Road Construction Approved QAP

Construction of Four lane expressway from start of DSIR zone of

Ahmedabad district to Adhelai village of Bhavnagar district (Ch.
71+060 to Ch. 109+019) section of Ahmedabad- Dholera Greenfield
alignment (NH-751) on EPC mode under Bharatmala pariyojana in
the state of Gujarat (Package-IV)

Table of Contents
1. DEFINITIONS .................................................................................................................... 6
1. 1. Quality System ............................................................................................................... 6
1. 2. Quality Assurance (QA)................................................................................................. 6
1. 3. Authority, Contractor, Authority Engineer .................................................................... 6
1. 4. Quality Assurance Manual ............................................................................................. 6
1. 5. Quality Plan.................................................................................................................... 6
1. 6. Quality Control (QC) ..................................................................................................... 6
1. 7. Quality Audit.................................................................................................................. 6
2. OBJECTIVE ........................................................................................................................ 7
3. SCOPE AND APPLICATIONS......................................................................................... 7
4. ORGANIZATION............................................................................................................... 9
5. DUTIES AND RESPONSIBILITIES .............................................................................. 10
6. SITE INSPECTION & DAILY REPORTS .................................................................... 15
6. 1. Site Inspections ............................................................................................................ 15
6. 2. Daily / Weekly Reports ................................................................................................ 15
6. 3. Borrow Area Inspection ............................................................................................... 15
7. PROGRESS CONTROL .................................................................................................. 16
7. 1. Construction Work Program ........................................................................................ 16
7. 2. Progress Control ........................................................................................................... 16
8. DESIGN QUALITY PLAN .............................................................................................. 17
8. 1. Design Control ............................................................................................................. 17
8. 2. Control of Design Changes .......................................................................................... 18
8. 3. As-Built Drawings ....................................................................................................... 19
9. PROJECT DOCUMENTATION .................................................................................... 20
9. 1. Document Control Procedure....................................................................................... 20
10. QUALITY CONTROL ..................................................................................................... 22
10. 1. Quality Control Flow Chart.................................................................................. 23
10. 2. Performance of Quality Control ........................................................................... 23
10.2.1. Testing Facilities ........................................................................................... 23
Quality Assurance Plan & Design Quality Plan 2



10.2.2. Test Specifications ........................................................................................ 24

10.2.3. Testing Frequency ......................................................................................... 24
10.2.4. Method Control ............................................................................................. 24
10.2.5. End-result Control ......................................................................................... 25
10.2.6. Quality Parameters ........................................................................................ 25
10.2.7. Reporting of Test Results.............................................................................. 25
10.2.8. Interpretation of Test Results ........................................................................ 25
10.2.9. Statistical Quality Control............................................................................. 25
10.2.10. Monitoring of Quality Control ...................................................................... 26
10. 3. Approval of Quarries and Borrow Areas ............................................................. 27
10. 4. Approval of Materials .......................................................................................... 29
10.4.1. Approval of Natural Materials ...................................................................... 29
10.4.2. Approval of Processed Materials .................................................................. 30
10.4.3. Approval of Manufactured Materials............................................................ 30
10.4.4. Approval of Designed Materials ................................................................... 30
10.4.5. Reporting and Recording Material Approvals .............................................. 31
10.4.6. Procurement, Handling and Storage of Material: ......................................... 31
10.4.7. Disposal Area for Excavated Material .......................................................... 33
10. 5. Sampling of Materials .......................................................................................... 33
10.5.1. Sampling Requirements ................................................................................ 33
10.5.2. Sampling Guidelines ..................................................................................... 34
10.5.3. Preparation and Storage of Samples ............................................................. 34
10. 6. Field Testing Laboratory ...................................................................................... 34
10. 7. Acceptance Testing .............................................................................................. 35
10.7.1. General .......................................................................................................... 35
10.7.2. Routine Acceptance Tests ............................................................................. 35
10.7.3. Special Acceptance Tests .............................................................................. 35
10.7.4. Quality Control Test Statement (Monthly Progress Report) ........................ 36
10. 8. Reporting of the Test Results ............................................................................... 36
10.8.1. Quality Test Inspections ............................................................................... 36
11. GUIDELINES FOR NON-CONFORMING WORKS .................................................. 37
11. 1. General ................................................................................................................. 37
11. 2. Concrete / Bituminous Works .............................................................................. 37
11.2.1. Non-conformance Other than Strength or Finish.......................................... 37
11.2.2. Non-conformance with Strength Requirements............................................ 37
11.2.3. Non-conformance with Finish Requirements ............................................... 38
12. INTERNAL QUALITY AUDIT ...................................................................................... 39



12. 1. Internal Quality Audit Procedure ......................................................................... 39

13. PROJECT COMPLETION ............................................................................................. 40
13. 1. General ................................................................................................................. 40
13. 2. As-built Drawings ................................................................................................ 40
13. 3. Final Completion Report ...................................................................................... 40
14. LIST OF TABLES ............................................................................................................ 40
14. 1. List of Equipment at Site testing Laboratory: ...................................................... 40
14. 2. List of Materials Tested on Site: .......................................................................... 41
14. 3. List of Materials to be certified by Manufacturer’s Certificate ........................... 41
15. MEASURING AND TESTING EQUIPMENT .............................................................. 42
16. Protection during Construction Stage ............................................................................. 43
17. QA Procedure for Setting out Works and Temporary Works ..................................... 43
List of Attachments:
Annexure Name of Document No.

Appendix I Quality Tests Inspections 2
A List of Laboratory Equipment’s 1
B Formats for Check Lists 5
C QA-QC Testing Formats 42
D Plant Calibration Formats 4
E Surveillance Formats 5
F Register / Record Formats 13
G RFI Format 2
H NCR Format 1
I Monthly Progress Report Format 1



List of Abbreviations
AE Authority Engineer
American Association of State Highway and Transportation
AASHTO
Officials
ASTM American Society for Testing and Materials
BIS Bureau of Indian Standards
BOQ Bill of Quantities
BS British Standards
CA Contract Agreement
CPWD Central Public Works Department
DPM Deputy Project Manager
GTS Great Trigonometrical Station
IRC Indian Road Congress
DRAIPL Dineshchandra R Agrawal Infracom Pvt. Ltd.
MKCIL MKC Infrastructure Limited
MORTH Ministry of Road Transport and Highways
NBC National Building Code
NCR Non-Conformance Report
NHAI National Highway Authority of India
OGL Original Ground Level
PM Project Manager
QA Quality Assurance
QC Quality Control
QAM Quality Assurance Manual
QAP Quality Assurance Plan
QMS Quality Management System
RFI Request for Inspection



Quality Assurance Plan

1. DEFINITIONS
The following definitions for terms stipulated in ISO 8402-1994 shall be applied:
1. 1. Quality System
The Quality System is defined as the organization structure, responsibilities, procedures,
processes and resources needed for implementing quality management.
1. 2. Quality Assurance (QA)

Quality Assurance is defined as all the planned and systematic activities implemented within
the Quality System and demonstrated as needed to provide adequate confidence that an entity
will fulfil the requirements for quality.
1. 3. Authority, Contractor, Authority Engineer
Client / Authority National Highway Authority of India

Authority Engineer (AE) GDRPL – VSPL (JV)
Contractor DRAIPL - MKCIL (JV)
1. 4. Quality Assurance Manual

Quality Assurance Manual (QAM) is a base document outlining policy, procedures,
responsibilities, compliance, acceptance criteria and documentation needed for the successful
implementation of a project.
1. 5. Quality Plan
A document setting out the specific quality practices, resources and sequence of activities
relevant to a particular product, project or contract.
1. 6. Quality Control (QC)

Quality Control is the operational techniques and activities that are used to fulfil requirements
for quality. All those planned and systematic actions are necessary to provide confidence that a
product or service will satisfy the given requirements for quality.
1. 7. Quality Audit
A systematic and an independent examination to determine whether quality activities and
related results comply with planned arrangements that have been implemented effectively.



2. OBJECTIVE
The objectives of the QAP are as follows:
1. Understanding the project requirements / features in totality.
2. Assessing the impact of environment on quality.
3. Developing quality systems to ensure that the process and product fulfil quality
requirements consistently.
4. Assignment of responsibilities with absolute clarity.
5. Establishing methods for meaningful evaluation.
6. Establishing documentation processes and systems to minute details.
Figure 1- Structure of Quality Management System
3. SCOPE AND APPLICATIONS

The present QAP is developed for use by the Contractor, for execution of works, as based on
provisions of the Contract Agreement (CA). The scope of the QAP related to construction
activities are:
1. Organisation structure of Contractor’s project implementation team including

assignment of duties and responsibilities and internal chain of command.
2. Operational skills and training of workforce.
3. Performance standards of machinery.



4. Laboratory infrastructure, equipment and personnel.

5. Calibration of equipment.
6. Document control
7. Methodology of working, test and inspection plan.
8. Control of materials including source selection.
9. Control of workmanship.
10. Plan for acceptance, non-conformities, correction and rejection.
11. Plan for adherence to safety, health and environmental consideration.



4. ORGANIZATION
Project In-charge (Project Manager) will be Authorized Representative of the Contractor at the
project site. He will be assisted with a team of the key professionals to monitor and implement
the project in accordance with scope and standards set forth in the CA.
Authority Authority
Engineer
EPC Contractor
Head Office Site
Client Design QS
Director
Business F&A
Development
Execution Admin
Engineering
Survey
HR
Quality
Quality
Project
Operation Highway
HSTE Structure
Finance HSTE
HR Plant &
Machinery
Figure 2- Organization Setup of the Project



5. DUTIES AND RESPONSIBILITIES

Duties and responsibilities for carrying out inspections and witnessing tests are defined in each
procedure. Detailed responsibilities of the key professionals of the project team have been
detailed as hereunder:
Position Reporting / Responsibilities
Design Director Shall be stationed at Head Office
responsible for the Contractor’s Design unit
Shall also be responsible to organize and execution of survey,
investigations, collection of data.
Preparation of preliminary and detailed design of project highway
and structures.
Shall visit the project site and co‐ordinate with the Proof Consultant,
Safety Consultant and AE’s representative to get the design and
drawings approved.
Proof Consultant The Contractor shall identity a Proof Consultant as per the provisions
of CA and get it approved by the Authority.
Evolve a systems approach with the Design Director so as to minimise
the time required for final designs and construction drawings.
Proof checking the detailed calculations, drawings and designs, which
have been approved by the Design Director.
Safety Consultant The Contractor shall identity a Safety Consultant as per the provisions
of CA and get it approved by the Authority.
Shall be responsible for safety audit of all such design details that
have a bearing on safety of Users as well as pedestrians and animals
involved in or associated with accidents.
 The recommendations of the Safety Consultant shall be incorporated
in the design of the project.
Project Manager Represent Contractor to Authority / AE at project level.
Co‐ordination with Authority, Local Administration, AE and other
liaising with other department as per requirement of project.
Administers the CA till completion of the Construction‐ conforms to
the quality, time schedule and all other CA requirements.
Approves purchases requisitions and ensures delivery schedules.
Make all correspondence to Authority and AE.
Ensure compliance to all provision’s quality and safety requirement
of all operations under the CA.
Responsible for providing trained personnel for specialized activities.
Monitors progress with respect to planning, reports to Authority / AE



on progress, quality and any constraints.
Conducts daily / weekly site meeting with key professionals.
Deputy Project Manager Update / report to PM regarding progress, quality and any constraint
(DPM) (Highway/Structure) on project highway.
Prepare daily plans of work from every weekly/monthly plans.
Monitor and ensure to execute the work as per planning and quality.
Checks all works done by sub‐ordinates / site staff.
Organizes manpower, materials, and equipment’s to achieve plans.
Co‐ordinates with other agencies when required.
Ensures safety in the works place as per project safety plan.
Inculcates good housekeeping practices.
Prepares S/C bills in time and submits to the billing Engineer.
Affords all facilities to quality audit.
Reports any errors to PM endeavours to improve
Conducts daily / weekly site meeting with staff.
Manager Reports / update to the PM.
(Planning/Billing/Contracts) Preparation, updating and revision of the construction program
schedules, preparation of daily progress report, weekly progress
report and monthly progress report for submission to Authority and
Management.
Check short‐term work programs from section In‐charge / Engineers
to match with overall program requirements and backlog coverage.
Initiate bulk material, work order/purchase order after reviewing the
site requirements.
Process inquiry, analysis of rates, negotiates with prospective S/C
recommends S/C or supplier agencies for approval by authorized
personnel (Management).
Preparation of cross sections and quantities of earth works, cut and
fills.
Training to junior staff or preparation of cross section and quantities
of earth works, cut and fills and liaison with the AE for approval of the
cross sections.
Prepares schedules at monthly and weekly intervals.
Monitor the construction activities according to work program.
Support PM for all contractual matters related to CA.
Controls receipt / issuance of all RFI, drawings, correspondences and
any other communication from the site office.
Prepares monthly progress report to AE and Authority.
Responsible for resource planning.



Manager Quality Control Shall be responsible for all QA, QC and acceptance requirements of
the project and will directly report to PM.
He will regularly supervise the activities of QC Engineer / Assistant.
He will provide all necessary assistance to the construction team with
reference to acceptance of all raw, manufactured, mixed materials
used in the project.
Preparation of QAP.
Providing inputs to PM for preparation of work methodology.
Setting up of field laboratories.
Calibration of equipment’s.
Preparation of JMF for flexible pavement and concrete mix design.
To maintain an effective documentation system for QA/QC
throughout the project.
To monitor and coordinate quality activities on site.
Ensure that tests are carried out as per relevant IS / applicable
international code of practice.
Maintain test records for all the construction material used in the
project.
To verify the system for reporting and disposing non‐conformance
and corrective action requests.
Have final say about acceptance of a material / work.
To perform internal quality audits on site in accordance with
applicable procedures.
Advising on, planning and organizing inspections, maintenance and
repairs.
Liaising with suppliers, customers and manufacturing / staff.
Manager Survey Reports to the DPM and PM.
Responsible for all the survey activities and correct the setting out of
the all components of the project.
Responsible for day survey activities and maintain records.
Review for the apparent discrepancies in dimensions and levels of
drawings provided by the design team.
Establishment of temporary benchmarks, centreline, reference and
traverse stations.
Taking of OGL and prepare cross sections longitudinal sections etc.
Provided Engineering input to the sections.
Setting out for junctions, structures, Kerb, Drain etc.
Understands client’s requirements, prepares Project Survey Plan and
Survey Scheme (sketches).



Locates GTS, Benchmarks, etc. in consultation with the Section
Engineers responsible. Constructs such survey features through the
Section Engineer.
Provides survey assistance for sections.
Ensures calibration of all measuring equipment to be used in survey.
Manager (Administration / Report to PM.
Liaoning / Documentation) Support Contract Project Management Team for all logistics to
ensure the smooth functioning of the Project.

Liaise with all local bodies and ensure administrative support to PM.
(e.g. Land Acquisition, Tree Cutting, Utility Shifting Communication,
Transport, etc.)
Ensure proper documentation for all project related correspondence.
Provide all logistics for project review meetings and workshop at
project site.
Senior Engineer Reports to the DPM.
(Highways / Structural) Prepares daily plans of work from agreed weekly / monthly plans.
Organize manpower, materials, and equipment to achieve plans.

Compiles to all procedures, drawings while execution.
Checks all work done by subordinates on regular basis especially
lines, levels, etc.
Maintains check records applicable to each activity.
Co‐ordinates with other agencies when required.
Ensures safety in the work place.
Affords all facilities to quality audits.
Quality Control Engineer Assisting QC Manager in setting up the field laboratories.
Day to day supervision of works of lab technicians.

Ensuring proper calibration of all laboratory equipment’s.
Preparation of JMF for flexible pavement and concrete mix design.
Conducting laboratory and field tests on random basis.
Calculation of test results from test observations carried out by lab
technician, analysis and interpretation of the test results.
Maintaining respective test records.
Selection of borrow areas.
Periodical checking of calibration of WMM plant, Hot mix plant,
Batching plants.
Preparation of summary test results for monthly progress report
(MPR).
Lab Technician Shall report to QA/QC Engineer
Shall be responsible for sample collection, testing and involve in QC



activities and sub‐contractor’s QC activities, implementation of
QA/QCM/ Quality Plan.
Shall be responsible for carrying out Inspection as per specification
HSTE In charge Implementation of Occupational Health, Safety, Traffic and
Environment management System (PSMP &PEMP) at project site.
Prepare project specific HIRAC and Aspect Impact assessment.
Carryout hazard identification and risk assessment of all activities and
recommend required control measures.
Prepare project specific ROR which is reviewed by IMS‐HO and
getting approval from Project Head and ensure the compliance.
Ensuring that all HSTE measures and applicable Legal issues for the
project are complied with throughout the duration of the contract
including implementation of revisions.
Reporting to Head‐HSTE & Head‐IMS (HO) on HSTE and Legal issue as
per procedures & guidelines.
Maintaining relevant records on HSTE and Legal issue as per
procedure.
Ensuring that all personnel engaged at the project receive induction
training, prior to issue of their access control passes and or allowed
for their respective job allocation.
Interact with Client / Consultants regarding all HSTE and Legal issues
pertaining to project
Coordinate with store and procurement team to plan and procure for
HSTE gadgets / PPE’s etc.
Advise the project management and line management in planning
and organizing measures necessary for establishing safe work
environment towards preventing accidents.
Investigation of incidents including Lost Time Accidents, fatal
accidents, dangerous occurrences, near misses and occupational
diseases and taking remedial measures and furnishing reports to IMS
Head on the above
 Provide training on HSTE related subjects to all in association with
concerned departments.
 Ensure Constitution of site HSTE committee, and carrying out
periodical (fortnightly / monthly) walk down by HSTE committee to
identify critical areas of deficiency and take necessary corrective
preventive actions. Ensure discussions on safety in the HSTE
committee meeting and define action plan.
 Conducting Audit & Inspection of Plant & equipment and Fire



fighting & Safety Appliances / Equipment Tools & Scaffolding etc. to
suggest corrective measures for safe operation.
Prepare monthly Project safety performance indicator based on the
scores given by the HSTE committee / team.
Ensure the effective monitoring & control measures of the
environment as per Environment management plan by engaging
external monitoring agencies.
Plan & conduct internal audit / Inspection at site.
Raising of Non‐Conformities on Safety & Environmental issues.
6. SITE INSPECTION & DAILY REPORTS
6.1 Site Inspections

To ensure the Contractor’s strict Contract compliance, it is mandatory that all personnel
charged with inspection responsibilities properly prepare themselves in advance through
detailed study and understanding of the Quality Plans and Technical Specifications.
The DPM will co-ordinate all construction activities of the project related to their respective
section. The Contractor’s engineers shall submit the RFI form to the AE with a request to
proceed with the inspection as per the provisions of CA. It is their responsibility to follow up /
complete the action on these RFI’s. A sample of the RFI is given in Annexure G.
AE and Contractor’s Representatives are authorized to inspect all works under execution and
materials furnished. Such inspection will extend to all parts of the works related to the project,
and to the preparation, fabrication or manufacture of the materials to be used. The Contractor is
not authorized to alter or waive any provision of the CA or standard documents.
The Contractor is responsible for keeping AE / Authority informed about the work progress
and the manner in which it is being done, and also to call the attention to any non-compliance
with the drawings or specifications.
6.2 Daily / Weekly Reports

A daily report will be completed by each Project Engineer of Contractor. These daily reports
will be reviewed and compiled by the PM.
The daily report from the PM must include but not be limited to the following items:
1. Quantities of work performed and accepted under his inspection.



