IRC:SP:112-2017

MANUAL FOR QUALITY CONTROL

IN
ROAD & BRIDGE WORKS

INDIAN ROADS CONGRESS

2017
 <-K. nctas

MANUAL FOR QUALITY CONTROL

IN
ROAD & BRIDGE WORKS

Publishect by:

INDIAN ROADS CONGRESS

Kama Koti Marg,
Sector-6, R.K. Puram,
New Delhi-110 022
NOVEMBER.2O17

Price : < 1500/-

(Plus Packing & Postage)
llltt:\' lt2 2011
IRCiSP:112-2017
I lrHl l,rrl)llnlr(xl November, 2017
CONTENTS

S. No. Description page

No.
Personnel ofthe ceneral Specificatjons and Standards Committee (l)
sEcTroN I INTRODUCTION 1
sEcTtoN 2 GENERAL APPROACH
2.1 Concept 3
22 Step wise procedure in Total euality Management 6
sEcTroN 3 PERSONNEL
31 Introduction 12
3.2 Integfal/Outsourced euatjty Assurance /Control Unit of 12
Contractor and jts Hie.archical position in Organization
3.3 QA,/QC Personnel of Contractor 12
34 QC Personnel of Engineer 14
(All Righb ReseNed. No paft of this publication shall be reproduced, SECTION 4 QUALITY ASSURANCE PLAN
translated or transmitted in any form or by any means without the
permission of the lndian Roads Congress) 4.1 Intfoduction 17
4.2 Objective 17
4.3 ceneral Principles 17
44 Quality Assurance plan for Different Stages of prolect 19
lmplementation
sEcTroN s QUALITY REQUIREMENTS FOR FACTORY MANUFACTURED
MATERIALS, PRODUCTS AND SPECIALIZED
5.1 Introduction 34
5.2 ceneral Principles 34
5.3 ResponsibilityofSupplier/tvlanufacturer 35
54 ResponsibilityofConcessionaire/Contractor 35
5.5 ResponsibilityofEngineer/ConsultanVEmployer/Authority 36
5.6 New l\,4ateriats 36
SECTION 6 FIELD LABORATORY SET UP
61 lntroduction 61
6.2 Objective 61
6.3 General Features 61
Printed by India Offset Press, Dethi-1 10 064
500 Copies
6.4 ProjectPreparation 63
 IRC:SP:112-2017

6.5 Construction 63 SECTION 11 : ACCEPTANCE/ NON CONFORMANCE/RECT|F|CAT|ON

6.6 lJpkeep and l\4aintenance 63 '11.1 Introduction '193
SECTION 7 : CALIBRATION OF INSPECTION, MEASURING AND TESTING 11.2 AcceptanceCriteria 194
EQUIPMENT 1'1.3 Failure to meetAcceotance Criteria 195
7.1 Introduction 73 11.4 Protocolfor Dealing with Non Conformance Works 195
7.2 Objective 73 11.5 Standard Formats 196
7.3 Scope SECTION 12 : THIRD PARTY QUALITY AUDIT
7.4 Type of Caljbration 75 12.1 Audit Objectives and Principles 200
7.S Requirements for Catibration 76 12.2 Third Party QualityAudit of Road Projects- ceneral Overview 200
7.6 Frequency of Calibration 76 12.3 Selection of Projects for Third Party Quality Audit 201
7.7 CalibrationRecofds 12.4 Scope of Third Party Quality Audit 201
7.8 Recall Procedures 77 12.5 Audit Team 2O1
SECTION 8; INSPECTION AND TESTTNG 12.6 National Level Project Monitor 201
8.1 Introduction 79 SECTION 13 : SAFETY, HEALTH AND ENVIRONMENT
8.2 Objective 79 13.1 Introduction 208
8.3 Scope 79 13.2 Transportation Planning & Health 208
8.4 ProjectPreparalton 79 13.3 Safety, Health & Environmental Safeguards During Construction 208
8.5 Construction 81 13.4 Quality Process to take care of Safety & Environment 211
86 Operation & Maintenance 84
8.7 Third Party Testing 85
8.8. Sampling 85
8.9
ceneral Guidetines for lnspection & Testing 86
SECTION 9 : DOCUMENTATTON AND COMMUNTCATTON
9.1 Introduction 177
9.2 General Principles of Documentation and Communication 177
93 Guidelines for Establishing Mechanism for Documentatton 174
9.4 cuidelines ior Security/Authentication of Documents 180
9.5 Sample Formats for Communication 180
SECTION 10: STATISTICAL ANALYS|S
10.1 Introduction 185
10.2 clossary of Terrns 186
10.3 Sampling and Gsting 188
10.4 Fundamental principles of Statistical Analysis '189
 IRC:SP:112-2017

PERSONNEL OF THE GENERAL SPECIFICATIONS

AND STANDARDS COMMITTEE (GSS)
(As on 24,h June,20lZ)

