INSPECTION AND TEST PLAN

: Contract UG-01: Design and construction of underground stations at Kapodra, Labheshwar chowk and
PROJECT
Central Warehouse and associated tunnels
EMPLOYER : GUJRAT METRO RAIL CORPORATION (GMRC) LTD

GEC : SYSTRA-AECOM-EGIS-CEG (Sub-Con)

CONTRACTOR : GÜLERMAK-SAM INDIA SURAT METRO UG-P1 JOINT VENTURE

INPECTION AND TEST PLAN - BASE SLAB CONSTRUCTION

GMRCL/P1/UG01/BS/ITP R(00)

INSPECTION BY

REFERENCE DOCUMENTS / ACCEPTANCE

GEC Rep
Engineer

Engineer
Manager
Sl No MATERIAL DESCRIPTION FREQUENCY VERIFYING DOCUMENTS

Station

QA/QC
STANDARDS CRITERIA

Site
1.0 PRIOR TO COMMENCMENT OF WORK

Design and Data Development Notice of No Objection Certificate from Before commencement of work
1.1 OCS & ODS Approval Certificate from Owner/Consultant O O O W
Owner/Consultant/ Approved status or with design alteration

GFC Drawings and technical

Method Statement/ ITP / Checklist / Adequacy to meet Scope, Performance and Notice of No Objection/Acceptance from
1.2 specifications for the O O h W
Working Drawings Technical Specification Requirements Employer
works
Prior to commencement of
work

Notice of No Objection Certificate from

1.3 Testing Facilities OCS and External Testing Laboratories Approved Letter/Closed RFI W W W O
Owner/Consultant/ Approved status

Vendors available in approved vendor list

Notice of No Objection Certificate from Prior to commencement of Notice of No Objection/Acceptance from
1.4 Source of Materials of Contract / Any other approved vendor O O H W
Owner/Consultant/approval letters works/Change of source Employer specially for additional vendors
by GEC/GMRCL

Once for each grade and type

of concrete ingredients and Notice of No Objection/Acceptance from
1.5 Concrete Mix Design OCS and IS 10262 Approval of Concrete Mix design O O H W
prior to production Employer
commencemenl

Approved Method Statement / Contract Arrangements to be made completely before

1.6 Plants and Equipments Visual Inspection H H O H
Specifications production commencement
Prior to commencement of
works
Approval letter from owner/consultant for RMC
Notice of No Objection Certificate from Owner /
1.7 Approval of batching Plant/ RMC Plant IS:4925 / OCS Plants/Trial Run of GLM SAM JV Plant with 'C' O O H W
Consultant for RMC Plant
Certificate

Page 1 of 13
 GMRCL/P1/UG01/BS/ITP R(00)

INSPECTION BY

REFERENCE DOCUMENTS / ACCEPTANCE Once prior to start and

Sl No MATERIAL
Calibration DESCRIPTION
Certificates for Measuring FREQUENCY
subsequent periodical VERIFYING DOCUMENTS
1.8 STANDARDS
Manufacturer's reccommendation To beCRITERIA
made available Calibration Reports O O H W
Equipments / Load Test Certificate calibrations as per calibration
plan

2.0 MATERIAL RECEIPT STORAGE HANDLING ANO DELIVERY

2.1 Reinforcement

Delivery Invoice & MTC to be available free from

2.1.1 Receiving Inspection Outline Construction Specification For each load of vehicle MTC & Delivery Challans & Inspection Report O O H W
loose scales, dirt, rust. deformations etc.

2.1.2 Sampling and Testing Refer to General Inspection and Test Plan Sampling Records and Test Certificates O O H W

Segregated with segregation tag, under cover and

After receipt of material and
2.1.3 Storage and Segregation Outline Construction Specification storage above levelled ground to avoid dirt and Visual Inspection H H O W
subsequent checks at random
contamination

2.2 Embedded items (G.I Pipe, Duct Pipe etc)

Delivery Invoice & MTC from the manufacturer to

2.2.1 Receiving Inspection Invoices / Chailans & MTC For each consignment MTC & Delivery Challans O O H W
be available

Prior to commencement of
2.2.2 Storage and Segregation Manufacture's Recommendations Received in proper shipments works and subsequently at Visual Inspection H H O W
random

2.3 Concrete/ PVC Cover block

Delivery Invoice & MTC from the manufacturer to

2.3.1 Receiving Inspection Invoices / Chailans & MTC For each consignment Delivery Challans/Inspection Report O O H W
be available

2.4 Shutter Oil / Demoulding agent

Delivery Invoice from the approved manufacturer

2.4.1 Receiving Inspection Invoices / Chailans & MTC For each lot Delivery Challans O O H W
lo be available

Prior to commencement of
Shall be in sealed, watertight drums stored in cool
2.4.2 Storage and Segregation Manufacturer's Recommendations works and subsequently at Visual Inspection H H O W
conditions and free from naked flames
random