2. Site instructions.
3. Unusual or unsatisfactory conditions.
4. Delays encountered.
5. Number of men or man-hours employed.
6. Equipment, Plant, methods used by the Contractor
7. Tests performed to satisfy quality control keeping in view the frequency of sampling as
laid down.
8. Weather conditions and effect on the works
9. Day-work records, if any.
6.3 Borrow Area Inspection
1. The contractor shall submit the inspection plan for borrow areas before
commencement of work.
7. PROGRESS CONTROL
This section outlines requirements and procedures for construction scheduling and control of
work progress.
7.1 Construction Work Program

The Contractor is required to submit a detailed work program for execution of the works as per
the QMS Process. This program must show the following, as a minimum:
1. Itemized work activities to be executed, based on the Contract’s BOQ, indicating start
and finish dates and scheduled achievement (progress).
2. Sequencing of work and activity interdependence.
3. Calendar dates for achievement of various milestones, and for completion of works by
section and of the project as a whole, within the time periods provided for in the
Contract.
7.2 Progress Control

1. The Contractor is required to undertake its activities in accordance with the approved
work program. Each month the contractor shall indicate the actual work completed as
compared to work scheduled in the QMS Process (Project Monitoring Process). In the
event portions of the work are in danger of being delayed, or actually are delayed, the
contractor is to determine a plan for remedial action.
2. Various circumstances may justify the changing of contract requirements for

completion of the project on a specific date. Among these circumstances the items not
within the control of the Contractor, such as: changes to contract requirements



(modification of Contract); suspensions of work; delays in providing access; force

majeure, etc. Generally, such occurrences will justify a delay in completion if they
affect activities on the critical path of the program. However, each instance must be
carefully evaluated and fully documented before a decision can be made.
3. The following are guidelines for controlling work progress:
a. Unauthorized changes to completion milestones should not be allowed, unless
authorized by a Contract modification.
b. Contractor shall monitor the progress of the work and should update their
completion percentages and report to AE / Authority through MPR.
c. When actual progress falls behind scheduled progress or when it appears that a
milestone will not be completed on time, the Contractor must identify the
reasons for delay. The Contractor should make recommendations for remedial
actions.
d. The Contractor should maintain accurate as-built information for scheduled
activities. Actual start and completion should be written on a copy of the
schedule to provide information for an 'as-built' schedule.
8. DESIGN QUALITY PLAN

The Contractor shall appoint a Design Director for the preparation of detailed designs and
drawings. The Design Director shall submit the designs and drawings to the Proof Consultant
and the Safety Consultant for review. After incorporation of the observations of Proof & Safety
Consultant (in any) and approved by Proof & Safety Consultant the design drawings shall be
forwarded to AE for their review and concurrence.
8.2 Design Control

This section of the Quality Plan outlines the requirements for the control and management of
the designs which are prepared by the Design Director:
1. All designs and drawings, including design calculations, shall be prepared by the
Design Director, based on the requirements of the CA and in accordance with
applicable design standards and criteria, codes, and methodology. The drawings shall
basically show details of the works and, where applicable, their sequence of
construction.
2. Prior to carry out any designs, the Contractor and the Design Director shall arrange to
conduct / procure all the survey and site data such as pavement evaluation, topography,
geotechnical survey etc. Data provided by the Authority as part of the Tender
Documents shall be verified through confirmatory survey and investigations.



3. The Design Director shall also prepare a design brief listing out all the design criteria to
be adopted for the designs of the works. This design brief shall then form the basis of
all designs and drawings of the works.
4. Drawings shall generally be prepared by computer aided design methods/applications.
5. The flow of design documents shall generally be as follows:-
a. The Design Director shall prepare all designs and documents and have them
internally checked as per their own design quality control plan. All designs and
drawings shall be signed and dated by the Design Director’s, draftsman, designer
and the design checker.
b. These documents shall then be submitted to the Proof & Safety Consultant for
review and then submitted to AE/Authority. The proof consultant / AE Design
review team shall check the drawings and calculations for completeness,
correctness, legibility and conformance to the contractual requirements.
c. Regular meetings shall be arranged between the Authority’s Representative and
Design Director in order to expedite the process of review and concurrence of the
designs and drawings.
6. The AE / Authority shall signify “no comment” or “comments made” or “resubmit” and
return one copy of the designs and drawings to the Contractor.
7. The notes “no comment” or “comments made” will enable the Contractor to proceed
with the construction of the relevant works. The Contractor shall issue these drawings
to the sub-contractor for construction.
8. Where the designs and drawings are marked “resubmit”, then such documents shall be
amended, modified or prepared again and resubmitted to the AE again after proof
checking. The process as mentioned above shall be repeated until the AE / Authority
signifies “no comment” or “comments made” on these documents.
9. The Contractor shall maintain a detailed register of all designs and drawings and the
status of their submissions and review by the AE/Authority.
8.3 Control of Design Changes

This section of the Quality Plan outlines the requirements for the control and management of
the designs changes as per QMS process- Design Change Management Process.
1. The Contractor may initiate design changes due to site conditions being different from
that envisaged during preparation of the initial designs, or for other reasons. The AE /
Authority may also order changes as provided for under the provisions of the CA. The
Contractor shall provide Design Director with all the necessary instructions and site
information, and the Design Director shall prepare the design changes, together with the
design change report, where applicable.



2. The process for submission, checking and concurrence the design changes by the
Design Director, Proof & Safety Checker and the AE / Authority’s Representative
shall be the same as set out for designs and drawings under items as above. The
Contractor shall keep the sub-contractors informed of any imminent design changes and
shall issue the revised drawings to the sub-contractor for construction soon after the
drawings are concurred by the AE / Authority. The Contractor shall update the design
and drawing register for the design changes made.
The flow of documents for review and approval of working drawings shall be as follows:
1. The Contractor shall submit 5 sets of working drawings to AE /Authority for approval
after proof checking.
2. The AE/Authority shall review the drawings and comments. The AE returns the
working drawings with their comments within the stipulated time mentioned in
agreement, using working drawings marked (or stamped) ‘Concurred’ or ‘Not
Concurred’.
3. The design documents marked Not Concurred, step 1 and step 2 above shall be repeated
4. The working drawing details are to be recorded in the Design/Drawing Register.
5. Then AE/Authority issues GFC drawings to Contractor at site for construction.
8.4 As-Built Drawings

1. The Contractor is responsible for the preparation of ‘as-built’ drawings. During the
progress of work, the EPC Contractor must maintain a complete set of ‘working
drawings’ marked up with the as-built details. The as-built set must be maintained up to
date, since often during construction as-built details may be required by others to
enable completion of design or redesign of a certain contract feature.
2. Upon receipt of any revised drawing, it should be checked to see if the as-built details
have been incorporated in the revision. If they have not, these details must be
transferred onto the revised drawings, which, in turn, will then be substituted, into the
as-built set.
3. During the progress of work, the Project Director (Authority) must observe closely the
‘as-constructed’ work and must also maintain a complete set of contract documents
marked up with the as-built details that he observes.
4. Upon completion of the works, the AE/Authority shall finalize the as-built drawings.
The AE shall approve these drawings and resolve with the Contractor any discrepancies
between the set of as-built drawings submitted in two hard copies and his own records.



9. PROJECT DOCUMENTATION
9.2 Document Control Procedure

All documentation prepared for the project would be identified and controlled in a manner that
will enable easy identification and retrieval of the document when required; similarly, any
revisions or changes to documents would be controlled to ensure that only the latest issue is in
use.
The following major documents identified for the project will be controlled by procedure as
below:
S.
Document Action Record Responsibility
No.
Put date stamp & distribution
Incoming register
Incoming stamp & put to PM & HO, Personal
1 with action taken
Letters after review of PM distributes Secretary
column
to concern & file original.
Action to Outgoing register PM/ Planning
2 Letters Reply, distribution, file with filling numbers Engineer to keep
(outgoing) column in allotted files
Date stamp, distribute to Update drawing
New drawing Planning
3 section & withdraw old register as per
receipt Engineer
drawing format
Planning
4 Old drawings Stamps Superseded Old drawing file
Engineer
List of records Department
Maintain master list Planning
5 Record control wise and take sign of
in file Engineer
concerned
Material Test Material
6 Review by Material Engineer Test record files
Report Engineer
Planning /
Running Bills
7 Submission copy to HO Bills Billing In-charge
to Authority
to maintain file
Document
generated by
Respective
8 section i.e. Review by PM, file Documents in files
section head
work,
procedures etc.
Monthly Planning &
9 Submission to client Report month wise
reports & Billing Engineer



photograph of
progress
Planning
10 MOM Prepare agenda & participate MOM file
Engineer
Codes,
Standards&
Material
Specifications Master list of
List requirements and mobilize Engineer /
11 (IRC, codes/standards as
at site Planning
MORTH, IS, controlled copies
Engineer
ASTM,
AASHTO)
Contract execution generates technical as well as non-technical documents. Documentation

control that will be followed for this project is explained by means of flow chart below and
notes explaining the procedure:
Incoming Documents Outgoing Documents
PM office Received copy, Records, Dispatch Outgoing
PM assigns action to PM Review of Action to Planning Engineer Filling,

Sections/Action by Self Documents Supersede, Reissuing,
Archiving, Shredding
Action by Sections
Figure 3- Flow chart for Documentation
1. PM office shall receive, acknowledge, record incoming documents.

2. PM shall assign actions to departments/self.
3. Actions by departments shall be reviewed by PM.
4. PM shall decide actions like file, supersede, reissuing, archiving, shredding and shall
instruct to planning engineer.
5. Documents going out shall be signed by PM.
6. PM office shall record outgoing mail/documents.
7. Arrows indicate direction of processing.



10. QUALITY CONTROL

The PM will be responsible to ensure the compliance of all quality parameters specified in the
CA. He will also be responsible to obtain the reviews from the AE as required in CA and
provide updated QC report to AE / Authority as & when required.



10.2 Quality Control Flow Chart

One of the most important tasks of the supervision during the execution of a road contract is
technical quality control, i.e., control as to whether the materials and work supplied by the
Contractor meet the technical requirements in the CA specifications.
10.3 Performance of Quality Control

10.3.1 Testing Facilities
Before the initiation of the earthwork, asphalt paving, concrete works etc., by the Contractor,
the corresponding facilities must be available:
1. Laboratories must be built and equipped.

2. Laboratory equipment must be procured and calibrated.
3. Test forms must be prepared.
4. Laboratory technicians must be employed and trained.
A list of minimum equipment needed for the site laboratory is enclosed as Annexure A. The
Contractor shall also get the tests carried out in NABL recognized testing laboratories for tests
of a special nature not covered by the equipment indicated in Annexure A as and when
required. The testing equipment must be regularly serviced as recommended by the suppliers.
A calibration chart must be available for each equipment.



10.3.2 Test Specifications

As per the provisions of the CA as set forth in Annexure l of Schedule D all materials, works
and construction operations shall conform to the Manual of Specifications and Standards for
Expressways (IRC SP: 99- 2013) published by Indian Roads Congress in November, 2013
referred to as the “Manual” and Indian Road Congress (IRC) Codes and Standards and
MORTH Specifications for Road and Bridge Works which shall include policy circulars;
guidelines; manuals and special publications issued in respect thereof by IRC or MORTH as
the case may be, from time to time and shall incorporate all amendments and / or modifications
to such codes and standards which are available to public 60 days before the Bid due date
unless otherwise specified in the Schedule.
Where the aforesaid Manuals, guidelines, codes, standards and specifications are silent on any
aspect; the following standards in order of preference shall be adopted in consultation with the
AE; unless otherwise specified in the CA.
1. Guidelines for Expressways, Part- 1 & 2, published by IRC on behalf of Ministry of
Road Transport and Highways (MORTH) in April 2010 referred to as the “Guidelines”
2. Bureau of Indian Standards (BIS)
3. American Association of State Highway and transport Officials (AASHTO)
4. American Society for testing Materials (ASTM)
5. Euro Codes
6. Suitable specifications / standards revised by the NHAI.
7. Good Industry Practice shall be adapted to the satisfaction of the AE.
All items of building works shall conform to Central Public Works Department (CPWD)
Specifications for Class 1 building works and standards given in the National Building Code
(NBC). If some specific provisions for building works are provided in IRC / MORTH
specifications; the same shall prevail over the CPWD/NBC provisions. For this purpose;
building works shall be deemed to include road furniture; fencing; roadside facilities;
landscape elements; toll plaza and any other works incidental to the building works.
10.3.3 Testing Frequency
The testing frequency shall be as per the criteria set forth in Clause 900 of MORTH
specifications.
10.3.4 Method Control
Method control is carried out according to the type of work. Where the work method is of
considerable importance and requires constant supervision to achieve the quality, or where in
some case, the quality is difficult to improve upon; there shall always be a Quality Control
Engineer on the site.



10.3.5 End-result Control

The frequency of end-result control depends on the quality parameters that are to be checked.
Parameters which can vary considerably shall be continuously controlled for ex. composition
of asphalt materials, the compaction of asphalt courses etc. As regards regular laboratory tests
as per the specification shall be performed. When the work has been started and in cases where
difficulties as regards compliance with quality requirements are encountered, laboratory testing
will normally be intensified.
10.3.6 Quality Parameters
Quality parameters which are usually more or less constant, e.g., the Los Angeles strength of
stone materials from the same quarry, are only controlled occasionally. The same applies to
parameters which can be checked fairly well with the naked eye, e.g., the particle form of
crushed stone. As regards the quality of manufactured materials produced by using advanced
technology, e.g., steel and bitumen, one usually trusts the manufacturer’s certificates, but when
in doubt additional tests can be carried out from approved NABL Lab as directed by
AE/Client.
10.3.7 Reporting of Test Results
The test results shall be recorded systematically in prescribed formats, which shall be signed by
the QC Manager / QC Engineer and the representative of the AE / Authority present during the
tests. The format for daily tests on highway works is given in Annexure C.
10.3.8 Interpretation of Test Results
The test results should be plotted on a graph sheet showing the dates / sample numbers on the
x-axis and the test values on the y-axis. The statistical “warning limits” and “action limits”
should be indicated on these graphs. When any test result falls outside the “warning limits”, the
cause should be investigated and suitable corrective action shall be taken thereafter. When any
test result falls outside the “action limits”, the process should be stopped, and a thorough
investigation shall be made into the entire process, and the cause for faulty performance shall
be determined. Suitable remedial action shall be immediately taken and the process shall be
brought under control.
10.3.9 Statistical Quality Control
Quality control based individual tests do not ensure well defined qualities of a product. One
has therefore, for many years in the industry, used statistical methods where works and
supplies are approved or rejected after an evaluation of the average and standard deviation of a
number of test results. In keeping with this practice, the EPC intends to use statistical methods
for the quality control. The IRC Manual for Quality Control (SP-112-2017) shall be consulted
for guidance.



10.3.10 Monitoring of Quality Control

The Contractor has the authority and responsibility for monitoring the use of the QAM and for
ensuring that the above policies are being implemented, and to consider the need for changes.
The Contractor is responsible for joint sampling, of all construction materials to be used in the
permanent works, with the staff of AE’s Representative prior to commencement of the works.
The testing shall be carried out under the supervision of the AE’s Representative in the
laboratory set up by the Contractor.
The obligations of the Contractor towards the Contract do not relieve the Contractor of their
responsibilities as per Contract Agreement.
1. The Contractor shall carry out such duties as specified in CA in issuing:

a. decisions
b. certificates
c. orders
2. The Contractor’s contractual duties are to

a. watch and supervise the works
b. test and examine materials and workmanship
c. exercise “process control” wherever needed
Therefore, the Contractor’s representative, assisted by qualified and adequate staff shall carry
out supervision and control such as:
a. sub-soil investigations
b. inspection of works and workmanship
c. geometric control and measurements
d. quality control of works and materials
The field staff is divided into categories, so that the supervisory organization is made up of
bodies with their own field of responsibility such as:
a. Structures
b. Highways
c. Materials and laboratory
It is naturally of great importance that each field of responsibility works in a competent and
well organized manner.



It is the PM’s responsibility that the supervision organization meets the functional
requirements and ensures the compliance of AE observations on the provision of the CA as a
part of Authority obligation/ role defined in CA.
10.4 Approval of Quarries and Borrow Areas

The Contractor is to obtain approval from the AE for each Quarry and Borrow Area to be used
in the Project prior to commencement of quarrying and / or borrow area excavation activities.
The primary aspects to be considered by the AE in granting approval are:
1. The proposed materials meet the specification requirements

2. The EPC has legal rights by the owner to excavate / remove materials from the
proposed quarry / borrow area.
The steps to be followed for approval of each Quarry / Borrow Area are:
1. The Contractor shall complete the “Materials Sources Data” form giving details
regarding size, location, orientation and access for the proposed quarry / borrow area
(rough map to be drawn). Also to be included are the list of materials to be sourced for
the Project Works (e.g., embankment, GSB, WMM etc.), and the estimated quantities
for these materials.
2. The results of laboratory tests conducted on the materials jointly sampled with the
Contractor (or his designated representative) are to be summarized on the approval
form, and complete copies of all tests are to be attached to the form.
3. The EPC shall attach to the completed “Materials Sources Data” form, his proposed
“Environmental Management Plan” for development, use and closing down of the
proposed quarry / borrow area. Photographs of the sources site, including access roads,
etc., should be included with the proposal, so that the base line conditions of the quarry
/ borrow area are clearly established.
4. Based on the EPC proposal, and on the site inspection team’s comments, the AE will
(within 7 days after receipt of the proposal) reply to the EPC in accordance with one of
the following:
a. The proposed Quarry / Borrow Area is approved as proposed.
b. The proposed Quarry / Borrow Area is approved subject to one or more required
changes / additions etc. (to be detailed by the Contractor).
c. The EPC is requested to revise and resubmit all or part of the proposal submittal,
giving details of required changes, additional requirements, etc.



With regard to approval of Quarries and Borrow Areas, the Contractor shall pay particular
attention to requirements of the Environmental Management Plan particularly with regards to:
1. Selection of area
a. Borrow Areas not to be within the Project Right-of-Way unless otherwise specified.
b. Borrow Areas preferred in non-productive, barren lands, raised lands, waste lands,
etc.
c. Borrow Areas to be located on agricultural land should first have the top 150 mm
minimum removed and stockpiled. The stockpiled topsoil is to be replaced and
spread over the original areas after excavation for borrow is completed.
d. For quarry areas, particular care is to be taken to ensure that testing (and approval)
is given only for areas to be indicated on the plan for which the materials have
homogeneous properties. Similarly, the depth and extent of overburden to be
removed prior to quarrying is to be accurately measured and clearly indicated.
2. Transport of Materials
a. All movements and access of equipment to be stationed in the designated areas are
to cause minimum compaction of the soil (in critical areas/ situations).
b. All transport vehicles should have covered sides and tailgates to prevent spillage of
materials.
c. All transport vehicles are to select appropriate routes and delivery times, and are to
adopt safe driving habits so as to ensure minimum of inconvenience to affected
village inhabitants, and to reduce accident potential. The EPC is responsible for the
repair / maintenance of all roads and facilities damaged by his transport equipment.
3. Development / Redevelopment of Borrow Pits and Quarries

a. Both during and following completion of the excavation activities in the borrow
areas, the EPC shall inspect the areas to ensure that the borrow pits and access roads
are properly graded and drained to ensure minimum erosion, and to prevent run-off
from either collecting or from damaging adjacent properties. All existing trees
within the boundary of the quarry /borrow areas should be preserved and protected.
b. Temporary stockpiles of blasted quarry materials and borrow areas soils are to be
located so as to ensure smooth flow of traffic within the areas and for access to
main roads, and are to be designed so as to minimize contamination and damage
from rainfall / run-off etc.
c. Borrow Areas (except in cases where the landowner has agreed that the borrow pit
is to be excavated so as to form an appropriate pond for agricultural purposes), will
be redeveloped by filling and providing 150mm thick layer of preserved topsoil.
d. EPC Contractor’s Representative shall continue to monitor the quarry / borrow
materials both by periodic sampling and testing of the materials as well as by



“visual” assessment. As soon as tests indicate any significant change in a material’s

property, or if a change is suspected visually, then the material properties are to be
certified by testing and if the variation(s) is considered to be significant, then a new
application for approval of source must be lodged, and the above procedure
repeated.
It is to be noted that all field activities for the above are not to commence until appropriate
Request for Inspection Forms are completed, submitted and approved.
10.5 Approval of Materials

All materials proposed by the Contractor to be used in the Project Works are to be first
approved by the AE. In general, there are four types of materials to be approved.
1. Natural Materials – materials with little or no processing except for perhaps screening
for oversize and/or removal of unsuitable particles, etc. An example of this is soil
embankment materials.
2. Processed Materials – materials that require significant processing, including removal
of unsuitable particles, crushing, screening and perhaps, blending of sizes. These
materials are homogeneous, but with specified gradations. An example of this is Wet
Mixed Macadam Base Course.
3. Manufactured Materials – Especially homogeneous construction materials, like
Portland cement and bitumen that are used for blending with natural materials
(generally sand or aggregate) to obtain a pavement mix.
4. Designed Materials – materials that involve the mixture to specific proportions of two
or more different, natural, processed or manufactured materials to obtain a modified
material giving a set of desired specific properties.
Approval of each of the above material types is required, however the requirements for
obtaining approval of materials for each type differs slightly:
10.5.1 Approval of Natural Materials
Natural materials are mined (i.e., excavated) and hence the first step, following assurance that
the material(s) is acceptable for its intended purpose, is to obtain approval for the Borrow Area
or Quarry.
Approval of the material for construction is then obtained by submittal of test results for all
tests required by the Specifications (i.e., to prove that the material meets all minimum
properties required), and, in some cases, by construction of trial sections to prove that this
material can be placed in the field so as to attain minimum required field properties (e.g. to
meet minimum density, etc.).



