………………………………………..

Project

Quality Assurance Plan

And
Method Statement

Contract ID No …………………………………………

Submitted by- Submitted to-

……………………… …………………………………

Submitted on:
Table of Contents
1. Quality Assurance Plan ...................................................................................................... 1

1.1 General ............................................................................................................................... 1

1.2 Quality................................................................................................................................ 1

1.2.1 Objective of Quality in Construction .......................................................................... 1

1.3 Quality Assurance .............................................................................................................. 1

1.4 Quality Assurance Plan (QAP) .......................................................................................... 3

1.4.1 Objectives of QA Plan................................................................................................. 4

1.5 Scope and Application of QAP .......................................................................................... 4

1.6 Content of Quality Assurance plan .................................................................................... 5

2. Organizational Setup.......................................................................................................... 6

2.1 General ............................................................................................................................... 6

2.2 Parties to the contract ......................................................................................................... 6

2.2.1 The Employer .............................................................................................................. 6

2.2.2 Engineer / Employer Representative .......................................................................... 6

2.2.3 The Contractor ............................................................................................................ 7

2.3 Organization Structure ....................................................................................................... 7

2.4 Job Description of Key Personnel...................................................................................... 8

2.5 Contractor’s Establishment on Site.................................................................................. 10

3. Quality Control of Work .................................................................................................. 11

3.1 General ............................................................................................................................. 11

3.2 PROCESS OF QUALITY CONTROL ........................................................................... 11

3.2.1 Quality Assurance Program ..................................................................................... 13

3.2.2 Qualified Laboratories.............................................................................................. 13

3.2.3 Qualifications of Laboratories and Sampling and testing Personnel....................... 14

3.2.4 Planning of Works..................................................................................................... 14

3.2.5 Verification Sampling and Testing of Project Material............................................ 15

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 3.2.6 Verification Sampling and Testing of Manufactured Material ................................. 15

3.2.7 Setting Specific Standards for Construction Performance ....................................... 16

3.2.8 Measuring Variances from the Standards ................................................................ 16

3.2.9 Minimizing adverse variances .................................................................................. 16

3.3 Quality Control Tests ....................................................................................................... 16

3.3.1 Quality Control Tests of Material before Works ...................................................... 17

3.3.2 Quality Control Tests during Construction .............................................................. 22

3.3.3 Stage Passing ............................................................................................................ 24

3.3.4 Acceptance of Tests for Finished Work .................................................................... 24

3.4 Non-Compliance and corrective Measures ...................................................................... 25

3.5 Monitoring of Quality Control ......................................................................................... 26

3.6 Quality Auditing & Reporting ......................................................................................... 26

3.6.1 Internal Correspondence .......................................................................................... 26

3.6.2 External Correspondence ......................................................................................... 27

3.6.3 Filing ......................................................................................................................... 27

3.6.4 Weekly/Monthly Testing Schedule ............................................................................ 27

3.6.5 Material Management Schedule ............................................................................... 27

3.6.6 Short Time Work Program ........................................................................................ 27

3.6.7 Tests Statement (Monthly Report)............................................................................. 28

4. Construction Method Statement ..................................................................................... 29

4.1 Introduction ...................................................................................................................... 29

4.2 Order of Sequence of execution of works........................................................................ 31

4.3 Method Statement of Works ............................................................................................ 32

4.3.1 Earthwork ................................................................................................................. 32

4.3.2 Construction of Structures ........................................................................................ 36

4.3.3 Steel Reinforcement (DOR Specification 2014)........................................................ 47

4.3.4 Form works (DOR Specification 1800) .................................................................... 48

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 4.3.5 Pavement ................................................................................................................... 50

4.3.6 Other Ancillary works ............................................................................................... 57

4.3.7 Road Maintenance (DoR Specification section-2900).............................................. 57

Figure 2.1 Organization Structure of Contractor ....................................................................... 7

Figure 3.1 Typical Flow Chart for Quality Control Process in Road Work ............................. 12

Figure 3.2 Material Quality Control Flow-chart ...................................................................... 20

Figure 4.1 Flow Chart of Construction of Structures................................................................ 36

Figure 4.2 Flow Diagram of Construction of Pavement Layer ................................................. 50

Figure 4.3 Flow Chart of Laying of Asphalt Concrete .............................................................. 55

ANNEX-II MATERIALS DELIVERY & TESTING SUMMARY SHEET

ANNEX-III TEST RESULT SUMMARY SHEET

ANNEX-IV LIST OF TESTS AND THEIR FREQUENCIES

ANNEX-V WORK REQUEST FORM

ANNEX-VI SITE INSTRUCTION BOOK

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Abbreviations

AASHTO American Association of State Highway and Transportation Officials

AC Asphalt Concrete

AIV Aggregate Impact Value

ASTM American Society for Testing and Materials

BOQ Bill of Quantity

BS British Standard

CBR California Bearing Ratio

O
C Centigrade

CM Contract Manager

CR Contractor’s Representative

CSC Construction Supervision Consultant

Cum. Cubic Meter

Cm Centimeter

Dia. Diameter

DoR Department of Roads

DoLI Department of Local Infrastructure

FD Field Density

HDPE High Density poly ethylene

IOW Inspector of Works

IRC Indian Road Congress

IS Indian Standard

KN Kilo Newton

LAA Los Angeles Abrasion

m2 Square meter

m3 Cubic meter

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MC Moisture Content

MDD Maximum Dry Density

ME Material Engineer

Mpa Mega Pascal

mm Millimeter

NC Non Confromance

NS Nepal Standard

OHS Occupational Health Safety

OMC Optimum Moisture Content

OST offsite Test

PI Plasticity Index

PM Project Manager

QA Quality Assurance

QAP Quality Assurance Plan

QC Quality Control

RCC Reinforce Cement Concrete

RE Road Engineer

SLT Senior Lab Technician

SWG Standard Wire gauge

sqm Square meter

T Ton

TS Technical Specification

WRF Work Request Form

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 1. QUALITY ASSURANCE PLAN
1.1 General

The definition, terms and conditions, general requirement and provision mentioned in the
Quality Assurance Plan (QAP) shall be read exactly as stated in the Technical Specification. The
defination and terms used in the QAP shall be clearly in accordance with the Technical
Specifications and unless otherwise defined in this document.

1.2 Quality
Quality is construction works means that a project is completed with the requirements of the
client meeting specification and contractual agreement. The quality of any product or service is
achieved when it conforms to the desired specifications. Achieving quality in construction
industry in long run is a tough issue and has been a problem. Inefficient or no practice of quality
management procedures will result in great loss of time, money, material, resources. For
example, in construction site, the designer would specify a particular grade of concrete. The
contractor will use the ingredients of the concrete such that the desired grade of concrete is
obtained.

1.2.1 Objective of Quality in Construction

The quality in construction relates to the following objectives:

 Satisfaction of Contract Specifications

 Completion of Project within Time

 Enhancing Customer/ Owner Satisfaction

 Motivation and Empowerment of Employees

 Avoiding Disputes and Claims

 Performance based on Purpose

1.3 Quality Assurance

Quality assurance is the planning and systemic activities implemented in a quality system to fill
quality requirements. So, quality assurance is looking at the quality requirements and making a
plan to meet requirements and focused on providing confidence that quality requirements will be
fulfilled.

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Quality Assurance is Not Quality Control. Contractors occasionally combine the ideas of
quality assurance and quality control while conducting everyday construction operations. It
makes sense to combine the two into a single process as they are in fact responsive to one
another. However, combining the two is incorrect.

Construction companies will struggle to guarantee high-quality outcomes from the construction
process until owner and employees correctly apply the differences between construction project
QA and construction project QC. These two elements of quality management are distinct from
one another. Each fulfills a certain set of procedures, objectives, and purposes.

The QA is process oriented and QC is product oriented. Quality assurance specifies

standards, quality control verifies compliance to standards. A successful QA program aims
to ensure that the quality procedures implemented during the design phase of a construction
project effectively meet the company-established standards for quality service, performance, and
production. The core specs focus on:

 Qualifications established for architects, designers, and engineers

 Markup rules pertaining to plans and drawings from preparation thru revision and into
final approval

 AND the assurance that specified materials comply with company-established quality
standards.

QC is the process that ensures that materials used on the project actually comply with properly
signed drawings and plans. Secondly, QC ensures that task-specific personnel actually perform
construction project processes according to the specified QA standards.

QA provides method, QC ensures accurate application.

Whereas Quality Assurance defines a method for determining the how and when of construction
standards, Quality Control ensures that workers, operators, and management correctly respond
to the specified QA standards. Quality Assurance defines a methodology that enables your team
to evaluate and identify construction standards that best satisfy:

 Specifications
 Legal provisions
 Construction safety necessities
 Customer quality expectations.

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Quality Control verifies correct applied quality methodology, material selection, and labor
performance efficiency. QC is also responsible for testing finished goods and services to ensure
compliance to the QA standards.

 QA establishes processes, QC selects according to established standards

Quality Assurance crafts procedures that enable management and work crews to identify
properly qualified suppliers. It sets the specs for supplier selection, including requirements for:

 Visit and inspection of supplier facilities

 Materials testing
 Existence of a supplier-side QA program
 Any other criteria necessary to ensure that the proposed supplier is qualified to meet the
company-established Quality Assurance specs.

Quality Control examines the established QA standards, certifies that prospective suppliers meet
the criteria, and follows through by testing supplied parts and services as dictated by the existing
company-establish construction project QA program.

1.4 Quality Assurance Plan (QAP)

The Quality Assurance Plan (QAP) is the documentation confirmation that identify procedures
used to obtain the standards of quality required by the contract plans and specifications for the
construction of the project are met. The purpose of this QAP document is to provide
organization policy and procedures for progressing the project from Quality Assurance to letting
in an effective manner to meet the Technical Specification as stated in Contract Document. This
document gives only an outline procedure to attain qulity of costruction project and thus stated
procedure shall be followed strictly to minimze the non conformity through as continual
improvement process.

This QA Plan:

 Identifies the organization, roles, and responsibilities of individuals who will be

participating in the project during construction.
 Provides a preliminary construction schedule with a summary of planned construction
activities, their sequence, interrelationships, durations, and terminations.
 Briefly summarizes the minimum qualifications of lead project participants from the
Engineer’s and Contractor’s organizations.

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  Provides a description of the construction inspection program that includes inspection
responsibility, anticipated inspection frequency, deficiency resolution, and inspector
qualifications.
 Describes key activities that will take place and processes that will be used to meet the
quality standards, including communication, technical records handling, review and
observation functions, sampling and testing requirements, acceptance/rejection criteria
that will be followed, and corrective measures to be used when deficiencies are found.
 Includes a summary of documentation procedures for work clarification and changes to
the work.

1.4.1 Objectives of QA Plan

The main objectives of this Quality Assurance plan is to attain quality of the construction work
in accordance with Technical Specification are but not limited the following:

 To assure that all the steps of Quality control have been properly planned and
implemented at the completion of each activity.
 To assure that the completed works meet or exceed desired performance criteria/quality
standards (specified in Drawings & Technical Specification which are part of the
Contract Documents.)

1.5 Scope and Application of QAP

This QAP is intended to use by client, the supervision consultant and contractor for the
execution of the work as described in specification and drawing.

Quality Assurance plan provides a highest importance to the achievement of the quality of
works and materials as envisaged in the design and specification. It is further envisaged the
highest standards of workmanship in the works such that the full value for the investments made
is realized and the road performs in the best way during the design life. The quality assurance
systems are needed for this contract at level but not limited the following

I. Design and project preparation

II. Construction

III. Operation and maintenance

IV. Production of manufactured Items

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The organizations involved in the design construction and operation and maintenance of this
contract are:

I. The client

II. The Design Consultant

III. The supervision Consultant

IV. The contractor

1.6 Content of Quality Assurance plan

The QAP shall include the following but not limited to:

a. The recapitulative tests schedule and testing program detailing the list of tests for
compliance, laboratory trails, site trails, trail sections, construction control tests and their
frequencies, tests for acceptance of the completed works with their dates. Recapitulative
list of “critical” acceptance testing procedures, for equipment or parts of the work which
corresponds to the tasks on the critical path according to the construction program.

b. Estimate the number of tests to be carried out, list and number of appropriate equipment
required to conduct them, list of tests to be conducted outside the site laboratory, if any,
identification of the outside laboratory where proposed to carry out the test.

c. List of staffs assigned to the laboratory, their position and responsibility in the quality
control procedure, their qualification and experience, general description and detailed
organization of the laboratory activities.

d. The list of sources of materials and/or manufactured article, their main characteristics,
their identification mode as provided by the supplier when required; the program of
supply and procurement of material and/or manufactured articles in accordance with the
program submitted by the contractor.

e. The list of tests and quality control procedure to be implemented by the contractor, if any
pointing out the “criteria” acceptance testing procedures relating to the contracted works,
which correspond to the tasks on the critical path inclined in the subcontracted works.

The contractor shall implement the quality control in compliance with the approved QAP.

