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Quality Control Manual Papua New Guinea PDF
Quality Control Manual Papua New Guinea PDF
Quality Control Manual Papua New Guinea PDF
Manual
Minor and Major Works DRAFT
Version 1
DRAFT Quality Control Manual
CONTENTS
1. INTRODUCTION 5
INDEX OF CHECKLISTS
SU01 General
SU02 Establishment
SU03 Clearing and Grubbing
SU04 Earthworks
SU05 Base and Sub-base Pavement courses
SU06 Bituminous Surfacing
SU07 Drainage
SU08 Roadside Furniture and Markings
SU09 Masonry Structures
SU10.1 Piling for Structures – Driven Piles
SU10.2 Piling for Structures – Bored Piles
SU11 Falsework
SU12 Formwork for Concrete
SU13 Steel Reinforcement
SU14 Concrete Work
SU15 Structural Steelwork
SU16 Protection of Steelwork
SU17 Miscellaneous Bridge Items
SU18 River Training and Bank Protection
SU19 Daywork
REVISION STATUS
Pages
Issue
Edition Version Affecte Description Approved By
Date
d
1 1 All First edition Gazelle Sep/03
Restoration
Authority
1. INTRODUCTION
The Quality Control Manual has been produced as a general guide for the Quality Control
of most civil works projects. The Checklists included in this Manual are based on the
Department of Works Specification for Road and Bridge Works August 1995.
The contract documents take precedence over this Manual and in the event of any
perceived conflict reference is to be made to the Project Manager for clarification.
Users of the Manual are invited to submit comments or to suggest changes. These should
be directed to the _________________________ , so that changes, if appropriate, may be
incorporated into future revisions.
The initial suite of Checklist has been developed from the Department of Works
Specification for Road and Bridge Works August 1995. These checklists are seen as the
first stage of development of the Quality Control Manual and further Checklists are
envisaged to be added to the manual as Specifications are reviewed and incorporated in
the system.
2.2 REFERENCES
As noted above the checklists form an integral part of Quality Control and the completed
checklists will form the majority of the Quality Documentation for the project. Other
documentation that will need to be referred to will included:
• Department of Works Specification for Road and Bridge Works August 1995
• Special Conditions of Contract
• Construction Drawings
• The Contract Administration Manual, particularly Procedure CA12 – Quality Control
• The Contractors Work Method Statements and Quality Control Documentation
2.3 RESPONSIBILITIES
A Project Audit Plan is attached, this is the first phase of developing an Audit Schedule for
a project as during the construction stage some processes will be carried out well and
would require less auditing and other processes will be seen as being only acceptable, or
even unacceptable and these processes will require more frequent auditing.
It should be noted that the Auditing scheduled in the Audit Plan is additional to everyday
surveillance activities, and is an opportunity for an independent individual to review the
work practices and quality of the project.
GENERAL
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
1.8.2 The Contractor maintains diversion roads to a standard that will ensure
proper passage for traffic in all reasonable weather conditions.
1.8.2 Temporary bridges have been designed for T44 loading in accordance with
NAASRA Bridge Design Specification 1976.
1.8.4 Temporary traffic control techniques and signage are operating effectively.
1.8.5 Road furniture removed as a result of temporary works has been reinstated,
if required, at project completion.
1.9 The Contractor has maintained all set out pegs in their correct position.
1.11 Construction traffic abides by any enforced load limits on roads and
structures.
1.12 The Engineer has been advised of any conflict with Public or Private
Utilities.
Signed:.......................................
Date:……...................................
ESTABLISHMENT
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
2.1.4 Disposal of any debris on site has been approved by the Engineer.
(iii)
2.1.4 On demobilisation, the site is in a neat and tidy condition.
(v)
2.2 ENGINEER’S ESTABLISHMENT
2.2.2 Within one month of Tender acceptance, the Contractor has erected a
temporary office for the Engineer.
2.2.2 The location of the office has been determined by the Engineer.
ESTABLISHMENT
2.2.6 The Contractor maintains the office in a clean and tidy condition, with
appropriate disposal of waste.
Comments:
Signed:.......................................
Date:……...................................
Project: .........................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
3.1 Trees and shrubs have been cleared by cutting or breaking off ≤ 250mm
above ground level.
