TRANSPORTATION INFRASTRUCTURE I C

2013
Standard Operating Procedure

Roads
Construction
 Standard Operating Procedure - 2013

Foreword

It gives me immense pleasure in releasing this first version of handbook of Standard

Operating Procedure (SOP) which will guide site engineers for generations to come .The
information provided here is meant to act as a guide in addition to the other standard
guides to assist the site operation team in preparing an operating plan which will define
action, priority, logic to ensure that all actions are performed in the most efficient way.
The SOP will also be a starting guide for the new engineering’s.

I am sure that the readers will find this manual useful in strengthening our commitment
towards achieving the best quality work. I welcome this book as a valuable contribution
to that goal and the best way to proceed, from a technical and operational stance.

Best Regards,

D K Sen
Executive Vice President & Head
Transportation Infrastructure Independent Company

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 Standard Operating Procedure - 2013

Dear All,

We are pleased to hand you over this compilation of Standard Operating Procedures (or
SOPs) which is expected to assist the site execution team as a ready reference in addition to
existing technical specifications (MORT&h, IRC and IS codes).

These SOPs have been designed to describe logical sequence of the steps to be followed for
executing key activities of road construction. Compliance to the SOPs will minimize variation
and promote quality through consistent implementation of a process or procedure within
the organization. SOPs will indicate compliance with organizational requirements. It will help
frontline engineers to plan the activity in advance and enhance operational efficiency.

These procedures essentially spell out what is required and expected of the front line
engineers while executing a particular activity. The procedures cover the scope,
responsibilities, reference codes, equipment/tool requirements, procedure, quality control,
checklist, safety for respective activities. The SOPs will also help in distinguishing and
standardizing the roles and responsibilities for different stakeholders with action checklists
for key staff members for each construction activity.

The sincere adherence to the standard procedures is bound to result in better work
preparedness, time savings, improved productivity and a better quality product.

While an attempt has been made to make this compilation exhaustive, this document needs
to be read in tandem with Project specific Contract Agreement and applicable technical
specifications for successful implementation of the projects under consideration.

This is a step forward to institutionalise the best practices followed in individual sites across
the organisations. We are sure that all stakeholders will find it quite beneficial.

Regards,
KV Praveen
GM & BU Head
Roads Runways & Elevated Corridor Business Unit

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 Standard Operating Procedure - 2013

TABLE OF CONTENTS

Table of contents ..................................................................................................................................... 4

1 Survey Work .......................................................................................................................................... 1
2 Site clearance ........................................................................................................................................ 3
3 EARTHWORK ...................................................................................................................................... 7
4. Subbase (GSB) AND Base (WMM) ..................................................................................................... 12
5 Bituminous Pavements ....................................................................................................................... 19
6 Dry Lean Concreat (DLC) with Paver .................................................................................................. 27
7 Paving Quality Concreat (PQC) with Paver ......................................................................................... 32
8 Hume Pipe Culvert .............................................................................................................................. 41
9 Box Culvert and Minor Bridge ............................................................................................................. 46
10 Bridges / Flyovers .............................................................................................................................. 51
11 Prestressing ....................................................................................................................................... 61
12 Void Former and Slab Concrete ........................................................................................................ 77
13 Formwork .......................................................................................................................................... 80
14 Back Filling......................................................................................................................................... 83
15 Stone Pitching ................................................................................................................................... 86
16 Turfing ............................................................................................................................................... 90
17 Hectometer and Km Stones .............................................................................................................. 92
18 Metal Beam Crash Barrier (MBCB).................................................................................................... 94
19 Road Marking .................................................................................................................................... 96
20 Traffic Signages ................................................................................................................................. 99
21 Pipe Casting - Verticle ..................................................................................................................... 103
22 Piling ................................................................................................................................................ 106
23 Pile Load Test .................................................................................................................................. 113
24 Fabrication of Steel Structures........................................................................................................ 117
25 Expansion Joints .............................................................................................................................. 126
26 Bearings........................................................................................................................................... 127
Annexure 1
Annexure 2
Annexure 3
Annexure 4

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1 SURVEY WORK
1.1.0 SCOPE
The scope covers the responsibilities, and
procedures applicable for Survey work. It
includes;
a) Providing permanent gridlines
b) Establishing benchmarks for level
control
c) Carrying out routine survey work
d) Maintaining survey records.
1.2.0 RESPONSIBILITY
Surveyors shall be responsible for;
a) Fixing Original Ground Levels(OGL) at
suitable cross section intervals
b) Establishing control points as per
survey plan, including marking of road
centre line
c) Maintaining records of day to day
survey activities
d) Carrying out post construction survey
and records for as built status
e) Conducting calibration of all survey
equipment as per PQP in coordination
with QC Engineer.
1.3.0 REFERENCES
a) Technical Specification of contract
agreement
b) MORT&H, Clause-109
c) IRC SP-57, Clause-4.4
1.4.0 EQUIPMENT/TOOLS
a) Total station with Prism
b) Auto levels & Leveling staff
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Standard Operating Procedure - 2013
1.5.0 PROCEDURE
Before commencement of work site
Engineer shall ensure to obtain;
a) Approval of the work method
statement (WMS).
b) The safety measures for the job.
c) Identify the risk involved during
execution of the activities & co-
ordinate with Safety Engineer’s to
comply/mitigate the same.
1.5.1 STEPS
a) The Proposed Centre Line (PCL) of the
new road project shall be fixed marked
on the existing road using total station
& chainages marked on the ground
using nails and paint.
b) The marking shall be done at 20m
interval on straight portion & 10m
interval on curve portion of the road.
The offset shall be marked on existing
road wherever applicable.
c) Temporary bench marks (TBM) shall be
fixed at every 250m on right of way
(ROW) line using an auto level. A pillar
of round shape 150ø mm with a steel
nail embedded on top of it shall be
established on hard ground concreted
with M15 Grade. The abstract copy of
TBM list shall be distributed to the
section in-charge every month.
d) Reduced levels (RL) shall be
established on the marked pillars and
closed at every GTS benchmark using
total station.
1.6.0 OPERATION PRECAUTIONARY
a) DO NOT;
1) Aim the telescope at the sun
2) Place the instrument directly on the
ground
3) Carry the instruments along with its
stand
b) Avoid heavy shocks and vibrations to
the instrument.
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 Standard Operating Procedure - 2013

c) Remove the battery before keeping the SUMMARY

instrument in the box.
d) Allow instrument to dry before keeping
it in box.
 The PCL of the new road project
e) Calibrate internally the instrument
every 3 months for auto levels and shall be marked using nails and
every 1 year for total stations. chainages marked with paint.
 TBM shall be fixed at every 250m
1.7.0 SAFETY PRECAUTION  RL shall be established on the
a) All staff and workmen should wear marked pillars and closed at every
reflective/PPE jackets within work area. GTS benchmark.
b) Safety cones and ‘Men at work’ boards  Abstract copy of TBM list shall be
should be used for survey work while distributed to Section In charge
working on live roads. every month.
c) Mobile phones to be avoided while on
moving roads.

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC SW/01/R&R/R0
Project Client
Consultant Contractor
Work Length RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR SURVEY WORKS
Checked & Found OK Signature
Sl No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg
Check for Permanent Pillar No.__________, co-
1
ordinates and reduced level.
2 Check for Reference pillars co-ordinates

3 Check for Reference pillars reduced level

4 Check for co-ordinates with respect to Reference pillar

5 Check for closing error for position and level

Check for existing ground level survey made and
6
records maintained
Remarks

L&T QA/QC Client/IE

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2 SITE CLEARANCE
2.1.0 SCOPE
The scope covers the responsibilities and
procedures applicable for site clearing
operations. It includes;
a) Cutting, removing, and disposing of
all organic materials not suitable for
incorporation in works including top
soil not exceeding 150mm in
thickness.
b) Excavation & Back filling to required
compaction of pits resulting from
uprooting of trees and stumps.
2.2.0 RESPONSIBILITY
Site Engineers shall be responsible to;
a) Prepare survey plan and ensure
mock-ups and trials, so that the
construction activities are as per
WMS planned
b) Ensure all activities are aligned to
meeting the cycle time requirements
for the area, thus to meet project
schedule and optimum utilization of
resources
c) Ensure strict conformance quality
and safety by supervisors and
workmen.
2.3.0 REFERENCES
a) Technical Specification of contract
document
b) MORT&H, Section-200
c) IRC SP-57
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2.4.0 EQUIPMENT/TOOLS
a) Dozer, Dumpers, Etc.
b) Measuring tape, Crow bar Spade, line
rope, lime powder, Etc.
2.5.0 PROCEDURE
Please refer Point No: 1.5.0
2.5.1 RECONNAISSANCE OF
OBSTRUCTION
a) Details of facilities/utilities that
needs to be dismantled or shifted
shall be listed & submitted to the IE
or his representative for further
instruction as per MORT&h - Clause
110.
b) Local authorities like Municipality,
Panchayats Etc. may also be
consulted/interviewed during the
reconnaissance process for further
information.
2.5.2 CLEARING & GRUBBING
a) Dozers and dumpers shall be used for
clearance & removal of shrubs,
stumps, Etc. falling within the limit of
excavation/embankment.
b) Major Tree cutting; Prior approval
shall be taken from the IE for the
number of trees to be cut, indicating
the size & girth of each tree falling
within the ROW and its subsequent
disposal/stacking. Larger trees shall
be cut to such depth below ground
level that in no case these fall within
500mm of the sub- grade.
c) Road side trees, pole lines, fences,
signs, monuments, buildings,
pipelines, sewers and other highway
facilities adjacent to the highway
which are not to be disturbed shall be
protected from injury or damage and
the shall be intimated to the IE.
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d) All concrete pavements, base courses
in carriage way and shoulders, Etc.
designated for removal shall be
broken into pieces and stock piled or
disposed as directed by the IE.
2.5.3 DISMANTLING OF STRUCTURES
a) For dismantling structures; the
connecting edges of structures shall
be cut, chipped and trimmed to the
required lines and grades without
weakening or damping any part of
the structure.
b) Due care shall be taken to ensure
that the reinforcement bars which
are left to be in place so as to project
into the new work as dowels or ties
are not damaged during removal of
concrete.
c) All structure dismantling shall be
done with care & the resulting
materials so removed shall not cause
any damage to the serviceable
materials and the structures nearby.
d) In dismantling pavements structures
like MS pipes guard rails, kerbs gutter
and fencing; where portions of
existing pavements are to be retained
in the finished work, shall be removed
to an existing joint or cut/chipped
true to the lines with face
perpendicular to the existing
structure. The area shall be restricted
from public entrance.
e) Pipe culverts that are removed shall
be cleaned and neatly piled in the
row within a lead of 1km.
f) Timber or lumber from old
structures, which are to be salvaged,
shall be neatly stored in piles in
locations suitable for loading as
directed by the IE.
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Standard Operating Procedure - 2013
g) Location of disposing area served
records shall be maintained and
submitted for billing.
2.6.0 SAFETY PRECAUTIONS
a) Care shall be taken while cutting
trees.
b) The cutting material shall not disturb
the live traffic.
c) The cutting crew shall wear PPE/
reflective jackets.
d) The cutting area shall be protected
with safety boards and cones.
e) Care shall be taken for ‘Not To
Disturb’ nearby passing live electrical
lines and utilities.
f) All dumper trucks shall be provided
with reverse horns.
g) Only experienced and licensed
operators shall be engaged for
excavation and hauling.
h) Flagmen shall be provided at all exit
points of the trucks/tippers.
i) If night work is to be carried out the
area shall be sufficiently provided
with lighting.
j) All pit’s which exceeds 1200mm in
depth, shall be barricaded.
k) Warning and cautionary boards shall
be displayed at well’s in-case of well
filling.
For Internal Circulation Only
 Standard Operating Procedure - 2013

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC SC/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR SURFACE PREPARATION-PQC
Checked & Found OK Signature
Sl. NO. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg

1 Method statement for excavation approved

2 Excavation plan prepared and approved

3 Grid pillars made and centre lines marked

Excavation area cleared off bushes, vegetation, trees,
4
etc.
Layout and area of excavation are marked on the
5
ground as per plan
Existing ground level survey made and record
6
maintained
Shoring materials/ dewatering equipment depending
7
upon soil and depth of excavation arranged
Excavation made upto 150 mm below the required
8
level by machine/manually
Proper side slopes/offset/ shoring made for proper
10
earth stability
Excavated earth is dumped beyond the width specified
11
from excavation
12 Bottom layer properly compacted for receiving PCC

13 Proper side supports made for PCC as per the drawing.

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2013

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC SC/02/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR CLEARING & GRUBBING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Trees, shrubs, bushes, stumps, roots, top organic soil
1
and other rubbish removed and disposed
2 Required excavation carried out

3 Excavated pits backfilled with suitable material

4 Compacted the backfill material properly

Remarks

L&T QA/QC Client/IE

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3 EARTHWORK
3.1.0 SCOPE
The scope covers the responsibilities and
procedures applicable for earthworks. It
includes;
a) Filling of embankment and subgrade,
to the lines, slopes, camber &
gradients as specified in the approved
drawings
b) Filling behind the abutments of
structures using granular material
3.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0
3.3.0 REFERENCES
a) Technical Specification of contract
document
b) P & P Drawings
c) MORT&H - Section 300
3.4.0 EQUIPMENT/TOOLS
a) Dozer, Excavators, Grader, Roller and
Dumpers Etc.
b) Measuring tape, Crow bar Spade and
line rope Etc.
3.5.0 PROCEDURE
Please refer Point No: 1.5.0
3.5.1 EARTH WORK IN FILLING
3.5.1.1 TOE LINE FIXING
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Standard Operating Procedure - 2012
a) The width of pavement for toe line
shall be calculated by referring the
drawings with due considerations to
the formation width (+) the offsets
and slopes of different layers (+)
depth the current layer from the
Formation Road Level (FRL).
b) The toe line/fixing of pegs to mark the
limits shall be done before the
commencement of excavation work.
c) Reduced level shall be transfer on the
peg by auto level and string line firmly
tides to peg.
3.5.1.2 HAULING AND DUMPING
a) The required quantity of earth-
material shall be calculated and
informed to the borrow
area/dumping area mate.
b) Dumping patter planned to ensure
uniform spread shall be determined
and explained to the dumping mate.
c) The excavated materials for
embankment shall be hauled to site
by dumper and dumped on the bed in
predetermined pattern.
3.5.1.3 SPREADING AND GRADING
a) Preparation of embankment/sub-
grade; Top layer control pegs at every
10m along Carriage-length (CL) shall
be fixed on both sides of the bed in
such a manner that they are not
disturbed by grader movement.
Required levels shall be marked on
the pegs with suitable vertical offset.
b) After rough initial spreading, a
cotton/nylon string shall be held at
the marks on the control pegs at both
sides. Its height from the bed top shall
be measured at fixed horizontal
offsets from the CL.
c) The embankment materials shall be
spread in uniform layers using dozers
such that, the compacted thickness
For Internal Circulation Only

shall not exceed 200mm with due
considerations to the loose thickness
(compaction factor) of material.
d) The grader operator shall be directed
according to level.
3.5.1.4 WATERING
a) The moisture content of the
embankment/subgrade material shall
be checked for Optimum Moisture
Content (OMC) and if found low then
required water shall be added by
sprinkling uniformly.
b) If the OMC is more than required,
drying shall be done by sun exposure.
c) The moisture content shall be
adjusted with allowance for
evaporation losses in a manner to
achieve 1% above to 2% below OMC
during compaction.
3.5.1.5 COMPACTING
a) While spreading of the material by
the grader, all the oversize materials
available (more than 2/3rd the
thickness of layer) shall be removed
manually.
b) Compaction shall be done
mechanically using vibratory rollers
of 80 to 100kN static weight for
entire width of pavement. The rolling
shall commence from the lower edge
and proceed towards upper edge.
c) Number of passes shall be decided
beforehand by conducting a trial.
Each pass of the roller shall overlap
1/3rd of the preceding pass.
The level tolerance for GSB will be as
per Table 900-1 of MORT&h.
d) During the compaction, any lower
spots found shall be filled with the
soil of same properties and high
spots shall be scarified and removed
manually. Each layer shall be tested
for compaction.
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Standard Operating Procedure - 2012
3.5.2 FILLING BEHIND STRUCTURES
a) All General earthwork shall be
stopped behind the structure in such
a way that the back-fill can be done
at an angle of 45+ф/2 from
horizontal. (as per Appendix 6 of IRC:
78-2000)
b) A filter media (if required as per
drawing) of wide and depth equal to
the thickness of the adjacent back-fill
soil shall be laid behind the structure.
c) Immediately behind the filter media,
soil from approved borrow shall be
provided to the entire width of the
roadway.
(Steps from earthwork in fill shall be
followed for dumping, grading and
compacting Etc. of the backfill)
d) Mini roller (2T static load) or suitable
plate vibrator shall be used for
compaction near the structure.
e) Care shall be taken to cover the weep
holes of the structure by NW geo-
textile or by any other suitable
approved means.
3.5.3 EARTH WORK IN WIDENING
AND AGAINST SLOPING GROUND
a) If filling is to be matched with
adjacent existing sloping ground
(built-up/otherwise) of slope steeper
than 1V:4H. Benching shall be done.
Soil shall then be dumped in a manner
that, there is continuity between the
bench and the new fill.
250 mm
250 mm
EXISTING 250 mm
EMBANKMENT 250 mm
300 mm 300 mm 300 mm 300 mm widening portion of embankment
Fig. 1 Bench Formation for existing
Embankment
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 Standard Operating Procedure - 2012

b) If the existing slope is flatter than SUMMARY

1V:4H the slope surface shall be
scarified before dumping for next
layer with normal compaction. Small
roller of 2T capacity shall be used  Borrow earth requirement to be
wherever necessary. calculated and informed.
 Fixing of pegs to be done to
mark the limits of embankment
3.5.4 EMBANKMENT CONSTRUCTION
width as per drawing (FRL+
UNDER WATER
offset).
When filling or backfilling is to be placed
 Dumping pattern shall be
under water, only acceptable granular
planned and materials shall be
material or rock shall be used unless
mechanically spread in uniform
otherwise approved by the IE.
layers with 1/3 overlap.
The material used shall comply with the
 The compacted thickness shall
requirements of clause 305.4.6 of
not exceed 200mm at any
MORT&h.
location.
3.6.0 BUMPING  OMC shall be checked and if it is
less, than required water may
If the surface is exhibiting bumping then it
be added by sprinkling and if it is
can either be due to poor material or due
more, than material shall be
to high moisture content
allowed to dry by exposure to
a) The poor material shall be removed
the sun.
to full depth, lower layer scarified,
fresh material placed and
compacted.
b) To remove high moisture the
defective area shall be scarified,
allowed to dry and compacted, the
material can also be replaced for
faster process.

3.7.0 QUALITY CONTRO L TEST

Test Code Reference Frequency

Plasticity index IS 2720 – Part 5 2test/3000cum
Material Dry Density
(MDD) & OMC IS 2720 - Part 8 2test/3000cum
Moisture content (MC) IS 2720 – Part 2 1 test/250cum
CBR IS 2720 – Part 16 1 test/3000cum
Sand content IS 2720 – Part 4 2 test/3000cum
Field density IS 2720 - Part 28 1 test/1000sqm
Embankment 95 % and Subgrade 97 % Compaction
Gradation of granular fil IS 2386 - Part 1 1/200cum

3.8.0 SAFETY REQUIRE MENTS

Please refer Point No. 2.6.0(a’ to m’)

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC EW/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR BASE PREPARATION
Checked & Found OK Signature
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg

1 Layout and area are marked on the ground as per plan

2 Vegetation & roots cleared from site

Compaction of the OGL satisfied/L&R required for
3
Embankment/Subgrade >95%/97%
Compaction after L&R -For embankment/Subgrade-
4
>95%/97%
Remarks

L&T QA/QC Client/IE

Loosening& Recompaction - L&R

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 Standard Operating Procedure - 2012

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC SC/02/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR EARTHWORK
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Is there any recent change in methodology

Safety steward is Available at Site and all the safety
2
measures for workmen and traffic is taken
3 Pep talk is conducted on safety, and quality aspects

4 EMB/SG material source approved

5 Toe line marked and checked

6 Water sprinkled on SG before GSB placed

7 Whether sufficient labour available

8 Whether sufficient soil Quantity uniformly dumped

Whether Over size material >75mm for EMB & >50mm
9
for Sub grade removed
10 Loose thickness checked

11 Whether sample taken for control test of (if required)

12 Whether pegs Fixed & Marked for levels

13 Trained supervisor available to give directions to grader

14 Sufficient QTY of water added

Whether available moisture checked and corrected for
15
OMC
Whether Nos. of Rolling pass applied as per Trial
16
Stretch
17 Whether Roller Impression rectified

18 Levels found with in tolerance

Remarks
L&T QA Client/IE

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 Standard Operating Procedure - 2012

4 SUBBASE (GSB) AND BASE (WMM) e) Identify the risk involved during
execution of activities and co-ordinate
with Safety Engineer to comply for the
safety measures to be adopted.

4.5.1 GRANULAR SUB BASE

4.5.1.1 MATERIAL
a) As far as possible GSB material to be
used shall be obtained from natural
4.1.0 SCOPE sources(Clause 401.2 of MORT&h
specifications & conforming to Grading
The scope covers the responsibilities and 1 of Table 400-2).
procedures applicable for construction of; b) Properties such as; Plasticity,
a) Granular Sub Base (GSB) Gradation Etc. shall be checked/tested
b) Wet mix Macadam (WMM) for and corrected by suitable blend of
coarse and fine aggregate or alternate
4.2.0 RESPONSIBILITY methods if required.
Please refer Point No: 1.2.0 c) If natural sources are not available,
crushed stone material may be used as
4.3.0 REFERENCES per Clause 401.2 of MORT&h
a) Technical Specification specifications & conforming to grading
b) Contract document 1 of Table 400-2.
c) Plan & Profile Drawings
d) MORT&h - Section 400, Clause 401 & 4.5.1.2 TOE LINE FIXING
406 a) The toe line/fixing of pegs to mark the
limits shall be done before the
4.4.0 EQUIPMENT/TOOLS commencement of excavation work.
a) GSB; Dozer, Grader, Excavator, b) Reduced level shall be transfer on the
Dumpers, Rollers, Wheel loaders Etc. peg by auto level and string line firmly
b) WMM; WMM Plant, Dumpers, tides to peg.
Grader/Paver, Rollers, Wheel loaders c) The width of pavement for toe line shall
Etc. be calculated by referring the drawings
c) Others like, Measuring tape, Crow bar with due considerations to formation
Spade and line rope, Pegs, Etc. width (+) the offsets and slopes of
different layers (+) depth of the current
4.5.0 PROCEDURE layer from the Formation Road Level
Before commencing of work site engineer (FRL).
shall ensure to obtain approval for;
a) Work Method Statement(WMS) 4.5.1.3 HAULING AND DUMPING
b) Mix design and source of material to be a) The required quantity of earth-material
used shall be calculated and informed to the
c) Plant calibration borrow area/dumping area mate.
d) Trial stretch results

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b) Dumping patter shall be determined
and explained to the dumping mate to
ensure uniform spread.
c) The excavated materials for
embankment shall be hauled to site by
dumper and dumped on the bed in
predetermined pattern.
4.5.1.4 SPREADING AND GRADING
a) Spreading with a Grader; Control pegs
shall be fixed at every 10 m along CL
on both sides of the bed in such a
manner that they are not disturbed by
Grader movement. Required levels
shall be marked on the pegs with
suitable vertical offset.
NOTE;
Areas where grader movement is not
possible shall be done with motor
grader or manually as per IE
instructions.
c) After rough initial spreading, a line
string shall be held at the marks on the
control pegs at both sides. Its height
from the bed top shall be measured at
fixed horizontal offsets along the CL.
d) All material to be used shall be spread
mechanically in uniform layers such
that the required compacted thickness
does not exceeding 200mm with due
considerations to the loose thickness
(compaction factor) of material.
e) The grader operator’s shall be directed
according to measurement in the
above steps to cut and fill at every
point. Each grader run shall overlap by
at least 1/3rd of the blade length.
4.5.1.5 WATERING
a) The moisture content of the
embankment/subgrade material shall
be checked for Optimum Moisture
Content (OMC) and if found less, than
required water may be added by
sprinkling.
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Standard Operating Procedure - 2012
b) If the OMC is more than required,
drying shall be done by exposure to the
sun. The moisture content shall be
adjusted with allowance for
evaporation losses in a manner to
achieve 1% above to 2% below OMC
during compaction.
4.5.1.6 COMPACTING
NOTE;
All the oversize materials available (more
than 2/3rd the thickness of layer) shall be
removed manually.
a) Compaction shall be done
mechanically using vibratory rollers of
80 to 100kN static weight for entire
width of pavement. The rolling shall
commence from the lower edge and
proceed towards upper edge.
b) Number of passes shall be decided
beforehand by conducting a trial. Each
pass of the roller shall overlap 1/3rd of
the preceding pass.
c) The level tolerance for GSB will be as
per Table 900-1 of MORT&h
specification. Each layer shall be tested
for compaction.
d) During the compaction, any lower
spots shall be filled with the soil of
same properties and high spots shall
be scarified and removed manually
and fresh material placed and
compacted.
4.5.1.7 BUMPING
a) If the surface is exhibiting bumping
then it can either be due to poor
material or due to high moisture
content.
b) The poor material shall be removed to
full depth, lower layer scarified, fresh
material placed and compacted.
c) To remove high moisture the defective
area shall be scarified, allowed to dry
For Internal Circulation Only
 Standard Operating Procedure - 2012

and compacted, the material can also
be replaced for faster process.
4.5.2 WET MIX MACADAM
4.5.2.1 MATERIAL
WMM material shall be produce in Wet Mix
plant as per mix design to comply with
grading requirement as per MORT&h
specification clause 406.
4.5.2.2 TOE LINE FIXING
Please refer Point No: 4.5.1.2
4.5.2.3 HAULING AND DUMPING
a) The required quantity of WMM
material shall be calculated by suitable
methods and informed to the WMM
Plant mate.
b) WMM Mix shall be transported to the
location by dumpers and placed as per
dumping pattern to maintain
uniformity.
80 to 100kN static weight for entire
width of pavement. The rolling shall
commence from the lower edge and
proceed towards upper edge.
c) Number of passes shall be decided
beforehand by conducting a trial. Each
pass of the roller shall overlap 1/3rd of
the preceding pass.
d) The level tolerance for GSB will be as
per Table 900-1 of MORT&h
specification.
e) During the compaction, any lower
spots shall be filled with the soil of
same properties and high spots shall
be scarified and removed manually.
Each layer shall be tested for
compaction.
4.5.2.6 BUMPING
Please refer Point No.4.5.1.7
4.6.0 QUALITY CONTROL TEST AND
THEIR FREQUENCY

4.5.2.4 SPREADING AND GRADING 4.6.1 GSB

a) After rough initial spreading, a
cotton/nylon string shall be held at the Test Reference Code Frequency
Plasticity index IS 2720 – Part 5 1 test per 200cum.
marks on the control pegs at both sides.
Moisture content IS 2720 – Part 2 1 test per 250cum.
Its height from the bed top is measured 1 test for every
at fixed horizontal offsets from the CL. Field density testIS 2720 - Part 28 500 Sqm. or min 6
b) The WMM material shall be spread tests.
mechanically in uniform layers of 250 Gradation 1 test per 200cum.

mm thickness in 2 layers of 125 mm

each with due considerations to the 4.6.2 WMM
loose thickness (compaction factor) of
Test IS Reference Frequency
the material. IS 2720 – Part 5 1 test per 100 cum.
Plasticity index
Aggregate Impact
IS 2386- Part 4,
Value 1 test per 200 cum.
4.5.2.5 COMPACTING Flakiness and
IS 2386- Part 1
a) While spreading of the material by the Elongation Indices 1 test per 200 cum.
grader, all the oversize materials Moisture content IS 2720 – Part 2 1 test per 250 cum.
1 test for every 500 Sqm.
available (more than 2/3rd the Field density tes IS 2720 - Part 28
or min 6 tests.
thickness of layer) shall be removed Gradation 1 test per 200 cum.
manually.
b) Compaction shall be done
mechanically using vibratory rollers of

14 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

4.7.0 SAFETY REQUIREMENTS: SUMMARY

a) Please refer Point No. 2.6.0(a’- m’).

b) If paving with a Paver; Temporary
 Mark the limits with pegs, width as
movable sheds to be provided with the
per drawing (FRL+ offset).
asphalt/WMM teams which can be
 GSB/WMM material requirement
erected at paving site to allow the
to be calculated & dumping
workmen to have lunch thereby
pattern to be planned to ensure
preventing the workmen from taking
uniform speed.
lunch/rest behind the equipment.
 The materials shall be
mechanically spread in uniform
layers using Graders, Sensor
Pavers, dozers, Etc. such that
compacted thickness not
exceeding 200mm for GSB & 250
mm for WMM.
 Required levels shall be marked on
the pegs with suitable vertical
offset.
 Each grader run shall overlap by at
least 1/3rd of the blade length.
 The moisture content shall be
checked for OMC and if it is less
than required water may be added
by sprinkling and if it is more than
required, shall be allowed to dry
by exposure to the sun.
 The compaction shall be done
mechanically using vibratory
rollers of 80 to 100kN static
weight for entire.
 Each pass of the roller shall
overlap 1/3rd of the preceding
pass.
 No. of passes shall be decided
beforehand by conducting a trial
for compaction.
 Level differences, if found to be
rectified

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC GSB/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR GRANULAR SUB-BASE LAYING
Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na
1 Sub grade layer is approved
2 Laying area marked
3 Subgrade surface is free from loose patches
There is no bumping on the subgrade due localised over
4
moisture
Total no. of Trips calculated with respect to the laying
5
area
Necessary information given to Plant/stock yard In
6
Charge for required Quantity of GSB
7 Is the required Quantity of GSB material dumped
The GSB material spreaded & moisture content
8
checked
9 Is the the Lab testing data available
Is the moisture content within acceptance ( +1/-2% of
10
OMC )
The quantity of water to be added is calculated &
11
sprinkled on the surface
12 Grading is made to the required slope & camber
13 Moisture Checked & found within requirement.
14 Compaction made by using vibratory roller
Density of the compacted layer is checked & found
15
within the specified limit
Safety precautions taken during construction and in
16
working area
Remarks
L&T QA Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC WMM/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR WET MIX MACADAM - GRADER
Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na
1 Sub grade layer is approved
2 Laying area marked
3 Subgrade surface is free from loose patches
There is no bumping on the subgrade due localised over
4
moisture
Necessary information given to Plant in Charge for
5
required Quantity of WMM
6 The necessary peg marking given
7 Necessary string line fixed & required level marking given
Is the shoulder material laid & ready to be compacted
8
along with WMM layer
9 Paving is made to the required slope & camber
10 Compaction made by using vibratory roller
11 Is there any segregation observed on the finished surface
12 Correction action taken as per Method Statement
Levels taken of the surface & found within the required
13
tolerance (Paver laid: +/- 10mm, Grade laid: +/- 15mm)
Surface regularity checked carried out with a 3 meter
14
straight edge & found within the required specification
Density of the compacted layer is checked & found within
15
the specified limit
Remarks
L&T QA/QC Client/IE

17 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

CHECKLIST 3

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC WMM/02/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
INSPECTION CHECKLIST WET MIX MACADAM - PAVER
Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na
1 Any recent change mix design and is approved
2 Is any recent change in methodology
Safety steward available at site and all the safety
3
measures for workmen and traffic taken
4 Pep talk is conducted on safety, and quality aspects
5 RFI has been raised
6 GSB layer approved
7 Water sprinkled on GSB before WMM placed
Whether quality monitoring equipment’s (depth gauge,
8
level instrument, etc.) available at site
Whether pegs & winch fixed for level/reference bean
9
attached
10 Whether sufficient no. of dumper available
11 Whether sensor Paver is ready

If there was segregation reported in last laying,

12
whether the root cause of the same has been attended

13 Whether Rollers are ready

14 Whether sufficient numbers of labour available at site

Whether light masts is/are available (in case of night

15
works)
Whether site maintaining trip register with time &
16
quantity
Supervisors deployed to control cleaning, inspect and
17 rectify surface before compaction and to control No.
of rollers
Remarks
L&T QA Client/IE

