GPT INFRAPROJECTS LTD QUALITY ASSURANCE PLAN FOR STRUCTURAL STEEL WORK

JC-25, Sector-III, Salt Lake City, Project Name :- Construction of Approach ramps for ROB over Bardhaman Yard in replacement of exisiting 2-lane ROB
Kolkata - 700064 Client: RAIL VIKAS NIGAM LIMITED

Inspection Details
Sl. No. Component Characteristics Checked Quantum Of Check Reference of Acceptance Client Reference Of Documents
Contractor PMC
(RVNL)
1.0. RAW MATERIALS
1.1 Steel Plates, Rolled Sections Visual
100%
Dimensional
All rolled Sections (other than plate)
Chemical Analysis MTC / Challan & off-site
conforming to E250 (Fe 410) B0 and Plates
Lab Test Report. Site
Mechanical Tests - UTS, yield conforming to E410(Fe 540) B0 as per
One sample test for Register
stress, elongation % & Bend IS:2062:2011
each heat no. W/P W R
test

Ultrasonic Test For 100% UT at site for As per ASTM SA-435/SA-435M MTC for Ultrasonic Test &
Lamination of Plates plates 16mm and Off-site Lab Test Report.
above Site Register.

1.2 Filler Materials / Welding Visual / IS Mark / MTC 100% IS :814 / AWS D1.1 P W/R R Batch Test Certificate,
Electrodes / Wire & Flux SAW, GMAW & SMAW Welding Process. Catalogue & Site Register

1.3 Paints & Primer Verification of Manufacturer’s 100% for each batch Technical Specification of contract of the P W/R R Batch Test Certificate,
MT C and Technical literature Contractor with RVNL / approved Catalogue, data Sheet
technical literature of manufacturer

1.4 HSFG Bolts , Nuts & Washer Visual 100% at site Technical Specification of Contract of the P W R/W MTC & Inspection Report
Contractor With RVNL/ IS:4000 / IS: 3757
Dimensional Random at site
Thread Matching Random at site
Test for Mechanical 3 Nos Test Samples IS : 1367 (Part III) / approved drawing Off-site Laboratory Test
Properties & Chemical Per Batch/Lot Report
Analysis

1.5 Stud Shear Connector Visual Random IRC 22-2008 / AWS D1.1 - ISO 13918 / P W R/W MTC & Inspection Report
Approved Drawings / Technical
Dimensional Random
Specification
3 Nos Test Samples Laboratory Test Report
Test for Mechanical
Per Batch/Lot
Properties & Chemical
Analysis

2.0. PRE- MANUFACTURING PROCESS

2.1 Welding Procedure Specification Visual 100% IS : 7307 (Part I) P W W/R Approved WPS
 Inspection Details
Sl. No. Component Characteristics Checked Quantum Of Check Reference of Acceptance Client Reference Of Documents
Contractor PMC
2.1 Welding Procedure Specification IS : 7307 (Part I) P W (RVNL)
W/R Approved WPS
NDT 100%
Destructive Testing 100%
2.2 Procedure Qualification Record Visual 100% IS : 7307 (Part I) P W W/R Inspection Report /
NDT/DT Reports
NDT 100%
Mechanical & Chemical 100%

2.3 Welder Qualification Visual 100% IS : 7310 (Part I) P W W/R Inspection Report /
NDT/DT Reports
NDT 100%
Mechanical & Chemical 100%

3.0. MANUFACTURING PROCESS

3.1 Materials Preparation Visual 100% Technical Specification of Contract of the P W/R R Dimensional Report
Contractor with RVNL/Drawing
Dimensional 100%
Marking & Cutting Edge 100%
Preparation

3.2 Layout of components & joints Dimensions 100% Measurement Approved Drawing P W W/R Inspection Report /
with calibrated tape & Approved Drawings
gauges

3.3 Jigs , Fixtures & Templates Dimensional Check 100% Measurement Approved Drawing P W/R R Jig Register
with calibrated tape &
gauges

3.4 Fit-Up Edge Preparation 100% Approved Drawing P W/R R Internal inspection report
Dimension & Alignment 100%
3.5 During Welding Welding Parameters (current, 100% Approved WPS P W/R R Welding Report
voltage, travel speed, type of
electrode & flux)

3.6 Post Weld Inspection Visual / Distortion / 100% Approved Drawing P W R/W Internal inspection report
Alignment

3.6.1 Bevel Groove joint : Bevel Tee & Ultrasonic Test 100% for Tension Zone IS 4260 -2004 P W R/W Protocol / Test Report
corner joints (Full penetration) & 25% for Compression
Zone.

