QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of

Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

QUALITY ASSURANCE PLAN (QAP)

HIGHWAYS & STRUCTURES

AUTHORITY:- NATIONAL HIGHWAYS AUTHORITY OF INDIA

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota
Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to
Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage) basis

CONTRACTOR : - M/s MLA-BSPCC( JV)

DESIGN DIRECTOR : - MR.KULSHEKHAR SHARMA
AUTHORITY’S ENGINEER :- M/s LEA ASSOCIATES SOUTH ASIA Pvt. Ltd. –
PIONEER INFRA CONSULTANTS Pvt. Ltd.
(ASSOCIATION)

Name Department Signature Date

Mr. PAWAN AGARWAL
Prepared By: Site Engineer
Mr. KULSHEKHAR
Reviewed By: SHARMA Sr. Project Manager
Approved M/s LEA ASSOCIATES Authority/ Authority’s
SOUTH ASIA Pvt. Ltd. –
By: PIONEER INFRA
Engineer
CONSULTANTS Pvt. Ltd.
(ASSOCIATION)

Current Revision History

Revision
Revision Number R-0
Date 19/04/2021

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Contents
QUALITY ASSURANCE PLAN 1

CHAPTER – 1 ; GENERAL 6

INTRODUCTION 7

GUIDELINES FOR USING THE PLAN 7

CHAPTER – 2 ; QUALITY MANAGEMENT PLAN 10

DEFINITIONS 11

REFERENCES 11

OBJECTIVES 12

SCOPE OF SERVICES / WORK: 12

DOCUMENT AND RECORD CONTROL SYSTEM: 12

SITE INSPECTIONS, DAILY REPORTS AND DIARIES 14

QUALITY CONTROL 16

SAMPLING OF MATERIALS 23

ACCEPTANCE TESTING 24

QUALITYCONTROLTESTSTATEMENT(MONTHLY PROGRESS REPORT) 25

CHAPTER – 3 ; RESPONSIBILITIES & DUTIES 26

RESPONSIBILITIES & DUTIES 27

ORGANISATION CHART FOR QUALITY MANAGEMENT 31

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

CHAPTER –4 ; QAP FOR BASIC CONSTRUCTION MATERIALS 32

QAP FOR BASIC CONSTRUCTION MATERIALS 33

FOR STRUCTURE WORKS 35

CHEMICALS 48

SEALANTS 56

CHLOROPRENE ELASTOMER 68

POLY TETRA FLURO ETHYLENE (PTFE) 69

PROPERTIES OF CHLOROPRENE SEAL FOR EXPANSION JOINTS 69

ASSEMBLED ACCESSORIES 71

POT-PTFE BEARINGS 71

ELASTOMERIC BEARINGS 72

TEST ON EXPANSION JOINTS 75

FOR HIGHWAY 77

EMBANKMENT, SUB-GRADE CONSTRUCTION (REF. MORTH SECTION 900 &

305.0) 77

SUB-BASE AND BASE COURSE (REF. MORTH SECTION 900) 78

BITUMINOUS WORKS. (REF. MORTH SPEC SECTION 900) 80

MARKING & OTHER ROAD APPURTENANCES. 89

CHAPTER – 5 ; QAP FORSITE ACTIVITIES 93

QAP FOR SITE ACTIVITIES 94

MIX DESIGN INCLUDING TRIAL MIX AND ACCEPTANCE CRITERIA 95

R.C.C WORK 96

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

EARTH WORK INSPECTION GUIDELINE 97

GSB & WMM WORK INSPECTION GUIDELINE 98

BITUMINOUS PAVEMENT WORK INSPECTION GUIDELINE

(BM/DBM/BC) 99

CHAPTER – 6; FORMATS FOR REPORTS AND RECORDS 103

REPORT & RECORDS 103

CHAPTER –7; IN HOUSE / ON SITE TESTING 106

IN HOUSE/ON SITE TESTING 107

SITE ACTIVITIES 114

CHAPTER- 8; OUTSIDE / INDEPENDENT TESTING 116

EXTERNAL INDEPENDENT TESTING 117

REQUIREMENTS OF TESTING LABORATORY 117

CHAPTER –9 ; METHOD STATEMENTS 118

METHOD STATEMENTS 119

STRUCTURE WORKS (GENERAL) 119

CONCRETE PRODUCTION AND TRANSPORT 119

FIXING OF PTFE-CUM-POT & ELASTOMERIC BEARING 119

ROAD WORK 120

CHAPTER – 10 ; NON CONFORMING PRODUCTS AND PROCEDURES 121

NON-CONFORMING PRODUCTS AND PROCEDURES 122

GUIDELINES FOR NON-CONFORMING FOR STRUCTURE / HIGHWAY 122

ADMIXTURES 123
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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

CEMENT AND OTHER MATERIALS 124

RECORDS 125
CHAPTER – 11 ; QC LAB FORMATES 127

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

CHAPTER–1

GENERAL

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

INTRODUCTION

National Highways Authority of India is a premier organization which has been taking up
several challenging highway / Expressway projects. NHAI has now entrusted the of
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis on item rate (percentage) basis to M/S MLA-BSPCC (JV). While speed is the criteria,
quality cannot be ignored under any circumstances. With this philosophy in view, the
Contractor has now prepared Quality Assurance Plan (QAP), to be followed for the design &
execution of Structures and Highways of the project. The Contractor has, in turn, appointed
Mr Kulshekhar Sharma, Design Director for design of Structures and Highways etc.
This QAP has been prepared to compile the general procedures and guidelines to be followed by
the construction supervision personnel in carrying out all aspects of the Construction Supervision
tasks. This Manual mainly provides procedures for carrying out tasks related to inspection,
testing and reporting. However, this Manual does not deal with day-to-day technical
requirements, nor does it provide solutions to technical problems, as these technical issues are
usually administered by the Specifications and other Contract Documents.
Every effort has been made to design this Manual so that adherence to its guidelines will result in
efficient, safe and consistent supervision of the works in strict conformance to the Specifications
and other Contract requirements. This has led to the basic framework of this Manual being based
on construction supervision procedures consistent with standard International practices for
construction of important bridge projects of this type, with specific guidelines and forms, where
appropriate, being generated based on standard practices in India in conformance with MoRTH
and IRC & IS standards and guidelines. In all cases, however, it is important that all users of this
Manual understand that the Contract Documents including the Specifications are the controlling
documents for the construction supervision process.
It is to be noted that although the intention of this Manual is to provide efficient, high quality
construction and safety, adherence to the adopted guidelines does not necessarily guarantee that
these attributes are achieved. This points to the need, therefore, for all users to exercise judgment
based on good engineering practice in all cases rather than blind adherence to the adopted
guidelines. This also points to the urgent need to periodically review and update relevant
guidelines and procedures, and hence the Manual is to be seen as an evolving guide.
GUIDELINES FOR USING THE PLAN
This Manual is divided into 11 chapters and all chapters elaborate the guidelines for the use of
this Manual. Chapters 4 to 7 guide the user regarding the testing of basic ingredients and site
activities, while Chapter 9 as coverage of method statements of activities commonly involved in
the construction of a bridge& Highway and Chapters 10 deals with non-conforming products
records and Chapter 11 deals with Checklist and formats.

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Chapter 3 gives suggested outline of Responsibility & Duties and Organization of the personnel
at site and chapter 2 deals with the Quality management Plan.

Every construction activity starts with the use of basic material which may be either in a raw
shape like aggregates, cement and steel or assembled accessories like bearings and expansion
joints, Etc. Measure materials procured from HO and Raw materials like Aggregate, Sand,
Admixture, Etc. purchase at site for using in any site activity have been covered in Chapter 4, and
is titled as Quality Assurance Plan (QAP) for Construction Material. This chapter is classified
into different parts on the bases of the type of materials and their sources. QAP includes the tests
including their frequencies that every material has to undergo before it is accepted and approved
for use in the work. QAP is given, which include name of the test, frequency, levels of testing,
reference code / standard and acceptance criteria.
Level 1 indicates the tests performed by the Contractor before requesting the Contractor for
accepting the material, which can be termed as criteria for pre-qualification of the material and its
source. This test may be in the form of Manufacturers Test Certificate (MTC) on the basis of the
test at random conducted by the manufacturer or it may be the test got conducted by the
Contractor at his own level before requesting the AE for its approval.
Level 2 indicates the tests to be conducted by the Contractor in the site laboratory at given
frequency. Some of these tests may not be possible to be carried out in the site laboratory; they
may have to be carried out in an external laboratory. In order to differentiate between tests in site
laboratory / in-situ and external laboratory, two sub-levels have been defined (2A and 2B)
Level 3 indicates the test conducted by an independent agency, which may be different from the
external laboratory covered in Level 2. In the case of more sensitive and important materials, it is
necessary to have an independent testing done. In such cases, samples are collected from the site
and sent to the Contractor’s centralized laboratory or to approved external laboratories for
independent testing and comments from the experts.
While Chapters 4 and 5 cover the QAP for the construction materials and the site activities, their
testing facilities are covered under Chapters 8 and 7. For important projects, it is essential that in-
house testing laboratory is established so as to perform the tests which are comparatively easier
to perform and/or are required to be conducted very frequently.
Chapter 8 indicates guidelines for selecting external/independent testing laboratory. While testing
the material, the observations during the testing are required to be recorded in a proper manner.
In order to simplify the recording and also to record every essential data, data sheets have to be
prepared. The formats of these data sheets are given in Chapter 11 with unique identification
numbers.
Chapter 9 deals with method statements of activities which are required for every major activity.
The chapter includes procedure for preparing the method statements. It is expected that method
statements shall be approved prior to carrying out a particular activity. It is essential that the
Contractor submits his own method statement depending upon his set up and arrangement of the
type of machinery for each and every item before proceeding with its execution. Generally, for
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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

the specialized items like bearings, Expansion joints, Reinforced soil work, specialized agencies
are engaged and depending upon their system, the method statements can be given only by those
selected specialized agencies. However, some common Items have been covered in this chapter
and it is desired that the execution of any activity be started only after the method statement is
approved and available with the site staff.
Chapter 9 deals with those items that fail to pass the conformity tests. Mainly two types of cases
arise, one where test reports arrive only after the incorporation of the material into the project
such as concrete and, the other where test reports arrive prior to the use of the material even
though the same may have been brought to the site. The chapter lays down the methodology to
deal with such situations.
The above guidelines are framed for the convenience of the site staff to follow the Manual and
make effective use of it. Once the various formulations of the Manual are followed, it is
imperative that the end results are bound to be of an excellent quality. Quality Audit tests, as per
Contract Agreement shall be conducted upon completion of the Project Highway.

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

CHAPTER – 2
QUALITY
MANAGEMENT PLAN

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

DEFINITIONS
The following definitions shall apply:

Quality System
The Quality System is defined as the organization structure, responsibilities, procedures,
processes and resources needed for implementing quality management.

Quality Assurance (QA)

Quality Assurance is defined as all the planned and systematic activities implemented within the
Quality System and demonstrated as needed to provide adequate confidence that an entity will
fulfill the requirements.

Authority, Authority’s Engineer, Contractors

• Authority - National Highways Authority of India
• Contractor - M/s MLA-BSPCC (JV)
• Authority’s Engineer - M/s M/s LEA ASSOCIATES SOUTH ASIA Pvt. Ltd. –
PIONEER INFRA CONSULTANTS Pvt. Ltd.
(ASSOCIATION)
• Design Director - Mr, KULSHEKHAR SHARMA

Quality Assurance Plan

Quality Assurance Plan (QAP) is a base document outlining policy, procedures, responsibilities,
compliance, acceptance criteria and documentation needed for the successful implementation of a
project. It has been prepared for Structures & Road Works.

Quality Control (QC)

Quality Control are the operational techniques and activities, e.g. inspections and tests, that are
used to fulfill requirements for quality and encompass all those planned and systematic actions
necessary to provide confidence that a product or service will satisfy the given requirements for
quality.

Quality Audit
A systematic and an independent examination by internal (HO) or external audit team shall be
deployed to determine whether quality activities and related results comply with planned
arrangements that have been implemented effectively.

REFERENCES
MORTH (5th Rev.)
IRC & IRC SP
Contract Agreement & GAD
ASTM & AASTHO

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

OBJECTIVES
The fundamental objectives of the QAP related to construction activities are:
1. To ensure correct setting out of works.
2. To ensure that the construction works are done in accordance with the appropriate procedures.
3. No material is incorporated in the work unless tested and accepted.
4. To achieve the desired workmanship.
5. To prevent any damage or deterioration of the works partially completed till the final
completion of the entire job.
6. To ensure maintain of quality records conforming to the required quality and effective
operation of the quality system.
7. To monitor the implementation of the QAP by regular surveillance and scheduled audits and,
where necessary, to suggest corrective action.
8. To carry out analysis of non-conformances and to implement corrective actions when required.
9. To collect and uniquely identify all documentation generated by quality control test and
inspections, as per requirements of the contract Agreement.
10. To monitor all performance tests.
11. To ensure that the QAP meets the needs of the Contactor Agreement by on-going review and
regular meetings with the Authority and Authority’s Engineer.

SCOPE OF SERVICES / WORK:

The scope of works covered under this document comprise of the:
 Engineering of Civil works related to Highway, Culverts etc.
 Construction of Flexible Pavement Road, Bridges and other related works.
 Maintenance of the project for a period as specified in the Contract after Successfully
completion of the project.
 Providing various project facilities as specified in the contract.
 Project Completion documentation and handover.

DOCUMENT AND RECORD CONTROL SYSTEM:-

DOCUMENT PREPARATION AND APPROVAL:

The process user will study the process requirements and specifications, prepare procedure /
guidelines / work instructions as per the guidelines provided in the document and obtain the
document no. from the document controller to codify the document as per the procedures. After
preparation of the document the originator will send the document for approval to the approving
authority. After the document is approved, it will be finally cleared by the reviewing authority for
issue. Issue to all documents to concerned users shall be controlled and recorded by the document
controller. Refer to established Guideline for document issue and control from site end.

Page 12
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

DOCUMENT ISSUE AND CONTROL:

The following steps will be followed for document issue & control:
Drawings and other project – specific documents received from the Authority / Engineer and
from H.O.:
Step-1 Head of function / SPM will study the document and decide to whom it should be
distributed.
Step-2 The doc. controller at site will first enter the details in document master list and take the
number of copies required and prepare a document distribution list in a register.
Step-3 The doc. controller will put the “Controlled Copy” stamp and also the copy no. on each
copy and issue to the identified users. When a revised document is issued, it will be ensured by
the document controller that the superseded documents are withdrawn from all points of use and
destroyed. In cases where superseded document has to be preserved for record, the same shall be
kept separately after putting „SUPERSEDED‟ stamp on it.
Step-4 The doc. controller will enter the relevant details regarding the issue of the document in
the distribution register.
B. System documents like manuals, procedures, guidelines and formats etc., received from the
document controller at H.O.
These system documents are sent in soft copies to the document controller at site in „Read Only‟
format. The document controller, in turn, distributes these documents to all concerned users
through LAN and maintains record of distribution.
In cases where hard copies are required for distribution, the control shall be exercised as stated in
Steps 2 to 4 in Para- A above.
C. Documents like drawings, procedures, methodologies, etc. generated at the project site: These
documents shall be handed over to the document controller by the originator after necessary
approval and review by competent authorities and with the proposed distribution list. There after
the document controller will follow the steps 2 to 4 in Para- A above.