2.5 Miscellaneous Materials (Binding wire, Welding Electrodes etc)

Page 2 of 13
 GMRCL/P1/UG01/BS/ITP R(00)

INSPECTION BY
a) For Binding Wire:-Annealed wire of 1.25 mm
REFERENCE DOCUMENTS / thickness ACCEPTANCE
Sl No MATERIAL DESCRIPTION For Binding Wire-IS:280 Welding FREQUENCY VERIFYING DOCUMENTS
STANDARDS CRITERIA
b) For welding electrodes :-
Electrodes -AWS 5.1(Welding electrodes
rebar<= 10mm -2.5mm(max), MTC for electrodes & Delivery invoice (where
2.5.1 Receiving Inspection from approoved manufature listed in Each Delivery O O H W
10 mm to 18mm - 3.15mm(max), applicable)
appendix 10,volume III of the contract
18mm to 28mm - 4.00mm(max),
specifications)
above 28mm rebar - 5.00 (max)

To be kept free from moisture and stored In a dry

2.5.2 Storage and segregation of electrodes As per manufacture's recommendations Subsequent to each delivery Visual Inspection H H O W
store room

3.0 PROCESS INSPECTION

3.1 Preparation of Formation/ Bed

GFC Drawings and technical

Co-ordinates and levels shall be within Survey check sheet (GMRCL/UG-01/GLM SAM
3.1.1 Survey Works specifications for the works, Method For each Slab Panel H H O W
specification tolerances. INDIA JV/CW/QR/085)
statement for the works

One test for either each 1000

Compaction of soil / filled sand at the Field Desity by Sand replacement method
3.1,2 Cl. 1.2.3.1 of OCS, Vol -4 95% of Maximum Dry density m3 placed or each layer O O H W
Formation level. (GMRCL/UG-01/GLM SAM INDIA/CW/QR/104)
whichever is the more frequent

GFC Drawings and technical

Placing of PCC / Blinding concrete of Survey check sheet (GMRCL/UG-01/GLM SAM
3.1.3 specifications for the works, Method Top Level shall be maintained . For each slab Panel H H O W
required grade INDIA JV/CW/QR/085)
statement for the works

Base Slab Waterproofing checklist

Method statement for lhe waterproofing MS for Base Slab waterproofing
3.1.4 Water proofing works. For each slab Panel (GMRCL/UG-01/GLM SAM INDIA O O H W
works. (GMRCL/P1/UG01/STN/MS/17)
JV/CW/QR/189)

3.2 Placing/ Fixing of Reinforcement

Construction Drawings I Bar Bending Bar Bending Schedule (GMRCL/UG-01/GLM

3.2.1 Fabrication of reinforcement Bar Bending Schedule H H O W
Schedule SAM INDIA JV/CW/QR/038)

Bar Bending Schedule (GMRCL/UG-01/GLM

3.2.2 Diameter, Shape and Spacings Construction Drawings/ Bar Bending Bar Bending Schedule H H O W
SAM INDIA JV/CW/QR/038)
Schedule

Should be properly joined with the coupler

Reinforcement & Formwork checklist
installed at D/Wall. Adequate Lap shall be
3.2.3 Joining of Reinforcement Each Slab Panel (GMRCL/UG-01/GLM SAM INDIA H H O W
provided & tied with binding wire of the required
JV/CW/QR/043)
thickness.
Approved Construction drawings/Method
Statement/Design data for lifting locations Page 3 of 13
 GMRCL/P1/UG01/BS/ITP R(00)
Each Slab Panel

INSPECTION BY
Approved Construction drawings/Method
Statement/Design data for lifting locations
REFERENCE DOCUMENTS / ACCEPTANCE
Sl No MATERIAL DESCRIPTION a) Longitudinal Tolerance - +/- 50mm FREQUENCY VERIFYING
Coupler bar positionDOCUMENTS
& Tightening report
Rebaring by approved epoxy in case the STANDARDS CRITERIA
3.2.4 b) Vertical Tolerance - +/- 40mm (GMRCL/UG-01/GLM SAM INDIA H H O W
position of coupler is out of tolerance.
c) Lateral Tolerance - +/- 20mm JV/CW/QR/039)

Reinforcement & Formwork checklist

3.2.5 Preparation of Construction Joint Approved Method Statement Approved Drawing I Method Statement (GMRCL/UG-01/GLM SAM INDIA H H O W
JV/CW/QR/043)

3.3 Form Work and Misc. Works

Placing & Fixing of Duct pipes for MEP Approved Method Pre Pour Inspection Checklist (GMRCL/UG-
3.3.1 Approved Combined Services Drawing (CSD) H H O W
works Statemen/Drawings/Designs 01/GLM SAM INDIA JV/CW/QR/036)