1 Kumar, lranoj Director General(RD) & Special Secretary to the covt. of India,
(Convenor) Ministry of Road Transport & Highways, New Delhi
2 Singh, B.N. Additional Director General, Ministry of Road Transport &
(Co-Conveno4 Highways, New Delhi
3 Verma, Dr. S.K Chief Engineer SR&T(R), Ministry oi Road Transport &
(Member Secretary) Highways, New Delhi
Members
4 Basu, Kaushik Chief Engineer, Ministry of Road Transport & Highways
5 Bhardwaj, R.S. Senior Principal Scientist, Central Road Research Institute,
New Delhi
6 Chacko, Dr. K.M. Director, Shriram Institute of Industral Research, Delhi
7 Eligar, J.H. Superintending Engineer, Ministry of Road Transport &
Highways
I Gupta, D.P DG(RD) & AS (Retd), Ministry of Road Transport & Highways,
New Delhi
9 Jain, Prof(Dr) S S. Professor, llT Roorkee
10 Jhamb, S.B. Addl. Director General(Retd.), Central public Works
Department, New Delhi
'11 Joshi, L.K. Secretary(Retd.), Ministry of Road Transport & Highways,
New Delhi
12 Lal, Bhure Chairman, Environment Pollution (prevention &
Control)
Authority, Delhi
'13 N4athur, Dr. Ajay Director General, The Energy & Resource Institute, New Delhl
14 Narain, Sunita Director General, Centre forScience & Environment, New Delhi
15 Goel, O.P Director General(Retd), Central public Works Department,
New Delhi
16 Pandey, LK. Chiei Engineer, Ministry of Road Transport & Highways,
New Delhi
17 Parrlkar,c.M. Naik Superintending Engineer, PWD Goa
18 Pateriya, Dr. l.K Directo(Technical), National Rural Road DevelopmentAgency,
New Delhi
19 Puri, S.K. DG(RD) & SS (Retd), Ministry of Road Transport & Highways,
New Delhi
20 Rajoria, K,B. Engineer-in-Chief(Retd.), Dethi PWD, New Dethi
21 Raju, Dr.c.VS. Engineer-in-Chief(Retd.), R& B Deptt., Hyderabad
22 Rajvanshi, Ms. Asha Head, ElAWild Life Institute, Dehradun
|l-F--
tRC:Sp:1,12_2017
tRC:Sp:.i12_20.17
23 Th6 Director Engineering Staff College of Engineering, Hyderabad
(Reddy, D.N.) MANUAL FOR QUALITY CONTROL IN ROAD & BRIDGE
WORKS
The CEO & PD National.Automotive Testing and R&D Infraskucture project,
(Sahay,Vishvajit) New Delhi
Sarangi, D Chief ceneral Manager, National Highways Authority
of lndia SECTION I
Sharma, D. C. Principal Scientist, Centfal Road Research Institute,
New Delhi
Sharma, M. P Chief Engineer, N4inistry of Road Transport & Highways, INTRODUCTION
New Delhi
28 Sharma, R. S. lvlanaging Dlrector, M/s STp Ltd New Delhi Three special publications. were published by IRC in different years
quality control on road and bridge works as mentioned regarding
29 Sharma, V K. Chtef General Manager (LA), National Highways below:
Authority of
30
lndia, New Delhi IRC:SP:11-1984 Handbook for euality Conlrol for Construction of Roads
Sinha, A.V (lDl& SS (Retd.), Ministry of Road Transport & Highways,
?G and Runways;
New Delhi
31 Sinha, B.N. Chief Engineer (Retd.), Central public Works Department,
IRC:SP:S7-2000 Guidelines for euality Systems for Road Construction;
New Delhi IRC:SP:47-1998 Guidetines for euality Systems for Road & Bridges.
32 Tawade, D O. Membe(Technic€l), National Highways Authority of lndia, The above pubrications were formurated in pre NHDp environment
New Delhi when bridges were mosfly
The Director General, constructed on stand-arone basis. Need was fert to merge
Society of Indian Automobile Manufacturers, New the three pubtcations to suit the
(N,,lathur, Vishnu) Delhi manner of imptementation of highway projects post Nndp
anO atso uflraOe the content to
The Director capture all aspects of quality assurance and control in line
Automotive Research Association of India, pune with ueii lnie"rnationat practices.
(Urdhwareshe, Mrs. Rashmi)
35 Vasantha, Dr C. Accordingly, it was decided in the 1"r meeting of project preparation,
Superintending Engineer, pWD Hyderabad 1:2
Management, Quality public. private
Contract
36 Verma, S K Assurance and. e-artnersriif Committee
on 06.06.2015 to merge the 3 speciat publication. u" uUou" ln;-upgrade (G_1) held
Advisor, Engineering Staff College of India, Hyderabad
37 Verma, MajVC. Director, M/s Oriental Structures Engineers pvt. Ltd., A sub-group was formed under the chairmanship of Co_Convenor the same.
New Delhi
38 Vyas, Neha Senior Environment Specjalist, World Bank, New Delhi to prepare the draft of the,,Manual for euality Control in noaawith a
other members
eriUge Worti;i
The sub-group prepared different sections of the puori""iiln *hrcn was discussed
Corresponding Members
'l Momin, C.W
"p""i"r 16 and lasfly on
Chief Engineer, pWD t/eghataya
2 Parsekar, U p Principal Chief Engineer, pWD Goa
D. Sarangi; Shri
Shri S.K. Nirmal
3 Sachdev,VK. Chief Engineer (Retd), Ministry of Road Transport Shri D P Gupta.
& Highways,
New Delhi G-'l Committee
4 Temjen, R. Temsu Addl. Chief Engineer, pWD Nagaland
5 Vanlaltluanga, R. Engineer-in-Chiel pWD Mizoram

Ex.Officio Members Singh, B.N. Convenor

1. President, IRC (Pradhan, N K.) Engineer-in-Chief cum Secretary Sarangi, D. Co-Convenor
to the covt.
of Odisha, Bhubaneshwar Nirmal, S.K.
2 Member-Secretary
Director ceneral (RD) & Spt. (Kumar,..Manoj) Ministry
of Road Transport and Highways,
Secretary to the Govt. of lndia New Delhi
Members
Secretary General (Nirmal, S.K.) Indian Roads Congress, New Delhi Banerjee, A.K. Kumar, Ashok
Bhasin, Col. A.K. Kumar, M. Kishore