3.1 The area to be cleared and grubbed has been adequately identified.
3.1 The area has been adequately grubbed by removing fallen trees, stumps,
logs, upturned roots, rotten wood and all other vegetable growth.
3.1 Holes, such as those left from stumps, in areas of embankments have been
backfilled and compacted.
3.2 The Contractor has adequate measures in place to prevent the spreading of
fires.
3.2 Un-burnable material if buried on site, is done outside the structural backfill
area.
3.3 After grubbing and stripping, the topsoil surface has been graded to
facilitate accurate survey.
3.6 Piles are extracted or cut off one metre below river bed level, or as directed
by the Engineer.
Signed:.......................................
Date:……...................................
EARTHWORKS
Project: .........................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
4.2.4 Joints between new and existing pavement are stepped 150mm (vertical)
x 300mm (horizontal) if the sub-base layer is ≥ 200mm.
4.7 Excavated rock suitable for stone pitching, gabions etc has been
reserved if required.
EARTHWORKS
4.12.3 Founding levels have not been affected by water inflow and are suitable
for pouring blinding concrete.
4.13 The Contractor complies with all applicable legislation, regulations and
by-laws associated with the handling, storage and use of explosives.
4.13 When blasting near buildings ground vibrations are less than those
specified in AS2187. Ground vibrations have been measured with a
Vibragraph supplied by the Contractor.
4.13 The Contractor has given 10 days notice of intention to blast, together
with location and methods to be adopted.
4.13 Explosives are stored in a secure place, clearly identified with warning
signs.
4.13 If the work is accessible by the general public, before any shots are fired,
knowledge of the apparent danger must be conveyed to all persons in
the area.
4.14.2 Compaction is performed by a vibrating roller or grid roller with static load
per 100mm width of roller of at least 1.75kN or 7.8kN respectively.
4.14.2 Compaction has been continued until movement of the surface under the
roller is negligible.
4.14.3 The 300mm layer below the sub-base, or other thickness, as directed by
the Engineer has been formed with material < 75mm nominal size, and
has a minimum 4 day soaked CBR of 8%. This material has been
compacted in 200mm layers loose, to 100% MDD (Characteristic Value).
4.14.4 The Contractor has provided 7 days prior notice of “Upper Layer”
placement and has submitted material samples for approval prior to
placement.
EARTHWORKS
4.15.2 Each layer has been compacted to 100% MDD (Characteristic Value).
4.15.2 Materials which cannot be suitably compacted are not located within
600mm of the underside of the sub-base.
4.15.3 The 300mm layer below the sub-base, or other thickness, as directed by
the Engineer has been formed with material < 75mm nominal size and
has a minimum 4 day soaked CBR of 8%. This material has been
compacted in 200mm layers loose, to 100% MDD (Characteristic Value).
4.15.4 The Contractor has provided 7 days prior notice of “Upper Layer”
placement and has submitted material samples for approval prior to
placement.
4.15.6 Topsoil has been spread in the areas and to the depths required. Stones,
roots or other material with least dimension greater than the depth of
spread have been removed.
4.18 BORROW
4.18 The Contractor has planned his earthworks operations to maximise the
use of suitable excavated material and to minimise the use of Borrow
material.
4.18 Borrow pits have been cross-sectioned by the Contractor in the presence
of a representative of the Engineer, before material is removed.
4.19.2 Fill below structural foundations above natural surface has been in
200mm layers compacted to 95% MDD (Standard Compaction).
EARTHWORKS
4.19.5a Abutment backfilling has not commenced until approved by the Engineer.
4.19.5b A drainage layer 300mm wide has been placed behind wall type
abutments, extending to a subsoil drain. Material used has 100%
passing a 75mm sieve & 25% passing the 4.75mm sieve.
Signed:.......................................
Date:……...................................
Project: .........................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
5.2 MATERIALS
Yes/No
5.2.1 The Contractor has provided a material source assessment at least 10
working days before material deliveries commence, to stockpile or
pavement.
5.2.2 Base and sub-base materials meet all requirements of Section 5.2.2 of
the Specification such as grading, PI, LL and CBR.
5.2.2 Imported material has not been added to the source material without the
Engineer’s approval.
5.2.3.1 Coronous material for use in base and sub-base layers has been
approved by the Engineer.
5.2.3.2 The method of selecting and processing Coronous material has been
approved by the Engineer.