Each Slab Panel

Reinforcement & Formwork checklist

Approved Method Statement / Drawings /
3.3.2 Erection of Formwork. Approved GFC Drawing I Formwork Design (GMRCL/UG-01/GLM SAM INDIA H H O W
Form Work Design
JV/CW/QR/043)

3.4 Final Inspection prior to Concreting ( Pre-pour Inspection) .

3.5 Concreting Works

3.5.1 Mixing Time Minimum 30 seconds Each Batch For each Slab Panel Batch Sheet Record O O H W

Pre-numbered and to be issued sequentially. Must

3.5.2 Delivery Docket Issued with each transit mixer Each transit load O O H W
record time of batching completion

Visual / Concrete Dispatch Docket

Each batch of concrete.
170 mm +/- 25 mm(Non conforming first slump Agitator
3.5.3 Workability Testing IS 1199:2018 O O H W
can be retested from the same sample) deliveries to be checked at the
point of discharoe at site

Concrete Pour Card (GMRCL/UG-01/GLM

3.5.5 Completion Time OCS Within 3 hours from the batch time Each Pour of Concrete O O H W
SAM INDIA JV/CW/QR/035)

3.6 Sampling of Concrete

Page 4 of 13
 GMRCL/P1/UG01/BS/ITP R(00)

INSPECTION BY

REFERENCE DOCUMENTS / ACCEPTANCE

Sl No MATERIAL DESCRIPTION FREQUENCY VERIFYING DOCUMENTS
STANDARDS CRITERIA Concrete Pour Card (GMRCL/UG-01/GLM
3,6.1 Concrete Cube Moulds (150x150x150 mm) IS 456/IS 516 As per IS 456 For each Slab Panel O O H W
SAM INDIA JV/CW/QR/035)

Concrete Pour Card (GMRCL/UG-01/GLM

3,6.2 Concrete samples for other tests IS 456 Refer to General ITP O O H W
SAM INDIA JV/CW/QR/035)

3.7 Post Pour Inspection

3.7.1 Checking As-built level of slab Approved Method statement & Drawing Approved GFC Drawings Each Slab Panel H H O W

Post Pour inspection checklist (GMRCL/UG-

01/GLM SAM INDIA JV/CW/QR/037)

Curing.Surface defects.position of inserts

3.7.2 Approved Method Statement Adequate curing & curing period shall be ensured. Each Slab Panel H H O W
etc.

GLM-SAM INDIA JV / Sub-Contractor shall not process activity beyond a witness point without written approval by GEC/GMRCL. The related quality records shall be
Major Category is Wittness Point
submitted toGEC/GMRCL for their review.

Page 5 of 13
 QUALITY ASSURANCE PLAN : COARSE AGGREGATES FOR CONCRETE WORKS
PROJECT: NHAI PROJECT NH4 TAMILNADU QAP NO. : QP/4372/QA/11

Client : National Highway Authority of India Rev : 0

Consultant : SAUTI COMPAGNIA GENERALE D'INGEGNERIA
Contractor : AFCONS INFRASTRUCTURE LTD.
Contract : Four Laning of Poonamallee - Kanchipuram section of NH4 Package 1

Sr. Frequency of
Particulars Applicable Standards Performance Standards Performance Agency Spec Frequency of Audit Remarks
No. performance

On receipt at main /
1 Storage MOST CL. 1014 1014 Stores / Site rep. PR 8571 ST 05 Once in three month
sub stores at site

Weekly / as and when

2 Sampling MOST CL. 1015 IS : 2430 QC dept / site rep, 1015 -do-
required

3 Tests -do-

a Grading MOST CL. 1007 IS : 2386 Part - 1 QC dept IS 383 -do- -do-

b Flakiness Index -do- IS : 2386 Part - 1 -do- 35 % max. -do- -do-

c Moisture content Use at site IS : 2386 Part - 3 Site rep, n.a. as and when required -do-

Specific gravity / water

d -do- -do- QC dept n.a. -do- -do-
absorption

e Impact value -do- IS : 2386 Part - 4 -do- n.a. -do-

Approved Out side

f Deletrious material MOST CL. 1007 IS : 2386 Part - 2 IS 383 -do-
agency ,

once for source / as

g Alkali aggregate reactivity Use at site IS : 2386 Part - 7 -do- -do-
and when required

Soundness Na2SO4 , 5
h -do- IS : 2386 Part - 5 -do- -do- -do- -do-
cycles

n.a. / total chloride content

i Chloride content -do- IS : 2386 -do- in mix shall be 0.1.% by -do- -do-
mass of cement
n.a. / total SO3 content in
Sulphuric anhydride
j -do- IS : 2386 -do- mix shall be 4.% by mass -do- -do-
content
of cement

k Petrographic analysis -do- IS : 2386 Part - 7 -do- IS : 383 As and when required -do-

N.B.: Project specifications are

1. M.O.S.T. standard , Third Revision April 1995, Reprint January 1999
2 Technical specification - Vol II and addendum etc.
3. Drawings and B.O.Q. cl.