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 2. ORGANIZATIONAL SETUP
2.1 General
Quality Assurance (QA) and Quality Control (QC) is the most important action to prevent any
defects or make improvements to the services to be delivered to its valued Employer. It is a function
that identifies documents and reviews for continual improvement of the process that deliver
products. It is the policies, procedure, and systematic actions established in the bid document where
the employer had primary listed out all the activities, processess to be performed by the contractor
and implementation of such resposibility to be bestowed at later stage to the construction site for the
purpose of ensuring quality. Therefore, QA and QC are the prime responsibility of contractor with
the continous support and supervision from employer, engineer. Hence, it is triparty relationship
between employer, enginerr and contract to deliver products as per requirement and specification.

2.2 Parties to the contract

There are three parties defined in the contract agreement

 Employer
 Engineer/Engineer Representative from Employer (Employer Representative)
 Contractor

2.2.1 The Employer

Name of Office: …………………………

Employer’s Representative will delegate some or most of his duties to supervision engineer. It
nevertheless remains his responsibility to ensure that those duties are discharged correctly.

2.2.2 Engineer / Employer Representative

The Engineer in a contract may be a site engineer or RE. The Engineer is responsible for the
administration and control of the contract, and in particular the supervision of the works to ensure
that the contractor fulfils the requirements of the contract. Engineer is assigned to construction site
to manage both technical and managerial functions.

The Employer may delegate in writing some of his powers under the contract to his representative
on site such as RE, and will formally notify the Contractor of the powers in question prior to
commencement of the works. Notwithstanding any delegation of powers, responsibility for those
powers remains with the Engineer.

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On most projects the Engineer’s Representative is supported by field staff engaged on specific
activities (e.g. setting out, measurements, quality control tests, etc.). Support staffs are not
authorized to give instructions to the contractor, nor either to accept or reject the works,
responsibility for which rests firmly with the Engineer

2.2.3 The Contractor

Name of Contractor: …………………………

The majority of construction of quality work is the responsibility of the Head Office of the
contractor since it supplies required human resources and construction materials except the locally
available items. It is therefore the responsibility of the site office to assure the execution of the
required quality control activities. The overall project management role is to be played by the
Contractor’s Representativ who have legal power (Power of Attorney from Board of Directors) to
act on behalf of contractor. He is also liaison to the Engineer and Employer. The contractor shall
take approval from the client before the mobilization of Contractor’s Representative. The
proposed CV of the Contractor Representative are in Annex-1.

2.3 Organization Structure

Contractor’s quality control organization will be as given in fig. 2.1

Figure 2.1 Organization Structure of Contractor

Contract Manager

Site Engineer Surveyor Lab Technician

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2.4 Job Description of Key Personnel
The job descriptions for the key personnel of the Quality Control Organization are as follows:

I. Contract Manager (CM)

The contract manager is responsible for contract management, communication and coordination and
construction of works in accordance to standard specification and contract document. His/her major
responsibilities are:

 Planning, scheduling, monitoring and controlling of tasks.

 Conformity of all materials and all workmanship performed strictly with the requirements of
specifications.
 Prepare QAP
 Set up of laboratory with adequate laboratory equipment operated by competent staff for
carrying out tests for selection and control and quality of material and workmanship in
accordance of specification.
 Inspect materials upon receipt.
 Prepare Monthly Progress Report, S-Curve, Bar Charts etc. and submit to Client.
 Define activities affecting quality of works
 Prepare and submit working drawing for approval.
 Ensure compliance with drawing, specification and environmental provision.
 Implement site instruction given by the client.
 Establish and maintain quality management system.
 Carry out construction activities in accordance Method Statement
 Correspondence with client
 Monitoring and Implementation of QAP.
 Maintain coordination with stakeholders and own staffs.
 Timely instruction and decision.

II. Site Engineer (SE)

 Day to day planning of site works

 Prepare construction method statements
 Prepare site specific working drawing
 Setting out of works and carry out construction in accordance with working drawing
 Carry out and monitor all test specified in QAP.

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  Implement QAP and control of quality of work and workmanship
 Implement work request form and site instruction
 Carryout construction activities in accordance Method Statement.
 Inform immediately to the client/PM for any obstruction to the progress of the work and or
any fact found in the drawing.
 Execute all works according to specifications, departmental procedure and instructions etc.
 Arrange all materials, plants and labor well in advance and has to see that progress of work
does not suffer for want of material
 Take measurement of the work done or supply and to record in the measurement book
 Keep note of important points on works in note book during the inspection of works and he
has to keep his not book up- to date.

III. Surveyor

 Setting out of works including joint survey.

 Marking of alignment and structure
 Checking of line and level
 Preparation of Survey Drawing and calculations
 Assist SE and CM in construction of work.

IV. Lab Technician

 Set up laboratory and testing facilities

 Carry out quality control test and process control
 Supervise compaction of subgrade, subbase and base likewise asphalt work.
 Prepare day to day testing of materials and maintain documentation of lab reports
systematically.
 Prepare laboratory and site testing Records and register
 Provide data to material engineer to maintain site record
 Jointly sampling of materials
 Carry field test such as FD, MC etc.
 Maintain test register
 Fully accountable to Engineer
 Supply test report to client

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2.5 Contractor’s Establishment on Site
The contractor has established contractor’s organization camps, infrastructures facilities on site
located at……………………………………………. The contractor shall remove the camp after
completion of contract.

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 3. QUALITY CONTROL OF WORK
3.1 General
In simple terms Quality control (QC) is a procedure or set of procedures intended to ensure
that a construction works or performed service adheres to a defined set of quality criteria i.e.,
specification or meets the requirements of the client.

The Contractor is responsible for achieving the quality standards specified in the contract
agreement. The Engineer is responsible for ensuring that the works are constructed to those
standards.

It is routine application, at prescribed frequencies, of a system of procedures for the sampling

and testing of materials prior to placing and following completion that ensures that specified
standards are achieved. Each procedure relates to a specific aspect of the works and usually
involves a test or combination of tests to determine compliance or otherwise with a
Specification. QC does not specify “who, where and how” the procedures will be implemented.

3.2 PROCESS OF QUALITY CONTROL

In addition to serving the prime function of assisting site staff in fulfilling technical and
procedural requirements of a contract, the QA Plan will also be used by the Employer
Monitoring Team as a basis for measuring contract performance against agreed standar
procedures. Quality Control of works is implemented in the following sequences:

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Figure 3.1 Typical Flow Chart for Quality Control Process in Road Work

I. Compliant testing for materials including laboratory trials,

II. Compliant testing for methods and equipment prior to commencement of work,
including site trials or trial sections,

III. Control testing during construction (process control),

IV. Acceptant testing on completed works or parts of works.

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 V. Contractor carries out all necessary tests and reports to the Engineer results of such
tests before submitting materials and/or finished works or part of works to Engineer for
approval

VI. For satisfying himself about quality of works, quality control tests shall be carried out
by Engineer himself or by any other agencies deemed fit by Engineer.

VII. Before commencement of works, Contractor demonstrates a trial run of all construction
equipment for establishing their capability to achieve requirement of Specifications and
tolerances to satisfaction of Engineer.

VIII. Supply, testing and monitoring shall be in compliance with a Quality Assurance Plan.

It is the responsibility of the contractor to carry out all necessary tests for material and works
and submit reports of such tests to the engineer for approval in accordance with the
specification. Additional tests may also be required to be conducted where in the opinion of the
engineer when such tests are needed.

The supply, testing and monitoring shall be in compliance with a quality Assurance Plan, as
per the provisions made in the contract. The list of sources of materials and/or manufactured
article, their main characteristics, their identification mode as provided by the supplier when
required; the program of supply and procurement of material and/or manufactured articles in
accordance with the program submitted by the contractor.

The list of tests and quality control procedure to be implemented by the sub-contractor, If any
pointing out the “criteria” acceptance testing procedures relating to the sub-contracted works,
which correspond to the tasks on the critical path inclined in the subcontracted works.

The contractor shall implement the quality control in compliance with the approved
QAP.

3.2.1 Quality Assurance Program

The intent of this program is to provide adequate assurance that the materials, workmanship
and completion of work incorporated in this project are in reasonable conformity with the
requirements of plans and specifications including any changes.

3.2.2 Qualified Laboratories

Laboratories those are capable of performing test procedures. This program includes, as a
minimum provision of checking test equipment and a requirement that the laboratory maintain

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records of all calibration checks. The laboratory must be located within the limits of the Works
area and be fully established before the Works commence. Subject to the approval of the
Engineer some tests may be carried out at an alternative laboratory containing more complex
testing equipment.

Testing equipment and apparatus are to be initially approved, and periodically checked by the
consultant to assure proper operation, accuracy, correct calibration and complete conformance
to specification requirements instructed by the engineer. The engineer/consultant shall
supervise, monitor and check all aspects of the testing procedures including sample storage,
preparation, testing and analysis and reporting of test results.

The Contractor must carry out regular routine testing in the site laboratory (supervised by the
Engineer) on all materials delivered to the site. This will include additional tests on site on
those samples collected at random as part of the quality control check system.

The Contractor shall be responsible to set up and maintain a fully equipped field laboratory for
routine tests for quality control requirement that do not require electrical power supply and are
relevant to the project specification. Field laboratory will be managed by suitably trained
personnel in material testing and quality control works, as specified in the contract document.
The requirement of a quality control organization will vary for different project depends on
size of project. The minimum suggested organization of quality control laboratory set-up at
field is as follow.

Field Laboratory- At ……………………..Road

3.2.3 Qualifications of Laboratories and Sampling and testing Personnel

The laboratory at the camp or contract premises will be fully equipped for performing all the
tests required for the projects as specified in the contract documents except some special tests.
The calibration will be done from the related government agency. The qualification and
calibration records will be documented properly. Sampling and testing personnel will be
capable to perform all the required tests.

3.2.4 Planning of Works

Planning of Construction Materials to the Site

Materials to the site will be stocked at such placed where no foreign materials will be mixed
up. Any materials from unapproved source or stock pile which do not comply with the
specification will be immediately removed from the site. The working site will be neat and

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clean i.e., the construction material will not be scattered. The gabion boxes will be woven in a
separate yard at one place so that it will be easy to control the box quality. Only approved
boxes will be transported to the site. The storing of cement and other materials will be
approved manner.

Work Instructions

Work instructions will be issued at different stages when required. Unusual section of work are
will be identified and considered as the work requiring work instructions. Work instructions
will be issued with the signature of Contract Manager or Site Engineer.

Check Lists

In consultation with the engineer, check lists will be developed for different structures e.g.
masonry wall, gabion wall, RCC structure, culvert, earth cutting work, side drainage, pavement
work etc. and approved from the engineer. Each of these lists will contain the check for all the
steps and test required. These will be filled up every day by site quality-controlled engineer
and signed by both the parties at its completion and submitted to the QC engineer. These lists
will be used in quality auditing

3.2.5 Verification Sampling and Testing of Project Material

Prior to the commencement of the Works, tests must be carried out by an approved laboratory
on material samples (or mix designs) submitted to the Engineer for approval. No deliveries of
materials will be permitted until samples and a Materials Control System have been approved
in writing.

These materials can generally be described as those that are used/produced to meet the
requirements of a specific project. They are characterized by being sampled at the
borrow/construction project site and tested either at the project site or at a qualified laboratory.
Aggregates, PCC, Mortar, Base and sub-base materials, gabion boxes etc. are considered
project produced materials.

3.2.6 Verification Sampling and Testing of Manufactured Material

These are the materials manufactured to meet the specific requirements and can be used on
numerous construction projects provided they meet the requirements for those projects. These
materials (GI wires, Geotextiles, cement, Bitumen etc.) will be sampled at the project site and
forwarded for testing to central laboratory of DoR or other recognized laboratory for testing.

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The manufacturer certification and/or manufacturer certified test reports will be documented
and a copy will be supplied as per provision of the contract.

3.2.7 Setting Specific Standards for Construction Performance

The standards set out in the drawings and specification of the contract documents will be
strictly followed.

3.2.8 Measuring Variances from the Standards

For measuring variances of materials and work from the standards as set out above, standard
formats will be developed and approved from the engineer. For lab tests, the formats are
included in the Annex-II and Annex-III.

3.2.9 Minimizing adverse variances

To minimize adverse variances, Contractor will develop and submit a stepwise control
procedure for most of the important items of work and will be strictly followed after its
approval. Procedures for some major items of work are presented in the Chapter 4. For the
work which is totally out of control will be rejected and reconstructed.

3.3 Quality Control Tests

 The Specification defines the quality control tests to be undertaken at each stage of the
Works, together with frequency and results that should be achieved. The list and
frequency of tests that shall be conducted are in Annex-IV. Works that are not covered
by the General Specification must be included in a Particular Specification, including tests,
frequencies and results for materials and workmanship. However, the number of tests
recommended as per Specification may be reduced at the decision of the Engineer if it
is felt that consistency in the quality of materials can still be maintained with reduced
numbe of tests. A summary of the tests undertaken should be maintained in a Record Book
the format of which is contained in Annex-II and Annex-III.
 A detailed description of each test procedure is contained in the Standard Test
Procedures
 Where any test result fails to meet the requirements of the Specification the
Employer/Engineer must be notified immediately by SMS, mail, telephone, and a copy
of the failed test report dispatched to him if required. The Employer will direct the
support staff on what action is required.