3.6.2 Bevel Groove joint : Double V - Radiography Test / UT 100% IS 1182 -1983 / IS 4260 -2004 P W R/W Protocol / Test Report
Butt joint
3.6.3
DPT 100% Contract Specifications / relevant IS code P W R/W Protocol / Test Report
Fillet joint in load
 Inspection Details
Sl. No. Component Characteristics Checked Quantum Of Check Reference of Acceptance Client Reference Of Documents
Contractor PMC
Contract Specifications / relevant IS code P W (RVNL)
R/W Protocol / Test Report
Fillet joint in load
Visual 100%
bearing section
4.0. PARTIAL TRIAL ASSEMBLY
4.1 Trial Assembly for Girders / Visual & Dimensional 100% As per approved drawing P W R/W Protocol / Test Report
Released For Blasting & Painting
Matching of Holes 100%
Work
Camber 100%
5.0 SURFACE PREPARATION AND PAINTING
5.1 a) Blasting Visual / Surface roughness 100% SA 2.5 of DIN EN ISO 12944 Part 4 / P W R Inspection Report for each
Roughness as per ISO 8503/1 segment

b) Shop Primer Visual & DFT 100% Contract specifications / manufacturer's P W R Inspection Report for each
technical literature segment

c) Intermediate Coat paint Visual & DFT 100% Contract specifications / manufacturer's P W R Inspection Report for each
technical literature segment

d) Top Coat Visual & DFT 100% Contract specifications / manufacturer's P W R Inspection Report for each
technical literature segment

5.2 Lettering & Match Marking Visual & Correctness 100% P W R Dispatch certificate
Approved Drawing & Trial Assembly

LEGEND :-
TC- TEST CERTIFICATE UT- ULTRASONIC TEST W- WITNESS (WORK MAY PROCEED AFTER WITNESSING AND APPROVAL)
DPT- DYE PENETRANT TEST DT- DESTRUCTIVE TEST R- REVIEW (REVIEW OF REFERENCE DOCUMENTS FOR STAGE / FINAL APPRO
NDT- NON DESTRUCTIVE TEST DFT- DRY FILM THICKNESS R/W - REVIEW OR WITNESS (AS THE CASE MAY BE TO BE DECIDED BY RVNL.)
P - PERFORMER
REMARKS (if any):
QAP No: GPT/BWN-
APPROACH/FAB/QAP/01

REVISION:00
Date:16/03/2015

Remarks

From reputed manufacturer

like JINDAL, SAIL,TISCO

Welding Consumable from

reputed manufacturers

Paints & primer from

reputed manufacturers like
AKZONOBEL

From Panchvaktram,
Deepak Fasteners(Unbrako),
Koco

Clearance by PMC/ RVNL

Testing at RVNL approved

laboratory
 Remarks
Testing at RVNL approved
laboratory

Testing at RVNL approved

laboratory

Testing at RVNL approved

laboratory

Welding to be carried out

by approved welders only

RT preferable
 Remarks

Grit/copper slag/sand
blasting
1-coat Epoxy Zinc dust
having DFT of 75 microns.
Product interzinc 52 or
equivalent, colour gray.

1-coat high build Epoxy MIO

having DFT of 125 microns.
Product intergard 475 HS
MIO or equivalent.

2-coat Polysiloxane having

DFT of 120 microns. Product
interfine 878 or equivalent.
Colour silver gray- RAL
7001.