10.5.2 Approval of Processed Materials

Approval of processed materials follows that noted above for “natural” materials, except that
usually the specifications are tighter (e.g. the material may also have to meet stringent
gradation limits), and a greater variety of tests (and production / storage) conditions are
required to be met.
10.5.3 Approval of Manufactured Materials
Approval of manufactured materials, based on specific Specifications requirements as per
section 5 of IRC: SP: 112: 2017, is generally given in two stages.
1. Initial Approval – given prior to receipt of the materials based on submittal of

appropriate testing results confirmed by the manufacturer (note that claims by
manufacturers, or tests etc. by distributors, etc. are not to be accepted).
2. Final Approval – given based on initial approval plus positive results being obtained for
all “acceptance” tests required by the Specifications, or as directed by the A.E./Client.
10.5.4 Approval of Designed Materials
Approval of “designed” materials for the present Project concerns those mix designs for
Portland Cement Concrete (for concrete pavements, box culverts, bridges etc.) and bituminous
mixes (flexible pavement materials including bituminous macadam, dense bituminous
macadam, bituminous concrete). Due to the complexity of these “mixed” materials, and the
plants for producing the range of materials sizes, final approval is deferred until completion of
the following steps:
1. Procedure for Approval of Raw Material

a. Approval of sources (generally quarries) for each of the processed material
constituents to be included in the final mix design.
b. Approval of each of the individual processed materials and manufactured materials
to be included in the final mix design.
2. Procedure for Mix Design

a. Tentative approval of a laboratory-based mix design, based on a mixture of
approved materials so that the mixture meets all Specification requirements.
b. Tentative approval of a plant mix design, based on proportioning of aggregate bins’
materials and manufactured materials to closely approximate the proportioning of
material types / sizes finalized for the laboratory-based mix design (so that the
mixture still meets the minimum Specifications requirements).
c. Lay a trial section of works (off the Project site) using the tentatively approved
plant mix design and placing the mixture in accordance with a previously approved
construction methodology that conforms to Specification’s requirements.



d. Based on successful laying of the mixes in accordance with the approved

Methodology, conformance of the placed mix to required placing temperatures,
levels and finish, etc., and conformance to quality control requirements as verified
by successful testing in accordance with the Specifications, the Contractor’s
representatives to give final approval of the mix design (Job Mix Formula) based on
the plant mix proportions.
10.5.5 Reporting and Recording Material Approvals

The Contractor’s shall notify in writing to the AE each time a new source, material and / or
mix design is either approved or the approval is revoked. This information is to be included in
the Monthly Quality Control Report to be submitted with the Monthly Progress Report.
Records are to be kept by the Contractor for approvals of all Borrow Areas, Quarries (all types)
and Mix Designs and all other necessary items. The current summaries are to be included as
part of the Monthly Progress Report.
Proper care will be taken while handling and storage of all incoming materials as well as
materials at in-process stage up to the completion of the project to protect their quality from
deterioration and prevent damage. Only experienced and qualified personnel will be involved
in these processes.
10.5.6 Procurement, Handling and Storage of Material:

10.5.6.1 Procedure for Material Procurement
1. User to issue material purchase requisition containing:
a. Specifications
b. Test requirements
c. Drawings if required
d. Planning section will process as below



MATERIAL
PROCUREMENT MANAGER/ APPROVED BY HEAD‐ PROJECT
PURCHASE MANAGER OPERATION / SECTION HEAD
PURCHASE OFFICER ENQUIRY,
RECEIVE QUOTATIONS
TECHNICAL ASSESSMENT
NEGOTIATION, PLACE ORDER‐ COMPARISON
PLANNING DEPARTMENT DEPARTMENT HEAD‐ SITE (PLANING)/
DEPARTMENT HEAD‐ SITE (QA/QC)
STORES CHECK AND STORES CHECK AND
RECEIVE MATERIAL RECEIVE MATERIAL
ISSUE FOR USE SATISFACTORY TESTED BY QC/AE
NOT SATISFACTORY
REJECTION
Figure 4- Flow Chart for Procurement of Material
2. Handling of Materials:
a. As and when the materials are received and routed through inward section of stores
and issued for actual use, necessary precautions will be taken for safe handling.
b. Cement bags will be stored at the work-site in go down with proper care.
c. Concrete mix will be shifted to work place through transit mixer or other suitable
carrier.
d. All other materials will be handled manually and / or using appropriate equipment
taking necessary precautions to prevent damage.
3. Storage of Materials: Following aspects will be taken into consideration for storage:



a. Access to storage area for stacking and retrieval

b. Cleanliness and good house-keeping practices
c. Fire protection
d. Identification and marking
e. Corrosion protection
f. Prevention of physical damage
g. Protective cover and seals
h. Periodic inspection to ensure that the specified storage conditions are maintained
i. Steel of different classifications and sizes will be stored separately
j. The expiry date of consumables will be clearly displayed and the items reaching
expiry date will be promptly intimated to the concerned agencies
k. Cement will be stored in Silos & Godown.
l. For Admixtures, sealants or other chemicals, manufactures test certificate will be
obtained and the same will be checked for meeting the specifications laid down in
the contract agreement, if required by testing in a independent laboratory
m. Other materials such as electrical fittings, paints etc. will be kept in suitable and
properly protected storerooms.
10.5.7 Disposal Area for Excavated Material
All the excavated material shall be the property of the Contractor unless otherwise specified,
suitable material obtained from excavation of roadway shall be used in embankment fill, filling
existing pits in the right of way and for landscaping.
The EPC shall remove unsuitable and surplus material, which in the opinion of the AE that
cannot be used in the works, from site and disposed-off at the approved location in accordance
with all statuary requirements as approved by the AE.
10.6 Sampling of Materials

10.6.1 Sampling Requirements
All construction materials to be used in the permanent works are to be sampled jointly by the
staff of Authority Engineer’s Representative and the Contractor Representative prior to
commencement of the Works. This includes sampling for materials to be tested for proposing
approval of the material source as well as sampling of materials for approval of the individual
construction materials. In both cases, and for each instance, the EPC must give notification of a
request for such sampling to the AE in advance (minimum 24 hours) by way of the Request for
Inspection (R. F. I.) – Annexure G. All assistance (e.g. sampling instruments and equipment,
sample bags, and labour etc.) that is required for carrying out the sampling activities are to be
provided by the Contractor.



10.6.2 Sampling Guidelines

All sampling is to be carried out in accordance with instructions to be given by the
Concessionaire. Sampling procedures are to follow recognized guidelines of good engineering
practice. These include:
1. Obtaining samples from at least three areas.

2. Ensuring that the sampled materials and locations are “typical” for the material to be
tested.
3. Ensure that all overburden etc. is removed within the stockpiles rather than from the
surface (top, side or base of the stockpile) in order to avoid the collection of segregated
materials.
4. Ensure that sufficient quantities are sampled to enable all tests to be conducted, plus
additional material, to be stored for subsequent testing if required.
5. Ensure that each sample bag is marked / labelled both inside and outside, giving the
sample number, material type, sample location, date and number of the bag, as well as
any additional information instructed by the Concessionaire or his authorized engineer.
10.6.3 Preparation and Storage of Samples
Samples collected are reduced and prepared as per Indian Standards (IS) methods, with an
additional sufficient quantity retained in appropriately sealed bags(s) or container(s) and
separately kept in the sample storage room of the laboratory for additional testing and / or
future reference as required. Concrete samples in particular are to be carefully cured and kept
in the curing tank of the laboratory. Access to stored samples is under the strict direct control
of the Contractor. Details of all samples stored are to be kept in a Register to be administered
by the authorized engineer of the Contractor.
10.7 Field Testing Laboratory

1. Field Testing Laboratories: The Field-Testing Laboratory layout as per section 6 of
IRC: SP: 112: 2017 with all required equipment’s as per list as Table 100-A of
MORTH specification and Annex 6.2 of IRC: SP: 112: 2017, including all furniture,
testing equipment and apparatus as required by the Specifications shall be provided and
maintained by the Contractor with the provision of all necessary utilities (e.g.,
electricity, water, sewerage and drainage). The design and layout of the laboratory shall
be convenient enough to conduct all tests. It is the responsibility of the Contractor, or
the authorized engineer, to ensure that the laboratory is proficiently guarded at all times
of the day and night (i.e., to control access and maintain security), is cleaned daily and
is properly maintained.



2. Testing equipment and apparatus are to be initially approved, and subsequently

periodically checked, by the Q.A. Engineer to assure proper operation, accuracy,
correct calibration and complete conformance to all Specifications requirements.
Likewise, all testing procedures detailed in the Specifications and procedures instructed
by the Contractor’s Representative as part of his Quality Control and Quality Assurance
Plan are to be strictly adhered to by the Contractor. The Contractor along with EPC is
to supervise, monitor and check all aspects of the testing procedures, including sample
storage, preparation, testing and analysis and reporting of testing results. All relevant
material testing details related to sample preparation, testing and analysis of results are
to be recorded on the relevant standard testing form(s) given in Annexure C.
10.8 Acceptance Testing

10.8.1 General
All materials included in the construction works for which quality control tests are specified,
and for which approval by the AE has been previously accorded, are to be inspected and
checked for acceptability in accordance with the Specifications requirements. Any of the
completed construction works in which unapproved and / or untested and / or unaccepted
materials are incorporated without approval or written permission from the Contractor are
deemed performed at the EPC risk and are considered as unacceptable and unauthorized.
10.8.2 Routine Acceptance Tests
All sampling and quality control testing, as well as check tests to verify quality of materials,
are to be got conducted by the EPC in the laboratory. The testing shall be got carried out under
the supervision of the Contractor’s and AE’s QA Engineer. However, the EPC is responsible to
provide necessary labour, tools and transport for the purpose of sampling by the laboratory
staff. The kind(s) of test(s) and frequency of testing should conform to the Minimum Quality
Control Testing Requirements of the MORTH Specifications. Sampling and Testing should be
in accordance with the relevant IS / ASTM / AASTHO / IRC methods. Tests are to be reported
on proper forms.
10.8.3 Special Acceptance Tests
The AE may order special tests to be conducted of materials and / or the completed Works as
required. The EPC will be responsible for the cost of special tests if the tests show that the
materials, plant or workmanship are not in accordance with the provisions of the Agreement.
Special tests are generally ordered by the Contractor when there is some concern with some
aspect of the routine acceptance tests (e.g., sampling technique, sample contamination, testing
equipment problem, operator error, etc.). Based on the above, the following procedure is to be
adopted for special testing:



1. The Contractor shall identify testing concern.

2. The Contractor shall identify what / how / where / when the special test is to be
conducted.
a. By the EPC within the Field Laboratory if set up by him.
b. By the internal independent testing (i.e., by the Contractor’s Q.A. Engineer within
the field Laboratory set up and maintained by the Contractor).
c. By external independent testing.
3. Following implementation of any relevant actions indicated based on the results of the
special test, record the test results, and also include the results as part of the “Quality
Control Test Statement” to be submitted with, and as part of the Monthly and Quarterly
Progress Reports.
10.8.4 Quality Control Test Statement (Monthly Progress Report)
The list of laboratory test results completed during the month, and their statistical
interpretations shall be included as an integral part of the Contractor Monthly Progress Report
to be submitted to the Client. This summary of field and laboratory test results is referred to as
a Quality Control Test Statement and is to include the following:
1. Item description, and kind of test;

2. Numbers of tests completed, passed and failed;
3. Analysis of test results and establishment of trends;
4. Any appropriate remarks or comments, based on trend detected and any corrective
action needed.
10.9 Reporting of the Test Results

As and when tests are carried out in site laboratory or at site for the work as per the daily
program i.e. RFI, the test results shall be incorporated in the approved register/format. Test
results shall be signed by Contractor’s representative (QC Manager / Engineer) and AE /
Authority’s representative. After incorporation in the register, test results are written in the
approved test formats in triplicate and the formats are again signed by EPC Contractor’s
representative (DPM / QC Manager / QC Engineer) and AE’s / Authority’s Main Signed
copies are filed in the site lab for record purpose and for all future reference as required by AE
/Authority as and when required.
10.9.1 Quality Test Inspections
Appendix-I give the Quality Control Tests and Acceptance Criteria.
Annexure-C gives recommended formats for testing.



11. GUIDELINES FOR NON-CONFORMING WORKS
11.2 General
In broad terms, it is necessary that the materials and workmanship conform to the agreement
requirements and as per section 11 of IRC: SP: 112-2017, and ideally non-conforming work
shall be rejected.
But special difficulties arise in the case of some items of work such as concrete, where the non-
conformance may only be known after a few days when cube results become available, in
which period work has progressed further. In some of the situations, acceptance after repair /
review for adequacy is feasible. Therefore, separate procedures are laid out for some of the
non-conforming situations. In case such items do not meet the requirements after the repair /
review, the non-conforming item should be rejected. It is also necessary to refer to the Expert
Consultant and / or designer in certain cases of non-conformance to seek their advice and
guidance.
11.3 Concrete / Bituminous Works

The primary means by which Quality Assurance shall be achieved is by the procedures
described in the relevant method statement. The non-conforming concrete / bituminous items
shall be further reviewed, as given below:
11.3.1 Non-conformance Other than Strength or Finish
In the event that any requirement other than strength and standard of finish are not met, the
following procedure shall be followed:
1. The EPC shall be notified without delay verbally, and in writing by the following
means:
a. Return of the Request for Inspection Form signed “not approved” with the reason
for rejection stated.
b. Issue of a Site Instruction or Site Order or letter stating the facts and confirming that
the works are not approved.
2. Approval to carry out concreting / asphalting of a similar nature shall be withheld.
3. The EPC shall be asked for his proposals to rectify the non-compliance, which may
involve re-submission / approval of materials from other source(s), new trial mixes,
revised method statement etc.
4. When satisfied with the measures taken to ensure future compliance, the Contractor
shall confirm approval to continue concrete/bituminous items for permanent works.
11.3.2 Non-conformance with Strength Requirements
1. The specification strength / density for concrete/bituminous works recognizes the
statistical possibility of specimen failure and thus limits of means, standard deviation



and minimum values of strength are specified. The rejection criteria are set out in this
Manual.
2. Materials that are stored for a long time shall be retested at regular intervals before use.
Any deterioration in the quality shall be detected and defective material rejected and
removed from site.
3. In the event the cube / density results fall short of the provision(s) of the specifications,
the non-compliance procedures described below shall be followed:
a. Approval of concreting / asphalting of similar works shall be withheld.
b. All aspect of concreting / asphalting shall be reviewed.
c. The cause of failure shall be identified and measures taken to remedy the problem.
4. Various repair / rectification procedures for commonly arising non-conformance are

spelt out in the Specifications and Codes of Practice. The EPC shall furnish his exact
proposals for rectification under consideration.
5. The fact of non-conformance and the proposed rectification procedure is conveyed to

the Contractor (or design consultant) for review and opinion about:
a. Acceptability of measure(s) proposed by the Contractor, if any.
b. Further non-destructive testing, if any.
c. Acceptability in case strength is achieved at a later age (e.g., 90 days).
d. Acceptability at the level of strength achieved for the stress levels in the concerned
members.
e. Acceptance of repair/ rectifications / strengthening measures with modifications, if
required, or rejection.
6. Rejection in case the item does not pass modified acceptance limits after repairs.
11.3.3 Non-conformance with Finish Requirements
1. Where the required finish is not attained, the non-conformance procedure for repair /
rectification in the Specifications shall be followed.
2. In addition the following procedure shall be followed:
a. Approval of similar work shall be withheld.
b. All aspects of work shall be reviewed.
c. The cause of poor finish shall be identified.
3. Revise specification / Instructions to avoid further recurrence of non-conformance.
Non-Conformance in case of earthwork, sub-base, base and other pavement course(s) are to be
treated as per the above guidelines, as applicable.



12. INTERNAL QUALITY AUDIT

The purpose of this procedure is to establish a system for verification of the implementation
and effectiveness of a Quality assurance Plan by means of a uniform and controlled method for
planning, scheduling, coordinating and performing quality audits and to assign responsibility
for these activities as per the QAP procedure.
12.2 Internal Quality Audit Procedure

Internal Quality Audit will be carried out to verify whether quality activities and related results
comply with planned arrangements as laid down in the Project Quality Plan and whether these
arrangements are implemented effectively and desired objectives are achieved.
The audit will be carried out by staff not having direct responsibility for corresponding
function of the project. The Internal Quality Audit will be carried out at a predetermined
interval and schedule in Annual Internal Quality audit Plan & Schedule for each function. The
frequency of the audit may be increased in some particular cases on the basis of the following
factors on demands:
1. Stake Holder’s complaints
2. Discrepancy in records
3. Contractual requirements
4. Changes in Quality Assurance System itself
5. Results of previous Internal Quality Audit
6. At the implementation stage of Quality Assurance System
Audit findings, conclusions and recommendations will be submitted in documentary form for
consideration by designated member of the management.
Before planning for each audit, it shall be informed to Chief Project Manager at least 15 days
prior with a detailed schedule of his audit area.
The following points will be covered in the reporting and follow-up of audit findings:
1. Specific examples of non-compliance/non-conformity or deficiencies will be

documented in the audit report and possible reasons for such deficiencies, where
evident, may be included.
2. Appropriate corrective actions may be suggested.
3. Implementation and effectiveness of corrective actions suggested in previous audit will
be assessed.



13. PROJECT COMPLETION
13.2 General
Upon completion of each Contract (section-wise), and on completion of the Project, there are
several documents to be prepared and submitted to the Authority. The following should be
checked with the Client as the project nears completion:
1. As-built Drawings
2. Final Completion report
Although the final documentation is to be submitted at the end of the Construction period, they
have to be prepared as the work progresses, and finalized when works are nearing completion.
13.3 As-built Drawings

It is the Contractor’s responsibility to prepare the As-built Drawings. The AE shall supervise,
monitor, and check the preparation of the As-built Drawings. The preparation of these
drawings must be undertaken and completed as the work proceeds and must not be left until
“substantial completion”. As the works are completed, they are to be surveyed and the
drawings to be prepared.
13.4 Final Completion Report

As the works progresses, interim measurements of the approved works are taken for monthly
certification. In parallel, as the work completes, final accurate measurement of the work must
be performed. This survey Control Document shall be used in the preparation of the record
(As-built Drawings). Although final documentation is to be submitted on completion of a
section / mile stone and / or at the end of Contract, they have to be prepared as work
progresses, and finalized when near completion.
14. LIST OF TABLES
14.2 List of Equipment at Site testing Laboratory:

Equipment at site testing laboratory shall be available for the entire test shall be conducted as
per Schedule of Concession Agreement. Any special test required shall be arranged from
outside accredited laboratory.



14.3 List of Materials Tested on Site:

All the materials except bought out materials shall be tested at site laboratory. Any special test,
if required, for any material shall be conducted at outside approved laboratory. The list of
materials is as follows:
1. Cement (Physical properties)

2. Coarse aggregates
3. Fine aggregates (Sand, Crusher Dust)
4. Concrete (Compressive Strength, Flexural Strength)
5. Soil/Earth/Sub grade Material
6. Material for GSB / DL / WMM material
7. Material for Bituminous product
8. Bitumen
9. Steel Reinforcement
14.4 List of Materials to be certified by Manufacturer’s Certificate
1. Steel Reinforcement
2. Paints
3. PVC Pipes
4. Reinforced Concrete Pipes
5. Joint Filler Material
6. Anti-stripping Compounds
7. Concrete Admixtures
8. Curing Compound
9. Cement
10. Traffic Signs
11. Earthing Material if any
12. Laboratory Equipment
13. Bearings
14. HT Strands
15. Sheathing Duct
16. Expansion Joint
17. All other items as specified in the contract documents.