1
IRC:SPi112-20'17
IRC:SP:112-2017

Bongirwar, PL. Pandey, l.K. sEcTtoN 2

Chand, Faqir Pandey, R.K.
Dash, Bimal Chandra Patwardhan, S V GENERALAPPROACH
Deepankar, AIok Puri, S.K.
De, D.C.
2.1 Concept
Raju, Dr. c.VS.
Gajria, Maj cen. K.T. Sharma, M.P Tglll'lg in the year 1998, when imptementation
111_, ^.- was announced,
(.luaontarerat
of 4_raning of cotden
there have been huge strides in development of;ads in lndia.
Gupta, D.P Sharma, R.S. The.road development programme is also very wide anO vast
startin! fiom expressways to
Indoria, R.P rural roads. Road infrastructure has seen a quantum
Sinha, A.V in
iump investme-nts during the past two
decades. The agencies involved in.road construction are quite
Jain, N.S. Slnha, N.K. disparate. The contracting
modes are arso different. But what is demanding tror ano'cormoi
to arr road projects is
Jindal, S.C. grulill starting. from project ptanning to Construction to Operation and
Pt1
uualry oT rne prolects/works should be such that the road performs according
Maintenance.
Corresponding Members to the specified
Venkateshan, T. Verma, l\4aj VC.
standardsduring the design life ntialso thaii) users enjoy safe and comfortable
rlding quality throughout the d ii) vehicle operating clsts are minimised and
Ex-Officio Members lii) resources of the nation are
enrichment of knowledge in the industrv,
President, IRC DG (RD) & SS, N/oRTH
(Pradhan, N.K.) (Kumar, Manoj)
This Manual endeavours to describe di
Management in Road projects. lt covers vario
Secretary ceneral. IRC
Manual does not embody extracts
(Nirmal, S.K.)
ations for Road & Bridge Works.
1.3 The document was approved by the General Standards and Specifications with N/ORT&H Specifications for
Committee (GSS) in its meeting held on 24th June 20 j 7 for placing before the IRC Council. The es, manuals and guidelines.
draft was flnally approved by the IRC Council in its 212'h meeting held at Udaipu(Rajasthan)
from 14rh to 15th Julv 2017. :1.? .. The role of euality
the following pictorialchart:
l\y'anual in overall procurement of works is best described
by

Place of Quality Manual in overall procurement of Works

'>
IRC:SP:112-20'17
2.1.3 At the outset, it is necessary to recall the definition of Total Quality Management as
stipulated in various international codes of practice along with other terminology associated
with it for proper appreciation of quality requirements.
ISO 8402: 1994
(i) Quality: The totality of features and characteristics of a product or service
that bears on its ability to satisfy stated or implied needs.
(ii) Total Quality Management: A management approach of an organisation
centred on quality, based on the participation of all its members and aiming at
long term success through customer satisfaction and benefits to all members
of the organisation and society.
(iii) Quality Policy:The overall quality intentions and direction ofan organisation
as regards quality as formally expressed by top management.
(iv) Quality l\y'anagement: The aspect of the overall management function that
determines and implements the quality policy.
(v) Quality Planning: Activities that establish the objectives and requiremenls for
quality and for application of quality policy.
(vi) Quality Assurance: All the planned and systematic activities implemented
within the quality system, and demonstrated as needed, to provide adequate
confidence that an entity will fulfill requirements for Quality.
(vii) Quality Control: The operational techniques and activities that are used to
fulfil requirements for quality.
(viii) Requirements of Quality: Expression of the needs or their translation into a
set of quantitatively/qualitatively stated characteristics of an entity.
(ix) Quality Systems: The organisation structure, responsibilities, procedures,
processes and resources for implementing Quality l\,4anagement.
(x) Ouality Plan:Adocument setting out the specific quality practices, resources
and sequence of activities relevant to a particular produc'..
(xi) Quality Audit: A systematic and an independent examination to determine
whetherquality activities and related result complywith planned arrangements
and whether these arrangements are implemented effectively and are
suitable to achieve objectives
BS 7850.1:1992
(i) Total QualityManagement:Amanagementphilosophyand company practices
that aim to harness the human and material resources of an organization in
the most effective way to achieve the objectives of the organization.
Transport Reasearch Board
(i) Ouality: The degree of excellence of a product or service; (2) the degree
to which a product or service satisfies the needs of a specific customer;
or (3) the degree to which a product or service conforms with a given
requirement
IRC:SP:112-2017
(D Quality assurance:All those planned and systematic actions are necessary
to provide confidence that a product or facility will perform satisfactorily In
service.
(ii) Quality conhol: Those QA actions and considerations necessary to assess
and adjust production and construction processes so as to control the level
of quality being produced in the end product.
Acceptance: Sampling and testing, or inspection, to determine the degree of
compliance with contract reouirements.
(v) Quality characteristic: That characteristic of a unit or product that is actually
measured to determine conformance with a given requirement. When
the quality characteristic is measured for acceptance purposes, it is an
acceptance quality characteristic (AQC).
(vi) Quality measure: Any one of several means that have been established
to quantify quality. Some examples of quality measures are the mean, the
standard deviation, the percent within limits, the average absolute deviation,
and the quality index.
American Society for Quality Control
(i) Quality: The totality of features and characteristics of a product or service
that bear on its ability to satisfy given needs.
(ii) Quality assurance: All those planned or systematic actions necessary to
provide adequate confidence that a product or service will satisfy given
needs.
American Society for Testing and Materials (ASTM-E699)
(i) Quality assurance: A planned syslem ofactivities whose purpose is to provide
assurance that the overall quality control program (see quality control) rs
in fact being effectively implemented. This system involves a continuing
evaluation of the adequacy and effectiveness of the overall quality control
program with a view to having corrective action initiated where necessary
For a specific material, product, service, etc., this involves verification, audits,
and evaluations of the quality factors that affect the specification, production,
inspection, and use ofthe material product, service, system, or environment.
(i) Quality control: A planned system of activities whose purpose is to provide a
level of quality that meets the needs of usersi also, the use of such a system.
The objective of quality control is to provide an overall system integrating
the quality factors of several related steps including: the proper specification
for what is wanted: produclion to meet the full intent of the specification:
inspection to determine whether the resulting material, product, service,
etc., is in accord with the specification: and review of usage to determine
necessary revisions of the specification.
BS 4778.Quality Vocabulary
(i) Quality: The totality of features and characteristics of a product or service
that bear upon its ability to satisfy stated or implied needs.
 IRC:SPr112-20'17 IRC:SP:1'12-2017

(ii) Quality Policy: The overallquality intentions and directions ofan oroanisation Classes of Quality Assurance Class Nomenclature
as regards quality as fully expressed by top management.
Nominal QA
(iii) Quality Management: The aspect of the overall management function that Q-1
determines and implements the quality policy. Normal QA Q-2
(iv) Quality System: The organisational struclure, responsibilities, procedures, High OA Q-3
processes and resources for implementing quality management.
Extra high QA
(v) Quality Assurance; All those planned and systematic actions necessary
to provide adequate confidence that a product or service will satisfy give; QualityAssurance class needsto bedecided prior to start of the project preparation However,
requirements for quality. during the course of project imprementation, euarity Assuran"e class of some of the items/
(vi) Ouality Control: The operational techniques and activities that are used to attributes may be upgraded to next class based on specific requirements. provision for such
fulfill requirements for quality. up-gradation needs to be built into a contract. This Manual is basically meant for Q-3 class
The above definltions are universar in nature and appry to a[ fierds. In the contexr of road of quality assurance which is applicable to projects in following situations:
projects, the definitions are used with suitable interpretation as considered
apolicable to road i) National Highways and State Highways
prolects ii) Coastal roads