AND APPROVAL)
AGE / FINAL APPROVAL)
DECIDED BY RVNL.)
GPT INFRAPROJECTS LTD QUALITY ASSURANCE PLAN FOR STRUCTURAL STEEL WORK
JC-25, Sector-III, Salt Lake City, Project Name :- Construction of Approach ramps for ROB over Bardhaman Yard in replacement of exisiting 2-lane ROB
Kolkata - 700064 Client: RAIL VIKAS NIGAM LIMITED

Inspection Details
Sl. No. Component Characteristics Checked Quantum Of Check Reference of Acceptance Client Reference Of Documents
Contractor PMC
(RVNL)
1.0. RAW MATERIALS
1.1 Steel Plates, Rolled Sections Visual
100%
Dimensional
All rolled Sections (other than plate)
Chemical Analysis MTC / Challan & off-site
conforming to E250 (Fe 410) B0 and Plates
Lab Test Report. Site
Mechanical Tests - UTS, yield conforming to E410(Fe 540) B0 as per
One sample test for Register
stress, elongation % & Bend IS:2062:2011
each heat no. W/P W R
test

Ultrasonic Test For 100% UT at site for As per ASTM SA-435/SA-435M MTC for Ultrasonic Test &
Lamination of Plates plates 16mm and Off-site Lab Test Report.
above Site Register.

1.2 Filler Materials / Welding Visual / IS Mark / MTC 100% IS :814 / AWS D1.1 P W/R R Batch Test Certificate,
Electrodes / Wire & Flux SAW, GMAW & SMAW Welding Process. Catalogue & Site Register

1.3 Paints & Primer Verification of Manufacturer’s 100% for each batch Conform to system (V), Table 1900-3 P W/R R Batch Test Certificate,
MT C and Technical literature MOSRTH specification, section 1900 / Catalogue, data Sheet
Technical Specification of contract of the
Contractor with RVNL / approved
technical literature of manufacturer

1.4 HSFG Bolts , Nuts & Washer Visual 100% at site Technical Specification of Contract of the P W R/W MTC & Inspection Report
Contractor With RVNL/ IS:4000 / IS: 3757
Dimensional Random at site
Thread Matching Random at site
Test for Mechanical 3 Nos Test Samples IS : 1367 (Part III) / approved drawing Off-site Laboratory Test
Properties & Chemical Per Batch/Lot Report
Analysis

1.5 Stud Shear Connector Visual Random IRC 22-2008 / AWS D1.1 - ISO 13918 / P W R/W MTC & Inspection Report
Approved Drawings / Technical
Dimensional Random
Specification
3 Nos Test Samples Laboratory Test Report
Test for Mechanical
Per Batch/Lot
Properties & Chemical
Analysis
 Inspection Details
Sl. No. Component Characteristics Checked Quantum Of Check Reference of Acceptance Client Reference Of Documents
Contractor PMC
(RVNL)
2.0. PRE- MANUFACTURING PROCESS
2.1 Welding Procedure Specification Visual 100% IS : 7307 (Part I) P W W/R Approved WPS
NDT 100%
Destructive Testing 100%
2.2 Procedure Qualification Record Visual 100% IS : 7307 (Part I) P W W/R Inspection Report /
NDT/DT Reports
NDT 100%
Mechanical & Chemical 100%

2.3 Welder Qualification Visual 100% IS : 7310 (Part I) P W W/R Inspection Report /
NDT/DT Reports
NDT 100%
Mechanical & Chemical 100%

3.0. MANUFACTURING PROCESS

3.1 Materials Preparation Visual 100% Technical Specification of Contract of the P W/R R Dimensional Report
Contractor with RVNL/Drawing
Dimensional 100%
Marking & Cutting Edge 100%
Preparation

3.2 Layout of components & joints Dimensions 100% Measurement Approved Drawing P W W/R Inspection Report /
with calibrated tape & Approved Drawings
gauges

3.3 Jigs , Fixtures & Templates Dimensional Check 100% Measurement Approved Drawing P W/R R Jig Register
with calibrated tape &
gauges