15. MEASURING AND TESTING EQUIPMENT

Contractor shall establish and maintain a system as per section 7 of IRC: SP: 112-2017 to
ensure that all measuring and test equipment used are calibrated and its status is maintained on
an established written calibration register.
The QC Engineer shall be responsible for the establishment and maintenance of the calibration
register. The schedule shall be reviewed closely & monitored, to ensure its compliance.
Equipment to be issued shall be checked to ensure that its capabilities are compatible with the
intended application. New equipment shall be calibrated prior to use on project.
As a minimum all calibrated survey equipment used on the project shall be calibrated prior to
commencement of works and then at the frequency detailed in the calibration register. Records
verifying the calibration shall be maintained in the register.
The Material Testing Laboratory employed by Contractor; certification shall be accepted as

evidence of maintenance of calibration requirements. The following information regarding the
testing laboratory shall be maintained in the records, say, Location, Name of the Agency, Date
of Calibration, and signature of authorized person, Next due date for calibration etc.
S. No. Instrument Frequency Calibration at

1. Auto levels Once in 3 Months Site
2. Total Station Once in12 Months External
3. Hot Mix Plants Once in 3 Months Site
4. Weighing Balance Once in12 Months Site
5. Batching plants Once in 1 Month Site
6. WMM Plants Once in 3 Months Site
7. Cube-Testing Machine Once in 12 Months Site Laboratory
Flexural Testing
8. Once in 12 Months Site Laboratory
Machine
All other equipments &
9. M/Cs as per Annex. 7.1 As Annex 7.1 As Annex 7.1
of IRC: SP: 112-2017



16. Protection during Construction Stage

In order to produce a quality end product, it is necessary to lay down procedures for preventing
any damage or deterioration of the various materials brought to site as well as the works
partially completed or fully completed till the completion of the entire job.
These procedures will have to be laid down in respect of the following:
(a) Storage of materials, like, cement, rebars, aggregates, bitumen, emulsions, inflammable
solvents, etc.
(b) Protection of the partially completed components of the road, both from the point of view
of structural stability (including the hydraulic factors) and from the adverse effects of the
environment.
(c) Prevention of accidents to the structure as well as all personnel working on the project due
to incomplete work or works in progress.
If any deterioration is noticed inspite of protective measures, the same is to be rectified before
taking up subsequent operations.
17. QA Procedure for Setting out Works and Temporary Works
17.1 A professional qualified surveyor is to be appointed to take responsibility of survey

control and setting out both the temporary as well as the permanent works and establishing and
maintenance of control stations, following approved work methods. Proper quality records
shall be maintained. Under this item, the various elements to be covered should include:
• Survey control stations

• Setting out points
• Schedule of stations and points
• Control and checking of stations
• Approval of stations and setting out
17.2 Temporary works
Construction of temporary works shall be the responsibility and liability of the contractor. The
work shall be done with the approval of the 'Engineer'
The design of the temporary works should also be got approved by the contractor from the
'Engineer'. Temporary works are generally as under:
(a) Centering and formwork

(b) Temporary structures built to enable/house operating plant/machinery
(c) Detours of temporary nature for traffic
(d) Services detour



The procedure for maintaining records of temporary works shall include:
• Design, drawings, method statement, etc.

• Checking and approval of proposal of temporary works
• Erection procedures
• Checking and approval of erection
• Certification by competent authority
• Monitoring during loading and use.
• Dismantling temporary works
The above items should be checked by the appropriate authorities from the 'Engineer'.
Appendix‐I
Page‐1
QUALITY ASSURANCE PLAN FOR MATERIAL TO BE USED "
Legend : FTR - Field Test Report RFI - Request for Inspection/ Inspection Proformae LTC - Third Party Laboratory Test certificate
A -Witness & Approval RM - Random witness & Final authority of approval C - Celibration of instruments & plants as per the requirements
MTC -Manufacture Test Certificate ST -Sampling as per freqency & Testing in witness of Client / S - Checks for horizontal and vertical Geometry.
Authority Engineer
R - Maintaining Site Testing, Stock Records & level Sheet.
Sr. No. Description of Name of Test Freq. Of Test Ref. Code Acceptance Criteria Scope Type of
Material Contractor Client Authority records
Engineer
1.0 Cleaning &
a Uprooting Vegetation, Grass, Bushes, 100% MORT&H Clause No. 201 Visual Check RFI, ST RM A R.F. I
Grubbing
Shrubs, Saplings etc.
b Removal of unserviceable materials 100% MORT&H Clause No. 201 Visual Check RFI, ST RM A R.F. I
within estate limit.
2.0 Cement
Ordinary Portland a Check apparent condition of Cement 100% IS : 8112, IS :12269 Visual Check ST RM A Visual Check
Cement (O.P.C) / prior to consumption. Dryness, Grade Mark etc.
Any other special
category of Cement
b Initial & Final Setting Time in minutes 1sample from IS : 456, IS : 12269, IS : 30 min. Minimum & 600 min. Maximum ST RM A MTC & LTC
2% of Bags in 8112, IS : 1489, IS :
Consignment of 4031
50MT
c Consistency of Cement Do IS : 12269, IS : 8112, IS < 33 % ST RM A MTC & LTC

: 4031
d Soundness of Cement Do < 10 mm ST RM A MTC & LTC
Page‐2
e Compressive Strength - For 53 Grade Do 3 days - 27 N/mm2, 7 days - 37 N/mm2& ST RM A MTC & LTC
OPC 28 days - 53 N/mm2
3.0 NP‐3/NP‐4 Pipes

a Hydrostatic Test as per IS : 3597 As per Table IS : 458 - 1988 According to Manual ST RM A MTC
15from IS : 458
b Three-edge bearing Test -1988 IS : 458 - 1988 ST RM A MTC
c Absorption Test IS : 458 - 1988 ST RM A MTC
4.0 Coarse Aggregate

for Structural a Gradation 1 sample/ IS : 383 & IS : 2386 - ST RM A LTC & FTR
Concrete 100cumet
b Specific Gravity Do IS : 2386 - ST RM A LTC & FTR
c Bulk Density Do IS : 2386 - ST RM A LTC & FTR
d Water Absorption Do IS : 2386 - Part-III Max. 2 % ST RM A LTC & FTR
e Flakiness & Elongation Index One per each IS : 2386 - Part-I Max. 30 % ST RM A LTC & FTR
Source
f Abrasion Value 1 sample/ IS : 2386 - Part-IV Max. 50 % ST RM A LTC

100cumet
g Impact / Crushing Value Do IS : 2386 - Part-IV Max. 45 % ST RM A LTC & FTR
h Presence of Deleterious material, Do IS : 383 Max. 5 % ST RM A LTC

Organic impurities.
5.0 Fine Aggregate for

Structural a Sieve Analysis 1 sample/ IS : 383 & IS : 2386 - ST RM A LTC & FTR
Concrete 100cumet
b Finess Modulus 1 sample/ IS : 383 & IS : 2386 - ST RM A LTC & FTR

100cumet
c Specific Gravity Do IS : 2386 - ST RM A LTC & FTR
d Bulk Density Do IS : 2386 - ST RM A LTC & FTR
e Water Absorption Do IS : 2386 - Part-III Max. 2 % ST RM A LTC & FTR
f Presence of Deleterious material, 1 sample / IS : 383 Max. 5 % ST RM A LTC & FTR

Organic impurities. 50 cumet LTC
ST RM A
Page‐3
g Silt Content As Req. IS : 2386 Max. 3 % ST RM A LTC & FTR
6.0 Bricks
a Samples for Dimensions 1 sample / IS : 3495 & MORTH - ST RM A LTC & FTR
50,000 Nos.
(5 Bricks)
b Compressive Strength 1 sample IS : 3495 & MORTH Not less than 10.5 Mpa ST RM A LTC & FTR
containing (5
Bricks)
c Water Absorption Do IS : 3495 & MORTH Max. 20 % ST RM A LTC & FTR
d Efflorescence Do IS : 3495 & MORTH Slite, Moderate & Severe ST RM A LTC & FTR
7.0 Reinforcement
Bars a Ultimate Tensile Strength 1 sample / IS : 1786 & IS : 1608 - ST RM A LTC
40 MT of each
dia.
Consignment or
part there of.
b Yield Strength (Proof Test) Do IS : 1786 & IS : 1608 - ST RM A LTC

c % Elongation Do IS : 1786 & IS : 1608 - ST RM A LTC
d Bend & Re-Bend Test Do IS : 1786, IS : 1608 & IS Satisfactory / Unsatisfactory ST RM A LTC
:1599
e Unit weight on scale Do IS : 1786 & IS : 1608, IS : Depends of Dia. Of Bar ST RM A LTC
432
f Size & Identification 100% IS : 1786 & IS : 1608 - ST RM A LTC
g Chemical Analysis 1 Sample / IS : 432, IS : 1786 & IS : Fe-415 (C=0.3, S=0.06, P=0.060), Fe-500 ST RM A LTC
lot for each 1139 (C=0.3, S=0.055, P=0.055), Fe-550 (C=0.3,
category S=0.055, P=0.050)
8.0 Water
a Ph Once for IS : 456 & I.S. 3025 Min. 6 ST RM A LTC
approval of
b Sulphate Source of IS : 456 & I.S. 3025 Max. 400 mg/lit ST RM A LTC
Page‐4
c Chloride Supply IS : 456 & I.S. 3025 Max. 500 mg/lit for R.C.C ST RM A LTC
d Inorganic matter IS : 456 & I.S. 3025 Max. 3000 mg/lit. ST RM A LTC
e Organic Matter IS : 456 & I.S. 3025 Max. 200 mg/lit. ST RM A LTC
f Suspended Solids IS : 456 & I.S. 3025 Max. 2000 mg/lit. ST RM A LTC
g Neutralization with 0.02 N HCL IS : 456 & I.S. 3025 Max. 25 ml ST RM A LTC
h Neutralization with 0.02 N NaOH IS : 456 & I.S. 3025 Max. 5 ml ST RM A LTC
9.0 Stone Rubble

a Gradation 1 Test / 100 MORT&H Specification According to Contract ST RM A LTC & FTR
cu.mt
b Impact Value / Crushing Value 1 Test / 200 IS : 2386 Part-4 Max. 30% ST RM A LTC & FTR
cu.mt
c Water Absorption 1 Test / 200 IS : 2386 Part - 3 Max. 2.0 % ST RM A LTC

cu.mt
10.0 Concrete
a Compressive strength of cube As per IS 456 IS 516 95 % of Cheracteristic comp. strength ST RM A LTC & FTR
b Slump test As Required IS 1199 As per Design Mix ST RM A FTR
c Rebound hammer IS 13311 Part 1 . + or - 25% of required 28 days strength ST RM A LTC
d Ultrasonic pulse velosity IS 13311 Part 2 Min. 3000 km/sec ST RM A LTC
11.0 Borrow Soil

a Sand Content 2 tests / IS : 2720 - Part - 4 ST RM A LTC & FTR
-
3000m3
b Atterberg's Limts 2 tests for each IS : 2720 - Part - 5 ST RM A LTC & FTR
type Max. LL-50%, PI-25%
c M.D.D. / O.M.C 2 tests for each IS : 2720 - Part - 8 Min. 1.75 g/cc minimum ST RM A LTC & FTR
type
d Free Swell Index 2 tests for each IS : 2720 - Part - 40 & 41 ST RM A LTC & FTR
type Max. 50%
Page‐5
e Field Compaction 1 tests / I.S. 2720 Part-28 & I.S. Table 300 :2, & clause 903.2.2 of MORTH ST RM A LTC & FTR
500mt2 2720 Part-29
f C.B. R As Required IS : 2720 - Part - 16 As per Design ST RM A LTC & FTR
12.0 Sub‐Grade
a M.D.D. / O.M.C 2 tests for each IS : 2720 - Part - 8 Min. 1.75 g/cc minimum ST RM A LTC & FTR
type
b Free Swell Index 2 tests for each IS : 2720 - Part - 40 & 41 ST RM A LTC & FTR
type Max. 50%
c Field Compaction 1 tests / I.S. 2720 Part-28 & I.S. Table 300 :2, & clause 903.2.2 of MORTH ST RM A FTR
500mt2 2720 Part-29
d C.B. R As Required IS : 2720 - Part - 16 As per Design ST RM A LTC & FTR
13.0 Granular Sub‐Base

a Gradation 1 Tests/400m3 MORT&H Specification Acco. to Design ST RM A FTR
b Impact Value 1 Tests / 200m3 IS : 2386 Part-4 Max. 40 % ST RM A FTR

c C.B.R. As Required MORT&H Specification Min. 30 % ST RM A LTC & FTR
d Atterberg's Limts 1 Tests/400 m3 IS : 2386 Part-5 L.L <25 & P.I <6 ST RM A LTC & FTR
e F.D. D 1Tests/1000sq. I.S. 2720 Part-28 98 % minimum ST RM A LTC & FTR
mt
f Moisture Content Prior to Comp. 1 Tests/400m3 MORT&H Specification Acco. to Design ST RM A LTC & FTR
g Deleterious Constituents As Required MORT&H Specification - ST RM A LTC

14.0 Cement Treated
Sub‐Base a Quality of Cement 1 Tests/ MORT&H Specification Acco. to MoRTH ST RM A LTC
5Tonnes
b Degree of pulverization Periodically - - ST RM A FTR
c Cement content Regularly MORT&H Specification Acco. to Design ST RM A RFI
d C.B.R. or UCS As Required MORT&H Specification Acco. to Design ST RM A LTC & FTR
e Moisture Content Prior to Comp. 1set- MORT&H Specification Acco. to Design ST RM A FTR & RFI
2testss/500sq.
m
f Deleterious Constituents As Required MORT&H Specification - ST RM A LTC
g Density of compacted layer 1set- I.S. 2720 Part-28 98 % minimum ST RM A FTR & RFI
2testss/500sq.
m
Page‐6
15.0 Wet Mix Macadam
a Gradation 1 Tests/200 m3 MORT&H Specification Acco. to MoRTH ST RM A FTR & RFI
b Aggregate Impact Tests 1 Tests/200 m3 IS : 2386 Part-4 Max. 30% ST RM A LTC & FTR
c Combined F.I & E. I 1 Tests/500 m3 IS : 2386 Part-1 Max. 35% ST RM A LTC & FTR
d Atterberg's Limts 1Tests/200m3 IS : 2386 Part-5 P.I <6 ST RM A LTC & FTR
e Density of Compacted Layer 1 set of Tests / I.S. 2720 Part-28 98 % minimum ST RM A FTR & RFI
1000 sq.mt
16.0 Dense Bituminous
Macadam a Quality of binder 1Tests/lot IS : 73 - ST RM A FTR
b Aggregate Impact Value 1 Tests/350m3 IS : 2386 Part 4 Max. 24% ST RM A LTC & FTR
c Los Angles Abrsion Value 1 Tests/350m3 IS : 2386 Part 4 Max. 30% ST RM A LTC & FTR
d Flakiness Index & Elongation Index 1 Tests/350m3 IS : 2386 Part 1 Max. 35% ST RM A LTC & FTR
e Stripping Value 1 Tests/ each IS : 6241 Min. 95% ST RM A FTR
source
f Water absorption of aggregate 1 Tests/ each IS : 2386 Part 3 Max. 2% ST RM A FTR
source
g Soundness (Magnesium and sodium 1 Tests/ each IS : 2386 Part 5 Max. 12% / 18% ST RM A FTR
sulphate) source
h Sand equivalent tests for fine aggregate 1 Tests/ each IS : 2720 Part 37 MIN. 50 (MORTH) ST RM A FTR
source
i Plasticity Index 1 Tests/ each IS : 2720 Part 5 Max. 4 (IRC:111) ST RM A FTR
source
j Polised Stone Value 1 Tests/ each BS : 812-114 Min. 55 ST RM A FTR
source
k Percentage of Fractured face 1 Tests/350m3 As per required specs. - ST RM A FTR
l Mix grading 2 Tests Per Day IS : 2720 (Part 4) Max. 5% passing 0.075mm sieve ST RM A FTR & RFI
m Stability of mix 3 Tests/400 MORT&H Specification As per design mix ST RM A FTR
TNS
n Temperature of binder in boiler, At regular As per std. engineering Acco. to MoRTH ST RM A FTR
aggregate in dryer and mix at the time of interval
laying and compaction
o Water sensitivity of mix 1 Tests/ each AASTHO T283 - ST RM A FTR
source
p Control binder and grading of mix 1 Tests/400 MORT&H Specification Acco. to MoRTH ST RM A FTR
TNS
q Rate of spread of Mix material At every 5th MORT&H Specification Acco. to MoRTH ST RM A FTR
truck load
r Surface Irregularity tests As per table no- Cl. 902.4 MORT&H - ST RM A FTR
900-2 of MoRTH
Page‐7
s Density of compacted layers 1 MORT&H Specification Min. 92 % of Gmm ST RM A FTR & RFI
Tests/700sq.m
17.0 Bituminous
Concrete a Mix Grading 2 Tests Per Day IS : 2386 Part-1 Max. 5% passing 0.075mm sieve ST RM A FTR & RFI
c Los Angles Abrasion Value Tests 1 Tests/350 m3 IS : 2386 Part-4 Max. 30% ST RM A LTC & FTR
e F.I & E.I 1 Tests/350 m3 IS : 2386 Part-1 Max. 35% ST RM A LTC & FTR
f Soundness : Sodium/Manesium Sulphate 1 Tests/ Source IS : 2386 Part-5 Max. 12% / 18% ST RM A FTR
g Polishing stone value 1 Tests/ Source BS : 812-114 Min. 55 ST RM A FTR
h Water Absorption 1 Tests/ Source IS : 2386 Part-3 Max. 2% ST RM A FTR
i Density of Compacted Layer 1 Tests/700sq.mtMORT&H Specification Min. 92 % of Gmm ST RM A FTR & RFI
j Stripping Value Tests 1 Tests/ Source IS : 6241 Min. 95% ST RM A FTR
k Sand Equivalent Tests 1 Tests/ Source IS : 2720 Part-37 MIN. 50 (MORTH) ST RM A FTR
l Plasticity Index 1 Tests/ Source IS : 2720 - Part - 5 Max. 4 (IRC:111) ST RM A FTR
m Percentage of fractured face 1 Tests/350 m3 - - ST RM A FTR
n Stability & Void analysis 3 Tests/400 TNS MORT&H Specification As per design mix ST RM A FTR
o Moisture susceptibility of mix 1 Tests for each AASTHO T283 - ST RM A FTR
mix type
p Temperature of binder in boiler, At regular As per std. Engineering Acco. to MoRTH ST RM A FTR
q Bitumen Content 1 Tests/ 400 MT MORT&H Specification Acco. to MoRTH ST RM A FTR
r Rate of Application of binder At every 5th MORT&H Specification Acco. to MoRTH ST RM A FTR
truck load
s Marshall Stability 1 Set/ 400 MT MORT&H Specification Acco. to MoRTH ST RM A FTR
18.0 Stone Matrix
Asphalt a Mix Grading 2 Tests Per Day IS : 2386 Part-1 Max. 5% passing 0.075mm sieve ST RM A FTR & RFI
c Los Angles Abrasion Value Tests 1 Tests/100 m3 IS : 2386 Part-4 Max. 25% ST RM A LTC & FTR
e F.I & E.I 1 Tests/100 m3 IS : 2386 Part-1 Max. 30% ST RM A LTC & FTR
f Soundness : Sodium/Manesium Sulphate 1 Tests/ Source IS : 2386 Part-5 Max. 12% ST RM A FTR
g Polishing stone value 1 Tests/ Source IS : 2386(P-114) Min. 55 ST RM A FTR
h Water Absorption 1 Tests/ Source IS : 2386 Part-3 Max. 2% ST RM A FTR
i Density of Compacted Layer 1 Tests/250sq.mtMORT&H Specification Min. 94 % of Gmm ST RM A FTR & RFI
j Stability & Void analysis 3 Tests/400 TNS MORT&H Specification As per design mix ST RM A FTR
k Moisture susceptibility of mix 3 Tests per day AASTHO T283 - ST RM A FTR
l Temperature of binder in boiler, At regular As per std. engineering Acco. to MoRTH ST RM A FTR
m Bitumen Content 1 Set/ 400 MT MORT&H Specification Acco. to MoRTH ST RM A FTR
n Rate of Application of binder At every 5th MORT&H Specification Acco. to MoRTH ST RM A FTR
truck load
o Plasticity Index for Mineral Filler 1 Set/ each IS : 2720 Part-5 Acco. to MoRTH ST RM A FTR
source
Page‐8
19.0 Dry Lean Concrete
a Aggregate Gradation & Deletrious Daily on IS :2386 Part 1 & 2 As per IS :2386 Part 1 & 2 ST RM A LTR
Content production
b Los Angles Abrasion Value/ AIV 1 Tests/each IS :2386 Part 4 As per IS :2386 Part 4 ST RM A LTR
source
c Soundness 1 Tests/each IS :2386 Part 5 As per IS :2386 Part 5 ST RM A LTR
source
d Water Absorption 1 Tests/each IS :2386 Part 3 Not nore then 2 percent ST RM A LTR
source
e Compressive strength 3Cube/1000sqm IS : 516 Average of 5 cubes not less then 10MPa and ST RM A LTR
for individual min 7.5MPa at 7 day
f MDD & OMC 1 Tests/each IS : 2720 Part 8 As per Design ST RM A LTR
source
20.0 Pavement Quality
Concrete
a Cube Strength of Concrete 3 Cubes & 3 IS : 516 As per design ST RM A LTR
Beams per 150
cum (one of 7
days and other
28 days)
b Thickness measurement for trail length 3 cores MORT&H Table 900-6 As per design ST RM A LTR
21.0 Bitumen
Grade of Bitumen : >>> VG‐10 VG‐20 VG‐30 VG‐40
a Specific Gravity, Min Number of IS : 1202 0.99 0.99 0.99 0.99 ST RM A
b Penetration at 25°C, 100 g, 5 s, 0.1 mm, Samples per lot IS : 1203 80 60 45 35 ST RM A
Min (As per IS
: 73,
c Softening point, °C, Min IS : 1205 40 45 47 50 ST RM A MTC, LTC &
IRC : SP : 53, &
d Ductility at 25°C, cm, Min IS : IS : 1208 75 50 40 25 ST RM A FTR
e Flash point (Cleveland open cup), 15462) IS : 1209 220 220 220 220 ST RM A
°C, Min
f Matter Solubility in Tricholoroethylene, IS : 1216 99 99 99 99 ST RM A
Percent, Min
g Water Content IS : 1211 Max. 0.2 % by Weight ST RM A
h Loss on heating IS : 1212 Max. 1% by Weight ST RM A MTC, LTC
i Absolute viscosity at 60°C, Poises IS : 1206 800-1200 1600- 2400- 3200- ST RM A
2400 3600 4800
j Kinematic viscosity at 135°C, cSt IS : 1206 250 300 350 400
k Stripping Value Tests IS : 6241 Min. 95% ST RM A LTC & FTR
22.0 Prime Coat/
Tack Coat a Quality of Binder Number of MORT&H Specification Min. 0.99 ST RM A MTC & LTC
Samples perlot
b Binder temperature (As per IS : 73, As per std. Engineering According to Design Grade ST RM A --
IS: 217,& IS :
c Rate of Application of binder As per std. Engineering ST RM A --
8887)
23.0 Admixtures
Page‐9
a Water Content 1 sample / IS : 9103 As per Table 1A & 1B of IS : 9103 - 1999 ST RM A MTC & LTC
Consignment of
50 MT
b Slump Tests Do IS : 9103 ST RM A MTC & LTC