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  Copies of all test results, together with a summary sheet for each test, should be
submitted to the employer at the end of each month, or at such other frequency required
by him. The formats are given in Annex-II and Annex-III.
 Many of the tests may be undertaken on site using basic test equipment. Others will
need to be carried out in an off-site laboratory equipped with more complex machinery
that has been approved by the Engineer. In all cases the tests are to be undertaken by
the Contractor at his own expense, the cost of which is deemed to be included in the
rate for the relevant work item.
 When a contract requires specialized materials or components to be used and the
Specification does not require tests on those items the Engineer must ensure that the
items proposed comply with the Specification.
 The contractor must submit samples at the earliest opportunity to allow sufficient time
for testing and analysis results and to avoid delays to the construction program.

Quality Control tests are undertaken in following stages of the works:

I. Quality Control Tests of Material Prior to Construction

II. Quality Control Test of Workmanship and Works during construction
III. Stage Passing
IV. Acceptance of Work after construction

3.3.1 Quality Control Tests of Material before Works Commented [u1]: Equipment Missing

All materils before use in the works shall be tested by the contractor for the tests indicated
under “Tests to be carried out prior to Construction” for an approval. The tests shall be
carriedout from each source identified by the contractor. The test samples shall be
representative of the material available from the source. Any change in the quality of material
with depth of strata shall be reported. Important tests for base subbase like the MC, MDD,
AIV, PI, CBR, marshal stability flow test for Asphalt concrete mix and other tests specified by
the engineer. The tests results shall form the basis for approval of the source and the material
for incorporation in the work and shall be approved by the engineer. For manufactured items,
however, such as concrete pipes, a test certificate obtained by the manufacturer from an
approved Test House shall be accepted.

3.3.1.1 Sampling of Materials

I. Sampling Requirement

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Sample is a portion, piece, or segment that is representative of a whole. All Construction
materials to be used in the permanent works are to be sampled jointly by the engineer and
contractor prior to commencement of the work. This operation includes sampling for materials
to be tested for approval of the material source as well as sampling of materials for approval of
the individual construction material. In both cases, and for each instance the engineer the
contractor must give notification of a request for such sampling to the engineer in
advance (48 hours) by way of the request for Inspection.

Sampling instruments and equipment, bag and labor are to be provided by the contractor. For
sampling activities, the consultant is to be represented by the material engineer or his
subordinate.

II. Sampling Procedure

All sampling is to be carried out in accordance with instructions to be given by the engineer.
Sampling procedures are to follow recognized guidelines of good engineering practice.
Sampling method shall be in accordance with

 Sampling of STONE, AGGREGATE, SAND AND FILLERS shall be done as per

ASTM–D75
 Cement shall be sampled according to IS 3535.
 Sampling of straight-run and cut-back bitumen shall be done in accordance with ASTM
D 140.
 The sampling of Reinforcing Steel shall be as per the NS 84-2042 and NS 191-2045
Sampling of soils and gravels shall be carried out as specified or as directed by the
Engineer.
 Sampling of Bituminous Mixtures shall be carried out in accordance with ASTM
Method D 979
 Obtaining samples from at least three locations.
 Ensuring that the sampled materials and locations are “typical” for the material to be
used Ensure that sufficient quantity are sampled to enable all tests to the conducted,
plus additional material, to be stored for subsequent testing, if required.

3.3.1.2 Preparation and storage of Samples

Sample collected are prepared as per standard methods, with an additional sufficient quantity
retained in sealed bags or container and separately kept in the sample storage room of the
laboratory for additional testing and future reference as required. Concrete samples are to be

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carefully cured and kept in curing tank of the laboratory. Detailed of all samples stored are to
be kept in a register to be administered by the material engineer. Ensure that each sample bag
is marked both inside and outside, giving the sample number, material type, sample location,
date and the number of bag as well as any other information as follow

SAMPLE TAG:

a. Project- ……………………..……

b. Contract Identification No…….....

c. Sample number …………………..

d. Date of sampling …………………..

e. Sampling material………………….

f. Depth ………………………….……

g. Location/Chainage …………..……

h. Sample taken by ……………….….

i. Tests to be performed ……………..

3.3.1.3 Approval of Material

I. The Contractor must obtain written approval from the Engineer before bringing
materials to the site. Approval will be based on testing of samples to demonstrate
compliance with the specification, together with approved storage and management
procedures that ensure consistent quality control will be maintained.

II. Records must be kept of all materials brought to the site, together with corresponding
tests to confirm compliance with the specification, and the location of all materials
incorporated into the permanent works. Materials that fail to meet the specification
requirements must be rejected by the Engineer and removed from the site by the
Contractor.

III. The Contractor must obtain written approval from the Engineer before commencing
each stage of the works. Approval will be based upon satisfactory preparation for the
works and quality control tests on the preceding stage of works together with other
requirements of the specification.

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IV. The quality control system comprises the methods, procedures and organization for the
quality control of the work. The quality control system is implemented in following
sequences. All materials proposed by the contractor to be used in the project work are
to be approved first.

Figure 3.2 Material Quality Control Flow-chart

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 I. Approval of Natural Material

Materials with little or no processing except for perhaps screening for oversize and removal of
unsatisfactory particles Approval of natural material shall be obtained for the borrow area.
Approval of construction material is obtained by submission of test results for all tests required
as per specification, and in some cases by construction of trail sections to prove this material
can be placed in the field so as to attain minimum required field properties.

II. Approval of Manufactured Material

Especially homogenous construction materials, like cement, bitumen that are used for blending
with natural material. Approval of manufactured materials is generally given in two stages:

Initial Approval- It is given prior to receipt of the materials based on submittal of appropriate
testing results confirmed by the manufacturer.

Final Approval- It is given based on initial approval in addition to positive results being
obtained for all “acceptance” test required by the specifications or as directed by the engineer.
The Quality Assurance System and plan of the manufactured shall also be examined before
approval.

III. Approval of Designed Material

Designed materials that involve the mixture of specific proportions of two or more different
natural, processed or manufactured materials to obtain a modified material giving a set of
desired specific properties. Final approval of designed material is deferred until completion of
the followings:

 Approval of sources for each processed material constituents to be included in the final
mix design.
 Approval of individual processed and manufactured material to be included in final mix
design
 Tentative approval of a laboratory mix design, based on proportioning of aggregate bins
materials and manufactured materials to closely approximate the proportioning of
materials for the laboratory-based mix design.
 Conduct trail section of works using tentatively approved plant mix design and placing
the mixture in accordance with a previously approved construction methodology that
conforms to specifications requirements.

IV. Materials storage and control on site

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The Contractor’s site management arrangements will be submitted to the Engineer for approval
prior to the delivery of any materials to the site. The submission will include the site layout,
handling arrangements and a delivery and draw-down system to record the position of all
materials in the final works.

All materials brought to the site shall be kept free from contact with deleterious matter and
shall be deposited as near as possible to the site of mixing. Aggregates of different sizes and
types shall be stored in different stockpile heaps that are separated from each other by suitable
partitions. Cement shall be stored in a weatherproof godown with proper humidity control and
water proofing arrangements may be acceptable to the Engineer. Gabion wires shall be stored
in a store

3.3.2 Quality Control Tests during Construction

During execution of the work, quality control for ensuring conformance to specification and
workmanship shall be exercised on the basis of tests indicated under, “Field Quality control
Tests During Construction”. The tests shall be carriedout by the contractor independently or
in the presence of employer representative, normally a sub-engineer, when available at site or
where association of the employer representative in test is prescribed. The sub engineer shall
record the result in his own handwriting. The contractor shall be fully responsible for all the
tests carried out for the work. The engineer during during site visit shall have a few tests
carried out in their presence and sign the Quality Control Register.

3.3.2.1 Quality Control of Workmanship

Testing is required to confirm that approved construction materials are correctly mixed, placed
and compacted during the works. Preparatory works for concrete must be checked and
approved at each stage, e.g., reinforcement, formwork, mixing control. In the case of backfill
behind abutments, each layer must be tested and approved before the next is placed, since
failure of an underlying layer will result in rejection of the layers above it. All testing and
approvals must be in writing using standard forms.

3.3.2.2 Quality Control of Works

The prescribed tests, frequencies and the procedure for stage passing by supervisory officer
shall be mandatory and shall form the part of the contract.

I. Random Check

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For the purpose of quality monitoring, only random checks are envisaged. For soils other road
materials being used at site, a representative sample from the borrow pit in use or stockpiled
material can be collected at random, Similarly, while checking placement moisture content
during compaction, a random sample can be collected and its moisture determined using a
Rapid Moisture Meter. For insitu density determinetion by sand replacement method, the
location of the tests can be selected at random. A similar approach can be adopted during
bituminous and cement concrete construction. However, where a compacted section is to be
checked, the entire compacted section should be divided into 10 sections, of equal length. Two
such sub-sections may be selected at random for carrying out the identified tests.

Where random checking has been recommended, the procedure to be adopted for random
checking shall be as follow;

The complete section to be checked shall be divided into ten sub sections of equal length viz.
0-50,50-100,100-150 etc. Of these only two sub sections shall be selected for carrying out tests
by draw of lots.

II. Hand feels tests

For checking the quality of work, generally it may not be possible to carry out the detailed
quality control tests and therefore, for the purpose of quality monitoring simple hand feel tests
can be performed. Normally various simple tests have been used by the experienced engineers
in the field to make a quick assessment of the quality of product. However, these procedures
have not been standardized and involve human judgement. Therefore, these tests which
provide useful guidance for supervisory officer during inspections should by no means be used
as a replacement of the specified quality control tests.

III. Laboratory

Field Laboratory: The Contractor is responsible for establishing a site laboratory for carrying
out quality control tests on his materials and workmanship to demonstrate compliance with the
Specification. Before commencement of the work the corresponding testing facilities must be
available for examples:

 Laboratory must be established and fully equipped

 Laboratory equipment must be calibrated and tested
 Test formats must be prepared
 Laboratory Technician must be employed and trained

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Offsite Laboratory: The tests which are required to be done during the initial stage/before lab
set-up such as those pertaining to suitability of construction materials, selection of quarries to
be carried out before incorporation in the works as part of quality control or as the tests which
cannot be carried out in the field laboratory. The contractor should send request letter to
employer for conduction of the tests in private laboratories, if its reasonable employer
will issue letter to offsite laboratory to conduct prescribed tests.

Test requiring high level of skilled and sophisticated test equipment and those tests which
cannot be conducted in the field will be carried out at the central laboratory of DoR, Pulchowk
Engineering college laboratory and Nepal Bureau of standard and Measuremen

3.3.3 Stage Passing

The engineer shall exercise quality control checks and certify the work of various stage on the
basis of tests and frequencies indicated in the Quality Assurance Plan (QAP). The material
engineer certifying the work at vrious stages as per prescribed shall be responsible for the
quality and quality of the work certified by him.

3.3.4 Acceptance of Tests for Finished Work

All materials required for construction works for which quality test are specified, and for which
approval by the Engineer has been previously given are to be inspected and checked for
acceptability in accordance with the specification requirement. Any of the completed
construction works in which unapproved or untested or unaccepted materials are incorporated
without approval or written permission from the consultant is supposed performed at the
contractor’s risk and is considered unacceptable and unauthorized.

3.3.4.1 Routine Acceptance of Tests

All sample and quality control tests as well as checks tests to verify quality of materials, are to
be conducted by the contractor at his own expenses under the direct supervision of the
consultant. The types of tests and frequency of testing should conform to the minimum Quality
Control Testing Requirements of the Specifications. Testing and sampling shall be in
accordance with relevant IS code.

3.3.4.2 Special Tests

Special tests are generally ordered by the engineer when there is some concern with some
aspect of the routine acceptance tests such as sampling technique, sample contamination, error

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in testing equipment, operator error etc. The engineer will get prior approval of client in issuing
the order of special tests.

The following procedure is generally adopted for special testing

 Identify routine testing concern and request from the material engineer and the senior
residential engineer that a special test required.
 Identify that what/how/where/when the special test is to be conducted (by contractor
within the field laboratory or by external independent testing or by internal independent
testing)
 Obtain approval of the client for making the special test, if needed by contract provision
 Based on the result of the special tests, identify who is responsible for the payment for
this test
 Following implementation of any relevant actions indicated based on the results of the
special tests, records and test results and also include the results as part of the
 “Quality Control Test Statement” to be submitted with and part of the supervision
consultant monthly and quarterly progress Report.

3.4 Non-Compliance and Corrective Measures

It is mandatory to meet quality standard, workmanship and test frequencies of each material
and works. Nonconforming works and material shall be rejected.

The non-conformance refers to not meeting quality standard as per contract requirement. These
may be non-conformance with strength and workmanship.

3.4.1.1 Non-Compliance other than strength

All the tests results will be compared to the standards specified by the Drawings and respective
specifications. Any non-complying result will be immediately informed to the corresponding
site staff and engineer with the approved corrective measures if any. Any suggestion or
instruction from the engineer will be strictly honored.

Return of the request for inspection form signed “not Approved” with the reason for rejection
stated. The contractor is asked for proposal to rectify the non-conformance, which may involve
re-submission of materials, new trails mixes and revised method statement.