18 | P a g e For Internal Circulation Only


5 BITUMINOUS PAVEMENTS
5.1.0 SCOPE
The scope covers the responsibilities and
procedures applicable for the
Construction of Bituminous Pavement.
5.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0
5.3.0 REFERENCES
a) Technical Specification of contract
document
b) Plan & Profile Drawings
c) MORT&h - Section 500 & 900
5.4.0 EQUIPMENT/TOOLS
a) Emulsion Sprayer, Paver, Rollers,
PTRs, Hot Mix Plant (HMP), Water
Tankers, Dumpers, Mechanical
Brooms, Compressors, Etc.
b) Measuring tape, String Line, Winches
& pegs, Hammers, Camber Board,
Straight edge, Jack hammer, Spades,
Rakes and Shovels, Etc.
5.5.0 PROCEDURE
Please refer Point No: 4.5.0
5.5.1 MATERIAL
a) Slow Setting Emulsion (SS1) and
Rapid Setting Emulsion (RS1)
b) Bitumen of approved grade
c) Aggregates from approved source.
5.5.2 STOCK-PILEING
19 | P a g e
Standard Operating Procedure - 2012
a) All the aggregate material to be used
as stock shall be cleaned.
b) The distance between the stock pile
and plant shall be kept as minimum as
possible such that they shall have
roughly the same lead from the plant.
c) Stable ground with proper drainage
facility shall be identified and used.
d) Higher ground as far as possible shall
be preferred for a natural drainage
facility.
e) Care shall be taken to ensure
aggregates of different sizes be stock
piled separately.
f) Depending upon the cold bin capacity,
front end loader of suitable capacity
shall be used for haulage from stock
pile to cold bin. The loader shall be
operated in such a way that the
bucket will go straight into the stock
pile, roll the bucket up and move
back.
(This process will avoid spilling and
segregation of aggregate)
g) Small tipping trucks may also be used
for feeding the cold bin.
h) All the stock piles shall be dozed and
made proper at the end of every day’s
work.
5.5.3 AGGREGATE FOR COLD BIN
The Cold Bin shall;
a) Always be full of aggregate so as to
ensure constant flow
b) Not be overfilled as it will lead to
inter-mixing of different sizes of
aggregates
c) Be calibrated for achieving better
control and efficiency of plant.
5.5.4 HMP PLANT OPERATION
a) HMP Plant shall be started by the,
plant-in charge after getting site
clearance.
For Internal Circulation Only

b) Before start of the plant, the plant in-
charge must ensure the following
details are available from the paving-
in charge;
1) Type of mix required
2) The chainages for laying
3) Estimated required quantity of
the mix
4) Route to be followed by the
trucks
5) Time restrictions or any other
type of requirements/restrictions
c) Hot bin dry samples shall be collected
from individual bins and tested
before start of the plant. This
exercise shall ensure;
1) No screens are broken /damaged
2) Carryover is under control & (Less
than 10%) temperature of
bitumen checked.
d) Recipe provided in the plant shall be
verified on a daily basis. If any
changes required, approval shall be
obtained from the material engineer
before and changes are made.
e) Aggregate moisture content shall be
checked, & dryer burner adjustment
shall be done accordingly.
f) The dryer shall be charged with
aggregate when the system shows
sufficient exhaust temperature.
g) If silo is full or plant is waiting for
trucks, the plant shall not be kept
filled.(with mix with or without
bitumen)
h) The mixing time shall be generally
kept at 25 to 30 sec. If any change
has to be made in already decided
set mixing time, then it shall be done
only after consulting with the
material engineer.
i) The temperature of mix shall be
checked and required adjustment, if
any shall be done. The mix
temperature shall be;
20 | P a g e
Standard Operating Procedure - 2012
1) Bitumen: 160⁰C – 170⁰ C
2) Aggregate: 160⁰C – 175⁰ C
3) Bituminous Mix: Max 170⁰ C
j) First sample of the mix for laboratory
test shall be taken only when the
plant has run for sufficient time (to
get stabilized). Generally after 10
batches, the first sample shall be
collected.
5.5.5 EMISSION CONTROL
a) To control the dust emitted from the
mixing process, a baghose emission
control technique is preferred.
b) Temperature of exhaust gas entering
into the bag shall be monitored
through electronic control device.
c) Suitable system shall be provided for
feeding the fines collected in the bag
house to the mix.
5.5.6 PREPARATION OF ROAD
SURFACE FOR PRIMING
a) Before the application of prime coat/
tack coat, the surface shall be
cleaned with the help of mechanical
broomer, compressor and manual
with brushes or any other
undesirable or loose materials any
other approved equipment/method
as specified by the IE.
The surface needs to be free from
dust or debris.
b) All the potholes on the surface shall
be repaired/filled and be brought to
the desired line & level.
5.5.7 APPLICATION OF BITUMINOUS
PRIMER
a) The bituminous primer shall be
sprayed/distributed uniformly over
the dry surface prepared as per
Clause 502.4.2 using self-propelled
sprayer equipped with self-heating
arrangement. Suitable pump of
For Internal Circulation Only

adequate capacity compressor and
spraying bar with nozzles having
constant volume or pressure system
capable of supplying primer at
specified rates and temperatures
shall be used so as to provide a
uniformly unbroken spread of
primer.
b) If the surface to be primed is very dry
or dusty as to cause freckling of
bituminous material, it shall be lightly
and uniformly sprinkled with water
immediately prior to priming.
(However, the bituminous material
shall not be applied till such time the
surface water has evaporated).
c) The primer shall be applied at the
rate as specified in Table 500-1.
5.5.8 BITUMINOUS MIXING FACILITY
a) The pre-mixed bituminous material
shall be prepared in an electronically
controlled hot mix plant of adequate
capacity and capable of yielding a
uniform quality mix.
b) At the time of mixing the temperature
of aggregate shall be maintained at
150-170⁰C. Bitumen shall be 150-
165⁰C and the mix temperature shall
not be more than 165⁰C. Electronic
limiting device for control of
temperature shall be provided.
c) The bitumen storage tanks shall be
fully insulated for retention of heat
for longer period.
d) The bitumen weighing system shall be
carefully calibrated at regular interval
to ensure the quality of mix.
e) An indirect method of heating can
also be adopted - preferably by
passing thermic oil of flash point more
than 200⁰C through insulated pipes.
All the pipe lines to and from the
storage tanks shall be insulated.
21 | P a g e
Standard Operating Procedure - 2012
5.5.9 LOADING, HAULING,
UNLOADING OF HOT MIX
a) The dumper truck bed shall be
checked and cleared. It shall be free of
soil, uncoated aggregate and
contaminants.
b) A thin coat of oil (preferably non-
petroleum) shall be applied to the
dumper bed to act as release agent.
c) The dumper shall be loaded in
multiple drops preferably in following
sequence;
(I) (II) (III)
Fig.2 Dumper Loading Sequence
d) The silo gate shall not be kept
continuously open hence no small
topping up of mix in the truck shall be
permitted.
e) The mix in the dumper shall be fully
covered with tarpaulin.
f) The tipper truck shall not bump the
paver at the time of unloading (except
the contact between tyres of tipper
and pushing idler (roller) of the
paver).
Rather the dumper driver shall backup
and stop just short of the paver so
that the paver backs up driven by its
own engine.
g) The bed of the dumper shall be raised
slightly so as that the mix rests against
the tail gate before the tail gate
opens. The tail gate shall be opened
so that the mix comes out in mass and
floods the paver hopper
h) The dumper or any part of it shall, in
any condition, not touch the paver.
5.5.10 SPREADING OF BITUMINOUS
MATERIAL (BM)
For Internal Circulation Only

5.5.10.1 SURFACE PREPARATION
a) All potholes shall be repaired and
brought to desired level by proper
methods.
b) The surface shall be cleaned free of
dust and other undesirable matters
with the help of mechanical broomer,
compressed air or by manual means.
Sometimes washing by water may
also be required.
c) Tack coat shall be applied uniformly
with the aid of either self-propelled or
towed bitumen pressure sprayer with
self–heating arrangement and
spraying bar with nozzles having
constant volume or pressure system
capable of spraying the tack coat at
specified rates and temperature so as
to provide a uniformly unbroken
spread of bitumen.
d) Work shall be planned so that no
more than the necessary tack coat for
the day’s operation is placed on the
surface.
e) After application of the tack coat and
prior to succeeding layers, allow the
tack coat to cure without being
disturbed until the water/cutter has
completely evaporate.
5.5.10.2 FIXING UP OF SENSOR
REFERENCE USING PIANO WIRE
a) A level sheet with levels at control
points shall be prepared in advance
for the pavement course to be
constructed.
b) Metallic strings supported on pegs
and arms shall be used as level
reference for the paver.
c) The pegs shall be firmly driven at
10m interval in straight row and at
5m interval on curves (the interval
can be reduced if deemed necessary
but shall not be more than 10m in
any case). Any deviations from this
22 | P a g e
Standard Operating Procedure - 2012
shall have a proper reasoning and
approval from the project manager in
writing. The same shall be reflected
in the paving report.
d) The levels in the level sheet, added
with suitable vertical offset shall be
exactly transferred to the arm tips
(where the string is to be supported).
e) The clamps of arm base shall be
carefully tightened so as not to
disturb the level as well as to ensure
absolutely zero sliding at the time of
drawing of string and paving. The
string shall be drawn and tightened
to the maximum extent to avoid any
sagging between the supports.
f) Care shall be taken not to disturb the
levels of the arm tips. In case of any
doubt of disturbance the levels shall
be re-checked.
USING REFERNCE BEAM;
a) Mobile reference; This consists of a
reference system that travels with
the paver such as a long beam or
tube attached to the paver. The
mobile reference system averages
the effect of deviations in the existing
pavement surface over a distance
greater that the wheelbase of the
tractor unit. Minimum ski length for a
contact device may be 3 m to 7 m
varying as per site condition.
b) Joint matching shoe; This usually
consists of a small shoe or ski
attached to the paver that slides on
an existing surface (such as a Kerb)
near the paver. In addition to grade
control, the screed can also be set to
control pavement slope and/or
crown.
c) Slope controller;
1) A slope controller uses a slope
sensor mounted on a transverse
beam attached to the screed to
determine screed slope, & then
For Internal Circulation Only

adjusts screed slope to the
desired amount.
2) Generally, one side of the screed
is set up to control grade and the
opposite side is set up to control
slope based on that grade.
3) The usual practice is to run grade
control on the side of the screed
nearest the pavement CL and run
slope control on the screed side
nearest the pavement edge
because it is easier to match the
CL joint if grade control is used on
that side of the paver.
5.5.10.3 SPREADING BY PAVER
a) The surface on which the bituminous
layer is to be laid shall be swept clean
of all loose and extraneous materials
by mechanical or by any other
suitable method.
The material which to be laid shall be
mix designed in accordance with
modified Marshall Method.
b) The material shall be spread by means
of self-propelled paver finisher with
electronic sensors (except in
inaccessible areas), to the required
thickness, lines and camber as per
approved drawings.
c) In the inaccessible areas the mix shall
be laid with suitable hand tools. At
the time of laying a minimum
temperature of 125⁰C shall be
maintained.
d) The thickness of compacted layer for
BM shall not exceed 100mm.
5.5.10.4 COMPACTING
a) As soon as the material is spread,
compaction shall commence and
completed within the rolling
temperatures. Rolling activity shall
finish prior to temp reaches 100 ⁰C.
23 | P a g e
Standard Operating Procedure - 2012
b) Rolling of longitudinal joints shall
commence immediately behind the
paving operations.
c) All deficiencies in the surface shall be
made good behind the paver before
the initial rolling commenced.
d) Rolling shall start from the lower edge
towards upper edge parallel to the
centre line of road, and each pass
shall overlap 1/3rd preceding pass.
e) The initial rolling shall be done with a
smooth wheeled roller of 80-100kN
static weight, followed by
intermediate rolling with a vibratory
roller of 80-100kN static weight.
f) The finishing rolling shall be done with
a smooth wheeled tandem roller of
60-80kN weigh in uni-directional
camber. Super-elevated portions are
rolled from the edges and shall
progress from lower to the upper
edge.
g) Rolling shall be continued till in situ
voids 4 - 8 % for BM.
h) All the joints shall offset at least
300mm from parallel joints in the
layer beneath. Longitudinal joints
shall coincide with either the lane
edge or the lane markings and shall
not be situated in wheel track zones
i) The surface levels of completed
construction shall vary within +6mm
to –6mm.
5.5.10.5 JOINT PREPARATION
a) The work shall be planned in a
manner so as to reduce the number of
joints to the minimum. A full width
paver shall be used to the extent
possible to avoid longitudinal joint
mid of carriageway.
b) In case extra widened locations where
the width of paving is more than the
width of paver then the longitudinal
joints shall be kept away from the
For Internal Circulation Only

paver wheel path. Two-paver in
echelon may also be introduced to
avoid longitudinal joint if possible.
c) The length of paving shall be so
planned that number of transverse
joints shall be kept to minimum.
d) Cutting shall be performed on the
exposed joint, vertically in a straight
line for a distance equal to the
specified layer thickness. Discard all
the loose material and clean the
portion.
e) Heating the full depth of the vertical
face with any approved joint heater.
f) Application of tack coat over the
vertical portion.
5.5.10.6 RECTIFICATION
a) Any rectification in bituminous work
shall preferably be done before
commencement of the rolling
process.
b) If segregation is observed in the
finished surface, then the material
from the defective area shall be
removed to full depth and made
good or replaced by fresh material.
24 | P a g e
Standard Operating Procedure - 2012
c) If the degree of segregation is not
high then correction can be done by
topping of by fines also.
5.6.0 QUALITY CONTROL TESTS AND
THEIR FREQUENCIES
Test Code Reference Frequency
Aggregate impact value IS 2386 – part 4 1 test/50cum
Los Angele’s abrasion
IS 2386 – part 4 1 test/50cum
value
Combined flakiness and
IS 2386 – part1 1 test/50cum
elongation index
3 representative
Stripping value IS 6241 specimen for each
source
1 test/method per
Soundness of aggregate IS 2386-part 5
source
Grading of aggregates 2 tests per day per plant for both
Water absorption of 3 representative specimens for each
aggregates source.
Binder content in the
2 test/day per plant
mix
Densities of compacted 1 test (a set of 6 determinations) for
layer every 250 Sqm.
Stability 1 test (a set of 3 Marshall Specimens)/
Quality of binder as per IS 73, IS 217, and IS 8887 and Modified
binder as per IRC SP-53.
5.7.0 SAFETY REQUIREMENTS
Please refer Point No. 4.7.0
SUMMARY
 The surface to be brought to the
desired line & level. Potholes to
be repaired.
 Bituminous primer shall be
sprayed/distributed using self-
propelled sprayer.
 The surface on which the tack
coat is to be applied shall be
cleaned of dust and any
extraneous material before the
application of the binder.
 The Bitumen mix shall be mix
designed in accordance with
modified Marshall Method.
 As soon as the material is spread,
compaction shall commence and
completed within the rolling
temperatures. Rolling activity
shall finish prior to temp reaches
100 ⁰C.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC BC/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR BITUMINIOUS COURSE
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether all the safety measures have been taken as
1
per the plan.
Methodology of work available with the Paving-
2
incharge.
3 Whether the Prime coat is cured and cleaned properly

4 Is the Tack coat rate of spray checked & recorded

Is the joint trimmed & preapred as per method
5
statement
Whether the program of DBM laying conveyed to Plant
6
and Machinary and QA/QC incharges.
0
Whether the thermometers (Upto 200 C capacity)
7
available at laying location.
8 The paver sensors are set properly
Whether alignment of paving has been marked with
9
lime powder and equipments positioned accordingly.
Whether the paver is being placed at the laying area
10
well in advance & the skeed of the paver is being
Whether DBM mix has been transported to paving
11
location with the tarpoline covering
0
Whether the DBM mix temperature found above 125 C
12
before spreading
Whether loose thickness has been checked to ensure
13
required compacted layer thickness.
Whether rolling pattern is followed as established in
14
the trial stretch.
Whether the final rolling temerature with Steel wheel
15
rollers is above 900C
Whether surface level has been checked and found
16
within the specified tolerance limit.
Wheather Transverse joints prepared as per Mehod
17
statement
Whether sufficient arrangements have been made for
18
protection of freshly laid DBM course.
Remarks
L&T QA Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PC-TC/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR PRIME/TACK COAT OVER(BM/DBM/BC/SDBC/DAC)
Checked & Found OK Signature
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg
Check for previous layer
1
approved
2 Check for setting out
3 Check for syrface preparation
Check for material RS/MS/SS
4
grade
Check for bituminoius emulsion
5
temperature (20-70ᵒC)
Check for rate od
6
spread(……Kg/m2)

Remarks

L&T QA/QC Client/IE

26 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

6 DRY LEAN CONCREAT (DLC) a) The mix shall be proportioned as per

WITH PAVER the approved mix design (with a
maximum aggregate cement ratio of
15:1).
b) The strength and density
requirements of concrete shall be
determined in accordance with Clause
601.6 of the MORT&h specification by
making trial mixes.
c) Minimum cement content in the lean
concrete shall not be less than 150
6.1.0 SCOPE kg/cum of concrete.
The scope covers the responsibilities and d) Water Content;
procedures applicable for the 1) The right amount of water for the
construction of Concrete Pavement using
lean concrete in the main work
Dry Lean Concrete with Paver.
shall be decided as per Clause
6.2.0 RESPONSIBILITY 601.3.2 of MORT&h specification.
Please refer Point No: 1.2.0 This will also ensure full
compaction under rolling.
6.3.0 REFERENCES 2) Too much water may cause the
lean concrete to be heaving up
a) Technical Specification of contract
before the wheels and picked up
document
on the wheels of the roller.
b) Plan & Profile Drawings
3) Too little may lead to, inadequate
c) MORT&h - Section 600 and 900
compaction, low in-situ strength
6.4.0 EQUIPMENT/ TOOLS and an open-textured surface.
e) Plant used shall be capable of
a) Pug Mill Plant, Dumpers, Paver,
proportioning the materials by
Rollers, Water tankers, Etc.
weight. Each type of material used
b) Measuring tape, Thermometers, Crow
being weighed separately in
bar Spade and line rope, String line
accordance with Clause 602.9.3.2 of
and Pegs, Etc.
MORT&h Specification.
c) Tie rod, Dowel bars, Joint sealant and
Separation membrane Curing f) The capacity of batching and mixing
compound. plant shall be at least 25 per cent
higher than the proposed capacity for
6.5.0 PROCEDURE the laying arrangements.
Please refer Point No: 4.5.0
6.5.3 TOE LINE MARKING AND
6.5.1 MATERIAL STRING LINE FIXING
DLC shall be produced in a batching Please refer Point No: 3.5.1.1
plan/pug mill plant as per mix design and
comply with the grading requirement in p 6.5.4 HAULING AND DUMPING
MORT&h Clause 601. a) The required quantity of DLC material
shall be calculated and informed to
6.5.2 MIXING OF DLC IN PLANT batching plant operator.

27 | P a g e For Internal Circulation Only


b) DLC shall be transported to the
location by dumpers and placed as
per dumping pattern to maintain
uniformity.
c) Segregation of concrete in the
dumpers shall be controlled by
premixing each fraction of the
aggregates before loading in the bin
of the batching plant, by moving the
dumper back and forth while
discharging the mix on it and other
means.
Paving operation shall be such that
the mix does not segregate.
d) Dumpers delivering concrete shall not
run on plastic sheeting nor shall they
run on completed slabs until after 28
days of placing the concrete.
6.5.5 PAVING COMPACTING &
FINISHING
a) Paving, Compacting and Finishing of
the DLC shall be carried out as rapidly
as possible to ensure that the time
between the mixing of the first batch
of concrete in any transverse section
of the layer and the final finishing of
the same shall not exceed 90 minutes
when the concrete temperature is
above 25⁰C and below 30⁰C and 120
minutes if less than 25⁰C.
b) This period may be reviewed by the IE
in the light of the results of the trial
run but in no case shall it exceed 2
hours.
c) Work shall not proceed if the
temperature of the concrete exceeds
30⁰C. If necessary, chilled water or
addition of ice may be resorted to for
bringing down the temperature in
consultation with the IE.
d) It is desirable to stop concreting when
the ambient temperature is above
35⁰C.
28 | P a g e
Standard Operating Procedure - 2012
6.5.5.1 PAVING
a) A day before placing of DLC, the
surface shall be given a fine spray of
water and rolled with one or two
passes of a smooth wheeled roller.
The DLC shall not be laid on a surface
softened by rain after its final
preparation.
b) Surface trenches and soft spots, if any
must be properly back-filled and
compacted to avoid any weak or soft
spot.
c) As far as possible, the construction
traffic shall be avoided on the
prepared subgrade.
d) Paving of DLC shall be preferably done
with Paver (with high amplitude
tamping bars & with electronic
sensor).
The paver shall be capable of laying
the material in one layer in an even
manner without segregation, to
ensure uniformity after compaction.
e) Laying of two-lane road; DLC shall be
placed and compacted across the full
width of the road in one go or, in two
lanes running forward simultaneously.
f) Transverse and longitudinal
construction joints shall be staggered
by 500-1000 mm and 200-400 mm
respectively from the corresponding
joints in the overlaying concrete slabs.
6.5.5.2 COMPACTING
a) Double drum smooth-wheeled
vibratory rollers of minimum 80 to
100KN static weight are considered to
be suitable for rolling DLC.
b) Compaction shall be carried out
immediately after the material is laid
and leveled.
c) In order to ensure thorough
compaction, rolling shall be continued
on the full width till there is no further
For Internal Circulation Only

visible movement under the roller and
the surface is closed.
d) The final surface shall be inspected
immediately on completion and all
loose, segregated or defective areas
shall be corrected by using fresh lean
concrete material laid and compacted
as per MORT&h Specification.
e) Rollers shall not be allowed to stand
on the compacted surface for the
duration of the curing period except
during commencement of next day’s
work near the location where work
was terminated the previous day.
f) MDD test shall be performed on the
compacted surface & the minimum
dry density obtained shall be 97% of
that achieved during the trial length
construction vide Clause 601.7 of
MORT&h Specification.
g) The final Lean Concrete (LC) surface
on completion of compaction and
immediately before overlaying shall
be well closed, free from movement
under roller and free from ridges, low
spots, cracks, loose material, pot
holes, ruts or other defects.
6.5.5.3 RECTIFICATION
a) Any level/thickness deficiency shall
be corrected after applying LC with
aggregates of size 10 mm or below
after roughening the surface.
b) Surface regularity shall be checked
with 3 m straight edge. Any
deficiency found shall be made up
with concrete with aggregates of size
10 mm and below.
c) Honeycombed surface shall be
repaired with concrete & aggregates
of size 10 mm and below shall be
spread and compacted.
29 | P a g e
Standard Operating Procedure - 2012
6.5.6 JOINTS
a) Contraction and longitudinal joints
shall be provided as per approved
drawings.
b) Longitudinal or transverse
construction joints on the compacted
material unless vertical forms are
used shall be cut back to a vertical
face till where the correct thickness
of the properly compacted material
has been obtained.
6.5.7 CURING
As soon as the lean concrete surface is
compacted, curing shall commence. One
of the following two methods shall be
adopted for curing;
a) The initial curing shall be done by
spraying with liquid curing compound
immediately after rolling is complete.
b) As soon as the curing compound has
lost its tackiness, the surface shall be
covered with wet hessian for three
days.
c) The curing compound used shall be
white pigmented or transparent type
with water retention index of 90 per
cent when tested in accordance with
BS 7542.
d) Curing shall be done by covering the
surface by gunny bags/hessian, which
shall be kept continuously moist for 7
days by sprinkling water.
6.6.0 QUALITY CONTROL TEST
a) Aggregate, Water, cement shall be
tested as per and MORT&H Section
900.
b) Field density test as per MORT&H
Clause 601.5.5.1.
c) Cube Strength shall determine as per
IS 516.
d) Temperature shall be checked check
for the mix on regular interval.
For Internal Circulation Only
 Standard Operating Procedure - 2012

6.7.0 SAFETY REQUIREMENTS SUMMARY

Please refer Point No. 4.7.0

 DLC Material should be

produced in plant as per mix
design to comply Grading
requirement as per MORTH
Clause 601
 The limits of the paving shall be
marked with pegs, width as per
drawing (FRL+ offset)..
 Paving of DLC shall be done with
electronic sensor paver. Defects
in levels, if found to be rectified.
 The compaction shall be done
mechanically using vibratory
rollers of 80 to 100kN static
weight for entire. No. of passes
shall be decided beforehand by
conducting a trial for
compaction.
 Contraction & longitudinal joints
shall be as be corrected as per
drawing.
 Curing shall be done by spraying
with liquid curing compound or
by covering gunny bags which
shall be kept continuously moist
for 7 days by sprinkling water.

30 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC DLC 01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR DRY LEAN CONCRETE
Checked & Found OK Signature
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg

1 Check on previous layer cleared for DLC

2 Check on previous layer cleaning & wetting

3 Check for setting out as per plan

Check for concreat surface levels and thickness of the
4
layer
5 Check for concreat temp at the placement point <30ᵒC

6 Concreat deposited within 60 min from Batching plant

Concreat compacted in position within 120 min from
7
batching plant
Rolling and compaction of layers done as approved trail
8
stretch
9 Check for grade and camber after compaction
Check for layer top level and tolerance level for grids
10
(+/-6mm)
11 Check for curing done properly
Check micro cracking of DLC after 24 Hrs to 36 Hrs
12
after compaction
13 Check compaction*

14 Check for surface irrugularities

Remarks
L&T QA/QC Client/IE/PMC
*Min 98% and Min 95% adt 0.5m from the edges of the reference density

31 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

7 PAVING QUALITY CONCREAT 7.5.2 MIXING IN PQC PLANT

(PQC) WITH PAVER a) Batching and Mixing of the concrete
shall be done at a central batching
and mixing plant with automatic
controls.
b) The approved location shall be at a
suitable place and distance which
takes into account sufficient space
for stockpiling of cement, aggregates
and stationary water tanks. This shall
however, be with duly considering
7.1.0 SCOPE the properties of the mix and the
The scope covers the responsibilities and transporting arrangements available.
procedures applicable for construction of
Paving Quality Concrete (PQC) using a 7.5.3 TOE LINE MARKING AND
Paver. STRING LINE FIXING
Please refer Point No: 3.5.1.1
7.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0 7.5.4 HAULING AND DUMPING
Please refer Point No: 6.5.4
7.3.0 REFERENCES
a) Technical Specification 7.5.5 PAVING
b) Contract document a) The PQC shall be laid over the sub-
c) Plan & Profile Drawings base constructed in accordance with
d) MORT&H – Section 600 and 900. the relevant drawings and
specifications.
7.4.0 EQUIPMENT/ TOOLS b) If the sub-base is found damaged at
a) Batching Plant, Dumpers, Pavers, some places or it has cracks wider
Rollers, Water tankers, Etc. than 10mm, it shall be repaired with
b) Measuring tape, Thermometers, Crow fine cement concrete or bituminous
bar Spade and line rope, String line concrete by laying separation layer.
and Pegs, Etc. c) Separation membrane (preferably
c) Tie rod, Dowel bars, Joint sealant and 125 Micron thick Tarpaulin sheet)
Separation membrane Curing shall be placed in position and the
compound. same shall be clean of dirt or other
extraneous materials and from any
7.5.0 PROCEDURE damage. Wherever overlap of plastic
Please refer Point No: 4.5.0 sheets is necessary, the same shall be
at least 300 mm and any damaged
7.5.1 MATERIAL sheeting shall be replaced.
PQC material shall be produce in a d) The separation membrane may be
batching plan as per mix design to comply nailed to the lower layer with
grading requirement as per MORT&h concrete nails. Dowel bars shall be
Clause 602.8.5.2 fixed over cradle or chairs.