DOCUMENT AMENDMENT:
In case the documents require any amendment, an amended document will be prepared with
appropriate revision number. The revised approved document shall be sent for review of the
competent authority. The same process of document issue and control shall be followed as far
regular drawings / documents. All the obsolete documents from shall be removed and destroyed.

RECORD CONTROL SYSTEM:

All the records required to demonstrate the effective operation of the Quality Management
System are identified by the pertinent department / personnel.
All the records identified shall be codified to ensure proper identification and traceability of the
record as per the guidelines on document codification.
Format of the record shall be designed by the pertinent department and approved by the
department head prior to issue of the record.
Each department shall be prepared a department wise master list of record incorporating the
record no., name of the record, location of the record, retention period etc. for effective control of
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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

all the pertinent records. Department head shall be ensured that the records used in the
department legible, readily identifiable and retrievable and shall be maintained in secure
conditions at appropriate locations to minimize damage and deterioration.
After the retention period for a file / register is over the record shall be disposed and new file /
register for the same purpose shall be created.
The retention period for various quality record shall be as per the documented procedure of the
respective departments.

CONTROL OF DOCUMENTS / SPECIFICATIONS / DRAWINGS OF EXTERNAL

ORIGIN:
All the documents / drawings of external origin i.e., issued by Authority / Authority’s Engineer
or any other relevant statutory / regulatory bodies etc. shall be received and registered in the
appropriate document receiving register with proper document code, revision and date of
receiving status. Distribute / issue to the pertinent user, after due entry in the register and
obtaining the signature of the recipient. Whenever the amendments or the amended version of the
documents or drawings are received, the same shall be registered in the register. The earlier
document / drawing will be stamped “MODIFIED” in red colour and the amended version(s)
issued to the pertinent user against acknowledgement after noting therein revision no. of the
documents before issue.

SITE INSPECTIONS, DAILY REPORTS AND DIARIES

SITE INSPECTIONS
To ensure the Contractor’s strict Contract compliance, it is mandatory that all personnel charged
with inspection responsibilities properly prepare themselves in advance through detailed study
and understanding of the Quality Plans and Technical Specifications.
The Authorities engineer shall be co-ordinate with the Contractor’s construction activities related
to his section. The Contractor shall submit the Request for Inspection Form (RFI) to the Authority
engineer. After this, SECTION HEAD (Structure/Highways) shall submit a copy to the Q.A.
/Q.C. Engineer by hand with a request to proceed with the inspection. It is the Project
Manager>>>Authority Engineer responsibility to follow up on the RFI. A sample of the RFI is
given in ch, 6. Project Manager is authorized to inspect all works done and materials furnished.
Such inspection shall be extended to all parts of the works related to his section, and to the
preparation, fabrication or manufacture of the materials to be used. The Project Manager is not
authorized to alter or waive any provision of the Contract Agreement conditions or documents.
The Project Manager>>>Authority Engineer is responsible for keeping all records and progress
of the work and the manner in which it is being done, and also to call the attention to any non-
compliance with the drawings or specifications. He is not authorized to approve or accept any
portion of the work, or to issue instruction contrary to the plans and specifications. The Project
Manager has the authority to reject unsatisfactory workmanship, defective materials and to
recommend suspension of any work that is being improperly performed, subject to approval by
the Contractor’s Project manager. The Project Manager after his satisfaction will ensure the
Page 14
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

quality of work done along with Q.A / Q.C Engineer who will give the approval of that activity to
be proceeds.
The Project Manager may exercise such additional authority only as may, from time to time, be
delegated to him by the Contractor.

DAILY INSPECTION REPORTS

A Daily Report will be completed by each Project Engineer (Highways). These Daily Reports
will be reviewed and compiled by the SECTION HEAD (Structure / Highways).

The Daily Report from the SECTION HEAD (Structure / Highways) must include but not be
limited to the following items:
 Quantities of work performed and accepted under his inspection
 Site Instructions
 Unusual or unsatisfactory conditions
 Delays encountered
 Number of man or man-hours employed
 Equipment, Plant, methods used by the Contractor
 Tests performed to satisfy quality control keeping in view the frequency of sampling as lay
down
 Weather conditions and effect on the Works
 Day work records, if any

FIELD WORK DIARIES

Each Project Engineer will keep a personal Diary Notebook to accumulate during the day all data
used to prepare his Daily Report. Notes made in their Diary Notebook will be recorded neatly,
clearly and will be dated, signed and in sufficient detail to be clearly understood. This Diary
Notebook will also include the Project Engineer working hours and work location details for each
day.
The Project Engineer Diary Notebook must be properly identified approved/unapproved, indexed
and periodically turned in to the Project Manager for his review and safe-keeping. At the end of
the day, these Diary Notebooks will be returned to each Project Engineer (Highways).
The Project Engineer (Highways) Daily Report will contain quantities of work satisfactorily
performed each day under their inspection. These quantities will be based on measurements if the
quantity is for a particular section of work that is complete or based on an estimate if the work is
ongoing. Sketches with dimensions and calculations should be attached to the report as required.
Mechanical Plant and Equipment should be inspected periodically. A sample form for the
Inspection Report is given in Chapter-06.

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

QUALITY CONTROL
TYPES OF QUALITY CONTROL
One of the most important tasks of the supervision during the execution is technical quality
control, i.e., control as to whether the materials and work supplied by the contractor meet the
technical requirements in the C.A. specifications. There are two types of Quality Control, which
are described below:

PRECONSTRUCTION
Preconstruction is usually carried out by the Contractor’s Q.A/Q.C Engineer whose job is to be
on the site and supervise the quality test during the execution of the works. At the same time, the
field staff will perform simple measurements, such as the recording of the thickness of fill layers,
the temperature of asphalt material, and the slump of cement concrete & no, of cube casting,
WMM, Batching plant production etc.

POST CONSTRUCTION
Post Contruction includes field tests as well as laboratory test e.g. control of the surface evenness
of compacted pavement layers and laboratory tests, e.g., Marshall Tests on asphalt materials.
Other tests are a combination of field and laboratory tests. An example of this is the compaction
control of earthworks where the achieved density is determined by means of a field test, and
where the IS, IRC, ASTM, AASHTO, etc. density with which the result should be compared is
found by means of a laboratory test. End-results control is carried out by laboratory technicians,
and most of the work consists of laboratory tests.

PERFORMANCE OF QUALITY CONTROL

TESTING FACILITIES
Before the contractor initiate earthworks, GSB, WMM and asphalt paving, concrete works etc.,
the corresponding test facilities must be available i.e.
• Laboratories must be built and equipped
• Laboratory equipment must be procured and tested
• Test formats must be prepared
• Laboratory technicians / Engineer must be employed and trained
• A list of minimum equipment needed for the site laboratory is enclosed at Appendix-III. The
Contractor may also get the tests carried out in recognized testing laboratories outside for
tests of a special nature not covered by the equipment indicated in Appendix- III. Such testing
must be preceded by approval of the authority engineer Team Leader. The testing equipment
must be regularly serviced as recommended by the suppliers. A calibration chart must be
available for each equipment.
START-UP PROBLEMS
It is important that start-up problems are solved before the Contractor starts work. There is often
a special need for technical control during the start of the work; because the Contractor has start-
up problems then specifications normally not only state the technical requirements which must be
Page 16
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

met by materials and works, but also the test methods which must be used for the end-result
control. In most cases, this is necessary to be able to define the requirements clearly.

TEST SPECIFICATIONS
Specifications and standards usually describe test methods by referring to publications issued by
the Ministry of Shipping, Road Transport and Highways (MORTH) the Indian Roads Congress
(IRC). Where the said specifications are silent in regard to the specification in question, in that
case, the specifications under the Bureau of Indian Standards (BIS), the American Association of
State Highway and Transportation Officials (AASHTO), the American Standards for Testing
Materials (ASTM) and the British Standards (BS) shall apply in that order.

TESTING FREQUENCY
The frequency of technical control is usually laid down at the beginning of a Project and is
generally related to the specifications. A testing plan is giving the frequency, standards,
acceptance criteria and agency responsible for the testing.

METHOD CONTROL
Method control is carried out according to the type of work. Where the work method is of
considerable importance and requires constant supervision to achieve the quality, or where in
some case, the quality is difficult to improve upon; there should always be a Quality Control
Engineer on the site. Where work methods are of less importance or quality is constantly being
achieved by the Contractor, there may be less need for continuous surveillance.

END-RESULT CONTROL
The frequency of end-result control depends on the quality parameters that are to be checked as
per MoRT&H clause 900. Parameters which can vary considerably are continuously controlled.
Examples are the composition of asphalt materials and the compaction of asphalt courses. As
regards regular laboratory tests, the specification usually determines the number of tests. When
the works are started and in cases where difficulties as regards compliance with quality
requirements are encountered, laboratory testing will normally be intensified.

QUALITY PARAMETERS
Quality parameters which are usually more or less constant, e.g., the Los Angeles strength of
stone materials from the same quarry, are only controlled occasionally. The same applies to
parameters which can be checked fairly well with the naked eye, e.g., the particle form of
crushed stone. As regards the quality of manufactured materials produced by using advanced
technology, e.g., steel and bitumen, one usually trusts the manufacturer’s certificates, but when in
doubt additional tests can be carried out.
REPORTING OF TEST RESULTS
The test results must be recorded systematically in a register, which must be signed by the Q.C.
personnel and the representative of the Contractor’s Q.A. Engineer present during the tests. The
format for daily testing on works is given in Chapter-06.
Page 17
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

INTERPRETATION OF TEST RESULTS

The test results should be plotted on a graph sheet showing the dates/ sample numbers on the X-
Axis and the test values on the Y-Axis. The statistical “warning limits” and “action limits”
should be indicated on these graphs. When any test result falls outside the “warning limits”, the
cause should be investigated and suitable corrective action taken. When any test result falls
outside the “action limits”, the process should be stopped, and a thorough investigation made into
the entire process, and the cause for faulty performance determined. Suitable remedial action will
be immediately taken and the process brought under control.

STATISTICAL QUALITY CONTROL

Quality control based individual tests do not ensure well defined qualities of a product. One has
therefore, for many years in the industry, used statistical methods where works and supplies are
approved or rejected after an evaluation of the average and standard deviation of a number of test
results. In keeping with this practice, the Contractor intends to use statistical methods for the
quality control. The IRC Handbook on Quality Control (IRC SP-11& 47) shall be consulted for
guidance.

MONITORING OF QUALITY CONTROL

The SECTION HEAD (Structure / Highways) has the authority and responsibility for monitoring
the use of the QAP and for ensuring that the above policies are being implemented, and to
consider the need for changes.
The Contractors are responsible for joint sampling of all construction materials to be used in the
permanent works with the staff of Contractor’s QA Engineer prior to commencement of the
works. The testing shall be carried out under the supervision of the Contractor’s QA Engineer in
the laboratory.
But the obligations of the Contractor towards the Contractor do not relieve the Contractor of their
responsibilities as per Contactor Agreement.
1. The Project Manager shall carry out such duties in issuing
• Decisions
• Certificates
• Orders
As are specified in the C.A.
2. The SECTION HEAD (Structure / Highways) representative’s contractual duties are to
• Watch and Supervise the works
• Test and Examine materials and Workmanship
• Exercise “Process control” wherever needed
Therefore, the Project Manager Representative, Project Engineer assisted by qualified and
adequate staff shall carry out supervision and control such as:
• Sub-soil investigations
• Inspection of works and Workmanship
• Geometric control and Measurements

Page 18
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

• Quality control of works and Materials

The field staff may be divided into categories, so that the supervisory organization is made up of
bodies with their own field of responsibility such as:
• Structures
• Highways
• Materials and laboratory
It is naturally of great importance that each field of responsibility works in a competent and
well-organized manner.
It is the Contractor’s project manager responsibility that the supervision organization meets the
functional requirements.

APPROVAL OF QUARRIES AND BORROW AREAS

The Contractor is to obtain approval from the Team Leader for each Quarry and Borrow Area
to be used in the Project prior to commencement of Quarrying and Borrow area excavation
activities as per guidelines IRC-SP-112 is extremely useful. Criteria of effective CBR as per
IRC-37-2021. While testing of CBR should be done as per established compaction CBR
relationship as per MoRT&H Fifth revision. The primary aspects to be considered by the
SECTION HEAD (Structure / Highways) in granting approval are:

• The proposed materials meet the specification requirements

• The contractor has legal approval by the owner to excavate / remove materials from the
proposed quarry / borrow area.

The steps to be followed for approval of each Quarry/ Borrow Area are:

3. The Contractor is to complete the “Materials Sources Data” form giving details regarding
size, location, orientation and access for the proposed quarry/ borrow area (rough map to
be drawn). Also, to be included are the list of materials to be sourced for the Project Works
(e.g., Embankment, GSB, WMM, Etc.), and the estimated quantities for these materials.
4. The results of laboratory tests conducted on the materials jointly sampled with the
SECTION HEAD (Structure / Highways) (or his designated representative) are to be
summarized on the approval form, and complete copies of all tests are to be attached to the
form.
5. The Contractor shall attach to the completed “Materials Sources Data” form, for
development, use and closing down of the proposed quarry/ borrow area. Photographs of
the sources site, including access roads, etc., should be included with the proposal so that
the base line conditions of the quarry/ borrow area are clearly established.
6. Based on the Contractor’s proposal, and on the site inspection team’s comments, the
SECTION HEAD(Structure / Highways) will (within 5 days after receipt of the proposal)
reply to the Contractor in accordance with one of the following:
• The proposed Quarry/ Borrow Area are approved as proposed.
• The proposed Quarry/ Borrow Area are approved subject to one or more required
Page 19
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

changes/ additions etc. [to be detailed by the SECTION HEAD (Structure / Highways)].

• The Contractor is requested to revise and resubmit all or part of the proposal submits,
giving details of required changes, additional requirements, etc.
• The proposed Quarry/ Borrow Area are rejected.

With regard to approval of Quarries and Borrow Areas, the SECTION HEAD (Structure /
Highways) shall pay particular attention to requirements of the Environmental Management
Plan particularly with regards to:

1. Selection of area
• Borrow Areas not to be within the Project Right-of-Way
• Borrow Areas preferred in non-productive, barren lands, raised lands, waste lands,
etc.
• Borrow Areas to be located on agricultural land should first have the top
(Overburden) 150mm minimum removed and stockpiled. The stockpiled topsoil is
to be replaced and spread over the original areas after excavation for borrow is
completed.
• For quarry areas, particular care is to be taken to ensure that testing (and approval)
is given only for areas to be indicated on the plan for which the materials have
homogeneous properties. Similarly, the depth and extent of overburden to be
removed prior to quarrying is to be accurately measured and clearly indicated.
Or
As per contract agreement Fly ash may be used as a filling material (As per
specification of IRC SP-58)
2. Transport of Materials
• All movements and access of equipment to be stationed in the designated areas are
to cause minimum compaction of the soil (in critical areas/ situations, the SECTION
HEAD (Structure / Highways) may require that all such equipment have tracks
rather than wheels).
• All transport vehicles should have covered sides and tailgate to prevent spillage of
materials.
• All transport vehicles are to select appropriate routes and delivery times, and are to
adopt safe driving habits so as to ensure minimum of inconvenience to affected
traffic moment, and to reduce accident potential.