c Initial & Final Setting Time - IS : 8142 Do IS : 9103 ST RM A MTC & LTC
d Compressive Strength Do IS : 9103 ST RM A LTC
e Flexural Strength Do IS : 9103 ST RM A LTC
f Bleeding - IS : 2386 Part-3 Do IS : 9103 ST RM A LTC
g Loss of Workability - IS : 1199 Do IS : 9103 ST RM A MTC & LTC
h Air Content - IS : 1199 Do IS : 9103 ST RM A MTC & LTC
24.0 Fly Ash
a Fineness - By Blaine's Permiability 1 sample / IS : 3812 Part- 2 Min. 250 sq.mt / kg ST RM A MTC & LTC
Tests in sq.mt / kg Consignment of
50 MT
b Particles retained on 45 microns IS sieve Do IS : 3812 Part- 2 Max. 40 % ST RM A MTC & LTC
(wet Sieve) in %
c Soundness by autoclave tests Max. Do IS : 3812 Part- 2 Max. 0.8 % ST RM A MTC & LTC
d Sio2+Al2O3+Fe2O3 in % by mass Do IS : 3812 Part- 2 Min. 70% (S) Min. 50 %(C) ST RM A MTC & LTC
e Avalable Alkalies in % by mass Do IS : 3812 Part- 2 Max. 1.5 % (S & C) ST RM A MTC & LTC
Page‐
10
" QAP " FOR IN PROCESS ACTIVITIES ‐ CIVIL WORKS
Legend : LTC - Third Party Laboratory Tests certificate MTC -Manufacture Tests Certificate ST -Sampling as per freqency A -Witness
& Testsing in witness of & Approval
C - Celibration of instruments & plants as per the requirements R - Maintaining Site Testsing, Stock Records & level Client / Authority Engineer
Sheet.
S - Checks for horizontal and vertical Geometry. RFI - Request for Inspection RM - Random witness & Final FTR - Field
approvalAuthority Tests Report
Sr. No. Description of Activities Norms / Code of Acceptance criteria Type of Check / Frequency of Check/Tests SCOPE Remarks
Reference Record Contractor Client Authority
Engineer
1.0 Surveying
a Tacking Initial Level MoRTH MoRTH Specification & Relevant Physically Once in a project's duration C,S,R RM A
Specifications & IRC Guidelines checked & RFI
b Tacking Intermediate Levels Approved MoRTH Specification & Relevant Record Once in a project's duration & As C,S,R RM A
drawings IRC Guidelines required
c Tacking Final levels MoRTH Specification & Relevant Once in a project's duration C,S,R RM A
IRC Guidelines
2.0 Excavation
a Before Excavation
Checking of Pegs condition as MoRTH Approved drawings / Physical 100 % on each location C,S,R RM A
per line and alignment Specifications & Approved " QAP " / MoRTH measurnment at
Approved Specification site & RFI
drawings
Checking of pit marking as per MoRTH Approved drawings / Physical 100 % on each location C,S,R RM A
drawings & Reduced Level Specifications & Approved " QAP " / MoRTH measurnment at
Approved Specification site & RFI
drawings
b After Excavation
Page‐
11
Dimensional confirmity- MoRTH Approved drawings / Physical 100 % on each location C,S,R RM A
Verticality / Slope, required Specifications & Approved " QAP " / MoRTH verification at site
depth / level Approved Specification & RFI
drawings
3.0 Earth work / Back Filling
a Check levels of layers MoRTH Approved drawings / Physical As per good engineering practice C,S,R RM A
Specifications & Approved " QAP " / MoRTH verification at site
Approved Specification & RFI
drawings
b Soil Moisture & Compaction IS : 2720 - " QAP " / MoRTH Specification Field Tests Record As per Approved " QAP " C,S,R RM A
Tests Part - 7 & 8
4.0 Granular Sub‐Base

a Check levels of layers MoRTH Approved drawings / Physical As per good engineering practice C,S,R RM A
Approved Specification & Relevant IRC & RFI
drawings Guideline
b Moisture & Compaction Tests MoRTH Approved drawings / Field Tests Record As per Approved " QAP " C,S,R RM A
Specifications Approved " QAP " / MoRTH
&Approved mix Specification & Relevant IRC
design, IS : 2720 - Guideline
Part - 7& 8
5.0 Cement Treated Sub‐Base
a Check levels of layers MoRTH Approved drawings / Physical As per good engineering practice C , S , R RM A
drawings Guideline
Specifications & Approved " QAP " / MoRTH
Approved mix Specification & Relevant IRC
design, IS : 2720 - Guideline
Part - 7 & 8
Page‐
12
c Curing on completed work IRC : SP : 89 MoRTH Specification & Relevant Visual check on up to 7 days C,S,R RM A
IRC Guideline site
d Unconfined Compressive Cl. 403.5 - MoRTH Passing Design Criteria Physical - C,S,R RM A
Strength Tests Specifications verification at
site&Field Tests
Record
6.0 Wet Mix Macadam
drawings Guideline
& Approved Specification & Relevant IRC
mix design, IS : Guideline
2720 - Part - 7
&8
7.0 Dense Bituminous Macadam
drawings Guideline
b Cleaning of Surface MoRTH Approved drawings / Physical 100 % on each location C,S,R RM A
drawings Guideline
c Application of Prime Coat MoRTH Approved drawings / Physical As required C,S,R RM A
drawings Guideline
d Application of Take Coat MoRTH Approved drawings / Physical As required C,S,R RM A
drawings Guideline
Page‐
13
e Compaction Tests MoRTH Approved drawings / Field Tests Record As per Approved " QAP " C,S,R RM A
Specification & Relevant IRC
Guideline
8.0 Bituminous Concrete
drawings Guideline
drawings Guideline

drawings Guideline

drawings Guideline
Guideline
9.0 Stone Matrix Asphalt
drawings Guideline
Page‐
14
drawings Guideline
drawings Guideline
drawings Guideline
Guideline
10.0 Dry Lean Concrete
a Check levels of layers MoRTH Approved drawings / Physical For each lane C,S,R RM A
Specifications Approved " QAP " / MoRTH meaurement at
Specification & Relevant IRC site
Guideline
b Moisture & Compaction Tests Cl 903.5.1.2- Approved drawings / Field Tests Record 3 density hole/ 2000sq.m C,S,R RM A
MoRTH Approved " QAP " / MoRTH
Specifications Specification & Relevant IRC
Guideline
c Surface Irregularity tests MoRTH Approved drawings / Physical Each days work C,S,R RM A
Guideline
11.0 Pavement Quality Concrete
a Check levels of layers MoRTH Approved drawings / Physical For each lane C,S,R RM A
Guideline
b Workability (Slump) IS : 1199, IS : 456, Approved drawings / Field Tests Record Each dumper load of concrete C,S,R RM A
IRC : 21 Approved " QAP " / MoRTH
Guideline
Page‐
15
c Surface Irregularity tests MoRTH Approved drawings / Physical As per Table 900-6 MORT&H C,S,R RM A
Guideline
d Texture depth As per Table – As per Table – 602.12 Field Tests Record As per Table – 602.12 C,S,R RM A
602.12 MORT&H MORT&H MORT&H
12.0 Side Shoulder
drawings Guideline
& Approved Specification & Relevant IRC
mix design, IS : Guideline
2720 - Part - 7
&8
13.0 Reinforcement Bars
a Preparation / Approval of Bar IS : 2562 - 1963 Approved drawings / Record copy duly 100% C,S,R RM A
Bending Schedule Approved " QAP " / MoRTH signed jointly
Guideline
b Check placement of MoRTH Approved drawings / Physical 100% C,S,R RM A
Reinforcement with Cover Specifications & Approved " QAP " / MoRTH verification at site
distance, Spacing of bars etc. Approved Specification & Relevant IRC & RFI
drawings Guideline
c Check Lapping of bars with MoRTH Approved drawings / Physical 100% C,S,R RM A
proper tying Specifications & Approved " QAP " / MoRTH verification at site
drawings Guideline
14.0 Cement Concrete
a P.C.C. :- Level and Thickness MoRTH Approved drawings / Physical 100% on each location C,S,R RM A
check Specifications & Approved " QAP " / MoRTH verification at site
drawings Guideline
Page‐
16
b Concrete Mix Design IS : 10262 Approved drawings / Lab tests Result Onces per Source C,S,R RM A
Approved " QAP " / MoRTH
Guideline
c Placing Concrete and IS : 456 Approved drawings / Visual check on 100% C,S,R RM A
Compacting Approved " QAP " / MoRTH site
Guideline
d Check Workability of Concrete IS : 456, IS : 1199 Approved drawings / FTR & RFI For ever 20 cu.mt of day's C,S,R RM A
(Slum Tests) & IS : 516 Approved " QAP " / MoRTH concreting
Guideline
e Check Compressive strength of IS : 456, IS : 1199 Approved drawings / LTC & FTR 1 sample for every 20 cu.mt C,S,R RM A
Concrete (Cube Tests) & IS : 516 Approved " QAP " / MoRTH of concreting or part there of
Specification & Relevant IRC for each day concreting.
Guideline
One sample consists of six cubes (3nos for each -7 days & 28
days)
f Check for Curing IS : 456 & IS : Min. 14 days (Visual Check) & Visual check on 100% C,S,R RM A
5613 rebound hammer tests resuls if site
req.
g Check Finishing & Workmanship ----- Approved drawings / Visual Check at 100% C,S,R RM A
after removal of Form Works Approved " QAP " / MoRTH site & RFI
Guideline
15.0 Brick Masonary
a Check the proportion, mixing IS : 2212 Approved drawings / Physical Random C,S,R RM A
and placement of Mortar Approved " QAP " / MoRTH inspection during
including ties if any. Specification & Relevant IRC execution & RFI
Guideline
b Plumb and Alignment IS : 2212 Approved drawings / 100% C,S,R RM A
Approved " QAP " / MoRTH
Guideline
Page‐
17
c Check for Curing ----- Min. 7 days (Visual Check) 100% C,S,R RM A
d Control of brick masonary IS : 2212 Approved drawings / Visual Check at 100% C,S,R RM A
height in day work Approved " QAP " / MoRTH site & RFI
Guideline
16.0 Plaster
a Surface Preparation and ----- Approved Construction drawings Verification 100% C,S,R RM A
Thickness / Approved " QAP " / Contract during work at
Specification site & RFI
b Check the proportion of Mortar ----- Approved Construction drawings By providing std. 100% C,S,R RM A
/ Approved " QAP " / Contract Measuring boxes
Specification & verification
during work
c Check the thickness, line and ----- Approved Construction drawings Verification 100% C,S,R RM A
level of Plaster / Approved " QAP " / Contract during work at
Specification site & RFI
d Check for Curing ----- Min. 7 days (Visual Check) Visual Check at 100% C,S,R RM A
site
Page‐
18
Category‐A
Planning Proformae
QUALITY PLAN FOR COARSE and FINE AGGREGATE A‐1
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC
Project
mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)
EPC Contractor: Authority Engineer: Client:

DRAIPL‐MKCIL (JV) GDRPL‐VSPL (JV) National Highway Authority of India (NHAI)
Description Performing Quality Assurance Frequency of

Sr. No. Acceptance Standard Performance Standard Frequency of Performance Frequency of Assurance
Tests/Items Agency Agency Audit
Before call of tenders and award Submission in the form of
1 PreqtJalifit;ation of source IS 383 IS 2386 and Project Specification QA/E QA/E/TP 1
of work report
Immediately after award of work
Submission in the form of
1A Confirmation of sources IS 383 IS 2386 and Project Specification E/C QA/E/TP and before commencement of 1
report
concreting
2 Procrement Project Specification Project Specification C QA/E/TP As per requirement Well in advance of requirement 1
3 Storage Project Specification Project Specification C QA/E/TP Immediately after receipt As required 1

4 Sampling Project Specification/IS 383 Project Specification/IS 383 E QA/E/TP As per IS 383. As per IS 383 1
5 Test 1
New Source or change in
5A Petrographic Analysis IS 383/2386 ASTM 295 IS 383 ASTM 295 Authorised TP QA/E/TP New source or change in quality 1
quality
IS 383 IS SP 23 IS 2386 Authorised TP QA/E/TP New source or change in New source or change in 1
5B Alaliteadivity
IS 2386/ASTM D1411 Authorised/TP QA/E/TP New source or change in New source or change in 1
5C Chloride & Sulphate IS 383 IS SP 23
quality quality
Project Specification/ IS 2386 Project Specification/ IS 2386 E/C QA/E/TP One sample One sample” 1
5D Deterious Material
Project Specification/IS 2386 Project Specification/IS 2386 E/C QA/E/TP New source / As per New source / As per 1
5E Crushing Value
requirement requirement
5F Abrassion(Optional)
Project Specification/IS 2386 Project Specification/IS 2386 E/C QA/E/TP New source / New source / 1
5G Impact Value
5H Soundness
5I Size and Gradation Project Specification IS 2386 E/C QA/E/TP Daily Da’ily 1
Project Specification IS 2386 E/C QA/E/TP One sample * per week One sample per week 1
5J Flakiness/Elongation
Coatinq and strippinq of bitumen AASHTO- Tl82 TP QA/E/TP One sample per week One sample per week 1
5K
aggregate mixtures
Sp. Gravity and Absorption Project Specification IS 2386 E/C QA/E/TP One sample * per week New source 1
5Li
(Normal Agg.)
Sp. Gravity and Absorption (Heavy Project Specification IS 2386 E/C QA/E/TP One sample “ per week New source 1
5Lii
ore)
Project Specification IS 2386 E/C QA/E/TP Daily Daily 1
5M Density/Moisture content
Prepared & Checked by Approved by
EPC Contractor's Representative Authority Engineer's Representative
QUALITY PLAN FOR BITUMEN A‐2
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode
Project
under Bharatmala pariyojana in the state of Gujarat (Package‐IV)

Acceptance Quality
Sr. N Description Tests/Items Performance Standard Performing Agency Frequency of Performance Frequency of Assurance Frequency of Audit
Standard Assurance Agency
1 Prequalification of source Project Specification IS‐73 Project Specification IS‐73 E/C QA/E/TP New Source New Source 1

Agency
2 Procurement Project Specification IS‐73 Project Specification IS‐73 Responsible for QA/E/TP Well in advance Well in advance 1
procurement
3 Storage Project Specification Project Specification C QA/E/TP After receipt at Site Once in month 1
4 Sampling Project Specification Project Specification E/C or Jointly QA/E/TP Each fresh lot Once in week 1
5 Test : Physical Project Specification IS‐73 Project Specification IS‐73 E/C QA/E/TP Each lot Once in week 1
Chemical Project Specification IS‐73 Project Specification IS‐73 E/C QA/E/TP As per requirement As per requirement 1
6 Records Project Specification Project Specification E/C QA/E/TP Daily Once in month
QUALITY PLAN FOR MIXING WATER/ICE (CRUSHED) A‐3
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐
Project
Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)

Quality
Sr. Acceptance Performing Frequency of Frequency of Frequency of
Description Tests/Items Performance Standard Assurance
No. Standard Agency Performance Assurance Audit
Agency
1 Prequalification Project Specification/ IS 456 Project Specification E QA/E/TP New source New source 1

IS SP ‐ 23
2 Confirmatory Tests Project Specification/ IS 456 Project Specification E/C QA/E/TP Before start of project As per requirement 1

IS SP ‐ 23 work
3 Sampling Physical an Project Specification Project IS 456 Specification IS E/C QA/E/TP New source thrice in a Thrice in a year 1

4 Chemical Tests Specification 456/ IS (Chemical E/C QA/E/TP year (change of season) (change of season) 1
Analysis) New source thrice in a Thrice in a year
year
5 Storage Project Specification Project Specification E/C QA/E/TP Daily Once in a month 1
6 Cleaning of Storage Tank Proiect Specification Proiect Specification E/C QA/E/TP Once in a Once in a 1
7 Adequacy of Storage Tank Project Specification Project Specification E/C QA/E/TP Before commen‐ Once in a month 1
cement of work
QUALITY PLAN FOR CONCRETE ADMIXTURE A‐4
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐
Project
751) on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)

Quality
Sr. Acceptance Frequency of
Description Tests/Items Performance Standard Performing Agency Assurance Frequency of Performance Frequency of Assurance
No. Standard Audit
Agency
Preoualification and Agency responsible Minimum 6 months before Before start of work and