The acceptance or rejection of any unapproved work shall be reported to the engineer When
satisfied with the measures taken to ensure future compliance, the engineer shall confirm
approval to continue work for permanent work

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3.4.1.2 Corrective Measures

A detail list of the possible areas of non-compliance of the test results and possible corrective
measures will be prepared and seek the approval of the engineer. When non-compliance
occurs, if it is possible and acceptable to correct, correction will be done in accordance with the
approved correction plan and methodology otherwise it will be rejected.

3.5 Monitoring of Quality Control

The engineer has the authority and responsibility for monitoring the use of the Quality Control
System for ensuring that the above policies are being implemented, and to consider the need
for change.

The contractor is responsible to carry out

 Sampling and testing

 Measurements
 The engineer shall carry out duties
 Decisions
 Certificates
 Order as specified in the contract

The engineer/RE contractual duties are to watch and supervise the works

 Tests and examine materials and workmanship

 Exercise ‘Process control” where ever needed

3.6 Quality Auditing & Reporting

A systematic and an independent examination to determine whether quality activities and
related results comply with planned arrangements are implemented effectively and are suitable
to achieve objectives.

3.6.1 Internal Correspondence

All the test results will be informed to the corresponding site and office staff through site
memo and recorded also. A copy of stepwise working procedure will be given to the site
engineer and supervisor and they will keep it all time with them in the site and strictly follow
it. Any change in the design or of working procedure will be immediately inform to the site
staff and send the change order to the project office.

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3.6.2 External Correspondence

The correspondence to the suppliers/vendors, engineer and other parties will be under this
category. Contractor will prepare and send to the supplier/vendor a specification of the
materials required and we will ask them the factory test certificates for each lot of supply. All
the quality related information or reports will be given as per provision of the contract.

3.6.3 Filing

Filing of data like site instructions from the engineer, material testing reports, factory test
certificates of construction materials (like bitumen, cement, Geotextile, Hume pipes etc.),
quality auditing (internal) reports, joint measurements, change orders, daily records of
materials and resources used etc. will be maintained properly and updated it as required. All
the lab test records as well as factory test certificates of materials will be maintained
systematically in the lab.

3.6.4 Weekly/Monthly Testing Schedule

The contractor shall prepare weekly test plan of material and works, submit to employer and
get approval as per the provision of the contract. Minimum content of the plan shall be planned
date, types of tests, venue (Laboratory or field), responsible person and time. Also include
availability of staffs and testing equipment. Then the tests shall be carried out jointly with lab
technician/IOW.

Weekly test schedule provides a clear picture of what to do and when to do? When the
different activities and their time schedule is previously known, it will be easy to manage all
the resources required for performing these activities, to control the quantity of materials and
works and hence easy to handle.

3.6.5 Material Management Schedule

It will be prepared based on the project schedule. Its use will be for planning the major tests
required for testing the material quality

3.6.6 Short Time Work Program

This will be prepared based on the main project schedule and submitted as per the provision
of the contract. It will be used for regular planning of different lab tests, field tests, manpower
planning etc.

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3.6.7 Tests Statement (Monthly Report)

The list of laboratory test results completed during the month, and the statistical interpretation
are to be included as an integral part of each of the supervision consultant monthly progress
Report to be submitted to client. The contractor shall submit summary of monthly test report
using formats given in Annex-II and Annex-III. The test statement shall include but not
limited the following:

 Item description and type of test

 Number of tests completed, passed and failed
 Analysis of test results and trends
 Remarks, comments based on the trend detected and any corrective action needed.

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 4. CONSTRUCTION METHOD STATEMENT
4.1 Introduction

Method Statement is a descriptive document that explains execution methods and procedures
of individual tasks involved in a construction project, often listed in a project tender. A
method statement explains how the work carried out, involvement of labor & other staffs,
plant & machinery, time required, and output expected. For more clarity of the description,
method statement must contain sketches, small drawings, schemes and flow charts to avoid
misconceptions from both client and contractor.

Method Statement is widely used in the construction industry to control identified quality,
health and safety risks, time and money. Method statements outline the safe way of
performing a specific job or accomplishing a project and ensure that necessary precautions or
control measures are communicated to those involved.

Method statements must be clear and should not be too complicated. They should be easy to
understand by those who carry out the work and their immediate supervisors to avoid any
confusion.

Prior to start of the construction activities at site, the Contractor shall submit to the Engineer
for approval, the detailed method statement. The method statement has two parts:

I. General Part

The general part of the method statement shall describe the Contractor’s proposals regarding
preliminary works, common facilities and other items that require consideration at the early
stage of the contract. The general part shall include information on:

 Sources of materials like coarse aggregates and fine aggregates, quantity and quality
of materials available in different sources.
 Sources of manufactured materials like bitumen, cement, steel reinforcement, pre-
stressing strands and bearings etc. He shall also submit samples/test certificates of
materials for consideration of the Engineer.
 Locations of the site facilities such as batching plant, hot mix plant, crushing plant,
etc.
 Details of facilities available for transportation of men/material and equipment.

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  Information on procedure to be adopted by the Contractor for prevention and
mitigation of negative environmental impact due to construction activities.
 Safety and traffic arrangement during construction.
 Implementation of activities provided in environment management plan.
 Any other information required by the Engineer.

II. Special part

Special part of the method statement shall be submitted to the Engineer by the Contractor for
each important item of work as directed by the Engineer. The statement shall be submitted at
least 4 weeks in advance of the commencement of the activity of item of work unless
otherwise stipulated in the contract. The statement shall give information on:

 Details of the personnel both for execution and quality control of the work;
 Equipment deployment with details of the number of units, capacity, standby
arrangement.
 Sequence of construction and details of temporary or enabling works like diversion,
cofferdam, formwork including specialized formwork for superstructure, details of
borrow areas, method of construction of embankment, sub-grade and pavement, pile
concreting, and products and equipment to be deployed. Wherever required technical
literature, design calculations and drawings shall be included in the method statement.

Method Statement is prepared as a request come from client before execution of the work.
Whatever the situations, each party has to make sure the risk involved in the Method
Statement submitted by contractor. Testing and acceptance procedure including
documentation: Engineer shall examine and approve the method statement with the required
modifications. The modified method statement if required shall be submitted within 14 days
of the receipt of the Engineer’s approval. The sole responsibility for adequacy and safety of
the method adopted by the Contractor shall rest on the Contractor irrespective of any
approval given by the Engineer.

A method statement should fundamentally contain the following key elements:

What work is to be done? - This includes scope, problem statement or description of work,
and equipment and tools to be used.

What are the tasks involved? - List all tasks or processes to finish the work. Also determine
the responsible staff or member for each task.

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 What are the hazards that may cause potential harm to workers? - perform a basic risk
assessment to identify hazards associated with the tasks.

What measures are to be implemented? - determine control and preventive measures

including emergency procedures in place.

Was the method statement validated? - validate the method statement by approving by the
client.

Role of Method statement in a project depends on task that to be executed. Hence the
detailing are varying project to project and task to task. Here, major contents a typical method
statement included shown.

I. Introduction and Scope of work

II. Applicable Project Specification and standard

III. Drawings

IV. Location of activities

V. Operation

VI. Responsibility

VII. Equipment Requirements for execution

VIII. Health and Safety

IX. Inspection and Test Plan

4.2 Order of Sequence of execution of works

The contractor shall take prior approval from employer before the execution of any
work. The contractor shall submit Work Request Form (WRF) as in Annex V with
Working Drawing and Method of Statement to employer for approval at least 2 days
(48 hours) before the construction work starts. Any changes in design and drawing shall
be immediately informed to enginner and employer and start the work only after consent
from employer. All the works deviation from design and constructed without approval of
employer shall be rejected by employer.

The Sequence of construction of main works is presented as follows.

I. Joint Construction survey

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 II. Site Clearance/Tree clearance if any

III. Earth work Excavation for road way

IV. Earthwork for filling in embankment construction

V. Earthwork Excvation for Structure

VI. Gabion and Masonry retaining structure including backfilling

VII. Bio-engineering works after completion of earthwork (June to September)

VIII. Hume pipe and RCC slab culverts including protection works

IX. RCC causeway and river training works

X. Construction of road side drain

XI. Construction of sub grade

XII. Construction of sub base

XIII. Construction of Shoulders

XIV. Construction of base

XV. Prime coat, tack coat and Pavement (Asphalt Concrete, DBST, Premix etc.)

XVI. Concreting Works (PCC/RCC) for Structures, Rigid Pavement.

XVII. Other ancillary works- road furniture, traffic signs etc.

XVIII. Preparation and approval of as built drawing.

XIX. Handover the project

XX. Maintenance of the project

4.3 Method Statement of Works

The overall construction work shall comply with Standard Specification for Road and Bridge
Works with its Ammendments.

4.3.1 Earthwork

4.3.1.1 Earth work in cutting (DoR Specification Section 905)

1 Approval of joint construction survey drawing

2 Find existing survey points and bench marks

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 3 Site clearance, cleaning and grumbling done as specified in section 200 including tree
cutting

4 Establish extreme points at uphill from where excavation starts

5 Excavation with adequate precaution against soil erosion, private property on hillside
and valley side.

6 Suitable excavated material shall be used in filling. Excess material shall be disposed
in environmentally safe point as specified in EMP

7 Slope of side cutting maintained perfectly in line and level as shown in the drawing or
as directed by the engineer. No points on slope shall vary from the designated slopes
by more than 150mm measured at right angle to the slope.

8 Formation level checked and shall be truly in line and level as shown on drawing

9 Joint measurement by taking level of formation level, measuring width of road and
slope ratio and slope length

4.3.1.2 Earth work excavation for foundation (DoR Spec. Section 907)

1 Excavation shall include removal of material for construction of foundation for

gabion work, retaining structure, head wall, cutoff walls, chutes, culverts, causeways
and other similar structures. Excavation will be done as per flow diagram.

2 Finalization of construction spot as specified in drawing

3 Before commencement of the excavation the contractor shall request for works filling
the WRF indicating location of work with typical working drawing and get approval
from the Engineer.

4 Layout for structure as shown in the drawing

5 Site clearance, cleaning and grumbling done as specified in section 200

6 Manual excavation with adequate precaution against wall collapse and slides.

7 Excess material shall be used in backfilling if the quality is better otherwise disposed
in environmentally safe point as specified in EMP

8 Slope of side cutting maintained perfectly vertical where natural soil stands. Where
the nature of soil or the depth of excavation does not permit vertical

9 Excavation the contractor will put necessary shoring and shuttering and planking.

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 10 The depth of excavation shall be as shown in the drawing or as directed by the
engineer. Bottom level checked with reference to Bench marks.

11 Joint measurement

4.3.1.3 E/W for Formation of Embankment (DoR Spec Section 909)

1 Before commencement of the excavation the contractor shall request for works filling
the WRF indicating location of work with joint construction survey drawing and get
approval from the Engineer.

2 The use of any borrow/quarry sites will be chosen by thinking of the stability & safety
of the works. All areas susceptible to erosion will be protected as soon as possible
either by temporary drainage works. Borrows/ quarries will be located away from the
inhabitant's centers, drinking water intakes, cultivable lands and drainage systems.
Permission of the Engineer will be obtained before opening up any borrows pits or
quarries.

3 Clearing Grubbing of embankment site by removing top 15cms organic soil and
stored for covering the embankment slopes if the embankment is not good for
vegetation growth.

4 Setup the boundary of embankment by fixing batter pegs and marking toe lines on
both sides at regular interval as directed by the engineer. The embankment shall be
built 300mm wider on either side of roadway than the specified formation width so
that to get proper compaction of the edge and side slopes after trimming excess width.

5 Removal of top organic soil of borrow pit to the specified depth not exceeding
150mm

6 Foundation for embankment construction after removing top soil shall be prepared as
follow:

 The embankment height less than 1.0 m over natural ground the ground surface
should be loosened up minimum 150 mm by scarifying and compacted to the
specified density
 For embankment less than 0.50 meter over an existing blacktop or gravel surface
the black topping shall be removed and the pavement/gravel surface should be

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 scarified to a minimum depth of 150mm. All particles shall be reduced to a
minimum size of 75mm and compacted accordingly.
 If the granular/blacktop lies within 0.50 to 1.0meter of the new subgrade level, the
same should be scarified to a depth of 50mm for achieving bond between old and
new material

7 The size of the coarse material in the mixture of earth used for embankment
construction should not exceed 75mm

8 The soil should be spread n line and level over the entire width of the embankment in
layers not exceeding 150 mm compacted thicknesses. Each layer is thoroughly
compacted by roller at moisture content within (±2%) of OMC.

9 Each layer below 500mm should be compacted to at least 93% of MDD. The top
500mm depth of the embankment constituting the subgrade should be compacted to
95% of modified Proctor density.

10 Ensure the longitudinal and cross profile should be in conformity with the approved
drawing.

11 Approval (surface level and compaction control tests) of each layer from the engineer
should be obtained for each finished layer. Subsequent layers shall be placed only
after the finished layer has been tested and accepted by engineer.