APPROVAL OF MATERIALS
All materials proposed by the Contractor to be used in the Project Works are to be first
approved. In general, there are four types of materials to be approved.

(1) Natural Materials – materials with little or no processing except for perhaps screening
for oversize and removal of unsuitable particles, etc. An example of this is soil
embankment materials.
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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

(2) Processed Materials – materials that require significant processing, including removal
of unsuitable particles, crushing, screening and perhaps, blending of sizes. These
materials are homogeneous, but with specified gradations. An example of this is Wet
Mixed Macadam Base Course.
(3) Manufactured Materials – Especially homogeneous construction materials, like
Portland cement and bitumen that are used for blending with natural materials
(generally soil or aggregate) to obtain a pavement mix.
(4) Designed Materials – materials that involve the mixture to specific proportions of two
or more different, natural, processed or manufactured materials to obtain a modified
material giving a set of desired specific properties.
Approval of each of the above material types is required, however the requirements for
obtaining approval of materials for each type differs slightly:

APPROVAL OF NATURAL MATERIALS

Natural materials are mined (i.e., excavated) and hence the first step, following assurance that
the material(s) is acceptable for its intended purpose, is to obtain approval for the Borrow
Area or Quarry.
Approval of the material for construction is then obtained by submittal of test results for all
tests required by the Specifications (i.e., to prove that the material meets all minimum
properties required), and, in some cases, by construction of trial sections to prove that this
material can be placed in the field so as to attain minimum required field properties (e.g. to
meet minimum density, etc.).

APPROVAL OF PROCESSED MATERIALS

Approval of processed materials follows that noted above for “Natural Materials”, except that
usually the specifications are tighter (e.g. the material may also have to meet stringent
gradation limits), and a greater variety of tests (and production/ storage) conditions are
required to be met. For GSB as per MoRT&H Clause 401 material grading V (as per
concessionaire agreement) and WMM as per MoRT&H Clause 406.

APPROVAL OF MANUFACTURED MATERIALS

Approval of manufactured materials viz. ordinary Portland Cement (OPC-43) for structural
concrete, Bitumen(VG-40) and PMB-40 for Dense Bitumen Macadam (DBM) and
Bituminous Concrete (BC) respectively based on specific Specification’s / Guidelines shall
be submitted from reliable sources, approval generally is given in two stages.
• Initial Approval – given prior to receipt of the materials based on submittal of
appropriate testing results confirmed by the manufacturer (note that claims by
manufacturers, or tests etc. by distributors, etc. are not to be accepted).
• Final Approval – given based on initial approval plus positive results being obtained
for all “acceptance” tests required by the Specifications, or as directed by the IE.

APPROVAL OF DESIGNED MATERIALS

Page 21
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Approval of “designed” materials for the present Project concerns those mix designs for
Portland Cement Concrete (for Flyover, Underpass, RE Wall, Utility Duct, Drain, Etc.) and

Page 22
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Bituminous mixes (flexible pavement materials including Bituminous Macadam, Dense

Bituminous Macadam, and Bituminous Concrete). Due to the complexity of these “mixed
materials” and the plants for producing the range of materials sizes, final approval are
deferred until completion of the following steps:
1. Approval of sources (generally quarries) for each of the processed material constituents to
be included in the final mix design.
2. Approval of each of the individual processed materials and manufactured materials to be
included in the final mix design.
3. Tentative approval of a laboratory-based mix design, based on a mixture of approved
materials so that the mixture meets all Specification requirements.
4. Tentative approval of a plant mix design, based on proportioning of aggregate bins
materials and manufactured materials to closely approximate the proportioning of
material types/ sizes finalized for the laboratory-based mix design (so that the mixture
still meets the minimum Specifications requirements).
5. Trial section of works using the tentatively approved plant mix design and placing the
mixture in accordance with a previously approved construction methodology that
conforms to Specification’s requirements.
6. Based on successful laying of the mixes in accordance with the approved Methodology,
conformance of the placed mix to required placing temperatures, levels and finish, etc.,
and conformance to quality control requirements as verified by successful testing in
accordance with the Specifications, the Contractor’s Q.A. Engineer is to give final
approval of the mix design (Job Mix Formula) based on the plant mix proportions.

REVOCATION (WITHDRAWAL) OF MATERIAL APPROVALS

Following approval of the job mix formula, the SECTION HEAD (Structure / Highways) and
all field support staff shall continue to monitor both the test results of the material and visual
characteristics of the approved mix as placed to identify at an early stage any significant
change in the mix design that may adversely influence the adherence of the approved mix
design to the Specifications. A new mix design (or adjustment of the plant proportioning of
materials to re-establish the approved job mix formula) will be required when it is observed
that significant changes in the mix design properties are causing the mix to no longer meet all
Specification requirements. In addition, a new mix design will be required when either the
approval of a material source or approval of one of the materials is revoked (i.e., withdrawn).
Mix Material approved shall be revoked by the SECTION HEAD (Structure / Highways)
after due consultation with the Contractor’s Q.A. Engineer.

REPORTING AND RECORDING MATERIAL APPROVALS

The Contractor’s Q.A. Engineer shall notify in writing to the SECTION HEAD (Structure /
Highways), the Contractor’s project manager and the Contractor each time a new source,
material and/ or mix design is either approved or the approval is revoked. This information is
to be included in the Monthly Quality Control Report to be submitted with the Monthly
Progress Report.
Page 23
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Records are to be kept by the Contractor’s Q.A. Engineer giving current approvals of all
Borrow Areas, Quarries (all types) and Mix Designs for all BOQ items. The current
summaries are to be included as part of the Monthly Progress Report.

SAMPLING OF MATERIALS:-
SAMPLING REQUIREMENTS
All construction materials to be used in the permanent works are to be sampled jointly by the
staff of Contractor’s Q.A. Engineer and the Contractor prior to commencement of the Works.
This includes sampling for materials to be tested for proposing approval of the material
source as well as sampling of materials for approval of the individual construction materials.
In both cases, and for each instance, the Contractor must give notification of a request for
such sampling to the SECTION HEAD (Structure / Highways) in advance (minimum 24
hours) by way of the Request for Inspection Form (RFI). All assistance (e.g. sampling
instruments and equipment, sample bags, and labour etc.) that is required for carrying out the
sampling activities are to be provided by the Contractor

SAMPLING GUIDELINES
All sampling is to be carried out in accordance with instructions to be given by the
Contractor’s Q.A. Engineer. Sampling procedures are to follow recognized guidelines of
good engineering practice. These include:
• Obtaining samples from at least three areas.
• Ensuring that the sampled materials and locations are “Typical” for the material to be
tested.
• Ensure that all overburden etc. is removed within the stockpiles rather than from the
surface (top, side or base of the stockpile) in order to avoid the collection of segregated
materials.
• Ensure that sufficient quantities are sampled to enable all tests to be conducted, plus
additional material, to be stored for subsequent testing if required.
• Ensure that each sample bag is marked/ labelled both inside and outside, giving the sample
number, material type, sample location, date and number of the bag, as well as any
additional information instructed by the Contractor’s Q.A. Engineer or his authorized
engineer.
PREPARATION AND STORAGE OF SAMPLES
Samples collected are reduced and prepared as per Indian Standards (IS) methods, with an
additional sufficient quantity retained in appropriately sealed bags or containers and
separately kept in the sample storage room of the laboratory for additional testing and/ or
future reference as required. Concrete samples in particular are to be carefully cured and kept
in the curing tank of the laboratory. Access to stored samples is under the strict direct control
of the Contractor’s Q.A. Engineer. Details of all samples stored are to be kept in a Register to
be administered by the authorized engineer of the Contractor’s Q.A. Engineer.

Page 24
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

ACCEPTANCE TESTING
GENERAL
All materials included in the construction works for which quality control tests are specified,
and for which approval by the Contractor’s Q.A. Engineer has been previously given, are to
be inspected and checked for acceptability in accordance with the Specifications
requirements. Any of the completed construction works in which unapproved and/ or untested
and or unaccepted materials are incorporated without approval or written permission from the
Contractor’s Q.A. Engineer is deemed performed at the Contractor’s risk and is considered as
unacceptable and unauthorized.

ROUTINE ACCEPTANCE TESTS

All sampling and quality control testing, as well as check tests to verify quality of materials,
are to be got conducted by the Contractor in the laboratory set up of the Contractor or in his
own field laboratory, as the case may be. In the latter case, the testing shall be got carried out
under the supervision of the Contractor’s QA Engineer. However, the Contractor is
responsible to provide necessary labour, tools and transport for the purpose of sampling by
the laboratory staff. The kinds of tests and frequency of testing should conform to the
Minimum Quality Control Testing Requirements of the MORTH Specifications. Sampling
and Testing should be in accordance with the relevant IS methods. Tests are to be reported on
proper forms, samples of which are shown in Appendix-III.

SPECIAL ACCEPTANCE TESTS

The Contractor’s Q.A. Engineer may order special tests to be conducted of materials and/ or
the completed Works as required. The Contractor will be responsible for the cost of special
tests if the tests show that the materials, plant or workmanship are not in accordance with the
provisions of the C.A.
Special tests are generally ordered by the Contractor’s Q.A. Engineer when there is some
concern with some aspect of the routine acceptance tests (e.g. sampling technique, sample
contamination, testing equipment problem, operator error etc.). Based on the above, the
following procedure is to be adopted for special testing:
1. The Contractor’s Q.A. Engineer shall identify routine testing concern and request
agreement from the Contractor’s Project manager that a special test is required.
2. The Contractor’s Q.A. Engineer shall identify what/ how/ where/ when the special test is
to be conducted.
3. By the Contractor within the Field Laboratory if set up by him.
4. By the internal independent testing (i.e. by the Contractor’s Q.A. Engineer within the field
Laboratory set up and maintained by the Contractor).
5. By external independent testing.
6. Following implementation of any relevant actions indicated based on the results of the
special test, record the test results, and also include the results as part of the “Quality
Control Test Statement” to be submitted with, and as part of the Monthly and Quarterly
Progress Reports.
Page 25
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

QUALITY CONTROL TEST STATEMENT (MONTHLY PROGRESS REPORT)

The list of laboratory test results completed during the month, and their statistical
interpretations shall be included as an integral part of the Contractor’s Q.A. Engineer’s
Monthly Progress Report to be submitted to the Client. This summary of field and laboratory
test results is referred to as a Quality Control Test Statement and is to include the following:

• Item description, and kind of test;

• Numbers of tests completed, passed and failed;
• Analysis of test results and establishment of trends;
• Any appropriate remarks or comments, based on trend detected and any
corrective action needed.

Page 27
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

CHAPTER – 3

RESPONSIBILITIES & DUTIES

Page 28
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

RESPONSIBILITIES & DUTIES

Following are the responsibilities and reporting works of personnel involved in the scope of
the procedure:
Position Reporting / Responsibilities
Senior Project Manager  Shall report to management & HO
 Approve project execution work plan and budget
 Communicate salient features of the project, roles,
expectations, to the project team
 Ensure on time in full project delivery as per the project plan
 Ensure compliance to statutory requirements with the
assistance of Contracts Head
 Build & maintain effective working relationships with
external entities- client, other contractors, Govt. agencies, local
community etc.
 Monitor resource productivity, physical and financial
progress in consultation with Project Controls
 Ensure adherence to contract specifications, HSE and quality
standards
 Prioritize and resolve conflicting issues on the project in
consultation with Construction head and Sector Head.
 Plan and ensure adherence to mobilization/ demobilization of
resources with Project Controls
 Ensure that all functions at the project site are
appropriately, trained and managed.
 Define and monitor performance targets for the project team.
 Ensuring that periodical material is carried out as per the
extant procedures.
Deputy Project Manager /  Shall report to the Project Manager
SECTION HEAD  Shall be responsible for control, supervision and direction for
implementation and execution of construction plans.
 Shall also be responsible for supervision of construction
activities and preparation of records, procedures and prepare
progress and completion reports.
 Shall be responsible for obtaining approval from
AE/Client where applicable. Obtain all preliminary clearances
from AE/ Client before commencement of works.
 Shall be arranging manpower resources and equipment
required for the execution of the work.
Engineers  Shall report to Deputy Project Manager
 Shall responsible for execution of each and every activity as
per approved method statement/ approved drawings/

Page 29
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Position Reporting / Responsibilities

Specifications, like as reinforcement steel fixing, formwork
fixing & alignment etc. with the assistance of foreman /
Supervisor.
 Shall responsible for ensuring quality & safety and maintains
documents and records
Supervisor  Shall responsible for each and every activities like as shifting
of construction material and equipment, checking of supporting
arrangement & formwork before and during concreting,
 He is also responsible for cleaning and housekeeping after
Concreting.

Survey Engineer/Surveyor  Shall report to Deputy Project Manager

 Shall be responsible for Levels, Co-ordinates as per
approved GFC drawings and Specifications.
QA/QC Manager  Shall be responsible for overall control of QA/QC activities
and implementation of QAP / Quality Plan.
 Shall be responsible for ensuring that all inspections are
Being carried out as per specifications.
QA/QC Engineer  Shall report to QA/QC Manager
 Shall be responsible for overall control of QC activities and
sub-contractors QC activities, implementation of QAP/ Quality
Plan.
 Shall be responsible for carrying out Inspection as per
specification.
Lab Technician  Shall report to QA/QC Engineer
 Shall be responsible for sample collection, testing and
involve in QC activities and sub-contractors QC activities,
implementation of QAP/ Quality Plan.
 Shall be responsible for carrying out Inspection as per
specification

Page 30
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Project HSE Head  Implementation of Occupational Health & Safety and

Environment management System (PSMP &PEMP) at project site.
 Carryout hazard identification and risk assessment of all
activities and recommend required control measures.
 Prepare project specific ROR which is reviewed HO and
getting approval from Project Manager and ensure the
compliance.
 Ensuring that all HSE measures and applicable Legal issues
for the project are complied with throughout the duration of the
contract including implementation of revisions.
 Reporting to Head-HSE

Page 31
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

Position Reporting / Responsibilities

Legal issue as per procedures & guidelines.
 Maintaining relevant records on HSE and Legal issue as per
procedure.
 Ensuring that all personnel engaged at the project receive
induction training, prior to issue of their access control passes and
or allowed for their respective job allocation.
 Interact with client / consultants regarding all HSE and Legal
issues pertaining to project
 Coordinate with store and procurement team to plan and
procure for HSE gadgets / PPE‟s etc.
 Advise the project management and line management in
planning and organizing measures necessary for establishing safe
work environment towards preventing accidents.
 Investigation of incidents including Lost Time Accidents,
fatal accidents, dangerous occurrences, near misses and
occupational diseases and taking remedial measures and
furnishing reports to IMS Head on the above
 Provide training on HSE related subjects to all in association
with concerned departments.
 Ensure Constitution of site HSE committee, and carrying
out periodical (fortnightly / monthly) walk down by HSE
committee to identify critical areas of deficiency and take
necessary corrective preventive actions. Ensure discussions on
safety in the HSE committee meeting and define action plan.
 Conducting Audit & Inspection of Plant & equipment and
Firefighting & Safety Appliances / Equipment Tools &
Scaffolding etc. to suggest corrective measures for safe operation.
 Prepare monthly Project safety performance indicator based
on the scores given by the HSE committee / team.
 Ensure the effective monitoring & control measures of the
environment as per Environment management plan by engaging
external monitoring agencies.
 Plan & conduct internal audit / Inspection at site
 Raising of Non-Conformities on Safety & Environmental
issues.