5.3.3 Lot sizes, number and frequency of material tests has been determined
by the Engineer.
5.4 CONSTRUCTION
5.4.3 Prior to overlaying existing formation, the surface has been scarified and
shaped as necessary. The total depth of scarified and added material
does not exceed the permissible layer thickness.
5.4.5 The final unbound pavement layer has a uniform surface free from loose,
5.4.6 The bituminous prime coat was applied to the base course after level,
compaction and surface finish had been approved by the Engineer.
5.6.3 The compaction standard for each lot has been represented by the
Characteristic Value of the Relative Dry Density.
5.6.3 The location of in-situ dry density testing has been chosen by a method of
random stratified sampling.
5.6.5 The surface of the pavement in every layer displays no visible vertical
movement under compaction equipment.
Signed:.......................................
Date:……...................................
BITUMINOUS SURFACING
Project: .........................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
6.1.2 The Contractor has tested the cutback bitumen for conformance with AS
2157.
6.1.4 The Contractor has measured and recorded the road temperature at
regular intervals.
6.1.5 Before spraying, the surface of the base course has been swept free of
loose stones, dirt and foreign material.
6.1.5 Spraying does not commence until the prepared surface has been
approved by the Engineer.
6.1.6 The spray bar operator has all nozzles in full view.
6.1.7 The spray bar and all measuring equipment on the distributor has been
recently calibrated and a record supplied to the Engineer.
BITUMINOUS SURFACING
6.1.8 Performance testing of the distributor has been made, if requested by the
Engineer.
6.1.9 The use of hand spraying has been approved by the Engineer.
6.1.10 The spray length has been measured and marked on the ground.
6.1.12 The width of primed surface is 150mm wider on each side than that
specified.
6.1.14 Prime coat is applied during dry conditions with road temperature ≥ 18˚C.
6.1.15 Adjacent structures and trees are protected from splattering prior to
spraying.
6.1.16 Traffic has not been permitted on the prime coat until fully penetrated and
dried in.
6.2.3 The Contractor has submitted details of adhesion agent for the Engineer’s
approval.
6.2.4 Aggregates are clean, hard, dry crushed stone or gravel which conform to
Section 6.2.4 of the Specification.
6.2.5 Single seal application uses 19mm then 13.2mm nominal size unless
directed by the Engineer.
BITUMINOUS SURFACING
6.2.7 All aggregate has been precoated. Precoating material is distillate with
10% bitumen and !% megamine BA applied within the range of 6-
12litres/m³.
6.2.8 The Contractor has supplied details of the plant and equipment as
required by the Engineer.
6.2.8 Plant and equipment conform to the requirements of Section 6.2.8 of the
Specification.
6.2.9 Before application of binder, the surface has been swept free of loose
stones, dirt and foreign material. Sweeping extends 200mm beyond the
edge of the area to the sprayed.
6.2.10 The application rate of bituminous binder material and cover aggregate
has been determined by the Engineer. The application rate falls within the
ranges tabulated:
6.2.13 After application, the quantity of material sprayed is checked against the
area covered and any necessary adjustments are made to subsequent
runs.
BITUMINOUS SURFACING
6.2.15 The aggregate is rolled by either pneumatic tyred or steel wheeled rollers
(if approved by the Engineer), until aggregate is firmly embedded.
6.2.16 Traffic is not permitted on the new work until sufficient rolling has taken
place.
6.2.16 “Wet Tar” and 20kph signs have been erected at 300m intervals.
6.2.17 The treated surface is checked during the maintenance period for
softening and bleeding.
Signed:.......................................
Date:……...................................
DRAINAGE
Project: .........................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
7.2 MATERIALS
Yes/No
7.2.1 RC pipes are of the correct class and are free of defects and damage to
ends.
7.2.2 Jointing mortar is one part Portland Cement to two parts fine sand with
enough water for a satisfactory consistency. All mortar is used within 30
minutes of adding water.
7.2.4 Culverts have been tested in the presence of the Engineer’s representative
prior to leaving the place of manufacture.
7.2.4 All culvert sections are free from defects or damage to edges.
7.2.4 The Contractor has submitted a base slab design for the Engineer’s
approval, if no such detail is shown on the drawings.