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4.3.2 Construction of Structures

Construction
Figure 4.1 Flow Chart of Construction of
of Structures Structure –Flow Chart

Approval of Working Drawing/ WRF

Setting out/Excavation

Contractor’s Representative Check line, level Engineer’s Representative

NO
Line
Level

YES

Foundation Excavation

Contractor’s Representative Check

Foundation Engineer’s Representative
Level

Rectify

NO Check for
Line, level
as per Drg.

YES
Send Approved Quality

NO Approval
of Quality Engineer’s Representative
Contractor’s Representative of material

YES

Commencement of
Construction Work

Contractor’s Engineer’s
Representative Control of Quality/Workmanship Representative
Test Sample preparation YES

Match line A

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4.3.2.1 Gabion Work (DoR Specification Section 2400)

1 Tool and Equpments: Gabion boxes and binding wire pick axe, showel, thread, geo
textile, compactor, stones, pliers etc.

2 Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical construction drawing and get approval
from the Engineer.

3 Approval of material e.g. stone, gabion wire as well as mesh

4 Mesh weaving mesh type 100x120mm, meshwire-10 SWG, Selvage wire 8 SWG and
binding wire 12 SWG heavy zinc coated

5 Construction and approval of demo block of gabion and get approval.

6 Layout of wall perfectly as shown in drawing or as directed by the engineer

7 Excavation of foundation as specified in Section 4.3.1

8 Assembling of gabion boxes by installing diaphragm, spiral lacing of selvedges

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 9 Laying of gabion boxes on prepared foundation in line and level and binding of
adjacent gabion box.

10 Laying of stone in gabion boxes in equal three layers

11 Erection of bracing from both direction at a distance of 0.33meter interval

12 Tying down the lids and spiral binding with 10SWG wire.

13 Placing another layer of gabion box with vertical joint staggered as shown in layer
plan and tying of gabions with binding wire from bottom, and sides of adjacent boxes

14 Same process will be repeated for another successive layer of gabion

15 Checking by engineer and Joint measurement

16 Laying of geo-textile and back filling with compaction (15cms each) and Compaction
tests of backfill material each layer (15cms each).

4.3.2.2 Stone Masonry Wall (DoR Spec Section 2600)

1. Tools and equipment: Concrete mixer, batching boxes, cube moulds, pick axe, trowel,
mason hammer, head pan, 5 Kg hammer, thread, compactor, stones.

2. Material approval (stone, sand, cement, aggregate)

3. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical working drawing prepared after site
verification and get approval from the Engineer.

4. Layout of wall with respect to approved working drawing

5. Foundation excavation mechanically and manually. If the depth is adequate check,

width, cross slope and foundation level with reference to the drawing

6. Fixation of thread/wooden template equivalent to the cross section of proposed wall

7. Laying of stone soling filling of voids if provided

8. Erection of formwork for edge for placing concrete

9. Lean concrete laying to required thickness and grade as shown in the drawing

10. Laying of masonry work to line, level and dimension as shown in the drawing after
getting approval from the engineer. The stone shall be laid on their natural bed in

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 horizontal course keeping height of each stone same, fine tooled on all bed, joints and
faces, full and true.

11. Lay outer layers of masonry first, fix the location of headers and bond stones and lay
them.

12. Prepare sample of mortar cube of 70.5X70.5x70.5 mm 6 nos for each 10 cum of
masonry work

13. Lay all stones, full with mortar both in bed and vertical joints and settled fully in
place with a wooden mallet, immediately on placement and solidity embedded in
mortar before it has set.

14. Clean and wet chips and spalls can be used whenever necessary to avoid thick joints
or bed of mortar. Ensure that no hollow spaces are left anywhere in masonry. Chips
and spalls shall be used in the interstice between the adjacent stones in hearting only
and shall not be more than 20% of the quantity of masonry.

15. Provision of weep hole of HDPE Pipe 100 mm dia as shown in the drawing

16. Make vertical joints truly vertical and staggered as far as possible. Finish top level of
wall by checking design level as shown in the drawing.

17. Cube test in laboratory jointly

18. Request for Field Inspection (RFI) and get approval from engineer

19. Joint measurement

20. Backfilling in layers and compaction up to 95% of MDD

4.3.2.3 Plum concrete (DoR Spec Section 2400)

The use of aggregate as a filter can be extended by using of stone of 150-300 mm size in a
normal concrete. The resulting concrete is termed as “Plum Concrete”. The large stones are
called plum and used in large concrete mass. The volume of plum should not exceed 30-40%
of the total volume of the finished concrete.

The length of stone shall not exceed 3 times its height. The water cement ratio shall be
adjusted at site to maintain good flow of concrete to fill the voids properly. The plums are
laid in layers using concrete as mortar. All plums shall be hard, durable, clean and free from
soft materials or loose pieces or deleterious substance and shall not have sharp corners.

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1. Material, tools and equipment- Concrete mixer, batching boxes, vibrator, cube moulds
150x150x150 mm, pick axe, trowel, mason hammer, head pan/wheel barrow, 5 Kg
hammer, thread, soil compactor,

2. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical construction drawing and get approval
from the Engineer.

3. Excavation of foundation is as described in Paragraph 4.3.1 (b)

4. Formwork shall be placed in position and approved before placing plum concrete. The
formwork shall be according to Section 4.3.4 of this methodology.

5. Provide at least 10-15 cms of concrete on the bed foundation as levelling course

6. Plum shall be washed and all dripping surface water removed before being embedded
in the concrete.

7. Lay the plum on the laid concrete approximately covering 30-40% of the volume of
concrete used for each layer. No stone shall be closer than 10 cm to an exposed
surface nor nearer than 10 cm to an adjacent stone.

8. Place the concrete to fill half height of the plum throughout the layer.

9. Prepare cube moulds of 150x150x150 mm 6 nos for each 20 cum of concrete.

10. Place another layer of plum in scatter position and fill the concrete to the half-height
of the newly laid plum.

11. Compaction is carried out in each layer of concrete with the help of vibrator.

12. The stones shall not be dropped in place, but each stone shall be laid and carefully
embedded so as to avoid any injury to the form or adjacent masonry and in such a
manner that no planes of weakness of unnecessary joins occurs in the structure.

13. Concrete shall be deposited in shallow layer and at such rate as to maintain, until the
completion of the unit, a plastic surface approximately horizontal throughout.

14. Each layer shall be thoroughly compacted before placing the successive layer. These
plums shall remain half embedded in the concrete and the other half exposed so as to
form a key with the next layer of concrete. No plums shall be used for concrete which
is laid under water.

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 15. Weep holes shall be provided by HDPE pipe. The end of the weep holes on the sides
shall be covered by geo-membrane and filled by gravels of size 40mm

16. All plum concrete/plum masonry shall be thoroughly wet for at least 7 days.

17. Joint Measurement

18. Backfilling in layers and compaction up to 95% of MDD

19. Cube test in the laboratory

4.3.2.4 Road side drain

There are two types of drain in the contract i.e. trapezoidal and tick type. The section of drain
is small so great care shall be taken during construction.

1. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical working drawing prepared after site
verification and get approval from the Engineer.

2. Layout of drain alignment with respect to approved working drawing.

3. Foundation excavation manually exactly in longitudinal level.

4. Fixation of thread/wooden template equivalent to the cross section of proposed drain

5. Laying of stone soling filling of voids if provided

6. Lean concrete laying to required thickness and grade as shown in the drawing

7. Laying of masonry work to line, level and dimension as shown in the drawing after
getting approval from the engineer. The stone shall be laid on their natural bed in
horizontal course keeping height of each stone same, fine tooled on all bed, joints and
faces, full and true.

8. Prepare sample of mortar cube of 70.5X70.5x70.5 mm 6 nos for each 10 cum of

masonry work or part of it.

9. Prepare sample of mortar cube of 150X150x150 mm 6 nos for each 20 cum of

Concrete work or part of it.

10. Finish top level of wall by checking design level as shown in the drawing.

11. Cube test in laboratory jointly

12. Joint measurement

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4.3.2.5 PCC and RCC work (DoR Spec Section 2000)

1. Material, tools and equipment- Concrete mixer, batching boxes, vibrator cube
moulds 150x150x150 mm, head pan/wheel barrow

2. Before commencement of the concrete work the contractor shall request for works
filling the WRF indicating location of work along with Concrete Pouring Card with
typical construction drawing of the member and get approval from the Engineer.

3. Reinforcement and formwork shall be approved beforehand.

4. Choose of concrete grade as shown in the drawing or as directed by the engineer

5. Concrete is mixed using mechanical mixer of one bag capacity. Avoid hand mixing of
concrete for the use in structural concrete except for isolated culvert up to 2 meter in
remote areas. Add 10% extra cement for such situation.

6. Concrete is batched with the use of batching box of 1 bag capacity.

7. After mixing, transport green concrete to formwork as quickly as possible in wheel

barrow to site.

8. Proceed with concreting contentiously, over the area between constructions joint.
Deposit concrete in horizontal layer to a compacted depth of not more than 450mm
when internal vibrator are used and not more than 300mm in other cases

9. Choose appropriate method of placing of concrete so as to avoid segregation.

10. Care should be taken to maintain cover and to avoid displacement of reinforcement or
movement of formwork. Free fall of concrete should not more than 1.0 meter

11. Compact concrete with needle vibrator for deep member and plate compactor for slab
in combination with needle vibrator. Compaction shall be complete before 30 min of
mixing.

12. Before concreting fix a stopping board at predetermined position for vertical joint
which has adequate lateral rigidity to withstand lateral displacement of bulging during
concreting.

13. Prepare cube moulds of 150x150x150 mm 6 nos for each 10 cum of concrete work or
part of it.

14. Joint measurement.

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4.3.2.6 RCC Hume Pipe culverts (DoR Spec Section 2400)

1. Tools anf Equipments: Chain pulley, concrete mixer, rope, mortar cube mould,
batching boxes.

2. Material approval (NP3 RCC Hume pipe, stone, sand, cement, aggregate)

3. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical construction drawing and get approval
from the Engineer.

4. Layout of individual components of the culvert in accordance with drawing.

5. Excavation for foundation for head wall in line and level as shown in the drawing.

6. Construction of bedding for pipe as shown in the drawing

7. Lower the pipe in bed either by pulley or by manual labor using chain pulley blocks.
When two or more pipes are laid adjacent to each other place them separated by
500mm or half diameter of the pipe and the longitudinal slope 1:20

8. While constructing head wall, first construct the wall up to the bottom level of pipe
(invert level), place the pipe in position and fill the pipe with suitable materials up to
the road level compact the material as required and construct the remaining part of the
wall.

9. The pipes are jointed either by collar or by flush joint. Fill the joint space with 1:2
cement mortars, which remain in position when forced with a trowel or rammer.

10. All joints made with care so that their interior surface is smooth and consistent with
the interior surface of the pipe. After finishing the joints are covered with wet jute at
least for four days.

11. Joint measurement before back filling

12. Back fill trenches after the pipes have been laid after jointing material has hardened.
On top of pipe up to 300mm thoroughly ram, tamp or vibrate the soil in two layers.
Carry out filling of the trench simultaneously on both sides of the pipe, such that
unequal pressure does not occur.

13. Provide minimum cushion of 600mm or diameter of pipe whichever is greater by

filling with the suitable material over the pipe after its laying.

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 14. The construction of apron and other protection works are carried out as shown in the
drawing.

4.3.2.7 Slab Culverts

Foundation

1. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical construction drawing and get approval
from the Engineer.

2. Approval of working drawing

3. Setout plan dimension of the foundation at the bottom of foundation trench and check
with respect to original reference line axis

4. Excavation for foundation for abutment in line and level as shown in the drawing.
Ensure embedment of foundation into the rock below the minimum depth of 500 mm
for hard rock and 1200mm for soft rock or as specified in the drawing. Provide
300mm thick M15 grade concrete footing, unless otherwise specified on the drawing.
Provide minimum 150mm for the base of structure.

5. Before laying foundation concrete check RL of bottom level. Provide side formwork
as per requirement and mark top level of concrete bed. Prepare Concrete cube
150x150x150mm

6. Lay concrete contentiously with compaction to the top level as already marked. Finish
the concrete level smooth with wooden batten

7. Carry dewatering where necessary for laying concrete so as to keep the water level
below foundation level with adequate precaution.

Sub structure

This part covers abutment, wing wall return wall abutment cap RCC dirt walls. Abutment
may be of masonry, plum, Brick or RCC.

1. Setting out of abutment and wing wall over concrete bed as shown on the drawing.
Make threaded or wooden frame/template equivalent to the section of abutment or
wing wall.

2. Lay masonry/brick work within the template. Make provision of weep holes.

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 3. Masonry work shall be done as described in Section 4.3.2.2 up to abutment cap level
and wing wall at slab top level.

4. Make provision of vertical expansion joints between abutment and wing walls.

5. Provide abutment RCC cap and dirt wall

6. Take measurement of foundation and sub- structure before back filling.

7. Back filling of behind abutment and wing wall with compaction up to desirable
height.

Super structure

1. Approval of Re- bar Schedule and temporary works

2. Approve concrete pouring card

3. Setout dimensions, line and level and check with respect to permanent line and
permanent bench marks.

4. Erect form works as described in Section 4.3.4 and get approval

5. Prepare and mix concrete as described in Section 4.3.2.5

6. Cast whole slab with reinforcement embedded for kerb and railing post.

7. Sampling of Concrete cubes for 7and 28 days test.

8. Provide wearing course after the slab has been casted

9. Curing by ponding for 7 days

10. Construction of other ancillary works, appurtenances as specified in the drawing

4.3.2.8 RCC Flush Causeway

1. Choose flush causeway to cross shallow water course.

2. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical construction drawing and get approval
from the Engineer.