?.1.4 There are three focal points of Total euality Management. These are euality
Assurance, Quality contror and Acceptance. Al the activities rerated to euarity spin aroun;
these focal points. Notwithstanding the contracting format used for a particurar project,
quality control vests with the contractori concessionaire, whereas acceptance
vests with the
Employer/Authority, who is normalyassisted byconsurtants in medium and rargesize projects.
Q!ality Assurance appries to al the entities invorved in the project. euafity Assuranca pran
of all.the entities involved in the project must be compatibre foflowing the broad parameters
specified in this Manuar. Acceptance criteria should be built into thl contract in clear and
unambiguous terms, which makes it obrigatory on the part of the contractor/concessionaire
to plan, build and forrow its Quarity Assurance and euarity control programme so as to fulfirl
the acceptance criteria. Whereas the Contractor/ Concessionaire anJ Engineer/Consultant
are required to have a project specific euality Assurance plan, the Emploter/Authority
may
have a generic Quality Assurance plan/euality policy. This Manual attempts to speciv
various aspects of the focal points mentioned above for road projects in general, without
any reference to particular contracting format. The contract should iake care to adapt to
the
provisions of this l\.4anual with modiflcations, if any, as applicable to a particular
contracting
format. The approach to quality requirements as applicable to four broad stages of a roai
project i.e. (i) project preparation, (ii) procurement, (iii) construction and (iv) operation
and
maintenance are discussed below.
2.2 Step wise procedure in Total euality Management
The following paragraphs of this section give an overview of different steps to be followed
in Total Quality Management of a road project in a sequential order, whereas details are
brought out in the succeeding sections.
2.2.1 Selection of the ctass of euality Assurance
Depending upon the rigors of control and cross verlfication, four classes of eualityAssurance
(QA) are prescribed:
iii) Roads in high altitudes
iv) Roads in high rainfall areas (average over 2OOO mm)
v) Large size projects on Major District Roads
Q-2 class QA is recommended for rural roads and average size projects/works on Major
District Roads. Q-1 class QA may be restricted to rurar roads in remote areas subject to
specific approval of the concerned road agency. e-4 class eA is applicabte ro expressways.
Q-4 class QA is also applicable to following specialised components of projecis following
lower class of OA.:
i) Tunnels
ii) Elevated highways
For quality management in rural roads, reference may be made to euality Assurance
Handbook for Rural Roads ofthe National Rural Roads Development Agency oithe Ministry
of Rural Development.
2.2.2 Personnel
Both the Contractor/Concessionaire and Engineer/Consultant are required to engage
adequat€ number of personner with required knowredge, experience and expertise to controt
quallty The knowledge and experience of rab technicians who actually carry out the tests is
tllo v€ry critical. The size and complexity of a project determines the range of personnel,
thck knowledge, experience and expertise. The quality personnel of the Contracior may be
Indcpendent of production and raying unit or part of it. This l\Ianuar suggests the rist of qu;rity
pcrlonn6l required with contractor/concessionaire and Engineer/consultant for projects
of dltferent slz€ and comprexity in section 3. The organizJtional structure of the quarity
control porgonnel along with qualification and experience requirements ofthe said personnel
8re alSo speclfied so that each of the personnel ls capable of meeting the requirements
of the chos€n field and the team has the right mix of personnel to atte;d to al ihe quarity
roqulr€msnts of a proiect.

6
 ll{CiSP:112-2017
IRC:SP:112-2017

2.2.3 Quality Assurance Plan exercise independent check as to whether the euality policy of the supplier is being
duly
Quality Assurance has already been defined as "All the planned and systematic activities complied with.
lmplemented within the quality system, and demonstrated as needed, to provide adequate
section 5 stipurates testing requirements of most of the factory manufactured materiars,
confidence that an entity will fulfill requirements for euality.', ln a way euality Assurance products and specialised items and whether site testing faciliiy avaitabte
is sum of Quality Control and Acceptance Quality Assurance plan (eAp) is, therefore, a for them. For
all such materials and products, the supp
document chronicling the actions to be taken and steps to be followed by each party to the
documents as specified in Section 5. Secti
project for successful implementation of the project duly fulfilling the euality Requirements.
Manufacturer/ Concessionaire / Contracto
The project cycle involves three broad stages i.e. project preparation, project Development ln fu(her confirming quality of such materia
and Construction. Therefore, for a single project, different quality assurance plan needs to laboratory or conducting third party testing.
be prepared by different parties in different stages. The requirement of eAp during different
stages of a project is summarized below: 2.2.5 Laboratory set up

