAL /PASSING
OF SUCH ACTIVITIES SHALL BE BY THE WAY OF
APPROVAL OF RFI/OK CARD

EACH RFI SHALL BE ACCOMPANIED BY ABSTRACT

OF TEST RESULTS. PROPER DOCUMENTATION
SHALL BE MAINTAINED FOR TEST RESULTS AND
LEVELS FOR EACH ITEM OF ACTIVITY, LAYER WISE.

START OF SETTING OUT ESTABLISHMENT OF TBMs, PCL,

TOELINES FORMATION LEVELS ETC.

NO
IS SETTING OUT VERIFIED
AND FOUND CORRECT

YES
START OF C&G, SUBMISSION OF PRELEVELS

NO
VERIFICATION OF PRELEVELS.
LEVELS TALLIED?

YES
C&G COMPLETED, SUBMISSION OF FINAL LEVELS

IS VERIFICATION OF FINAL
LEVELS DONE AND AGREED
 2

INSPECTION/ VERIFICATION OF PLANT AND MACHINERY.

NO
ARE THE MACHINERY AND
PLANTS AS PER
SPECIFICATIONS?

YES

STARTING OF EMBANKMEN, SUBMISSION

OF MATERIAL FOR APPROVAL

NO
VERIFICATION OF MATERIAL
PROPERTIES, LIKE ATTERBERG
LIMITS,DENSITY, OMC ETC.,

RESULTS SATISFY?

YES

CONSTRUCTION OF EMBANKMENT, LAYER WISE

NO
VERIFICATION OF FIELD
DENSITY, OMC, LAYER WISE

RESULTS SATISFY?

YES

STARTING OF SUB GRADE, SUBMISSION OF

MATERIAL FOR APPROVAL

NO
VERIFICATION OF MATERIAL
PROPERTIES LIKE CBR, OMC,
DENSITY AND ATTERBERG LIMITS

RESULTS SATISFY?

YES
 3

CONSTRUCTION OF SUBGRADE LAYER WISE

NO
VERIFICATION OF FDD,
OMC, LAYER WISE.

RESULTS SATISFY?

YES

STARTING OF GSB, SUBMISSION

OF MATERIAL FOR APPROVAL

NO
VERIFICATION OF MATERIAL PROPERTIES LIKE
CBR, OMC, DENSITY, ATTERBERG LIMITS
(THESE ARE ESSENTIAL WHEN THE GSB IS
PROVIDED WITH NATURAL MATERIAL LIKE
NATURAL GRAVEL/MORRUM) ETC.,

RESULTS SATISFY?

YES

CONSTRUCTION OF GSB LAYER WISE

NO

VERIFICATION OF FDD,
PROFILE ETC.,

RESULTS SATISFY?

YES
 4

STARTING OF WMM; SUBMISSION OF MATERIAL, PLANT, MACHINERY

AND RFI FOR APPROVAL

NO
VARIFICATION OF MATERIAL
PROPERTIES LIKE AIV, PI, PLANT &
MACHINERY ETC.,
RESULTS SATISFY?

YES

CONSTRUCTION OF WMM LAYER WISE

NO

VARIFICATION OF FDD, PROFILE

ETC.,

RESULTS SATISFY?

YES

LAYING OF PRIME COAT, SUBMISSION OF MATERIAL FOR APPROVAL

NO

VARIFICATION OF MATERIAL
PROPERTIES

RESULTS SATISFY?

YES
 5

SPREADING OF PRIME COAT ALONG WITH CHECKING FOR RATE OF SPREAD

LAYING OF TACK COAT, SUBMISSION OF MATERIAL FOR APPROVAL

NO
VARIFICATION OF MATERIAL
PROPERTIES

RESULTS SATISFY?

YES
SPREADING OF TACK COAT ALONG WITH CKECKING FOR RATE OF SPREAD

CONSTRUCTION OF BITUMINUS BINDER COURSES AND SUBMISSION OF RFI,

MATERIAL FOR APPROVAL

NO
VARIFICATION OF MATERIAL
PROPERTIES LIKE QUALITY OF BINDER,
AGGREGATE, MIX DESIGN PLANT &
EQUIPMENT ETC.,

RESULTS SATISFY?

YES

CONSTRUCTION OF BITUMINUS BINDER COURSE, LAYER WISE

NO
VARIFICATION OF BITUMINUS BINDER
COURSES FOR PROFILE, GRADATION,
DENSITY ,BITUMEN CONTENT ETC.,
LAYERWISE.

RESULTS SATISFY?

YES
 6

CONSTRUCTION OF BITUMINUS WEARING COURSES, SUBMISSION

OF RFI, MATERIAL FOR APPROVAL

NO

VARIFICATION OF MATERIAL PROPERTIES

LIKE QUALITY OF BINDER, PROPERTIES OF
AGGREGATE, PROPERTIES OF MIX, MIX
DESIGN, PLANT & MACHINERY ETC.,

RESULTS SATISFY?

YES

CONSTRUCTION OF BITUMINOUS WEARING COURSES

NO

VARIFICATION OF BITUMINOUS
WEARING COURSES LIKE PROFILE
DENSITY BITUMEN CONTENT AND
GRADATION

RESULTS SATISFY?

YES

END