1 IS 9103/ ASTM C494 IS 9103/ ASTM C494 QA/E/TP 1
recommendation for procurement commencement of work when source is changed
2 Procurement Project Specification Project Specification ‐do‐ QA/E/TP Before start of concreting Well in advance 1

3 Storage Project Specification Manufacturer/ Project E/C QA/E/TP After receipt at site Once in a month 1
Specification
4 Samplir\g Project Specification/IS 9103 Project Specification/IS E/C or Jointly QA/E/TP On arrival of fresh stock/ Minimum New stock or once in 3 1
9103 once in 3 months months
5 Tests
5.1 Chemical Analysis IS SP‐23 IS 9103 IS 9103 E QA/E/TP As per require‐ ment or As per requirement 1
minimum once in a year
5.2 Ph IS SP‐23 IS 9103 E QA/E/TP Minimum 1 sample per month Minimum 1 sample per 1
IS 9103 month
New source/ As and when
5.3. Performance ASTM C494 ASTM C494 E QA/E/TP New source/ As and when required 1
required
5.4. Records Project SpecifiCation Project Specification E/C OA/E/TP Daily Once in a month 1
TEST FREQUENCY SCHEDULE A‐5
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐
Project
Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)

Ouality
Performance Frequency of Frequency of Frequency of
Consignment Identification No. Specified Test Performing Agency Assurance
Standard Performance Assurance Audit
Agency
a) Chemical Properties
b) Physical Properties
c) Special Requirement5 (As
specified)
1) Admixture shall be stored as per direction of manufacturer in a 10 Ton cylinder horizontal container specially designed to take pressure and to minimise wastage.
2) Admixture shall be agitated once in a day and solids if any shall not be allowed to settle
3) Monthly statement of consumption of admixture shall be maintained.
4) Total chloride, sulphate content and Ph value of admixture when 4 kg. of admixture ›s added to 160 kgs. of water shall not exceed permissible limits of chloride, sulphate content and pH
Category‐B
Inspection Proformae
DATA SHEET FOR SIEVE ANALYSIS‐AGGREGATE B‐1
Project Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of
Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment
(NH‐751) on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)
Client:
EPC Contractor: Authority Engineer:
National Highway Authority
DRAIPL‐MKCIL (JV) GDRPL‐VSPL (JV)
of India (NHAI)
SAMPLE NO.: DATE OF SAMPLING:
QUANTITY OF AGGREGATE: METHOD OF TEST:
SOURCE: DATE OF TESTING:
TO BE USED IN STRUCTURE: SAMPLING & TESTED BY:
WEIGHT OF SAMPLE:
CUMULATIVE MASS %CUMULATIVE
IS SIEVE NO. MASS RETAINED ACCEPTABLE LIMIT
RETAINED RETAINED
REMARKS:
Note:
Plot a Grain Size Distribution Curve
FORMWORK INSPECTION CHECK LIST B‐2
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of
Project Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐
Client:
National Highway Authority of India
DRAIPL‐MKCIL (JV) GDRPL ‐ VSPL (JV)
(NHAI)
LOCATION: DATED:
CONTRACTOR 'S INSPECTION REQUEST NO.
CONTRACTORS DRG OR SKETCH NO.
S.No. DESCRIPTION YES NO N.A.
Formwork design/drawing/sketch approved including de‐shuttering
1
arrangements
2 Trial panel approved (If required)
3 Formwork alignment correct
4 Formwork levels correct, including screeds
5 Formwork dimensions correct
6 Formwork member spacing correct
7 Formwork member material quality acceptable
8 False work member sizes correct
9 False work member spacing correct
10 False work member material quality acceptable
11 Gaps between primary and secondary members closed/ wedged
12 Face boarding/plywood/metal thickness correct
13 Joints between panels closed (no gaps)
14 Joints between panels flush(no steps/lips)
15 Panel flatness acceptable
16 Gaps between secondary members and face panels closed
17 Tie rod material and sizes correct
18 Tie rod spacing correct
19 Tie rods tight, face cones flush
20 Spacers between shutter surface tightly fitting
21 Box outs, cast‐in items , ducts fixed correct, securely
Pre‐stressing, sheathing and vents, alignments and spacing of supports
22
acceptable
23 Empty sheathing secured against floatation
24 Pre‐stressing anchorage positions and fixing acceptable
25 Chamfers/fillets sizes, straightness, fixing acceptable
26 Form work clean
27 Form work release oil material approved
28 Form work release oil applied correctly
29 Construction joint preparation satisfactory
30 Contraction/expansion joint preparation satisfactory
31 Safe access constructed
32 Adequate workspace provided for labour, equipment
33 Shutter vibrators (if required) location andfixing arrangements approved
Prepared & Inspection by Approved by
REINFORCEMENT INSPECTION CHECK LIST B‐3
Client:
(NHAI)
LOCATION: DATED:
CONTRACTOR 'S INSPECTION REQUEST
NO.:
CONTRACTORS DRG OR SKETCH NO.:
1 Working drawing checked & approved
2 Latest revision being used
3 Bar schedules approved
4 Reinforcing steel material approved
5 Bar bending & cutting satisfactory
6 Corrosion treatment of bars if required, satisfactory
7 Bar sizes correct
8 Bar spacing correct
9 Bar lap lengths correct
10 Bar laps at correct locations
11 Bar tied as specified
Bar assembly rigid and adequately supported (including spacers/chair
12
supports)
13 Cover to bottom bars correct
14 Cover to side bars correct
15 Cover to top bars correct
16 Cover blocks approved including fixing
INSPECTION CHECK LIST BEFORE APPROVAL TO CONCRETE B‐4
Client:
National Highway Authority of
India (NHAI)
LOCATION: DATED:
CONTRACTOR 'S INSPECTION REQUEST
NO.:
CONTRACTORS DRG OR SKETCH NO.:

1 Method statement approved
Batching plant mixtures in work ing order (separate dispenser for
2
admixture , if required, available)
3 Stand‐by batcher in working order
4 Water, sand, coarse aggregate, admixture, cement stock approved
5 Water, sand, coarse aggregate, admixture, cement stock sufficient
Concrete conveying arrangement (including transit mixtures) available in
6
working condition and of sufficient capacity
7 Formwork approved
8 Reinforcement approved
9 Pre‐stressing sheathing approved
10 Concreting equipment in working order
11 Stand‐by crane, vibrators present
12 Tromie in working order (for under water work)
Concrete gang present, including carpenter, steel fixer, mechanics and
13
electricians
14 Access provided
15 Safety arrangements adequate
16 Lighting provided
17 Communication between various points provided
18 Arrangements for suspension/stoppage of Concrete provided
19 Curing arrangements made
20 Laboratory notified
EPC Contractor's Authority Engineer's
Representative Representative
PROFORMA FOR CONCRETE DELIVERY AND POUR RECORD B‐5
Client:
(NHAI)
1. CONCRETE BATCHING DELIVERY TICKET NO:
a Location of pour: Date:
b Concrete grade: Mix Temp:
c W/C ratio: Slump:
d Cement contents: No. of cubes taken
e Max. Aggregate Size
f Admixture: (Type and dosage)
g Batching started, Hrs: Batching finished, Hrs :
h Quantity batched, Cum: Truck no:
2. TRUCK ARRIVED ON SITE :
a Slump test result(S): mm at Hrs.
b Discharge started: Hrs.
c No of site cubes taken: Hrs.
d Place where cubes taken:
e Placement temperature of concrete
f Ambient temp
g Weather condition
EPC Contractor's Representative Authority Engineer's
Representative
POST CONCRETE INSPECTION B‐6
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar
Project district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode
Client:
(NHAI)
Note: Post concreting inspection shall be carried at various stages such as after stripping of side shuttering, each stage of
pre‐ stressing, decentring and/or as per designer stipulation.
Location: Stage of Insepection:
Date of Pour: Date of Inspection:
Specified Class: S or NS*
Type of Remark
S.No. Observation
(S or NS*)
Alignment S or NS
1 Position/Dimensions of member Level S or NS
Dimensions S or NS
No defects
Surface defects (honey combing / sand streaks / (Note type and extent
2 Minor defects
air bubbles/ cold joints) of defect)
Major defects
3 Class of finish S or NS
No cracks
4 Cracks Cracks Date first observed
Nature of cracks
5 Any other defect
6 Non‐conformance report no. Report no / Not applicable
Remarks :
ln case of NS report in item (1) to (5), it should be examined by competent authority before approval or non‐approval. lf
required, a separate non‐conformance report (including sketches, photographs, etc.,) shall be prepared for further action.
*S= Satisfactory NS= Not satisfactory
AGGREGATE IMPACT VALUE TEST ‐ AIV B‐7
Project Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751)
on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)
Client:
(NHAI)
Location : Tested By :
Material : Date :
Quarry No. : Range of sieve 10.0 to 12.5mm

Date Sample : No, of Blows 15
Location : Height of fall 380mm
Method of
sampling : By means of scoop Method of CrushinSudden
3 4 5
2 6
1 WT. Aggregate WT. Aggregate WT. Aggregate
WT. Container + Aggregate Impact
Sample No. WT. Container before retained on passing on
Aggregate value
(Gms.) compaction 2.36mm sieve 2.36mm sieve
(Gms.) %
(Gms.) (Gms.) (Gms.)
(2‐1) (3‐4)
REMARKS: AVERAGE %
FIELD DENSITY TEST CORE CUTTER METHOD B‐8
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to
Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐
Project
Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in the
state of Gujarat (Package‐IV)

Material : Date :
Reduced Level: Layer NO, MDD = gm/cc

Bulk Density: gm/cc Layer Thickness OMC = %
Sl.No. CHAINAGE Unit 1 2 3 4 5
1 Mass of mould+ Compacted soil
2 Mass of mould
3 Mass of Compacted soil (2‐1)
4 Volume of mould
5 Wet Density of soil (3/4)
Moisture Determination ‐ ‐ ‐ ‐ ‐ ‐ ‐
6 Wt. Wet soil+
7 Wt. Dry soil +
8 Wt. Water (6) ‐ (7)
9 Moisture content (8)/(7)x1 00
Field Dry density of soil (5)/1
10
+(9)/1 00
Degree of compaction (10/MDD X100) %
Average degree of Compaction
Standard Deviation
REMARKS:
FLAKINESS INDEX TEST B‐9
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai
village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera
Project
Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in the state of
Gujarat (Package‐IV)

Material : Date :
1 2 3
4
Total Weight of Weight of Aggregate Weight of Aggregate
Sieve Range (mm) Flakiness Index
Aggregates retained Passing
(%)
(Gms.) (Gms.) (Gms.)
63‐50
50‐40
40‐31.5
31.5‐25
25‐20
20‐16
16‐12.5
12.5‐10
10‐6.3
REMARKS: Average: %
EPC Contractor's Authority Engineer's
Representative Representative
ATTERBERG LIMITS B‐10
Project district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under
Bharatmala pariyojana in the state of Gujarat (Package‐IV)
Client:
(NHAI)
Material : Date :
Description Liquid Limit Plastic Limit
Determination No. UNIT 1 2 3 4 1 2
No. of Blows/Penetration in mm
1. Wt. of Container + Wet Soil Gms.
2. Wt.of Container + Dry Soil Gms.
3. Wt. of Water Gms.
4. Wt. of Container Gms.
5. Wt. of Dry Soil Gms.
6. Moisture Content (3/5x100) Gms.
Moisture Content (%)
Depth of Penetration (mm)
Liquid Limit:‐ % Plastic Limit:‐ % Plasticity Index:‐ %

COMPACTION TEST
B‐11
(MODIFIED PROCTOR)
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch.
Project 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in
the state of Gujarat (Package‐IV)
EPC Contractor: Client:
Authority Engineer:GDRPL‐VSPL (JV)
DRAIPL‐MKCIL (JV) National Highway Authority of India (NHAI)
Sample No. Date of Sampling
Chainage/Location Date of Testing
Source of Material Type of Material
Mould No : Wt. of Mould, W1 (g) : Volume of mould, V (cc):
Trial No : I II III IV V VI
% of water Added (%)
Wt. of wet soil + mould, W2 (g)
Wt. of wet soil, W3=(W2‐W1) (g)
Wet density, Yb = W3/V (g/cc)
Container No.
Wt. of container,W5 (g)
Wt. of wet soil + cont., W6
Wt. of dry soil + cont.,W7 (g)
Wt. of water, W8=(W6‐W7) (g)
Wt. of dry soil, W9=(W7‐W5) (g)
Water content w =W8/W9 (%)
Dry density Yd = 100x (Yb/100+w) (g/cc)
2.24
2.22
2.2
2.18
2.16
2.14
2.12
2.1
Dry density in (g/cc)
2.08
2.06
2.04
2.02
2
1.98
1.96
1.94
1.92
1.9
1.88
1.86
1.84
1.82
1.8
Moisture content(%)
MDD : ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐gm/cc OMC : ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐%
FIELD DENSITY TEST B-12
Project Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad- Dholera Greenfield alignment (NH-751)
on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package-IV)

DRAIPL-MKCIL (JV) GDRPL-VSPL (JV) National Highway Authority of India (NHAI)
RFI No. : Date of Testing:
Chainage : Layer & Layer No :
Lab Maximum Dry Density(g/cc) : OMC (%) :
Sand Pouring Cylinder No : Rapid Moisture meter No:
Bulk Density of sand (gm/cc.) : Weight of Sand in Cone w3 (gms).:
Source of material (Name & chainage)
Test Number
Test pit location
Offset from centre line (m)
Depth of hole (mm)

FIELD DENSITY
Weight of wet material from hole (Ww) (g)
Weight of sand + cylinder before pouring (W1) (g)
Weight of sand + cylinder after pouring (W2) (g)
Weight of sand in hole (W4=W1-W2-W3) (g)
Volume of Hole (V = W4/Ys)
Bulk density of material {Yb=Ww / V} (g/cc)

MOISTURE CONTENT (By Rapid moisture method)
Moisture meter reading (%)
Corrected moisture content (from Graph) (%)
RESULTS
Field max. dry density {Yd=100XYb/(100+W)}(g/cc)
Compaction achieved (100xYd/Ymdd) (%)
Specified Compaction (%)

ACCEPTANCE CRITERIA
Mean Density Specified compaction+{1.65-(1.65/(no.of pits )^0.5 )}x SD
Standard Deviation
Mean Density
Result
CBR TEST ‐ (As per IS 2720 Part 16) B‐13
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district
Project (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under

Sample No : MDD: __________gm/cc OMC: _____ %

Location: : Surcharge Wt. Applied:_______kg
Source: : Proving Ring No. / Capacity :
Type of Compaction: Static / Dynamic Date of Casting :
Condition of Specimen at Test: Soaked Date of Testing :
Mould No
Before Before After Before After
Description After Soaking
Soaking Soaking Soaking Soaking Soaking
Mould + Wet Soil (gm)
Weight of Mould (gm)
Weight of Wet Soil (gm)
Volume of Mould (cc)
Wet Density (gm/cc)
Container No
Weight of Container (gms)
Wt. of Container + Wet Soil (gms)
Wt.of Container + Dry Soil (gms)
Wt. of Water (gms)
Wt. of Dry Soil (gms)
Moisture Content (%)
Dry Density (gm/cc)
% of Compaction
Proving Ring Constant 1 Div =
Mould No. From Graph
Blows
Penetration Dial Dial Dial
Kg Kg Kg Mould No.
in 'mm' Reading Reading Reading
0.50
2.5 mm
1.00 Corrected
1.50 Load (kg)
5.0 mm
2.00
2.50 2.5 mm
4.00 CBR Value %
5.0 mm
5.00
7.50 Average
10.00
12.50 CBR Value.............at ............. of Compaction.
BITUMEN EXTRACTION TEST B‐14
Project (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala
pariyojana in the state of Gujarat (Package‐IV)

Chainage : Sampled by :
Source : Date of Sampling :
Location / Chainage : Date of Testing :
Type of Material :
Total weight of sample taken = Gms
Description Trial 1
1) Initial Wt. of Sample (gms)
2) Initial Wt. of Filter Paper (gms)
3) Final Wt. of Filter Paper (gms)
4) Final Wt. of Sample (gms)
5) Weight of Fines (gms) (3‐2)
6) Weight of Bitumen (gms) (1‐4‐5)
7) Binder content (%) (6/1)*100 Total Wt.
IS Seive Cumulative Wt. Cumulative % Wt.

Wt. Retained (gm) % Passing JMF LIMITS Limits as per MoRTH
size 'mm' Retained (gm) Retained (gm)
45.00 100 100

37.50 95 100
26.50 63 93
13.20 55 75
4.75 38 54
2.360 28 42
0.300 7 21
0.075 2 8
Remarks :
MARSHALL STABILITY TEST B‐15

Sample No: Date of casting
Location: Date of Testing
Source : Bulk Sp Gr (Gsb):
Type of Material: Eff Sp Gr (Gse):
% of Bitumen(Pb) Sp Gr of Bitumen (Gb):
%of Aggregate(Ps) Proving Ring Const. 1 Div =
Description Test 1 Test 2

Wt of Sample in Air
1
(gm)
Wt of Sample in Water
2
(gm)
Wt of SSD Sample in
3
Air (gm)
Bulk Volume (cc) 4=(3‐2)
Correction factor
Corrected
Volume (cc)
Bulk Density of
5=1/4
Specimen (gm/cc)
Ave. Bulk Density
6
(gm/cc)
Theoretical Spec. 7=100/((Ps/Gse)
Gravity +(Pb/Gb))
%Air Voids 8=((7‐6)/7)*100
9=100‐
VMA
(6xPs/Gsb)
VFB 10=((9‐8)/9)*100
Load (Kg)
Stability (Kg)
Ave.Stability (Kg)
Flow (mm)
Ave.Flow (mm)
FIELD DENSITY TEST B‐16
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019)
Project
section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)

Sample No : : Date Sampling :
Location: : Date Testing :
Layer: : Sampled by :
Marshall Density (A): : Tested By :
Density Determination
SAMPLE NO.
Core No (a)
Chainage KM (b)
Location
Distance from
Kerb/Edge (c)
Thichness (mm) (d)
Wt. in Air (gms) (e)
Wt. in Water (gms) (f)
SSD Wt. (gms) (g)
Bulk Volume (cc) (h)=(g‐f)
Density (g/cc) (i)=h/e
Compaction % (j)=i*100/A
GRADATION FOR STONE MATRIX ASPHALT 13MM (MoRT&H Table 500‐37) B‐17
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch.
Project 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in
the state of Gujarat (Package‐IV)

Sample No : Date OF Sampling :
Location: : Date of Testing :
Layer: : Sampled by :
Souse of Material : Tested By :
Type of material : Total weight (gms.) :
Weight Cumulative % Design % MoSRT&H Spec.
I.S.Sieve % Retained % Passing JMF Limits
Retained (gms) Retained Passing Limits
26.50
19.00 100.00
13.20 90‐100
9.50 50‐75
4.75 20‐28
2.36 16‐24
1.180 13‐21
0.600 12‐18
0.300 10‐20
0.075 8‐12
Pan
SMA 13mm Gradation