Project stage Requirements of QAP by different parties to project Section 6 gives a broad oufline of the Contractor,s site laboratory General infrastructure
Project Preparation DPR consultant will prepare QAP for Project preparation.
3l:,::TU"in'::
Client will have a general protocol for association with DpR
consultant and scrutinyiverification of data, design and drawings. In originat/crushed form and various types of mixes is atso gi""" a"",',t";T:oiln ilrt;'"?l;
laboratory, where testing of materiars is proposed to be carr-ied out
'" by any entity invorved with
Independent Engineer/Authority's Engineer will have a protocol
r91d pl9jectt must satisfy the requirements of Section 6 as a minimum. The requirements
to review drawings in BOT/EPC Contract.
of Section 6 also apply to the laboratory for testing of different materiats retated to project
Development Employer/Authority will have a general protocol for bid document Preparation as well as Operation and Mainter ance.
preparation, bid evaluation and awaro.
Construction Contractor/Concessionaire will prepare eAp
2.2.6 Calibration of lnspection, Measuring and Testing Equipments
Calibration is defined as specific type of measurement performed on measurement
Supervision manual prepared by Engineeri Consultant will standards,
malerial and measuring instruments to establish the relationship
contain Quality Assurance mechanism to be followed bv the .measures between the
Engineer/Consultant Indicated values and known values of a measured quantity. The term covers
calibrations
carded out using appropriate reference equipment at any location The requirements
Employer/Authority will have a general protocol for euatity for
oqulpment calibration, measurement and tri ceability are given in ISO/|EC .17025. The
Control. laboratory's ntenance and calibration of equipment will typically
of
comprise ing, calibration and safety checks (where applicabte).
l\y'odel structure of QAPs as above and protocol for Employer/Authority/Engineer are given
in Section 4
Whllesstabli mme, aspects of measurement traceability, procedurei,
and
Int€rvals on and checks, need to be considered for each item of
2.2.4 Quality Requirements for Factory Manufactured Materials, products and lMT.equipment in reration to the particurar test method for which it may be used.
calibration of
Specialized ltems cqulpmont is a must for certainty/reriabirity of the test resurts. caribraiion requirement
ranges
Supplier's quality policy indicates commitment of the management of the supplier to achieve lrom sl.ves to nucrear density meter. caribration of prant and equipments such as Hot Mix
and sustain quality of the product to meet purchaser's stated or implied needs, whether Plrnt, concrote Batching prant etc. are arso very important. caribr;tion requrremenrs, rypes
contractually required or not. In case of road projects, supplier's euality policy in respect of callbrallon, intervar of caribration, and method of caribration of different rMT equipments
of factory manufactured materials, products and specialjzed items such as steel, bitumen, typlcally used in a road project, re ection 7.
bearings, expansion joints, road signages, crash barriers etc. is very important. Section 5 Intcrval for callbration specified by he time tn
gives a broad contour of the minimum elements of quality policy of suppliers of such products. In Soctlon 7, the manufacturer's re Externar r