7.3 Where select material is not specified below the bedding layer, the top
150mm of formation is compacted to the relative density of the adjacent
embankment material.
7.3 The width of trenches is just enough to permit satisfactory jointing of pipes
and compaction of backfill materials.
7.3 Rock above invert level is excavated to 150mm below invert level and
backfilled with selected material.
7.3 Soft and spongy foundation material has been removed to a depth as
directed by the Engineer for a width 1.5 times the diameter or span of
culvert from the centreline of the barrel and backfilled according to Section
7.5 of the Specification.
7.3 Culverts are bedded on sand 75mm thick. Pipe bedding is shaped to fit the
underside of the culvert and graded to provide uniform bearing.
DRAINAGE
7.4 PLACING
7.4.1 RC pipes are laid from the outlet end with socket ends upstream and
spigots downstream.
7.4.1 Mortared joints are kept damp until the Engineer approves backfilling.
7.4.5 For multi-cell culverts, a 15mm gap is provided between adjacent cells and
filled with cement mortar or approved bitumen filler.
7.4.5 Mortared joints are protected form the sun and cured for 48 hours.
7.5 BACKFILLING
7.5 Backfill material is not placed until the culvert has been inspected and
approved for backfill.
7.5 The backfill material is free from lumps and vegetable matter and stone >
75mm and has at least 50% retained on 2.46mm sieve. PI ≤ 12%.
7.5 Material under the haunches of pipes and near the sides of culverts is
compacted with hand held equipment.
7.5 For corrugated steel pipe, special care is taken to prevent distortion.
DRAINAGE
7.5 Backfill around culverts extends 300mm above their top and for one
diameter either side of their centreline for pipe culverts or half the wall
height for box culverts, measured from the wall face.
7.5 Culverts laid in a trench are backfilled to the full height, length an width of
trench.
7.5 Drainage structures once installed are not damaged by heavy construction
equipment.
7.7 Culverts not re-laid are taken to the Engineer’s compound and stacked as
directed.
7.10.1 Backfill over the slotted pipe is as specified (ie Type A, B or C).
7.10.2 Bedding for slotted pipe is 50mm thick filter material spread and compacted
to a uniform grade.
7.10.2 Filter material is placed above the slotted pipe 300mm thick and compacted
by vibrating plates or tampers. Additional lifts of filter material do not
exceed 200mm loose. Filter material is compacted to 90% MDD.
7.11.3 No earth or rock falls into the mix as the concrete is poured.
7.11.4 Precast concrete drainage units use concrete Grade 30. All formwork and
casting is submitted for the Engineer’s approval. Precast unit dimensions
are within a tolerance of ±3mm.
7.13.3 For cast in-situ work, where an extrusion process is used, the concrete is
Grade 30 (for testing only needs to meet Grade 25 requirements).
DRAINAGE
7.13.3 The extruded concrete surface is free of voids, honeycombing and has a
steel trowelled finish.
7.13.3 Where the Contractor uses an extrusion mould, a test section is provided
for approval by the Engineer.
7.13.4 Precast concrete sections are constructed using Grade 30 concrete and
have an individual tolerance of ±3mm to the specified dimension.
7.13.4 Cast in-situ work has expansion joints at 20m intervals & construction joints
at 5m intervals.
7.13.4 Expansion joints are 6mm bitumen impregnated fibre board in the full
cross-section.
7.13.4 Construction joints are grooves 40mm deep and 6mm wide.
7.13.4 Cast in-situ concrete work is cured in an approved manner for at least 7
days.
7.13.7 Horizontal and vertical alignments of the product do not vary from those
specified by more than ±10mm. Overall dimensions of the product are not
less than those specified on Drawings.
7.13.8 Where the product is not placed on a pavement layer, the sub-grade is
compacted and a bedding layer of sub-base material placed to a
compacted thickness of 75mm at 95% MDD.
Signed:.......................................
Date:……...................................
Project: .........................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
8.2.3 Steel beam guardrail, posts and terminal sections are Armco Flex-Beam
Guardrail or similar approved by the Engineer. No punching, cutting, or
welding is done in the field. Holes for special details have the Engineer’s
approval.
8.2.3 Bolts for guardrail extend 6mm beyond nuts, except where required for
adjustment, extend no more than 12mm.
8.2.4 Posts are set to a line, level and spacing conforming to the line and grade
of roadway.