Page 32
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

ORGANISATION CHART FOR QUALITY MANAGEMENT

PROJECT
MANAGER

QA/QC
MANAGER

QUALITY QUILITY QUILITY

ENGINEER ENGINEER ENGINEER
(S) (LAB) (H)

LAB LAB LAB

TECH. TECH. TECH.

HELPER HELPER HELPER

Page 33
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

CHAPTER –4
QAP FOR BASIC CONSTRUCTION
MATERIALS

Page 34
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

QAP FOR BASIC CONSTRUCTION MATERIALS

This part of the Plan deals with the complete spectrum of tests to be performed on various
construction materials which may be carried out by the Contractor to ascertain their quality. Before
any material is used in its unaltered original form or incorporated to produce any derivative, the
same shall be subject to performance testing as per the provisions of this chapter. At the outset, it
may be noted here that the test requirements, including the frequencies of tests indicated in this
Manual, are the basic minimum needs. The material is generally expected to perform much better
than the respective minimum requirements. Similarly, frequencies of material testing are generally
the minimum requirements which can slightly be reduced or increased in case the respective
material performs better / less than anticipated. It is highlighted here that the Contractor has set up a
separate centralized testing laboratory in addition to the individual laboratories set up by the
Contractors.

Three levels (viz. Levels 1, 2 and 3) of tests have been identified. Depending on the material and
prevailing best practices, the level of its testing has been decided. While all the materials are
required to be tested before being allowed to be incorporated in the structure& Highway, further
tests depend on the importance of the material. Usually all the materials will undergo Level 2
testing out of which some tests may be done in the in-house / site laboratory set up by the
Contractors and the remaining may be done in an approved external laboratory if the facility is
not available in in-house / site laboratory. For example, an admixture is required to be tested at
Level 1 which represents usual testing in the manufacturer’s laboratory. In addition, it will
undergo Level 2 testing and moreover, some of its tests would undergo Level 3 testing due to
high sensitivity of the material. On the other hand, cement can be tested in the in house lab as
well, especially for some of the simpler tests such as Setting Time, Mortar Cube strength etc.
whereas, chemical tests can only be done in an external laboratory. Therefore, cement qualifies
for all levels viz. Levels 1, 2A, 2B and 3 of testing. Here again, Level 3 testing is required due to
sensitivity and importance of the material. Some of the tests shall be done in the Contractor’s
centralized testing laboratory or in an approved external laboratory depending on the available
test facilities.

Page 35
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - M/S MLA BSPCC JV

In some of the specialized materials like pre-stressing hardware, bearings and expansion joints,
many test facilities may or may not available in external laboratories. In such cases, even the
Level 3 tests need to be performed in the manufacturer’s works laboratory. While this Chapter
gives broad acceptance standards of performance criteria for materials in addition to frequency,
check level and reference, Chapter 11 gives the detailed test Performa to be filled up
corresponding to each of the tests.

It is very important and essential to obtain a signed certificate of conformance / nonconformance

of the material to meet the targeted requirements of the relevant codes and standards.

Page 36
 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

FOR STRUCTURE WORKS

COARSE AGGREGATES
Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Particle Size and 1. Once for every 1 IS: 383-1970,
source approval 2 A, IS: 2386 (Part I)-
2. Once in a week 2B 1963
MORTH Rev. 5th
a) Sieve Analyses 1 IS: 383-1970,
2 A, IS: 2386 (Part I)- Single –Sized Aggregate
2B 1963 Nominal IS Sieve Percentage
MORTH Rev. 5th Size Designation passing (by
Weight)
20 mm 40 mm 100
20 mm 85 – 100
10 mm 0 – 20
4.75 mm 0–5

10 mm 12.5 mm 100
10 mm 85 – 100
4.75 mm 0 – 20
2.36 mm 0–5
b) Flakiness Index As per MORTH 1, 2 A IS 2386 part-1 35 % maximum value as per MORTH
2) Deleterious 1. Once for every 1 IS: 383-1970 Deleterious Material Percentage of
source approval 3 IS: 2386 (Part-II) - Crushed Coarse
1963 1. Coal & lignite Aggregate by
1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

Test Frequency Check Ref. Codes Acceptance Standards

Level
2. Clay Lumps Weight (max.)
3. Material finer than 75 micron 1
IS 1
4. Soft for Section Headent 3
5. Shale -
Total 5
3) Specific Gravity 1. Once for every 1 IS: 383-1970 Test is required for maintaining uniformity of material
source approval IS: 2386 (Part III)- brought from the source.
2A, 1963
2B
4) Mechanical Properties 1. Once for every 1 IS: 383-1970
source approval IS: 2386 (Part IV)-
2. Once in a week 2A, 1963
2B
a) Aggregate As per MORTH 1 IS 383 45 % Maximum by weight for concrete
Crushing Value 3 IS 2386 P-iv 30% Maximum by weight for wearing surfaces.
b) Impact Value As per MORTH 1 IS 383 45 % Maximum by weight for concrete
(Alternate to (a) above) 2 IS 2386 P-iv 30% Maximum by weight for wearing surfaces.

c) Abrasion Value As when required 1 IS 383 50 % Maximum by weight for concrete

Source approval 2A, IS 2386 P-iv 35% Maximum by weight for wearing surfaces.
2B
5) Soundness 1 Once for every 1 IS: 383-1970 Maximum Average Loss of Weight after 5 cycles tested
source approval IS: 2386 (Part V)- with :
2. Once in 3 3 1963 (i) Sodium Sulphate - 12%
1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

Test Frequency Check Ref. Codes Acceptance Standards

Level
months (ii) Magnesium Sulphate - 18%
6) Surface moisture 1. Once for every 2 IS: 383-1970 Test required to adjust the water content in the mix
source approval IS: 2386 (Part III)- design before starting concrete production mixing.
2. At every change 3 1963
of
mix design
3. Every time
making
the concrete
7) Alkali Aggregate 1. Once for every 1 IS: 383-1970 Innocuous aggregate
source approval IS: 2386 (Part VII)-
3 1963

8) Petro graphic Examination 1. Once for every 1 IS: 383-1970 Information required for approval of source.
source approval IS: 2386 (Part VIII)-
a) Source of supply, that is, 3 1963
precise location of source from
where the materials were obtained;
b) Trade group of principal rock
type present;
c) Physical characteristics;
d) Presence of reactive minerals;
and
e) Service history, if any.

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

FINE AGGREGATES
Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Particle Sizes 1. Once for every 1 IS: 383-1970 Fine Aggregate should be of grading from Zone-I to
source IS: 2386 (Part I) Zone-III as given below.
approval 2A, 1963 IS Sieve Percent by weight passing for
2. Once in a week 2B MORTH Designation
(Rev.5th) Zone I Zone II Zone III
. 10 mm 100 100 100
4.75 mm 90-100 90-100 90-100
2.36 mm 60-95 75-100 85100
1.18 mm 30-70 55-90 75-100
600 μm 15-34 35-39 60-79
300 μm 5-20 8-30 12-40
150 μm 0-10 0-10 0-10
2) Deleterious 1. Once for 1 IS: 383-1970 Deleterious Material Percentage of uncrushed
every source IS: 2386 (Part II) fine aggregate by
approval 3 -1963 weight (max.)
2. Once in a 1. Coal & lignite 1
month 2. Clay lumps 1
3. Materials finer than 3
75 micron IS Sieve
4. Soft for Section -
Headents 1
5. Shale 5
Total (1 to 5)
3) Silt Content 1. Once for every 1 IS:383-1970 Maximum 3% by weight
source
1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

Test Frequency Check Ref. Codes Acceptance Standards

Level
approval 2A,
2. Once daily 2B
4) Specific Gravity 1. Once for 1 IS: 383-1970 Test is required for maintaining uniformity of
& Density every source IS: 2386 (Part material brought from the source.
approval 2A, III) -1963
2. Once every 3 2B
months
5) Water absorption 1. Once for 1 IS: 383-1970 Test required for adjusting the water content in the
every source IS: 2386 (Part- mix design before starting any concrete mixing.
approval 2A, III)-1963
2. Once daily 2B
6) Soundness 1. Once for 1 IS: 383-1970 Maximum Average Loss of Weight after 5 cycles
every source IS: 2386 (Part tested with :
approval 3 V)-1963
2. Once every 3 (i) Sodium Sulphate - 10%
months (ii) Magnesium Sulphate - 15%

7) Fineness 1. Once for 1 IS: 383-1970 2.0 to 3.5

every source IS: 2386 (Part
approval 2A, V)-1963
2. Once every 3 2B MORTH
months (5thRev) Clause
1008

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

WATER

Test Frequency Check Ref. Codes Acceptance Standards

Level
1) Chemical 1) Once for every IRC: 21-2000
source
2) Quarterly
a) pH Value 2, 3 IRC: 21-2000 Minimum 6
b) Chlorides (as CI) 3 IS :3025 (Part 32) 2000mg/l for concrete not containing embedded
steel & 500mg/l for RCC and PSC.

c) Sulphates (as so3) 3 IS :3025 (Part 28) 400 mg/l

d) Neutralization with NaOH (with 3 IS :3025 (Part 22) Max. 5 ml of .02 normal NaOH to neutralise 100
phenolphthalein as indicator) ml sample of water

e) Neutralization with H2SO4 (with 3 IS :3025 (Part 23) Max. 25 ml of .02 normal H2SO4 to neutralise 100
mixed indicator) ml sample of water
2) Physical 1) Once for every
source
2) Quarterly
a) Suspended matter 3 IS :3025 (Part 17) 2000 mg/l max.

b) Organic matter 3 IS :3025 (Part 18) 200 mg/l max.

c) Inorganic matter 3 IS :3025 (Part 18) 3000 mg/l max.

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

STEEL AND IRON

Reinforcement bars (CTD, TMT)

Test Frequency Check Ref. Codes Acceptance Standards

Level
1) Chemical Tests 1) Once for every 3 IS:1786
source approval
MORH (Rev. 5th )
2) Once for every
lot
3) Once every 3
months
a) Carbon 0.30% max.
b) Sulphur 0.06% max.
c) Phosphorus 0.06% max.
d) Sulphur + 0.11% max.
2) Physical Test 1) Once for every 3 IS:1786
source approval MORH (Rev. 5th )
a) Ultimate Tensile 8% more than the actual 0.2% proof stress but not
2) Once for every less than 545 MPa
lot
b) 0.2% Proof Stress 500 MPa Min
3) Once every 3
c) % Elongation 12% min.
months
d) Bend Test To be satisfactory

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

e) Re-bend Test To be satisfactory

f) Mass per 6.31 + 3% for 32 mm dia., 4.830 ± 3% for 28 mm dia.,
3.850 ± 3% for 25 mm dia., 2.470 ± 3% for 20 mm dia., 1. 580 ±
5% for 16 mm dia., 0.888 ± 5% for 12 mm dia.

MILD STEEL
Test Frequency Check Ref. Codes Acceptance Standards
Level
Chemical Composition Once for every source 1 IS:2062- Grade Designation C Man S P Si Carbon
approval 1999 equal

Once in a project for 3 Fe410WA 0.23 1.5 0.05 0.05 0.04 0.42
every source Fe410WB 0.22 1.5 0.046 0.045 0.00
Fe410WC 0.20 1.5 0.040 0.04 0.04 0.39

Nitrogen Content P 0.012%

Nb, V &Ti content (all or any) 0.2%

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

Phosphorus

Mechanical Tests 1. Once for every 1 IS:1663- Minimum 440 MPa

Tensile Test source approval 1972 Minimum 200 MPa
Yield Strength 2. Once in a project for 3 IS:1608- Brinell – Maximum 192, Rockwell – Maximum 95, Min. 40 % in
Hardness Test every source 1972 50 mm
Elongation IS:1500-
1983
IS:1501-
1984
IS:1586-
1988

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

GALVANISING
Test Frequency Check Ref. Codes Acceptance Standards
Level
Mass of Zinc Coating One test per lot 1 IS:6745-1972 400g/m2 minimum total mass of Zinc (inside and outside) per
3 surface area (inside and outside) of the coated surface.
Visual Test One test per lot 1 IS:2629-1985 The Zinc coating shall be free from imperfection like flux, ash
3 and dross inclusions, bare patches, black spots, pimples,
lumpiness, rust stain, blister, white deposit etc.
Free Bore Test One test per lot 1 IS:2633-1986 A 230 mm long rod shall be passed through the tube to ensure a
3 free bore.
Nominal bore of tube after galvanizing dia of rod
8mm
10mm
15mm
20mm
25mm
Uniformity of One test per lot 1 IS:4736-1986 The galvanized coating shall withstand 4 one minute dips.
Galvanized Coating 3
Adhesion Test One test per lot 1 IS:2629-1985 Galvanized tubes upto and including 50mm nominal bore when
3 bent cold through 900 round grooved, former having radius at
the bottoms of groove equal to 8 times its outer dia. shall not
develop any crack in the coating. For tubes more than 50mm
nominal bore, this shall be tested by pivoted hammer test.