Notwithstanding whether a supplier is empanelled or not, the euality policy of the supplier for callbratlon must be accredited by NABL. as well a
shall be furnished by the Contractor/Concessionaire to the Engineer / Consultant, who will evldence of the accreditation of the calibrating raboratory shourd be made availabre in
the
ascertain that the Quality Policy of such supplier shall be commensurate with the details laboralory Recall procedures ofthe I\ITequipments are given in section 7. The requirements
given in Section 5. In large and complex projects, the Engineer/Consultant may further of Sectlon 7 also apply to calibration of testing equipments related to project preparation
and Operation and l\.4aintenance.
lRCrSPil l2-2017
2.2.7 lnspection and Testing
Inspection and Testing generally covers the following:
(i) Alignment and surface regularity
(ii) Reinforcementdetaiting
(iii) Positioning of furniture/accessories
(iv) Testing of constituent materials and flnished products
(v) Field/in situ testing
Whereas the requirements of tests for different malerials/products/works are given in
N/oRT&H Specifications for Road & Bridge Works/Section 5 of this Manual, detaits of testing
procedure are given in applicable code of practice. Test frequency is given in MoRT&H
Specifications for Road & Bridge Worksisection 5 ofthis Manual/ appticable codes of practice.
Section 8 of this N4anual deals with general overview of testing procedures. lt includes both
in-process and final inspection and testing. The activities include surveys, measurements
and tests in laboratory as well as site. General principlesiguidelines about inspection and
testing including source approval, receiving inspection, in process inspection, final inspection,
sampling of materials from quarries, borrow pits, stock piles, trucks/pavers etc., maintaining
integrity of samples, testing method for each of the tests, handling procedures, recording
of observations, formats for recording observations in various tests etc. are covered in
Section 8.
2.2.8 Documentation andCommunication
Documentation of Ouality Assurance and Quality Control processes with proper authenticity
are critical for arriving at acceptance or otheMise of a finished product. The Contractor/
Concessionaire and Engineer/Consultant shall establish mechanism for documentation well
in advance. Documentation shall be in both soft and hard format. proper arrangement for
securityiauthenticity of documentation shall be made by both Contractor/Concessionaire
and Engineer/Consultant General principles and guidelines for establishing mechanism for
documentation are explained in Section g. Communication between different oarties to the
Contract is an important aspect. Though it is not limited to only euatity Control aspects,
communication related to Quality Control occupies a larger share of the total communication.
Communication should be fasl, reliable and well documented both in soft and hard format.
E{ools may be followed for faster communication and contract management. General aspects
of such e-tools are discussed in Section g. Besides, sample formats for RFl, Notices etc. are
given in Section 9.
2.2.9 StatisticalAnalysis
Variability of materials, workmanship and construclion process is a reality in road construction
like any other manufacturing process. Adding to the variability of materials and processes,
there is also considerable variation in the testing process resulting in measurement errors.
Acceptance procedure is therefore, required to factor in variability of test results or in other
words statistical analysis of test results. Section 10 gives an idea about various methods
of statistical analysis practiced internationally. Section .lO ouflines the salient aspects of
sampling, criteria for selection of Lot (Population in statististical terms). Section 10 gives
'10
IRC:S P:'1 '1
2-201 7
fundamental principres of statisticar anarysis and indicates rerationship berween mean
varue
of the test results carrred out on the sample in respect of particurar euarity characteristic
of
a material/item of work vis-a-vis specification limit for that particular euality characteristic.
2,2,10 Acceptance/non conformance/rectification
Acceptance criteria for different materiars/finished products/items of work are given in different
soctions of l\4oRT&H specifications for Road & Bridge works whereas acceptance criteria
of some additional Quality Characteristics of factory manufactured mateflats, products and
specialized items as detaired in section s of this Manuar are mentioned in appiicabre
codes
of practice as mentioned therein. section 1l prescribes euafity characteristics of materiars/
works where statistical analysis is to be carried out for final a'cceptance and also specifies
the procedure for statisticar check of such euafity characteristics. section .ll details the
procedure/protocol for acceptance/rejection of rawfactory manufactured
materiars/mixes/
flnlshed products/works based on quarity contrortest resu16 and supplemented by
statistical
6nalysis where ever applicable. Section ll prescribes various options available in case of
fallure of a sample to meet acceptance criteria and arso gives a detaired protocor to
dear with
non-conformance works.
2.2.1'l Third pafty Quatity Audit
lso.19011 specifies third party audits as audits performed by externar agencies primariry
for lhe purpose of certification. In the context of road projects, Third party euality Audlt is
rovlew by an independent entity (a separate firm/group oi experts) of how well the key areas
a
of Iproject quality plan is being followed and whether it's effective in getting
the quality
r€sults originally envisaged. section 12 gives a generar overview of third party quarity
audii.
Secllon 12 specifies criteria for serection of road projects for third party quarity audit. rt
outlln€s_scope of third party quality audit and general requjrements of audit team. A sample
torms of reference for third party quality audit is also given in Section 12.
2,2.12 Safety, Health and Environment
Although safety, hearth and environmentar issues are not precisery part of this r\,4anuar,
quallty in such issues at work places has huge importance to the nearby communities,
road
u8gr8 and construction workers during construction stage as well as nearby communities and
road us€rs post construction. rt is further established that better care for safety, Hearth and
Envlronment at work places automatically enhances quality in road constructton.
taotlon 13 makes a modest approach to identify and list those aspects of safety, health and
onvlronment during road construction.
11
IRC: S P: 1 '1 2-20 1 7
SECTION 3
PERSONNEL
3.1 Introduction
Both the Contractor and Engineer are required to engage adequate number of personnel with
required knowledge, experience and expertise to control quality. Right type of quality control
personnel with Contractor and Engineer is a must to achieve desired quality of the project.
This section gives an outline of the type of personnel and their qualification and experience
for different size of projects.
3.2 Integral/Outsourced Quality Assurance/Control Unit of Contractor and its
Hierarchical Position in Organisation
The Quality Assurance/Control Unit of Contractor may be a unit of inhouse personnel of the
Contractor or a unit oulsourced from a consulting flrm exclusively for the project. Both the
practices have inherent advantages and disadvantages. Contractor should choose a system
convenient to its internal capacity and demand of delivery But in either case, the head of
the unit shall report to Project Manager or head of the project team of the Contractor and will
have say on all raw and mixed materials, plants and equipments brought to site for use in the
work. The Contractor shall furnish details of its Quality Assurance/Control Unit in the euality
Assurance Plan.
3.3 QA/QC personnel of Contractor
The Contractor shall have dedicated key and sub-professional for euality Assurance/Control.
Their numbers and position depend on size and complexity of a particular poject. Tentative
details of key and subprofessional persons in the organization ofthe Contractor vis-a-vis size
of projects is given below:
Size of the Project Details of Key & Sub-Professional
< Rs, 300 crore Material Engineer-1, OC/Asst. QC Engineer-2, LabTechnician-4
I Rs. 300 crore Material Engineer-1, QC/Asst. QC Engineer-3, LabTechnician-6
Additional/specialized personnel may be required to be engaged by the Contractor for
complex projects such as tunnel/innovative structures or projects involving new materials
etc. which may be decided on case to case oasts.
3.3.1 The typical organizational charts of quality control personnel of Contractor for
different size of projects are given at Annexure 3.1.
3.3-2 Role and Responsibility of Contractor's QNQC personnel
The role and responsibility of Contractor's QA,/QC personnel are broadly described below:
IRC:SP:112-2017
Material Engineer
Material Engineer shall remain responsible for all euality Assurance, euality Control and
Acceptance requiremenls of the project and will direcfly report to the project lvlanager or
project head He will regularly supervise the activities of eC/Asst. eC Engineer. Miterial
Engineer will provide all necessary assistance to the construction team with reference to
acceptance of all raw manufactured, mixed materials used in the project. His responsibilities
Include the following:
a Preparation of Quality Assurance Plan;
a Providing inputs to Project Manager for preparation of work methodology.
a Setting up of field laboratories;
a Calibration of equipments;
a Preparation of JMF for flexible pavement & concrete mix design;
a To maintain an effective documentation system for eA"/eC throughout the
project;
o To monitor and coordinate quality control activities on site;
. Ensure that tests are carried out as per relevant lsiapplicable international
code of practice;
a Maintain the test records for all the construction material used in the Droiect
and submit them to Project Managerbefore foMarding them to the Consult;nt.
a To verify the system for reporting and disposing non-conformance and
corrective action requests;
a Have llnal say about acceptance ofa material/work;
a To perform internal quality audits on site in accordance with aoolicable
proced ures;
o Advising on, planning and organizing inspections, maintenance and repairs;
. Liaising with suppliers, customers and manufacturing/development staff.
QC/As8t. QC Engineer
gc/Asst, OC Engineer will be dhectly responsible for quality control. He will report to the
Materlal Engineer He will supervise the activities ofthe Lab Technician. Besides he will carrv
out lhe following activities himself.
a Assisting l\.4aterial Engineer in setting up the field laboratones;
a Day to day supervision ofworks of Lab Technicians:
o Ensuring proper calibration of all laboratory equipments;
a Preparation of JN/F for flexible pavement & concrete mix design;
a Conducting laboratory and field tests on random basis:
a Calculation oftest results from test observations carried out bv Lab Technician.
analysis and interpretation of the test results;
a Maintaining respective records;
a Selection of borrow areas:
13
IRCTSP:112-2017
IRC:SP:112-2017

o P€riodical checking of calibration of WN.4M plant, Hot mix plant, Batching

plants; Annexure 3-1

a Preparation of summary test results for monthly progress report.

Lab Technician TYPICAL ORGANISATION CHARTS OF
QUALITY CONTROL PERSONNEL OF CONTRACTOR
Lab_Technician will work under the guidance of ec/Assistant eC Engineer He will carry out
the following activities: Size of Project < Rs. 300 crores
a Sampling of construction materials and preparatjon for testing as per
tS Code;
o Conducting laboratory test of aggregate, cement, soil, bitumen and other
materials;
o Recording of test observations;
. lnspection of batching plant, hot mix plant and WMI\i1 plant at the time of
production;
QC/Asst. QC
a Conducting field tests at site and recording test observations. Engineer QCiAsst. QC
(Earthwork, Engineer
3.4 QC personnel of Engineer Concrete and (Pavement
Misc. works) courses)
The number and position of QC personnel of the Engineer depend on mode of contract apart
from size and complexity ofthe project. Tentative list of key and sub-professional for difierent
types of projects is given below:
Size of the Project Details of Key & Sub-Professional
< Rs. 300 crore Material Englneer-1, QC/Asst. QC Engineer-1, Lab
Technician-2
> Rs. 300 crore l\4aterial Engineer-1, QC/Asst. QC Engineer-2, Lab
Technician-4

