QUALITY ASSURANCE PLAN

Scope of Job Fabrication and supply of Bow Sting Girders span 58 MTR , 2 nos. sets as per Given Drawing.
Client Surat Municipal Corporation, Gujrat.
Name of Project : - Construction of Bridge across Tapi River and along Varachha Creek near Varachha Water Works (4 lane) at Surat. On EPC basis.
Contractor :- M/S VIJAY M. MISTRY CONST. PVT. LTD., AHMEDABAD
Manufactured By: M/S SATURN PREFAB INDIA PVT. LTD. PLOT NO :- 727-728 SEC - 03 PITHAMPUR, DHAR (M.P.) 454775
QAP No. SPIPL/VMMCPL/TPI/2021-22/02 dt. 04/09/2021
CA No. Bridge Cell/Out/No. 2606
IRS-B1-2001 & IRS welded bridge code/ IS:2062/-2011/IS 4225/ASTM SA-435/IS:1852/IS:5905/IS:2590/IS:9595/IS:4353/
Specifications
IS:7310/IS:3935/BS-110/IRSM-39/IRS:M-46/ISO 6892 etc and the relevant approved drawing and the contract agreement.
Inspection Details
Component / Reference Fabricators Quality
S No. Characteristic Check Frequency & type of check Inspecting Format & Record Acceptance Criteria Remarks
Operations Document Control Extent of Inspection
Agnency
1 2 3 4 5 6 7 8 9 10 11
1.0 Raw Material
Identification and
correlation with Mill Test
As per Mill T.C. and Tests
Steel Plates, Certificate from Supplier Verification of reference 100% Witness of 1. Plates: IS 2062-
1.1 required by RDSO from Challan, Mill T.C. VMMCPL/TPI Fabricator’s record
Structural Section e.g., SAIL,JINDAL,ESSER, document Test Sample at Lab 2011, Gr. E 350 BR,
GOVT./ NABL approved lab
, TISCO, VIZAG &
Rashtriya Ispan etc.

Physical condition i.e.,

Complete visual 100% of each heat/ Fabricator’s Record as IS 2062-2011 Gr. E
Pitting, rusting, straightness, Visual IS 2062:2011 VMMCPL/TPI
inspection Cast no. per IRS B1-2001 350 BR
rolling defect, etc.

IS 2062-2011 Gr. E
Mechanical Test as per IS 250 B0 fully killed &
Heat/Cast no.
2062-2011, Gr. E250/E350, normalized or control Raw material clearance
section wise as per
Quality B0 for MS Plate & Lab Tests NABL approved lab Challan, Mill T.C. Lab test reports VMMCPL/TPI .-do- cooled, rolled section shall be by
IS 2062-2011
BR/A for rolled section (Angle, ISMC) VMMCPL/TPI
E250/E350 Gr. BR
UTS, YS, % El, Bend test, IS2062-2011 Gr.
E250 A

Charpy test at 00C for plates

Heat/Cast no.
with 12mm and above as per
Lab Tests NABL approved lab Challan, Mill T.C. Lab test reports VMMCPL/TPI section wise as per Fabricator’s Record .-do-
IS 2062-2011 E250/E350
IS 2062-2011
Gr. B0

as per IS 2062-
Chemical Test as per IS
Lab Tests NABL approved lab Challan, Mill T.C. Lab test reports VMMCPL/TPI 2011, Heat/Cast no. .-do- .-do-
2062-2011
section wise

For and on behalf of Fabricator For and on behalf of Contractor For and on behalf of Client
M/S Saturn Prefab India Pvt.Ltd M/s Vijay M. Mistry Const. Pvt. Ltd.

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 Inspection Details
Component / Reference Fabricators Quality
SN Characteristic Check Frequency & type of check Inspecting Format & Record Acceptance Criteria Remarks
Operations Document Control Extent of Inspection
Agnency
1 2 3 4 5 6 7 8 9 10 11
Ultrasonic test for 12mm
thk. & above Plates, as per IS 4225 or ASTM SA Check by
By ASNT Level -II operator Challan, Mill T.C. Test reports VMMCPL/TPI 100% .-do-
IS 4225 or ASTM-SA 435/435M VMMCPL/TPI
435/435M
Fabricator’s record &
Measurement with calibrated Measurement of
Dimension Challan VMMCPL/TPI 100% VMMCPL/TPI
steel tape/Dmeter etc. Dimension
record