32 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

7.5.5.1 PQC BY FIXED FORM PAVER

a) The concrete shall be discharged
from the dumper without
segregation into a hopper spreader
which shall be equipped with means
for controlling its rate of deposition
on to the sub-base.
b) The spreader shall be operated to
strike off concrete up to a level, Fig.3 Const. of conc. Pavement slab with
requiring a small amount of cutting Slipform paver
down by the distributor of the
spreader to ensure that the vibratory
compactor thoroughly compact the
layer.
c) The vibratory compactor shall be set
to strike off the surface slightly high
so that it is cut down to the required
level by the oscillating beam. If
necessary, poker vibrators shall be
adjacent to the side forms and edges Fig.4 Schematic drawing explaining
of the previously constructed slab. operation of typical slip form paver
d) The machine used shall be capable of
b) The deposited concrete shall be
being rapidly adjusted for changes in
struck off to the necessary average
average and differential surcharge
and differential surcharge by means
necessitated by changes in slab
of the strike off plate or a screw
thickness or cross fall.
auger device extending across the
e) The final finisher shall be able to
whole width of the slab.
finish the surface to the required
c) The equipment for striking-off the
level and smoothness as specified,
concrete shall be capable of being
care being taken to avoid bringing up
rapidly adjusted for changes of the
of excessive mortar to the surface by
average and differential surcharge
overworking.
necessitated by change in slab
thickness or cross fall.
7.5.5.2 CONSTRUCTION BY SLIP FORM
d) The slip form paving machine shall
PAVER
compact the concrete by internal
The slip form paving train shall consist of
vibration and shape it between the
power machine which spreads compacts
sides forms with either a conforming
and finishes the concrete in a continuous
plate or by vibrating and oscillating
operation;
finishing beams.
a) Concrete shall be deposited without
segregation in front of slipform paver
7.5.6 SURFACE TEXTURE
across the whole width and to a
a) After the final regulation of the slab
height which at all times is in excess
and before the application of the
of the required surcharge.
curing membrane, the surface of

33 | P a g e For Internal Circulation Only


concrete slab shall be brush-textured
in a direction at right angles to the
longitudinal axis of the carriageway.
b) The brushed surface texture shall be
applied evenly across the slab in one
direction by the use of a wire brush
not less than 450 mm wide (longer
brushes are preferred).
Fig.5 Texturing of Concrete Pavement
c) The brush shall be made of 32 gauge
tape wires grouped together in tufts
spaced at 10 mm centers. The tufts
shall contain an average of 14 wires
and initially be 100 mm long. The
brush shall have two rows of tufts.
d) The brush shall be replaced when the
shortest tuft wears down to 90 mm
long.
7.5.7.0 JOINTS
a) Transverse construction joints shall
be placed whenever concreting is
completed after a day’s work or is
suspended for more than 30 minutes.
These joints shall be provided at the
regular location of contraction joints
using dowel bars. The joint shall be
made butt type.
b) Transverse joints shall be contraction
and expansion joints constructed at
the spacing described in the
drawings.
c) Transverse joints shall be straight
within tolerances along the intended
line of joints (which is the straight
line transverse to the longitudinal
34 | P a g e
Standard Operating Procedure - 2012
axis of the carriageway at the
position proposed by the Contractor
and agreed to by the IE) except at
road junctions or roundabouts where
the position shall be as described in
the drawings.
d) The expansion joints shall consist of a
joint filler board (MORT&h
specification clause 602.2.7) and
Dowel bars (MORT&h specification -
Clause 602.6.5) and as detailed in the
drawings.
e) The alignment of dowel bars shall be
inspected as described in MORT&h
Specification-Clause 602.10.7 in any
two consecutive transverse joints.
NOTE;
1) If the position or alignment of the
dowel bars at one of these joints
does not comply with MORT&h
Specification-Clause 602.6.5, & if
that joint remains the only one that
does not comply after the next 3
consecutive joints of the same type
inspected, then the method of
placing dowels shall be deemed to
be satisfactory.
2) If there are deficiencies in the first
expansion joint that is constructed
as a trial, the next expansion joint
shall also be a trial joint. If this also
be deficient, further trial expansion
joints shall be made as part of the
trial length.
3) The adjacent slabs shall be
completely separated from each
other by providing joint filler board.
4) The filler board shall be positioned
vertically with the prefabricated
joint assemblies along the line of
the joint within the tolerances given
in MORT&h Specification - Clause
602.6.2.1 and at such depth below
the surface as will not impede the
passage of the finishing straight
For Internal Circulation Only

edges or oscillating beams of the
paving machines.
f) Space around the dowel bars,
between the sub-base and the filler
board shall be packed with a
suitable compressible material to
block the flow of cement slurry.
g) At all construction joints, steel bulk
heads shall be used to retain the
concrete while the surface is
finished.
h) When positioning of bulk
head/stop-end is not possible,
concreting to an additional 1 or 2 m
length may be carried out to enable
the movement of joint cutting
machine so that joint grooves may
be formed and the extra 1 or 2 m
length is cut out and removed
subsequently after concrete has
hardened.
7.5.8.0 CURING
a) Immediately after the surface
texturing, the surface and sides of the
slab shall be cured with the help of a
mechanical sprayer.
b) Approved resin-based aluminised
reflective curing compound which
hardens into an impervious film or
membrane shall be used.
c) The mechanical sprayer shall
incorporate an efficient mechanical
device for continuous agitation and
mixing of the compound during
spraying In addition to spraying of
curing compound.
d) The rate of spread shall be in
accordance with the manufacturer’s
instructions checked during the
construction of the trial length and
subsequently whenever required by
the IE.
e) The fresh cured concrete surface shall
be protected for at least 3 hours by
35 | P a g e
Standard Operating Procedure - 2012
covering the finished concrete
pavement (with tents, during adverse
weather conditions) as directed by
the IE.
f) After three hours, the pavement shall
be covered by moist hessian and the
same shall then be kept damp for a
minimum period of 14 days after
which time the hessian may be
removed.
g) The hessian shall be kept continuously
moist. All damaged/torn hessian shall
be removed and replaced by new
hessian on a regular basis.
h) The curing compound used shall;
1) Be of approved type & become
stable and impervious to
evaporation of water from the
surface of the concrete within 60
minutes of application.
2) Have a water retention efficiency
index of 90 per cent in accordance
with BS Specification No. 7542.
3) Contain sufficient flake aluminium
in finely divided dispersion to
produce a complete coverage of
the sprayed surface with a
metallic finish.
4) Not react chemically with the
concrete and the film or
membrane shall not crack, peel or
disintegrate within three weeks
after application.
Fig.6 Curing of finished concrete
Pavement
For Internal Circulation Only

7.5.9.0 CUTTING AND SEALING OF
JOINT GROOVES
a) Cutting of grooves for joints shall be
commenced after a minimum of 6-8
hours as per MORT&h specification
of casting the Pavement Concrete.
b) Joints shall be cut with power-blade
as per the size and location
mentioned in approved drawings
subsequently the grooves shall be
cleaned thoroughly using water jets.
c) After drying of grooves sealing
compound shall be poured/applied
and packed properly.
7.5.10 QUALITY CONTROL TEST
a) All ingredients for the PQC shall be
checked and verified as per MORT&h
Specification - Section 900.
b) Cube and beam samples shall be
prepared & checked for Compressive/
Flexural strength at 7 and 28 days and
recorded in specified formats.
c) Surface regularity of paved surface
shall be checked for compliance.
d) Texture depth shall be as describe in
MORT&h-Section 600.
e) Manufacturer’s Test Report for Curing
compound, Cement, Filler board and
joint sealant shall made available for
all batches of materials being use.
Checks before laying PQC;
a) Levels shall be checked by a joint
team of construction and QA staff
before PQC (is planned).
b) Check only if surface regularity within
the acceptable limits shall IR is placed
signed by the manager in charge.
c) After repairs are done the
levels/surface regularity and repairs
including de-bonding layer/bitumen
spray Etc. shall be checked again by
joint team as above.
36 | P a g e
Standard Operating Procedure - 2012
d) Checks for the Paver;
1) The super smoother shall be
checked for any defects/irregular
surfaces.
2) The vibrators shall be checked for
proper functioning and spacing.
3) Alignment and cleanliness of
dowel bars shall be checked by
straight edge and adjustments
made.
e) Work should NOT be undertaken
under windy conditions or under
low/high temperature as per
specifications.
f) Supervisors/ Chief mason shall ensure
proper finishing and ensure that there
is no extra slurry on the finished
surface.
g) While finishing there shall be negative
allowance provided for ‘swelling’.
h) While finishing particular care shall be
taken to avoid a “canal’ formation
between the filler lane and the
shutter lane.
i) In the filler lane, the joint between
the old PQC and fresh PQC shall be
neatly made and all excess
mortar/concrete shall be removed
within one hour of paving.
j) Adequate lighting shall be provided
well in time in the event of night
paving, particularly behind the paver.
k) Late Night paving should be avoided
as far as possible to ensure proper
check/quality.
l) Tents and Tarpaulins to protect from
rain/high winds shall be available
nearby.
m) Hessian Cloth rolls shall be positioned
in advance.
n) Level sheets of the previous layer of
CTB/repaired surface should be
available.
For Internal Circulation Only

Checks after laying PQC;
a) While it is still green, the surface
regularity checks shall be done with
the straight edge while the finishing
is being done. Any excess/deficient
material shall be removed/added.
b) Mist shall be sprayed immediately
after laying PQC to prevent plastic
shrinkage cracks.
c) Texturing shall be done immediately
after the finishing is over.
d) Hessian Cloth shall be placed after
texturing and wet curing done there
after continuously.
e) Joint cutting shall be commenced as
soon as the concrete is hard.
f) QA team and construction team shall
jointly check if there are any
defects/cracks.
g) If there are any non-conformity, the
same shall recorded in an NCR.
Further laying in non-conforming
areas to be done only after
rectifications are made.
h) Levels shall be taken and sheets shall
be handed over to QA for checks.
7.6 SAFETY REQUIREME NTS
Please refer Point No. 4.7.0
37 | P a g e
Standard Operating Procedure - 2012
SUMMARY
 Produced PQC material in
batching plant as per mix design
& MORT&h Specification - Clause
602.
 Mark the limits with pegs , width
as per drawing (FRL+ offset)
 Prior to laying concrete - lay
separation membrane.
 Paving of PQC can be done by
fixed form paver or by slip form
paver.
 Concrete slab shall be brush-
textured in a direction at right
angles to the longitudinal axis of
the carriageway.
 Transverse construction joints
shall be placed whenever
concreting is completed after a
day’s work or is suspended for
more than 30 minutes.
 Immediately after the surface
texturing, the surface and sides
of the slab shall be cured by the
application of approved resin-
based aluminized reflective
curing compound
 Pavement shall be covered by
moist hessian and the same shall
then be kept damp for a
minimum period of 14 days
 Cutting of grooves for joints shall
be commenced next day
(minimum 6-8 hours as per
specification) of casting the
pavement concrete.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PQC/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR SURFACE PREPARATION-PQC
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Whether location/Chainage is identified

2 Are the workers are provided with PTEs & dust masks
Whether level, Surface regularity & field compaction of
3
CTB Top layer surface is checked & approved
Whether level of DLC top layer surface is found within
4
the specified tolerance.
Whether the Air compressor & brooms are available at
5
the laying location along with the worker
Whether the curing period of the CTB layer is complete
6
as per specification
7 Is the DLC layer dry
Whether DLC layer is free from dust, foreign materials,
8
surface water or standing water.
9 Whether Micro cracking checking done
Whether a mock up session carried out with the
10
operators & other associates before starting the job.
11 The surface protected for 24 Hrs
Remarks
L&T QA/QC Client/IE

38 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PQC/02/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR LAYING-PQC
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Whether location/Chainage is identified
2 Whether center-line marking done
3 Whether formwork fixed as per drawings
4 Whether Client and Consultant have been informed
5 Whether paving plan has been prepared for PQC laying.
6 Whether the thermometers available at laying location.
7 Whether all the additional for working in night shift.
Whether methodology of work & specification available
8
with the Paving-in charge
Whether longitudinal and transverse joint have been cut
9
vertically as per methodology
Whether Dowels/Tie bars fixed as per
10
drawings/specifications
Whether all the safety measures have been taken as per
11
the project HSE plan.
Adequate nos. of equipments and manpower including
12
Plant and machinery crew available
Whether requisition for PQC given to the Production in
13
charge.
Whether the program of PQC laying conveyed to Plant and
14
Machinery and QA/QC in charges.
Whether Haul roads and access roads are properly
15
identified for movement of dumpers.
Pegs are properly fixed, sensor wires are stretched to the
16
required length and secured properly.
Whether PQC mix has been transported to paving location
17
with the tarpaulin covering
0
Whether the PQC mix temperature found between 15 C
18
and 30C while spreading
Whether Surface finished/broomed as specified
19
requirement
Whether surface level has been checked and found within
20
the specified tolerance limit
Whether curing for the laid surface done as per
21
specification
Whether sufficient arrangements have been made for
22
protection of freshly laid PQC
Remarks
L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 3

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PQC/03/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR POST PQC WORKS
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Whether the forms removed as per specified time

2 Whether curing done on the laid surface for 7 days

3 Whether Construction joint prepared

Whether the concrete is ready for joint installation
4
after 14 days of out of which 7 days are drying
5 Whether joint groove are widened before sealing

6 Whether the dirt,soil,etc removed from joint

Whether Permanent Joint sealing provided as per
7
drawings /specification
Remarks
L&T QA/QC Client/IE

40 | P a g e For Internal Circulation Only


8 HUME PIPE CULVERT
8.1.0 SCOPE
The scope covers the responsibilities and
procedures applicable for;
a) Widening of existing Hume pipe
culvert/Construction of a new Hume
pipe culvert as per approved
drawings.
b) Carriage of Hume Pipe to site,
preparation of bed for laying pipe,
laying, construction of Head wall,
Floor protection, Slope pitching Etc.
8.2.0 RESPONSIBILITY
8.2.1 SITE IN-CHARGE
Site Engineer shall be responsible for;
a) Control, Supervision and Direction for
Implementation of the procedure.
b) Check the dimension and quality of
Hume pipe’s when received at site.
c) Damaged pipe shall be rejected with
information to store/Agency.
8.2.2 SITE ENGINEER
Carry out the work as per the drawings.
8.2.2 QA/QC ENGINEER
a) Carry out Lab, Field Test and Field
Inspection/Checking.
b) QC engineer will be responsible for
source approval of pipes and for
production of concrete.
41 | P a g e
Standard Operating Procedure - 2012
8.3.0 REFERENCES
a) Good for construction drawings
b) Project Quality Plan (PQP)
c) Section 2906 of MORT&H
Specification for Roads and Bridges
8.4.0 EQUIPMENT/TOOLS
The following equipment’s shall be
deployed in the construction work of
Hume pipe culverts;
a) Mixer Machine with weigh batcher,
Batch Mix Plant & Transit Mixer
b) Hand Rammer/Vibrator
c) Trailer/open body truck
d) Water Tanker & Water Pump
e) Hydra Crane/Tripod/JCB
f) Shuttering Plate and Stays Etc.
8.5.0 MATERIALS
SI. No Description Specification
1 Cement
OPC 43/53 Grade
(IS:8112/IS:12269)
2 CoarseAggregate Table 2 of IS 383
3 Fine Aggregate Table 4 of IS 383
4 Water IS 456
5 Concrete Mix As approved Mix Design
6 GranularMaterial MORT&h Specification
7 Hume Pipe IS : 458
8.6.0 PROCEDURE
8.6.1 SETTING OUT
a) Stream Levels shall be checked for at
least 50m on either side of culvert in
order to confirm the flow direction.
b) Engineer in charge shall take OGL of
the working area for verification.
c) Location of pipe line and head wall
shall be marked on the ground and
checked before excavation is allowed.
d) After clearing grubbing work is
completed, setting out of the hume
pipe culvert shall be made form head
walls and bed of the pipe as per
approved drawing.
For Internal Circulation Only

e) Length of Hume pipe and Head wall
shall be verified with schedule of pipe
culverts.
8.6.2 EXCAVATION
a) After layout of the structure as per
approved drawing, excavation of
trenches for foundation bed of pipe
and head walls shall be done to
proper lines, length, grade and level
as shown in the GFC.
b) In case of old/existing embankment,
the trenches shall be cut at 150 mm in
excess on either side or one fourth of
the diameter of the pipe whichever is
more to the founding level of pipe
bed. The trench shall be as nearly
vertical.
c) In case during the excavation soft,
spongy or any unstable soil
encountered the same shall be
removed in consultation with
Engineer in charge.
d) In case rock strata are encountered
the excavation shall be taken down at
least 200mm below the bottom of
pipe with prior permission of the IE.
e) All trenches shall be back filled by
granular soil and compacted.
f) The trench shall be kept free from
water until the pipes are installed and
joints hardened.
8.6.3 GRANULAR BEDDING
a) Granular material bedding shall be
provided below the pipes as per
specified thickness in the drawing &
rammed properly by hand rammer or
plate compactor.
b) If height of fill over pipe is more than
4m, then base to be prepared with
150mm M15 PCC.
42 | P a g e
Standard Operating Procedure - 2012
8.6.4 LAYING OF PIPES
a) The arrangement for lifting, loading,
unloading & lowering of the pipes (by
suitable means) into the bed shall be
approved by IE.
b) Laying shall start from the out let end
& completed at the inlet end to
specified lines & grades.
c) The gap between two rows of pipes
shall be at least 450mm (min) or half
the diameter of the pipe, whichever is
maximum.
d) Proper precaution shall be taken so
that the pipes are placed without
damage.
e) Hume pipe is laid to the required
gradient, if not mentioned in drawing
1:1000 shall be adopted.
f) Normally, class of pipe used is NP4 for
road projects.
8.6.5 JOINTING
a) The hume pipe’s shall be joined by
‘Tongue and Groove joint’ filled with
cement soaked spurn yarn and then
filled with cement mortar 1:2.
b) The joining shall be made with care so
that the interior surface is smooth &
in consistency with the interior
surface of the pipe.
c) The joints shall be kept damp for at
least 3days.
d) All joints to be cured within 7 days.
8.6.6 HEADWALLS
a) Concreting of head wall/face wall
shall be carried out in two stage or
Single stage concreting according to
site conditions & No. of rows of pipes.
1) In case of single stage concreting;
End pipe shall be supported on
steel shutter directly with
additional support (if required)
and concreting done in one go.
For Internal Circulation Only

Extra-excavated area shall be
provided for support.
Fig 7 Single Stage Concreting
2) In two stages concreting; First lift
shall be done up to bottom of
Hume Pipe & then the last pipe
(resting on head wall) resting on
the same shall be placed as shown
in Fig.6. Second stage concreting
shall be carried after that
Fig 8 Two Stage Concreting
b) Curing with damp sacks or by direct
sprinkling of water shall be done to
the structure for a minimum period of
14 days.
c) The procedure & design for
formwork in the above section shall
be strictly followed.
d) The form works shall be removed in
case of vertical shuttering after 24
hours of casting. After removal of
form work any irregularity found in
the surface shall be neatly finished.
NOTE;
1) Material for formwork shall confirm
to section-1500 & IRC-87.
2) Specification of road & bridgework
section-1700 & 2200 shall be
43 | P a g e
Standard Operating Procedure - 2012
followed for construction of
headwall, Cradle & Catch pit.
3) M-15 shall be used for PCC and M20
for head wall as per approved mix
design.
4) Concrete shall be made with Batching
Plant or Mixer Machine at site.
8.6.7 BACKFILLING
a) Backfilling material shall be approved
by IE & shall not contain boulders,
large roots, excess soils or other
vegetable contains.
b) Backfilling up to 300mm above the
top of the pipe shall be carefully done
& thoroughly rammed tamped or
vibrated in layers not excess of
150mm thickness.
c) If height of fill is more than 4 m, then
concrete to be filled up to 360mm
from bottom.
d) Particular care shall be taken to
thoroughly consolidate the materials
under the hunches of pipes. Filling of
the hunch shall be carried out
simultaneously on both sides of the
pipe in such a manner that unequal
pressures do not occur.
8.6.8 APRON & STONE PITCHING
Apron & Stone pitching along with other
pitching works shall be done as per
MORT&h specification-Section 2500 after
completion of pipe culvert.
8.6.9 POINTS TO BE REMEMBERD
a) Pipe gradient to be maintained for
free flow of water.
b) Head wall concreting to be vibrated
properly, top level of head wall to be
maintained to true line and level.
c) Proper compaction around and top of
pipes to be ensured to avoid later
settlement.
For Internal Circulation Only
 Standard Operating Procedure - 2012

d) Pipe stacking at site to be planned SUMMARY

properly in order to avoid
unnecessary shifting and accidents.
e) If the cushion over pipes is less than
1m, then full encasing of pipes to be  Stream Levels to be checked for
done. at least 50m on either side of
culvert &Location of pipe line
8.7.0 RECORDS TO BE MAINTAINED and head wall to be marked.
a) Check list  Excavation for pipe bed & head
b) Pour card wall to be done in proper line,
c) Approved ready for inspection report length & grade.
d) Joint records  Granular material bedding to be
e) Hume pipe test certificates provided below the pipes and
compacted as per specified
8.8.0 SAFETY
thickness in drawing.
Please refer Point No. 4.7.0  The laying shall start from the
out let end & completed at the
inlet end to specified lines &
grades.
 The pipe shall be jointed with
tongue and groove joint and
then filled with cement mortar.
 The joints shall be kept damp
for at least 3days. All joints to
be cured for 7 days.
 Head wall concreting can be
done in two stage or single
stage.
 The form works shall be
removed in case of vertical
shuttering after 24 hours of
casting.
 Backfilling material shall be
approved by Engineer In charge.
 Care shall be taken to
thoroughly consolidate the
materials under the hunches of
pipes.
 Apron & Stone pitching to be
done as specification.

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC HUM/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR HUME PIPE
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Are working drawings approved for construction

2 Are the pipes and source of pipe approved

3 Is the setting out for pipe approved

Is the trenching/excavation is according to the
4
specification
5 Is the jointing of pipes appropriate

6 Is the backfilling approved by the Engineer

Remarks
L&T QA/QC Client/IE

45 | P a g e For Internal Circulation Only

 Standard Operating Procedure - 2012

9 BOX CULVERT AND MINOR BRIDGE
9.1.0 SCOPE
The scope covers the responsibilities and
procedures applicable for;
a) Widening of existing box culvert.
b) Construction of new box culverts as per
approved drawings.
c) Excavation, Foundation, Raft Slab, Head
and Wing walls construction.
9.2.0 RESPONSIBILITTY
Planning department will be responsible for
arranging resources.
9.2.1 SITE ENGINEER
a) All operations at site & reconciliation.
a) MORT&H Specifications for Roads &
Bridges Works 4th revision.
b) IS 456-2000 Code of practice for plain
and reinforced concrete. Special
publication IRC – 13.
c) IS 1786 High strength deformed steel
bars and wires for concrete
reinforcement.
d) IS code 269, IS code 383 specifications
of the MORT & H section 1000,1500
1700, 1006 and 2900, IS-8112 ,IS -
12269, IS – 4082,MORT&h Specification
1000-1,1000-2.
e) EHS manual, Project Quality plan (PQP).
& GFC drawings.
9.4.0 EQUIPMENT/TOOLS
Sl. No Plant Equipment
1 Transit Mixer
2 Excavator
3 Concrete Pump, Boom Placer
4 Needle Vibrator
5 Concrete Batching Plant
6 Bar bending Machine
7 Chute, Tremmie

b) Carry out work as per the approved GFC

9.5.0 MATERIALS
drawings
c) Prepared BBS and get it approved &
submitted to steel yard for cutting and SI. No Description Specification
bending OPC (43/53 grade)
1 Cement
(IS 8112,IS 12269)
d) Surveyor shall responsible for setting Reinforced Fe 415/Fe 500
2
outs all points. steel (IS 1786)
Coarse Table 2 of
3
aggregate IS 383
9.2.2 QA/QC ENGINEER Fine Table 4 of
4
a) Carry out Lab, Field Test and Field Aggregate IS 383
5 Water IS 456
Inspection/Checking.
As per
b) Source approval of all construction 6
Concrete
approved mix
Mix
materials, production of concrete Etc. design
c) Store keeper and QC engineer are
responsible to ensure approved. 9.6.0 PROCEDURE
d) Brand of steel and cement is used.
9.6.1 SETTING OUT
9.3.0 REFERENCES a) Please refer Point No. 4.7.0 (‘a – ‘c)

46 | P a g e For Internal Circulation Only


b) Normally box structures are done in 3
stages; Bottom slab, Wall and Top slab.
c) Haunch and Starter of the wall shall be
done along with bottom slab.
9.6.2 BOTTOM SLAB
a) Excavation shall commence only after
finalising and checking of the location
of for the culvert.
b) After excavation, all loose soil particles
shall be removed from the stratum
before PCC is done.
c) The excavated stratum shall be checked
with respect to the soil bearing capacity
considered in the drawing.
d) PCC shall be laid as per specifications in
the stratum. Over PCC, the layout of
culvert shall be marked before
commencing reinforcement.
e) Reinforcement spacing shall be marked
on the ground as per drawing and
approved BBS before commencing of
work.
f) Not more than 50% of reinforcement to
be lapped at any location as per
drawing. Proper cover shall also be
ensured. Always maintain minimum
laps to reduce wastage and cost.
g) After completion of reinforcement, it
shall be re-checked with approved
drawing and BBS.
h) Once reinforcement is completed, side
shuttering to be commenced.
9.6.3 WALLS
a) After completion of bottom slab,
reinforcement for wall shall be taken
up.
b) Wall formwork shall be commenced
only after completion of wall
reinforcement.
c) Proper walk way platform shall be fixed
before wall concreting.
47 | P a g e
Standard Operating Procedure - 2012
9.6.4 DECK SLAB
a) Deck slab staging shall commence only
after completion of wall formwork.
b) Once staging is completed, soffits for
deck slab shall commence.
c) Deck slab soffit shall be checked for its
level and gaps in the formwork shall be
closed prior to commencement of
reinforcement.
d) Deck slab reinforcement shall be tied as
per details given in the approved
drawings and approved BBS.
e) Once reinforcement is completed, side
shuttering shall commence.
f) Side formwork shall be checked for its
alignment and verticality.
g) After completion of side formwork,
deck slab concrete can be commenced.
h) Deck slab concrete to be done in layers
and care to be taken to avoid cold
joints.
9.6.5 IMPORTANT POINTS TO BE
REMEMBERED
a) At some locations (construction joints)
depending upon situation, water
stoppers can be used to avoid water
seepage.
b) Construction joints to be prepared
properly and cleaned thoroughly.
c) Form-work quality, alignment, gaps Etc.
shall be checked before the start of
concreting.
d) Required cover shall be maintained as
mentioned in the drawings, (normally
its 75mm below ground level and
50mm at other locations).
e) Dimensions and diameter of bent
reinforcement to be checked with
approved BBS once reinforcement is
received from steel yard.
f) While concreting, cold joints shall be
avoided. Proper vibration shall be
ensured and concrete to be laid in
layers.
For Internal Circulation Only

g) Height of free fall of concrete shall not
exceed 1.50m to avoid segregation.
h) Immediately after concreting, post
inspection to be done, and if any
defects found it the same shall be
cleared immediately.
i) Normal stripping of formwork duration
shall be is 24 hrs. for vertical surface &
15 days for slabs.
j) Weep holes shall be given & same shall
be opened immediately after removal
of the formwork.
k) Minimum 14 days curing to be ensured
for all concreting work.
l) Return walls/Wing walls shall be taken-
up & completed along with culvert
m) Curtain walls, aprons, quarter coning,
pitching also shall be taken up
immediately after completion of the
structures.
n) Filter media shall be used for width of
600mm along the walls.
o) Filling shall be done in layers of not
exceeding 150mm and be well
compacted.
p) Proper key shall be provided at
construction joints & the surface shall
be roughened before concrete set’s.
q) Care shall be given for filling around
box structure as the road settles, if
compaction of filling is not ensured.
r) Material wastage shall be controlled to
the possible extent.
s) All tie rod holes shall be finished after
removal of shutters.
NOTE;
If there are many typical box culverts,
precast option is best for faster
construction.
9.7.0 SAFETY
a) Please refer Point No. 4.7.0
b) Warning and cautionary boards to be
fixed at all structure locations.
48 | P a g e
Standard Operating Procedure - 2012
Housekeeping shall be done regularly
and if contaminated waste is there it
will be disposed-off in an environment
friendly manner.
c) Special care to be taken for deep
excavation.
9.8.0 RECORDS TO BE MAINTAINED
a) Check list & Pour card
b) Approved ready for inspection report
c) Approved Bar bending schedule (BBS)
d) Test certificate for weep hole pipes
e) Productivity record to be maintained
f) Concrete and steel reconciliation
records.
9.9.0 QUALITY CONTROL TEST
Please referrer Annexure 1
SUMMARY

Stream Levels to be checked for
at least 50m on either side of
culvert.
 Box structures shall be done in 3
stages: Bottom slab, Wall and
Top slab.
 Haunch and Starter of the wall to
be done along with bottom slab.
 Depending upon situation water
stoppers are also to be used at
all construction joints to avoid
water seepage.
 After concreting, immediately
post inspection to be done and if
any defects it should be cleared
immediately.
 All records shall be maintained in
SUMMARY
the prescribed format.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
BOX/01/R&R/R0
Project Client
Consultant Location
Pour no Mix Grade Ref. Drawing No./Rev. No
Theoritical Quantity Actual Quantity
Date Start Finish
IN – SITU CONCRETE CHECKLIST & POUR CARD(1)
Checked & Found OK
Preperation Remarks/Issues
Yes No Na
a) PCC Top Level

b) PCC Surface cleaned

c) Allignment Checked

d) Centre lines checked

REINFORCEMENT

a) Dia & Shape (as per BBS)

Extra Reinforcement (apart
b)
from drawing)
c) Extra Laps (if any)
d) No. of Chairs & Length
e) Binding as per specification
f) Cover to Reinforcement
FORMWORK
a) Center lines
b) Shuttering line, Level & lump
BEFO c) Demoulding agent applied
RE d) Concrete top level
CON e) Supports adequate
CREA
EMBEDED ITEMS (if any)
TING
a) BOLTS
b) INSERTS

L&T – ECCD QA/QC Concessionaire/PMC IE

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 Standard Operating Procedure - 2012

IN – SITU CONCRETE CHECKLIST & POUR CARD(2)

Checked & Found OK
Preperation Remarks/Issues
Yes No Na
a) Date of Concreting
b) Weather
c) Ambient Temperature
d) Mix grade
CON
e) Vibrator & needle
CREA
f) Slump
TING
g) Time of concrete start
h) Time of concrete end
i) No. of cubes for sampling
j) Cube identification

L&T – ECCD QA/QC Concessionaire/PMC IE

a) De-shutturing on and at time
b) Surface of the structure
c) Plump within acceptance
POST Repair of surface with respect
d)
CON to approved method (if any)
CREA Dimensions are within specified
e)
TING requirement
f) Curing method
g) Curing started on at time
h) Any other observations

CLEARED FOR POUR DATE : TIME :

L&T – ECCD QA/QC Concessionaire/PMC IE

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 Standard Operating Procedure - 2012

10 BRIDGES / FLYOVERS m) IS-4000 (Fasteners- ROB )

n) IRC 24 (Fabrication- ROB)
o) Clause 3.12.8.16.2 of BS: 8110 - 1:
1997 - for Use of Mechanical
Couplers.
p) B1 - Bridge code (Railways- RDSO)
q) PQP & GFC Drawing.

10.4.0 EQUIPMENT/TOOLS

10.1.0 SCOPE Sl. No Plant Equipment

The scope covers the responsibilities and 1 Transit Mixer
work procedure for construction of 2 Excavator
Bridges/Flyovers/ROB. 3 Concrete Pump, Boom Placer
4 Needle Vibrator
10.2.0 RESPONSIBILITY 5 Concrete Batching Plant
a) Please refer Point No. 9.2.0 6 Bar bending Machine
7 Chute, Tremmie
10.3.0 REFERENCES
10.5.0 MATERIALS
a) Construction agreement and technical
Specifications
SI. No Description Specification
b) IRC 78 -2000 (Standard specification
OPC (43/53 grade)
of codes of practice for road bridges) 1 Cement
(IS 8112,IS 12269)
c) IRC SP -47 (Guide lines for quality
Reinforced Fe 415/Fe 500
system for road bridges) 2
steel (IS 1786)
d) IS -456 (Code of practice for plain and
Coarse Table 2 of
reinforced concrete) 3
aggregate IS 383
e) IS -2502 (Code of practice for bending Fine Table 4 of
and fixing of bars) 4
Aggregate IS 383
f) IS -1786 (Specification of high 5 Water IS 456
strength deformed steel bars and As per
wires for concrete reinforcement) Concrete
6 approved mix
Mix
g) IS-8112 (Specification of 43 grade design
OPC)
h) IS -12269 (Specification of 53 grade 10.5.0 PROCEDURE
OPC)
i) IS-516 (Methods and test for strength 10.5.1 SETTING OUT
of concrete) a) Please refer Point No. 4.7.0 (‘a – ‘c)
j) IS-383 MORT&h (Specification for b) Location of all piers and abutments
roads and bridges published by Indian shall be marked and checked before
roads congress- 4th revision) excavation. Surveyor shall be
k) IS 9417 (Welding details) responsible for setting out.
l) IS-2062 (M.S Steel for steel girder- c) Depending upon depth of excavation
ROB) working space to be provided.

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 Standard Operating Procedure - 2012

10.5.2 FOOTINGS be filled with boulders till river bed

a) Excavation width shall be planned level (annular concrete).
according to the depth of foundation NOTE;
from OGL. Side slope of excavation 1) Not more than 50% of
shall be 1:2 in ratio, if the excavation reinforcement to be lapped at any
is deeper, then benching shall be location. Correct lap length to be
provided all round depending upon ensured as per drawing.
existing soil strata and if required 2) Always minimum laps to be used in
shoring also shall be done for sandy order to control wastage and cost.
soils. 3) Mechanical couplers could be used
b) Drawing founding level (as designed) for splicing of rebar’s in-lieu of
shall be adopted based on the bore conventional lapping in order to
log data. If any changes actually at optimize use of rebar’s.
site, it shall be brought to the notice
of designer immediately.
c) A general criterion for resting
foundation is 1.50m in soft rock and
600mm in hard rock.
d) Once the founding level is reached,
the levels and soil strata shall be
checked as per bore log data,
drawings and verified. Fig 9 Pile Footing
e) If soil strata found Ok, the base shall
be wetted and PCC done in
10.5.3 PIER/ABUTMENT
consultation of Engineer in-charge.
a) The Pier/Abutment reinforcements
f) Over PCC, layout of footing shall be
shall commence after the completion
marked & and subsequently,
of footings construction.
reinforcement spacing shall be
b) Construction joint-key shall be
marked on the PCC as per drawing
provided on the surface of the
and approved BBS before
footing which is to receive the next
commencing of work.
stage concrete (it shall be roughened
g) After completion of reinforcement the
properly for better bondage).
same shall be checked with drawing
c) Reinforcement shall be checked with
and approved BBS.
drawing before fixing of the wall
h) Side formwork shall be commenced
shutters.
after completion of reinforcement
d) After reinforcement is ready, vertical
i) Required cover shall be maintained as
wall formwork shall commence.
mentioned in the drawing (normally
e) Required reinforcement cover shall
its 75mm below ground level).
be maintained as per GFC drawings.
j) After all checks footing concrete shall
(Normally it is 50mm when planning
be done as per standard procedure.
for multiple lifts).
k) After the concrete has hardened, the
f) Top width of structure & alignment
trenches formed between footing and
of lift shall be checked before
rock/soil shall be refilled with M15
concreting.
concrete, and above rock/soil it can

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 Standard Operating Procedure - 2012

g) While concreting, cold joints shall be

avoided & proper vibration shall be
ensured and concrete shall be laid in
layers.
h) After concreting, immediately post
inspection to be done and if any
defects shall be rectified
immediately.
i) Normal stripping of formwork
duration for vertical surfaces is 12 to Fig 10; Pier and Pedestal
24 hrs., depending upon concrete
setting time and shape/size of 10.5.5 PEDESTALS
structure. a) Pedestal reinforcement shall be
completed as per GFC drawings.
10.5.4 ABUTMENT/PIER CAPS b) Formwork shall be fixed and checked
a) After completion of piers, staging shall for its alignment and measurements
be started for abutment/pier caps as c) Pedestal concrete shall be done after
per formwork drawing to the required reinforcement and shuttering is found
level. in order.
b) Soffit for pier cap is fixed after d) Top level of pedestal concrete shall be
completion of staging and checked for in true level as its base for bearing.
level and dimensions.
c) Cap reinforcement is commenced 10.5.6 BEARINGS
after completion of soffit. a) POT bearings pockets shall be
d) After completion of reinforcement, provided in the pedestals for bearing
the same shall be checked with bottom sleeves (with respect to
drawing and approved BBS. bearing drawings). These pockets will
e) Side formwork and pedestal/Seismic be grouted with GP2 after erection of
reinforcements shall then be bearings.
commenced as per drawings. b) Elastomeric Bearings shall be fixed
f) After completion of form work and over pedestals to true level before
reinforcement, Cap concrete can be placing the girders.
done. The concrete to be done in
layers and according to rate of pour
mentioned in form work drawing.
g) The cap soffit formworks shall be
removed after 14 days (as per Normal
conditions) and shall be cross
checked with the cube compressive
strength on 14th day .