PREPARED BY APPROVED BY
 QUALITY ASSURANCE PLAN : FINE AGGREGATES FOR CONCRETE WORKS
PROJECT: NHAI PROJECT NH4 TAMILNADU QAP NO. : QP/4372/QA/12

Client : National Highway Authority of India Rev : 0

Consultant : SAUTI COMPAGNIA GENERALE D'INGEGNERIA
Contractor : AFCONS INFRASTRUCTURE LTD.
Contract : Four Laning of Poonamallee - Kanchipuram section of NH4 Package 1

Sr. Frequency of
Particulars Applicable Standards Performance Standards Performance Agency Spec Frequency of Audit Remarks
No. performance

On receipt at main /
1 Storage MOST CL. 1014 1014 Stores / Site rep. PR 8571 ST 05 Once in three month
sub stores at site

Weekly / as and when

2 Sampling MOST CL. 1015 IS : 2430 QC dept / site rep, 1015 -do-
required

3 Tests -do-

a Grading MOST CL. 1008 IS : 2386 Part - 1 QC dept IS 383 -do- -do-

b Moisture content Use at site IS : 2386 Part - 3 Site rep, n.a. as and when required -do-

Specific gravity / water

c -do- -do- QC dept n.a. -do- -do-
absorption

Approved Out side

d Deletrious material -do- IS : 2386 Part - 2 IS 383 -do- -do-
agency ,

once for source / as

e Alkali aggregate reactivity -do- IS : 2386 Part - 7 -do- -do- -do-
and when required

Soundness Na2SO4 , 5
f MOST CL. 1008 IS : 2386 Part - 4 -do- -do- -do- -do-
cycles

Total chloride content in

g Chloride content Use at site IS : 2386 -do- mix shall be 0.1.% by -do- -do-
mass of cement
Total SO3 content in mix
Sulphuric anhydride
h -do- IS : 2386 -do- shall be 4.% by mass of -do- -do-
content
cement

i Petrographic analysis -do- IS : 2386 Part - 7 -do- IS : 383 as and when required -do-

N.B.: Project specifications are

1. M.O.S.T. standard , Third Revision April 1995, Reprint January 1999
2 Technical specification - Vol II and addendum etc.
3. Drawings and B.O.Q. cl.

PREPARED BY APPROVED BY
 QUALITY ASSURANCE PLAN : WATER FOR CONCRETE WORKS
PROJECT: NHAI PROJECT NH4 TAMILNADU QAP NO. : QP/4372/QA/13

Client : National Highway Authority of India Rev : 0

Consultant : SAUTI COMPAGNIA GENERALE D'INGEGNERIA
Contractor : AFCONS INFRASTRUCTURE LTD.
Contract : Four Laning of Poonamallee - Kanchipuram section of NH4 Package 1

Sr. Frequency of
Particulars Applicable Standards Performance Standards Performance Agency Spec Frequency of Audit Remarks
No. performance

1 Storage ( cleaning ) MOST CL. 1010 MOST CL. 1014 Stores / Site rep. MOST CL. 1014 As & when required Once in three months

Approved Out side once for source / as

2 pH value -do- IS : 3025 Min 6 -do-
agency , and when required

Total Organic solids

3 -do- -do- -do- Max 200 mg / l -do- -do-
( mg / L )

Total Inorganic solids

4 -do- -do- -do- Max 3000 mg / l -do- -do-
( mg / L )

Chlorides content
5 -do- -do- -do- Max 500 mg / l -do- -do-
( mg / L )

Sulphate content
6 -do- -do- -do- Max 500 mg / l -do- -do-
( mg / L )

Suspended matter
7 -do- -do- -do- Max 2000 mg / l -do- -do-
( mg / L )

should not require more

than 2 ml of 0.1 N NaOH
8 Acidity -do- -do- -do- -do- -do-
for 200 ml water having Ph
as indicater
should not require more
than 10 ml of 0.1 N HCl for
9 Alkalinity -do- -do- -do- -do- -do-
200 ml water having MeO
as indicater
N.B.: Project specifications are
1. M.O.S.T. standard , Third Revision April 1995, Reprint January 1999
2 Technical specification - Vol II and addendum etc.
3. Drawings and B.O.Q. cl.