110
100
90
80
70
60
% Passing
50
40
30
20
10
0
0.01 0.1 IS Sieve in MM 1 10 100
Category‐C
Calibration Proformae
CALIBRATION CHART OF BATCHING FOR AGGREGATE GUAGE C‐1
Client National Highway Authority of India (NHAI)
Authority
GDRPL‐VSPL (JV)
Engineer
EPC Contractor DRAIPL‐MKCIL (JV)
CALIBRATED DATE:
DIAL GAUGE READING
LOAD APPLIED
TRIAL‐1 TRIAL‐2 TRIAL‐3
(KG) AVERAGE
LOADING UNLOADING LOADING UNLOADING LOADING UNLOADING
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
REMARKS:
CALIBRATION CHART OF BATCHING FOR WATER METER C‐2
Authority Engineer GDRPL‐VSPL (JV)
CALIBRATED DATE:
DIAL GAUGE READING
S.No. WATER WATER WATER
METERE METERE METERE AVERAGE
MEASURED MEASURED MEASURED
READING (LTRS) READING (LTRS) READING (LTRS)
(LTRS) (LTRS) (LTRS)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
REMARKS:
CALIBRATION CHART OF BATCHING FOR CEMENT GUAGE C‐3
CALIBRATED DATE:
DIAL GAUGE READING
LOAD APPLIED
(KG) AVERAGE
LOADING UNLOADING LOADING UNLOADING LOADING UNLOADING
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
REMARKS:
CALIBRATION REPORT (CUBE TESTING MACHINE) C‐4
CALIBRATED DATE: TEMP:
GAUGE NO: CAPACITY
EQUIPMENT: MODEL:
FORCE MEASURING DEVICE: SL.NO
CERTIFIED: PLACE:
S.No. DEFLECTION IN DIAL GAUGE IN ACTUAL LOAD AVERAGE OF THREE INDICATED LOAD IN GAUGE
1
2
3
4
5
6
7
8
9
10
REMARKS:
Category‐D
Surveillance Proformae
MATERIAL QUALITY SURVEILLANCE FORM D‐1
Project
Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in the state of Gujarat
(Package‐IV)
Contact No.
Manufacture/Suppller/ Perchase order Inspection Agency Inspection at
Source
Inspection Certificate Delivery Challan Disringulshing Mark Date of MFR/supply
Shipping storage and other Remarks (Satisfactory/Not satisfactory)
TEST RECORD
Method of Obtained
S.No. Test Acceptance range Remarks
test value
REMARKS:
Inspected by In Presence of
EPC Contractor's Representative EPC Contractor's Representative
PRODUCT QUALITY SURVEILLANCE FORM D‐2
Contact No.
Manufacture/Suppller/So Perchase order Inspection Agency Date of MFR/supply
urce
Inspection Certificate Delivery Challan Distinguishing Mark
Drawing Nos. Tender specification clause
Shipping storage and other Remarks
Method of
S.No. Test Acceptance range Obtained value Remarks
test
REMARKS:
SURVEILLANCE FORM FOR PRE‐CONCRETING OPERATIONS D‐3
Authority
GDRPL‐VSPL (JV)
Engineer
Contact No.
Elements of Structure Identification No. Location
SURVEILLANCE OPERATIONS
Work Description
1 Line, level and dimensions as per drawing
2 Availability of adequate approved material
Placing of reinforcement (including
3
support/spacers etc)
4 Formworks and scaffolding as per drawing
5 Box outs/embedded parts,if any
6 Cleaning of forms
7 Arrangements of plant & equipments
8 Walkway for pouring and inspections
9 Safery arrangements
10 Curing arrengments
REMARKS:
QUALITY SURVEILLANCE FORM FOR WORKMANSHIP OF CONCRETE D‐4
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village
Project of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment
(NH‐751) on EPC mode under Bharatmala pariyojana in the state of Gujarat (Package‐IV)
Authority
GDRPL‐VSPL (JV)
Engineer
Contact No.
Elements of Structure Identification No. Location
SURVEILLANCE OBSERVATION
Mixing of concrete
• Check the concrete class and the respective mix design already approved.
• Check the condition of aggregates to be used.
• Check the weighing and water dispensing methods adopted during the mixing.
• Check that the mixer machine has been cleaned properly.
• Check that the required mixing time is allowed.
Transportation/conveyance (as specified, but generally to cover following)
• Check if the equipment are in proper working order.
• Check if the specified methods are being followed.
• Check if the stipulated time limits are observed.
• Check if the non‐conforming wet concrete is being rejected and disposed off.
Placing of concrete
• The concrete is not segregated during pour. The height of dropping is controlled.
• The concrete is poured in layers.
• The vibrators are being applied systematically to compact uniformly and adequately, avoiding over vibration.
• The cold joints are not allowed to be developed.
• The underwater concrete is being poured only by tremies or pipeline.
• The forms are not getting displaced or deformed during the concrete pour and vibrating.
• No cement slurry is getting lost. Suitable numbers of carpenters are present to watch and repair formwork during
pour, if required.
• The concrete is being poured within the allowable time limits from the time of batching.
• The concrete cubes are being casted as per required frequency.
• The curing arrangements are satisfactory.
• The equipment is in working condition
• The equipment is cleaned properly.
• The quality of wet concrete is as per specifications. (slump, homogenous mix etc )
• Continuous supply of concrete assured.
REMARKS:
Category‐D
Category‐E
Proformae for Registers and Records
PARTICULARS OF WORK E‐1
Project
(Package‐IV)
Address of Contractor:
Contractor Agreement
Contract Ammount:
no.:
Applicable schedule of
Period of Completion:
rates:
Stipulated date of
Date of Work Order:
completion:
Actual date of starting
work:
Extensions
1.
2.
INCUMBANCY
Period
S.No. Designation* Name
From To
* Departmental officers designation covering all officers having execution responsibilities of the project
REGISTER OF DRAWINGS E‐2
Authority
GDRPL‐VSPL (VS)
Engineer
1. Receipt of Drawings
Drawing Revision Date of No. of Status of

S.No. Brief title Issued by further action Sin. & Date
No No receipt copies drgs
2. Reissue of Drawings
Drg
Sl no of
Drawing Revision No. of Status of supersedes
S.No. Brief title receipt Issued to Signature
No No copies drgs Drg no
register
(if any)
REMARKS:
Authority Engineer's Representative
EPC Contractor's Representative
CEMENT REGISTER E‐3
Address of Contractor:
Closing Blance at the Site Previous week (bags)
Quality Received Qty Used Closing blance at the end of day

Date Purpose
bags/MT (bags/MT)
Bags/MT Source
EPC Contractor's Representative
Authority Engineer's Representative
CONSUMPTION OF CEMENT FOR DIFFERENT ITEMS OF WORKS
E‐4
(THEORETICAL AND ACTUAL)
(A) Weekly record of items of work
Quantity of work done during the
S No. item of work
week
(B) Abstract for the week ending (Indicate cement consumption)
Actual
Rate of cement
Item of Quantity of work done Cement required to be consumed Cement
S.No per unit
work theoretically (Bags/MT) consumed
(Bags/MT)
(Bags/MT)
Quantity Unit
RECORD OF CALIBRATION OF EQUIPMENT E‐5
Date Calibrated & Person
Date of Inspection & Person Result of
Item Certifying (for vendor or Date of next Calibration
Approving (for department) Inspection
contractor)
DAILY PROGRESS REPORT E‐6
Project district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under
Signature with date
Activity Wether
Date Item of work Special Problem Remarks
Location condition
Recorded Checked
REGISTER OF INSPECTION NOTES E‐7
Project
(Package‐IV)
No. and Number &
No of
date under date of Reviewed
inspection Reviewed by Signature Signature Remarks
which compliance by
Note
received submitted
REGISTER OF OBSERVATION MEMOS ISSUED FROM THE QUALITY CONTROL CELL E‐8
Project (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under
No. and Number &
Observation date under date of
Year Reviewed by Signature Reviewed by Signature Remarks
Memos No. which compliance
received submitted
Category‐F
Proformae for Procedurl Guidelines of QA System
GUIDELINES FOR NON‐CONFORMING WORKS F‐1
Project
(Package‐IV)
1. General
In broad terms, for the Quality Assurance of the finished work it is necessary for the materials and workmanship
to conform with the Contract requirements. Ideally, non‐conforming work shall be rejected.
The statement above is true in general terms, but special difficulties arise in the case of concrete, where the non‐
conformance may only be known after 28 days cube results become available, in which period work has
progressed further. In some of the situations, acceptance after repair/ review for adequacy is feasible.
Therefore, separate procedures are laid out for some of the non‐conforming situations. In case the feasible
items do not meet the requirements after such repair /review, the non‐conforming item should be rejected.
2. Concrete/Asphalt Work
The primary means by which Quality Assurance shall be achieved is by the procedures described in relevant
material qualification and workmanship method statement. The non‐conforming concrete/ asphalt items shall
be further reviewed, as given below;
2.1 Non‐Conformance other than Strength or Finish
In the event that any requirement other than strength and standard of finish is not met, then the following
procedure shall be followed:
1. The contractor shall be notified without delay verbally, and in writing by the following means:
(a) Return of the request for Inspection Form signed "not approved" with the reason for rejection stated.
(b) Issue of a Site Instruction or Site Works Order or letter stating the facts and confirming that the works are
not approved.
2. Approval to carryout concreting/asphalting of a similar nature shall be withheld.
3. The Contractor shall be asked for his proposals to rectify the non‐compliance, which may involve re‐
submission of materials, new trial mixes, revised method statement.
4. The acceptance or rejection of any unapproved concrete/asphalt work shall be referred to the Engineer.
5. When satisfied with the measures taken to ensure future compliance, the Engineer shall confirm approval to
continue concrete/asphalt for permanent works.
2.2. Non‐Conformance with Strength Requirements
1.The specification strength/density for concrete/asphalt recognises the statistical possibility of cube failures
and thus limits of means, standard deviation, minimum values of strength are specified. The rejection criteria is
set out in the agreement.
2. In the event of cube/density failures outside the provision of the Contract then the non‐compliance
procedures described in the specification shall be followed:
(a) Approval of concreting/asphalting of similar works shall be withheld.
(b) All aspects of concreting/asphalting shall be reviewed.
(c) The clause of failure shall be identified and measures taken to remedy the problem.
3. Various repair/rectification procedures for commonly arising/non‐conformance are specified in contract. The
contractor shall furnish his exact proposals for rectification under consideration.
4. The fact of non‐conformance and the proposed rectification procedure is conveyed to the engineer/design
organization of owner (or design consultant) for review and opinion about:
(i) Acceptability of measure proposed by the contractor, if any.
(ii) Further non‐destructive testing, if any.
(iii) Acceptability in case strength is achieved at a later age (e.g., 90 days)
(iv) Acceptability at the level of strength achieved for the stress levels in concerned members.
(v) Acceptance of repair/rectification/strengthening measures with modifications, if required, or rejection.
5. Rejection in case the item does not pass modified acceptance limits after repairs.
2.3. Non‐Conformance with Finish Requirements
1. Where the required finish is non‐attained then the non‐conformance procedure for repair/ rectification as
described in the Specification shall be followed.
2. In addition, the following procedures shall be followed:
(a) Approval of similar work shall be withheld.
(b) All aspects of work shall be reviewed.
(c) The cause of poor finish shall be identified.
3. Revised specifications/instructions to avoid further recurrence of non‐conformance shall be issued.
2.3.1. Non‐conformance in case of earthworks, base and other pavement coarse can be treated as per
guidelines under Section 2.1 , 2.2, and 2.3 0.0 applicable.
3. Records
1. It is mandatory that all instances of work outside the specification are recorded in writing and conveyed to
the contractor. This ensures that:
(a) The contractor is irrefutably informed.
(b) A record of non‐compliance is built up to give a general guide to the contractor's performance.
2. The records of repair/rectification, retesting, inspection and acceptance shall be kept as part of 'as‐built'
documentation.
3. Record of all references to designers for concessions/rectification and approval given by them shall be kept.
4. Record of compliance to the modifications in procedures, testing, etc., if any shall be kept.
QUALITY AUDITS F‐2
Project
(Package‐IV)
1. Programme
The Quality Assurance Manager shall establish, document and implement a programme for audits which shall
objectively evaluate the adequacy of the functions, systems and procedures as referenced in the Quality
Manual.
The audit programme shall define:
1. The functions, systems and procedures to be audited.
2. Personnel qualified to perform audits.
3. Frequency of audits
4. Method of reporting findings and recommendations.
5. The means for having corrective actions agreed upon and implemented.
Audit shall include an evaluation of process audit and product audit.
1.Quality practices, systems, procedures and instructions.
2.Certification documents and records..
3. Quality of (intermediate or) end product.
Audit shall be carried out by appropriately trained personnel who are not directly responsible for the area
being audited.
Audits shall be performed in accordance with documented audit procedures and/or checklists which identify
essential characteristics.
Management responsible for the area audited shall review, agree and correct deficiencies revealed in the
documented audited results.
All action taken to correct deficiencies shall be re‐audited to verify compliance and a closeout report issued.
2. Example of Quality Audit Report
The scope and depth of the Quality Audits shall be determined by the Quality Assurance Team responsible to
the Management. The procedures for quality audit of concrete, asphalt and wet
mix macadam are given below for illustrating the principles.
Annexure‐ A
List of Laboratory Equipment's
Authority
GDRPL ‐ VSPL (JV)
Engineer
Contractor DRAIPL‐MKCIL (JV)
S. No. Description
A GENERAL
1 Weigh Balances
a 5 ‐ 20 Kg capacity Electronic type ‐ Accuracy 1 gm
b 500 gm capacity‐Electronic Type Accuracy 0.01 gm
c Electronic 5 kg capacity Accuracy 0.5
d Platform Balance scale‐300 kg capacity
e Chemical Balance 100 gm capacity‐accuracy 0.001 gm
Oven‐electrically operated, thermostatically controlled (including thermometer), stainless steel interior, From
2
0°C to 200°C Sensitivity 1°C
3 Sieves : as per IS:460 ‐ 1962
a I.S. sieves 450 mm internal dia of sieve sets as per BIS of required sieve sizes complete with lid and pan
IS sieve 200 mm internal dia (brass frame and steel/or brass wire cloth mesh) consisting of sieve sets of required
b
sieve sizes complete with lid
4 Sieve shaker capable of aking 200 mm and 450 mm dia sieves‐electrically operated with switch
5 Stop watches 1/5 sec. accuracy
Glassware comprising beakers, pipettes, dishes, measuring cylinders (100 to 1000 cc capacity) glass rods and
6
funnels, glass thermometers range 0'C to 100'C and metallic thermometers range up to 300C.
7 Hot plates 200 mm dia (1500 watt.0
8 Enamel trays
a 600 mm x 450 mm x 50 mm
b 450 mm x 300 mm x 40 mm
c 300 mm x 250 mm x 40 mm
d Circular plates of 250 mm dia
9 Water Testing Kit
B FOR SOILS
1 Water still
2 Liquid limit device with ASTM grooving tools as per IS:2720
3 Sampling pipettes fitted with pressure and suction inlets, 10 ml. Capacity
Compaction apparatus (Proctor) as per IS:2720 (Part 7 ) complete with collar, base plate and hammer and all
4
other accessories.
S. No. Description
Modified AASHTO Compaction apparatus as per IS : 2720 (Part 8)1974 or Heavy Compaction Apparatus as per IS
5
complete with collar, base plate hammer and all other accessories
Sand pouring cylinder with conical funnel and tap and complete as per IS:2720 (Part 28) 1974 including modern
6
equipment.
7 Ennore Standard Sand
Sampling tins with lids 100 mm dia x 75 mm ht. 1/2 kg capacity and miscellaneous items like moisture tins with
8
lid 50 grams etc.
Lab CBR testing equipment for conducting CBR testing, load frame with 5 Tonne capacity, electrically operated
9
with speed control as per IS:2720 (Part 160) and consisting of following:
a CBR moulds 150 mm dia ‐ 175 mm ht.
b Tripod stands with holding dial gauge holder
c CBR plunger with settlement dial gauge holder
d Surcharge weight 147 mm dia 2.5 kg wt.
e Spacers disc 148 mm dia 47.7 mm ht. With handle
f Perforated plate (Brass)
g Soaking tank for accommodating 6 CBR moulds
h Proving rings of 1000 kg, 2500 kg and 3000 kg capacity
i Dial gauges 25 mm travel ‐ 0.01 mm/division
10 Standard/Dynamic penetration test equipment
11 Speedy moisture meter complete with chemicals
12 Hydrometer & Hydrometer jar
13 Unconfined Compression Test Apparatus
Direct shear test apparatus having 12 variable speed and 2 KN proving ring with all the assessories given in IS
14
:2720 Part 13.
C FOR BITUMEN AND BITUMINOUS MIXES
Constant temperature bath for accommodating bitumen test specimen, electrically operated, and
1
thermostatically controlled (to accommodate minimum six Specimens)
2 Penetrometer, including adjustable weight arrangement and needles as per IS:1203‐ 1958
3 Soxhlet extraction or centrifuge type apparatus complete with extraction thimbles with solvent and filter paper
Marshall compaction apparatus automatically operated as per ASTM 1559‐62 T complete with accessories (with
4
180 N Marshall Moulds
5 Ductility meter
6 Softening point (Ring and ball app)
7 Digital/Distant reading thermometer
8 Rifle box
9 Core cutting machine suitable for upto 150 mm dia core
10 Thermometers
Cannon Manning Viscometer for determination of absolute viscocity and Cannon Fenske Viscometer for
11
determination of Kinematic viscosity
S. No. Description
12 Gas stove and Cylinder
D FOR CEMENT, CONCRETE AND AGGREGATES
1 Water still
2 Vicat needle apparatus for setting time with plungers as per IS:269‐ 1967
3 Moulds
a 150 mm x 300 mm ht. Cylinder with capping component along with the capping set and compound
b Cube 150 mm, and 100 mm (each size)
4 Concrete permeability apparatus
High frequency mortar cube vibrator for cement testing
5
Cement motor mould (70.6mmW*70.6mmL*70.6mmH)
6 Concrete mixer power driven, 1 cu.ft. capacity
7 Variable frequency and amplitude vibrating table size 1 m x 1 m as per the relevant British Standard
8 Flakiness & Elongation index test apparatus
9 Aggregate impact test apparatus as per IS:2386 (Part 4) 1963
10 Los‐angels abrasion test apparatus as per IS:2386 (Part 4) 1963
11 Flow table as per IS:712‐1973
12 Equipment for slump test
13 Equipment for determination of specific gravity or fine and coarse aggregate as per IS:2386 (Part 3) 1963
14 Compression and Flexural strength testing achine of 200 T capacity with additional dial for flexural testing
15 Core cutting machine with 10 cm dia diamond cutting edge
16 Needle vibrator
17 Air entrainment meter
18 0.5 Cft, 1 Cft cylinder for checking bulk density of aggregate with tamping rod
19 Soundness testing apparatus for cement (Lee chattlier)
20 3 liter, 15 liter and 30 liter cylinder as per IS:2386 Part 3 for checking bulk density of aggregate with tamping rod
E FOR CONTROL OF PROFILE AND SURFACE EVENNESS
1 Total Station
2 Precision automatic level with micrometer attachment
3 Distomat or equivalent
4 Theodolite ‐ Electronically operated with computerized output attachment
5 Precision staff
6 3 meter straight edge and measuring wedge
7 Camber template 2 Lane
S. No. Description
a Crown type cross‐section
b Straight run cross‐section
8 Steel tape
a 5 m long
b 10 m long
c 20 m long
d 30 m long
e 50 m long
9 Roughometer (Bump Integrator)
Annexure‐ I
Monthly Progress Report Format
Monthly Progress Report
Construction of Four lane expressway from start of DSIR zone of Ahmedabad district to Adhelai village of Bhavnagar district (Ch. 71+060 to Ch. 109+019) section of Ahmedabad‐ Dholera Greenfield alignment (NH‐751) on EPC mode under Bharatmala pariyojana in the
Project state of Gujarat (Package‐IV)
Authority Engineer GDRPL ‐ VSPL (JV)
No. of Test conducted up to
During No. of Test conducted During Month No. of Test conducted up to this months No. of Test conducted by Independent Engineer
No of test Required previous months
Sl.No Type of Test Month Frequency Test method Remarks
during Month
(QTY) Conducted Pass Fail Conducted Pass Fail Conducted Pass Fail During month Upto last month To date
A OGL (m 2)
i) Proctor Density Test (MDD & OMC) Types of soil IS 2720 Part‐8
ii) Compaction Test for OGL (m2) 1 Tests for every 1000 m2 IS 2720 Part‐28
3
B Borrow Area (M )
i) Sand Content 2 tests for 3000 cu.m of soil IS 2720 Part‐4
ii) Plasticity Test Each type to be tested, 2 tests IS 2720 Part‐5
iii) Density Test Each soil type to be tested, 2 tests IS 2720 Part‐8
iv) Deleterious Content Test As and when required by the Engineer IS 2720 Part‐27
v) Moisture Content Test Two Tests IS 2720 Part‐2
3
vi) CBR Test for Sub‐Grade 1 Test for every 3000 m IS 2720 Part‐16
C For Earth Work in Embankment / Sub‐Grade (Field Compaction Test)
i) Compaction Control for Embankment 1 Test/ 3000 sqm. IS 2720 Part‐28
ii) Compaction Control for Sub‐Grade 1 Test/ 2000 sqm. IS 2720 Part‐28
D Cutting Soil for Embankment/ Sub‐Grade
i) Sand Content 2 tests for 3000 cu.m of soil IS 2720 Part‐4
ii) Plasticity Test Each type to be tested, 2 tests IS 2720 Part‐5
iii) Density Test (MDD) Each soil type to be tested, 2 tests IS 2720 Part‐8
iv) Deleterious Content Test As and when required by the Engineer IS 2720 Part‐27
v) Moisture Content Test Two Tests IS 2720 Part‐2
vi) CBR Test for Sub‐Grade 1 Test for every 3000 m3 IS 2720 Part‐16
vii) Compaction Control for Embankment 1 Test/ 3000 sqm. IS 2720 Part‐28
viii) Compaction Control for Sub Grade 1 Test/ 2000 sqm. IS 2720 Part‐28
E For Granular Subbase (m3)
i) Gradation One test per 400 cu.m MoRT&H Table 400‐1
ii) Atterburg Limits One test per 400 cu.m IS 2720 Part‐5
iii) Moisture content prior to compaction One test per 400 cu.m IS 2720 Part‐2
iv) Density of Compacted Layer One test per 1000 sq.m IS 2720 Part‐28
v) Deleterious constituents As required
vi) CBR Test in soaked condition As required IS 2720 Part‐16