3.4 Fit-Up Edge Preparation 100% Approved Drawing P W/R R Internal inspection report
Dimension & Alignment 100%
3.5 During Welding Welding Parameters (current, 100% Approved WPS P W/R R Welding Report
voltage, travel speed, type of
electrode & flux)

3.6 Post Weld Inspection Visual / Distortion / 100% Approved Drawing P W R/W Internal inspection report
Alignment

3.6.1 Bevel Groove joint : Bevel Tee & Ultrasonic Test 100% for Tension Zone IS 4260 -2004 P W R/W Protocol / Test Report
corner joints (Full penetration) & 25% for Compression
Zone.
 Inspection Details
Sl. No. Component Characteristics Checked Quantum Of Check Reference of Acceptance Client Reference Of Documents
Contractor PMC
(RVNL)
3.6.2 Bevel Groove joint : Double V - Radiography Test / UT 100% IS 1182 -1983 / IS 4260 -2004 P W R/W Protocol / Test Report
Butt joint
3.6.3
DPT 100% Contract Specifications / relevant IS code P W R/W Protocol / Test Report
Fillet joint in load
Visual 100%
bearing section
4.0. PARTIAL TRIAL ASSEMBLY
4.1 Trial Assembly for Girders / Visual & Dimensional 100% As per approved drawing P W R/W Protocol / Test Report
Released For Blasting & Painting
Matching of Holes 100%
Work
Camber 100%
5.0 SURFACE PREPARATION AND PAINTING
5.1 a) Blasting Visual / Surface roughness 100% SA 2.5 of DIN EN ISO 12944 Part 4 / P W R Inspection Report for each
Roughness as per ISO 8503/1 segment

b) Shop Primer Visual & DFT 100% Contract specifications / Conform to P W R Inspection Report for each
system (V), Table 1900-3 MOSRTH segment
specification, section 1900
/manufacturer's technical literature

c) Intermediate Coat paint Visual & DFT 100% Contract specifications / Conform to P W R Inspection Report for each
system (V), Table 1900-3 MOSRTH segment
specification, section 1900
/manufacturer's technical literature

d) Top Coat Visual & DFT 100% Contract specifications / Conform to P W R Inspection Report for each
system (V), Table 1900-3 MOSRTH segment
specification, section 1900
/manufacturer's technical literature

5.2 Lettering & Match Marking Visual & Correctness 100% P W R Dispatch certificate
Approved Drawing & Trial Assembly

LEGEND :-
TC- TEST CERTIFICATE UT- ULTRASONIC TEST W- WITNESS (WORK MAY PROCEED AFTER WITNESSING AND APPROVAL)
DPT- DYE PENETRANT TEST DT- DESTRUCTIVE TEST R- REVIEW (REVIEW OF REFERENCE DOCUMENTS FOR STAGE / FINAL APPROVA
NDT- NON DESTRUCTIVE TEST DFT- DRY FILM THICKNESS R/W - REVIEW OR WITNESS (AS THE CASE MAY BE TO BE DECIDED BY RVNL.)
P - PERFORMER
REMARKS (if any):
QAP No: GPT/BWN-
APPROACH/FAB/QAP/01

REVISION:00
Date:16/03/2015

Remarks

From reputed manufacturer

like JINDAL, SAIL,TISCO

Welding Consumable from

reputed manufacturers

Paints & primer from

reputed manufacturers

From Panchvaktram,
Deepak Fasteners(Unbrako),
Koco

Clearance by PMC/ RVNL

 Remarks

Testing at RVNL approved

laboratory

Testing at RVNL approved

laboratory

Testing at RVNL approved

laboratory

Welding to be carried out

by approved welders only
 Remarks

RT preferable

Grit/copper slag/sand
blasting
2-coat Zinc phosphate
chlorinated rubber primer
having DFT of 100 microns

1-coat high build

chlorinated rubber MIO
having DFT of 75 microns

1-coat chlorinated rubber

paint having DFT of 30
microns.