PREPARED BY APPROVED BY
 QUALITY ASSURANCE PLAN : REINFORCEMENT STEEL FOR CONCRETE WORKS
PROJECT: NHAI PROJECT NH4 TAMILNADU QAP NO. : QP/4372/QA/14

Client : National Highway Authority of India Rev : 0

Consultant : SAUTI COMPAGNIA GENERALE D'INGEGNERIA
Contractor : AFCONS INFRASTRUCTURE LTD.
Contract : Four Laning of Poonamallee - Kanchipuram section of NH4 Package 1

Sr. Frequency of
Particulars Applicable Standards Performance Standards Performance Agency Spec Frequency of Audit Remarks
No. performance

On receipt at main /
1 Storage MOST CL. 1014 MOST CL. 1014 Stores / Site rep. PR 8571 ST 05 Once in three month
sub stores at site

Collecting Manufacturer's At the earliest , before

2 MOST CL. 1015 MOST CL. 1015 Purchase det. 1015.1 -do-
Test certificate use

Approved Out side

3 Sampling MOST CL. 1015 IS : 10790 ( Part-2 ) IS : 1786 / IS : 432 Every lot -do-
agency ,

4 Tests MOST CL. 1009.3 IS : 1786 / IS : 432 -do-

a Unit weight Proj spec. -do- -do- -do- -do- -do-

b Ultimate tensile strength -do- -do- -do- -do- -do- -do-

0.2 % Proof stress / Yield

c -do- -do- -do- -do- -do- -do-
stress

d % Elongation -do- -do- -do- -do- -do-

e Bend / Re bend test -do- -do- -do- -do- -do- -do-

f Surface characteristic -do- -do- -do- -do- as required -do-

Once for a source, as

g Chemical analysis -do- -do- -do- -do- -do-
required

N.B.: Project specifications are

1. M.O.S.T. standard , Third Revision April 1995, Reprint January 1999
2 Technical specification - Vol II and addendum etc.
3. Drawings and B.O.Q. cl.

PREPARED BY APPROVED BY
 QUALITY ASSURANCE PLAN : FRESH AND HARDENED CONCRETE WORKS
PROJECT: NHAI PROJECT NH4 TAMILNADU QAP NO. : QP/4372/QA/15

Client : National Highway Authority of India Rev : 0

Consultant : SAUTI COMPAGNIA GENERALE D'INGEGNERIA
Contractor : AFCONS INFRASTRUCTURE LTD.
Contract : Four Laning of Poonamallee - Kanchipuram section of NH4 Package 1

Sr. Frequency of
Particulars Applicable Standards Performance Standards Performance Agency Spec Frequency of Audit Remarks
No. performance

Approval from Clients after

Established methods with As & when required,
1 Concrete mix design MOST Cl. 1704 QC Dept. verification of project Once in three month
confirmation through trials . before start of works
requirements
Once at start ,
Calibration of weigh batcher / as mutually agreed with
2 MOST CL. 1707 -do- Proj spec. thereafter as and when -do-
batching plants clients / calibration plan
required.
Consistency test , Production
3 Use at site IS : 1199 Site rep. / QC dept. -do- regular close interval -do-
point ( Slump )

Consistency test , Placement

4 Use at site / Cl 1704 -do- -do- -do- -do- -do-
point ( Slump )

5 Production of concrete MOST CL. 1708 n.a. Site rep. -do- As & when required -do-

Sampling and casting of cube Min. as per MOST

6 -do- n.a. -do- n.a. -do-
specimen Table no . 1700 - 8

7 Compressive strength 7 Days -do- IS : 516 QC dept. / site rep. Proj spec. as required -do-

Compressive strength 28
8 -do- -do- -do- -do- -do- -do-
Days

Compressive strength , other

9 -do- -do- -do- -do- -do- -do-
days , if any

N.B.: Project specifications are

1. M.O.S.T. standard , Third Revision April 1995, Reprint January 1999
2 Technical specification - Vol II and addendum etc.
3. Drawings and B.O.Q. cl.

PREPARED BY APRROVED BY
 QUALITY ASSURANCE PLAN : ADMIXTURE FOR CONCRETE WORKS
PROJECT: NHAI PROJECT NH4 TAMILNADU QAP NO. : QP/4372/QA/16

Client : National Highway Authority of India Rev : 0

Consultant : SAUTI COMPAGNIA GENERALE D'INGEGNERIA
Contractor : AFCONS INFRASTRUCTURE LTD.
Contract : Four Laning of Poonamallee - Kanchipuram section of NH4 Package 1

Sr. Frequency of
Particulars Applicable Standards Performance Standards Performance Agency Spec Frequency of Audit Remarks
No. performance