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

CHEMICALS
CEMENT (OPC-53 GRADE)
Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Chemical Test 1. Once for every IS:12269 – 1987
source approval
2. Once for every lot
3. Once every 3
months
a) Chlorides (as Cl) 1 0.05% max
b) Ratio of Alumina to that 0.66 min
c) Magnesia 3 6.0% max
d) Total sulphur content (SO3) 2.5% max where C3A % by mass is 5 or less
3.0% max where C3A % by mass is >5
e) Loss on Ignition 4.0% max
f) Insoluble Residue 2.0% max
g) Lime saturation factor 0.8 – 1.02
2) Physical Tests 1. Once for every
source approval
2. Once for every lot
1
3. Once every 3
months
2A / 2B
Setting Time IS:4031 (Part 5)-
Initial 1988 Not less than 30 mins.
Final Not more than 600 mins.
b) Soundness IS:4031 (Part 3)-
1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

i. Le Chatelier Expansion 1988 10 mm (Max.)

ii. 0.8% (max.)
c) Compressive Strength IS:4031 (Part 6)-
At 72 ±1 hr 1988 Not less than 27 MPa
At 168 ±2 hrs Not less than 37 MPa
At 672 ±4 hr Not less than 53 MPa
d) Fineness (Blain‟s air ) IS:4031 (Part 2)- 225 M2 / Kg Minimum
1988

CEMENT (OPC-43 GRADE)

Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Chemical Test 1. Once for every IS:8112 – 1989
source approval
2. Once for every lot
3. Once every 3
months
a) Chlorides (as Cl) 1 0.05% max
b) Ratio of Alumina to that 0.66 min
c) Magnesia 3 6.0% max
d) Total sulphur content (SO3) 2.5% max where C3A % by mass is 5 or less
3.0% max where C3A % by mass is >5
e) Loss on Ignition 5.0% max
f) Insoluble Residue 2.0% max
g) Lime saturation factor 0.66 – 1.02
2) Physical Tests 1. Once for every 1
1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

source approval
2. Once for every lot 2A / 2B
3. Once every 3
months
a) Setting Time IS:4031 (Part 5)-
1. Initial 1988 Not less than 30 mins.
ii. Final Not more than 600 mins.
b) Soundness IS:4031 (Part 3)-
i.LeChatelier Expansion 1988 10 mm (max.)
ii.Autoclave test 0.8% (max.)
c) Compressive Strength IS:4031 (Part 6)-
At 72 ±1 hr 1988 Not less than 23 MPa
At 168 ±2 hrs Not less than 33 MPa
At 672 ±4 hr Not less than 43 MPa
d) Fineness (Blain‟s air IS:4031 (Part 2)- 225 M2 / Kg Minimum
1988

CEMENT (OPC-33 GRADE)

Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Chemical Tests 1. Once for every IS:269-1989
source approval
2. Once for every lot 1
3. Once every 3 months
a) Chlorides (as Cl) 3 0.05% max by mass
b) Ratio of Alumina to 0.66 min
that
1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

c) Magnesia 6.0% max by mass

d) Total sulphur content Not more than 2.5% by mass where C3A % by mass is
(SO3) 5 or less
Not more than 3.0 max by mass where C3A % by
mass is >5
e) Loss on Ignition 5.0% max
f) Insoluble Residue 4.0% max by mass
g) Lime saturation factor 0.66 – 1.02
2) Physical Tests 1. Once for every
source approval
2. Once for every lot
3. Once every 3 months
a) Setting Time IS:4031 (Part 5)-
i. Initial 1988 Not less than 30 mins.
ii. Not more than 600 mins.
1
b) Soundness IS:4031 (Part 3)-
i. Le Chatelier 1988 10 mm (max.)
2A/2B
Expansion 0.8% (max)
ii. Autoclave test
c) Compressive Strength IS:4031 (Part 6)-
i. At 72 ±1 hr 1988 Not less than 16 MPa
ii. At 168 ±2 hrs Not less than 22 MPa
iii. At 672 ±4 hr Not less than 33 MPa
d) Fineness (Blain‟s air IS:4031 (Part 2)- 225 M2 / Kg Minimum
1988

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

a) Dry Material Content

b) Ash content
c) Relative Density
d) Chlorides ion content

e) pH

1.
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Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

EPOXY
Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Pot life Open Time 1. Once for every F.I.P Min. 20 minutes.
Thixotropy source approval Or
As per Not less than 60 minutes at upper temperature limits
Angle of internal friction Manufacturer
data sheet Sag flow should not exceed 30 mm in 10 minutes at
(Squeezibilty) upper limit of specified application temperature
15 Kg
200 Kg Minimum area of spread in mm2
400 Kg 3000
7500
1
10,000
2) Curing rate Comp. Strength of 50x50x50mm size cubes should be
a) 12 hrs. 20N/mm2
b) 24 hrs. 60 N/mm2
c) 168 hrs. 75 N/mm2
3) Compressive Strength Comp. Strength of 50x50x50mm size cubes should be
24 hrs. 60 N/mm2
168 hrs. 75 N/mm2
4) Bonding of cured bonding Should have concrete failure with no evidence of
agent to concrete surface joint failure with concrete of strength 40 MPa
to be joined
5) Tensile bonding strength Should have concrete failure with no evidence of
joint failure with concrete of strength 40 MPa
6) Shear Strength Should have 12 N/mm2 higher than the concrete

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

Test Frequency Check Ref. Codes Acceptance Standards

Level
strength
7) Heat Resistance Shear strength at failure should have a strength 10
N/mm2 higher than the concrete strength
8) Colour Should match the colour of concrete.
9) Shrinkage Max. 0.4% after 7 days at the upper limit of specified
temperature range

NON-SHRINK GROUT

Test Frequency Check Ref. Codes Acceptance Standards

Level
1) Compressive 1. At the approval of Age (days) Compressive Strength (MPa)
source Flowable W/P = 0.18 Pourable
2. At every change of W/P=0.165
source 1 24 27
3 45 54
1
7 55 66
As per
28 65 78
manufacturer
2) Compressive Age (days) Compressive Strength (MPa)
Data sheet
Flowable W/P = Pourable W/P =
0.18 W/P=0.165 0.18% of
aggregate
1 50% 75% 100%
3 28% 30% 32%
7 50% 52% 55%

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

28 70% 75% 78%

3) Flexural Strength Age (Days) Flexural Strength (MPa)
W/P=0.18
1 2.5
3 7.0
7 9.0
28 10.0
4) Time for expansion
(after mixing) 20 minutes preferably
120 minutes preferably
a) Start
b) Finish

WATERPROOFING COMPOUND

Test Frequency Check Ref. Codes Acceptance Standards

Level
1) Permeability 1. Once for every 3 Permeability to water of the standard cylindrical specimens
source approval prepared with the recommended proportion of the water
2. Once for every lot proofing compound shall be less than 50% of permeability of
IS:2645-1975
3. Once in the project similar specimens prepared without waterproofing compound .
Or
for every change
As per
of source
manufacturer
2) Setting Time 3 Initial - Not less than 30 mins.
Data sheet
Final - Not more than 600 mins.
3) Compressive 2A, 2B Compressive strength at 72 hrs. – Not less than 160kg/cm2 or
80% of the 3 day compressive strength of cubes prepared

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

without waterproofing compound.

Compressive Strength at 168 hrs. – Not less than 220 kg/cm2 or
80% of the 7 day compressive strength of cubes prepared
without waterproofing compound.
4) Chloride Content 3 As per the values declared by the manufacturer
5) Sulphate Content 3 As per the values declared by the manufacturer

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

POLY TETRA FLURO ETHYLENE (PTFE)

Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Surface texture 1. Once for Without dimples or the ratio pf dimples (lubrications
every source cavities) to the gross area should not be more than 25%,
approval depth of cavity not more than 2mm.
1
2) Density at 23 ± 20C 2. As per the 2.13 to 2.19 g/cc
requirement of BS:3784
3) Tensile Strength 24 MPa (min.)
the respective 3 BS:6564Part 2 - 1991
4) Elongation at Break 300% (Minimum).
item
5) Resistance to heat No sign of melting & loss in mass shall not exceed 0.5%
6) Dimensional Mass change shall not exceed 0.5%

PROPERTIES OF CHLOROPRENE SEAL FOR EXPANSION JOINTS

Test Frequency Check Ref. Codes Acceptance Standards

Level
1) Hardness 63 ± 5 Shore A
2) Tensile Strength 1. Once for 11 MPa minimum
1
3) Elongation at Break every source 350% Minimum
approval MORTH(5th
4) Tear Propagation Strength
2. Once for Revision) Clause 2607
a) Min. 10 N/mm
every Lot
3
b) Min. 10 N/mm
5) Shock Elasticity Min. 25 %

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

6) Abrasion Min. 220 mm3

7) Residual Compressive Max. 28 %
strain (22h/70 deg C/30 %
strain)
8) Ageing in hot air (14 days/70 deg C)
a) Max. Change in Hardness + 7 Shore A
b) Max. Change in Tensile – 20%
strength
c) Max. change in elongation – 20%
at fracture
9) Ageing in Ozone (24h/50 No cracks
pphm/25 deg C/20 % strain
10) Swelling behavior in Oil (116 h/25% C)
a) Volume Change Max. 5 %
b) Change in Hardness Max. 10 Shore A
11) ASTM Oil No. 3
a) Volume Change Max. 25 %
b) Change in Hardness Max. 20 Shore A
12) Cold Hardening Point Min. –35 deg C

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

ASSEMBLED ACCESSORIES

POT-PTFE BEARINGS
Test Frequency Check Ref. Codes Acceptance Standards
Level
Dimensional Tolerance All bearing to be 1,2A MORTH
tested for overall Specifications
dimension for Road &
a) Plan dimensions Bridge Works 0 to 5 mm or 0.5% of plan dimension whichever is
(5th Revision) higher
b) Overall Height Clause 2006; 0 to 3 mm or 01% of overall height whichever is higher
c) Height of any steel component IRC: 83 0 to +1mm
i) Mentioned (Part-I) Class 2 of IS:4897
ii) Unmentioned
d) Height of confined Elastomeric -0 to 0.5%
pressure pad
Stainless steel sliding surface All bearing to be 1
tested for overall
a) Flatness dimension 0.0004L where L= length in direction of measurement
b) Surface Finish Ra ≤ 0.25 pm as per IS:3073
Load Test All bearing to be 1 All bearings shall be load tested to 1.1 times maximum
Vertically & tested design capacity including seismic forces. Bearing tested
Rotation capacity at higher loads cannot be used.
4) Friction Test Two bearings 1 The coefficient of friction shall be less than or equal to
selected at 0.05 at the design load.
random per lot

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

5) Ultrasonic Test All castings to be 1 Quality level of castings shall be Level 3 as per IS:9565
tested
6) Dye Penetration All welding to be 1 There shall be no holes or flaws.
tested
7) Raw Material 1. Once for every 1 Forecast steel; refer Clause 3.2.6 of this Manual.
source approval For PTFE, refer Clause 3.4.3 of this Manual.
2.All raw material For stainless steel, refer Clause 3.2.8 of this Manual
to be tested For elastomeric, refer Clause 3.4.2 of this Manual.
For mild steel, refer Clause 3.2.7 of this Manual.

ELASTOMERIC BEARINGS
Test Frequency Check Ref. Codes Acceptance Standards
Level
1) Visual Inspection All bearings shall be 1,2A IRC:83 (Part There shall be no visible defects in surface finish, shape
tested II) -1987; or any other specifically defects.
2) Dimension Test All bearings shall be 1,2A MORTH
tested (5thRev)
a) Overall linear plan dimensions Clause 2005 - 3, +6 mm
b) Total mean Bearing thickness - 2.5, +5 mm
c) Parallelism
i)Top surface of bearing with respect 1 in 200
to bottom surface as datum
ii)One side surface with respect 1 in 100
to the other as datum
d) i)Thickness of individual inner ± 12% (maximum of 2 mm)
layer + 20% (maximum of 1mm)
ii)Thickness of individual - 0, + 3 mm

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

Test Frequency Check Ref. Codes Acceptance Standards

Level
outer layer
iii) Side cover
e) i)Plan dimensions of - 3mm, + 0
laminates ii)Thickness of ± 10%,
laminates 1 in 100
iii) Parallelism of laminate
w.r.t. bearing base as datum
3) Axial Load Test Two bearings selected at 1 Deflection under axial load of 5 MPa to 15MPa for
random from each lot shall individual bearings shall not vary by more than 20%
be tested of the mean value for the entire lot.

4) Shear Modulus Two bearings selected at 1 Shear Modulus shall be 1 ± 0.2 MPa provided that
random from each lot shall there is no instability, defect or damage.
be tested

5) Elastic Modulus Two bearings selected at 1 Elastic Modulus shall be 1 ± 0.2 of

random from each lot shall 1/(0.2/S2+0.0005), where S is the shape factor,
be tested provided that there is no defect or damage.

6) Adhesion Two bearings selected at 1 No peeling or separation

random from each lot shall
be tested

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

7) Ultimate Two bearings 1 Not less than 60 MPa

selected at random from each
lot shall
Test Frequency Check Ref. Codes Acceptance Standards
Level
be tested
8) Tests on Two bearings selected at random 1 The elastomeric shall satisfy the requirement of Clause
from each lot shall 3.6.3 of this manual.
be tested

1.
Page 59
 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

TEST ON EXPANSION JOINTS

Test Frequency Check Ref. Codes Acceptance Standards
Level
Tests on Neoprene seal Once on all As per Clause 3.6.5 of this Manual.
the joints
Cyclic motion The test sample subjected to 5000 expansion & contraction
cycles at minimum 30 cycles / hour. If any sign of distress or
permanent set of any component due to fatigue, will lead to
rejection of entire lot of supply.
Water Tightness Once for The joint shall be tested in a recognized laboratory for water
each lot MORTH tightness under a pressure of 4 bars and joint shall not reveal
Specifications any leakage.
Debris Expelling Test 1 for Road& The %age expelled shall not be less than 75.
Bridge Works
Pull out test The minimum stretching of the joint before slip off shall be at
th
(5 Revision) least 150% of the rated movement capacity of the seal.
Clause 2607
Vehicular Breaking / Traction Test As per MORTH Rev. 5th section 2612.3.1 of v
Erosion Protection Test Adequacy of the treatment for protection of steel section against
corrosion.
Test on Anchorage system Once for The anchorage system shall be tested in a recognized laboratory
Dynamic Loading characteristics each lot for optimum configuration under dynamic loading.

Satisfactory Past Once for The manufacturer shall submit evidence that the similar joints
each lot have performed satisfactorily at other locations.

1.
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 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of NH-
12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state of
Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

Raw material
Conformation of the grade of As per IS 2062
steel
Process Inspection Process inspection including inspection of all manufacturing
process adapted to manufacturer.
Complete Dimensional Check Dimensional check shall be carried out as per approved
drawing.