3.5 Qualification and experience of key and sub-professional to be engaged by the Size of Project > Rs. 300 crores
Contractor/Consultant is given at Annexure 3.2

ac/Asst ac
Engineer

14
15
IRC:SP:112-2017
Annexure 3.2
QUALIFICATION AND EXPERIENCE OF QUALITY CONTROL
PERSONNEL OF CONTRACTOR/ENGINEER
I Material Engineer
The l\.4aterial Engineer shall be graduate in civil engineering from a recognized university. He
shall have professional experience of 12 years in construction of highways/roadsi airfield
runways. He shall have experience of 5 years in similar capacity in construction / construction
supervision of highway projects. He shall have experience as l\.4aterial/ Geotechnical
Engineer in construction / construction supervision of at least 2 highway projects. He must
be familiar with material property of road construction material, technical specifications and
procedures of material tests and testing equipments. He shall not be more than 65 years of
age. The l\ilaterial Engineer should preferably have post graduate degree in Geo-Technical
Engineering/Soil l\,4echanics and Foundation Engineering. He should also preferably have
experience as l\.4aterial Engineer in highway construction projects outside the country.
ll Quality Control Engineer
Quality Control / Assistant Quality Control Engineer shall be at least craduate / Diploma in
Civil Englneering having minimum 2/5 years of work experience (2 year in case of Graduate
and 5 year in case of Diploma) in the field of quality control in road/bridge construction
projects. He should be conversant with testing ofdifferent materials/finished products, testing
apparatus, calibration, sampling, testing, recording test observations in proper formats and
determination of test results.
lll Lab Technician
Lab Technician shall be at least Diploma in Civil Engineering /Science Graduate /lTl having
minimum 2/5 years of work experience (2 yeat in case of Diploma and 5 year in case of
Science Graduate /lTl ) in the field of testing of materials.
'16
IRC:SP:112-2017
sEcTtoN 4
OUALITYASSURANCE PLAN
4,1 Introduction
Doflnition of the following terms as stipulated in ISO 8402 of 1994 is reproduced below for
proper appreciation of the subject:
Quallty Policy: The overall quality intentions and directions of an organisation as regards
quallty as formally expresssed by top management;
Quallty Assurance: All the planned and systematic activities implemented within the quality
tystom and demonstrated as needed to provide adequate confidence that an entity will fulfill
rcqulrsments for quality;
Quallty Plan: A document setting out the specific quality practices, resources and sequence
of actlvities relevant to a particular product, project or contract.
A road project goes through several stages and involves several stakeholders from inception
to lmplsmentation. Quality offinal product is possible only if quality is ensured in each stage.
Quallty Assurance Plan of each of the major stakeholders consistent with its own Quality
Pollcy is crucial to ensure quality of a particular stage.
4.2 Objective
The objectives of preparing a Quality Assurance Plan (QAP) are as follows:
o Understanding the project requirements/features in totality;
. Assessing the impact of environment on quality;
. Developing quality systems to ensure that the process and product fulfil
quality requirements consistently;
. Assignment of responsibilities with absolute clarity;
. Establishing methods for meaningful evaluation;
. Establishing documentation processes and systems to minute details.
4.3 Gsneral Principles
Tha dltforont stages of a project cycle such as project preparation, procurement and
lmPlamantatlon have different concerns with respect to quality. The following general
pflnolplgr are intended to address those concerns of quality:
(l) Preparation of Quality Assurance Plan starts with review of contract
documents and all project related information. This will help in identifying
thrust areas of the project from quality perspective. This will also help in
exercising control over works programme and methodology;
(ll) Next step is evolving organisational structure of the particular stakeholder
cl6arly delineating therein the personnel fesponsible for quality. The
organisational structure shall be followed by establishment of interpersonal
17
...''.'-F-
IRC:SP:112-2017
IRCTSP:'112-20'17

relationship within the organisation and entity(ies)/individual(s) outside the 4.4 Quality Assurance Plan for different stages of project lmplementation
organisation for implementation and overseeing;
(iii) Data collection, validation, storage and retrieval are essential requirements 4.4.1 PAed Preparation
of project preparation. Accuracy and reliability of data is key to success of Project preparation is traditionally carried out by a consulting firm engaged by the Client.
a project. Assignment of responsibilities among the personnel for all the Project preparation is arso carried out by DBFor concessioniire/Epc-contractor thouoh a
activities starting from planning of survey and investigation to storage ofdata consulting firm engaged by italthough the scope ofproject preparation in such case is confined
is essential for good project preparation; wlthin the boundaries set out by the schedule-B & c of concession/contract agreement and
(iv) lt is necessary to establish qualjty requirements of the material sources following relevant Manuar of lRc i.e. lRc:sp:73184/86. Accordingry the activitiei and outputs
keeping specifications, terrain, climate, project completion schedule, Govt. of project pfeparation by DBFor concessionaire/Epc contractor is limited comDared to
regulations etc. in view so that the same are satisfied before identification of the one prepared by Client. However, the quality concerns and responsibility assignmenl of
a particular quarry; Porsonnel remain the same.
(v) lt is necessary to establish quality requirements of the machinery to be 4.4.1.1 OutputDesirabitity
deployed for a particular project keeping project completion schedule,
packaging, specifications/capacities envisaged etc. in view; Project preparation should be such that the project is technically sound, assures optimal
(vi) Documentation of project related information and communication between oo8t utilisation, adequatery provides for safety requirements and social & environmental
the parties to the contract are very important requjrements to achieve qualitv ;ofoguards, is easy to implement and ensures intended performance over design life. eAp
apart from project implementation itself. eAp shall establish these tw; ls a tool that guards the project preparation process in achieving its stated desirabre outputs.
aspects in detail considering all the aspects of project implementation;
4.4.1.2 QAP for Project Preparation Consultant
(vii) Site laboratory is the real bastion of quality control. Infrastructure and other
requirements of site laboratory are given in |\,4ORT&H Soecifications and Modol Structure is given at Annexure 4.1.
also Section 6 of this Manual. eAp sha customise it to meet the soecific 4.4.1.3 General Protocol for Client to Supervise project preparation
needs of a particular project;
(viii) Calibration is defined by the International Bureau of Weights and l\Ieasures cllonl has to play a crucial rore in preparation of good project report. crient's participation
as: "Operation that, under specified conditions, in a first step. establishes rhould spread over entire duration of project preparation. A critical requirement is that
a relation between the quantity values with measurement uncertainties cllent's views on different reports submitted by the consurtant should be communicated to
provided by measurement standards and corresponding indications with tho consultant within the prescribed time period so that project can be prepared within the
rch€dul6d time and services of the key personnel are truly utilised.
associated measurement uncertainties (of the calibrated instrument or
secondary standard) and, in a second step, uses this information to establish (i) Client's participation can be meaningful lf availability of minrmum counrerpaft
a relation for obtaining a measurement result from an indication."procedure personnel ofthe Client exclusively assigned to project preparation is ensured.
for calibration of instruments and frequency thereof as recommended by the The foltowing table gives desirable workload with different rank of officers for
manufacturers and standardised by NABL shall be elaborated in eAp keeping handling average size DpR:
in view the specific needs of the project and planning for field labofatory;
(ix) Verification process (raw materials, mix, finished state) is the domain Designation of officer Maximum number of DPRs
of quality control. lt covers inspection, sampling of materials and testing to be assigned
The details of tests to be conducted, frequency of tests etc. are given in Asst. Executive Engineer/Deputy 2 with no other responsibility/'l with
MORT&H Specifications and Section 5 of this Manual and tests have ro oe Manager other responsibilities
conducted as per relevant BIS or other applicable code of practice/stanqaros Executive Engineer/ l\,4anager/ 4 with no other responsibility/2 with
but protocol for such activities with laid down procedure in detait keeping the Deputy General l\y'anager other responsibilities
specific needs of a particular project in view shall be established in the eAp;
Superintending Engineer/General 4 with other responsibilities
(x) Three aspects are of relevance in accepting or rejecting an item of a work i.e. Manager
result of verification process, statistical analysis and correction, corrective/
preventive actions when a Non Conformance Report (NCR) is generated. (il) Cllont's counterpart personnel must frequenfly interact with KeV personnei
QAP shall establish the procedure for handling NCRS for different category of the Consultant. The interaction should be both at site and office. For tnrs
of works. purpose Client's personnel shall visit the site often. Client's personnel shatl
18 19
IRC:SP:112-2017 IRC:SP:112-2017