MOST CL. 1012 / MOST CL. 1012 /

1 Storage ( cleaning ) Manufacturers' Manufacturers' Stores / Site rep. MOST CL. 1012 As & when required Once in three months
recommendation recommendation

once for source / as

2 Sampling Proj spec IS : 9103 QC Dept as agreed with clients -do-
and when required

Approved Out side

3 Chemical analysis MOST CL. 1012 IS : 9103 / IS : 6925 Proj spec / IS : 6925 -do- -do-
agency / Manufacturer

4 pH value -do- IS : 9103 -do- Proj spec / IS : 6925 -do- -do-

Comparision with Mix once in a Month/ fresh

5 Performance evaluation -do- -do- QC Dept -do-
design trial lot , whichever early

N.B.: Project specifications are

1. M.O.S.T. standard , Third Revision April 1995, Reprint January 1999
2 Technical specification - Vol II and addendum etc.
3. Drawings and B.O.Q. cl.

PREPARED BY APPROVED BY
 KOLKATA METRO RAIL CORPORATION
EAST WEST METRO CORRIDOR PROJECT - CONTRACT UG1
INSPECTION AND TEST PLAN - PRECAST SEGMENT PRODUCTION WORKS
DOC.No.: UG1-AFC-000-QUA-ITP- 025 , REV - A, Date of Issue: 16-04-2011

KMRCL/GC
TTAJV -

TTAJV -
QA/QC
ACCEPTANCE VERIFYING

Other
SL NO MATERIAL DESCRIPTION REFERENCE DOCUMENTS / STANDARDS CRITERIA FREQUENCY OF TEST DOCUMENT

1.0 PRIOR TO WORKS COMMENCEMENT

Volume 3 and Volume 4 of the Notice of No Objection Certificate from Owner / Consultant / approved Approval Certificate from Owner /
1.1 Design and Data Development Contract Specifications and ODS status
Before commencement of work or with design alteration H H R Consultant

Method Statement / ITP / Checklist /

GFC Drawings and technical Adequacy to meet Scope, Performance and Technical Specification Notice of No Objection/Acceptance
1.2 Working Drawings specifications for the works Requirements
H H R from Employer
(UG1 AFC 100 QUA MST 002)
Prior to commencement of work

Appendix 14, Volume III of OCS and Notice of No Objection Certificate from Owner / Consultant / approved
1.3 Testing Facilities External Testing Laboratories status
H H R Approved Letter / Closed NFI

Appendix 10, Volume III of OCS and/or Notice of No Objection/Acceptance

1.4 Source of Materials any additional approved vendor
Notice of No Objection Certificate from Owner / Consultant / approval letters Prior to commencement of works / Change of source H H R from Employer specially for
additional vendors

Cl. 5.2.1 & 5.2.2 of OCS, Volume 5, Once for each grade and type of concrete ingredients and Notice of No Objection/Acceptance
1.5 Concrete Mix Design Section 5
Approval of Concrete Mix design
prior to production commencement
H H R from Employer

Approved Method Statement /

1.6 Plants and Equipments Contract Specifications
Arrangements to be made complete before production commencement H H R Visual Inspection

Prior to commencement of works

Approval letter from owner /
IS:4925 / Appendix 10, Volume III of Successful Calibration and trial run of TTAJV B Plant / Notice of No consultant for RMC Plants / Trial
1.7 Approval of batching Plant / RMC Plant the Contract Specifications Objection Certificate from Owner / Consultant for RMC Plant
H H R Run of the TTAJV Plant with C /
Certificate

1.8 Calibration Certificates for Measuring

Equipments / Load Test Certificate --- To be made available
Once prior to start and subsequent periodical calibrations as
per calibration plan
H H R Calibration reports

2.0 MATERIAL RECEIPT, STORAGE, HANDLING AND DELIVERY

2.1 Reinforcement Works

Clause 5.1.3.1 , Section 5, Volume 5 of Delivery Invoice & MTC to be available free from loose scales, dirt, rust, MTC & Delivery Challans &
2.1.1 Receiving Inspection For each load of vehicle H H R Inspection Report
OCS deformations etc.
Sampling Records and Test
2.1.2 Sampling and Testing Refer to ITP for Rebars (UG1 AFC 000 QUA ITP 020) H H R Certificates

Clause 5.1.3.4 , Section 5, Volume 5 of Segregated with segregation tag, under cover and storage avove levelled
2.1.3 Storage and Segregation After receipt of material and subsequent checks at random H W R Visual
OCS ground to avoid dirt and contamination

2.2 Spacers

Delivery Challans / Inspection

2.2.1 Receiving Inspection Invoices / Challans Delivery Invoice from the manufacturer to be available For each load of vehicle H H R Report

2.3 Lifting Sockets/Gaskets

2.3.1 Receiving Inspection Invoices / Challans & MTC Delivery Invoice & MTC from the manufacturer to be available For each lot/consignment H H R MTC & Delivery Challans