Fig 11 Precast girders are erected

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10.5.7 GIRDERS
a) Precast girders are casted at precast
yard and shifted to erection location
by means of trailers and cranes.
b) Each Girder shall be braced properly
with temporary supports after
erection.
c) End diaphragms/cross girders soffit
shall commence after placement on
accurate location.
d) End diaphragms /cross girders
reinforcements shall be tied after
soffit is checked and found ok.
e) After checking of reinforcements,
cross girder side shuttering shall
commenced.
f) Cross girder Side formworks shall be
checked for its alignment and
measurements followed by cross
girder concreting.
10.5.8 DECK SLAB
a) Precast deck planks shall be erected
over girders as a part of deck slab or
false planks according to given design.
b) Gaps between planks shall be closed
with suitable approved material.
c) Deck slab reinforcement shall
commence and checked with respect
to the GFC drawings and approved
BBS.
d) Side shuttering shall also start after
completion of reinforcement.
e) After checking of reinforcements and
side shuttering deck slab concrete is
commenced.
f) Deck slab concrete pouring sequence
shall be planned such that cold joints
are avoided.
g) The deck slab concrete shall be cured
for minimum 14 days.
h) Deck slab soffit can be removed after
14 days or if before; it shall be
consulted with designer.
54 | P a g e
Standard Operating Procedure - 2012
10.5.9 FINISHING WORKS
a) After the deck slab attains 70%
strength, crash barrier works shall be
commenced.
b) After concrete attains its full strength
wearing course shall be done.
c) Expansion joints shall be done only
after completion of wearing course to
get better riding quality.
d) Minimum 7 days curing period is
required for expansion joints.
e) Proper compaction to be ensured for
side filling along abutment, filling shall
be done in layers not exceeding
200mm.
f) After completion of filling approach
slabs are casted and cured till it
attains its required strength.
g) Before traffic diversion over bridge,
load test shall be done according to
drawing and construction agreement.
10.6.0 IMPORTANT POINTS TO BE
REMEMBERED
a) Care shall be taken while fixing
founding level of footings.
b) Required cover blocks shall be tied
along with the reinforcement.
c) Height of free fall of concrete shall not
exceed 1.50m in order to avoid
segregation.
d) Construction joints shall be prepared
properly and cleaned thoroughly.
e) All specialized items such as
expansion joints, bearings shall be
well ordered in advance as it takes
time considering the lead time.
f) While working in River Bridge,
monsoon duration shall be taken into
account and sequence to be planned
accordingly.
g) Reinforced stacking shall be done
properly over wooden sleepers and
not on ground.
For Internal Circulation Only
 Standard Operating Procedure - 2012

h) Dimensions and diameter of all bent Quantity of

reinforcement shall be checked with concrete in No. of samples
approved BBS once reinforcement is cum
received from steel yard. 1-15 1 for 7 days+1 for 28 days
6-15 1 for 7 days+2 for 28 days
i) The jacks used for lifting deck slab
16-30 1 for 7 days+3 for 28 days
shall be calibrated before it’s used.
31-50 1 for 7 days+4 for 28 days
Spare jacks also shall be made
1 for 7 days+ 4+1 for
available while lifting.
51 and above every 50cum or part
j) All tie rod holes shall be finished after thereof 28 days
removal of shutters. (One sample is a set of 3 cubes of
FORMWORK; 150mm x 150mm x 150mm)
a) Formwork shall be planned in advance
,but proper pouring and vibrating of 10.8.0 SAFETY
concreting shall be ensured. Climbing Please refer Point No. 9.8.0
brackets provisions shall be done.
b) Pier /Abutment lift formwork to be 10.9.0 RECORDS TO BE MAINTAINED
planned well in advance according to
a) Check list.
the casting height.
b) Pour card.
c) Formwork quality, alignment, gaps
c) Approved ready for inspection report.
Etc. to be checked before start of
d) Joint records.
concrete.
e) Approved Bar bending schedule (BBS)
f) Test certificate for weep hole pipes.
10.7.0 QUALITY CONTROL TESTS g) Test certificates for Strands, bearing
AND THEIR FREQUENCIES plates, wedges( if PSC Girders)
a) Physical test on cement at a h) Stressing records (if PSC girders).
frequency of 1test per batch and i) Grouting records (if PSC girders).
Manufacture’s Test Certificate (MTC) j) Steel girder fabrication records.
shall be maintained. k) Steel girder material certificates.
b) Gradation test for coarse/fine l) OGL record.
aggregates, at a frequency of 1 test
per week.
c) Tests on water, at a frequency of once
per source after monsoon.
d) Physical and chemical requirements of
admixtures MTC shall be maintained.
e) Tests on reinforcement at a frequency
of once per batch/ lot per diameter
Test certificate to be maintained.
f) Workability of concrete by slump
cone test at a frequency of once per
session at concrete placing area.
g) Compressive strength of concrete
shall be done at a frequency as
follows:

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 Standard Operating Procedure - 2012

SUMMARY

 Location of all pier & abutment

to be marked on the ground &
Excavation to be done for
foundation.
 Once founding level is reached
PCC shall be done.
 Pier/Abutment reinforcements
shall be commenced after
completion of footing.
 After reinforcement is ready,
vertical wall form work shall be
commenced.
 After completion of
pier/abutment, staging shall be
done for pier caps.
 Soffit for pier cap is fixed; after
that side formwork &
reinforcement is done.
 After that Cap concrete shall be
done.
 The cap soffit formworks shall
be removed after 14 days.
 After pier cap completion,
pedestals are constructed.
 Pockets are provided in
pedestals for bearing bottom
sleeves with respect to bearing
drawing.
 Precast girders are erected over
bearings.
 Precast deck planks are erected
over girders according to given
design.
 Deck slab shuttering,
reinforcement, concreting done.
The deck slab concrete to be
cured for minimum 14 days.
 Deck slab soffit can be removed
after 14 days.
 After concrete attains its full
strength wearing course to be
done.

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC FW/01/R&R/R0
Project Client
Consultant Location
Pour no Mix Grade Ref. Drawing No./Rev. No
Theoritical Quantity Actual Quantity
Date Start Finish
CHECKLIST FOR FORMWORK INSPECTION
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Formwork Design / Drawing / Sketch approved

2 Formwork alignment correct

3 Match Cast / Segment setup checked

4 Blockouts for Post Tensioning Anchors checked

5 Joints between panels closed(No gaps)

6 Box outs, cast-in -items, ducts fixed securely

7 Formwork Clean

8 Shutter Vibrators

9 Ducts for shear key

10 Ducts for manhole checked

11 Safe access constructed

12 Formwork release oil applied properly

13 Construction/Expansion joint preparation satisfactory

14 Adequate work space provided for labours, equipment

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC CI/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) Type Of Structure
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR CONCRETE INSPECTION
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Method Statement approved
Water, Sand, Coarse Aggregate, Cement, Admixture
2
approved
3 Formwork approved

4 Reinforcement approved

5 Concreting equipment in working order

Concreting gang present including Carpenter, Steel
6
fixer,..etc
7 Access provided

8 Safety arrangement adequate

9 Adequate lighting provided (if night shift)

10 Form vibrators

11 Needle vibrators
Plastic sheet for covering the concreted surface of
12
segment
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 3

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC RI/02/R&R/R0
Project Client
Consultant Contractor
Work Type Of Structure
Location/Chainages Ref. Drawing No./Rev. No
Span Start Finish
CHECKLIST FOR REINFORCEMENT INSPECTION
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Working drawing checked and approved
2 Latest revision being used

3 Bar Bending Schedule approved

4 Reinforcement material approved

Bar-bending and cutting satisfactory as per approved
5
BBS
6 Bar size as per BBS

7 Bar spacing correct as per BBS

8 Bar lap length as per BBS

9 Bar lap at correct locations

10 Bar tied with specified binding wire

12 Cover to bottom bars correct

13 Cover to side bars correct

14 Cover to top bars correct

15 Cover Block fixed properly

16 Lifting frame checked

19 Formwork checklist completed

17 Reinforcement or OHE Mast checked

Additional reinforcement around shear key hole
18
checked
Bar assembly rigid and adequately supported (including
11
spacer and chairs)
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 4

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SC/01/R&R/R0
Project Client

Consultant Contractor

Work Type Of Structure

Location/Chainages Ref. Drawing No./Rev. No

Span Start Finish

CHECKLIST FOR DECK SLAB CONCRETE

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Concerned drawing available

2 Strata/levels found acceptable

3 Mix and its materials approved

4 Formwork/scaffolding approved

Bar bending schedule /

5
Reinforcement approved
Adequate cover blocks/chairs/
6
spacers provided
Adequate approved strip for
7
expansion joint provided

8 Slump found within the range

9 Required cubes cast

Placing/compaction/finishing
10 /workmanship for concrete found
acceptable
Grove cut at expansion joint
11
satisfactory

12 Pre-stressing sheathing approved

Required equipment/ lighting/

13
communication provided
Concrete conveying arrangement
14
found acceptable

15 Curing arrangement done

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

11 PRESTRESSING f) IS: 12269-1987: Specification for 53

grade ordinary Portland cement.
g) IS: 516-1959: Methods of tests for
strength of concrete.
h) IS: 383-1970: Specification for course
and fine. IS -456, 516, & 383
i) GFC drawings & PQP.
j) Construction Agreement (CA) and
technical specifications.

11.1.0 SCOPE 11.4.0 EQUIPMENT/TOOLS

The scope covers the responsibilities and
procedure for; SI. No Equipment/Tools
a) Precast Girder casting and 1 Multistrand Jack
b) Pre-stressing works (Post tensioning) 2 ChainPulley block
Grout pump with pressure devices
11.2.0 RESPONSIBILITY 3
with agitator
a) Precast engineer shall be responsible 4 Concrete Batching Plant
for calculating and placing the request 5 Transit Mixers
to store for all pre-stressing materials 6 Gantry
7 Tool box
and execution of work at site.
8 Concrete Pump/Boom placer
b) Precast yard engineer shall be
9 Needle Vibrator
responsible for preparing the pre-
10 Grouting hose pipe
stressing program and achieving the
11 Multi pulling Hydraulic Jack (200MT)
same as per project construction
12 Hydraulic Pumps (750bar)
schedule.
13 Calibrated pressure guage
c) QC Engineer shall be responsible for 14 Gloves
testing all construction materials.
11.5.0 MATERIAL
11.3.0 REFERENCES
a) MORT&h Specifications for Road and SI. No Description Specification
Bridge works published by Indian
OPC 43/53-grade-IS
Roads Congress, New Delhi, (4th 1 Cement
8112/IS 12269
Revision). 2 Reinforcement Steel Fe-415/Fe 500-IS 1786
b) IRC: 18-2000: Design Criteria for Pre-
3 Coarse Aggregate Table 2of IS 383
stressed Concrete Road Bridges, 4 Fine Aggregate Table 4 of IS 383
(Post-Tensioned Concrete). 5 Water IS 456
c) IRC: SP 47-1998: Plain, reinforced, As per approved mix
6 Concrete mix
design
pre-stressed and composite concrete. Pre-Stressing HT
7 IS: 4268
d) IS: 2502-1963: Code of practice for Strands
bending and fixing of bars for Pre- Stressing
8 BS: 8110
couplers
concrete reinforcement. 9 HDPE sheathings IRC: 18:200
e) IS: 1786-1985: Specification for high 10 Anchorage Cones BS : 4447/FIP 1993
strength deformed steel bars and
wires for concrete reinforcement.

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 Standard Operating Procedure - 2012

11.6.0 PROCEDURE shutter joints shall be compacted/

fixed with foam sheets to avoid slurry
The following sequence of activities shall
leakage and for tightening the
be followed;
shutters properly as per requirement.
a) Profiling
g) At the live & dead end anchorages/
b) Cutting and threading of tendons
strand coupler pockets of required
c) Stressing of tendons
size shall be fixed with shutters as per
d) Grouting of tendons
the site drawing.
e) End Cap Concreting

11.6.3 REINFORCEMENT
11.6.1 STORAGE
a) All Reinforcement bar for precast I-
a) H.T.S. Strands, anchorages and
Girder shall be cut & bent to required
sheathing shall be covered for
shape and size as per approved
Protection from dust/rain water Etc.
drawing & specification.
b) Necessary care will be taken to avoid
b) Reinforcement bars shall be placed &
damage of sheathing by other heavy
tied with 18 Gauge G.I. Binding Wire.
Materials.
c) Sufficient number of cover blocks
c) Wedges will shall be protected from
shall be provided to maintain the
corrosion by applying rust preventive
required cover.
oil.
d) One coat of Inhibitor solution can be
applied to protect the reinforcement
11.6.2 FORMWORK
bars from corrosion (if mentioned in
a) Formwork; Steel moulds shall be used
contract specification).
for Pre-Stress with Post Tension ‘I’
NOTE;
Girders casting work.
Mild Steel binding wire to be used for
b) Mould Curve Profile in the steel
rebar tying instead of G.I binding wire as
mould shall be provided as Per GFC
this would promote bimetallic corrosion
drawing.
due to contact of galvanized steel &
c) One coat of shuttering oil shall be
ungalvanized steel within the concrete
applied to the steel moulds uniformly
mass.
on all the surface and any excess oil
shall be wiped off (shuttering oil shall
11.6.4 STEPS
not be coated over the
reinforcement).
11.6.4.1 PROFILING
d) All the shutters shall be cleaned
Profiling is the layout of pre-stressing
thoroughly after de-shuttering,
tendon according to the co-ordinates
grinding if necessary before reuse.
given in the reference drawings.
e) All the shutters shall be free from
a) Steps in profiling ;
damages like bend, kink, Etc.
1) Preparing cone boxes and fixing
f) Bottom & Side shutters shall be
guides to it
cleaned thoroughly before fixing
2) Installation of tendons &
&shall be fixed to the dimensions,
3) Checking of Identification Tag
shape as per the approved drawings.
details
Check for the sizes, line, level/plumb
b) Cable supports/Chairs shall be welded
after tightening with tie rods. All the
to the vertical stirrups and sheathing

62 | P a g e For Internal Circulation Only


shall be tied with the help of binding
wire so as to avoid displacement of
cable during concreting. Care shall be
taken in providing smooth profile such
that there is no sudden kinks.
c) The packing of HTS strands shall be
removed just prior to use.
d) The strand shall be de-coiled on an
elevated platform along its length and
the required length of catch strand
shall be marked, cut and recorded in
the format correlating the Cable No.
to Coil No. (The coils may be mounted
on a rotating table to facilitate de-
coiling).
e) The strands shall be cut as per
approved drawings to length and
inspected for defects like opening of
wires, if any.
f) The cut strands shall be threaded
inside the duct for full length. Strand
shall be cleaned up before the
threading operation.
g) In case any Delay in stressing
operation after inserting the strands,
the ends of strands protruding
beyond the face of girders shall be
wrapped with plastic sheets to
protect from water/dust
h) Precautions during profiling;
The following precautions shall be
taken during profiling process
1) Between the points given the
cable must retain a regular
curvature without undulations or
sharp changes in the direction,
which will cause entries in the
friction loss at the time of
stressing.
2) The cable axis must coincide with
anchorage axis for a length.
3) The cable must be placed in the
concrete section in such a way so
as to allow easy concreting and
sufficient cover.
63 | P a g e
Standard Operating Procedure - 2012
11.6.4.2 SHEATHING / TENDON
LAYING
a) Pre stressing strands shall be uncoiled
& cut as per drawing adding due
allowances for profiling and gripping
length of jacks. Abrasive disc cutter or
cutting wheel as per the drawing as
be used.
b) Both ends of strands in cable shall be
numbered/ identified in order to
place the strand in correct
configuration in the bearing plate to
prevent twisting of cable in the duct.
c) All the strands in cables shall be
cleaned thoroughly with cotton/cloth
using Kerosene /petrol in order to
remove oil/rust/dust Etc.
d) Tendon supports/steel chairs, made
out of reinforcement bars, shall be
installed before tendon installation at
an adequate interval.
e) The cables strands shall be tied
together (specified in drawing) with
binding wire at suitable regular
intervals and threaded into Bright
Metal/HDPE Sheathing. The sheathing
lengths shall be joined together with
couplers as per IRC specifications.
f) Approved Bright Metal Sheathing
ducts including Bright Metal couplers
of specified size and shape shall be
placed over chairs/templates spaced
at 0.5 meter to the required
alignment profile within the
permitted tolerance as per the
approved drawing and properly tied
with binding wire to avoid any
disturbance of alignment and profile
at the time of concreting and
vibration.
g) Bright metal Duct joint connection to
end anchorage cones/strand couplers,
grout and air vent pipes shall be
sealed properly by adhesive tape / or
For Internal Circulation Only

other approved means tightly to avoid
slurry leakage into the duct.
h) Grout and air vents shall be provided
at the highest point as per the
drawing and properly
jointed/connected with bright metal
coupler joint and sealed properly with
adhesive tape tightly.
i) The sheathing ducts shall be
connected to the tube units for
grouting.
j) The joints shall be sealed with
adhesive tapes to avoid cement slurry
leakage.
k) Both ends of the sheathing duct shall
be closed after strand installation and
the protruding length of strands shall
be wrapped suitably to protect from
entry of unwanted materials during
concreting.
11.6.4.3 THREADING OF H.T
STRANDS, INSERTION OF ANCHOR
HEAD
a) The threading method adopted is
‘Push-Through’ method. In this
method the H.T Strands are
individually or few nos inserted in the
duct.
b) The protruding strands are cleaned.
This is done to remove dust; grease
or oil stains on the Strands.
c) The anchor head is cleaned well to
remove anti corrosive oil, which is
applied before dispatch. The taper
holes shall also be cleaned to remove
any dust / oil stains sticking on to the
taper holes.
d) The H.T Strands shall be inserted one
by one into the anchor head and they
shall be secured firmly by wedges.
11.6.4.4 CONCRETING
64 | P a g e
Standard Operating Procedure - 2012
a) Concrete shall be sampled and tested
for Slump & Compressive strength
tests.
b) Concrete shall be poured in the I
Girders moulds in the proper
sequence & layer by layer, starting
from middle point to end points by
Boom Placer/Pump in horizontal
layers of 300-400mm up to the beam
top and compacted with needle
vibrators to avoid honeycombing, air
voids, cold joints, Etc. to achieve a
dense, durable concrete and smooth
surface finish
c) De-shuttering shall be done after
minimum of 24 hours/after sufficient
period of concrete
d) Moist curing shall be done
continuously for a minimum period of
14 days covering all surfaces with
Hessian cloth
NOTE;
1) The formwork level, line, alignment,
dimension, Etc. including pockets
for stressing area shall be checked
for the requirement as per the
drawing
2) The reinforcement bar size and pipe
sleeves, holes / openings for bolts
fixing Etc. shall be checked as per
the approved drawing
3) Bright metal/HDPE sheathing duct,
Grout pipes & Air vents, End
anchorages and Prestressing
strands shall be checked as per the
requirements.
11.6.4.5 STRESSING:
a) Stressing shall be carried out stage
wise as per the tendon sequence
specified in the drawing.
b) Stressing shall be applied at equal
incremental pressure with
measurement of strand elongation up
to the required pressure to achieve
For Internal Circulation Only

the required elongation of strand and
locked with the wedges into the
bearing plate/strand coupler.
c) The total net elongation shall be
calculated after observing and
measuring the wedge draws in / slips.
d) If the required elongation is not
achieved at the specified total
pressure, additional stresses subject
to a maximum of 5% of the specified
stress shall be applied as per the
approved drawing till the minimum
required elongation is achieved and
final net elongation to be calculated.
e) If the specified elongation is achieved
before applying the required total
pressure, further stressing shall be
continued till minimum required
pressure is reached but restricted to
not more than 5% of the specified
elongation as per the approved
drawing.
f) The total net pressure and total net
elongation achieved for each tendon
(strand) shall be recorded after
considering the slip / wedge drawn in
the approved format(if the
percentage of variations in elongation
is beyond the limit of (+/-) 5% of
required elongation, it shall be
informed to design office).
g) The wedges & HT strands shall be
cleaned to remove dust or oil traces
from the threads of the wedges.
h) After completion of each tendon
stressing and locked with wedges, the
strand protruding beyond the wedges
shall be cut after 24 hrs. of stressing
operation completion by using cutting
wheel (leaving 25 mm). The sealing of
tendons end in the pocket (recessed)
area shall be fixed with end cap and
sealed with adhesive tape /other
approved material.
65 | P a g e
Standard Operating Procedure - 2012
i) The 1st stage stressing shall be done
after 3 days or on achieving 30N/mm2
whichever is later.
j) After checking the slip for 24 hours
the girder shall be shifted from
casting bed to stacking bed.
k) The 2nd stage Stressing shall be done
in the stacking yard after 21 days or
on achieving 45Mpa whichever is later
l) After checking the 24 hours slip the
strands protruding from the anchor
heads shall be cut and grouting shall
be carried out.
m) A stressing record shall be prepared
for each cable to be stressed on which
all steps and occurrences of the
procedure are recorded. The stressing
record sheet shall be filled up by the
pre-stressing technician in charge of
the operation.
NOTE;
1) Stressing shall be carried out with
the relevant experienced personnel
with proper safety precautionary
measures.
2) Stressing shall start only after
concrete attains field cube strength
of 80% of desired grade of concrete
strength /or 7days whichever is
later as specified in the approved
drawing (for M50 grade 40N/mm2).
3) The approved stressing
components of bearing
plate/strand couplers and wedges
shall be calibrated using stressing
jacks (for accommodating the jacks,
a gap of about 1.5 mtr shall be
provided) pressure gauges as per
the tendon sequence specified in
the approved drawing. In the dead
end, bearing plate wedges
arrangement shall be fixed
properly.
4) The required elongation of the
strands shall be calculated based on
For Internal Circulation Only

the design force to be applied
including losses, strand coil
number, actual area of strand and
modules of elasticity and total
length of strand.
11.6.4.6 GROUTING
a) The grout shall be pumped into the
duct by a positive displacement
grouting pump.
b) Grout is flushed through the live end
of grout pipe and overflown from the
intermediates & dead end air vent
pipes till all the air and water inside
the duct is removed & the required
grout consistency is over flown.
c) All the vent pipes shall be locked and
the grout to be allowed for building
up in the duct to the required
pressure (of 5 Kg/cm2 & maintain
the pressure for about 1 min) and
then grouting pipes shall be locked.
d) After the final setting of grout, the
grout & vent pipes shall be cut and
sealed with approved material to the
concrete surface level.
NOTE;
1) The sheathing ducts shall be
grouted after 24 hours (min.) of all
the strands in the beam are
stressed and wedged properly with
wedges.
2) Before grouting, the protruding
extra strands shall be cut with
cutting tool and sealed properly
with adhesive tape and approved
material as per the manufacturer's
direction.
3) In the strand coupler end, the
strands inserted into the coupler
shall also be properly protected
before grouting.
4) The duct shall be flushed out
completely by water and air from
66 | P a g e
Standard Operating Procedure - 2012
the dead end vent for removing oil,
dirt, Etc. from the strands and duct.
5) The over flown grout shall be
deemed from the area
immediately. The grout cubes shall
be made in the 100 mm size cubes
and tested at the age of 07 days for
checking the grout compressive
strength (Required Strength - 17 N /
mm2) Grout Cube Test Results shall
be maintained as per the enclosed
format.
6) Cement grout of maximum W/C of
0.45 mixed with approved grout
admixture of chloride free non-
aluminium based expanding agent
(Viz. Intraplast-N200 by SIKA - 0.4%
by weight of cement) or approved
equivalent in dosage as specified by
the manufacturer.
7) The mix shall be prepared and
continuously agitated in the
colloidal mixer (mixer with agitator)
to the uniform consistency till the
grout is pumped. (The grout used
shall pass through finer mesh sieve
2mmx2mm to avoid the pump
blockage).
11.6.4.7 END CAP CONCRETE
a) The rebar shall be tied as per the
approved drawings.
b) The side formwork shall be placed and
secured properly.
c) Before placing the end shutter,
Nitobond EP shall be applied on the
old concrete to achieve proper
bonding between old & new concrete.
d) After the concreting is done, it shall
be cured to achieve the strength.
11.6.4.8 HANDLING & STOCKING
a) Post tension members shall be lifted
after attaining required strength of
For Internal Circulation Only

80% of desired grade of concrete
strength as per designer's instruction.
b) As per the GFC drawing proper
arrangements shall be made during
casting for lifting & handling.
c) I Girders shall be shifted to the stack
yard by Hydraulic cranes under proper
supervision.
d) I Girders shall be stacked at specified
location & gaps, layers. Wooden
runners shall be used at required
places to avoid the damages.
11.6.4.9 GROUTING OF TENDONS
a) The tendon shall be prepared for
grouting; 10days after tensioning, but
not before 24 hours after tensioning.
b) Grout vents shall be provided at
anchorages for each cable.
c) Grout caps shall be fixed on both sides
of anchor heads and tightly secured.
d) Ducts shall be flushed with water (for
cleaning & wetting the duct walls). The
entire water shall be drained through
lowest drain pipe or by blowing
compressed air through the duct.
e) As soon as flushing is completed the
grout operation shall be started.
f) The locking pressure 5 kg/sq.cm is to
be maintained for approximate one
minute.
g) Once the desired pressure of injection
reaches, the valve at the entry point
shall be closed.
h) Records for grouts shall be recorded
and maintained.
NOTE;
1) The proportions of grout materials
shall be based on field trials
conducted before commencement of
grouting.
2) Water shall be added in mixer first,
followed by cement and admixture
3) The additive admixture is mixed with
cement in proportion as
67 | P a g e
Standard Operating Procedure - 2012
recommended by additive
manufacture.
4) The grout mix shall have water
cement ratio not exceeding 0.45.
Cebex 100 in right proportion shall be
added to the grout mix to avoid the
shrinkage of the grout mix.
5) The compressive strength of 100mm
cubes of the grout shall not be less
than 17 MPa at 7 days.
6) The temperature of the grout shall
not exceed 25ᵒ C during pouring.
7) Mixing time of grout shall be 2 to 3
minutes so as to obtain uniform and
thoroughly blended grout.
8) The grout shall be continuously
agitated with agitator till it is
injected. Water shall not be added
once the grout is mixed thoroughly.
11.7.0 HEALTH, SAFETY &
ENVIRONMENT
a) No stressing equipment or accessories
shall be used that are not complete as
supplied from the manufacturer or
post-tensioning supplier.
b) Stressing shall take place on a proper
working platform, as required by the
regulation agency. Hands shall be kept
out of jack while stressing operation is
taking place and while retracting.
c) All persons shall stand clear of
equipment, hoses or electric cords
while stressing is taking place.
d) Always use remote switch and not the
toggle switch located on the pump
unit. As if a tendon fail or a blowout
occur, the jack grippers fail; the jack,
pump, hoses and electrical cords shall
all be thrown off the structure.
leading to anyone standing close the
hoses or cords shall be dragged off
the structure with the equipment.
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 Standard Operating Procedure - 2012

e) Safety stewards shall be engaged for shall be used, and goggles shall be
monitoring to avoid unsafe conditions worn during the process.
& unsafe acts. p) Only intact and tight pressure hoses
f) All the persons involved shall be given shall be used.
Pep talk before start of the Pre- q) No stranger shall be allowed in the
stressing activity. immediate vicinity of the stressing
g) All the staff and work men shall be equipment during stressing to avoid
provided with necessary personal injury in event the tendon or concrete
protective equipment (Safety fails.
helmets, safety hand gloves, safety r) The pump and jack shall be securely
shoes, safety belts, safety goggles, tied to a solid object when working at
retro-reflective jackets Etc.) always at an elevated level.
site.
h) Drinking water facility shall be 11.8.0 QUALITY CONTROL TEST &
provided at site. THEIR FREQUENCY
i) First aid box with necessary medicines Please refer Annexure 2
shall be available at site office.
j) General Lighting shall be provided in 11.8.0 SAFETY
work place. Please refer Point No. 9.8.0
k) Only certified plant & machineries
shall be put in operation. 11.9.0 RECORDS TO BE MAINTAINED
l) The operators shall have relevant a) RFI
experience and valid license to b) Pre concrete checklist
operate machineries. c) Pour card
m) A warning sign, “Stressing Operations d) Stressing
in Progress” shall be put up at i. Preparation sheet for stressing
locations where stressing operations ii. Stressing record sheet.
would be carried out. e) Grouting
n) Strand bundle protruding from the i. Record sheet for grouting
bearing plate must be encased in a ii. Record sheet for strand cutting &
plastic or sheet metal pipe to prevent threading
injury by the sharp ends of the
strands.
o) During the process of strand cutting,
only abrasive disc cutters with guard

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SUMMARY
 Formwork; Bottom & side shutters
to be cleaned thoroughly before
fixing.
 One coat of shuttering oil to be
applied to steel mould, joints to be
fixed with foam sheet to avoid
leakages.
 All Reinforcement bar for precast I-
Girder shall be cut & bent to
required shape and size as per
approved drawing & specification
 The cable consisting of number of
strands specified in drawing will be
tied together with binding wire at
suitable regular intervals and
threaded into Bright Metal/HDPE
Sheathing. Sheathing ducts shall be
connected to the tube units for
grouting
 Profiling shall be carried out
according to the ordinates given in
the reference drawings.
 Concrete shall be poured in the I
Girders moulds in the proper
sequence
 Stressing shall be started after
concrete attains field cube strength
of 80% of desired grade of concrete
strength
 The 1st stage stressing shall be
done after 3 days or on achieving
30N/mm2 whichever is later.
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Standard Operating Procedure - 2012
 The 2nd stage Stressing shall be
done after 21 days or on
achieving 45Mpa whichever is
later.
 After checking the 24 hours slip
the strands protruding from the
anchor heads shall be cut and
grouting shall be carried out
 The sheathing ducts shall be
grouted min. after 24 hours of all
the strands in the beam are
stressed and wedged properly
with wedges.
 The side formwork shall be
placed and secured properly.
Before placing the end shutter,
Nitobond EP shall be applied on
the old concrete to achieve
proper bonding between old &
new concrete.
 Post tension members shall be
lifted after attaining required
strength of 80% of desired grade
of concrete yard by Hydraulic
cranes under proper supervision
and stacked
 Grouting of tendon can be done
between 10 days after tensioning
but not before 24 Hrs after
tensioning
 Grout caps shall be fixed on both
sides of anchor heads and tightly
secured.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/01/R&R/R0

Project Client

Consultant Contractor

Work Length (m) RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR PROFILE SHEATING

Distance from Bulk
0 mm 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm
head

X
1x1x
Y
X
2x2x
Y
3x3x X

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PST/02/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECK LIST FOR PRESTRESSING WORK
Checked & Found OK
Sl No. DESCRIPTION Remarks/Issues
Yes No Na
1 Check for top & side shutters removed
2
Concrete cubes strength of minimum 40N/mm
2
available before starting the pre-stressing
Check for pre-stressing jack pressure calculations &
3
force to be applied including losses etc
Check that all strands are cleaned and approved pre-
4
stressing components
5 Calibrated jacks and gauges used for stressing.
Pre-stressing operations in sequence of sheathing &
6
stressing sequence as per drawings.
Check of all pre- stressing strands for any slip after 12
7
hours of stressing operations
Remarks
L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 3