1.
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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

FOR HIGHWAY
EMBANKMENT, SUB-GRADE CONSTRUCTION (REF. MORTH SECTION 900
& 305.0)
S. NO. Type of Test Frequency Location Acceptance Criteria
/ Check
level
1.1 Borrow Material (MORTH Spec. 903.2.1)
(i) Sand Content (IS: Two tests per 3000 Borrow
2720 Part 4) cum of soil. Pit
/2
(ii) Plasticity Test (IS: Two tests per 3000 Borrow LL<50%
2720 Part 5) e.g. cum of soil. Pit PI<25%
LL, PL & PI /2
(iii) Density Test Two tests per 3000 Borrow Max laboratory dry
(IS:2720 Part 7 & cum of soil Pit Unit weight
8) /2 Embankments upto 3m height, not
subjected to extensive flooding: Not
less than 15.2 KN/cum..
Embankments exceeding 3 m height or
any height subject to long periods of
inundation: Not less than16.0 KN/cum..
Sub-grade/earthen shoulder/ verge/back
fill: Not less than 17.5 KN/cum.
(iv) Deleterious content As and when Borrow Permissible limit
Test (IS:2720 Part required by the Pit
27); Engineer. /3 Sulphate 0.5%
Clause 305.2.1.3 of
MORTH Specs; Organic matter 1.0%
Clause 2.5.5 of
IRC:SP:11-1998
(v) Moisture content One test for every In situ -2% to+1% of OMC
Test (IS: 2720 Part 250 cum of soil. /2
2)
(vi) CBR test on One CBR test for Borrow Not less than the design CBR value of
material to be every 3000 cum or Pit 10% at the specified dry density(4 days
compacted in the closer as and when / 2 soaked value)
sub-grade on required by the
soaked/un soaked Engineer.
samples (IS:2720
Part 16)

Page 77
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S. NO. Type of Test Frequency Location Acceptance Criteria

/ Check
level
1.2 Compaction control One Density set In situ Relative compaction as 95% of max.
(IS:2720 Part 28) for each 3000 sq.m /2 laboratory dry density
on each layer of compacted area Embankment not less than 95%
(MORTH Spec. for the body of the
903.2.2 embankment, Sub-grade/earthen shoulder not less
one set per 2000 than 97%
sq.m of compacted Expansive soils
area for sub-grade a) Sub-grade and 500 mm portion
i.e. top 500 mm just below the sub- grade top - not
portion of allowed.
embankment. b) Remaining portion of embankment
not less than 90%
1.3 Horizontal As requested In situ + 10 mm for carriageway edges
Alignment /2 + 25mm for roadway edges
(MORTH Spec.
902.2)
1.4 Surface Levels A required In situ Sub-Grade
(MORTH Spec. /2 + 20mm
902.3)

SUB-BASE AND BASE COURSE (REF. MORT&H SECTION 900)

S.NO. Type of Test Frequency Location / Acceptance Criteria

Check
level
1 Granular (MORTH Spec. 401)
(i) Gradation (IS: 2720 One test per 400 Approved As per Table 400- 1 of MORTH Specs
Part 4 as per job mix cum. source for R & B Works.
formula /2
(ii) Atterberg Limit One test per 400 Approved LL & P.I. not more than 25 and 6%
(IS:2720 Part 5) cum. source / 2 Respectively.
(iii) Moisture content One test per 400 In situ OMC –2% to OMC + 1%
prior to compaction Cum.. / 2A
(IS:2720 Part 28)
(iv) Density of compacted One test per 1000 In situ Mean density not less than the
layer (IS:2720 Part sq.m /2 Specified density +
28) 1.65 − 1.65 
 (No. of samples)0.5 
 
times the standard deviation

Page 78
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S.NO. Type of Test Frequency Location / Acceptance Criteria

Check
level
(v) Deleterious (IS:2720 As required Approved Permissible limit
Part 27) source / 3 Sulphate 0.2%
Organic matter 1.0%
(vi) C.B.R. (IS:2720 Part As required Approved Not less than the design CBR value of
16) source / 2 30%
(vii) Impact Value As required Approved As per IS 2386 P-iv & IS 5640 > 40%
(IS:2386 Part IV) source / 2
(viii) Water absorption (IS: As required Approved 2% maximum. If this value is more than
2386 Part III) source / 2 2%, soundness test to be carried out.
(ix) Soundness (IS:2386 As required Approved 12% maximum with Na2 So4
Part 5) source / 3
(x) Horizontal Alignment As required In situ + 10 mm , + 25mm
MORTH /2
Spec. 902.2
(xi) Surface Level As required In situ +10mm
MORTH, Spec. 902.3 /2
2 Wet Mix Macadam (MORTH Spec. 406)
(i) Aggregate Impact One test per 1000 In situ / 2 Max. 30%.
Value (IS:2386 Part cum of aggregate
4)
(ii) Grading (IS: 2720 One test per 250 In situ / 2 As per Table 400-11 of MORTH Specs
Part 4) cum of aggregate for R & B Works.
(iii) Flakiness and One test per 500 In situ / 2 Max. 35%
Elongation Index cum of aggregate
(IS:2720 Part 1)
(iv) Atterberg limits of One test per 200 In situ / 2 Not Exceeding (PI) 6%
portion of aggregate cum of aggregate
passing 425 micron
sieve (IS:2720 Part 5)
(v) Density of compacted One test per 1000 In situ / At least 98% of the max. dry density.
layer (IS:2720 Part 8) sqm. 2A
(vi) Abrasion value As required In situ Max. 40%
(IS:2386 Part 4) /2
(vii) Fractured Faces As required In situ 90% of material > 4.75 mm size shall
/2 have at least 2 fractured faces.
(viii) Water absorption As required In situ Max. 2%. Soundness test to be
/2 conducted in case water absorption is
more than 2%.
(ix) Horizontal Alignment As required In situ + 25mm, + 10mm
(MORTH Spec. / 2A

Page 79
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S.NO. Type of Test Frequency Location / Acceptance Criteria

Check
level
902.2)
(x) Surface Level As required In situ + 10mm
(MORTH Spec. /2
902.3)

BITUMINOUS WORKS. (REF. MORTH SPEC SECTION 900)

S.NO. Type of Test Location Acceptance Criteria

Construction / Check
level
1 Prime coat/Tack Coat (MORTH Spec. 502 and 503)
(i) Quality of binder Number of HM Plant Bitumen Emulsion complying with
(IS:73,217 & 8887) samples per lot 2 IS:8887 of a type and grade as specified
and tests as per in the contract or as directed by
IS:73, IS:217 and Engineer.
IS:8887 as
applicable
(ii) Temp. of binder for At regular close In situ
application interval /2
(iii) Rate of spread of Not less than 3 In situ 7-10 kg/10 sq.m of liquid bituminous
binder tests per day; /2 material for prime coat over surface of
low porosity.
2.5-3.0 Kg/10 sq.m. of liquid bituminous
material for tack coat.
2 Dense Bituminous Macadam/Bituminous Concrete (MORTH Spec. 507 and 509)
(i) Quality of binder Number of HM Plant Bitumen Emulsion complying with
(IS:73,217 & 8887) samples per lot /2 IS:8887 of a type and grade as specified
and tests as per IS: in the contract or as directed by Engineer
73,IS:217 and IS:
8887 as applicable
(ii) Aggregate Impact One test per 350 HM Plant Aggregate Impact Value DBM 27%
Value / Los Angles cum. of aggregate / 2 max. & BC 24% max
Abrasion Value Los Angeles Abrasion Value
(IS:2386 Part 4) DBM 35% max & BC 30% max
(iii) Flakiness Index & One test per 350 HM Plant Max. 35%
Elongation Index cum. of aggregate / 2
(IS:2386 Part 1)
(iv) Stripping value Initially one test of HM Plant Minimum retained coating of Bitumen
(IS:6241) 3 representative /2 Aggregate Mixtures 95%
specimens for each

Page 80
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S.NO. Type of Test Location Acceptance Criteria

Construction / Check
level
source of supply.
Subsequently
when warranted by
changes in the
quality of agg.
(v) Water absorption of Initially one test HM Plant Max. 2% for DBM
aggregate (IS:2386 specimens for each /2 Max. 2% for BC
Part 3) source of supply.
Subsequently
when warranted by
changes in the
quality of agg.
(vi) Soundness Initially, one HM Plant Sodium Sulphate 12% max.
(Magnesium and determination by /3 Magnesium Sulphate 18% max.
sodium sulphate) each method for
(IS:2386 Part 5) each source of
supply, then as
warranted by
change in the
quality of the
aggregates.
(vii) Sand equivalent test As required for HM Plant Not less than 50
for fine aggregate source app. /2&3
(IS:2720 Part 37)
(viii) Plasticity Index As required for HM Plant Not more than 4% for fraction passing
(IS:2720 Part 5) source app. /2 0.425mm sieve
(ix) Stone Polish Test As required, for HM Plant 55 minimum (for BC)
(BS 812 Part – Bituminous /3
114) Concrete.
(x) Percentage of When gravel is HM Plant When crushed gravel is proposed for use,
fractured faces used, one test per /2 not less than 90% by weight of the
350 cum of crushed material retained on the 4.75mm
aggregate. sieve shall have at least two fractured
Faces
(xi) Mix grading One set of tests on HM Plant The combined grading for the particular
individual /2 mixture shall be within the limits given
constituents and in Table 500.10 of MORTH, Specs. for R
mixed aggregate & B. Works when tested in accordance
from the drier for with IS:2386 Part I for DBM & Table
each 400 ton 500 – 18 for BC.

Page 81
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S.NO. Type of Test Location Acceptance Criteria

Construction / Check
level
subject to a
minimum of two
tests per day.
(xii) Stability of mix For each 400 HM Plant As per Table 500.11 for DBM and Table
tonnes of mix /2 500.19 for BC of MORTH Specs for
produced, a set of R & B Works.
3 Marshall
specimens to be
prepared and
tested for stability,
flow value, density
and void content
subject to a
minimum of two
sets being tested
per plant per day.
(xiii) Water sensitivity of Initially one test of HM Plant 80% min DBM & BC
mix (Retained 3 representative /2
tensile strength) – specimens for each
AASHTO T 283 source of supply.
Subsequently
when warranted by
changes in quality
of agg. (if
required)
(xiv) Swell test on the As required for the HM Plant Refer Section 6.18 of MS2. Applicable
mix Bituminous /2 only to Hveem Method of Mix Design
Concrete
(xv) Control of At regular close HM Plant Bitumen mixing temp 150-165°C
temperature of interval /2 Aggregate mixing temp 150-170°C
binder in boiler, Mixed Material 165°C max., Laying:
aggregate in the 140oC min. temp. on Rolling 90°C min.
dryer and mix at the
time of laying and
rolling.
(xvi) Control of binder One test for each HM Plant As shown in Table 500-10 for DBM and
content. 400 tonnes of mix /2 Table 500-18 for BC of MORTH, Specs
subject to a for R&B Works.
minimum of two
tests per day per

Page 82
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S.NO. Type of Test Location Acceptance Criteria

Construction / Check
level
plant.
(xvii) Rate of spread of Thickness check at In situ After every 5th truck load
mixed material regular interval / 2A
(xviii) Density of One test per 700 In situ 98% of the Compacted Density of the
compacted layer sq.m area /2 Mix as established by the Job Mix
Formula in the laboratory or 92% of
GMM.
(xix) Surface levels As required In situ + 6 mm
(MORTH Spec. /2
902.3)

MARKING & OTHER ROAD APPURTENANCES.

S. Type of Test Frequency Check level Acceptance Criteria
NO.
1 Hot Applied Thermoplastic Road Marking Material
(MORTH Specs 803.4.2.2) & (803.4)
(i) Luminance As required In situ-Test White : Day light luminance at 45
Certificate from degrees –65 percent min. as per
suppliers lab/ AASHTO M249
independent lab Yellow: Day light luminance at 45
degrees- 45 percent min. as per AASHTO
M249
(ii) Drying Time As required In situ-Test When applied at a temperature specified
certificate from by the manufacturer and to the required
suppliers lab/ thickness, the material shall set to bear
Independent lab traffic in not more than 15 minutes.
(iii) Skid Resistance As required In situ-Test Not less than 45 as per BS 6044.
certificate from
suppliers lab/
Independent lab
(iv) Cracking resistance As required In situ-Test The material shall show no cracks on
at low temperature certificate from application to concrete blocks.
suppliers lab/
Independent lab
(v) Softening Point As required In situ-Test 102.5 ± 9.5°C as per ASTMD 36.
certificate from
suppliers lab/
Independent lab

Page 83
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

(vi) Flow Resistance As required In situ-Test Not more than 25 percent as per
certificate from AASHTO M249

Page 84
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S. Type of Test Frequency Check level Acceptance Criteria

NO.
suppliers lab/
Independent lab
(vii) Yellowness Index As required In situ-Test Not more than 0.12 as per AASHTO
(for white certificate from M 249
thermoplastic paint) suppliers lab/
Independent lab
(viii) Glass Beeds As required Certificate from As per Table 800-10 of MORTH Specs.
principal
supplier
2 Road Delineators (MORTH Section 500

(i) Physical As required As per MORTH Section 806

Test certificate
(ii) Dimension Test For every As per MORTH Section 806
from supplier
Supply
lab /
(iii) Installation For every As per MORTH Section 806
independent lab
installation
3 Hectometer / Kilometer / Boundary Stones
(i) Material Once in the Test certificate As per MORTH Section 804 and 805
Beginning from supplier
(ii) Dimension For every lab / As per MORTH Section 801 and 805
supply/ independent lab
installation
4 Traffic Signs/overhead signs
(i) Material Once in the Test certificate As per MORTH Section 801 and 802
beginning from supplier
(ii) Dimension For every lab / As per MORTH Section 801 802
supply/ independent lab
installation
5 Reinforced Earth Wall
(a) Reinforcing One sample Manufacturer’s As per BS 8006 and other relevant ones,
material Metallic per Lot Premises ASTM, Section 3100 of MORT&H
Strip / Geotextile / Specifications as relevant to particular
Geogrid type type of material
6 Backfill Material
(i) Grading (IS:383) One sample Site lab / Not more than 15% of the particles shall
per 500m3 independent lab pass 75 micron sieve
(ii) Chemical salts One sample Non-reactive with reinforcing element in
per 500m3 adverse manner

(iii) Atterberg limits and Two sample Pl<6% , Φ > 30°

shear parameters per 3000m3

Page 85
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

S. Type of Test Frequency Check level Acceptance Criteria

NO.
(iv) Other parameters As per earth work specifications
7 G.I. Drainage Pipe and Drainage Spout
(i) Spouts One sample Independent lab Dia. Min. 100 mm and continuing from
per Lot flyover to the drainage with no openings
and should be tested for no leakage
(ii) Pipe material Two sample Independent lab All material shall be corrosion resistant
per Lot and steel components shall be of mild
steel conforming to IS: 2062. (hot dip
galvanize after assembly)
(iii) Sealant around All Independent lab Poly supplied sealant
assembly (IS:1834)
8 Mastic Asphalt
(a) Binder One sample Site lab As per MORT&H Specifications for
per Lot Road and Bridge Works
(b) Filler (Limestone One sample Site lab Powder passing the 0.075 mm sieve and
powder) per Lot having calcium carbonate content not less
(IS:1514) than 80% by weight.
(c) Mix proportions One sample Site lab As per JMF to be laid between 175° and
per Lot 210°C

Page 86
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

CHAPTER – 5

QAP FORSITE ACTIVITIES

Page 87
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

QAP FOR SITE ACTIVITIES

This Chapter deals with those tests / conformations which are related to execution activities at

site. These tests do not require any laboratory testing; instead they are some kind of in-situ tests

directly relating to site activities. The items of testing /conformation under this chapter include

trial mixes and mix design of concrete, testing the concrete for workability, initial and routine

load tests on piles, some of the site tests on pre-stressing hardware etc.

These are essentially those checks which will provide reasonable assessment of the Contractor’s

workmanship associated with site working. In case the concrete does not meet the requirement of

specified minimum workability, the Contractor may be asked to rectify his procedure of concrete

mixing and correction for water absorption of the aggregates. It may even require re-calibration

of batching plant.

The following tables of checklists indicate requirements of frequencies, respective codes and

standards and acceptable limits.