Prior to commencement of works and subsequently at

2.3.3 Storage and Segregation Manufacturer's Recommendations Received in Packed watertight containers H W R Visual
random

2.4 Curing Compound, if applicable

2.4.1 Receiving Inspection Invoices / Challans Delivery Invoice from the approved manufacturer to be available For each lot H H R Delivery Challans

Shall be in sealed, watertight drums stored in cool conditions and free from Prior to commencement of works and subsequently at
2.4.2 Storage and Segregation Manufacturer's Recommendations H W R Visual
naked flames random

2.5
Miscellaneous Materials (Binding
wire, Welding Electrodes etc)

For Binding Wire --- IS:280, a) For Binding Wire:- Annealed Wire of 1.25 mm thickness, b)
For Welding Electrodes --- AWS For welding electrodes:-
5.1 (Welding electrodes from Rebar <= 10mm ---- 2.5 mm (Max), MTC for electrodes & Delivery
2.5.1 Receiving Inspection Each Delivery H R R Invoice (where applicable)
approved manufacturers listed in 10 mm to 18 mm ---- 3.15 mm (Max),
Appendix 10, Volume III of the 18 mm to 28 mm ---- 4.00 mm (Max) and
Contract Specifications) above 28 mm rebar ---- 5.00 mm (Max)

2.5.2 Storage and Segregation for welding

electrodes
As per manufacturer's
To be kept free from moisture and stored in a dry store room Subsequent to each delivery H R R Visual
recommendations

3.0 PROCESS INSPECTION

3.1 Cage Fabrication
Should be strictly adhered to the Bar Bending Schedule / Construction
3.1.1 Diameter, Shape, Spacings and Numbers
(where applicable)
Design / Construction Drawings / Bar
drawings and shape maintained to the respective alignment with the aid of For each Segment H H H
KODEN Printout Report / TARABEN
/ Check List No
Bending Schedule
jigs

3.1.2 Jointing
/Welding)
of Reinforcement (Binding Approved Construction Drawings / Each joint should be properly tied with binding wire of required thickness /
For each Segment H H R
In house Tests (UG1 AFC 000 QUA QRF
007)
Works Methodology welding with 1.6 mm MIG electrode where required

3.1.3 Inspection Controls Works Methodology Accepted Cage tagged with white, Rejected Cage tagged with red For each Segment H H R
 KOLKATA METRO RAIL CORPORATION
EAST WEST METRO CORRIDOR PROJECT - CONTRACT UG1
INSPECTION AND TEST PLAN - PRECAST SEGMENT PRODUCTION WORKS
DOC.No.: UG1-AFC-000-QUA-ITP- 025 , REV - A, Date of Issue: 16-04-2011

KMRCL/GC
TTAJV -

TTAJV -
QA/QC
ACCEPTANCE VERIFYING

Other
SL NO MATERIAL DESCRIPTION REFERENCE DOCUMENTS / STANDARDS CRITERIA FREQUENCY OF TEST DOCUMENT

3.2 Mould Inspection

3.2.1 Cleaning Works Methodology Should be free from dirt. laittance and contamination Each Mould prior to casting H H H

Works Methodology / Working

Arc Length:- +/- 1.00 mm, Thickness:- +/- 3.00 mm and Width:- +/- 1.00 mm
3.2.2 Dimension Check Drawings of Mould / Cl 9.5.1.17, For one set of moulds daily H H W/R
and Diagonal:- +/- 1.00 mm Check List Format No:- UG1 AFC
Section 9, Volume 5 of the OCS 200 QUA QRF 201

Works Methodology/Manufacturer's To be applied with the aid of spray / roller brush with uniform application
3.2.3 Mould Oil Application Each Mould H H W/R
recommendations throughout

3.3 Pre Construction Activity

3.3.1 Lifting Sockets/Gaskets Installations H W S/R Check List

Approved Method Statement Proper Installation to be done to prevent concrete entering into the gaskets Each Segment
3.3.2 Other Embedded Items H W S/R Check List

3.4 Cage Installation

Approved Construction Drawings / Clear Cover to main reinforcement:- 25 mm (Min) or as mentioned in the
3.4.1 Spacing and thickness of Rebar Cover H H W/R
Method Statement drawings. Covers shall be provided in the form of spacers
Check List UG1 AFC 200 CNS QRF
Every Cage 202
Approved Method Statement / Minimum Cover to be maintained throughout the cage while placing and the
3.4.2 Cage Positioning H H W/R
Construction Drawings cast in embedded items to be installed prior to positioning of cage

3.5 Concreting
Approved Method Statement / Concrete Pour Record (UG1 AFC
3.5.1 Final Inspection prior to concrete Item 3.1 to 3.7 is properly implemented, recorded and accepted Each Segment H H H 200 CNS QRF 201)
Construction Drawings