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PST/03/R&R/R0
Project Client
Consultant Girder Type
Work Girder Identification No. Cement Brand OPC/53 Grade
Grout Mixing admixture Ref. Drawing No./Rev. No
Grout Start Time Finish Time Cement Batch No.
Theoritical Cement Consumption Actual Consumption
CHECK LIST FOR GROUTING WORK
Checked & Found OK
Sl No. DESCRIPTION Remarks/Issues
Yes No Na
Check for grouting operation started min.24 hours of
1
stressing completed
All the HDPE sheathing duct are cleaned with air, water
2
as per the requirements through vents
Check for cement grout prepared to a w/c of 0.4 with
3
approved OPC- 53 grade cement and admixture.
HDPE ducts cleaned with grout till the require
4 consistency coming out from all the vents and then
locked
Check for all HDPE ducts are filled with cement grout
5
and build up a pressure of 5 Kg/cm2 for 1 min
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 4

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PST/04/R&R/R0
Project Client
Consultant Girder Type
Work Span No. Date of inspection
Grout Mixing admixture Ref. Drawing No./Rev. No
Cement Type W/C Ratio
Grout Start Time; Grout Finish Time;
Date of Stressing
Date Dia. Of Duct
CHECK LIST FOR GROUTING WORK LIST
Temp. of Cement
Cable Starting Finishing
Cable No. Grouting Consumed Pressure Kg/cm2/Mpa
Length Time Time
(˚C) (Bags/Kgs)

Remarks
L&T QA/QC Client/IE

CHECKLIST 5

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PST/05/R&R/R0
Project Client
Consultant Girder Type
Work Date of inspection
Grout Mixing admixture Ref. Drawing No./Rev. No
Cement Type W/C Ratio
Span No. Date of Stressing
Grout Start Time; Grout Finish Time; Dia. Of Duct
CHECK LIST FOR GROUTING 1
Temp. of Cement
Cable Starting Finishing
Cable No. Grouting Consumed Pressure (Kg/cm2/Mpa)
Length Time Time
(˚C) (Bags/Kgs)

Remarks
L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 6

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PST/06/R&R/R0
Project Client
Consultant Contractor
Location Date of inspection
Grout Mixing admixture Date of Grouting
Cement & Grade Type W/C Ratio

Span No. Name Of admixture

Start Time; Finish Time; Temp. of water during mixing

CHECK LIST FOR GROUTING 2
Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na
1 Grout is tested and results obtained
2 After closing outlet & air vents, grouting pressure
3 Maintained at 0.5 Mpa for at least 1 minute
4 Grouting Observation
5 Passage of grouting through vents
Remarks
L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 7

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/07/R&R/R0
Project Spec
Size Density
Date ; Start: Finish:
PRESTRESSING FORMAT
Span No. Date:
Location start time:
Span length: Date of concreting:
NO. of cables(total): Min. cube strength :
Stressing cable No.: Cube strength of stressing:
HT strands details Prestressing jack information
Coil No.: MTC No.: Make & No.
Actual Modules of elasticity of strand: Jack type
Actual cross section ared of strand: Stressing ram area in Sq. cm
Length of strand (anchor to anchor end): Lock off ram area in Sq.cm
Thickness (mm): Designed stressing force (KN) :

Modified elongation = Design elongation* ( Thena. Area 8Theo MOE) / (Act. Area * act. MOE)
Tolerance in Max. +5%
* * elongation Min. -5%
Modified Pressure = (Stressing force in KN 1000/9.81) / (Ram Area jack efficiency)
Tolerance in
Max. +5%
pressure
STRESSING CHART
CABLE NO. CABLE NO.
Jack No. : Gauge No. : Jack No : Gauge No :
Pump No. : Cable Type : Pump No : Cable type :
SI NO Pressure Piston Pressure Piston
Cumulative
(Kg/Sq. Elongation (mm) Reading Cumulative elongation (mm)
Reading (mm) elongation (mm) (Kg/Sq. cm)
cm) (mm
1
2
3
4
5
A. zero correction (mm) : A. zero correction (mm) :
B. Gross elongation (mm) : B. Gross elongation (mm) :
C. Less wedge drew in stressing end (mm): C. Less wedge drew in stressing end (mm):
D. Less elongation in jack (grip length) (mm): D. Less elongation in jack (grip length) (mm):
E. Less wedge draw in passive end (mm) : E. Less wedge draw in passive end (mm) :
F. Net elongation F=B – (C+D+E): F. Net elongation F=B – (C+D+E):
G. After 24 Hrs. slip G. After 24 Hrs. slip
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 8

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/08/R&R/R0
Project Spec
Size Density
Date ; Start: Finish:
STAGE STRESSING REPORT
Date of Casting Const.Strength Achived
Date & Time Length of cable Rmtr
Design Force Design elongation mm
Pressure Gauge No. Actual Area mm2
HST Coil No Design Area mm2
Girder No Modified Pressure Kg/Cm2
Cable No Max(5%) Pressure Kg/Cm3
Jack Type Min(5%) Pressure Kg/Cm4
Jack Ram Area Modified Elongation mm
Jack No Max(5%) Elongation; Min(5%) Elongation; mm
NORTH SIDE SOUTH SIDE
Pressure Initial Final Pressure Initial Cummulative
Difference Cummulative Final Reading Difference(
Gauge Reading Reading Remarks Gauge Reading( Elongation Remarks
(mm) Elongation(mm) (mm) mm)
No.(KG/Cm2) (mm) (mm) No.(KG/Cm2) mm) (mm)
('1) ('2) ('3) ('3)-('2) ('1) ('2) ('3) ('3)-('2)

0-50 0-50
50-100 50-100
100-150 100-150
150-200 150-200
200-250 200-250
250-300 250-300
300-350 300-350
350-400 350-400
400-450 400-450
450- 450-
A) Across Elongation = A) Across Elongation =
B) Slip at Stressgin End = B) Slip at Stressgin End =
C) Grip Length Elongation C) Grip Length Elongation
D) Net Elongation (A-B-C) = D) Net Elongation (A-B-C) =
Slip After 24 Hrs =

Remarks

L&T QA/QC Client/IE

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12 VOID FORMER AND SLAB
CONCRETE
12.1.0 SCOPE
The scope covers the responsibilities,
procedures and methodology to be flowed
for fixing of Void-Former.
12.2.0 RESPONSIBILITES
12.2.1 PROJECT MANAGER
The Project Manager shall be wholly
responsible for all the operational process
and liaison with customer.
12.2.2 SITE INCHARGE
The Site Incharge shall be responsible to
ensure;
a) The proper sequence of works along
with appropriate preceding &
succeeding activities.
b) Confirm the resources availability at site.
12.2.3SITE ENGINEER
The site Engineer shall be responsible to
carry out the entire scope of work through
finalized sub-contractors/agencies.
12.2.4 AQ/QC INCHARGE
a) The QA/QC Engineer shall be
responsible to conduct the relevant
field & laboratory tests, and
maintaining all such details in relevant
records as per the ISO requirements.
b) He shall ensure that all tests in house
and third party are conducted as per
Quality test plan.
77 | P a g e
Standard Operating Procedure - 2012
c) The HSE officer is responsible to
examine the risk / hazard for this
particular activity and to prepare a
plan to eliminate the risk/hazard and
to protect the safe environment &
ensure workmen safety.
12.3.0 REFERENCE
a) IRC: SP: 64-2005 Guidelines for the
Analysis and Design of Cast-in-Place
Voided Slab Superstructure.
12.4.0 EQUIPMENT/TOOLS
a) Trailer & Crane
b) Welding machine
c) Batching plant
d) Transit mixers
e) Steel slings of at least 2T capacity
f) Formwork
g) Needle vibrators(3nos along with
60/*10mm needles)
h) Masking tapes
i) Shovels
j) Measuring tape
12.5 PROCEDURE
13.5.1 TRANSPORTATIO N
a) The GI void-former is transported from
stockyard to site using the trailer.
Ensuring that while loading and
transporting the void-former does not
bend.
b) Ensuring that maximum 2 rows of
voids-former stacked at once, and does
not swing excessively or struck with any
other object that may damage or bend
the void-former.
c) Check and clean using a wire brush
and/or water, any foreign matter or
debris, soil adhered to the void-former.
12.5.2 FIXING OF VOID FORMER
a) The location shall be marked on the
void-former as per drawings using paint
For Internal Circulation Only

or by pegs on the soffit shutter of the
slab.
b) Void-formers shall be placed once the
bottom reinforcement for voided
beams and shear reinforcement are in
placed.
c) Bottom main reinforcement shall be
tied along with shear reinforcement
and shift the markings on the former.
d) The bottom and side support of the
void-former shall be tack-welded using
at least 12mmø tor steel at spacing not
more than 2m.
Ensure that the inner diameter of the
void-former is exactly as per the
drawing from the soffit and no
movement occurs.
e) Collars shall be used to join two void-
formers together made with the same
material as of void-former.
f) The perimeter of collar and void-former
joint shall be sealed using adhesive
tape with end stoppers provided to
close the either ends so that no slurry
from concrete leaks in to the void-
former.
g) The top reinforcement of voided beam
is tied.
h) The top supports of the void-former are
also tack welded both transversely and
diagonally to restrain the uplift using at
least 12mm tor steel at a spacing not
more than 2m.
12.5.2 POURING CONCRETE FOR
BEAM/SLAB
a) The joints are checked of ply, floor
forms, verticals, Etc. for any gaps and
rectified for bigger gaps & covered by
adhesive tape to avoid impressions.
b) The entire surface area of slab
shuttering where the concrete falls,
shall be free from binding wires, pieces
of wood, waste cotton, Etc. Cleaning
78 | P a g e
Standard Operating Procedure - 2012
could be done with air and/or water
before concrete.
c) The working condition of needle
vibrators and other stand by equipment
are checked.
d) The concrete surface of the pier shall
be wetted with water. Excess standing
water if any, after cleaning shall be
removed.
Fig.12 Void former in girder
e) Fill the concrete in three layers in
alternative as one layer in one side
beams, the next layer in other side
beams, and the next in another side
beams and so on and compact each
layer using needle vibrators.
f) After completion of beams, the
concrete for slab shall be started.
PROCESS;
1) Start from one end of 250mm thick
single layer to reach the other end
of 250mm thick slab transversely.
2) Start from the construction joint of
one end to reach the other end
longitudinally and compacting using
needle vibrators.
3) Void formers are prone to trapping
air on their underside if concrete is
placed from both sides and then
compacted. Hence, concrete shall
be placed from one side and
maintaining at a head, until it
appears at the other side. Vibration
to be continuous(the void former
will need to be fixed so as to resist
For Internal Circulation Only

the pressure of the plastic
concrete).
4) When the top of the concrete is
fully visible from above, then
placing can continue normally in
layers as per the WMS.
12.6.0 QUALITY CONTROL TESTS AND
THEIR FREQUENCIES
a) Workability of concrete by slump cone
test, at a frequency of once per session
at concrete placing area.
b) Gradation test for coarse/fine
aggregates at a frequency of 1 test per
day.
c) Tests on water at a frequency of once
per source after monsoon.
d) Physical and chemical requirements of
admixtures MTC shall be maintained.
e) Tests on reinforcement at a frequency of
once per batch/ lot per diameter Test
certificate to be maintained.
f) Workability of concrete by slump cone
test at a frequency of once per session
at concrete placing area.
g) Compressive strength of concrete,
frequency as follows.
h) After completion apply rough texture to
the surface of slab using wire brush.
NOTE;
1) Conduct slump test to concrete and
unload the concrete if it is between
150mm-190mm.
2) The slurry used for priming shall be
wasted.
3) The out let trunk of the pump shall be
placed at a height not more than
300mm above top reinforcement.
4) Plastic tarpaulins shall be kept ready to
protect concrete is case of rain.
12.7.0 SAFTEY REQUIREMENTS
a) All working platforms shall be tied at
the both ends firmly.
79 | P a g e
Standard Operating Procedure - 2012
b) The working condition of the
reinforcement cutting and bar bending
machines limit switches shall be
ensured before starting the day’s work.
c) The electrical connections for vibrators
/lighting shall be given by qualified
/experienced P&M personnel through
ELCB only.
d) Ensure that all moving parts of vibrator
/ compressor, if any shall be provided
with guards.
e) If concrete is being done by crane, then
its reach shall be reviewed.
f) Suitable hand gloves shall be used for
cutting, bending and shifting of
reinforcement and concreting.
g) All transport vehicles shall have
wooden wedges and safety cones.
h) Transit mixer helper shall have a whistle
at work area.
SUMMARY
 Mark the location of void-former
as shown in the drawings using
paint or by pegs.
 Tack-weld the bottom support
of the void-former.
 After ensuring the void-former
centrally at its position, tack-
weld the side supports.
 Seal the perimeter of collar and
void-former joint using masking
tape and provide end stoppers
to close the either ends.
 Tacks weld the top supports of
the void-former both
transversely and diagonally to
restrain the uplift using at least
12mm tor steel at a spacing not
more than 2m.
 Fill the voided beam with
concrete in three layers and
compact each layer using needle
vibrators.
For Internal Circulation Only
 Standard Operating Procedure - 2012

13 FORMWORK 13.4.1 FORMWORK FOR SLAB USING

FLEX SYSTEM

Flex system formwork;

1) Mainly executed using CT props.
2) Average load bearing capacity of a
prop is 3MT/ no.
3) Widely available types of props are
CT 250, CT 300, CT 340 & CT 410
4) Number of props to be used shall
be calculated according to deck slab
live + dead load with factor of
safety and also the formwork
drawing shall be referred.
STEPS;
a) Before commencement of deck slab
13.1.0 SCOPE
formwork, the ground level shall be
The scope covers the procedure and
compacted well such that it does not
responsibilities for Formwork.
settle if water flows (by rains).If bed
13.2.0 RESPONSIBILITY PCC needs to be done it’s better that
PCC shall be done before deck slab, else
good compaction can’t be ensured.
13.2.1 FORMWORK ENGINEER
b) Tripods shall be fixed with CT props for
a) Methodologies and type of formwork
stability else bracing to be provided
to be adopted shall be formulated in
(horizontally and diagonally).
coordination of site team.
c) Over CT prop, 4 way head shall be fixed.
b) Arranging materials, optimum
d) Walers shall be used as primary
utilization of materials and maintaining
member and H beams as secondary
the cost as per ACE.
member over the 4 way head.(Standard
walers are available in size of 800mm,
13.2.2 SITE ENGINEER
1200mm, 1600mm, 2000mm and
a) Site engineer is responsible for
2400mm.)
execution of work at site, material
e) Over H-Beam plywood/floor form shall
preservation, achieving the repetition
be used as soffit. Care shall be taken
as per plan.
while nailing plywood in H-beams, not
13.3.0 REFERENCES more than 1/4 inches nails to be used.
f) Soffit shall be checked for its level,
a) Doka formwork manual including
Gaps/joints closed with masking tape to
details of materials and design.
avoid cement slurry leakage.
b) Approved formwork drawings.
g) H beam spacing differs according to the
slab thickness and load of the same.
13.4.0 TYPES OF FORM WORK
NOTE;
This system can be adopted for culvert
works up to clear vent of 30m.

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13.4.2 FORMWORK FOR SLAB USING
HEAVY DUTY STAGGING SYSTEM
Heavy duty formworks are;
a) There are 2 types of towers;
1) 1524 x 1524
2) 2250 x 1524
that shall be adopted according to the
requirement.
b) Height of tower frames available is
900mm, 1200mm and 1800mm.
c) Average safe bearing capacity of a
tower is 25 MT.
d) This system shall be used for deck slabs
having height more than 3m from
ground level.
STEPS;
a) Before commencement of deck slab
formwork, the ground level shall be
compacted well that it does not settle
(else PCC shall be done).
b) Before commencing of work over the
PCC/ground, the location of staging
towers shall be marked as per drawing
c) Foot plate and tower spindle of the
formwork system shall be the bottom
most part of the staging.
d) HD Towers are inserted over spindles,
and erected to true plumb and level by
adjusting the bottom tower spindles.
(800 mm is the minimum possible
height adjustment for top & bottom
spindle).
e) After alignment of first step, second
step is erected over the first step.
f) HD couplers and spring lock pin are
used to join first and second tower.
Likewise multiple towers can be
erected one over other according to
requirement.
g) Once the tower height increases more
than 5.50m, the towers shall be inter
connected with ledger pipes and
clamps for stability.
81 | P a g e
Standard Operating Procedure - 2012
h) The top tower spindle shall be fixed
along with U head (this tower spindle
helps is adjusting level of soffit).
i) Over U head, walers shall be fixed
above which plywood/Floor forms shall
be used as soffit material.
j) After checking of soffit for its level, all
gaps/joints shall be covered with
adhesive tape to avoid cement slurry
leakage.
k) Shuttering oil to be applied before
commencement of reinforcement.
13.4.3 STAIR TOWER SYSTEM
a) 2250 x 1520 x 1200 height tower will be
used for stair system.
b) Additionally stair bracket shall be fixed
for greater heights
c) Grid iron (steps) shall be fixed in stair
bracket.
d) Inner and outer hand railing shall also
be fixed.
e) Stair tower has to connect with ledger
pipe with any nearby structure for
stability at each 5.50m interval.
13.4.4 WALL FORMWORK
DOKA/wall formwork;
a) H beam steel walers, tie rods and
plywood are the main components doe
wall formwork.
b) Normal size of H beams available (H16)
are 1.8, 2.0, 3.0, 2.40m and 3.60m.
c) If require height, H beam shall be
joined by beam connection splice
plate.
d) Spacing of H beams differs with
respect to the wall thickness and
pressure of concrete (generally its
300mm).
e) Normally 12mm film coated plywood
shall be used.
f) If Cranes are available, bigger size
panels can be pre-fabricated for faster
work. Lifting bracket shall be fixed in H
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 Standard Operating Procedure - 2012

beams for handling the shutters with b) Supporting brackets shall be used for
crane. supporting shutters as it is shorter in
STEPS; length and convenient too.
a) Top and bottom of H beams shall be c) Floor forms shall be joined with floor
fixed with 25mm plank for stability of H form clips.
beams & lifted with crane. d) Before fixing floor forms it shall be
b) Doka tie rods with wing nuts and cleaned and oiled properly.
anchor plates shall be used for e) Lapping plate shall be used to adjust
tightening the shutter according to the length of shutters.
requirement.
c) Required spacers are fixed in wall to
13.4.6 IMPORTANT POINTS TO
maintain the required width. Walers
REMEMBER
shall be then fixed perpendicular to H-
a) Stacking of materials shall be done
beams.
properly at site.
d) Walers are joined continuously with
b) While deshuttering, the material shall
splice plates and connecting pin.
be lowered with rope and not be
e) Walers and spacing of tie rods shall be
thrown.
fixed as per approved drawing or Doka
c) Formwork flow chart shall be prepared
manual.
for optimum utilization of materials.
f) Before fixing of shutter, it shall be
d) Training tobe given to subcontractor
cleaned and oiled properly.
workmen
g) When multiple wall lifts has to be done,
e) Before deshuttering any staging, area
stop anchors and anchor cone are fixed
shall be barricaded and tag to be fixed
in the below lift (when climbing
for safety.
brackets are used)
f) Deshuttering on the right time to
h) After removal of shutter, the anchor
maximize the number of repetition of
cone shall be removed and replaced
formwork.
with climbing cone. With the help of
g) Wall formwork boards shall be stacked
climbing cone, climbing brackets shall
properly so that it can be used for many
be fixed.
repetitions.
i) Climbing brackets shall be used for 2nd
h) Any drilling work shall be done with
lift & also acts as platform for resting
proper tools.
shutters and workmen movement.
i) Foam to be used at all joints.
j) If the same tie rod holes are used and
shutters are maintained properly the
same shutters can be used for many
number of repetitions.
k) Top scaffold bracket shall be fixed with
H beam for walk way platform

13.4.5 FOUNDATIONS
a) Floor forms with pipe walers shall be
used as foundation shutters.

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14 BACK FILLING
13.1.1 SCOPE
The scope covers the responsibilities and
procedure for ;
Back filling of trenches after the abutment,
wing wall, return wall, Box culvert & pipe
culvert is completed.
13.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0
13.3.0 REFERENCES
a) MORT&H specifications clause No: 2900,
2504.2.2,
b) IRC 78
c) Technical specification of contract.
13.4.0 EQUIPMENT/TOOLS
Excavator, Mini Roller, Dumper
13.5.0 PROCEDURE
13.5.1 BACK FILLING OF PIPE
CULVERTS:
a) Backfilling shall be done after pipe
installation is completed and backfill
material approved
b) The back fill material shall be placed in
layers and thoroughly consolidated
/compacted. Pneumatic or light
mechanical tamping equipment shall be
used.
83 | P a g e
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c) Filling of trench shall be carried out
simultaneously on both sides of the
pipe in such a manner such that the
unequal pressure does not occur.
d) Particular care shall be taken to
thoroughly consolidate the materials
under the haunches of the pipe.
e) The minimum thickness of the material
for cushion above the top of pipe shall
be 300mm for filling.
f) Above the cushion layer, approved
borrow area material shall be placed
and compacted with 10-15 ton roller
(density of 95% for embankment & 97%
for sub grade.) The thickness of layer
shall be 200mm.
g) The backfill material shall be Crushed
Sand/River sand free from boulders,
large roots, and other organic matters.
13.5.2 BACK FILLING OF BOX
CULVERTS WITHOUT PROVISION FOR
WEEP HOLE
a) The Backfill material shall be approved
GSB material as per clause 401.4.2 of
MORT&h Specifications.
b) The GSB material shall be laid to the
width not less than 2 meter behind the
box culvert wall.
c) The GSB material shall be filled in layers
& the thickness of the layer shall be 200
mm.
d) Additional excavated area for work
space up to raft level shall be filled with
granular material and thoroughly
consolidated.
e) Rolling shall be carried out to achieve
the required density.
13.5.2 BACK FILLING OF BOX MINOR
BRIDGES, MNB, MJB, ROB & RETURN
WALLS
a) Filter media shall be provided behind
the abutment, wing wall, return wall
and where weep holes
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 Standard Operating Procedure - 2012

b) The material for the filter shall be

gravel or crushed stone to prevent
escape of embankment material
through the voids of weep holes (in
abutments) as well as to allow free
movement of water without creating
any uplift head.
c) The width of the filter media shall
consist of two layers of each 300mm or
as per approved mix design.
d) The gradation of the filter material shall
satisfy the requirements of clause
2504.2.2 of MORT&H. The filter shall be
compacted to a firm condition.
e) The filter media shall be provided
300mm below the bottom weep hole of
the abutment and up to the top of Sub
grade.
f) Provide porous block / geo textile
material near weep hole with filter
media.
g) Back fill material shall be approved
embankment & sub grade material as
per Appendex-6 of IRC 78.
h) Backfilling shall be done in layers and
thoroughly compacted to the required
density (upto embankment 95 % of
MDD & 97% for sub-grade level )
i) The material shall be clean, free from
boulders, large roots, excessive
amounts of sods or other vegetable
matter and lumps.

13.6.0 SAFETY PRECAUTIONS

Please refer Point No. 4.7.0

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CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC BFL/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR BACK FILLING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Drawings, method statements are approved by client
The back filling soil and filter media are approved by
2
client
3 Filter media laid as per suitable method.

4 Porus block provided nearby weep hole.

Filter media commenced from below 300mm of first
5
weep holes layer
6 The back filling layers checked and it is ok.
The guardrail fixed and erected as per plan and method
7
statement.
8 The back filling area protected

9 Staff and workmen weared PPE

Safety precautions taken during construction and in
10
working area
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

15 STONE PITCHING b) Filter media

15.1.0 SCOPE
The scope covers the responsibilities and
procedures for furnishing and laying of
1) Filter material shall consist of sand,
gravel, stone, coarse sand or
approved material.
2) One layer of filter material shall be
provided underneath the pitching
to allow free movement of water
without creating any uplift head on
pitching.
3) The gradation of the filter media
shall satisfy the requirements of
clause No; 2504.2.2 of MORT&h.
c) Stone pitching:
1) Size of stone shall be 300mm X 300

stone pitching on embankment slopes. mm and stone weight shall be

40kg(min).
15.2.0 RESPONSIBILITY 2) The banks and side slopes of

Please refer Point No: 1.2.0 embankment shall be trimmed to

the required depth as per drawing
15.3.0 REFERENCE & depressions filled and thoroughly
compacted.
a) Section 2504 of MORT&h Specification,
3) To maintain uniform slope and
b) IRC 89
profile line and pegs shall be put up
c) Approved GFC Drawing
at interval of 3 meter.
15.4.0 EQUIPMENT/TOOLS 4) Approved filter granular material
shall be laid over prepared base and
Chisels, hammer, surfacing tools
suitably compacted to the thickness
15.5.0 PROCEDURE as per drawings.
5) The lowest course of pitching shall
be started from the toe wall and
15.5.1 MATERIAL
built up in courses upwards.
a) Pitching Stone:
6) The toe wall shall be constructed as
1) The stone shall be sound, hard,
per drawing and clause no: 1405.3
durable and fairly regular in shape.
of MORT&h.
2) Stones subject to marked
7) Stone pitching shall be commencing
deterioration by water or weather
in a trench below the toe of the
shall not be accepted.
slope.
3) The weight of stone shall be
8) Stone shall be place by hand to the
minimum 40Kg. & thickness shall be
required length and depth
300mm.
confirming to the drawing.
4) The size of spalls shall be minimum
9) Stones shall be set normal to the
25mm and suitable to fill the voids
slope, and placed so that the largest
in the pitching.
dimension shall be perpendicular to
5) Quarry stone shall be
the face of the slope.
used/preferred.t

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 Standard Operating Procedure - 2012

10) The pattern of laying shall be such

that the joints are broken and voids
are minimum by packing the spalls
wherever is necessary and top
surface is as smooth as possible.

15.5.2 PROCEDURE FOR DRY RUBBLE

SFLOORING
a) The base of the flooring shall be
prepared to the specified levels and
slopes and compacted suitably with
hand rammers or other means to have
even bedding.
b) The thickness of flooring shall be made
with one stone only.
c) The stones shall then be laid closely on
prepared base in one layer.

15.5.3 PROCEDURE FOR FLEXIBLE

APRON
a) The flexible apron comprising loose
stone boulders shall be provided
beyond curtain walls.
b) The weight of stone shall not be less
than 40 kg.
c) The dimensions of apron shall be
provided per drawing.

15.6.0 SAFETY PRECAUTIONS

Please refer Point No. 4.7.0

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC SP/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR STONE PITCHING
Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na
1 Drawings, method statements are approved by client

2 Pitching Stones are approved by client

The thickness, weight and shape of stone as per
3
drawing
The size of spalls thickness is minimum 25mm to fill the
4
voids
5 Filter material are approved by client

6 The sides of banks are trimmed to required slope

7 Uniform slope (1:2) maintained at entire pitching area

8 Depressions are filled and thoroughly compacted

The filter material laid over the prepared base and it is
9
compacted
10 The filter material thickness verified and it is ok

11 The toe wall provided

12 The lowest course of pitching started from toe wall

The stone pitching is commenced in a trench below the
13
toe of slope
All process of stone pitching done as per approved
14
method statement
15 Staff and workmen weared PPE
Safety precautions taken during construction and in
16
working area
Remarks

L&T QA/QC Client/IE

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CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC SP/02/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR RIGID APRON & CONICAL PITCHING
Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na

1 Excavation made by - JCB/Excavator

2 IS the balance excavation of 100mm trimmed manually

Is the bed compacted & free from any isolated loose
3
area
4 The level of PCC botton checked

5 Did the level found acceptable as per drawing

6 Is the bed requiring any water sprinkling before PCC

7 The concreat is brought from (………plant name………….)

The required level mark has been given for PCC
8
concreat
Is the stones/concreat blocks available for pitching of
9
required
10 Packign made with spalls
The slope of earth moulding is trimmed to required
11
level & Slop
The stone/concreat blocks for conical pitching are
12
required
13 Is the pitching well packed

14 Staff and workmen weared PPE

Safety precautions taken during construction and in
15
working area
16 Staff and workmen weared PPE
Safety precautions taken during construction and in
17
working area
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

16 TURFING f) Trimmed surface shall be loosened to a

minimum depth of 25 mm and stones
having size more than 50mm, stumps or
any undesirable foreign materials shall
be removed.
g) Grid of size 75mm*75mm shall be
marked on the embankment slope.
h) Grass bunches shall be fixed in the grid
in a staggered manner.
i) After fixing the grass bunches, the
16.1.0 SCOPE prepared grid shall be watered
The scope covers the responsibilities and regularly for 4 weeks.
procedure for furnishing and laying of live j) The turfing will be inspected for the
perennial turf forming grass on compliance after 4 weeks.
embankment slopes and earthen shoulders.
16.6.0 SAFETY PRECAUTIONS
16.2.0 RESPONSIBILITY
a) The turfing area shall be protected from
Please refer Point No: 1.2.0 live traffic.
b) Please refer Point No. 4.7.0
16.3.0 REFERENCE
Section 307 of MORT&h specification

16.4.0 EQUIPMENT/TOOLS
JCB, Spade

16.5.0 PROCEDURE
a) The turf grass shall consist of well
rooted growth of permanent and
desirable grass indigenous to the
locality where it is to be used.
b) Grass shall be free from weeds or other
undesirable matter and have a length
of approximately 50mm(min).
c) Template of 1:2 with spirit level at top
shall be prepared and fixed.
d) Embankment slopes shall be prepared
by trimming as per the approved
drawing with the help of JCB and spade.
(Ensure/Check that the side slopes with
template are checked.)
e) Dressed/cut soil shall be kept minimum
500mm away from the bottom starting
point of slope.