Page 88
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

MIX DESIGN INCLUDING TRIAL MIX AND ACCEPTANCE CRITERIA

Test Frequency Reference Acceptance

Code

Trial Mix 1. For every design IRC : 21- Initially

Target Mean Mix 2000
Strength 2. For every change in & Target Mean Strength (TMS) = Specified
source of any material IS 10262 Characteristic Strength + Current Margin

Later on during construction

Target Mean Strength = Specified

Characteristic Strength + 1.64 x Standard
Acceptance Qty. of No. IRC : 21- Mean strength of any group of 4
Criteria Concrete of 2000 consecutive samples > Specified
(m3) Samples & IS 456 Characteristic Strength + 3 MPa
1-5
6-15 2. Strength of any sample not less than
16-30 Specified Characteristic Strength - 3 MPa
31-50
51 and 3. The test strength of the sample shall be
above the average of the strength of 3
addl 50m3 specimens. The individual variation
or part should not be more than ± 15% of the
thereof average

Page 89
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

R.C.C. WORK
Test Frequency Reference Acceptance
Code

Workability Every Transit IS:516-1959 As per requirement of the item under

Mixer execution. Refer Clause 302.11.2 of
IRC:21-2000

Compressive Strength As per IS 456 IRC:21-2000 As per Clause 4.1 of this Manual
&
7 Days Strength MOR
28 Days Strength

Permeability Test
Once in a Maximum 25mm on a specimen of
month 150mmφ and 160mm height

EARTH WORK INSPECTION GUIDELINE

ITEM INSPECTION Ref. REMARKS
ITEM Code
Check 1. Location
compaction of 2. Length
Base (OGL) and 3. Lane
Before commence earth each layers of
4. Degree of Compaction (>95%)
work earth work MORTH
5. Removing of Loose Materials
Check for Preparatory (Sec.500)
Works 1. The level shall be recorded in level
Record level of
book
OGL, Emp. & S
2. Visuals inspection shall be done for
-Grade top
each layer.
Check Tipper & 1. The condition shall be checked prior to
During execution of Excavator MORTH start the work
embankment (Sec.500) 2. No. machinery shall be checked as per
work programme.

Page 90
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

Check Roller 1. The condition shall be checked prior to

MORTH
start the work.
(Sec.500)
2. Vibration system shall be checked.

Page 91
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

ITEM INSPECTION Ref. REMARKS

ITEM Code
Check Motor 1. Hydraulics system shall be checked
Grader 2. Width of hydraulic blade shall be
checked
3. Capacity of grading shall be checked as
per manual.
Check toe 1. For each layer toe marking shall be
marking checked as per drawing
2. Toe record of each layer shall be kept at
site
Check layer 1. The thickness of every layer shall be
thickness& Checked and recorded.
Compaction 2. Water shall be sprinkled on finished
surface prior to dump next layer
3. The compaction for Emb.>95% & SG
> 97 %

GSB & WMM WORK INSPECTION GUIDELINE

ITEM INSPECTION Ref. REMARKS

ITEM Code

Mix proportion The ingredient of raw material shall be

mixed to achieve the grading as per
MORTH
1. Location
Check 2. Length
compaction of 3. Lane
Before commence GSB /
Base (S-Grade
WMM work MORTH 4. Degree of Compaction shall be checked
top)
Check for Preparatory (Sec.500) 5. Loose / oversize Materials shall be
Works removed
1. The level shall be recorded in level
book
Record level of 2. Visuals inspection shall be done for
GSB/ WMM top each layer.
3. Variation from Design Level of Surface
shall be checked
During execution of Check Tipper & MORTH 1. The condition shall be checked prior to

Page 92
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

ITEM INSPECTION Ref. REMARKS

ITEM Code
Before commence GSB / Mix proportion
WMM work MORTH The ingredient of raw material shall be
(Sec.500) mixed to achieve the grading as per
Check for Preparatory MORTH
embankment Excavator / (Sec.500) start the work
poclane 2. Required machinery shall be checked as
per work program.
Check Roller 1. The condition shall be checked prior to
start the work.
2. Vibration system shall be checked.
Check Motor 1. Hydraulics system shall be checked
Grader 2. Width of hydraulic blade shall be
checked
3. Capacity of grading shall be checked as
MORTH per manual.
Check toe (Sec.500) 1. For each layer toe marking shall be
marking checked as per drawing
2. Toe record sheet shall be kept at site
Check layer 1. The thickness of every layer shall be
thickness & Checked and recorded.
Compaction 2. Water shall be sprinkled on finished
surface prior to next layer.
3. The compaction for >98%

BITUMINOUS PAVEMENT WORK INSPECTION GUIDELINE (BM/DBM/BC)

ITEM INSPECTION Ref. REMARKS
ITEM Code
1. Location
2. Length
Check
1.Before priming 3. Lane
Compaction of MORTH
Check for Preparatory Base (Sec.500) 4. Degree of Compaction shall be
Works checked
5. Booming of Loose Materials shall
be done

Page 93
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

ITEM INSPECTION Ref. REMARKS

ITEM Code
1. Variation from Design Level of
Surface shall be checked
2. Variation from Design Thickness of
Confirm elevation
Base shall be checked
/
3. Surface Irregularity by 3mm straight-
Leveling of Base
edge shall be checked
4. Variation from Design cross fall or
camber shall be checked
Check Techno 1. Speed of Bituminous Distributor shall
MORTH
meter be checked during spraying of Prime
(Sec.500)
Coat.
Check Spray 1. Size of nozzles shall be checked
Bars 2. Spray bar width shall be checked
3. Hand Sprayer Attachment shall be
2. During application checked
of prime coat
Check Heating 1. Heating device shall be checked
Check Bituminous
Device MORTH
Distributor
Check Flow (Sec.500) 1. Rate of Application for Prime Coat
Indicator shall be checked
Rate of Prime 1. Rate of Prime Coat per unit area shall
Coat be checked
Check weather 1. Prime coat shall not be applied
conditions when weather is foggy or rainy.

3.Before mixing and Check Prime Coat 1. Thickness of prime coat shall be
spreading bituminous checked
mix Check of Tack 1. Rate of Spray shall be checked
coat
When Batched MORTH
Check Equipment 1. Working condition of bituminous
Bituminous mix viz. (Sec.500)
Condition Paver, steel-wheeled Tandem Roller,
BM / DBM / BC Pneumatic Tired Roller, Plate
arrives at the paving Compactor /Hand Tamper for small
site. areas shall be checked prior to start
the laying.

Page 94
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

ITEM INSPECTION Ref. REMARKS

ITEM Code
Check Job-Mix 1. Stability
Formula 2. Flow
3. Air Voids
4. Aggregate voids filled with bitumen
Check 1. Weigh Hoppers/Scales
Bituminous 2. Heating Tanks for Bitumen
Batching Plant 3. Aggregate Dryers
4. Conveyors
5. Aggregate storage bins
6. Temperature gauges
7. Heating temperature of
BM/DBM/BC and aggregates during
mixing
Check Weather 1. Batching shall not be allowed during
Condition inclement weather.
Laying of mix 1. Bituminous mix(BM/DBC/BC)
shall not be laid when it is too windy or
cold.
Check Quality of 1. Homogeneity of Mix
Mix 2. Lustre
3.Segregation
4.Take samples for Marshall stability test,
compacted density and bitumen content
Check Surface to 1. Surfaces shall be thoroughly cleaned
be Paved
Check 1. Paver must be self-propelled
Bituminous Paver mechanical spreading and finishing
equipment.
2. Adjustable screed.
3. Provided with full width
roller/Tamper
4. Pavers shall not be left
ridges/indentation on the spread mix.

Page 95
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

ITEM INSPECTION Ref. REMARKS

ITEM Code
4.DURING Check Laying of 1. Laying shall be commenced on lower
SPREADING / Material side of roadway.
PAVING WITH 2. Previously laid course shall be cut
BITUMINOUS vertical and painted with bitumen
before laying the adjacent course.
3. Longitudinally Joints on upper layers
shall be laterally displaced min.
300mm from the joint of the lower
layer.
4. Transverse joint in the successive /
adjoining shall be having min offset of
2m.
MORTH
(Sec.500)
Check 1. Compaction shall be immediately
Compaction of followed after placing the mix.
Laid Surfacing. 2. Initial rolling shall be started after
paver as close as possible.
3. Rolling shall be continued until them
in specified compaction is attained
and all surface movement has cease.
4. Final rolling shall be done with
smooth wheel roller to eliminate
marks during rolling.
5. Cores shall be cut for checking field
compaction.

Note: - BM= Bituminous Macadam DBM= Dense Bituminous Macadam

BC= Bituminous Concrete

Page 96
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design
Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate (percentage)
basis
CONTRACTOR: - MLA BSPCC (JV)

CHAPTER – 6

FORMATS FOR REPORTS AND

RECORDS

Page 103
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

6.0 REPORT & RECORDS From:

REQUEST FOR INSPECTION (RFI)
Project Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section
of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in
the state of Rajasthan (Package-1) on item rate (percentage) basis

Authority : National Highway Authority of India (NHAI)

Authority’s Engineer : M/s --------------------------------------------
Contraqctor : M/s -------------------------------------------------
RFI NO: Date Time
We request you to kindly arrange for the inspection/Survey checking/Approval of Following Material / Works
HIGHWAY STRUCTURE SURVEY MATERIAL MISC

Description Road/ Structure Work;

Chainage/Structure No:
1. Section/Chainage:
2. LHS/RHS:
3. Inspection Date & Time:
4. Brief Description of work:
5.Safty Precautions: Done Not Done
For Contractor For Authority’s Engineer
Signature Signature
Name Name
Date Date
Time Time
Comments / Recommendations

For Contractor For Authority’s Engineer

Approved Not Approved

Received Copy Received Copy

Signature: For Contractor Representative Signature for Authority’s Engineer representative

Remarks by Authority’s Engineer representative

Activity Code For Structure : Activity Code For Highway :

PCC : CG : Clearing and Grubbing
Foundation : EMB : Embankment
Pier/Abutment : SG : Sub Grade
Pier cap : GSB : Granular Sub Base
Slab : WMM : Wet Mix Macadam
Other : DBM : Dense Bituminous Macadam
BC : Bituminous Concrete

Page 103
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

DAILY REPORT

Date: Weather
F/N
A/N
Location:

ACTIVITIES (Item No., Description, Locations, Quantity or Work etc)

MANPOWER (Engineers, Foremen, Operators, Skilled Workers, others)

EQUIPMENT (Type, No working/ idle)

REMARKS (Visitors, Site Instructions, Emergency Work Orders etc)

Name:
Designation:
Date :

Page 104
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

MECHANICAL PLANT / MACHINERY INSPECTION REPORT

Contractor : Package/Section No. :

Inspection : Date & Time :
Plant / Machine : Type Model No. :
Manufacturer : Date of Manufacture:
General Conditions

Condition O.K./
Description Remarks/ Defects
Poor/ Not O.K.
Overall Appearance
Tyres/ Drums/ Tracks
Steering Brakes
Operator : Understanding/ Training
Environmental Condition

Specification Requirements

Description of Rating O.K./

Spec. Clause No. Specification Poor/ Not O.K. Remarks/ Defects
Requirement

Final Recommendations:
Date :
Copy to:

1. Project Engineer (Highways)

2. Highway Engineer /Q.A. Engineer
3. Contractor
Name :
Designation:
Date :

Page 105
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

CHAPTER –7

IN HOUSE / ON SITE TESTING

Page 106
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

IN HOUSE/ON SITE TESTING

As already has been explained in Chapter 4 earlier, this Chapter deals with those tests that are to be

carried out on a day to day basis either in the site laboratory or in an external laboratory depending

upon the available facilities for ease and regularity of quality checks. Even though the tests are

carried out prior to incorporation of the material into the structure under the Level 1 testing, the same

are tested during their use on a regular basis under Level 2 testing. Since it is not possible to carry

out all the tests relating to a particular material at the site, only the tests which cannot be done in the

in-house laboratory are done in an external laboratory. The tests which are carried out in the in-house

laboratory are covered under Level 2A of testing and the ones carried out in external laboratory are

covered under Level 2B of testing. For example, in the case of coarse aggregates it is not easily

feasible to carry out tests for deleterious materials at site; therefore, the same has been considered in

the Level 2B testing to be done in an external laboratory. Similarly, other chemical tests like Alkali

reactivity can only be carried out in an external laboratory under Level 2B testing. Similarly, most of

the chemical tests on cement cannot be carried out at site which are covered in Level 2B testing

while most of the physical tests like setting time, compressive strength etc are covered under Level

2A testing itself. Similarly, some of the tests on reinforcement, plasticizers, epoxy, pre-stressing

hardware, calibration, etc are covered under this chapter. However, it is not out of place to mention

that for comparatively sensitive and important materials, further independent tests are carried out in

another independent laboratory even though the items are tested under Level 2A and/or 2B.

The tables below give names of the tests as the conformance requirements have already been covered

in Chapter 4.

Page 107
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

COARSE AGGREGATES
Tests Reference
Sample Facilities / Equipment required
Code for
Size at site
Testing
Particle Size & Shape 2000 g IS :2386 Part I 1. Square Hole Sieves of Size
-1963 80mm, 63 mm, 50mm, 40 mm,
31.5 mm, 25mm, 20mm,
16mm, 12.5mm, 10mm
2. Thickness Gauge
3. Length Gauge
Size and Grading of Aggregates 4. Balance (more than 3 Kg
capacity) with 0.1 % accuracy
5. Oven (100 to 110 °C Capacity)
200 g IS :2386 Part 6. Wire Basket of lesser than 6.3
III –1963 mm mesh,
Specific Gravity, water 7. A stout water container
absorption & Density 8. Two dry soft absorbent cloths
each not less than 75 x 45 cm.
6500 g IS :2386 Part 9. A shallow tray not less than
IV -1963 650 cm2
Mechanical Properties 10. .An airtight container
11. Cylindrical metal measure of
11.5 cm φ, 18 cm height
12. 15 cm dia. Open-ended steel
Crushing Value Impact Value cylinder, with plunger and base
plate
13. Cylindrical Tamping Rod of
16mm φ, 60 cm length and
rounded at one end
14. Compression Testing Machine
capable of applying a load of
40 T

Page 108
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

FINE AGGREGATES

Tests Sample Reference Code Facilities/Equipment

Size for Testing required at site

1.Size and Grading of Approx. IS :2386 (Part I, 1. Square Hole Sieves of

Aggregates 6kg II, III) –1963 Size 10mm, 6.3mm,
4.75mm
2. Fine mesh, wire cloth
sieves of size 3.35 mm,
200 g 2.36mm, 1.18mm, 600µ,
2.Silt Content 300µ, 150µ, 75µ
3. Balance (more than 3 Kg
capacity) with 0.1 %
accuracy
4. Oven (100 to 110 °C
Capacity)
3.Specific Gravity, water
5. Soft Brush
absorption,
6. Wire Basket of lesser than
6.3 mm mesh,
Bulk Density and Surface
7. A stout water container
Moisture
8. Two dry soft absorbent
cloths each not less than 75
x 45 cm.
9. A shallow tray not less
than 650 cm2
10. .An airtight container
11. Pycnometer
12. Means of warm air
13. Filter Papers
14. Funnel
15. Cylindrical metal measure
of 3, 15 and 30 l capacity
16. Cylindrical Tamping Rod
of 16mm φ, 60 cm length
and rounded at one end
17. Flask of glass or non
corrosive metal
18. 1000 ml measuring
cylinder

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 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