3. Layout of causeway head walls as shown in the drawing.

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 4. Excavate foundation for upstream and downstream cut-off walls; keep it sufficiently
deep to avoid exposure to scouring in line and level as shown in the drawing.

5. Keep top level of causeway same as that of bed of water course

6. Build cutoff walls in masonry work as described in Section 4.3.2.2 or gabion as

described in Section 4.3.2.1

7. Carry subgrade preparation in exact line, level and profile as shown in the drawing

8. Carryout stone soling over sand bed, in perfect line and level

9. Divide whole length of causeway in to panel as shown in the drawing. Erect

formwork and planks to separate each panel

10. Erect reinforcement as shown in the drawing

11. Encase dowel bars by HDPE pipes and place as shown in the drawing or as directed
by the engineer.

12. Place machine mixed concrete and compact as described in Section 4.3.2.5. Prepare
sample of concrete for tests

13. Providing US and DS protection work

14. Provide guidepost as required

4.3.2.9 RCC Vented Causeway

1. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical construction drawing and get approval
from the Engineer.

2. Approval of material

3. Layout of individual components of the causeway in accordance with drawing.

4. Excavate foundation for upstream and downstream cut-off walls; keep it sufficiently
deep to avoid exposure to scouring.

5. While constructing head wall, first construct the wall up to the bottom level of pipe
(invert level), place the pipe in position and fill the pipe with suitable materials up to
the crown level compact the material as required and construct the remaining part of
the wall.

46 | P a g e
 6. The pipes are jointed either by collar or by flush joint. Fill the joint space with 1:2
cement mortar, which remain in position when forced with a trowel or rammer.

7. All joints made with care so that their interior surface is smooth and consistent with
the interior surface of the pipe. After finishing the joints are covered with wet jute.

8. Carry bed preparation in exact line, level and profile as shown in the drawing

9. Carryout stone soling over sand bed, in perfect line and level

10. Divide whole length of causeway in to panel of 4 meter as shown in the drawing.
Erect side formwork and planks to separate each panel

11. Erect reinforcement as shown in the drawing

12. Encase dowel bars by HDPE pipes and place as shown in the drawing or as directed
by the engineer.

13. Place machine mixed concrete and compact as described in Section 4.3.2.5

14. Provide 150mm thick M20 Concrete slab with a cross slope of 5% toward
downstream side of deck slab or as shown in the drawing. In the same time prepare
sample of six moulds for tests

15. Discontinue wearing coat at expansion joint locations. Expand joint filler up to the top
of wearing coat.

16. Batter the downstream side of headwall on the outside and round the corner

17. Raise end portion of the faces wall and protect entire top of causeway by desirable
non-erodible wearing coat.

18. For cement concrete wearing course provide 8mm dia bars@200mm c/c reducing to
100mm in both direction over the strip length of 300mm near the expansion joint or as
per design

19. Use open type filler joint with appropriate nose protection

4.3.3 Steel Reinforcement (DOR Specification 2014)

1. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with approval of formwork

2. Submit typical bar bending schedule and get approval from the Engineer for cutting
and placing of reinforcement.

47 | P a g e
 3. Straighten the bars which get bend during transportation or handling. And cutting as
shown in the drawing.

4. Place reinforcement bars accurately in position as shown on drawing. Make the

skeleton of reinforcement rigid by tying all bars crossing one over another at every
intersection using annealed binding wire not less than 1mm diameter.

5. Position the bars on cover blocks of required thickness to provide cover to

reinforcement.

6. Position the vertical projected reinforcement from sub-structure by means of timber,

steel pipe with slot cuts in them accurately or with blocks tied to the reinforcement.

7. Separate layers of reinforcement by spacer or chair bars at a maximum length of 1

meter.

8. All construction joints bend aside reinforcing bars and bend back to the original
position, by ensuring that concrete around the bars is not damaged beyond the bend.

9. Stagger the lapped splices and located at point along span where stress are low.

10. Lap length shall be 65 times diameter in tension and 45 times diameter in
compression or as shown in the drawing.

11. Checked by engineer and get approval for concreting

12. Joint measurement before concreting.

4.3.4 Form works (DOR Specification 1800)

1. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical erection drawing and get approval from
the Engineer.

2. Examine all materials and component used for formwork, for damage of excessive
deterioration before use and reuse only if found suitable after repair. Preparation and
stockpiling of prepared forms adjacent to sites so as to protect with damp, water
excess heat etc.

3. Use familiar material such as plywood, steel, concrete and masonry for false work.
For metal forms, the thickness should be adequate to keep them true to shape. Use
counter sunk bolts and permit use of approved internal steel ties or plastic spacers.

48 | P a g e
 4. Bamboo props shall not be provided.

5. Ensure false work is designed to meet the requirements of permanent structure

including ease of erection and dismantling and is approved by the engineer.

6. Provide proper and safe access to all parts of formwork for inspection

7. Make formwork robust and use bellies of 100 mm dia. of height not more than 4m
provide cross and diagonal bracing of 75mm dia. ballies in both directions. For metal
forms, the diagonal bracing shall be of the same size of angles used for column.

8. Check for design deficiencies such as shoring or re shoring, insufficient allowance for
unsymmetrical or eccentric loading due to placement sequence of concrete.

9. In case of falsework erected on normal ground, ensure distribution of loading to the

ground through timber or base plates to avoid differential settlement.

Preparation before concreting

1. Make the formwork sufficiently tight and rigid by the use of ties and bracings to
prevent any displacement or sagging between the supports.

2. Apply thin coat of form oil inside surface of the formwork

3. Check line level rigidity depression of slab

4. Make the formwork leak proof to prevent escape of cement slurry during compaction

5. Make ensure that the formwork does not hinder the shrinkage of concrete.

Removal of formwork

Removal of form work depends upon the nature of structure, climate and other condition.
Lower the centering gradually and uniformly to avoid shock and vibration so as to permit the
concrete to take self-weight. Formwork shall be removed as directed by the engineer or as
described below.

Table 4.1 Removal Time of formwork

SN Types of Members Nos of days

1 Wall, abutment, sides of slab, vertical faces of structure 1-2 days

2 Soffits of slab 3 days

3 Props under slab 14 days

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 4 Props under girder 21 days

5 Soffits of girder 7 days

4.3.5 Pavement
Figure 4.2 Flow Diagram of Construction of Pavement Layer

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4.3.5.1 Sub-Grade (DoR Specification section-1200)

The subgrade is top 500 mm compacted layers in embankment or cutting just beneath the
pavement crust. The subgrade in embankment is compacted to a higher standard than the
lower layers of the embankment. In cutting the cut formation which serves as the subgrade, is
treated similarly to achieve the specified density to provide a suitable foundation for the
pavement.

Equipment

 Vibrating roller
 Water browser
 Motor grader
 Level machine
 FD measurement apparatus

Construction Methodology

1. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical working drawing and get approval from
the Engineer.

2. Ensure the soil of subgrade meets the specified requirement in term of physical
properties and the specify CBR value for pavement design.

3. If the subgrade soil does not possess the engineering properties like high plastic black
cotton soil and other weak soil yielding very low soaked CBR values, the same should
be improved in CBR and workability by replacing suitable material having high CBR
value as instructed by the engineer.

4. For a road in cutting, prepare the subgrade in accordance with excavation of roadway
formation.

5. Prepared the subgrade in the perfect level and camber with the help of grader and
existing potholes are properly repaired

6. If the surface is gravel, the surface is loosened to a depth of 200mm cambered

perfectly.

7. Sprinkling with water to OMC and compaction by roller at OMC (± 2%) to at least
95% MDD.

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 8. Rolling is carried out longitudinally from outer edge proceeding toward center at
straight portion of road. In case of curve rolling is carried out from lower level edge
toward upper level edge (outer edge) by moving roller parallel to centerline of road

9. Sub-base course shall be laid after obtaining approval from the engineer for subgrade.
Such approval would require surface level data and compaction control test data.

4.3.5.2 Sub- base (DoR Specification section-1200)

Equipment

 Vibrating roller
 Water browser
 Motor grader
 Trippers
 Loader
 FD measurement apparatus
 Wheel barrow or hand tractor
 Level machine

Construction Methodology

1. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical erection drawing and get approval of
subgrade layer from the Engineer.

2. Selection of the sources of material for the sub- base courses. Approval of sources by
the Engineer.

3. If the material is the combination from different approved sources, mechanical mixing
properly done at stock pile yard.

4. Conformity tests which will be carried out from stockpile material as specified in
QAP

5. Fixation of width and depth of laying of sub base with respect to centerline by driving
pegs on both side of the road.

6. Before laying of subbase material remove extraneous material from the prepared sub-
grade, repair any defects on prepared subgrade, lightly sprinkle with water and roll
with 2-3 passes of 80-100 KN road roller.

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 7. The subbase material spread in layer by motor grader not more than 150mm
compacted

8. If the total thickness is more than 150mm successive layer shall be laid after obtaining
approval from the engineer for previous layer. Such approval would require surface
level data and compaction control test data.

9. Compaction will be done at OMC at a tolerance limit of ±2%. OMC shall be

maintained by spiking water and thoroughly mixing for uniform wetting.

10. Rolling is carried out longitudinally from outer edge proceeding toward center at
straight portion of road.

11. In case of curve rolling is carried out from lower level edge toward upper level edge
(outer edge) by moving roller parallel to centerline of road.

12. Shoulder shall be constructed simultaneously with subbase construction.

13. Density test as specified in specification section 1200 and QAP

14. Joint measurement/ Final level checking with level machine

4.3.5.3 Base course (DoR Specification section-1200)

Equipment

 Vibrating roller
 Water browser
 Motor grader
 Trippers
 Loader
 Wheel barrow or hand tractor
 Level machine
 FD measurement apparatus

Construction Methodology

1. Selection of the sources of material for the base course and approval of sources by the
Engineer

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2. Before commencement of the work the contractor shall request for works filling the
WRF indicating location of work with typical erection drawing and get approval of
base layer from the Engineer.

3. Confirmatory tests of material from stockpiling at project site.

4. Wet mixing at stock pile and transportation to road side.

5. All ruts, deformations, soft spots should be repaired and the surface compacted to
required density before placing base there of

6. Marking by driving pegs on either side of road edge, then the aggregate uniformly
deposited on the prepared surface, spread over the surface covering full width of
carriage way to specified depth not more than 150mm.

7. After spreading the material should be mixed by grading to full depth. By grading
bring the material from edge to the center forming windows. Spray the window with
water if required.

8. Stone dust must be available at stock at road side to add when segregation occurred.

9. The window is spread back the road depositing all the material to give the correct
camber

10. A second application of water may be required to obtain the correct to obtain the
correct moisture content for compaction.

11. The layer compacted with the use of vibrating roller to 98% dry density.

12. The compacted thickness of any layer laid, processed and compacted at a time should
not be more than 150mm where greater thickness is required the graded crushed stone
shall be laid in two layers or more.

13. Successive layers shall be laid only after the approval of the previous layer by the
engineer. The approval shall be level data and compaction of such layer.

14. Finally, surface is finished by rolling with steel tire static roller.

15. The hole made for field density test shall be filled with M15 concrete with
compaction.

16. Joint measurement by taking level at finished surface.

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4.3.5.4 Asphalt Concrete (DoR Specification section-1300) Commented [u2]: Premix and DBST Add

This work shall consist of mixing graded aggregate and bitumen binder in a central asphalt
batching plant, transporting, spreading and compacting the mixture (asphalt) on a primed
base course, existing bituminous or concrete surface.

Figure 4.3 Flow Chart of Laying of Asphalt Concrete

Method of statement is stated hereunder.

Equipment

 Asphalt Batching Plant-One

 Tendon roller-One

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  Pneumatic roller-One
 Self-propelled mechanical paver-one
 Thermometer-2 Nos
 Tripper with cover- as required depending upon production rate
 Bitumen distributor (with deep rod, tray)-One
 Electronic Balance-One
 Containers for sample collection-12 Nos for each day
 Level machine

Construction Methodology

1. Installation of Asphalt concrete plant in a selected area

2. Source approval for coarse aggregates, fine aggregate and filler material as specified
in Technical Specification and QAP

3. Marshal stability test and determination of bitumen content.

4. Traffic diversion and traffic management

5. Cleaning of surface, dust removal and get approval from the engineer before
application of tack coat and apply tack coat over prepared base course using bitumen
distributor.

6. Preparation of asphalt concrete in a batching plant of adequate capacity by ensuring

manufacturing and rolling temperature.

7. For VG-30 Bitumen, Aggregate is heated in between 1500 to 1700C, bitumen

temperature 1500-1650 C and mix material temperature 1500-1650 C.