Contact surface for

Challan, Mill T.C ,
bolting area red axide
a) Dimension Inspection Report, Property class for bolt
HSFG Nut Bolt & Co- relation With TC and Verification of primer (IS 2074) use
1.2 b) Physical condition c) Lab test report of VMMCPL/TPI As per requirement Fabricator’s record as per approved
DTI Washaer Sample Test To be done Reference Document only procure by RDSO
Material Qty approved NABL drawing
Approved vender as
approved Lab
per BS:111/R6

Shear Connector
Dimension Mechanical & Manufacturer’s Procured from RDSO
1.3 Stud as per Drg. EN Lab Test at NABL accredited .-do- VMMCPL/TPI As per requirement .-do- .-do-
Chemical Test Test Certificates, Approved vender
ISO-13918-08
Verification of
Challan., Paints to be procured
Manufacturer’s Test Verification of Manufacturer’s Test As per contact
1.4 Paint Lab Test at NABL accredited Manufacturer’s VMMCPL/TPI Each Batch from vendors approved
Certificate, Inspection Reference Document Certificate agreement
Test Certificate by RDSO
Certificate, Challan
Challan.,
Verification of
Tests as per Specification as per code requirement Manufacturer’s VMMCPL/TPI Random Lab test record .-do- .-do-
Reference Document
Test Certificate
Challan., Consumables should
Welding As per specification and as Verification of
1.5 as per code requirement Manufacturer’s VMMCPL/TPI As per requirement Fabricator’s Record be of RDSO appvd.
Consumables approved by RDSO Reference Document
Test Certificate Brand
2 Manufacturing Process

Lay out of
Relevant IS/IRS Clearance by
Components & Measurement with calibrated Approved Measurement of Iinspection Report of
2.1 Dimension VMMCPL/TPI 100% Codes & Approved VMCCPL/TPI
Joints a) Normal b) steel tape & gauges Drawing Dimension Inspection Official
Drawings Offficials
Bolted Connection

Record of Jigs &

Dimension, Intersection fixtures as per Clearance by
Measurement with calibrated Approved Measurement of
b) Jigs & Templates lines, pitch, gauge, dia. Of VMMCPL/TPI 100% performa issued by IRS B1-2001 VMCCPL/TPI
steel tape & gauges Drawing Dimension
Holes & No. of holes VMCCPL/TPI Offficials
Offficials

Inspection Report
c) Cutting, of Inspection Inspection Report of
Dimension, Freedom from Visual & Measurement IRS B1-2001, IS
Straightening, Edge Visual/ Measurement Official & VMMCPL/TPI 100% Inspection Official &
defect of dimension 1852-85
preparation Fabricator’s Fabricator’s Record
Record

For and on behalf of Fabricator For and on behalf of Contractor For and on behalf of Client
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M/S Saturn Prefab India Pvt.Ltd M/s Vijay M. Mistry Const. Pvt. Ltd.

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 Inspection Details
Component / Reference Fabricators Quality
SN Characteristic Check Frequency & type of check Inspecting Format & Record Acceptance Criteria Remarks
Operations Document Control Extent of Inspection
Agnency
1 2 3 4 5 6 7 8 9 10 11
3 Welding:

IRS B1-2001 IS
Only VMMCPL/TPI
a) Submission of 9595-96 WBC- Verification of IRS B1-2001 IS 9595-
Review of WPSS Verification VMMCPL/TPI 100% Fabricator’s Record Certified Welders to be
WPSS 2001, IS 7310 Reference Document 96 WBC-2001
engaged in the job
&7307

Witnessing of established Verification of WPQR Sheet to be

Visual, DT & NDT at approved As per code IS 7310(I)-74,
b) WPQR WPSS Review of Welder Reference Document & VMMCPL/TPI 100% recorded in presence
lab requirement IS 7307
Qualification test Test Report of VMC Rep.