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC TS/01/R&R/R0
Project Client
Consultant Contractor
Work Area(Sqm) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR TURFING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Drawings & method statement are approved by client

2 The SOD source are approved by client

3 The SOD length is 50mm and is freed of debris

4 The sides of bank are trimmed to the required slope

The embankment soil is loosened nd free from stones,
5
sticks and stumps
6 The SOD bed is moistended to loosened depth

7 The SOD strip is laid edge to edge

After laid od SOD's its is lightly tamped with suitable
8
method
trufing area thoroughly moistended by sprinkling with
9
water after SOD
All process of turfing done as per approved method
10
statement
11 Staff and workmen wear PPE

12 Safety precautions are taken in working area

Remarks

L&T QA/QC Client/IE

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17 HECTOMETER AND KM STONES
17.1.0 SCOPE
The scope covers the responsibility and
procedure for supply, painting, and
lettering and fixing of
Hectometer(Hm)/Kilometer (Km) Stones.
17.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0
17.3.0 REFERENCE
a) Section 804 of MORT&h Specification
b) IRC 8, IRC 26
17.4.0 PROCEDURE
a) Km stone shall be located on left/both
sides of the road (seperate for each
direction of travel) & Hm stones shall
be located on the same side of the road
as kilometer stones.
b) Km/Hm stones shall be fixed at right
angles to the centre line of carriageway
or as per approved drawings.
c) The Hm/Km stones shall/may be made
of local stones, concrete or any other
material available locally or as per
approved drawings.
d) Km stones shall correspond to the
designs as in plate 1, 2 and 3 of IRC 8 or
as per approved drawings.
e) The shapes and dimensions of standard
letters /numerals shall be as per plate 4
and 5 of IRC-8 or as per approved
drawings.
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f) The Km stones script and sequence of
inscription shall be as per paragraph 4
of IRC-8 and paragraph 4 of IRC-26 for
Hm stones.
g) The edge clearance of Km stones shall
be;
1) Top – 50mm
2) Bottom – 75mm
3) Sides- 50mm
4) Spacing between lines – 50mm
h) The numerals shall be 80mm high and
shall conform to the type shown in
plate of IRC -26 or as per drawings for
HM stones.
i) The colour of background shall be white
with black letters and numerals, for
names of stations and distances.
j) The semicircular portion of kilometer
stones shall be painted canary yellow
for NH 8 Green for SH.
k) Route numbers written on the
semicircular portion shall be in black
colour on canary yellow or in white
colour on brilliant green back ground.
l) The Km/Hm stones shall be fixed in
position with rammed spalls in
moorum, lime, surkhi concrete of lean
cement concrete all round or as per
approved drawings.
m) They shall be planted securely just
beyond the edge of the formation with
their side bearing the inscription facing
and parallel to the center line of the
road for Hm/Km stones.
n) The inscription carried by the stones
shall be the numerals marked in an
ascending order in the direction of
increasing range away from the starting
point.
o) Hm stones must be painted or
engraved.
p) The colour of numerals shall be black
on a white back ground for Hm stones.
For Internal Circulation Only
 Standard Operating Procedure - 2012

17.5 SAFETY PRECAUTIONS

a) The HM / KM Stones Installation area
shall be protected from live traffic.
b) Warning signboards shall be put up at
HM/KM Stones during installation.
c) Any labour, if being used in the job shall
be screened and trained.
d) All workmen at work area shall wear
PPE’s and reflective jackets.
e) Ensure the soft shoulder width as per
approved drawing

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18 METAL BEAM CRASH BARRIER
(MBCB)
18.1.0 SCOPE
The scope covers the responsibilities and
procedures for furnishing and erection of
metal beam crash barrier.
18.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0
18.3.0 REFERENCE
a) Section 810 of MORT&h
b) IS 1367, 1364
18.4.0 PROCEDURE
a) Crash barrier post/anchor post shall be
erected in proper position and free
from distortion, burying or any other
damage.
b) For installation of the posts, pits shall
be dug to the depth as per approved
drawings and equipment.
c) All post pits dug shall be such size as
will permit proper setting of the posts
and allow sufficient room for
concreting.
d) Holes drilled in rock for anchor posts
shall be backfilled with concrete.
e) All posts shall be vertical with a
tolerance not exceeding 6 mm in a 3
meter length.
f) The anchor post shall be set to proper
location and elevation with templates
and carefully checked.
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g) Holes for field connection shall be
drilled with the railing in place in the
structure at proper grade and
alignment as per approved drawings
NOTE;
Posts for metal beam guardrails on
bridges shall be bolted to the structure
as per drawings
h) All guardrail anchors shall be set and
attachments made and placed as
indicated in approved drawings or as
directed by the IE.
i) All railings shall be erected, drawn and
adjusted so that the longitudinal
tension will be uniform throughout the
entire length of the rail.
j) The railing shall be carefully adjusted
prior to fixing in place, to for proper
matching at butting joints and correct
alignment of camber.
k) All bolts or clips used for fastening the
guardrail or fittings to the posts shall be
drawn up tightly.
l) Each bolt shall have sufficient length to
extend at least 6 mm through and
beyond the full nut. In case the bolts
extrudes the same shall be cut off flush
with the nut.
m) Splices and end connections shall be as
per designs and shall be of such
strength as to develop full design
strength of the rail elements.
n) The railing barrier shall be erected true
to line and grade.
18.5.0 SAFETY PRECAUTIONS
a) The MBCB area shall be protected from
live traffic.
b) Put warning sign boards at MBCB area.
c) Any labour, if being used in the job shall
be screened and trained.
d) All workmen at work area shall wear
PPE’s and reflective jackets.
e) Ensure the soft shoulder width as per
approved drawing.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC CB/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR ROAD MARKING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Drawin & method statement are approved by client

2 The line and grade of rail are made as per plan

3 Aligmnent and camber of rail maintained as per plan

4 Splices and end connections are made as per plan

5 Holes are dug & backfilled with suitable material

6 After backfilling the anchor are held securely in place

7 All post are bolted to the structure as per drawing

Before installation of posts all bolts and clips are
8
checked and OK
The guardrail fixed are erected as per plan and method
9
statement & protected
10 Safety precautions are taken in working area

Remarks

L&T AQ/QC Client/IE

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19 ROAD MARKING
19.1.0 SCOPE:
The scope covers the responsibilities and
procedure for road marking using
thermoplastic paint and a road marking
machine.
19.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0
19.3.0 REFERENCE
a) Section 803.4 of MORT&h specification
b) BS-3262 (part-1,2,3 ), BS 6044
c) AASHTO M249
d) ASTM D-36
19.4.0 EQUIPMENT/TOOLS:
Road Marking machine, Thermoplastic
Paint
19.5.0 PROCEDURE:
The pavement temperature shall not be
less than 10ᵒ C during application of the
Thermoplastic Road Marking Paint.
a) The Surface to receive the paint shall be
cleaned with a broomer or wire brush
to free it from dirt, grit or other foreign
matter.
b) In case the paint is to be laid over
cement concrete, a coat of primer shall
be applied on the surface (for better
bounding of paint with the surface).
c) Marking on the road surface shall be
done before laying of paint.
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Standard Operating Procedure - 2012
d) Thermoplastic Road Marking Paint shall
be heated in a mechanically agitated
preheater.
NOTE;
The normal workable temperature of
thermoplastic road marking paint shall
be maintained between 180 – 200ᵒ C or
as recommended by manufacturer.
e) The paint thereafter shall be
transferred to the paint applicator and
be applied in intermitted or continuous
lines of uniform thickness of 2.5 mm.
along the remarked lines.
f) Where arrow or letters are to be
provided, the thermoplastic compound
shall be hand-sprayed.
g) In addition to the beads included in the
material, a further quality of glass
beads of Type – 2, conforming to the
specification shall be sprayed uniformly
into a mono-layer on to the hot paint
line in quick succession of the paint
spraying operation.
The glass beads will be applied at the
rate of 250 gms. per Sqm area
h) The finished lines shall be free from
ruggedness on sides and ends and be
parallel to the general alignment of the
carriageway. The upper surface of the
lines shall be level, uniform and free
from streaks.
i) Though the drying time of paint is 8 –
10 minutes, yet considering the
temperature, the traffic shall be
allowed only after 30 minutes.
19.6.0 SAFETY PRECAUTIONS
a) Hot applied thermoplastic road marking
material should not be used in its
molten form by anybody not formally
trained in safe handling procedures.
b) Thermoplastic materials shall be stored
safely and securely in areas not subject
to excessive heat or contamination
from fuels, oils or greases.
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 Standard Operating Procedure - 2012

c) Maintain equipment in good working

order and ensure temperature gauges
are accurate and calibrated regularly.
d) Do not overheat material and do not
maintain working temperature for
longer than is necessary (maxi. 6
hours).
e) To avoid danger of hot material
splashing, great care shall be taken
when adding material to hot material
already in the preheater.
f) Well charged preheaters shall be used
not overfilled to allow for expansion of
the molten thermoplastic.
g) Long sleeved flame retardant overalls
with industrial safety shoes/boots,
gauntlet type, heat resistant gloves
shall be worn by workers.
h) Proper respiratory protection shall be
used when working in areas of poor
ventilation
i) All operatives are fully conversant with
equipment manufacturer safety
instructions for lighting, feeding and
shutting down of preheaters.

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC RM/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR ROAD MARKING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Drawin & method statement are approved by client

Thermoplastic paints and glass beads are approved by
2
client
Heater condition and its laying condition is checked and
3
is OK
4 Thermometer of heater working properly
Thermoplastic material heated to specified
5
temperature
6 All surfaces are cleaned of dust, dirt, grease and oil
Before the thermoplastic, that marking area are
7
marked by chalk
8 The laying machine is checked and is OK

9 Glass beads are applied at the rate of 250gms/sqm

10 Thermoplastic paint is laid in a molten condition

11 The thermoplastic thickness is checked

Remarks

L&T QA/QC Client/IE

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20 TRAFFIC SIGNAGES
20.1.0 SCOPE
The scope covers the responsibilities and
procedure for fixing all traffic signs for
highways other than Expressways.
20.2.0 RESPONSIBILITY
Please refer Point No: 1.2.0
20.3.0 REFERENCE
a) Section 801 of MORT&h
b) Road Signs, IRC : 67
20.4.0 PROCEDURE
20.4.1 MATERIAL
a) The type of the sheeting to be used
should depend upon the type,
functional hierarchy and importance of
the road.
b) Sheeting shall be new and unused and
shall show no evidence of cracking,
scaling, pitting, blistering, edge lifting
or curling and shall have negligible
shrinkage or expansion.
c) Where existing signs are specified for
refurbishment, the sheeting shall have
a semi-rigid aluminium backing pre-
coated with aggressive-tack type
pressure sensitive adhesive.
d) The sheeting used of signs shall be
either reflectorized or non-reflectorized
as per specifications
e) When of reflectorized type
99 | P a g e
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1) They shall be of made of enclosed
lens or of high intensity grade with
encapsulated lens fixed over
aluminum sheeting as per Clause
801.3 of MORT&h Specification
2) They shall have a smooth outer
surface & has the property of retro-
reflection over its entire surface.
f) After cleaning with soap and water and
in dry condition, the sheeting shall
have the minimum co-efficient of
retro-reflection as indicated in Table
800-1 of MORT&h.
g) When totally wet, the sheeting shall
not show less than 90 per cent of the
values of retro-reflectance indicated in
Table 800-1.
h) At the end of 7 years, the sheeting
shall retain at least 75 per cent of its
original retro-reflectance.
i) The Colour shall be durable and
uniform in acceptable hue when
viewed in day light or under normal
headlights at night.
j) Unless otherwise specified, the general
colour scheme shall be as stipulated in
IS : 5 ‘Colour for Ready Mixed Paints’
k) The sheeting shall be weather-
resistant and show colour fastness.
NOTE;
A certificate of having tested the
sheeting for properties in an
unprotected outdoor exposure facing
the sun for two years and its having
passed these tests shall be obtained
from a reputed laboratory, by the
manufacturer of the sheeting.
20.4.2 FABRICATION
a) For informatory signs with inscriptions,
either the message shall be printed
over the reflective sheeting (screen
printing), or cut letters (cut-outs) be
used with non-reflective black sheeting
which must be bonded well on the
base sheeting (aluminium).
For Internal Circulation Only

b) Surface to be reflectorised shall be
effectively prepared to receive the
retro-reflective sheeting by de-greased
either by acid or hot alkaline Etching
and all scale/dust removed to obtain a
smooth plain surface.
c) There shall be no opportunity for
metal to come in contract with grease,
oil or other contaminants prior to the
application of retro-reflective sheeting.
d) Sheeting with heat-activated adhesives
may be spliced with an overlap not less
than 5 mm or butted with a gap not
exceeding 0.75 mm.
e) The sheeting shall either have a
pressure-sensitive adhesive of the
aggressive-tack type requiring no heat,
or a tack free adhesive activated by
heat-applied in a heat-vacuum
applicator, in a manner recommended
by the sheeting manufacturer.
f) The adhesive shall form a durable
bond to smooth, corrosion and
weather resistant surface of the base
plate such that it shall not be possible
to remove the sheeting from the sign
base in one piece by use of sharp
instrument.
g) Where screen printing with
transparent colors is proposed, only
butt jointing shall be used.
h) Signs with a maximum side dimension
not exceeding 600 mm shall not be less
than 1.5 mm thick. All others shall be
at least 2 mm thick.
i) The thickness of the sheet shall be
related to the size of the sign and its
support and shall be such that it does
not bend or deform under the
prevailing wind and other loads.
j) In respect of sign sizes not covered by
IRC: 67, the structural details
(thickness, Etc.) shall be as per the
approved drawings.
100 | P a g e
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k) If the surface is rough, approved
surface primer shall be used.
NOTE;
1) Complete sheets of the material shall
be used on the signs except where it is
unavoidable: at splices, sheeting with
pressure sensitive adhesives shall be
overlapped not less than 5 mm.
2) The material shall cover the sign
surface evenly and shall be free from
twists, cracks and folds.
20.4.3 INSTALLATION
a) Sign posts, their foundations and sign
mountings shall be so constructed to
hold them in a proper and permanent
position against the normal storm wind
loads or displacement by vandalism.
b) Signs with an area upto 0.9 Sqm shall
be mounted on a single post,(for
greater area two or more support shall
be provided).
c) Sign supports may be of mild steel,
reinforced concrete or GI.
d) Post-end shall be firmly fixed to the
ground by means of properly designed
foundation as per
Specifications/Approved drawings.
e) All components of signs and supports,
other than the reflective portion and
G.I. posts shall be thoroughly descaled,
cleaned, primed and painted with two
coats of epoxy paint. (Any part of mild
steel post below ground shall be
painted with three coats of red lead
paint.)
f) The signs shall be fixed to the posts by
welding in the case of steel posts and
by bolts and washers of suitable size in
the case of reinforced concrete or G.I.
posts.
g) After the nuts have been tightened, the
tail of the bolts shall be furred over
with a hammer to prevent removal.
For Internal Circulation Only

20.6.0 SAFETY PRECAUTIONS
a) The Sign boards Installation area shall
be protected from live traffic.
b) Warning sign boards shall be put up at
sign boards Installation areas.
c) Any labour being used in the job shall
be screened and trained.
d) All workmen at work area shall wear
PPE’s and reflective jackets.
e) After cleaning, metal shall not be
handled, except by suitable device or
clean canvas gloves, between all
cleaning and preparation operation and
application of reflective
sheeting/primer.
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SUMMARY
 The signs shall be either
reflectorized or non-reflectorized
 Cautionary and mandatory signs
shall be fabricated through
process of screen printing
informatory signs with
inscriptions,
 Either the message shall be
printed over the reflective
sheeting, or cut letters of non-
reflective black sheeting, which
must be bonded well on the base
sheeting
 Sign posts, their foundations and
sign mountings shall be so
constructed so as to hold these in
a proper and permanent position
against the normal storm wind
loads or displacement
 The signs shall be fixed to the
posts by welding in the case of
steel posts and by bolts and
washers of suitable size in the
case of reinforced concrete or G.I.
posts.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC TS/01/R&R/R0
Project Client
Consultant Contractor
Work Span(Km) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR TRAFFIC SIGNS
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Drawing,method statement are approved by client

2 All materials approved by client and its suitable

3 Location of traffic signs are identified

4 The colour, configurations and size are made as per IRC

5 Surface to be reflectionised are prepared as per IRC

6 Aluminium sheets are degreased and cleaned

7 In rough surface, approved prime used

8 All fabrication process are checed and found OK

Process of traffic sign installation done as per approved
9
method statement
10 Sign post, support materials are tested and checked

11 Sign post foundation done as per drawing

Sign boards verticality, position and their supports are
12
OK
All adhesive paints are approved for sign boards, posts
13
and support
14 Staff and workmen wear PPE

15 Safety precautions are taken in working agrea

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

21 PIPE CASTING - VERTICLE
d) The pitch shall also be not less than the
maximum size of aggregate plus the
diameter of the rebar’s used.
e) Cover must be as per drawings or as per
IS 458 – Clause 6.4.2012.

21.5.1 PROCESS
a) Initially placement of mould, pallet, re-
enforcement cage, is done over inner
core fitted with vibrator in vertical pipe
21.1.0 SCOPE casting machine
b) After all above arrangements, the
The scope covers the responsibilities and
procedures for casting of Hume pipes by concrete shall be mixed in a mechanical
vertical method mixer.
c) Concrete mixing shall be continued
21.2.0 RESPONSIBILITY until there is a uniform mixing and not
Manufacturing In-charge dropped freely so as to cause
segregation.
21.3.0 REFERENCE d) The concrete shall be consolidated by
a) Technical specification of contract, spinning, vibrating, or spinning with
b) IS 458, 456. vibrations or any other approved
method.
21.4.0 EQUIPMENT/TOOLS e) Filling the concrete in the mould is
a) Pipe casting machine done with distributor and vibrated with
b) Cage forming machine vibrator.(Tolerances, dimensions must
c) Pipe mould be as per clause 8&9 of IS-458 or as per
drawings.)
21.5.0 PROCEDURE f) Outer mould with pipe after casting
shall then be placed to de-moulding
21.5.1 MATERIAL area
a) Before casting of pipes confirms all g) Placement of set ring shall be done to
materials & reinforcement shall be avoid de-shaping of spigot profile.
approved. h) The pipes shall then be covered with
b) Reinforcement must be as per IS 458 – plastic sheet to prevent loss of water
Clause 5.4, 6 & 7.3 or as approved due to evaporation.
c) The pitch of circumferential i) The pallet rings shall be removed when
reinforcement shall be not more than the pipe is hard & transported to the
1) 200mm for pipes of nominal storage area.
internal diameter 80mm to 150mm. j) Water or self-curing compound shall be
2) 150mm for pipes of nominal sprayed on the outer surface of the
internal diameter 200mm to pipe for curing.
350mm.
3) 100mm pipes of nominal internal
diameter 400mm and above.

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 Standard Operating Procedure - 2012

21.6.0 SAFETY PRECAUTIONS

a) The Pipe manufacturing area shall be
protected.
b) Warning sign boards shall be placed
nearby casting machine.
c) Any labour, if being used in the job shall
be screened and trained.
Fig.13 Cage Forming Machine

Fig.14 Cage Stacking

Fig.15 Casting & Finishing Area

Fig16 Pipe Mould

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 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC VHP/01/R&R/R0
Project Client
Consultant Contractor
Work Span(Km) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR VERTICAL HUME PIPE CASTING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Drawing,method statement are approved by client

2 All materials approved by client and its suitable

3 The reinforcemnt cages are checked and found OK

4 Cover of reinforcement are checked and OK

5 Casting mould condition are checked and found OK

6 Concreat mix Design approved by client

7 Concreat mixer is checked and its condition is OK

8 Concreat mix is observed and is found homogenious

9 Concreat is compacted by approved method

10 Demoulding done by proper method

11 Pipe dimension and surfaces are ok

12 Safety precautions are taken in working agrea

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

22 PILING i) Bentonite tank

j) Mud pump
k) Theodolite/ total station , level
instrument
l) Sounding chain
m) Transit mixer and concrete batching
plant.

22.5.0 PROCEDURE
Construction methodology for bored cast
in situ pile work includes:
a) Boring of pile to; required depth and
diameter as per approved drawing
22.1.0 SCOPE
b) Stabilising the bore by bentonite
The scope covers the responsibilities and
slurry or polymer
procedure for constructing Bored Caste
Insitu Pile’s. c) Reinforcement steel cutting and
bending; as per approved drawing and
22.2.0 RESPONSIBILITY bar bending schedule.
d) Cage making and lowering of cage
within completed bore.
21.2.1 PILLING INCHARGE
e) Concreting of pile by tremie pipe with
Arranging & optimum utilization of
required grade of concrete as per
materials and maintaining the cost as per
approved mix design.
ACE.

22.5.1 PILE BORING

21.2.2 SITE INCHARGE
a) Precise survey shall be done to mark
Site engineer is responsible for execution
of work at site, material preservation, the pier points and pile point.
achieving the repetition as per plan. b) Layout shall be done as per approved
drawing.
22.3.0 REFERENCES NOTE;
a) Approved GFC drawings 1) It is always a better practice, to
b) PQP cross check the pile points by tape
c) Project technical specification measurement as it is difficult to
d) MORT&H specification maintain the pile points once boring
e) IS 2911 part I section II activity is started,
2) Well planned reference points shall
22.4.0 EQIPMENT/TOOLS: be marked in co-ordination with
a) Hydraulic piling rig / conventional rig field engineer and those shall be
b) Crane protected from any damage.
c) Excavator c) Before starting boring, verticality of
d) Dumper shaft of rig to be checked by
e) Welding equipment theodolite(preferably).
f) Steel casing of 2-3m length each d) Steel liner/guide casing shall be
g) Trimie pipe with hopper placed precisely at pile location be
h) Water tanker pushed below.

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Guide casing placing;
1) The pile point shall be made visible
by hand excavation. From the
center point, two reference pegs
shall be set at 900mm to each other
at a distance equal to 1 mt.
2) The temporary casing of required
diameter and at least 2 mt. long,
shall be pitched and centralized
over the center point of pile as
guide for the auger.
3) Temporary casing shall be installed
using a vibrator hammer or by the
drilling rig. The casing shallextend
about 250 to 300 mm above
working platform.
Fig.17 Guide Casing
e) Boring shall be started with augur
attachment/bucket attachment &
continued upto the required depth
with continuous circulation of
bentonite slurry to stabilise the bore.
Fig. 18 Bentonite arrangement for Pile
boring
107 | P a g e
Standard Operating Procedure - 2012
f) After reaching the required depth, the
same is checked by a sounding chain.
Fig.19 Pile Boring
22.5.2 REINFORCEMENT CUTTING,
BENDING, CAGE BINDING AND
LOWERING OF CAGE:
a) Cutting and bending of the rebar’s
shall be done as per approved BBS.
(To decide the lap location it is better
to have template.) Number of vertical
main bar and spacing of ring/ spiral
shall be as per approved drawing.
b) Sufficient cover block of circular shape
with central hole shall be fixed with
ring/ spiral.
c) Cover blocks shall be of same strength
of pile concrete. Spacer rings (Dia
16mm min. and max. 10m spacing /
normal practice) shall be welded with
vertical bars at suitable spacing all
along the length, this is important to
maintain rigidity of cage during lifting
and lowering within bore.
d) Cage shall be lowered vertically by
crane, each cage at lap locations shall
be welded or clamped to avoid
slippage of bottom cage under
gravity, during this welding/ clamping
operation proper holding/ hanging
arrangement of bottom cage ( within
the bore ) to be assured. Top cage will
be held by crane.
e) After completion of cage lowering
bore hole shall be washed by fresh
bentonite slurry.
For Internal Circulation Only

f) It shall be assured that there shall not
be any thick deposition soil and
bentonite at bottom of bore.
Fig.20 Reinforcement cutting /bending
Fig.21 Reinforcement Cage lowering
22.5.3 CONCRETE POURING:
a) Concreting shall be done by tremie
pipe. Minimum diameter of tremie
pipe shall be 200mm. Crane shall be
used to hold the hopper and tremie.
With progress of pour, tremie shall
be lifted in such a way that tremie tip
gets embedded in concrete 1.5m
(min).
b) Concreting shall be continued upto
overflow till all contaminated
concrete come out from bore.
c) After completion of concreting, muck
shall be disposed from site at suitable
approved location.
108 | P a g e
Standard Operating Procedure - 2012
Fig.22 Pouring of Concrete
d) Slump shall be tested in each transit
and Cubes shall be casted for
required numbers as per
specification requirement for testing.
22.6.0 SAFETY PRECAUTIONS:
a) The area shall be provided with hard
barricading to restrict general public
entry.
a) All vehicular equipment’s shall be
fitted with reverse horn
b) Survey equipment’s shall be
calibrated.
c) Sufficient area lighting shall be
provided for night activity.
d) Welder and cutters shall be with all
safety gadgets.
e) Deployment of flag man to control
equipment movement.
f) Any incomplete bore hole shall be
protected / covered properly.
g) Precaution shall be taken to avoid
contamination of local water body by
bentonite slurry.
22.7.0 IMPORTANT SPECIFICATION
REQUIREMENT
a) Minimum grade of concrete for bored
cast in situ pile M20 (MORT&H
1104.2)
b) Minimum cement content 400 kg/m3,
maximum water cement ratio 0.5.
(MORT&H 1104.2)
For Internal Circulation Only

c) Slump should be 150mm to 200mm,
maximum limit 200mm (MORT&H
1104.2)
d) Bentonite slurry density 15 gm.cc, PH
value 9.5-12, liquid limit not less than
400%, marsh Cone viscosity 30-40 (
MORT&H 1115.2.3 )
e) Minimum tremie diameter 150mm
f) Allowable cross sectional variation
+50mm/ -10mm. Allowable verticality
deviation 15mm.
g) Allowable variation in final position
50mm. Allowable variation in top level
+/- 25mm -MORT&H 1116.1 (ii)
h) Number of routine test on working
piles: 2% of total pile but minimum 2
nos.
109 | P a g e
Standard Operating Procedure - 2012
SUMMARY
 Boring of pile of required depth and
diameter is done as per approved
drawing
 Stabilising the bore by betonite slurry
 Reinforcement steel cutting and
bending as per approved dwg. and
bar bending schedule. Cage making
and lowering of cage within
completed bore is done
 Concreting of pile by tremie pipe
with required grade of concrete as
per approved mix design.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PIL/01/R&R/R0
Project Client
Consultant Contractor
Work Pile No RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR PILE FOUNDATION
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Preliminaries

a Accepted Sub Soil investigation report - available?

b Is the piling system established and approved?

Has the test pile been installed, test carried out and
c
found satisfactory?
Registers for checking boring and concreting
d
available at site as per method statement?
2 Survey

a Centre line marked?

b TBM available?

c Longitudinal and Cross reference pillar marked?

d Location marked?

3 Boring

a Equipment

Tripod & Winch, Condition - Satisfactory?

Thickness and length of casing - available?

Dimension and condition of bailer & chisel found
correct?
e Mud Circulation

f Quantity of approved bentonite - available?

5 Concereting
Bore hole washed and cleaned with fresh
a
benetonite slurry till consistancy of inflow and
b Measured the depth of boring & found correct?
Methodology of concreting - available at site?
c
Arrangement of concreting - proper?
Consumption of concrete checked and entered in
d
register as required?
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PIL/02/R&R/R0
Project Client
Consultant Contractor
Work Pile No RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR PERMISSION FOR BORING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Method statement Approved
2 Pile center and circumference marked
3 Verticality of guide
4 Casing checked
5 Reference points marked
6 Reinforcement cage available at site
Remarks
L&T QA/QC Client/IE

CHECKLIST 3

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PIL/03/R&R/R0
Project Client
Consultant Contractor
Work Pile No RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR PERMISSION CAGE LOWERING
Checked & Found OK
Sl. No. DESCRIPTION Drawign Ref Remarks/Issues
Yes No Na
1 Is Pile boring completed
Casing Top RL
Ground RL
2 Cut off level
Casing Bottom
Depth of permanent liner
3 Rebar cage is fabricated as per the Drawing
4 Approved BBS is available at site
5 For 100% lapping / couplers checked
6 Provision of cover blocks checked
7 All arrangements for cage lowering is ready
Sufficient number of spacers provided to prevent
8
buckling of cage while lowering.
9 Lifting conditions of Crane checked
Remarks
L&T QA/QC Client/IE

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 Standard Operating Procedure - 2012

CHECKLIST 4

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PIL/04/R&R/R0
Project Client
Consultant Contractor
Work Pile No RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
TREMMIE CHART
Pile no Final Sounding
Diameter of pile Cut off Level
Depth of Pile As per the tube top level
Founding level Concrete top level
Cumulative
Sl.No Tremmie PIPE No. Length(M) Remarks/Issues
Length(M)

Remarks
L&T QA/QC Client/IE

CHECKLIST 5

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC PIL/05/R&R/R0
Project Client
Consultant Contractor
Work Pile No RFI No
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
PILE BORING DETAIL CHECKLIST
Pile No Boring tool cut off level
Diameter of Pile Top casing depth
Depth of pile from cut off level Existing GL
Hard / Soft rock levels Bore depth from COL
Founding Level Bore depth on rock
Permanent liner length Casing length
Sign by
Date Time Depth Penetration per hour Sign by L&T Remarks
Client

Remarks
L&T QA/QC Client/IE

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23 PILE LOAD TEST
23.1.0 PILE LOAD TEST BY KENTLEDGE
METHOD
23.1.1 SCOPE
The scope covers the responsibilities and
procedure for, conducting initial /routine
pile load test by;
a) Reaction frame method/ Kentledge
Method using sand bags/concrete
blocks.
b) Vertical Load Test by Anchor Pile
Method
c) Lateral Load test
d) High strain dynamic pile testing
23.1.2 REFERENCE
a) IS 2911 part4
b) MORT&h specification
c) Approved drawing
d) Approved scheme of kentledge setup
23.1.3 PLANT AND EQUIPMENT
a) Crane
b) Structural steel sections and built up
beams (as per design)
c) Concrete blocks of suitable size and
required quantity as per test load
d) Hydraulic jacks, pumps, dial gauges of
required capacity
e) Suitable datum bar arrangement
23.1.4 PROCEDURE
a) Excavation of surrounding area of test
pile shall be done to get proper space
113 | P a g e
Standard Operating Procedure - 2012
and head room for movement of
worker and placing of equipment.
b) Dismantling and redevelopment of pile
head shall be done upto the sound
concrete (appx. 1.2-1.5m) level.
c) Before performing test, concrete of
redeveloped part shall achieve the
original pile strength.
d) Jacks shall be placed on top of the test
pile in symmetrical manner. Jacks shall
be placed in such a manner that load
applied shall be axial; Centre of Gravity
(CG) of kentledge shall also pass
through the centre of jacks and centre
of pile.
e) The primary beam (main beam) and
secondary members as per approved
drawing shall be placed.
f) Concrete blocks shall then be placed in
a symmetrical manner, taking care of
overall stability of kentledge
arrangement. (Kentledge weight shall
be 25% more than the test load to
maintain stability of setup.)
g) Datum bar shall be fixed as per required
specification. Datum bar support shal
be at a distance 3 times diameter of
pile from pile face or minimum 1.5m.
h) Jacks shall be connected to pumps and
fix gauges at required locations for
settlement checking. Minimum 2
gauges shall be fixed to record
settlement.
i) Kentledge load shall be transferred on
to the test pile by operating the jacks.
(Loading shall be strictly as per
guideline of IS 2911 part 4.)
j) Load shall be transferred in progressive
manner at the rate of 20% of safe
capacity. Maintained loading or Cyclic
loading method (adopted when both
frictional capacity and end bearing
capacity are required to be
determined).
For Internal Circulation Only
 Standard Operating Procedure - 2012

k) Settlement shall be measured as per

guideline of IS 2911 part 4.
l) Apply the load to pile in equal
increments and at an increment of 20%
of the design load. The load increment
shall be adjusted to the nearest least
count of the pressure gauge and ram
area of hydraulic jacks.
m) Record the settlement with each Fig. 24 Pile load test by Concrete Blocks
increment of test load at an interval of
1, 2.25, 4, 6.25, 9, 16, 25, 30 minutes
from the time of application of load and
thereafter at an interval of 30 minutes
up to a minimum time interval of 2
hour. Settlement observations in mm
from the time of application of load
shall be recorded in a tabular format.
n) Final loading shall be as mentioned in
drawing. For initial load test it shall be 2
times of safe capacity and for routine
load test shall be 1.5 times of safe Fig.25 Sectional Elevation for Pile Load
capacity. Test
o) A load vs. settlement chart and graph r) The test shall be stopped after reaching
shall be prepared after completion of the test load or 12 mm settlement
loading and unloading. Unloading shall whichever takes place earlier.
be as per the guideline of IS 2911 part s) After completion of the load test all the
4. strain dial gauges, hydraulic jacks with
p) The test load shall be held constant for power pack, connections to datum bars
a period of 24 hrs. Etc. shall all be removed from the top
q) Total settlement at the end of of the test pile.
application of test load shall be t) The load test arrangement i.e.
calculated and results of load test be kentledge load, MS girders, datum bars,
analyzed. pillars Etc. in a symmetrical manner.

23.2.0 VERTICAL LOAD TEST BY

ANCHOR PILE METHOD
In this method mechanism is same as
kentledge method but in kentledge method
reaction is taken against the kentledge
load, in anchor pile method reaction is
taken against a group of anchor pile.