8. Transportation of hot mixed asphalt quickly and laying of mix in within the minimum
temperature of 1400C a specified thickness by means of approved self-propelled
mechanical paver in perfect camber

9. Initial rolling is done in a minimum temperature of 900 C with tendon roller,

beginning from the edge and proceeding toward center longitudinally.

10. Intermediate rolling with pneumatic roller. This should be followed by rolling while
the material is still workable. Rolling shall be continued until the voids measured in

56 | P a g e
 the compacted layer are within the range of 2-4% and average density after
compaction shall be not less than 98%.

11. Any high spots or depressions noticed after the roller has passed over the whole area
once should be corrected by removing or adding premixed material. Rolling should be
recommencing thereafter. Each pass should have an overlap of at least one third of the
track made in the preceding pass

12. For single lane no longitudinal joint provided, while double lane road longitudinal
joints may be required depending on the paver width.

13. Straight edge is used to check the cross fall regularly.

14. Joint cut is performed vertically and tacking is applied thoroughly before laying the
AC mix

15. Traffic management is carried out as above.

16. Core cutting and joint measurement for the pavement

4.3.6 Other Ancillary works

Sub surface drain

 Prepare and make approval of the drawing
 Transportation of approved material (perforated pipes, filter material, Geo-textile) etc
to the site.
 Layout of the system at site.
 Approval of the section by the Engineer.
 Construction of section in sequence as shown in the approved drawing.
 Conduct flushing test for any blockage.
 Approval of the completed section
 Joint measurement.

4.3.7 Road Maintenance (DoR Specification section-2900)

 Assignment of length man with tools and other accessories as required.

 Arrangement of Flags, Traffic Cones, etc for complete safety.
 Supervision supervisor.
 Joint Record for the payment

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Annexes

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ANNEX- I
CV

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 ANNEX- II
Materials Delivery & Testing Summary Sheet

60 | P a g e
 Book -1 Annex-II

Materials Delivery & Testing Summary Sheet

Contract No. ………………

Contractor’ name-

Period: -----------------------to -------------

Name of the Road-

a. Coarse Aggregate /Fine Aggregate

Test Result Frequency
Cumulative Test

Date Source Name Quantity Unit Test parameter Remarks

Quantity No Specified Actual Specified Actual

Gradation

Crushing strength

Flakiness

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…………

……………..

…………….

…………..

………………

62 | P a g e
 Materials Delivery & Testing Summary Sheet
Contract No. ………………
Annex-II
Contractor’ name-

Period: -----------------------to -------------

Name of the Road-

b. Cement
Test Result Frequency
Cumulative Test

Date Brand Name Quantity Unit Test parameter Remarks

Quantity No Specified Actual Specified Actual

Setting Time

Compressive strength

……………

…………………

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…………….

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 Annex-II
Materials Delivery & Testing Summary Sheet
Contract No. ………………

Contractor’ name-

Period: -----------------------to -------------

Name of the Road-

c. Reinforcement Steel
Test Result Cumulative Frequency
Cumulative Test

Date Brand Name Lot No Dia.mm Quantity Unit Test parameter Remarks

Quantity No Specified Actual Specified Actual

DoR Lab
Elongation

Tensile strength

Bend rebend

………….

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………………

……….

66 | P a g e
 Annex-II
Materials Delivery & Testing Summary Sheet
Contract No. ………………

Contractor’ name-

Period: -----------------------to -------------

Name of the Road-

d. Gabion Wire
Test Result Cumulative Frequency
Cumulative Test

Date Brand Name Lot No Dia.mm Quantity Unit Test parameter Remarks

Quantity No Specified Actual Specified Actual

DoR Lab
Mass of zinc

Tensile strength

Adhesion

diameter

67 | P a g e
……….

……………

…………

……………….

68 | P a g e
 Annex-II
Materials Delivery & Testing Summary Sheet
Contract No. ………………

Contractor’ name-

Period: -----------------------to -------------

Name of the Road-

e. Sub-base Material
Test Result Frequency
Cumulative Test

Date Brand Name Quantity Unit Test parameter Remarks

Quantity No Specified Actual Specified Actual

Gradation

CBR

Plasticity Index

Crushing Ratio

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FI

PI

……………………..

……………………..

……………………..

70 | P a g e
 Annex-II
Materials Delivery & Testing Summary Sheet
Contract No. ………………

Contractor’ name-

Period: -----------------------to -------------

Name of the Road-

f. Base Material
Test Result Frequency
Cumulative Test

Date Brand Name Quantity Unit Test parameter Remarks

Quantity No Specified Actual Specified Actual

Gradation

CBR

Plasticity Index

Crushing Ratio

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FI

AIV

Crushing Ratio (min)

LAA

PI

…….

……….

…………..

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 ANNEX- III
TEST RESULT SUMMARY SHEET

73 | P a g e
 Book-2
SOIL COMPACTION TEST SUMMARY SHEET Annex-III
Contract No. ………………

Period: -----------------------to -------------

Road Formation/Behind Structure:

GPS Coordinate of
Hole Test Results

Embankment Depth
MDD FDD
Location in the or below Relative
Date of Test In- situ dry In- situ dry
Remark
works Back filling surface X Y OMC Compaction s
density density

(m) (gm/cm3) (gm/m3) (%)

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 COMPACTION TEST SUMMARY SHEET FOR SUB-BASE, BASE

Contract No. Annex-III

Period: -----------------------to -------------

Component: Base/Sub-base

GPS Coordinate of Hole Test Results

MDD
FDD
Depth
Location in the below In- situ Relative
Date of Test In- situ field
surface
Road (cm) X Y OMC maximum Compaction Remarks
density
dry density (%)
(gm/m3)
(gm/cm3)

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 MORTAR/CONCRETE TEST CUBE SUMMARY SHEET

(To be kept in a book)

Annex-III

Contract No. ………………. Road No……. Concrete Grade…………… Batching …………… Cement Brand……….

Source of Coarse Aggregate……………… Source of Fines aggregate…………………

……….. day
results
Request Specified Remarks
Slump Compliance
Form Date of Cast Structure Name Location Strength Test Compressive (Follow-up
(mm) Cube Age Density Test (Y/N)
No. MPa Certificate Date of Test Strength action)
Mark (days) (N/mm2 Result
No. (N/mm2)

76 | P a g e
 ANNEX- IV
LIST OF TESTS AND THEIR FREQUENCIES

77 | P a g e
 Table-1 Recapitulative Test Schedule and Frequencies

Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

1 Cement Initial-45 min

Setting Time 200 Ton or part of it 3352.00 17 IS 4031 Part 5 Vicat apparatus Field Lab SLT

(SS DoR-614) Final-600 min

Fineness >225 sqm/kg 200 Ton or part of it 17 IS 4031 Part 2 Blaine’s apparatus Field Lab SLT

Soundness <10mm 200 Ton or part of it 17 IS 4031 Part3 Vicat apparatus Field Lab SLT

Comp. Strength -7days 22 N/mm2 200 Ton or part of it 17 IS 4031 Part 6 Cube crushing machine Field Lab SLT

Comp. Strength-28 days 33 N/mm2 200 Ton or part of it 17 IS 4031 Part 6 Cube crushing machine Field Lab SLT

Table -6.5 SS 1 set (3nos) for 10-50 cum

2 Sand DOR / Table-1 and

78 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

(SS DoR-613)

Gradation additional 1 test for 9369.00 312 Sieves, balance, trays Field Lab SLT

IS 2116 (1980) IS 2386 Part 1

50 cum of mortar

1 set (3nos) for 10-50 cum

and

Measuring cylinder,
Clay/Mica content <2% additional 1 test for 312 IS 2386 Part 2 Field Lab SLT
Balance

50 cum of mortar

Stone
3 (SS DOR – 2602)
3 sets of tests per IS 2210 Balance, oven, desiccator,

Water absorption <5% 15 Field Lab SLT

source IS 2386 Part 3 glass vessel

79 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Pycnometer, balance,
3 sets of tests per

Specific Gravity >2.5 15 IS 1124 basket, Immersing bucket, Field Lab SLT

source
oven

1 set for 1-5 cum

2 set for 5- 15 cum
3 set for 15-30 cum
4 set for 30-50 cum Cube mould 150x150x150
Cement
Concrete (SS Table 20.3 SS For more than 50cum, 4 set of
DOR – 2000) DOR samples plus one additional
Crushing Machine
for each 50 cum or part
4 Compressive Strength Section -2000 thereof. 3524.00 453 IS 456 Field Lab SLT

Tamping Rod

80 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Cube mould
Cement Mortar
5 (SS DOR-2511) Compressive Strength 5.0-7.5MPa 1 set for 10 m3 or part of it 14868.00 1487 IS 2250-1981 70.5x70.5x70.5 Field Lab SLT

crushing machine

6 RCC Hume 900-512.5

3 edge Hydraulic testing
pipe- NP3 (SS
DOR- 701) Three edge bearing 600- 17.50 NS-80 :2045 Factory OST
machine

450-15
NS-80 :2045;
Dimension & Table 7.1 and
Reinforcementa 7.2 of DOR SS NS-80 :2045 Measuring Tape, Vernier Factory

3 from each

7 Water Quality as required IS 456 Chemical Test Field Lab SLT

source

8 GI wire Diameter (Gauge) Tolerance 2.5% Table- 24.3 5350 coil Tab- 24.3 NS 163/169- Gauge meter/Vernier DoR central OST

81 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

(SS-DOR 2400)

Section 2400 Sec. 2400 2045 lab

HCL acid, Antimony

Table- 24.3 Tab- 24.3 NS 163/169- Trioxide Balance, DoR central

Zinc Coating > (260to290) OST

Section 2400 Sec. 2400 2045 measuring cylinder, lab

Vernier caliper, stop watch

Table- 24.3 Tab- 24.3 NS 163/169- Tensile strength test DoR central

Tensile Strength 300-550Mpa OST

Section 2400 Sec. 2400 2045 machine lab

Table- 24.3 Tab- 24.3 NS 163/169- DoR central

Adhesion No flaking off Cylindrical Mandrel OST

Section 2400 Sec. 2400 2046 lab

82 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Measuring cylinder,
No Copper Table- 24.3 Tab- 24.3 NS 163/169- DoR central

Uniformity Beaker, Balance, Vernier, OST

deposition Section 2400 Sec. 2400 2047 lab

stop watch

9 Reinforcement -one sample up to IS 432 and IS DoR,

Attached
Elongation Annex-A 31.52 1 OST
Steel (SS-DOR
2014) 10mm dia. for each 1786 NBSM

25 Ton

-one sample for 10- DoR,

As specified in
Weight NS 1 NS-191 Balance, Vernier caliper OST

16 mm dia for each NBSM

35 Ton and
As specified in
Bend and Rebend NS 1 IS 1599,1786 DoR, OST
-one sample for

83 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

NBSM

more than 16mm dia

DoR,
Attached
Tensile Strength Annex-A for each 45 Ton 1 NS-203 T. strength machine OST

NBSM

10 Aggregate for Table-2

Gradation 250 Ton 10071.00 40 IS 2386 Part 1 Sieves , balance, trays Field Lab SLT
concrete work
(SS-DOR 2003) IS 383 (1970)

IS2386 Standard gauge

Flakiness Index <25 250 Ton 40 Field Lab SLT

Part 1 383x150x6mm

Water absorption <2% 250 Ton 40 IS 2386 Balance, oven, desiccator, Field Lab SLT

84 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

part 3 glass vessel

LAA machine, Abrasive

IS 2386

LAA <45% 250 Ton 40 charge, sieves, Balance, Field Lab SLT
part 4

Trey

Steel cylinder, tamping rod,

IS 2386 Balance, Compression

ACV <45 250 Ton 40 Field Lab SLT

part 4 testing machine, Sieve

12.5 and 2.36

Pycnometer, balance,
IS 2386

Organic impurities >2.5 250 Ton 40 basket, Immersing bucket, Field Lab SLT
part 2

85 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

oven

11 NS 221:2047-part
Bitumen One set of tests for 3 / IS 1203 Penetrometer, water bath,

VG-30 / VG -10 Penetration at 250C, Min 45 / 80 each 50 ton of 824 ton 17 Metallic cylinder, transfer DoR Lab OST

(DOR SS-618) supply or part of it Bath, Bath Thermometer

Absolute Viscosity at 600C One set of tests for each 50 viscometer apparatus,
Poises ton of supply or part of it thermometer, stop watch
NS 237:2050-part
8/IS:1206-2
2400-3600 /
800-1200 17 DoR Lab OST

One set of tests for each 50 viscometer apparatus,

ton of supply or part of it thermometer, stop watch
NS 237:2050-part
8/IS:1206-2
Kinematic Viscosity at
1350C, cSt, Min 350 / 250 17 DoR Lab OST

86 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Pensky-Martens Close bath,

One set of tests for each 50 pulling machine,
ton of supply or part of it thermometer
NS 237:49 part VII
/ IS: 1448-69
Flash Point (Cleveland opn
cup), 0C, Min 220 / 220 17 DoR Lab OST

One set of tests for each 50 Gooch Crucible, Solvent,

ton of supply or part of it 17 Conical Glass Flask
NS: 221:2047 Part
IV / IS:1216
Solubility Test in
trichloroethylene, percent,
Min 99 / 99 DoR Lab OST