D APPROVAL)
GE / FINAL APPROVAL)
ECIDED BY RVNL.)
GPT INFRAPROJECTS LTD QUALITY ASSURANCE PLAN FOR STRUCTURAL STEEL W
JC-25, Sector-III, Salt Lake City, Project Name :- Construction of Approach ramps for ROB over Bardhaman Yard in re
Kolkata - 700064 Client: RAIL VIKAS NIGAM LIMITED

Sl. No. Component Characteristics Checked Quantum Of Check

1.0. RAW MATERIALS

1.1 Steel Plates, Rolled Sections Visual
100%
Dimensional
Chemical Analysis
Mechanical Tests - UTS, yield One sample test for
stress, elongation % & Bend each heat no.
test

Ultrasonic Test For 100% UT at site for

Lamination of Plates plates 16mm and
above

1.2 Filler Materials / Welding Visual / IS Mark / MTC 100%

Electrodes / Wire & Flux

1.3 Paints & Primer Verification of Manufacturer’s 100% for each batch
MT C and Technical literature

1.4 HSFG Bolts , Nuts & Washer Visual 100% at site

Dimensional Random at site
Thread Matching Random at site
Test for Mechanical 3 Nos Test Samples
Properties & Chemical Per Batch/Lot
Analysis

1.5 Stud Shear Connector Visual Random

Dimensional Random
3 Nos Test Samples
Test for Mechanical
Per Batch/Lot
Properties & Chemical
Analysis

2.0. PRE- MANUFACTURING PROCESS

2.1 Welding Procedure Specification Visual 100%
NDT 100%
Destructive Testing 100%
2.2 Procedure Qualification Record Visual 100%
NDT 100%
Mechanical & Chemical 100%

2.3 Welder Qualification Visual 100%

NDT 100%
Mechanical & Chemical 100%
 3.0. MANUFACTURING PROCESS
3.1 Materials Preparation Visual 100%
Dimensional 100%
Marking & Cutting Edge 100%
Preparation

3.2 Layout of components & joints Dimensions 100% Measurement

with calibrated tape &
gauges

3.3 Jigs , Fixtures & Templates Dimensional Check 100% Measurement

with calibrated tape &
gauges

3.4 Fit-Up Edge Preparation 100%

Dimension & Alignment 100%
3.5 During Welding Welding Parameters (current, 100%
voltage, travel speed, type of
electrode & flux)

3.6 Post Weld Inspection Visual / Distortion / 100%

Alignment

3.6.1 Bevel Groove joint : Bevel Tee & Ultrasonic Test 100% for Tension Zone
corner joints (Full penetration) & 25% for Compression
Zone.

3.6.2 Bevel Groove joint : Double V - Radiography Test / UT 100%

Butt joint
3.6.3
DPT 100%
Fillet joint in load
Visual 100%
bearing section
4.0. PARTIAL TRIAL ASSEMBLY
4.1 Trial Assembly for Girders / Visual & Dimensional 100%
Released For Blasting & Painting
Matching of Holes 100%
Work
Camber 100%
5.0 SURFACE PREPARATION AND PAINTING
5.1 a) Blasting Visual / Surface roughness 100%

b) Shop Primer Visual & DFT 100%

c) Intermediate Coat paint Visual & DFT 100%

d) Top Coat Visual & DFT 100%

5.2 Lettering & Match Marking Visual & Correctness 100%

LEGEND :-
TC- TEST CERTIFICATE UT- ULTRASONIC TEST
DPT- DYE PENETRANT TEST DT- DESTRUCTIVE TEST
NDT- NON DESTRUCTIVE TEST DFT- DRY FILM THICKNESS

REMARKS (if any):

 QUALITY ASSURANCE PLAN FOR STRUCTURAL STEEL WORK
Construction of Approach ramps for ROB over Bardhaman Yard in replacement of exisiting 2-lane ROB
Client: RAIL VIKAS NIGAM LIMITED

Inspection Details
Reference of Acceptance Client Reference Of Documents
Contractor PMC
(RVNL)

All rolled Sections conforming to E250 (Fe MTC / Challan & off-site
410)GrA and Plates conforming to Lab Test Report. Site
E250(Fe 410) B0 as per IS:2062:2011 Register
W/P W R

As per ASTM SA-435/SA-435M MTC for Ultrasonic Test &

Off-site Lab Test Report.
Site Register.