Fig. 23 Pile load test by Sand bags

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Fig.26 Detail of anchor pile arrangement
23.3.0 LATERAL LOAD TEST
24.3.1 PROCEDURE
a) The area around the test pile shall be
excavated and dressed
b) Jack shall be placed horizontally against
the pile peripheral surface
c) Minimum 2 gauges (01mm sensitivity)
are fixed to record deflection (as per
guideline of
IS 2911 part 4 clauses 7.1, 7.2, 7.3)
d) Load is applied at increment 20% of
safe capacity
e) Reaction is then measured against the
excavated vertical earth face through
concrete block and MS sections. (as per
approved scheme )
f) Deflection shall be recorded at each
increment of loading and a load Vs.
deflection is prepared as per guide line
of IS 2911 part 4 Clause 7.4 (a,b,c)
Fig.27 Lateral Load Test
115 | P a g e
Standard Operating Procedure - 2012
23.4.0 HIGH STRAIN DYNAMIC PILE
TESTING
This is an analytical method with few field
activities to determine the capacity of pile
by dynamic loading method.
Basic purpose is to determine pile capacity
and structural integrity of the pile and the
settlement against the capacity evaluated.
23.4.1 STEPS FOR PILE DYNAMIC TEST
a) The top of pile (approximately 1.5 to 2
times of pile diameter) shall be
redeveloped with same grade of
concrete as that of pile.
b) A ply board cushion of 40 to 50mm
shall be provided on top of pile. Pile top
is further provided with a fabricated
steel cap of 20mm thick MS plate.
c) Transducers and accelerometers shall
be attached to the pile surface at
approximately 1.5 times the diameter
of pile below the pile top. Transducers
and accelerometers are also connected
to the PDA equipment.
d) A hammer of suitable size and shape as
decided in consultation with specialised
agency shall be arranged. (hammer
weight shall be 1 to 2% of capacity of
pile by thump)
e) The Hammer shall be dropped (free fall)
from a predetermined height on pile
centre by winch machine or by crane. 2-
3 repetition may be required to get
proper data.
f) Data collected in PDA through
transducers and accelerometers shall
be further analyzed by CAPWAP
programme to predict the pile capacity.
g) The analysis results in
1) Pile capacity including skin
friction & toe bearing
2) Load vs. settlement curve,
3) Resistance along shaft
For Internal Circulation Only

Fig.25 Pile Dynamic Test
23.6.0 SAFETY
a) Area shall be barricaded to restrict
general entry.
b) All workers should be with PPE.
c) Strict observation shall be there to
check any settlement the pile test
arrangement.
116 | P a g e
Standard Operating Procedure - 2012
SUMMARY
 Surrounding area of test pile
shall be excavated
 Dismantling/redevelopment of
pile head shall be done upto
the sound concrete
 Jacks shall be placed on top of
the test pile in symmetrical
manner as per drawing.
 Datum bar shall be fixed as per
required specification.
 Jacks shall be connected to
pumps and fix gauges at
required locations for
settlement checking.
 Load shall be transferred in
progressive manner at the rate
of 20% of safe capacity.
 Settlement shall be measured
 Record the settlement with
each increment of test load at
an interval of 1, 2.25, 4, 6.25, 9,
16, 25, 30 minutes from the
time of application of load and
thereafter at an interval of 30
minutes up to a minimum time
interval of 2 hour.
 A load vs. settlement chart and
graph shall be prepared after
completion of loading and
unloading.
 The test load shall be held
constant for a period of 24 hrs.
 Total settlement at the end of
application of test load shall be
calculated and results of load
test be analyzed.
For Internal Circulation Only
 Standard Operating Procedure - 2012

24 FABRICATION OF STEEL b) Prior to start of the fabrication work, all

STRUCTURES structural steel materials shall be
checked and verified by the QA/QC
Incharge.
c) All rolled sections & structural
members shall be placed on suitable
elevated surface to prevent distortion
and for ease to work.
d) Steel shall be checked, sorted out,
straightened and arranged by grade &
quality. Each lot shall be verified with
the Test Certificates supplied by the
25.1 SCOPE
supplier for Heat No. & sizes to ensure
The scope covers the responsibilities and
traceability.
procedure for various activities involved in
structural works. e) Structural steel with surface defects
such as pitting, cracks, damaged and
24.2.0 RESPONSIBILITY test failed materials shall not be taken
a) Fabrication in charge. into account for fabrication and need to
b) QA/QC Incharge be stacked separately or removed from
shop.
24.3.0 REFERENCE f) If rust is there on the plate it shall be
a) General specification for Steel cleaned by wire brush after that it shall
Structure. be processed for fabrication. Approved
b) Fabrication drawings. cutting plan shall be available wherever
c) Relevant approved GFC Drawings and required for optimum use of the steel.
Specifications. g) At MTC we shall check the chemical &
d) Approved WPS for carry out welding physical properties.
activities. h) In physical properties checking point
e) Approved Quality Assurance Plan (QAP) are; UTS, YS, %EL & Impact test & in
f) Steel for General Structural Purposes chemical properties checking point are;
(Gr.A/B): IS 2062, Gr –B. carbon, manganese, sulphur,
g) Tolerance for Fabrication Steel phosphorus, silicon content Etc.
structure: IS -7215. ELECTRODES;
a) The electrodes used for the job shall be
h) Rolling & Cutting Tolerance: IS-1852.
kept under dry conditions.
i) Welder Qualification: ASME SEC IX.
b) Any electrodes damaged by moisture
j) Welding Procedure: IS 9595.
shall not be used.
k) Welding Electrodes: IS 814.
c) Any electrode which has part of its flux
24.4.0 PROCEDURE coating broken away or is otherwise
damaged, shall be rejected.
d) Any electrode older than six (6) months
24.4.1 MATERIALS
from the date of manufacture shall not
a) Fabrication shall be carried out as per
be used.
the approved fabrication drawings
released.

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e) Electrodes shall be stored, baked,
handled and used in accordance with
the manufacturer’s instructions.
f) Low hydrogen electrodes where ever
applicable shall be dried properly in
Baking oven by manufacture’s
recommendations as per WPS prior to
use.
g) It shall be made in a sequence that will
balance the applied heat of welding
during welding.
24.4.2 MARKING &CUTTING
a) The marking / lay out of individual
structures shall be reviewed and
verified as per drawing and part list.
b) The cutting of material shall be carried
out with oxy-plasma flame with a
cutting torch or identical.
PROCEDURE for Automatic Machine;
1) Firstly plate shall be aligned properly
at bed.
2) As per thickness; voltage, current & a
programme shall be set in machine.
3) Marking of the materials shall be
done with a cutting allowance of 2 to
3 mm.
4) Care shall be taken for cleaning the
cut faces from distortion and burns.
5) The cut edges shall be ground prior
to fitment.
c) After cutting all members shall be
straightened and made free from burrs
and simultaneously be grounded
d) Holes for bolts shall be done by drilling
only, & not by gas cutting process
e) Holes shall be drilled done after the
members are tightly clamped wherever
necessary. All matching holes shall align
with each other. Finished holes shall be
1.5 mm larger in diameter than the dia.
of bolt passing through and shall be
free from burrs
f) Cutting of stiffener plates and Gusset
plates shall be done as per the
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Standard Operating Procedure - 2012
fabrication/nesting drawings & grinding
the edges of plate
g) All assembly work shall be carried out
on fabrication platform and proper jigs
and fixtures with sufficient in number
shall be provided to avoid distortion
during welding
24.4.3 STORAGE OF RAW MATERIAL
a) The cut material shall be keep at
proper stacking yard with the help of
wooden block.
b) Every 1 meter, 1 wooden block shall be
keep to reduce the bending.
24.4.4 FIT UP, WELDING & ASSEMBLY
a) The structural steel member shall be
fitted to the automatic saw machine.
b) Welding shall be done on one side of
the beam, beam reversed and welding
done on other side (in one go).
c) Each girder shall bear mark
number/identification number with
hard punch/suitable marking with paint
(where punching is not possible) which
will help to identify the member & its
position in respect of the whole
structure.
d) In case of spliced member all the splices
shall be aligned on a prepared bed as
per required camber / curvature and
then it will be bolted or welded as per
approved drawing.
CHECKS;
1) Each girder shall have dimension
check-up as per drawing & IS7215
with proper identification number.
2) Welding shall be checked visually &
welding gauge.
3) The Welded beam shall be 100%
inspected by the QC Engineer as per
approved QAP.
24.4.5 WELDING PROCEDURE
For Internal Circulation Only

a) Prior to welding, weld procedure shall
be established as per
specification/requirement.
b) Qualified welders shall be engaged for
the job
c) All welding and the welded work shall
generally conform to IS: 816-1969 and
9595-1996 unless otherwise specified.
d) The electrodes used for assembly work
for mild steel shall conform to IS: 814-
2004.
e) Welding shall not be done under such
weather conditions which might
adversely affect the efficiency of the
welding.
24.4.5.2 WELDING RECTIFICATION
a) Checking shall be done for alignment of
fusion faces with proper gap for pass of
butt joints so as to achieve full
penetration with complete fusion
b) All welding process shall comply the
approved Welding Procedure
Specification (WPS)
c) On completion of each run;
1) All slag & spatters shall be
removed,
2) Weld and the adjacent base metal
shall be cleaned by wire brushing,
chipping, or grinding.
3) Checking of visible defects if any
shall be removed before deposition
of subsequent run.
4) Full penetration butt-weld shall be
completed by chipping, gouging to
sound metal and then deposition
sealing run of weld metal be carried
out.
d) Welding sequence shall be established
after carefully studying each case so as
to minimize distortion and shrinkage.
e) Each layer of deposited weld shall be
thoroughly cleaned before further
deposition of weld metal is
commenced. When necessary the
119 | P a g e
Standard Operating Procedure - 2012
deposited metal shall be ground free of
profile irregularities.
f) Articular attention shall be given to the
toe of each layer of welding at the
junction to the fusion face of the joint
to avoid slag traps or lack of fusion in
subsequent welding deposits.
24.4.5.3 INSPECTION, T ESTING AND
REPAIR OF WELD JOINT S
a) Before examination the weld joints, the
surface of weld metal shall be cleaned
of slag, spatter beads, scale Etc. by wire
brush or chisel.
b) Checking of all finished welds (100%) by
visual inspection shall be done to
identify the following type of weld
defects by the QC engineer prior to
offering for final inspection.
1) Blowholes, exposed porosity,
infused weld
2) Surface crack and burn through
3) Under cut burning and Arc Strike
4) Excess convexity or concavity,
overlapping, unequal leg length,
root groves Etc.
5) Dimensional errors & Misalignment
of members
6) Correctness and shape of the
welded joints
7) Penetration of weld metal,
reinforcement
8) Craters & Spatters,
9) HAZ Etc
c) During final examination, all temporary
attachments and welds located on the
parent metal shall be removed. Any
damage to parent material shall be
repaired by welding and grinding.
d) During the visual inspection the points
to be checked are.
e) All NDT works like radiography,
ultrasonic examination shall be carried
out by experienced/qualified personnel
as per approved job procedures as per
For Internal Circulation Only
 Standard Operating Procedure - 2012

requirement mentioned in drawings e) All craters in weld and breaks in the

and specifications. weld run shall be thoroughly filled
f) Acceptance of inspection shall be as per with weld.
the project specification / applicable f) Undercuts, beyond acceptable
codes. limits, shall be repaired with
TESTING; dressing so as to provide smooth
1. Ultrasonic Test transition of weld parent metal.
a) Test shall be conducted to detect g) Weld at the location of such defects
gas inclusion (pores), slag inclusion, plus 10 mm from both ends of
shallow welds, cracks, lamination defective weld by means of gouging
Etc. or grinding wheel and shall be re
b) Prior to starting of ultrasonic test welded. Inspection records shall be
the welded joint shall be generated as per the approved
thoroughly cleaned of slag and QAP/ITP at site.
other material. 3. TRANSPORTATION:
c) Surface of the basic metal adjacent a) As per job size and weight of
to welded joint on both sides shall structural item, necessary scheme
be mechanically cleaned by a of transportation shall be prepared.
grinder or a metal brush to provide b) Trailer may be used for
the contact of the whole ultrasonic transportation of fabricated
probe surface with surface of basic structures from fabrication yard to
metal. erection spot.
d) The welded joint then shall be
covered with a thin coat of
24.4.6 PAINTING
transformer oil, turbine or machine
a) Steel structure surface shall be
oil to ensure acoustic contact.
prepared as stated in the
e) The joints so treated shall be
drawing/Technical Specification.
marked and the marks shall be
b) The surface shall be cleaned by
entered into the documentation.
grit/sand blasting or by mechanical
2. Radiography Tests
means as per technical specification.
a) Test shall be carried out as per
c) Metalizing shall be done as per
approved job procedure in all ‘Tee’
specification requirement.
and ‘Cross’ weld locations to
d) Number of prime coat and final coat
determine gas inclusion slag
shall be as per specification.
inclusion, shallow welds and cracks
e) All paints shall be as per
inside the weld.
specification/BOQ requirement.
b) The welded joints shall be cleaned
f) Paint shall be applied as per
of slag and scales and visually
manufacturer’s recommendation.
examined.
c) The welds shall be marked into
24.5.0 SAFETY & SECURITY DURING
separate portions depending on the
FABRICATION
length.
a) Every individual entering the
d) In case of defects in welds, the
construction work premises shall use all
rectification of the same shall be
necessary (PPE).
done by appropriate procedure.

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b) Full body Harness, fall arrestor, Hand
gloves, Safety goggle shall be used
depending upon the nature of work.
c) No electric arc cutting shall be
permitted at site.
d) The execution area shall be kept clean
and tidy.
e) Every working gang shall maintain
proper housekeeping at work place.
f) Scrap material shall be disposed of at
separate scrap area.
g) Only authorised electricians are allowed
to work on electrical installations.
h) Utmost precautions shall be taken
during Gas-cutting and Welding work at
site. Storage, shifting and use of gas
cylinders shall be done with proper safe
procedure.
i) Grinding machines shall be operated by
competent grinders only.
j) Proper working platform for working at
height shall be ensured.
k) Safety belts shall be issued to all
personnel who have to climb
l) Fall arrestor shall be used while
climbing the columns.
24.6.0 RECORDS
All stage wise inspection report shall be
maintained as per approved Quality
Assurance Plan (QAP).
121 | P a g e
Standard Operating Procedure - 2012
SUMMARY
 Fabrication to be carried out as
per approved Drawing.
 All rolled sections & structural
members shall be placed on
suitable elevated surface to
prevent distortion and for ease to
work.
 The marking / lay out of
individual structures shall be
reviewed and verified as per
drawing.
 The cutting of material shall be
carried out with oxy-Plasma
 After cutting all members should
be straightened and should be
made free from burrs and
grounded.
 All assembly work shall be carried
out on fabrication platform and
proper jigs and fixtures with
sufficient checks
 Holes for bolts shall be done by
drilling only.
 Cutting of stiffener plates and
Gusset plates shall be done as per
the fabrication/nesting drawings.
 The structural steel members
fitted to automatic saw machine,
welding is started & completed in
one go.
 Checking of all finished welds
(100%) by visual inspection will
be done to identify the weld
defects.
 Tests like ultrasonic test,
radiography test can be carried
out
 The surface which is to be
painted shall be cleaned by
gritflame with a Cutting / sand
blasting or by mechanical means
as per technical specification.
For Internal Circulation Only
 Standard Operating Procedure - 2012

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC FAB/01/R&R/R0
Project Client
Consultant Material Spec
Type of Work Ref. Drawing No./Rev. No
Material Description Start; Finish;
Method Technique
CHECKLIST FOR MAGNETIC PARTICLE INSPECTION
Sl No. Beam Mark No. OBSERVATION Rectification Area Remarks/Issues

1
2
3
4
5
6
Remarks
L&T QA/QC Client/IE

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC FAB/02/R&R/R0
Project Spec
Size Density
Type of Source ; Y Ray Penitrameter
Sensitivity Technique
Start: Finish: Format No
CHECKLIST FOR RADIOGRAPHY INSPECTION
Beam Mark
SL NO. Location OBSERVATION Rectification Area Remarks/Issues
No./Identification No.
1
2
3
4
5
6
Remarks
L&T QA/QC Client/IE

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 LARSEN & TOUBRO LIMITED

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INFRASTRUCTURE IC
CHECKLIST 3

FAB/03/R&R/R0
Project Client
Type of Work Consultant
Ref. Drawing No./Rev. No Start: Finish:
CHECKLIST FOR WELD VISUAL REPORT FOR BEAM

Beam Mark
Sl.No Drawing No. Size Type S/F Welder No. OBSERVATION Remarks/Issues
No./Identification No.

Remarks

L&T QA Client/IE

For Internal Circulation Only

Standard Operating Procedure - 2012
 Standard Operating Procedure - 2012

CHECKLIST 4

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
FAB/04/R&R/R0
Project Client
Item Make Batch No. Expiry Surface Temperature
Remover Dwelling time
Penetrant Ref. Drawing No./Rev. No

Developer Start: Finish:

CHECKLIST FOR DYE PENETRATION TEST REPORT

Sl No. Drawing No. Mark No. Size Welder No. OBSERVATION Remarks/Issues

10

Remarks

L&T QA Client/IE

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 LARSEN & TOUBRO LIMITED
INFRASTRUCTURE IC
FAB/05/R&R/R0
Project Client

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Ref. Drawing No./Rev. No Report No.
CHECKLIST 5

Type of Work Start: Finish:

CHECKLIST FOR FINAL INSPECTION REPORT FOR STRUCTURAL BEAM

Dimension Observation
SL NO. Mark No Quality Remarks/Issues
Total Out of Depth Straightness Web-off Beam &
ESTL L&T
Length squareness (+/- 3mm) (max 10mm) center Flange width
1

11

12

For Internal Circulation Only

Standard Operating Procedure - 2012

25 EXPANSION JOINTS
25.1.0 SCOPE
The scope covers the responsibilities and
procedures for Fixing of Compression Seal
type Expansion Joint at Major bridges and
Fly over.
25.2.0 RESPONSIBILITY:
Please refer Point No: 1.2.0
25.3.0 REFERENCE
a) Approved GFC drawings
b) PQP
c) Project technical specification
25.4.0 PLANTS AND EQUIPMENT
a) Welding aids
b) Compressor
c) Asphalt cutter
d) Wooden/Steel supports
e) Needle Vibrator
f) Compression seal expansion Joint
assembly
g) Nitobond-EP
25.5.0 PROCEDURE
a) A recess of 300x180mm shall be left in
concrete on either side deck slab as
well as on crash barrier locations as
provision for expansion joint.
b) The portion of recess as well as of
expansion gap shall be covered with
16mm MS sheets supported by
necessary angles in order to continue
126 | P a g e
Standard Operating Procedure - 2013
the laying of BC over the deck slab
without any discontinuity.
c) BC shall be laid over the deck slab in full
width as per the required level and
grade, which afterwards, shall be cut
and removed from the portion of recess
and the gap.
d) MS angles of 100x100x12mm size shall
be fixed at both side of the expansion
gap using necessary supports
maintaining a clear gap of 38mm
between the two slabs.
e) Anchor loops as well as R-bars shall be
fixed on both side of the expansion gap
as per the approved drawing by welded
connections at appropriate locations.
f) 3 nos. of 12mm dia. transverse
reinforcement bar shall be provided on
either side of expansion gap at the
locations shown in approved drawing.
g) Compression seal shall be fixed within
the expansion joint gap using binder at
the faces the concrete. Top of the
compression seal shall be covered with
a layer of another epoxy material,
which shall be flushed to the wearing
surface.
h) The recess-area shall be cleaned of any
loose concrete or asphalt material with
compressed air jet.
i) Exposed faces of concrete in recess-
portion shall be given a coat of epoxy
adhesive (Nitobond-EP, a FOSROC
product) as per the manufacturer’s
guideline in order to have a perfect
bond between the old and fresh
concrete.
j) Concrete of M35 grade shall be poured
within the recess and compacted with
pokers.
k) Top level of the concrete shall be
flushed to the road FRL maintaining the
level and grade as per the approved
drawing.
For Internal Circulation Only
 Standard Operating Procedure - 2013

26 BEARINGS 26.5.1 FIXING OF POT BEARINGS WITH

TEMPLATES
a) Templates with acceptable rigidity shall
be placed in such a way that the holes
in the girders match those of the
bearing.
b) The template shall be placed in respect
with the desired alignment and level
with the help of anchor screws fastened
to the lower faces of the template using
26.1.0 SCOPE steel washers.
The scope covers the responsibilities and c) The anchors shall be tied or welded to
procedures for Fixing of POT bearing under the reinforcement of the soffit in order
girders. to restrain the template from getting
disturbed.
26.2.0 RESPONSIBILITY d) The pedestal shall then be concreted
Please refer Point No: 1.2.0 but to a level that is about 25mm below
its desired level.
26.3.0 REFERENCE: e) The template shall then be replaced
a) IRC 83 Part III for POT, POT –CUM- with the pot bearing and shall be fixed
PTFE, Pin & Metallic Guide Bearings. to the anchor screws using elastomer
b) Approved GFC drawings. washers in the exact orientation in
c) PQP which the template was fixed.
d) Project technical specification. f) The final level of the bearing shall be
checked for conformance and after
26.4.0 EQUIPMENT/ TOOLS: achieving the same the screws shall be
a) Survey instrument grouted with high strength, non-
b) Plum-bob, Spirit Level, Etc. shrinkable and flowable grout, SIKA
c) Materials: 214.
1) Pot Bearings
2) Templates 26.5.2 FIXING POT BEARINGS
3) Anchor Screws. WITHOUT TEMPLATES
4) Elastomer washers a) The bearing pedestal shall be concreted
5) SIKA 214/Likewise Approved up to a level that is about 5mm below
6) Steel Washers the desired finish level.
b) Cavities in the form of tunnels shall be
27.5 PROCEDURE: left in the pedestal, which shall enable
The work procedure developed pertains to the placing of anchor screws of the
two cases bearing.
1) Fixing of pot bearings with
c) The pot bearing shall be placed after
templates.
being fastened to the anchor screws
2) Fixing of pot bearings without
using elastomer washers in such a
templates.
manner that the anchor screws are
placed in the cavities left in the
pedestal.

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 Standard Operating Procedure - 2013

d) The bearing shall be checked for

alignment and level and after
conformance the anchor screws shall
be grouted with high strength, non-
shrinkable and flowable grout, SIKA
214.

26.6.0 QUALITY CONTROL & TEST

The quality and behavior of CTT POT
bearings is to be checked by several tests:
- Vertical load tests
- Vertical and horizontal load tests
- Friction tests
- Rotation test

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 Standard Operating Procedure - 2013

CHECKLIST 1

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC POT/01/R&R/R0
Project Client
Consultant Contractor
Work Span(Km) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR POT/PTFE BEARING(20f2)
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Seating of Bottom Plate
Has the bearing been placed in proper position and
a
level
Is the grouting material sieved through 1.18mm sieve
b
available
c Is mixing arragement checked

d Is the pouring arrangement for grout checked

Has the grout evenly spread all around and below the
e
bottom plate
2 Fixing of Top Plate
Is the pier segment properly placed over the pier and
a
secured on the jacks/ crib supports around the pier
Are all the pockets properly cleaned and soaked in
b
water
Is the grouting material sieved through 1.18mm sieve
c
available
d Is mixing arragement checked

e Is the pumping arrangement for grout checked

Has the Epoxy mortar applied all around the top plate
f
set
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2013

CHECKLIST 2

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC POT/02/R&R/R0
Project Client
Consultant Contractor
Work Span(Km) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish
CHECKLIST FOR POT/PTFE BEARING
Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
1 Deatails of manufacturer recorded
Manufacturering process as per approved MORT&h
2
specification
3 Use of bearing in other projects checked

4 Report obtained from the clients referred at Sl.No. 2

5 Has the manufacturer submitted QAP being checked

6 Material satisfies the test requirement as per QAP

7 Continuous supply of bearing without any delay

As the agency agreed to furnish a performance bond
8
for 10 years
Authorised representative be available while
9
installation
Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2013

ANNEXTURE 1

Test on concrete

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 Standard Operating Procedure - 2013

TEST ON CONCRETE

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
GEN2/01/R&R/R0
Project Client
Consultant Span
Date Start Finish
TESTS DURING PRE-STRESSING WORKS
Sl.No. Test Type As per IS Code Frequency of Test Specification Requirement
Shall confirm to IS 8112/12269 for
1 Cement 4031 Part-1 to 6 1 Tests per every lot or MTC.
43/53 grade
2 Water 3025 Once per source Shall confirm to clause 1010 of MoRT&H
3 Reinforcement Steel 1786 Once per every lot per dia or MTC Shall confirm to IS 1786 of grade S415

4 Admixtures 9103 MTC for every lot Shall confirm to clause 1012.2of
Gradation of Shall confirm to table 1000-1 for coarse
5 2386 Part-1 Once for every 15 days
aggregates aggregate and 1002-2 for fine aggregate
6 Flakiness Index 2386 Part-1 Once for every month 35% Maximum
Aggregate Impact
7 2386 Part-4 Once for every month 30% Maximum
Value
Workability of Once per each session per each 25-75 mm for M10 & M15, and 75 -125
8 1199-1959
concrete grade of concrete mm for all other grade
No. of Sample is a set of 3 nos. of
Qty
samples 150x150x150mm cubes , in addition to
1-5 cum 1 this 1 sample to be taken for 7 days
6-15 cum 2 strength determination. The compressive
Compressive 16-30 cum 3 strength shall confirm to the design
9 516 31-50cum 5
strength of concrete target strength (table 1700-5 of
MoRT&H) if any individual cube strength
4+1 for 50cum
if less than the target strength by
51 above and part
3N/sqmm standard deviation shall be
thereof
applied.

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ANNEXTURE 2

Test for Pre-stressing

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TEST FOR PRESTRESING

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
GEN/01/R&R/R0
Project Client
Consultant Span
Date Start Finish
TESTS DURING PRE-STRESSING WORKS
Sl.No. Test Type As per IS Code Frequency of Test Specification Requirement
1 Cement 4031 Part-1to 6 1 Tests per every lot or MTC. Shall confirm to IS 8112/12269 for 43/53
2 Water 3025 Once per source Shall confirm to clause 1010 of MoRT&H
3 Reinforcement Steel 1786 Once per every lot per dia or Shall confirm to IS 1786 of grade S415
4 Admixtures 9103 MTC for every lot Shall confirm to clause 1012.2of MoRT&H
Shall confirm to table 1000-1 for coarse
5 Gradation of aggregates 2386 Part-1 Once for every 15 days
aggregate and 1002-2 for fine aggregate
6 Flakiness Index 2386 Part-1 Once for every month 35% Maximum
7 Aggregate Impact Value 2386 Part-4 Once for every month 30% Maximum

8 Workability of concrete
Compressive strength of
9 516
concrete
1199-1959 Once per each session per 25-75 mm for M10 & M15, and 75 -125 mm
Qty No. of samples
1-5 cum 1 Sample is a set of 3 nos. of 150x150x150mm
6-15 cum 2 cubes , in addition to this 1 sample to be
16-30 cum 3 taken for 7 days strength determination.
31-50cum 5 The compressive strength shall confirm to
the design target strength (table 1700-5 of
4+1 for 50cum MoRT&H) if any individual cube strength if
51 above and part less than the target strength by 3N/sqmm
thereof standard deviation shall be applied.

BS
10 Anchorages 4447/Manufactures’ Every lot
specification
a Tube unit
I. Flange 218x218+/-2mm
1 piece per lot
Total length 248+/-3mm
Hardness 180-220 BHN
a) Wedges-45mm
I. Other diameter 25+/-0.5mm
II. Length 1 piece per lot 45+1mm-0mm
III. Hardness 15N scale 88-93BHN
IV. Case depth 0.25-0.45mm
b) Bearing plate
l. Outer Diameter 150+/-2mm
1 piece per lot
ll. Thickness 50+/-2mm
llI. Hardness 157-203BHN
11 Sheathing Clause 1802.2 of MoRT&H/Manufacturer’s
a) Diameter 75mm
Workability-When a 1100mm
long piece bent to 1800mm
b) No failure/opening
radius on either sides for 3
cycles
Transverse load rating-load at
c) which a deformation less then IRC 18-2000 Every lot Min. 700N
5% is obtained
Tension load-load at which
d) there is no deformation nor Min.1400N
slippage of couplers
Water loss-loss of water at
e) 0.05Mpa pressure maintained Not more than 1.5% by volume
for 5 minutes

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TEST FOR PRESTRESING

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
GEN/01/R&R/R0
Project Client
Consultant Span
Date Start Finish
TESTS DURING PRE-STRESSING WORKS
As per approved
12 Sheath laying, profiling & fixing Each cable 5mm variation in profile
drawings
As per approved
13 Formwork - +50mm/-10mm in dimensions.
drawings
Pre-stressing steel/HT strands
14
class-2 1205 type
Every lot
Nominal dia 12.7+0.66mm/-0.15mm
Breaking strength 183.7KN or 18737kg
0.2% proof load 165.3KN or 16860kg
IS 14268
elongation 3.5% minimum

Relaxation loss not more than 1.8% after

Relaxation
100hrs., 2.5% after 1000hrs.

15 Chemical composition
a) Carbon 0.6% Min.-0.9% Max.
b) Silicon 0.1% Min.-0.35% Max
IS 228
c) Manganese 0.5% Min.-0.9% Max
d) Sulpher 0.05% Max.
e) phosphorous 0.05% Max.
16 Pre-stressing Each cable
Clause 1807 of
I. Preparation of cable Before placing each cable -
MoSRT&H
II. Stressing of cable -
17 Grouting Each cable -
I. W/C ratio Each preparation 0.4
Once at the starting for each The outlet consistency shall be same as that
II. Consistency IRC18-2000
operation of Grout/Cable of inlet

6 cubes from daily mix of 100

III. Compressive strength Min. 17Mpa at 7 days age
mm size

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ANNEXTURE 3

Checklists

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SW/01/R&R/R0

Project Client

Consultant Contractor

Work Length RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR SURVEY WORKS

Checked & Found OK Signature
Sl No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg
Check for Permanent Pillar
1 No.__________, co-ordinates and
reduced level.
Check for Reference pillars co-
2
ordinates
Check for Reference pillars reduced
3
level
Check for co-ordinates with respect
4
to Reference pillar
Check for closing error for position
5
and level

Check for existing ground level

6
survey made and records maintained

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SC/01/R&R/R0

Project Client

Consultant Contractor

Work Length(m) RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR SURFACE PREPARATION-PQC

Checked & Found OK Signature
Sl. NO. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg
Method statement for excavation
1
approved
Excavation plan prepared and
2
approved
Grid pillars made and centre lines
3
marked
Excavation area cleared off bushes,
4
vegetation, trees, etc.
Layout and area of excavation are
5
marked on the ground as per plan
Existing ground level survey made
6
and record maintained
Shoring materials/ dewatering
7 equipment depending upon soil and
depth of excavation arranged
Excavation made upto 150 mm
8 below the required level by
machine/manually
Proper side slopes/offset/ shoring
10
made for proper earth stability
Excavated earth is dumped beyond
11
the width specified from excavation
Bottom layer properly compacted
12
for receiving PCC
Proper side supports made for PCC
13
as per the drawing.

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SC/02/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR CLEARING & GRUBBING

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Trees, shrubs, bushes, stumps,
1 roots, top organic soil and other
rubbish removed and disposed
2 Required excavation carried out
Excavated pits backfilled with
3
suitable material
Compacted the backfill material
4
properly

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
EW/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR BASE PREPARATION

Checked & Found OK Signature
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg
Layout and area are marked on the
1
ground as per plan

2 Vegetation & roots cleared from site

Compaction of the OGL

3 satisfied/L&R required for
Embankment/Subgrade >95%/97%
Compaction after L&R -For
4
embankment/Subgrade- >95%/97%

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SC/02/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR EARTHWORK(1of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Is there any recent change in
1
methodology
Safety steward is Available at Site
2 and all the safety measures for
workmen and traffic is taken
Pep talk is conducted on safety, and
3
quality aspects

4 EMB/SG material source approved

5 Toe line marked and checked

Water sprinkled on SG before GSB

6
placed

7 Whether sufficient labour available

Whether sufficient soil Quantity

8
uniformly dumped
Whether Over size material >75mm
9 for EMB & >50mm for Sub grade
removed

10 Loose thickness checked

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CHECKLIST FOR EARTHWORK(2of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether sample taken for control
11
test of (if required)
Whether pegs Fixed & Marked for
12
levels
Trained supervisor available to give
13
directions to grader

14 Sufficient QTY of water added

Whether available moisture checked

15
and corrected for OMC
Whether Nos. of Rolling pass applied
16
as per Trial Stretch

17 Whether Roller Impression rectified

18 Levels found with in tolerance

Remarks

L&T QA Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
GSB/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish

CHECKLIST FOR GRANULAR SUB-BASE LAYING (1of2)

Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na

1 Sub grade layer is approved

2 Laying area marked

Subgrade surface is free from loose

3
patches
There is no bumping on the subgrade
4
due localised over moisture
Total no. of Trips calculated with
5
respect to the laying area
Necessary information given to
6 Plant/stock yard In Charge for
required Quantity of GSB
Is the required Quantity of GSB
7
material dumped
The GSB material spreaded &
8
moisture content checked

9 Is the the Lab testing data available

Is the moisture content within

10
acceptance ( +1/-2% of OMC )
The quantity of water to be added is
11
calculated & sprinkled on the surface

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CHECKLIST FOR GRANULAR SUB-BASE LAYING (2of2)

Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na
Grading is made to the required
12
slope & camber
Moisture Checked & found within
13
requirement.
Compaction made by using vibratory
14
roller
Density of the compacted layer is
15 checked & found within the specified
limit
Safety precautions taken during
16
construction and in working area

Remarks

L&T QA Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
WMM/01/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish

CHECKLIST FOR WET MIX MACADAM - GRADER(1of2)

Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na

1 Sub grade layer is approved

2 Laying area marked

Subgrade surface is free from loose

3
patches
There is no bumping on the subgrade
4
due localised over moisture
Necessary information given to Plant
5 in Charge for required Quantity of
WMM

6 The necessary peg marking given

Necessary string line fixed & required

7
level marking given
Is the shoulder material laid & ready
8 to be compacted along with WMM
layer
Paving is made to the required slope &
9
camber
Compaction made by using vibratory
10
roller
Is there any segregation observed on
11
the finished surface

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CHECKLIST FOR WET MIX MACADAM - GRADER(2of2)

Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na
Correction action taken as per Method
12
Statement
Levels taken of the surface & found
13 within the required tolerance (Paver
laid: +/- 10mm, Grade laid: +/- 15mm)
Surface regularity checked carried out
14 with a 3 meter straight edge & found
within the required specification
Density of the compacted layer is
15 checked & found within the specified
limit

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
WMM/02/R&R/R0
Project Client
Consultant Contractor
Work Length(m) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish

INSPECTION CHECKLIST WET MIX MACADAM - PAVER(1of2)

Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na
Any recent change mix design and is
1
approved

2 Is any recent change in methodology

Safety steward available at site and

3 all the safety measures for workmen
and traffic taken
Pep talk is conducted on safety, and
4
quality aspects

5 RFI has been raised

6 GSB layer approved

Water sprinkled on GSB before

7
WMM placed
Whether quality monitoring
8 equipment’s (depth gauge, level
instrument, etc.) available at site
Whether pegs & winch fixed for
9
level/reference bean attached
Whether sufficient no. of dumper
10
available

11 Whether sensor Paver is ready

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INSPECTION CHECKLIST WET MIX MACADAM - PAVER(2of2)

Checked & Found OK
Sl NO. DESCRIPTION Remarks/Issues
Yes No Na
If there was segregation reported in
12 last laying, whether the root cause
of the same has been attended

13 Whether Rollers are ready

Whether sufficient numbers of

14
labour available at site
Whether light masts is/are available
15
(in case of night works)
Whether site maintaining trip
16
register with time & quantity
Supervisors deployed to control
cleaning, inspect and rectify surface
17
before compaction and to control
No. of rollers

Remarks

L&T QA Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
DBM/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR DENSE BITUMINIOUS LAYER (1of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether all the safety measures
1
have been taken as per the plan.
Methodology of work available with
2
the Paving-incharge.
Whether the Prime coat is cured and
3
cleaned properly
Is the Tack coat rate of spray
4
checked & recorded
Is the joint trimmed & preapred as
5
per method statement
Whether the program of DBM laying
6 conveyed to Plant and Machinary
and QA/QC incharges.
Whether the thermometers (Upto
0
7 200 C capacity) available at laying
location.