Ring and ball arrangements,

Water bath, stirrer,
One set of tests for thermometer

Softening point (R&B),0C,

Min 47 / 40 each 50 ton of 17 NS/IS:1205 DoR Lab OST

87 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

supply or part of it

NS 221:47 part 4 Gooch Crucible, Solvent,

Test on residue from rolling
thin film overn test: 17 DoR Lab OST

IS-1216-1978 Conical Glass Flask

One set of tests for each 50 viscometer apparatus,

ton of supply or part of it thermometer, stop watch
(a) Viscosity ratio at 600C,
Max
NS 221:2046 Part
4/4 17 III / IS 1206-2 DoR Lab OST

One set of tests for

each 50 ton of
NS 221:2046 Part
(b) Ductility at 250C, cm Min 40 / 75 17 I / IS 1206-2 DoR Lab OST

supply or part of it

88 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

12 Subgrade Compaction mould,

IS 2720

Field density >95% 1 test per 1000 m2 209876.00 210 controlled fall rammer, Field Lab SLT
part 7

SS DOR 1000 sieve, balance

Balance, CBR machine

IS 2720
For each new source and in
Soaked CBR >5 every 1500 cum or part of it 21 set, Mechanical Loading Field Lab SLT

part 16

Press

as specified at For each new source and in

MDD / OMC lab every 1500 cum or part of it 21 IS 2720 part 8 Oven, can, balance Field Lab

Swell <1% 21 IS 2720 OST

For each new source and in

89 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

every 1500 cum or part of it

part 40

Atterberg limit apparatus,

IS 2720
For each new source and in
Plasticity Index <40% every 1500 cum or part of it 21 grooving tools, evaporation Field Lab SLT

part 5

dish

IS 2720
For each new source and in
Particle size <60mm every 1500 cum or part of it 21 sieve, balance, oven Field Lab SLT
Part-4

IS 2720
For each new source and in
Organic Content <3% every 1500 cum or part of it 21 Chemical, Flask OST
part 22

90 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

13 Granular Sub
Table 12.1 SS
DOR 1 for 400 m3, every IS 2386

Gradation 49559.00 248 Sieves , balance, trays Field Lab SLT

base material
SS DOR 1201 section 1201 change of source Part 1

Balance, CBR machine

>30% at 95% 1for 400m3, every IS 2720

CBR (soaked) 100 set, Mechanical Loading Field Lab SLT
MDD change of source part 16

Press

Atterberg limit apparatus,

1 for every 400 m3, every IS 2720

Plasticity Index <6 33 grooving tools, evaporation Field Lab SLT
change of source part 1

dish etc.

one test in every IS 2720 Balance, Sand Pouring

91 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Field Density and MC >95% 100 Cylinder, Standard sand, Field Lab SLT
1000 sqm part 8

Chisel

1 for 400m3, every IS 2720 part 8 Heavy Mould, rammer,

as specified at
MDD/OMC lab 50 Field Lab SLT

change of source ASTM D1557-70 sieve, ,measuring cylinder

Liquid Limit <25 1 for 400m3, every 181 ISTM 2720-5

change of source

Impact testing machine with

1 for 400 m3, every change of hammer, IS Sieve, Balance,
AIV 40% source 248 IS 2386 part 4 Oven, cylindrical Field Lab SLT

14 Crusher run Gradation 1 for 400 m3, every 49559.00 248 IS 2386 Part 1 Sieves , balance, trays Field Lab SLT
Table 12.1 SS

92 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

DOR

Sub base section 1201 change of source

Material (SS
DOR 1201 &
1204)

1 for 400 m3, every Standard gauge

Combined FI & EI 35% 248 IS 2720 part 5 Field Lab SLT

change of source 383x150x6mm, Balance

Atterberg limit apparatus,

1 for 400 m3, every
Plasticity Index <6 248 IS 2720 part 5 grooving tools, evaporation Field Lab SLT

change of source

dish

Balance, CBR machine

>30% at 95% 1 for 400 m3, every
CBR (soaked) 100 IS 2720 part 5 set, Mechanical Loading Field Lab SLT

93 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

MDD change of source

Press

1 for 400 m3, every

Liquid Limit <25 248 Manual Counting Field Lab SLT

change of source

Balance, Sand Pouring

One test in every

Field Density and MC >95% 100 IS 2720 part 8 Cylinder, Standard sand, Field Lab SLT

1000 sqm.

Chisel

1 for 400 m3, every y IS 2720 part 8 Mould, rammer, Vernier

as specified at
MDD/OMC lab 50 Field Lab SLT
change of source ASTM D1557-70 caliper, measuring cylinder

94 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

LAA machine, Abrasive

1 for 400 m3, every

Los Angeles Abrasion 40% 248 IS 2386 part 4 charge, sieves, Balance, Field Lab SLT

change of source

Trey

Impact testing machine

1 for 400 m3, every with hammer, IS Sieve,

Aggregate Impact Value 30% 248 IS 2386 part 4 Field Lab SLT
change of source Balance, Oven, cylindrical

steel cup

1 for 400 m3, every Pycnometer, balance,

Water absorption <2% 30 IS 2386 part 5 basket, Immersing bucket, Field Lab SLT

Uncrushed <10% 1 for 400 m3, every 30 IS 2386 part iv Balance, trays, sieve Field Lab SLT

95 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

change of source

Surface Level, Width and

Thickness As per design 20 meter 3629

Table 12.8 of
15 Crushed Stone SS DOR 1 for 400 m3, every

Gradation 29156.00 146 IS 2386 Part 1 Sieves , balance, trays Field Lab SLT
Base Course
(SS DOR 1204) section 1200 change of source

1 for 400 m3, every

Uncrushed <10% 30 IS 2386 part iv Balance, trays, sieve Field Lab SLT

change of source

LAA machine, Abrasive

1 for 400 m3, every

Los Angeles Abrasion <40% 146 IS 2386 part iv charge, sieves, Balance, Field Lab SLT
change of source
Trey

96 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

16 Crushed Stone AIV machine, measuring

1 for 400 m3, every IS 2386 part 4
Base Course
(SS DOR 1204) Aggregate Impact Value <30% 29156.00 58 cylinder, test mould, 2.36 Field Lab SLT
change of source IS 5640

mm sieve

Pycnometer, balance,
1 for 400 m3, every

Water absorption <2% 30 IS 2386 part 5 basket, Immersing bucket, Field Lab SLT
change of source

oven

Balance, Oven, IS Sieve,

Sodium Sulphate
Soundness 1 for 400 m3, every

<12% 58 IS 2386 part 5 Container, Wire mesh OST

(SSS) if Water aborption >
2% change of source

basket

97 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

1 for 400 m3, every

Liquid limit of material
passing 425 microns <25 146 IS 2720-5 Field Lab SLT
change of source

1 for 400 m3, every Standard gauge

Combined FI &EI <35% 146 IS 2386 part 1 Field Lab SLT

change of source 383x150x6mm, Balance

1 for 400 m3, every Balance, CBR machine

CBR >80% 58 IS 2720 part 16 Field Lab SLT

change of source set, balance, oven

Atterberg limit apparatus,

1 for 400 m3, every
PI of material passing 425
microns <6 146 IS 2720 part 1 grooving tools, evaporation Field Lab SLT
change of source
dish etc.

98 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Sand cone density

one test in every apparatus, Balance,

Field Density/OMC >98% 58 IS 2720 part-8 Field Lab SLT

1000 m2 standard sand, Chisel,

rapid moisture meter

cylindrical mould,
1 for 400 m3, every
as specified at
MDD/OMC lab 30 IS 2720 part-8 controlled fall rammer, Field Lab SLT

change of source

sieve, balance, oven

smoothness As per design 1 Test per 40 sqm 5247

Thickness As per design 1 Test per 25 meter 1452

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 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Table- Section
Surface Level As per design 1 Test per 10meter 3629

1202

17 Aggregate for Table 13.33 1 test for every 500

Gradation 5833.00 58 IS 2386 Part 1 Sieves , balance, trays Field Lab SLT

Asphalt Section-1300 cum of part of it

DOR SS 1300 LAA machine, Abrasive

1 test for every 500

Los Angeles Abrasion <30% 12 IS 2386 part 4 charge, sieves, Balance, Field Lab SLT
cum of part of it

Trey

Impact testing machine

Aggregate Impact Value <24% 1 test for every 500 12 IS 2386 part 4 with hammer, IS sieve, Field Lab SLT

100 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

cum of part of it Balance, Oven, cylindrical

steel cup

17 Aggregate for 1 test for every 100 Standard gauge

Combined Flakiness &
Asphalt Elongation Index <35 58 IS2386 Part 1 Field Lab SLT
cum of part of it 383x150x6mm

DOR SS 1300 Balance, Oven, IS Sieve,

Sodium Suplhate
Soundness 1 test for every 500

<12% 12 IS 2720 part 5 Container, Wire mesh Field Lab SLT

cum of part of it

Magnesium Sulphate <18% basket

Thermostatically controlled

1 test for every 500

Stripping Value Minimum 12 IS 6241 water bath, Oven, Sieve, Field Lab SLT

101 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

retained coating
95%
cum of part of it
Mixer,

Pycnometer, balance,

1 test for every 500

Water absorption <2 12 IS 2386 part 5 basket, Immersing bucket, Field Lab SLT

cum of part of it

oven

1 test for every 500 cum of

<55 part of it
Polishing (Polished Stone
Value) 6 BS 812-114 Field Lab SLT

1 test for every 500 cum of part

Water Sensitivity <80% of it AASHTO 283 Field Lab SLT

102 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Asphalt Mix
(DOR SS
1307/1308/13
As per mix
18 09)
design and Table
13.33 one test per 400 ton
Grading and bitumen
content 12833.00 129 IS 2386 Part 1 Sieves , balance, trays OST

of mix or part of it

Loading Machine, Oven or

one test per 100 ton

Marshal Stability- 50 blow >9 KN 129 AASHTO T245 hot plate, Water bath, OST

of mix or part of it
thermometer

one test per 100 ton AASHTO T245

Flow value 2.00-4.00 (mm) 129 OST

of mix or part of it

103 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

one test per 100 ton

Air void in total volume 3.00-5.00% 129 OST
of mix or part of it

one test per 100 ton

Compression/immersion
ratio >0.75 129 OST
of mix or part of it

Thickness / Core cutting 1 test per 700 sqm 162033.00 810 OST

1 test per 700 sqm

Density of Cpmacted
Pavement >92% 324 OST

Surface level and

Smootness Every 50 meter or at 726

104 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Prime Coat
19 (DOR SS 1300) IS:217 for

One set of test for a cutback

As specified in 170.00

Quality of Binder tanker or lot of 50 4 bitumen and As specified in SN11 OST

SN11
tonne IS:8887 for

emulsion

1 test per 1000 m2

Spray Rate 0.9 and not less than 161971.0 162 IRC 16-2008 Tray, Deeping rod, balance Field Lab SLT

two tests per day

Binder Temperature

Regular Intervals IRC 16-2008 Thermometer Field Lab SLT

for application

105 | P a g e
 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

Tack Coat (DOR

20 SS 1300) IS:217 for

One test for a cutback

As specified in

Quality of Binder tanker or lot of 50 85.00 2 bitumen and As specified in SN11

SN11

tonne IS:8887 for

emulsion

1 test per 1000 m2

Spray Rate 0.50 and not less than 80988.00 81 IRC 16-2008 Tray, Deeping rod, balance Field Lab

two tests per day

Binder Temperature Regular Intervals 500-800C IRC 16-2008 Thermometer Field Lab

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 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

for application

21 Fill material
1 for 1500 cum, each

Particle size <75mm 722972.00 482 IS 2720 Part-4 Sieve, balance, oven Field Lab SLT
Formation of layer

Embankment
(DOR SS 900)

1 for 1500 cum, each

Organic matter <3% 482 IS 456 Chemical Test Field Lab OST
layer

Atterberg limit apparatus,

1 for 1500 cum, each

Plasticity Index <45% 482 IS 2720 part 5 grooving tools, evaporation Field Lab SLT

layer

dish

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 Road Name: ANNEX IV

Specification Conducted
Material /
BOQ Nos tests
Specification
SN Number Tests limit Test Frequency Code Reference Equipment Remarks

Quantity Required

Requirement At by

cylindrical mould,
1 for 1500 cum, each

MDD/OMC Lab Test 180743.00 482 IS 2720 part 8 controlled fall rammer, Field Lab SLT

layer

sieve, balance, oven

Balance, Sand Pouring

One set per 1000 m2,
Field density >95% 722972.00 1445 IS 2720 part 8 Cylinder, Standard sand, Field Lab SLT

each layer

Chisel

Balance, CBR machine

set, Mechanical Loading

Soaked CBR >5 1 for 1500 cum 180743.00 121 IS 2720 part 16 Press OST

Note: All the mentioned frequency frequncy are just indicative number and shall be calculated on the basis of actual quanity in BOQ. The test beyond above
mentioned test shall be added as per requirement.

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WORK REQUEST FORM (WRF)

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 ANNEX VI

SITE INSTRUCTION BOOK

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 ANNEX VII

DAILY DIARY BOOK

Commented [u3]: Weekly Meeting Report

Monthly Progress Report

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