3.5.2 Mixing Time Cl. 5.2.4 (4) of OCS, Vol -5, Section 5 Thoroughly mixing of the ingredients to be ensured Each Batch N/A R R Batch Weight Record

Pre-numbered and to be issued sequentially. Must record time of batching

3.5.3 Delivery Docket Issued with each transit mixer Each transit load N/A R R
completion

Visual / Concrete Despatch Docket

Cl. 5.2.1(2) & 5.2.3(4) of Section 5, 70 mm to 120 mm (Non conforming first slump can be retested from the Each batch of concrete. Agitator deliveries to be checked at
3.5.4 Workability Testing H P W/R (UG1 AFC 000 QUA QRF 020) /
Volume 5 of OCS same sample) the point of discharge at site Concrete Pour Record (UG1 AFC
200 CNS QRF 201)

Cl. 5.2.1(2) & 5.2.6(9) of Section 5, Fresh Concrete Temperature at the point of discharge of transport vehicle
3.5.5 Temperature At random N/A P W/R
Volume 5 of OCS should vary from 5oC to 32oC

Cl. 5.2.4(5) of Section 5, Volume 5 of Concrete Pour Record (UG1 AFC

3.5.6 Completion Time Within 2 hours from the batch time Each Pour of Concrete P S R 200 CNS QRF 201)
OCS

3.6 Sampling of Hardened Concrete

Minimum 3 cubes for lifting strength of each segment and furthermore 1 set
Cl. 5.2.3(2) of Section 5, Volume 5 of of 3 cubes for 1-5 m3 and 2 sets of 3 cubes each for 6-15 m 3 for maturity (7 Lifting strength for each segment and maturity strength for Concrete Pour Record (UG1 AFC
3.6.1 Concrete Cube Moulds (150x150x150 mm) H H R 200 CNS QRF 201)
OCS days and 28 days) for each production cycle. (Set:- 1 cube for 7 days and 2 each production cycle / day
cubes for 28 days)

3.6.2 Concrete Moulds for other tests Section 5, Volume 5 of the OCS H P W/R ---

ITP - 019, Item 9.2.2 to 9.2.5

3.6.3 Computation
of Concrete
Analysis of Chemical Analysis Cl. 5.1.6(3) and 5.2.5 (2) of Section 5,
N/A R R
UG1 AFC 000 QUA QRF 017 & UG1
AFC 000 QUA QRF 018
Volume 5 of OCS

3.7 Demoulding

As per design data / works To be demoulded not before the achievement of the lifting strength as
3.7.1 Time of Demoulding For each Segment H H R
methodology computed by the designer

Contract Documents / Construction

3.7.2 Dimension check Clause 9.5.1.17, Section 9, Volume 5 of the OCS For each Segment H H R
Drawings

Check List UG1 AFC 200 CNS QRF

3.7.3 Surface Check Works Methodology To be free from any surface defects / irregularities etc. For each Segment H H R 204

Clause 9.5.1.3, Section 9, Volume 5 of All segments should bear the indelible marks prior to dispatch viz. type of
3.7.4 Identification Mark For each Segment H H R
the OCS / Works Methodology segment, date of casting etc.

3.8 Repairing of the Segments

Works Methodology /Approved Notice of No Objection Certificate from Owner / Consultant for the repair Notice of No Objection/Acceptance
3.8.1 Material and Proportion Check Each segment H H R from Employer
Method Statement methodology

Works Methodology /Approved Clause 9.5.1.17, Section 9, Volume 5 of the OCS for dimension check and
3.8.2 Surface / Dimension Check Each Segment H H R Visual
Method Statement surface to be free from further defects / irregularities

3.9 Lifting and Storage

Works Methodology /Approved

3.9.1 Strength Check prior to lifting Should be lifted not before 10 MPa strength is achieved Each Segment H H R
Method Statement / Design data

Clause 9.5.1.4, Section 9, Volume 5 of Shall be stored / stacked on edge, on a prepared level base with timber
3.9.2 Storage Each Segment H H R
the OCS packing as relevant

OCS / Approved Method Statement /

4.0 CORRECTIVE ACTIONS Construction Drawings
All corrective actions initiated by "H" are properly implemented Each Panel P P/R R All check lists referred to above

5.0 RELEASE All properties conforming to specifications N/A H R

Prepared by : TRANSTONNELSTROY-AFCONS JV QA/QC REVIEWED BY : TRANSTONNELSTROY- AFCONS JV Approved By: KMRCL / GC

NAME : NAME : NAME :

SIGN. : SIGN. : SIGN. :

DATE : DATE : DATE :

H - Hold Point W - Witness Inspection S - Operation survelliance R - Review of Document P - Perform