8.2.4 Posts are backfilled with approved material and thoroughly tamped.
8.2.4 Bolts at expansion joints are located at the centre of slotted holes. All other
bolts are drawn tight.
8.4.7 Approaches to single lane bridges are marked with a yellow coloured bar
marking system as specified in Section 8.4.7 of the Specification.
Signed:.......................................
Date:……...................................
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
9.1.2 Mortar used consists of one part Portland Cement to two parts of clean
well graded fine sand with sufficient water to be workable.
9.1.3 Stones are bedded in mortar to a depth of 60% of the stones thickness.
9.1.4 Mortared joints are well rodded to a depth of 75mm minimum and kept
damp for 48 hours.
9.2 ROCKWALLING
9.2.1 Stones are durable and greater that 0.016m³ in volume with minimum
height of 150mm and minimum plan dimensions of 300mm.
9.2.1 The base of the wall is embedded at least 300mm unless founded on
rock, where it should be securely keyed.
9.2.4 Grouted and Masonry Rockwalling is capped with a 25mm mortar layer.
Signed:.......................................
Date:……...................................
DRIVEN PILES
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
GENERAL
Yes/No
10.1 Pile materials (steel, concrete or timber) conform to specified
requirements.
10.1 Tubular steel piles with closed ends are driven with a driving shoe.
10.3.2 Handling, transporting and pitching ensures piles are not damaged.
INSTALLATION
10.3.2 RC piles are lifted and stacked at two points, 1/5th of their length from
each end.
10.3.2 RC piles are pitched by lifting at a point 3/10ths the length from the head.
10.3.3 The necessary cushioning is provided between driving helmet and pile.
10.3.4.1 Contractor has provided a pile driving equipment list for the Engineers
approval.
10.3.4.1 Water jetting is not performed with steel H-piles.
DRIVEN PILES
10.3.4.2 The appropriate hammer has been provided in accordance with Section
10.3.4.2 & 10.3.4.3.
10.3.4.7 Piling with followers is performed only with written permission of the
Engineer.
10.3.4.8 Water jet equipment can deliver at least 700MPa at two 20mm nozzles.
10.3.6 Prior to driving, piles are identified with a unique number and marked in
increments of 500mm from the pile toe.
10.3.6 All pile driving is supervised and installation data recorded on the
Employers standard form. Duplicate copies of the standard form to be
submitted to the Engineer.
10.3.6 Asbuilt location plan of the piles installed is provided and includes the
information specified in Section 10.3.6 (a) to (e).
Comments:
Signed:.......................................
Date:……...................................
BORED PILES
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
GENERAL
Yes/No
10.1 Pile materials (steel, concrete or timber) conform to specified
requirements.
INSTALLATION
10.4.1 Engineer or representative is present during boring.
10.4.2 Boring equipment is fitted with suitable controls to ensure alignment can
be monitored prior to and during boring.
10.4.3 Boring logs are submitted to the Engineer within 3 working days of
completion.
10.4.4 Boreholes are covered at all times when work is not in progress.
10.4.4 Lining tubes, if required, are provided during excavation to ensure stability.
10.7.2 The final level of concrete is suitably above the required finished level to
ensure pile head concrete quality.
10.7.5 Sand has been approved by the Engineer prior to filling of the piles.
BORED PILES
LOAD TESTING
10.6 Load testing equipment and procedures match those specified in Section
10.6.
10.6 Load test results and driving records are submitted to the Engineer within
7 days of the test.
10.6 The Contractor has been advised of the Engineers interpretation of the
load test results within 7 days of their receipt.
Signed:.......................................
Date:……...................................
FALSEWORK
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
11.1 GENERAL
Yes/No
11.1 The Contractor has provided the Engineer with detailed Drawings and
calculations for proposed Temporary Works at least four weeks before work
commences.
11.1 Temporary Works are not used without written consent of the Engineer.
11.1 Falsework is released at the time and in the order consented by the
Engineer.
11.1 All timber is well seasoned and free from knotholes, loose knots and other
defects.
11.1 Equipment for removing falsework is not operated upon or attached to any
portion of the new structure without the Engineers approval.
Comments:
Signed:.......................................
Date:……...................................