IS :814 / AWS D1.1 P W/R R Batch Test Certificate,

SAW, GMAW & SMAW Welding Process. Catalogue & Site Register

Conform to system (V), Table 1900-3 P W/R R Batch Test Certificate,

MOSRTH specification, section 1900 / Catalogue, data Sheet
Technical Specification of contract of the
Contractor with RVNL / approved
technical literature of manufacturer

Technical Specification of Contract of the P W R/W MTC & Inspection Report

Contractor With RVNL/ IS:4000 / IS: 3757

IS : 1367 (Part III) / approved drawing Off-site Laboratory Test

Report

IRC 22-2008 / AWS D1.1 - ISO 13918 / P W R/W MTC & Inspection Report
Approved Drawings / Technical
Specification
Laboratory Test Report

IS : 7307 (Part I) P W W/R Approved WPS

IS : 7307 (Part I) P W W/R Inspection Report /

NDT/DT Reports

IS : 7310 (Part I) P W W/R Inspection Report /

NDT/DT Reports
Technical Specification of Contract of the P W/R R Dimensional Report
Contractor with RVNL/Drawing

Approved Drawing P W W/R Inspection Report /

Approved Drawings

Approved Drawing P W/R R Jig Register

Approved Drawing P W/R R Internal inspection report

Approved WPS P W/R R Welding Report

Approved Drawing P W R/W Internal inspection report

IS 4260 -2004 P W R/W Protocol / Test Report

IS 1182 -1983 / IS 4260 -2004 P W R/W Protocol / Test Report

Contract Specifications / relevant IS code P W R/W Protocol / Test Report

As per approved drawing P W R/W Protocol / Test Report

SA 2.5 of DIN EN ISO 12944 Part 4 / P W R Inspection Report for each

Roughness as per ISO 8503/1 segment

Contract specifications / Conform to P W R Inspection Report for each

system (V), Table 1900-3 MOSRTH segment
specification, section 1900
/manufacturer's technical literature

Contract specifications / Conform to P W R Inspection Report for each

system (V), Table 1900-3 MOSRTH segment
specification, section 1900
/manufacturer's technical literature

Contract specifications / Conform to P W R Inspection Report for each

system (V), Table 1900-3 MOSRTH segment
specification, section 1900
/manufacturer's technical literature

P W R Dispatch certificate
Approved Drawing & Trial Assembly
TRASONIC TEST W- WITNESS (WORK MAY PROCEED AFTER WITNESSING AND APPROVAL)
TRUCTIVE TEST R- REVIEW (REVIEW OF REFERENCE DOCUMENTS FOR STAGE / FINAL APPROVAL)
Y FILM THICKNESS R/W - REVIEW OR WITNESS (AS THE CASE MAY BE TO BE DECIDED BY RVNL.)
P - PERFORMER
QAP No: GPT/BWN-
APPROACH/FAB/QAP/02

REVISION:00
Date:05/01/2018

Remarks

From reputed manufacturer

like JINDAL, SAIL,TISCO

Welding Consumable from

reputed manufacturers

Paints & primer from

reputed manufacturers

From Panchvaktram,
Deepak Fasteners(Unbrako),
Koco

Clearance by PMC/ RVNL

Testing at RVNL approved

laboratory

Testing at RVNL approved

laboratory

Testing at RVNL approved

laboratory
 Welding to be carried out
by approved welders only

RT preferable

Grit/copper slag/sand
blasting
2-coat Zinc phosphate
chlorinated rubber primer
having DFT of 100 microns

1-coat high build

chlorinated rubber MIO
having DFT of 75 microns

1-coat chlorinated rubber

paint having DFT of 30
microns.
G AND APPROVAL)
STAGE / FINAL APPROVAL)
BE DECIDED BY RVNL.)