8 The paver sensors are set properly

Whether alignment of paving has

9 been marked with lime powder and
equipments positioned accordingly.

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CHECKLIST FOR DENSE BITUMINIOUS LAYER (2of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

Whether the paver is being placed at

10 the laying area well in advance & the
skeed of the paver is being heated.

Whether DBM mix has been

11 transported to paving location with
the tarpoline covering

Whether the DBM mix temperature

12 0
found above 125 C before spreading

Whether loose thickness has been

13 checked to ensure required
compacted layer thickness.
Whether rolling pattern is followed
14
as established in the trial stretch.
Whether the final rolling temerature
15 with Steel wheel rollers is above
900C
Whether surface level has been
16 checked and found within the
specified tolerance limit.
Wheather Transverse joints prepared
17
as per Mehod statement
Whether sufficient arrangements
18 have been made for protection of
freshly laid DBM course.

Remarks

L&T QA Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
BC/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR BITUMINIOUS COURSE(1of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether all the safety measures
1
have been taken as per the plan.
Methodology of work available with
2
the Paving-incharge.
Whether the Prime coat is cured and
3
cleaned properly
Is the Tack coat rate of spray
4
checked & recorded
Is the joint trimmed & preapred as
5
per method statement
Whether the program of DBM laying
6 conveyed to Plant and Machinary
and QA/QC incharges.
Whether the thermometers (Upto
0
7 200 C capacity) available at laying
location.

8 The paver sensors are set properly

Whether alignment of paving has

9 been marked with lime powder and
equipments positioned accordingly.

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CHECKLIST FOR BITUMINIOUS COURSE(2of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

Whether the paver is being placed at

10 the laying area well in advance & the
skeed of the paver is being heated.

Whether DBM mix has been

11 transported to paving location with
the tarpoline covering

Whether the DBM mix temperature

12 0
found above 125 C before spreading

Whether loose thickness has been

13 checked to ensure required
compacted layer thickness.
Whether rolling pattern is followed
14
as established in the trial stretch.
Whether the final rolling temerature
15 with Steel wheel rollers is above
900C
Whether surface level has been
16 checked and found within the
specified tolerance limit.
Wheather Transverse joints prepared
17
as per Mehod statement
Whether sufficient arrangements
18 have been made for protection of
freshly laid DBM course.

Remarks

L&T QA Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PC-TC/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR PRIME/TACK COAT OVER(BM/DBM/BC/SDBC/DAC)

Checked & Found OK Signature
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg

1 Check for previous layer approved

2 Check for setting out

3 Check for syrface preparation

4 Check for material RS/MS/SS grade

Check for bituminoius emulsion

5
temperature (20-70ᵒC)

6 Check for rate od spread(……Kg/m2)

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
DLC 01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR DRY LEAN CONCRETE

Checked & Found OK Signature
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na Site Engg QA Engg
Check on previous layer cleared for
1
DLC
Check on previous layer cleaning &
2
wetting
3 Check for setting out as per plan
Check for concreat surface levels
4
and thickness of the layer
Check for concreat temp at the
5
placement point <30ᵒC
Concreat deposited within 60 min
6
from Batching plant
Concreat compacted in position
7
within 120 min from batching plant
Rolling and compaction of layers
8
done as approved trail stretch
Check for grade and camber after
9
compaction
Check for layer top level and
10
tolerance level for grids (+/-6mm)
11 Check for curing done properly
Check micro cracking of DLC after 24
12
Hrs to 36 Hrs after compaction
13 Check compaction*

14 Check for surface irrugularities

Remarks

L&T QA/QC Client/IE/PMC

*Min 98% and Min 95% adt 0.5m from the edges of the reference density

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PQC/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR SURFACE PREPARATION-PQC

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether location/Chainage is
1
identified
Are the workers are provided with
2
PTEs & dust masks
Whether level, Surface regularity &
3
field compaction of CTB Top layer
Whether level of DLC top layer surface
4
is found within the specified tolerance.
Whether the Air compressor & brooms
5
are available at the laying location
Whether the curing period of the CTB
6
layer is complete as per specification
7 Is the DLC layer dry
Whether DLC layer is free from dust,
8
foreign materials, surface water or
9 Whether Micro cracking checking done
Whether a mock up session carried out
10
with the operators & other associates
11 The surface protected for 24 Hrs

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PQC/02/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR LAYING-PQC(10f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether location/Chainage is
1
identified
2 Whether center-line marking done
Whether all the drawings relevant to
3
PQC course available with Paving
Whether methodology of work &
4
specification available with the
Whether longitudinal and transverse
5
joint have been cut vertically as per
Whether formwork fixed as per
6
drawings
Whether Dowels/Tie bars fixed as
7
per drawings/specifications
Whether all the safety measures
8
have been taken as per the project
Adequate nos. of equipments and
9
manpower including Plant and
Whether Client and Consultant have
10
been informed
Whether requisition for PQC given to
11
the Production in charge.
Whether the program of PQC laying
12
conveyed to Plant and Machinery

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CHECKLIST FOR LAYING-PQC(20f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether Haul roads and access
13
roads are properly identified for
Whether paving plan has been
14
prepared for PQC laying.
Whether the thermometers available
15
at laying location.
Whether all the additional for
16
working in night shift.
Pegs are properly fixed, sensor wires
17 are stretched to the required length
and secured properly.
Whether PQC mix has been
18 transported to paving location with
the tarpaulin covering
Whether the PQC mix temperature
0
19 found between 15 C and 30C while
spreading
Whether Surface finished/broomed
20
as specified requirement
Whether surface level has been
21
checked and found within the
Whether curing for the laid surface
22
done as per specification
Whether sufficient arrangements
23 have been made for protection of
freshly laid PQC

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PQC/03/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR POST PQC WORKS

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Whether the forms removed as per
1
specified time
Whether curing done on the laid
2
surface for 7 days
Whether Construction joint
3
prepared
Whether the concrete is ready for
4 joint installation after 14 days of
out of which 7 days are drying
Whether joint groove are widened
5
before sealing
Whether the dirt,soil,etc removed
6
from joint
Whether Permanent Joint sealing
7 provided as per drawings
/specification

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
HUM/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR HUME PIPE

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Are working drawings approved for
1
construction
Are the pipes and source of pipe
2
approved

3 Is the setting out for pipe approved

Is the trenching/excavation is
4
according to the specification

5 Is the jointing of pipes appropriate

Is the backfilling approved by the

6
Engineer

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
BOX/01/R&R/R0
Project Client

Consultant Location

Pour no Mix Grade Ref. Drawing No./Rev. No

Theoritical Quantity
Actual Quantity
Date
Start Finish

IN – SITU CONCRETE CHECKLIST & POUR CARD(1of2)

Checked & Found OK
Preperation Remarks/Issues
Yes No Na
a) PCC Top Level
b) PCC Surface cleaned
c) Allignment Checked
d) Centre lines checked
REINFORCEMENT
a) Dia & Shape (as per BBS)
Extra Reinforcement (apart
b)
from drawing)
c) Extra Laps (if any)
d) No. of Chairs & Length
e) Binding as per specification
f) Cover to Reinforcement
FORMWORK
a) Center lines
b) Shuttering line, Level & lump
BEFO c) Demoulding agent applied
RE d) Concrete top level
CON
e) Supports adequate
CREA
TING EMBEDED ITEMS (if any)
a) Bolts
b) Inserts

L&T – ECCD QA/QC Concessionaire/PMC IE

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IN – SITU CONCRETE CHECKLIST & POUR CARD(2of2)

Checked & Found OK
Preperation Remarks/Issues
Yes No Na
a) Date of Concreting
b) Weather
c) Ambient Temperature
d) Mix grade
CON
e) Vibrator & needle
CREA
TING f) Slump
g) Time of concrete start
h) Time of concrete end
i) No. of cubes for sampling
j) Cube identification

L&T – ECCD QA/QC Concessionaire/PMC IE

a) De-shutturing on and at time
b) Surface of the structure
c) Plump within acceptance
POST Repair of surface with respect
CON d) to approved method (if any)
CREA Dimensions are within specified
e)
TING requirement
f) Curing method
g) Curing started on at time
h) Any other observations

CLEARED FOR POUR DATE : TIME :

L&T – ECCD QA/QC Concessionaire/PMC IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
FW/01/R&R/R0
Project Client

Consultant Location

Pour no Mix Grade Ref. Drawing No./Rev. No

Theoritical Quantity
Actual Quantity
Date Start Finish

CHECKLIST FOR FORMWORK INSPECTION(1of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Formwork Design / Drawing / Sketch
1
approved

2 Formwork alignment correct

3 Match Cast / Segment setup checked

Blockouts for Post Tensioning

4
Anchors checked
Joints between panels closed(No
5
gaps)
Box outs, cast-in -items, ducts fixed
6
securely

7 Formwork Clean

Formwork release oil applied

8
properly
Construction/Expansion joint
9
preparation satisfactory

10 Safe access constructed

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CHECKLIST FOR FORMWORK INSPECTION(2of2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Adequate work space provided for
11
labours, equipment

12 Shutter Vibrators

13 Ducts for shear key

14 Ducts for manhole checked

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
CI/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) Type Of Structure

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR CONCRETE INSPECTION

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Method Statement approved

Water, Sand, Coarse Aggregate,
2
Cement, Admixture approved
3 Formwork approved

4 Reinforcement approved
Concreting equipment in working
5
order
Concreting gang present including
6
Carpenter, Steel fixer,..etc
7 Access provided

8 Safety arrangement adequate

Adequate lighting provided (if
9
night shift)
10 Form vibrators

11 Needle vibrators
Plastic sheet for covering the
12
concreted surface of segment

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
RI/02/R&R/R0
Project Client
Consultant Contractor

Work Type Of Structure

Location/Chainages Ref. Drawing No./Rev. No

Span Start Finish

CHECKLIST FOR REINFORCEMENT INSPECTION (10f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Working drawing checked and
1
approved

2 Latest revision being used

3 Bar Bending Schedule approved

4 Reinforcement material approved

Bar-bending and cutting satisfactory

5
as per approved BBS

6 Bar size as per BBS

7 Bar spacing correct as per BBS

8 Bar lap length as per BBS

9 Bar lap at correct locations

10 Bar tied with specified binding wire

Bar assembly rigid and adequately

11 supported (including spacer and
chairs)

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CHECKLIST FOR REINFORCEMENT INSPECTION (20f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

12 Cover to bottom bars correct

13 Cover to side bars correct

14 Cover to top bars correct

15 Cover Block fixed properly

16 Lifting frame checked

17 Reinforcement or OHE Mast checked

Additional reinforcement around

18
shear key hole checked

19 Formwork checklist completed

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SC/01/R&R/R0
Project Client

Consultant Contractor

Work Type Of Structure

Location/Chainages Ref. Drawing No./Rev. No

Span Start Finish

CHECKLIST FOR DECK SLAB CONCRETE(10f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Concerned drawing available

2 Strata/levels found acceptable

3 Mix and its materials approved

4 Formwork/scaffolding approved

Bar bending schedule /

5
Reinforcement approved
Adequate cover blocks/chairs/
6
spacers provided
Adequate approved strip for
7
expansion joint provided

8 Slump found within the range

9 Required cubes cast

Placing/compaction/finishing
10 /workmanship for concrete found
acceptable
Grove cut at expansion joint
11
satisfactory

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CHECKLIST FOR DECK SLAB CONCRETE(20f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

12 Pre-stressing sheathing approved

Required equipment/ lighting/

13
communication provided
Concrete conveying arrangement
14
found acceptable

15 Curing arrangement done

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/01/R&R/R0

Project Client

Consultant Contractor

Work Length (m) RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR PROFILE SHEATING

Distance from Bulk
0 mm 500 mm 1000 mm 1500 mm 2000 mm 2500 mm 3000 mm
head

X
1x1x
Y

X
2x2x
Y

3x3x X

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/02/R&R/R0

Project Client

Consultant Contractor

Work Length(m) RFI No

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECK LIST FOR PRESTRESSING WORK

Checked & Found OK
Sl No. DESCRIPTION Remarks/Issues
Yes No Na
Check for top & side shutters
1
removed
Concrete cubes strength of minimum
2
40N/mm2 available before starting
Check for pre-stressing jack pressure
3 calculations & force to be applied
including losses etc
Check that all strands are cleaned
4 and approved pre-stressing
components
Calibrated jacks and gauges used for
5
stressing.
Pre-stressing operations in sequence
6 of sheathing & stressing sequence as
per drawings.

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/03/R&R/R0

Project Client

Consultant Girder Type

Work Girder Identification No. Cement Brand OPC/53 Grade

Grout Mixing admixture Ref. Drawing No./Rev. No

Grout Start Time Finish Time Cement Batch No.

Theoritical Cement Consumption Actual Consumption

CHECK LIST FOR GROUTING WORK

Checked & Found OK
Sl No. DESCRIPTION Remarks/Issues
Yes No Na

Check for grouting operation started

1
min.24 hours of stressing completed
All the HDPE sheathing duct are
2 cleaned with air, water as per the
requirements through vents
Check for cement grout prepared to
3 a w/c of 0.4 with approved OPC- 53
grade cement and admixture.
HDPE ducts cleaned with grout till
4 the require consistency coming out
from all the vents and then locked
Check for all HDPE ducts are filled
5 with cement grout and build up a
pressure of 5 Kg/cm2 for 1 min

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/04/R&R/R0

Project Client

Consultant Girder Type

Work Span No. Date of inspection

Grout Mixing admixture Ref. Drawing No./Rev. No

Cement Type W/C Ratio

Grout Start Time; Grout Finish Time; Date of Stressing

Date Dia. Of Duct

CHECK LIST FOR GROUTING WORK LIST

Cement
Temp. of Pressure
Cable No. Cable Length Consumed Starting Time Finishing Time
Grouting (˚C) Kg/cm2/Mpa
(Bags/Kgs)

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/05/R&R/R0

Project Client

Consultant Girder Type

Work Date of inspection

Grout Mixing admixture Ref. Drawing No./Rev. No

Cement Type W/C Ratio

Span No. Date of Stressing

Grout Start Time; Grout Finish Time; Dia. Of Duct

CHECK LIST FOR GROUTING 1

Cement
Temp. of Pressure
Cable No. Cable Length Consumed Starting Time Finishing Time
Grouting (˚C) (Kg/cm2/Mpa)
(Bags/Kgs)

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/06/R&R/R0

Project Client

Consultant Contractor

Location Date of inspection

Grout Mixing admixture Date of Grouting

Cement & Grade Type W/C Ratio

Span No. Name Of admixture

Start Time; Finish Time; Temp. of water during mixing

CHECK LIST FOR GROUTING 2

Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na

1 Grout is tested and results obtained

After closing outlet & air vents,

2
grouting pressure
Maintained at 0.5 Mpa for at least 1
3
minute

4 Grouting Observation

5 Passage of grouting through vents

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/07/R&R/R0
Project Spec
Size Density
Start: Finish: Date

PRESTRESSING FORMAT(1of2)
Span No. Date:
Location start time:
Span length: Date of concreting:
NO. of cables(total): Min. cube strength :
Stressing cable No.: Cube strength of stressing:

HT strands details Prestressing jack information

Coil No.: MTC No.: Make & No.

Actual Modules of elasticity of strand: Jack type
Actual cross section ared of strand: Stressing ram area in Sq. cm
Length of strand (anchor to anchor end): Lock off ram area in Sq.cm
Thickness (mm): Designed stressing force (KN) :

Modified elongation = Design elongation* ( Thena. Area 8Theo MOE) / (Act. Area * act. MOE)

Tolerance in Max. +5%

elongation Min. -5%
Modified Pressure = (Stressing force in KN * 1000/9.81) / (Ram Area * jack efficiency)
Tolerance in Max. +5%
pressure Min. -5%
STRESSING CHART

CABLE NO. CABLE NO.

Jack No. : Gauge No. : Jack No : Gauge No :

Pump No. : Cable Type : Pump No : Cable type :
SI NO
Pressure Piston Elongation Cumulative Pressure Piston Cumulative elongation
(Kg/Sq. cm) (mm) (mm) elongation (mm) (Kg/Sq. cm) (mm) (mm)

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PRESTRESSING FORMAT(2of2)
A. zero correction (mm) : A. zero correction (mm) :
B. Gross elongation (mm) : B. Gross elongation (mm) :
C. Less wedge drew in stressing end (mm): C. Less wedge drew in stressing end (mm):
D. Less elongation in jack (grip length) (mm): D. Less elongation in jack (grip length) (mm):
E. Less wedge draw in passive end (mm) : E. Less wedge draw in passive end (mm) :
F. Net elongation F=B – (C+D+E): F. Net elongation F=B – (C+D+E):
G. After 24 Hrs. slip G. After 24 Hrs. slip

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
PST/08/R&R/R0
Project Spec
Size Density
Date ; Start: Finish:

STAGE STRESSING REPORT(20f2)

Date of Casting Const.Strength Achived

Date & Time Length of cable Rmtr

Design Force Design elongation mm

Pressure Gauge No. Actual Area mm2

HST Coil No Design Area mm2

Girder No Modified Pressure Kg/Cm2

Cable No Max(5%) Pressure Kg/Cm3

Jack Type Min(5%) Pressure Kg/Cm4

Jack Ram Area Modified Elongation mm

Jack No Max(5%) Elongation; Min(5%) Elongation; mm

NORTH SIDE SOUTH SIDE
Pressure
Pressure Initial Final Initial Final
Difference Cummulative Gauge Difference( Cummulative
Gauge No. Reading Reading Remarks Reading(m Reading Remarks
(mm) Elongation(mm) No.(KG/Cm mm) Elongation (mm)
(KG/Cm2) (mm) (mm) m) (mm)
2)
('1) ('2) ('3) ('3)-('2) ('1) ('2) ('3) ('3)-('2)

0-50 0-50
50-100 50-100
100-150 100-150
150-200 150-200
200-250 200-250
250-300 250-300
300-350 300-350
350-400 350-400
400-450 400-450
450- 450-

A) Across Elongation = A) Across Elongation =

B) Slip at Stressgin End = B) Slip at Stressgin End =

C) Grip Length Elongation C) Grip Length Elongation

D) Net Elongation (A-B-C) = D) Net Elongation (A-B-C) =

Slip After 24 Hrs =

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SFT/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR SAFETY

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
All workers wearing personal
1
protective equipments
Emergency medical kit and other
2
emergency facilities are provided
All lights are properly covered using
3
insulated wires,wire mesh covering
All hot cutting scraps are quenched
4
and removed properly
Safety officer/Supervisors are on
5
constant duty at site
Proper warning/instruction boards in
6
Hindi and English provided at site
Proper staging done to working
7
platform
Ladder placed at safe angle and
8
secure footing
Electric wires / equipment kept at
9
safe distance
Scaffolding on firm ground&Saftey
10
belt provided to all workers at height
Operators of machinery & cranes are
11
trained and having certificate

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
BFL/01/R&R/R0
Project Client

Consultant Contractor
Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR BACK FILLING

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Drawings, method statements are
1
approved by client
The back filling soil and filter media
2
are approved by client
Filter media laid as per suitable
3
method.
Porus block provided nearby weep
4
hole.
Filter media commenced from below
5
300mm of first weep holes layer
The back filling layers checked and it
6
is ok.
The guardrail fixed and erected as
7
per plan and method statement.
8 The back filling area protected

9 Staff and workmen weared PPE

Safety precautions taken during
10
construction and in working area

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SP/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR STONE PITCHING(1of2)

Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na
Drawings, method statements are
1
approved by client
Pitching Stones are approved by
2
client
The thickness, weight and shape of
3
stone as per drawing
The size of spalls thickness is
4
minimum 25mm to fill the voids

5 Filter material are approved by client

The sides of banks are trimmed to

6
required slope
Uniform slope (1:2) maintained at
7
entire pitching area
Depressions are filled and thoroughly
8
compacted
The filter material laid over the
9
prepared base and it is compacted
The filter material thickness verified
10
and it is ok

11 The toe wall provided

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CHECKLIST FOR STONE PITCHING(2of2)

Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na
The lowest course of pitching started
12
from toe wall
The stone pitching is commenced in
13
a trench below the toe of slope
All process of stone pitching done as
14
per approved method statement

15 Staff and workmen weared PPE

Safety precautions taken during

16
construction and in working area

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
SP/02/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR RIGID APRON & CONICAL PITCHING (1of2)

Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na

1 Excavation made by - JCB/Excavator

IS the balance excavation of 100mm

2
trimmed manually
Is the bed compacted & free from
3
any isolated loose area

4 The level of PCC botton checked

Did the level found acceptable as per

5
drawing
Is the bed requiring any water
6
sprinkling before PCC
The concreat is brought from
7
(………plant name………….)
The required level mark has been
8
given for PCC concreat
Is the stones/concreat blocks
9
available for pitching of required

10 Packign made with spalls

The slope of earth moulding is

11
trimmed to required level & Slop

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CHECKLIST FOR RIGID APRON & CONICAL PITCHING (2of2)

Checked & Found OK
Sl. No DESCRIPTION Remarks/Issues
Yes No Na
The stone/concreat blocks for
12
conical pitching are required

13 Is the pitching well packed

14 Staff and workmen weared PPE

Safety precautions taken during

15
construction and in working area

16 Staff and workmen weared PPE

Safety precautions taken during

17
construction and in working area

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
TS/01/R&R/R0
Project Client

Consultant Contractor

Work Area(Sqm) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR TURFING

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Drawings & method statement are
1
approved by client
The SOD source are approved by
2
client
The SOD length is 50mm and is freed
3
of debris
The sides of bank are trimmed to the
4
required slope
The embankment soil is loosened nd
5
free from stones, sticks and stumps
The SOD bed is moistended to
6
loosened depth
7 The SOD strip is laid edge to edge
After laid od SOD's its is lightly
8
tamped with suitable method
trufing area thoroughly moistended
9
by sprinkling with water after SOD
All process of turfing done as per
10
approved method statement
11 Staff and workmen wear PPE
Safety precautions are taken in
12
working area

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
CB/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR ROAD MARKING

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Drawin & method statement are
1
approved by client
The line and grade of rail are made
2
as per plan
Aligmnent and camber of rail
3
maintained as per plan
Splices and end connections are
4
made as per plan
Holes are dug & backfilled with
5
suitable material
After backfilling the anchor are held
6
securely in place
All post are bolted to the structure
7
as per drawing
Before installation of posts all bolts
8
and clips are checked and OK
The guardrail fixed are erected as
9
per plan and method statement &
Safety precautions are taken in
10
working area

Remarks

L&T AQ/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC RM/01/R&R/R0
Project Client

Consultant Contractor

Work Length(m) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR ROAD MARKING

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Drawin & method statement are
1
approved by client
Thermoplastic paints and glass beads
2
are approved by client
Heater condition and its laying
3
condition is checked and is OK
Thermometer of heater working
4
properly
Thermoplastic material heated to
5
specified temperature
All surfaces are cleaned of dust, dirt,
6
grease and oil
Before the thermoplastic, that
7
marking area are marked by chalk
The laying machine is checked and is
8
OK
Glass beads are applied at the rate
9
of 250gms/sqm
Thermoplastic paint is laid in a
10
molten condition
The thermoplastic thickness is
11
checked

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
TS/01/R&R/R0
Project Client

Consultant Contractor

Work Span(Km) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR TRAFFIC SIGNS(10f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Drawing,method statement are
1
approved by client
All materials approved by client and
2
its suitable
Location of traffic signs are
3
identified
The colour, configurations and size
4
are made as per IRC
Surface to be reflectionised are
5
prepared as per IRC
Aluminium sheets are degreased and
6
cleaned
In rough surface, approved prime
7
used
All fabrication process are checed
8
and found OK
Process of traffic sign installation
9 done as per approved method
statement
Sign post, support materials are
10
tested and checked
Sign post foundation done as per
11
drawing

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CHECKLIST FOR TRAFFIC SIGNS(20f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Sign boards verticality, position and
12
their supports are OK
All adhesive paints are approved for
13
sign boards, posts and support

14 Staff and workmen wear PPE

Safety precautions are taken in

15
working agrea

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC VHP/01/R&R/R0
Project Client
Consultant Contractor
Work Span(Km) RFI No.
Location/Chainages Ref. Drawing No./Rev. No
Date Start Finish

CHECKLIST FOR VERTICAL HUME PIPE CASTING

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na
Drawing,method statement are
1
approved by client
All materials approved by client and
2
its suitable
The reinforcemnt cages are checked
3
and found OK
Cover of reinforcement are checked
4
and OK
Casting mould condition are checked
5
and found OK
Concreat mix Design approved by
6
client
Concreat mixer is checked and its
7
condition is OK
Concreat mix is observed and is
8
found homogenious
Concreat is compacted by approved
9
method
10 Demoulding done by proper method

11 Pipe dimension and surfaces are ok

Safety precautions are taken in
12
working agrea

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
FAB/01/R&R/R0
Project Client

Consultant Material Spec

Type of Work Ref. Drawing No./Rev. No

Material Description Start; Finish;

Method Technique

CHECKLIST FOR MAGNETIC PARTICLE INSPECTION

Sl No. Beam Mark No. OBSERVATION Rectification Area Remarks/Issues

10

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
FAB/02/R&R/R0
Project Spec

Size Density

Type of Source ; Y Ray Penitrameter

Sensitivity Technique

Start: Finish: Format No

CHECKLIST FOR RADIOGRAPHY INSPECTION

Beam Mark
SL NO. No./Identification Location OBSERVATION Rectification Area Remarks/Issues
No.
1

10

Remarks

L&T QA/QC Client/IE

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 LARSEN & TOUBRO LIMITED
INFRASTRUCTURE IC
FAB/03/R&R/R0
Project Client

Type of Work Consultant

192 | P a g e
Ref. Drawing No./Rev. No Start: Finish:

CHECKLIST FOR WELD VISUAL REPORT FOR BEAM

Beam Mark No./
Sl.No Drawing No. Size Type S/F Welder No. OBSERVATION Remarks/Issues
Identification No.

2
3

Remarks

L&T QA/QC Client/IE

For Internal Circulation Only

Standard Operating Procedure - 2013
 Standard Operating Procedure - 2013

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
FAB/04/R&R/R0
Project Client

Item Make Batch No. Expiry Surface Temperature

Remover Dwelling time

Penetrant Ref. Drawing No./Rev. No

Developer Start: Finish:

CHECKLIST FOR DYE PENETRATION TEST REPORT

Sl No. Drawing No. Mark No. Size Welder No. OBSERVATION Remarks/Issues

10

Remarks

L&T QA/QC Client/IE

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LARSEN & TOUBRO LIMITED
INFRASTRUCTURE IC
FAB/05/R&R/R0
Project Client

Ref. Drawing No./Rev. No Report No.

Type of Work Start: Finish:

CHECKLIST FOR FINAL INSPECTION REPORT FOR STRUCTURAL BEAM

Dimension Observation

SL NO. Mark No Out of Quality Remarks/Issues

Total Length Depth Straightness Web-off center Beam & Flange
squareness (+/- ESTL L&T
(+/-3mm) (+/- 3mm) (max 10mm) (+/-4mm) width
5mm)
1
2

11

12

Remarks

L&T QA/QC Client/IE

For Internal Circulation Only

Standard Operating Procedure - 2013
 Standard Operating Procedure - 2013

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
POT/01/R&R/R0
Project Client

Consultant Contractor

Work Span(Km) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR POT/PTFE BEARING(10f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Seating of Bottom Plate

Has the bearing been placed in

a
proper position and level
Is the grouting material sieved
b
through 1.18mm sieve available

c Is mixing arragement checked

Is the pouring arrangement for grout

d
checked
Has the grout evenly spread all
e
around and below the bottom plate

2 Fixing of Top Plate

Is the pier segment properly placed

a over the pier and secured on the
jacks/ crib supports around the pier
Are all the pockets properly cleaned
b
and soaked in water
Is the grouting material sieved
c
through 1.18mm sieve available

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 Standard Operating Procedure - 2013

CHECKLIST FOR POT/PTFE BEARING(20f2)

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

d Is mixing arragement checked

Is the pumping arrangement for

e
grout checked
Has the Epoxy mortar applied all
f
around the top plate set

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2013

LARSEN & TOUBRO LIMITED

INFRASTRUCTURE IC
POT/02/R&R/R0
Project Client

Consultant Contractor

Work Span(Km) RFI No.

Location/Chainages Ref. Drawing No./Rev. No

Date Start Finish

CHECKLIST FOR POT/PTFE BEARING

Checked & Found OK
Sl. No. DESCRIPTION Remarks/Issues
Yes No Na

1 Deatails of manufacturer recorded

Manufacturering process as per

2
approved MORT&h specification
Use of bearing in other projects
3
checked
Report obtained from the clients
4
referred at Sl.No. 2
Has the manufacturer submitted
5
QAP being checked
Material satisfies the test
6
requirement as per QAP
Continuous supply of bearing
7
without any delay
As the agency agreed to furnish a
8
performance bond for 10 years
Authorised representative be
9
available while installation

Remarks

L&T QA/QC Client/IE

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 Standard Operating Procedure - 2013

ANNEXTURE 4

Notes

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 Standard Operating Procedure - 2013

NOTE

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 Standard Operating Procedure - 2013

NOTE

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 Standard Operating Procedure - 2013

NOTE

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 Standard Operating Procedure - 2013

NOTE

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 Standard Operating Procedure - 2013

Published by Roads Runway & Elevated Corridor BU, L & T Construction Ltd. All rights reserved. No part of this publication
may be reproduced or distributed in any form or by any means, without permission of RREC BU, L & T Construction. Ltd

Larsen & Toubro Limited

Transportation Infrastructure I C, Landmark – 5th Floor, Suren Road, Off. Andheri-Kurla Rd.,
Andheri (E), Mumbai - 400 093. Tel : +91-22-6181 7500, Fax : +91-22-6181 7580

203 | P a g e For Internal Circulation Only