7.13 WATER
Tests Sample Reference Code Facilities/Equipment
Size for Testing required at site
1) pH value 1. Specialized Testing Kits
for testing Chlorides and
Sulphates
2) Chlorides (as Cl) 1 liter of As per the kits 2. pH value testing Strips
middle of the 3. Titration Equipment with
stream manufacturer Pipette
3) Sulphates (as SO3)

CEMENT

Tests Sample Reference Code Facilities/Equipment required

Size for Testing at site
1. Physical Tests 1. Vicat Apparatus
2. Le Chatelier Test Apparatus
Consistency of Standard IS:4031 (Part 4) 3. Vibrating Machine
cement paste –1988 4. Cube Moulds of 70.6mm
size
2.Setting Time IS:4031 (Part 5) 5. Standard Weights
–1988 6. Balance (for a load of 1000g
Initial ±1g)
Final 7. Water Bath
8. Gauging Trowel
Soundness by Le -Chatelier IS:4031 (Part 3) 9. Planetary Mixer
Expansion –1988
10. Flow Table
11. Tamping Rod
3.Compressive Strength
12. Poking Rod
IS:4031 (Part 6)
13. Graduated Glass Cylinder
3 days -1988
(150 to 200 ml capacity)
7 days
14. Standard Sand
28 Days

Page 110
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

CONCRETE
Tests Reference Code Facilities/Equipment
Sample Size
for Testing required at site

Compressive Quantity (m3) No. of samples IS : 516 - 1959 1. Cube Testing

Strength Machine
1 to 5 1 2. 150 mm size Cube
6 to 15 2 moulds
16 to 30 3 3. Water Bath/curing
07 days 31 to 50 4 tank
51 and above 4 and one 4. Vernier Caliper
28 Days additional 5. Weighing Balance
sample for 6. Tamping steel Bar
every 16mm in diameter,
additional 50 0.6 m length and
m3 or part bullet pointed at the
thereof lower end (For trail
mix)

PLASTICISER

Tests Sample Reference Code Facilities/Equipment required

Size for Testing at site
1. Cube Testing Machine
1. Compressive Strength, percent IS :9103-1999 2. 150 mm size Cube moulds
of control sample 3. Water Bath
4. Vernier Caliper
2. Loss of Workability (slump in 5. Weighing Balance
mm) deviation from control 6. Tamping steel Bar 16mm in
sample diameter, 0.6 m length and
bullet pointed at the lower
end
7. Slump Cone
8. Container with mixing
arrangement

Page 111
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

BENTONITE
Tests Sample Reference Code Facilities/Equipment required
Size for Testing at site

Silt Content As MORTH 1.75 micron sieve

required Specifications 2.Conpenetrometre
Liquid Limit (Fifth Revision)

Page 112
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

SOIL
Sample Reference Code Facilities/Equipment required
Tests
Size for Testing at site
5 &30kg 1000 & 2250CC Proctor moulds
Proctor test IS 2720 P-8 Complete accessories as per
120gm
Atterbreg Limit IS 2720 P-5 code
10gm
FSI IS 2720 P-40
App. Glass Graduated Cylinder
CBR IS 2720 P-16
5kg CBR machine with accessories
Chemical test BS 1377P-3
BS 1377 Complete accessories as per
Compaction test IS 2720 P-28
In situ code

GSB & WMM

Sample Reference Code Facilities/Equipment required
Tests
Size for Testing at site
App.30k 2250CC Proctor moulds
g Complete accessories as per
Proctor test IS 2720 P-8
120gm code
Atterbreg Limit IS 2720 P-5
App. CBR machine with accessories
CBR IS 2720 P-16
5kg Complete accessories as per
AIV IS 2386 P-4
code
Compaction test IS 2720 P-28
6.5 kg Complete accessories as per
In situ code

BITUMEN
Sample Reference Code Facilities/Equipment required
Tests
Size for Testing at site
Complete accessories as per
code
Penetration IS 1203 P-3
Complete accessories as per
Softening point IS 1203 P-5
code
Ductility IS 2386 P-8
CBR machine with accessories
Viscosity IS 1203 P-6
Complete accessories as per
code

Page 113
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

GREEN CONCRETE
Tests Sample Reference Code Facilities/Equipment required
Size for Testing at site

Slump Test One test IS : 1195 Slump Cone

per pour Tamping Rod
of
concrete

CALIBRATION
Equipment /Machine Frequency of calibration Check Level
Batching Plant In the beginning and 2A
(MORTH Specifications thereafter, once every
Clause 602.9.3.2) month

Weighing Balances Once in 12 months of use 2A

Page 114
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

Deflection Gauges 2B
Once in 12 months of use

Testing Kits 2B
Once in 12 months of use
Jacks 2B
Once in 12 months of use
Cube Testing Machines 2B
Once in 12 months

Page 115
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

CHAPTER- 8
OUTSIDE / INDEPENDENT TESTING

Page 116
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

EXTERNAL INDEPENDENT TESTING

As already explained in the Introduction, testing of the materials for quality control needs to
be carried out in external laboratories for two reasons. One because certain test facilities are
not available at the site and the other because independent testing of certain materials
qualifying Level 3 of Chapter 3 need to be tested in external laboratory. The testing
laboratory under Level 3 may be the Contractor’s centralized laboratory for some of the tests.
This chapter lays down the minimum requirements that a testing laboratory needs to fulfill for
any given test(s). It is not necessary that one laboratory carries out all the tests. Laboratories
for various tests shall be selected based on the facilities available with the same and.

REQUIREMENTS OF TESTING LABORATORY

The testing laboratory shall meet the following minimum requirements:

a) Should have a library of all the relevant codes and standards containing guidelines for
carrying out the tests and those indicating the acceptance criteria.
b) The external agency should have as an NABL Accredited (By Department of Science and
Technology, Govt. of India)
c) All the required equipment for the relevant testing in good working condition should be
available.
d) Equipment requiring calibration should be calibrated at the required frequency. Relevant
calibration certificates should be available for inspection.
e) Facilities for obtaining required atmospheric conditions for tests such as temperature and
relative humidity should be available.
f) Equipment should be of adequate capacity to carry out the relevant tests.

Page 117
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

CHAPTER –9

METHOD STATEMENTS

Page 118
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

METHOD STATEMENTS

In order to understand and act upon the difficulties likely to be encountered during an

operation, it is essentially required to follow a Method Statement of each major activity.

The Method Statement to be followed by the Contractor in respect of each major activity

shall be step-wise sequencing of tasks, and should be detailed and meaningful. The Engineer

shall either straightaway give his consent or ask for modification before acceptance. Samples

of some important activities and details about what would be expected in the respective

Method Statement are listed below:

STRUCTURE WORKS (GENERAL)

(i) Foundation
(ii) Pier/Abutment
(iii) Pier/Abutment cap
(iv) Girder casting
(v) Deck Slab
(vi) Parapet Casting and erection

CONCRETE PRODUCTION AND TRANSPORT

Detailed proposed set-ups for the production and transport of concrete:
(i) Location and layout of batching plants;
(ii) Details of plant size, type and estimated outputs;
(iii) Details of cement storage and handling;
(iv) Details of aggregate stockpiles and storage capacities;
(v) Details of water supply and chilling arrangements;
(vi) Details of proposed transport of concrete.

FIXING OF PTFE-CUM-POT & ELASTOMERIC BEARING

(vii) Manufacturer of the bearings;
(viii) Date of supply of the bearings;
(ix) Expected date of installation;
(x) Precise sequence of operations such as preparation of pockets, placements of sleeves,
placement and aligning of bearing, grouting, tightening of bolts etc;
(xi) Likely difficulties which may be faced and corrective measures;
(xii) Location where the bearing was tested;
(xiii) Manufacturer's warrantee period.

Page 119
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

ROAD WORK
(vii) Cleaning and grubbing
(viii) Earth Work
(ix) GSB & WMM
(x) Bituminous Work

Method Statements on the above-mentioned principles shall be prepared for all major site
activities. The Engineer shall decide as to which activities require method statement.

Page 120
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

CHAPTER – 10
NON CONFORMING PRODUCTS AND
PROCEDURES

Page 121
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

NON-CONFORMING PRODUCTS AND PROCEDURES

GUIDELINES FOR NON-CONFORMING FOR STRUCTURE / HIGHWAY

General
In broad terms, it is necessary that the materials and workmanship conform to the Contract
requirements, and ideally non-conforming work shall be rejected.

But special circumstances arise in the case of some items of work such as concrete, where the
non-conformance may only be known after a few days when cube results become available,
in which period work has progressed further. In some of the situations, acceptance after
repair/ review for adequacy is feasible. Therefore, separate procedures are laid out for some
of the non-conforming situations. In case such items do not meet the requirements after the
repair/ review, the con-conforming item should be rejected. It is also necessary to refer to the
Contractor’s Project manager and/or designer in certain cases of non-conformance to seek
their advice and guidance.
Concrete / Bituminous work
The primary means by which Quality Assurance shall be achieved is by the procedures
described in the relevant method statement. The non-conforming concrete/ bituminous items
shall be further reviewed, as given below:
Non conformance other than strength or Finish
In the event that any requirement other than strength and standard of finish are not met, the
following procedure shall be followed:

1. The Contractor shall be notified without delay verbally, and in writing by the following
means:
a) Return of the Request for Inspection Form signed “not approved” with the reason for
rejection stated.
b) Issue of a Site Instruction or Site Order or letter stating the facts and confirming that the
works are not approved.
2. Approval to carry out concreting/ asphalting of a similar nature shall be withheld.
3. The Contractor shall be asked for his proposals to rectify the non-compliance, which may
involve re-submission/approval of materials from other sources, new trial mixes, revised
method statement etc.
4. When satisfied with the measures taken to ensure future compliance, the Contractor’s
Project Head shall confirm approval to continue concrete / bituminous items for permanent
works.
Non conformance with strength requirement
1. The specification strength/ density for concrete/ bituminous works recognizes the
statistical possibility of specimen failure and thus limits of means, standard deviation,
minimum values of strength are specified. The rejection criteria are set out in this Manual.

Page 122
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

2. Materials that are stored for a long time shall be retested at regular intervals before use.
Any deterioration in the quality shall be detected and defective material rejected and
removed from site.
3. In the event the cube/ density results fall short of the provisions of the C.A., the non-
compliance procedures described below shall be followed:
(a) Approval of concreting/ asphalting of similar works shall be withheld.
(b)All aspect of concreting/asphalting shall be reviewed.
(c)The cause of failure shall be identified and measures taken to remedy the problem.
4. Various repair/ rectification procedures for commonly arising non-conformance are spelt
out in the Specifications and Codes of Practice. The Contractor shall furnish his exact
proposals for rectification under consideration.
5. The fact of non-conformance and the proposed rectification procedure is conveyed to the
Contractor’s Project manager (or design consultant) for review and opinion about:
(i) Acceptability of measures proposed by the Contractor, if any.
(ii) Further non-destructive testing, if any.
(iii) Acceptability in case strength is achieved at a later age (e.g., 90 days).
(iv) Acceptability at the level of strength achieved for the stress levels in the concerned
members.
(v) Acceptance of repair/ rectifications/strengthening measures with modifications, if
required, or rejection.
6. Rejection in case the item does not pass modified acceptance limits after repairs.
Non-conformance with Finish requirement
1. Where the required finish is not attained, the non-conformance procedure for repair/
rectification in the Specifications shall be followed.
2. In addition the following procedure shall be followed:
(a) Approval of similar work shall be withheld.
(b) All aspects of work shall be reviewed.
(c) The cause of poor finish shall be identified.
3. Revise specification/ Instructions to avoid further recurrence of non-conformance.
Non-Conformance in case of earthwork, sub-base, base and other pavement courses are to
be treated as per the above guidelines, as applicable.

ADMIXTURES
In case the material test shown on compliance prior to its use, the complete material lot
shall be removed from the site at once and the procedure stated above shall be followed.
But, in case results arrive after the particular admixture has been used in the concrete, the
Contractor shall be required to give his methodology of rectification, strengthening and get
it approved by the Engineer-in-Charge (Structures) before execution. Such a rectified
structure shall be subject to appropriate non-destructive testing, if felt necessary by the
Engineer-in-Charge (Structures). If no satisfactory method is found, the structural members
incorporating the non-compliant material shall be dismantled at no cost to the owner/client.
In the case of proprietary materials such as admixture, bearings, expansion

Page 123
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

joints etc, the respective manufacturer shall invariably be consulted for analysis of the
problems and possible rectification measures.

CEMENT AND OTHER MATERIALS

The procedure indicated above shall be adopted.

RECORDS
It is mandatory that all instances of works outside the Specifications are recorded and
intimated in writing to the Contractor. This ensures that: -
1) The Contractor is irrefutably informed.
2) A record of non-compliance is built up to give a general guide to the Contractor's -
performance.
The Quality Assurance Engineer shall summaries the following information for each
category of work:
1) The total number of inspections and tests.
2) The number of "first time approvals” i.e. the number of times the material or
workmanship is approved on the first test or inspection.
3) The number of second, third, fourth etc. inspections or tests of the same work required
before final approval.
4) The percentage of first time approvals, second, third, etc. over suitable time intervals.
From the above information, the Engineer-in-Charge shall be reviewed the Contractor's
superintendence and take action where necessary to improve matters. From increases or
decreases in the number of first time approvals, the improvement or deterioration in
Contractor's performance can be monitored. The record of repair/rectification, retesting,
inspection & acceptance shall be kept as part of "As built documentation”. Record of all
references to designers for opinion/rectification and approvals given by them shall be
properly maintained. Record of compliance to the modifications in procedures, testing
etc., if any, shall also be properly maintained.

Page 124
 QUALITY ASSURANCE PLAN
Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of
Deoli-Kota Section of NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction
(Design Km.167.624 to Km. 205.724) in the state of Rajasthan (Package-1) on item rate
(percentage) basis
CONTRACTOR: - MLA BSPCC (JV)

NON CONFORMANCE REPORT

Revision : -0 QC:- 03A

1.
Contractor Name…… Date:
Notification No.

NON CONFORMANCE

Location:
Description: ………………………………………………………………………….
………………………………………………………………………………………….
……………………………….: .......................................................................................

Attachments:……………………………………………………………………………

Quality Plan Reference:………………………………………………………………..

Specification Reference:……………………………………………………………….

Drawing Reference:…………………………………………………………………….

Other Reference:……………………………………………………………………….

(Signed) Contractor’s Representative Date

Name ……………………………………Designation. …………………………..

2. REMEDIAL ACTION: APPROVED AUTHORITY ‘S ENGINEER

…………..…………………………………………………………………………….

………………………………………………………………………………………….

(Signed) ( AE / Material Manager) Date

Page 125
 QUALITY ASSURANCE PLAN

Reconstruction & Rehabilitation Bituminous Pavement Works and Incidental Works of Deoli-Kota Section of
NH- 12 (New NH- 52) from Km. 165.00 to Talabgaon Junction (Design Km.167.624 to Km. 205.724) in the state
of Rajasthan (Package-1) on item rate (percentage) basis
CONTRACTOR: MLA BSPCC (JV)

CHAPTER – 11
QC LAB FORMATES

Page 127