Project: ......................................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
12.1 GENERAL
Yes/No
12.1 There are no gaps in the formwork that will permit loss of material.
12.1 Formwork is rigid and adequately braced to maintain position and shape.
12.1 Check width and length of formwork, diagonal for square and plum with
spirit level.
12.2 CONSTRUCTION
12.2.1(a) Formwork is not warped or buckled and concrete contact surface is free
of defects and of the correct class.
12.2.2(a) Check that formwork used for exposed surfaces has the correct surface
finish.
12.2.1(b) The design of mild steel formwork has been reviewed by the Engineer
before work commences.
12.2.1(b) Check for Mild Steel forms that all bolt and rivet heads are countersunk
and welds have been ground back.
12.2.2 Forms are designed and constructed such that removal can be made
without injury to concrete or forms.
12.2.2 Block-outs and embedded items (if any) are in the correct place.
12.2.2 There are no wires or bolts extending to the surface of the concrete.
12.2.2 Internal tie bolts can be extracted without damage to the concrete.
12.2.2 Holes left behind from internal ties are filled with mortar to the Engineers
satisfaction.
12.2.2 Check formwork re-entrant angles are chamfered and corners filleted.
12.2.3 Check that the formwork release agent doesn’t contact reinforcement.
12.2.3 Different release agents are not used on visible sections of the same
structure.
12.2.4 Formwork remains in position per the requirements of Clause 5.4.3 and
Table 5.4.1 of AS3610 and in no case is removed before the concrete
can support its own weight.
Signed:.......................................
Date:……...................................
STEEL REINFORCEMENT
Project: ...................................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
13.2 MATERIALS
Yes/No
13.2 The Contractor has produced a Manufacturer’s certificate as evidence that
all steel complies with the relevant specification. If such a certificate can not
be produced the steel shall be tested in accordance with Section 13.2 of the
specification. The certificates and/or samples have been supplied at least 3
weeks before fixing steel on site.
13.3 PROTECTION
13.3 Steel is stacked in racks above ground and is clear of mud.
13.3 Placed steel is free of dirt, detrimental scale, paint, oil or other foreign
substances.
13.4 CUTTING AND BENDING
13.4 Reinforcement is cold bent around the appropriate pin diameter.
13.5 Tie wire is annealed and not less than 1.25mm in diameter.
STEEL REINFORCEMENT
13.6 SPLICING
13.6 Bars are spliced and lapped as shown on the Drawing or as approved by
the Engineer.
Comments:
Signed:.......................................
Date:……...................................
CONCRETE WORK
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
14.6.5 Preliminary mixes have been made and tested, or approved on the basis
of past test results by the Engineer before placement.
14.6.2 The Contractor has provided details of any proposed grout mix for the
Engineers approval, together with 6 test specimens.
14.8.3 Check that ready mixed concrete is placed at temperatures less than or
equal to the values tabulated below.
Concrete Temperature
Grade (˚C)
15 - 30 33
40 30
CONCRETE WORK
14.8.2 Check delivery dockets for mix details. Take slump test to make sure it
is in accordance with the mix design and specification.
14.9.7 Check that the face of construction joints are prepared as follows:
• Surface roughened
• Foreign matter removed
• Saturated with water
• Covered with cement grout
14.9.2 Concrete is not dropped from a height of more than 2 m which may
cause segregation. A tremie or approved pump is to be used to place
from height.
14.9.5 High frequency internal vibrators are being used to place the concrete
(except for no fines concrete which shall be placed without tamping,
rodding or vibrating).
14.9.2 Concrete chutes are metallic and free of hardened concrete coatings.
14.9.2 Approval for use of concrete pumps has been granted by the Engineer.
14.9.3 Concrete is not placed under water unless approved by the Engineer
and that the quantity of cement is increased by 25%.
14.9.5(c) One vibrator is provided for each 5m³ of concrete placed/hour with a
minimum of 2 vibrators.
14.9.5(g) Vibrators are not used to make concrete flow over distances that will
cause segregation.
14.8.2 Check that the concrete is placed within the time limits in the
specification.
CONCRETE WORK
14.11.4 Exposed concrete surfaces other than slabs, are cured for at least 7
days. Slabs shall be cured for at least 14 days.
Comments:
Signed:.......................................
Date:……...................................