Verification of Inspection Report of IS 7310(I)-74,

Measurement of As per approved
c) Preheating Visual with thermal Chalk Reference Document & VMMCPL/TPI Random Inspection Officials & IS 7307, IRS-B1-
Temperature WPSS
Test Report Fabricator’s Record 2001

As per Inspection Report of

d) Baking of To have moisture free Visual Check of Electrodes & Verification of
Manufacture’s VMMCPL/TPI 100% Inspection Officials & IRS B1-2001
Electrode, Flux Electrode & Flux beating Reference Document
recommendations Fabricator’s Record

e) Selection of
Reference to WPSS, IRS As per approved As per list of vendors
correct Electrodes Visual .-do- VMMCPL/TPI 100% .-do-
Class, etc. WPSS approved by RDSO,
& Flux

f) Current Measurement of Amp. & Visual with Ammeter & As per approved
.-do- VMMCPL/TPI Random .-do- IRS B1-2001
Condition Voltage Voltmeter WPSS

g) Sequence of As per approved

To control distortion Visual .-do- VMMCPL/TPI Random .-do- IRS B1-2001
Welding WPSS

h) Provision of
As per IRS B1-
Run-on & Run off To avoid crater defects Visual .-do- VMMCPL/TPI 100% .-do- IRS B1-2001
2001
Plates

For and on behalf of Fabricator For and on behalf of Contractor For and on behalf of Client
M/S Saturn Prefab India Pvt.Ltd M/s Vijay M. Mistry Const. Pvt. Ltd.

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 Inspection Details
Component / Reference Fabricators Quality
SN Characteristic Check Frequency & type of check Inspecting Format & Record Acceptance Criteria Remarks
Operations Document Control Extent of Inspection
Agnency
1 2 3 4 5 6 7 8 9 10 11

a) For Fillet Welds: Visual,

D.P.Test Fillet Size,
Visual Inspection & Relevant IS/IRS
Inspection of Penetration, Leg Length, Visual, Gauge & Macro Approved Drg. & Clearance by
4 Verification of VMMCPL/TPI 100% Fabricator’s Record Code, Approved Drg.
Welding Throat thickness, etc. b) for Eatching WPSS VMMCPL/TPI
dimension by gauges & WBC-2001
Butt weld visual & 100%
Radiography Test

a) Diamension as per
Test required the head of a stud
ISO 13918-2008 b)
to be displaced laterally by ISO 13918, IRS Clearance by
Stud Welding Visual and Bend test Visual & bend test VMMCPL/TPI 100% Fabricator’s Record Stud material
approx. 25% of its height using latest VMMCPL/TPI
properties as per ISO
a 6 Kg. Hammer.
6892.

a) Camber on Jack b) Dead

Load deflection c)
Dimension d) Fairness of
Complete dimensional Inspection Report of
holes e) Temporary One complete Clearance by
5 Trial Assembly Visual & Dimensional Approved. Drg. check of Control VMMCPL/TPI Inspection Official & IRS B1-2001
fasteners f) Imfringement g) Girder span VMMCPL/TPI
Assembly Fabricator’s Record
Butting of compression
edges h) Level i) Fairness of
holes.

Component completeness of Girder fabrication Inspection Report of

Visual Dimensional & Stage clearance Verification of Stage Clearance by
6 Final Clearance 1st span after dismentling & VMMCPL/TPI with approved Jigs- Inspection Official & IRS B1-2001
Structural Record clearance Record VMMCPL/TPI
2nd span onword 100% Fabricator’s Record

IRS B1-2001
Surface The surface should be free
Appendix-VII
Preparation by from scale, slag, oil, rust, Clearance by
7 Visual IRS B1-2001 Visual VMMCPL/TPI At Random Fabricator’s Record IS: 6586
Grit Blasting & grease, paint and other VMMCPL/TPI
IS: 5905
Metalizing foreign material
IS: 2590.

a) One coat of aluminum

metalizing, b) Eich Primer
IS-5666, c) One coat of Zinc IRS B1-2001
Cleaning & 1)Visual Checking, 2) Combine Clearance by
8 chromate primer as per IS IRS B1-2001 Visual VMMCPL/TPI At Random Fabricator’s Record IS:104, IS:51, IS:
Painting DFT by Elcometer VMMCPL/TPI
104, d) Two Coat of 2339, IS: 5666
aluminum paint as per IS
2339

Note: 1) During fabrication, internal inspection to be done by VMMCPL/TPI to ensure that only RDSO/ Railways approved welders carry out welding as per approved WPSS, work is as per dimensional tolerances and other quality
aspects and should satisfy itself before sending inspection call to Railway Officials for Trial Assembly or components inspection.

2) Final Clearance by VMMCPL/TPI with Client

3) Material Grade Shall be as per approved Drawings

For and on behalf of Fabricator For and on behalf of Contractor For and on behalf of Client
M/S Saturn Prefab India Pvt.Ltd M/s Vijay M. Mistry Const. Pvt. Ltd.

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