during Month
vii) Proctor Density Test Source Approval/when required IS 2720 Part‐8
viii) Ten percent Fines Value Source Approval/when required IS 2386 Part‐4
3
F For Cement Treated Subbase (m )
One test for each source or min one
i) Quality of Cement MoRT&H
test on 5 tonnes
ii) Cement Content Regularly MoRT&H
iii) Degree of Pulverization Periodically as considered necessary ‐
iv) CBR on set of 3 specimens As required MoRT&H
v) Moisture content prior to compaction One set of two tests per 500sqm MoRT&H
vi) Density of compacted layer One set of two tests per 500sqm MoRT&H
vii) Deleterious constituents As required IS 2720 Part‐28
G For Wet mix Macadam (m3)
i) Aggregate Impact Value One test per 1000 cu.m of aggregate IS 2386 Part‐4
ii) Grading of aggregate One test per 250 cu.m of aggregate MoRT&H Table 401
iii) Combined Flakiness and elongation Indices One test per 500 cu.m of aggregate IS 2386 Part‐1
Atterberg Limits of portion of aggregate passing 425
iv) One test per 200 cu.m of aggregate IS 2720 Part‐5
micron sieve
v) Density of Compacted Layer One set of three tests per 1000 sq.m IS 2720 Part‐28
vi) Water absorption of Aggregate Source Approval/when required IS 2386 Part‐3
vii) Proctor Density Test (MDD & OMC) Source Approval/when required IS 2720 Part‐8
H For Prime Coat / Tack Coat
Number of samples per lot and tests as
i) Quality of Binder per IS:73, IS:217 and IS:8887 as
applicable
ii) Binder temperature for application At regular close intervals
iii) Rate of Spread of Binder/Prime coat (m2) Three tests per day IRC SP 11
iv) Rate of Spread of Binder/Tack coat (m2) Three tests per day IRC SP 11
I Bitumen (VG‐40)
IS: 1203 ‐ 1978
i) Penetration Test (Lot) Each lot 1 test
(Page No.28)
IS : 1205 ‐ 1978
ii) Softening Point (Lot) Each lot 1 test
(Page No.37)
iii) Absolute viscosity (Lot) Each lot 1 test IS 1206
IS : 1206 (Part III) ‐ 1978
iv) Kinematic viscosity (Lot) Each lot 1 test
(Page No.64)
IS : 1208 ‐ 1978
v) Ductility (Lot) Each lot 1 test
(Page No.73)
during Month
IS : 1202 ‐ 1978
vi) Specific Gravity (Lot) Each lot 1 test
(Page No.22)
IS: 1209 ‐ 1978
vii) Flash point (Lot) Each lot 1 test
(Page No.83)
IS : 1212 ‐ 1978
viii) Loss on heating (Lot) Each lot 1 test
(Page No.100)
IS : 1211 ‐ 1978
ix) Water Content (Lot) Each lot 1 test
(Page No.96)
IS : 6241‐ 1971
x) Stripping Value Test (Lot) Each lot 1 test
(Page No.4)
xi) Matter Solubility in Tricholoroethylene (Lot) Each lot 1 test IS 1216
J Dense Bituminous Macadam
Number of samples per lot and tests as IS 73, IRC:SP 53 and IS
i) Quality of Binder
per IS 73, or IRC SP‐53, IS 15462 15462 as applicable
One test per 350 cu.m of aggregate for
ii) Aggregate Impact Value/Los Angles Abrasion Value each source and whenever there is IS 2386 Part‐IV
change in the quality of aggregate
iii) Combined Flakiness and Elongation Indices each source and whenever there is IS 2386 Part‐I
One test for each source and whenever
Soundness test (Sodium or Magnesium Sulphate
iv) there is change in the quality of IS 2386 Part‐V
test)
aggregate
v) Water absorption of Aggregate there is change in the quality of IS 2386 Part‐III
aggregate
vi) Sand equivalent test there is change in the quality of
aggregate
vii) Plasticity Index there is change in the quality of
aggregate
viii) Polished stone value there is change in the quality of IS 2386 Part‐IV
aggregate
One test per 350 cu.m of aggregate ASTM D 5821, IS 2386 ‐
ix) Percentage of fractured face
when crushed gravel is used Part 1
One set for individual constituent and
mixed aggregate from dryer for each
x) Mix grading
400 tonnes of mix subject to two tests
per day per plant
Three tests for stability, flow value,
Stability and voids analysis of mix including density and void contents for each 400
xi)
theoretical maximum specific of loose mix tonnes of mix subject to minimum of
two tests per day per plant
One test for each mix whenever there is
xii) Moisture Susceptibility of mix (AASHTO T283) change in the quality or source of ASHTO 283
coarse of fine aggregate
Temperature of binder in boiler, aggregate in dryer
xiii) At regular intervals
and mix at the time of laying and compaction
One set for each 400 tonnes of mix
xiv) Binder Content subject to minimum of two tests per MS‐2, ASTM D 5581
day per plant
during Month
xv) Rate of spread of mix material After every 5th truck load
xvi) Density of Compacted Layer One test per 700 sq.m area AASTHO T 166
xvii) Stripping Value of Aggregate Source Approval/when required IS 6241
xviii) with sodium sulphate Source Approval/when required ‐
xix) with magnesium sulphate Source Approval/when required ‐
xx) SG/Water absorption of Aggregate Source Approval/when required IS 2386 Part‐3
xxi) Mix Grading (dry) Each 400 tones of mix MoRT&H Table 500‐10
xxii) Stability of mix Each 400 tones of mix ASTM D 1559
K Bituminous Concrete (M3)
Number of samples per lot and tests as IS 73, IRC:SP 53 and IS
i) Quality of Binder
per IS 73, or IRC SP‐53, IS 15462 15462 as applicable
ii) Aggregate Impact Value/Los Angles Abrasion Value each source and whenever there is IS 2386 Part‐IV
iii) Flakiness and Elongation Index each source and whenever there is IS 2386 Part‐I
Soundness test (Sodium or Magnesium Sulphate
iv) there is change in the quality of IS 2386 Part‐V
test)
aggregate
v) Water absorption of Aggregate there is change in the quality of IS 2386 Part‐III
aggregate
vi) Sand equivalent test there is change in the quality of
aggregate
vii) Plasticity Index there is change in the quality of
aggregate
viii) Polished stone value there is change in the quality of IS 2386 Part‐IV
aggregate
One test per 350 cu.m of aggregate
ix) Percentage of fractured face
when crushed gravel is used
One set for individual constituent and
mixed aggregate from dryer for each
x) Mix grading
400 tonnes of mix subject to two tests
per day per plant
Three tests for stability, flow value,
Stability and voids analysis of mix including density and void contents for each 400
xi) AASTHO T 245
theoretical maximum specific of loose mix tonnes of mix subject to minimum of
two tests per day per plant
One test for each mix whenever there is
xii) Moisture Susceptibility of mix (AASHTO T283) change in the quality or source of ASHTO 283
coarse of fine aggregate
during Month
Temperature of binder in boiler, aggregate in dryer
xiii) At regular intervals
and mix at the time of laying and compaction
One set for each 400 tonnes of mix
xiv) Binder Content subject to minimum of two tests per ASTM D 2172
day per plant
xv) Rate of spread of mix material After every 5th truck load
xvi) Density of Compacted Layer One test per 700 sq.m area AASTHO T 166
xvii) Stripping Value of Aggregate Source Approval/when required IS 6241
xviii) with sodium sulphate Source Approval/when required ‐
xix) with magnesium sulphate Source Approval/when required ‐
xx) SG/Water absorption of Aggregate Source Approval/when required IS 2386 Part‐3
xxi) Mix Grading (dry) Each 400 tones of mix MoRT&H T10
xxii) Stability of mix Each 400 tones of mix ASTM D 1559
L Stone Matrix Asphalt (M3)
Number of samples per lot and tests as
IS 73, IRC:SP 53 and IS
i) Quality of Binder per IS 73, IRC SP‐53 and IS 15462 as
15462 as applicable
applicable
One test per 100 cu.m of each source
ii) Aggregate Impact Value/Los Angles Abrasion Value and whenever there is change in the IS 2386 Part‐4
quality of aggregate
iii) Combined Flakiness and Elongation Indices One test per 100 cu.m for each source IS 2386 Part‐1

One test of each source and whenever
iv) Polished stone value there is change in the quality of IS 2386 (P‐114)
aggregate
One test of each source and whenever
v) Water absorption of Aggregates there is change in the quality of IS 2386 Part‐3
aggregate
Three test per day of each source and
vi) Water Sensitivity of mix whenever there is change in the quality ASHTO T283
of aggregate
vii) Mix Grading Two tests per day IS 2386 Part‐1
viii) Soundness(Magnesium Sulphate/Sodium Sulphate) there is change in the quality of IS 2386 Part‐5
aggregate
One test per 50cu.m of aggregate when
ix) Percentage of fractured faces ‐
crushed aggregate is used
x) Binder Content Each 400 tones of mix MORT&H
Control of temperature of binder and aggregate for
xi) At regular intervals
mix and of the mix at the time of laying and rolling
xii) Density of Compacted Layer One test per 250 sq.m area AASTHO T 166
xiii) Rate of Spread of Mixed Material After every 5th truck load
xiv) Plasticity Index for Mineral Filler One test for each source IS 2720 Part‐5
M Dry Lean Concrete (DLC)
Gradation of Aggregate (Individual /Combined) 1 Test/Day IS 2386, Part 1
Strength of concrete 3 Samples/1000 sqm. IS 516
Field Compaction Test (By Sand Replacement
3 density holes/2000 sqm. IS 2720, Part 28
Method)
during Month
N Pavement Quality Concrete (PQC)
Gradation of Aggregate (Individual /Combined) 1 Test/Day IS 2386, Part 1
Deleterious Constutuents 1 Test/Source IS 2386, Part 2
Water Absorption 1 Test/Source IS 2386, Part 3
Moisture Content Test 1 Test/Day IS 2386, Part 3
Los Angeles Abrasion Test 1 Test/Source IS 2386, Part 4
Combined Flakiness & Elongation 1 Test/Week IS 2386, Part 1
Sand Equivalent Test 1 Test/Source IS 2720, Part 37
Soundness of aggregates 1 Test/Source IS 2386,Part 5
Compressive Strength of Concrete 2 cubes and 2 beams per 150 cu.m or IS 516

part of or mínimum 6 cubes an 6 beams
Flexural Strength ( 3 for 7days & 3 for 28 days) IS 516
Core Strength As Required IS 516
One test for each load at both
Workabilty of Concrete IS 1199
Batching plant site and paving site
O Structural Concrete Work (M3 )
1 Cement
‐
i) Consistency for Every Batch/Lot IS 4301 Part‐4
ii) Initial setting time & final setting time for Every Batch/Lot IS 4301 Part‐5
iii) Fineness for Every Batch/Lot IS 4301 Part‐6
iv) Compressive strength (3 Days) for Every Batch/Lot IS 4301 Part‐6
v) Compressive strength (7 Days) for Every Batch/Lot IS 4301 Part‐6
vi) Compressive strength (28 Days) for Every Batch/Lot IS 4301 Part‐6
2 Water Source Approval/when required IS 456
3 Steel Reinforcement Source Approval/when required IS
4 Admixture Source Approval/when required IS
5 Coarse & Fine Aggregates :
‐
i) Gradation Test for Coarse Aggregate 1 Test / day IS 383
ii) Gradation Test for Fine Aggregate 1 Test / day IS 383
iii) Flakiness Index 1 Test / day IS 2386 Part‐1
iv) Aggregate Impact Value/Los Angles Abrasion Value 1 Test / day IS 2386 Part‐4
v) Soundness Test Source Approval/when required IS 2386 Part‐5
6 Concrete Compressive strength (7 Days) m3 IS 516
during Month
7 Concrete Compressive strength (28 Days) m3 IS 516
P Calibration
i) Concrete Batching Plant (CP‐30) One test for every year ‐
ii) Concrete Batching Plant (CP‐60) One test for every year ‐
iii) Sand pouring cylinder 150mm dia. One test for every month IS 2720 Part‐28
iv) Sand pouring cylinder 200mm dia. One test for every month IS 2720 Part‐28
v) Sand pouring cylinder 100mm dia. One test for every month IS 2720 Part‐28
vi) Rapid moisture meter One test for every month ‐
vii) Compressive testing machine 2000KN One test for every year ‐
viii) Flexural Testing Machine One test for every year ‐
ix) Proving ring 50KN One test for every year ‐
x) Proving ring 30KN One test for every year ‐
xi) Proving ring 25KN One test for every year ‐
xii) WMM Plant 160TPH One test for every year ‐
xiii) HM Plant 160TPH One test for every year ‐
xiv) Bitumen Sprayer One test for every year ‐

Annexure
NCR Format
IE/AE/Supervisions Consultant
Concessionaire
Non Conformance Report
Inspected by: Report
(NCR) No.
RFI No: Date:
Nin Conformance: Location: Details:
Detailed Description of Non Conformance :
NCR Category
Name &
Signature
1 2 3 4 5 6 7
Recommended Remedial Action:
lssued by Name/ Designation / Signature Completion Target Date:
Copy
1‐ File IE/AE/Supervision Consultant: 2.Concessionaire 3. Client:
Category:
1. Safety Arrangements Minor /Major
2. Defective Concrete works . Minor /Major
3. Defective Road Works . Minor /Major
4. Tests not conducted as specified . Minor /Major
5. Check lists and records not authenticated . Minor /Major
6. Non‐compliance with specifications and standards . Major
7. Non‐compliance with Recommendations .
8. Product not to acceptable standards. (Requires rejection). . Major
. Major
Standard Format for Acceptance on Compliance to NCR
Authority
IE/AE/Supervisions Consultant
Concessionaire
Non Conformance Report
Inspected by: Report (NCR) No.
RFI No: Date:
Non Conformance: Location: Details:
Detailed Description of Non Conformance :
NCR Issued NCR Category
by
(Name/Desig
1 2 3 4 5 6 7
nation)
Remedial Action Taken:
Witnessed by IE and Concessionaire (Name/ Designation / Signature) Completion Date:
Copy
1‐ File IE/AE/Supervision Consultant: 2.Concessionaire 3. Client:
Category:
1. Safety Arrangements Minor /Major
2. Defective Concrete works . Minor /Major
3. Defective Road Works . Minor /Major
4. Tests not conducted as specified . Minor /Major
5. Check lists and records not authenticated . Minor /Major
6. Non‐compliance with specifications and standards . Major
7. Non‐compliance with Recommendations .
8. Product not to acceptable standards. (Requires rejection). . Major
. Major
Annexure‐ G
RFI Format
Date Time
Request by: Contractor Date/Time Note:

1. Contractor to submit the Request by
minimum of 48 hours in advance of work
requirements.
Comments: 2. Engineer to return approved or disapproved
original and one copy to the contractor before
the work proceeds.
Request to begin activity is:
APPROVED/DISAPPROVED
Name:
Designation:
Signature:
Date:
REQUEST FOR INSPECTION / APPROVAL
RFI No. Date :
Request for Inspection on

Survey Subgrade SMA Box Culverts
Clearing & Grubbing GSB DLC & PQC Minor Bridge
Excavation CTSB Drainage & Protection Major Bridge
Scarifying WMM RE Wall SVUP
Dismantling Works Prime Coat Road Marking LVUP
Lab Tack Coat Formwork VUP
OGL DBM Structural Concrete VOP
Embankment BC Reinforcement Flyover (Interchange)

Work Particulars
Chainage :
:
Description of works
Layer : Date: Time of Inspection:

Requested by : Received by :
Name : Name :
Signature : Signature :
Date : Date :
Time : Time :
Comments (if any) :-
Tick to indicate Approved to Commence Work

Remedial Works required as above but no further approval
Remedial Works required as above but reinspection and approval reqired
For EPC Contractor For Authority/Client Engineer

Signature: Signature :
Name : Name :
Date : Date :

Road Construction Approved QAP

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Construction of Four lane expressway from start of DSIR zone of

Construction of Four lane expressway from start of DSIR zone of

10.2.2. Test Specifications ........................................................................................ 24

Construction of Four lane expressway from start of DSIR zone of

12. 1. Internal Quality Audit Procedure ......................................................................... 39

Annexure Name of Document No.

Construction of Four lane expressway from start of DSIR zone of

Construction of Four lane expressway from start of DSIR zone of

Quality Assurance Plan

1. 2. Quality Assurance (QA)

1. 3. Authority, Contractor, Authority Engineer

Client / Authority National Highway Authority of India

1. 4. Quality Assurance Manual

1. 6. Quality Control (QC)

Construction of Four lane expressway from start of DSIR zone of

Figure 1- Structure of Quality Management System

3. SCOPE AND APPLICATIONS

1. Organisation structure of Contractor’s project implementation team including

Construction of Four lane expressway from start of DSIR zone of

4. Laboratory infrastructure, equipment and personnel.

Construction of Four lane expressway from start of DSIR zone of

Figure 2- Organization Setup of the Project

Construction of Four lane expressway from start of DSIR zone of

5. DUTIES AND RESPONSIBILITIES

Construction of Four lane expressway from start of DSIR zone of

Construction of Four lane expressway from start of DSIR zone of

Construction of Four lane expressway from start of DSIR zone of

Construction of Four lane expressway from start of DSIR zone of

Construction of Four lane expressway from start of DSIR zone of

6. SITE INSPECTION & DAILY REPORTS

6.1 Site Inspections

6.2 Daily / Weekly Reports

1. Quantities of work performed and accepted under his inspection.

Construction of Four lane expressway from start of DSIR zone of

6.3 Borrow Area Inspection

7.1 Construction Work Program

7.2 Progress Control

2. Various circumstances may justify the changing of contract requirements for

Construction of Four lane expressway from start of DSIR zone of

(modification of Contract); suspensions of work; delays in providing access; force

8. DESIGN QUALITY PLAN

8.2 Design Control

Construction of Four lane expressway from start of DSIR zone of

8.3 Control of Design Changes

Construction of Four lane expressway from start of DSIR zone of

8.4 As-Built Drawings

Construction of Four lane expressway from start of DSIR zone of

9.2 Document Control Procedure

Construction of Four lane expressway from start of DSIR zone of

Contract execution generates technical as well as non-technical documents. Documentation

PM office Received copy, Records, Dispatch Outgoing

PM assigns action to PM Review of Action to Planning Engineer Filling,

Figure 3- Flow chart for Documentation

1. PM office shall receive, acknowledge, record incoming documents.

Construction of Four lane expressway from start of DSIR zone of

10. QUALITY CONTROL

Construction of Four lane expressway from start of DSIR zone of

10.2 Quality Control Flow Chart

10.3 Performance of Quality Control

1. Laboratories must be built and equipped.

Construction of Four lane expressway from start of DSIR zone of

10.3.2 Test Specifications

Construction of Four lane expressway from start of DSIR zone of