STRUCTURAL STEELWORK
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
15.1 GENERAL
Yes/No
15.1.1 The Contractor has submitted 3 copies of Workshop drawings for
review by the Engineer, one month prior to commencement of
fabrication.
15.1.1 The Contractor has submitted his program of work, including details of
weld sequences, distortion control & preheating to the Engineer, 14
days before commencement of fabrication.
15.1.1 Fabrication has not commenced until the Engineer has consented to the
use of the Shop Drawings, procedures and the program of work.
15.2 MATERIALS
15.2.2(1) Test certificates have been supplied to the Engineer, to prove the steels
compliance with appropriate standards.
15.3 FABRICATION
15.3.2 The appropriate method of cutting steel has been used, surfaces are of
the required Class and corners rounded to a radius of 2mm.
15.3.4(3)(a) The correct electrodes are being used and are stored in warm dry
conditions.
STRUCTURAL STEELWORK
2214-1988.
15.3.4(5) Welding is not commenced until the Engineer has approved the
Welding Procedure and the Contractor has submitted test assembles
duplicating actual conditions.
15.3.4(6)(d) Welding is not performed if the air temperature < 10ºC, unless the
materials are preheated to a temperature warm to the hand, within a
distance of 75mm from the point of welding, both laterally and in
advance of the welding.
15.3.4(6)(d) Welding is not preformed if surfaces are moist, during periods of strong
wind or in showery weather, unless the work and operators are
adequately protected.
15.3.4(11)(a) Welded components have been inspected and tested as necessary and
approved by the Engineer prior to being despatched from the
workshop.
15.3.5(3)(e) The first two shear studs welded on each member, have been tested by
bending to 45º by striking with a hammer.
15.3.5(3)(f) Any shear studs not showing 360º weld fillet, or have been repaired by
welding, or who’s length is more than 1.5mm greater than specified,
have been struck with a hammer and bent 15º.
15.3.6(1) All holes have been drilled with burrs and other defects removed.
15.3.6(2) The diameter of a completed hole is 2mm larger that the bolt except for
HSFG bolts, where the hole diameter is not more than 3mm larger than
the bolt.
15.4.1 The steelwork has been trial assembled prior to despatch to the site.
15.4.1 All components have been match marked prior to despatch to facilitate
reassembly in the field. Matchmark plans have been furnished to the
Engineer.
15.5 All fabrication has been executed to the shapes and dimensions shown
on the plans and to the tolerances specified in Section 15.5 of the
specification.
STRUCTURAL STEELWORK
15.7 Straps and chains used for lifting components are padded to prevent
damage to steelwork and its protective coating.
15.7 Components are inspected and passed by the Engineer upon delivery.
15.8.5 Contact surfaces bought together to form a joint are free of paint, oil,
dirt, loose rust, scale, burrs and other defects.
15.8.6 High tensile bolts are assembled with one hardened washer under the
nut or bolt head. The washer assembled with convexity outwards.
15.8.6 High tensile bolts are not tensioned until the joint is inspected by the
Engineer.
15.8.7(1) The Contractor has supplied test certificates for each batch of HSFG
bolts at least one month before their use.
STRUCTURAL STEELWORK
Comments:
Signed:.......................................
Date:……...................................
PROTECTION OF STEELWORK
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
Yes/No
16.1.1 All surfaces to be protected are thoroughly dry and free from oil, grease
and dust or other deleterious substances.
16.1.1 Steelwork has been abrasive blast cleaned to the appropriate class of
finish.
16.1.2 Prime coat has been applied (if required), within three hours of blast
cleaning.
16.4 Paint is not used which has exceeded its shelf life.
16.6 Damaged areas have been cleaned back to base metal and edges
bevelled ready for Touch Up painting per Section 16.3.3. Touch Up
painting overlaps existing by 50mm.
16.8 Completed joints have been painted as specified within 10 days of the
joint being made.
16.9.3(b) Buried seismic restraint components not cast in concrete have been
adequately protected.
PROTECTION OF STEELWORK
Signed:.......................................
Date:……...................................
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
17.2 BEARINGS
Yes/No
17.2.1 Bearings are in the correct position.
17.2.1 Sliding bearings are set to the correct offset, dependant on ambient
temperature.
17.2.2 The Contractor has submitted physical & mechanical property test
certificates of each bearing to the Engineer.
17.2.2(c) Mortar under bearings extend beyond the bearing by the thickness of the
mortar pad and is battered off at 1 to 1.
17.3.4 Waterstops are centre bulb or valve type manufactured from PVC with
fixing strip along edges.
17.3.5 Test certificates detailing the joint filler stress/strain relationship have
been submitted.
17.3.6 Joint sealants to trafficked surfaces are hot poured coal tar based,
acceptable to the Engineer. Sealant is applied in accordance with
Manufacturer’s recommendations.
17.3.6 Joint sealant not exposed to vehicle trafficking is gun grade two part
polysulphide sealant and is applied after the primer has set but within its
active period.
17.4 SCUPPERS
17.4 Drainage scuppers are uPVC pipes arranged so as not to stain exposed
surfaces with water discharged.
17.5 Sand for epoxy mortar is hard, sharp, siliceous and free of organic
material conforming to the grading of Section 17.5 of the Specification.
Comments:
Signed:.......................................
Date:……...................................
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
18.1.6 All gabion edges have been selvedged with 3.4mm diameter wire where
required.
18.1.9 Filling material is hard durable stone minimum dimension 100mm and
maximum dimension 250mm.
18.1.10 Gabion and reno mattress materials conform to the following tolerances:
Wire diameter ± 2.5%
Length ± 3%
Width ± 25mm
Other dimensions ± 3%
18.1.11 Gabions and mattresses are laced together along all adjoining corners
and sides.
18.1.12 At least two rows of empty gabions are wired together at the face of
uncompleted work prior to filling gabions closest to the completed work.
18.1.13 Gabions ≥ 1m high are cross tensioned in each compartment at 3rd points
in height.
18.3 For river training, gabions have been placed with their tops ~600mm
above normal flow level.
18.6.2 Overlapping fabric joints are 300mm above water level and 900mm below
water level.
18.6.2 The Contractor handles the fabric with care to prevent it being pierced.
18.10 PLANTINGS
18.10 Plantings of grasses, legumes, seeds or cuttings have been performed at
the most appropriate time to ensure propagation.
Comments:
Signed:.......................................
Date:……...................................
DAYWORKS
Project: ............................................................
Numbers shown refer to the relevant section of the Department of Works Specification, for
Road and Bridge Works.
Yes/No
19.1.1 Type and extent of work to be undertaken as Dayworks has been
agreed in advance of performance.
19.1.1 Labour rates for Dayworks are as listed in the Bill of Quantities. Rates
include a basic rate plus a rate for skill as specified by the Registered
Award, as set out by the Industrial Relations Act of PNG. This rate has
been further increased to allow for Contractors profit and overhead.
19.1.1 Written approval has been given by the Engineer for any overtime
related to Dayworks.
19.3.2 All Dayworks plant is in first class mechanical condition and has been
made available for inspection and approval by the Engineer.
19.3.4 The Contractor has kept the plant in good repair to ensure proper
output is maintained.
19.3.9(iv) Plant hire hours include delay for minor normal repairs, provided such
accumulated delay in any one day < 1/10th of the work time for that day.
19.3.9(vi) Payment has not been made for work affected by adverse weather
conditions.
19.3.9(vii) Time spent by plant travelling within the site has been approved by the
Engineer.
19.3.10 Further to Clause 52.4 of the Conditions of Contract, the Contractor has
prepared “Daywork Agreement Sheets” which have been signed by
both Contractor and Engineer.
DAYWORKS
Comments:
Signed:.......................................
Date:……...................................
Project: .......................................................................
Date Sample Location Chainage O/S Depth Density Moisture Moisture Density Conform Comment
sampled number Range ** Require s (Y/N) s
d
Project: .......................................................................
Results
Required
Project: .......................................................................
Date sampled Sampl Bulk Maximum Voids Voids Bitumen Marshall Flow Bitumen Particle Size Conform
e Density Density % Filled % Stability mm Content Total Distribution (Y/N)
numbe kN Mix (Y/N)
r
Results
Required
Project: .......................................................................
FORM DW01
“PROJECT NAME”
ACTIVITY……………………………………………………………………………………………………….
1.
2.
3.
4.
5.
6.
7.
MATERIALS
SIGNED……………………………
(Project Manager’s Rep)
SIGNED……………………………
(for Contractor)
DATE……../….…./……... DATE……../….…./……...