interact with material engineer, survey engineer, bridge engineer and trafflc . Accident black spot rectiflcation proposal;
engineer at site during survey and investigation and team leader, highway . Bridge rehabilitation proposal;
engineer and bridge engineer during alignment finalisation and project scope
finalisation as a minimum.
. Drain outfall.
The above requirements should be inbuilt into Quality Policy/l\4anual of the Client.
(iii) Client's personnel shall verify/witness 1% of total field/laboratory tests and
4.4.1.4 General Protocol for lndependent Enginee Authority's Engineer
various surveys including traffic surveys as a minimum. to Review
Drawlngs in BOT/EPC Contract
(iv) Client's personnel not below the rank of Superintending Engineer/General
Manager shall verify the alignment of the entire length of a project at site Indspondent Engineer (lE)/Authority's Engineer (AE) shall follow the procedures mentioned
including widening scheme, bypasses and realignments. Based on the b6low but not limited to itwhile reviewing the drawings prepared by Concessionaire/Contractor
inspection report of the Superintending Engineer/General Manager, the of a BOT/EPC contract:
alignment shall be approved by Client's personnel not below the rank of . Site visit and verification of correctness of data as given in Schedule A of
Chief Engineer/Chief General Manager. contract;
(v) Client's personnel shall scrutinise following parts of reports and drawings as . Study of DPR prepared by Client;
a minimum: . Review of Schedule B, C & D of contract agreement and identification of
. Reasonableness of trafflc data; ambiguity/discrepancy/lack of clarity, if any;
o Analysis of groMh rates; a Action underthe provision ofcontract agreementto resolve the discrepancies
o Capacity augmentation plan such as addition oflanes, paved shoulders, and establish clarity;
service road etc; a Comparative study of various survey and investigation data/results as per
o Widening scheme; DPR and that prepared by Concessionaire/Contractor. In case of major
differences, lE/AE shall reconfirm accuracy of survey and investigation data/
. Alignment plan, junction lay out etc;
results prepared by Concessionaire/Contractor;
. Design life of pavement;
. Scrutiny of the design reports and drawings as per requirement of Schedule
. Approach/scheme for overlay, partial/full reconstruction of existing
B, C & D of contract agreement and site validation of the drawings from
carriageway;
technical, social, environmental, health and safety considerations.
a Typical cross sectionsi
Thc above requirements shall be inbuilt into Quality Assurance Mechanism of Construction
. Approach/scheme for reconstruction, widening and/or rehabilitation of Supervlslon Consultant/lndependent Engineer/Authority's Engineer.
existing bridges based on 100% site verification;
a Departure from standards; 1,4,2 Procurement
O BOQ; Procurement is another key activity in the project development cycle. The principles of
. Basic rate of materials; pr00uroment as set out by World Bank in their draft Procurement Policy 2014 for Procurement
. Comparison of average cost; In World Bsnk Investment Project Finance is summarised below:

. SupplementarySpeciflcations; a Value for money;

. Schedules of bid documents; a Economy;
. Traffic diversion plans. . Integrity;
(vi) Aftef scrutiny of final drawings, Client's personnel not below the rank of r Flt for purpose;
Superintending Engineer/General Manager shall verify the following at site . Efficiency;
as a minimum before final aooroval of DPR: a Transparency;
o Alignment plan; o Falrnsss,
o Lay out plan for grade separated and major at-grade intersections; Thala pollola! are nonetheless equally applicable to procurement of projects with domestic
. Provisions such as service road, underpass, bus bay, truck terminal fundlng lrraapcctlve of whether contract is EPC, BOT or ltem Rate. Pursuance of the above
mantlonad pollcles roqulre a stringent protocol to be meticulously followed by the Employer/

21
IRC:SP:112-2017 IRC:SP:112-2017

Authority. A sample but not exhaustive protocol is given below: aflcctlvo supervision of the project within the provision of contract document and carry out
Employer/Authority shall ensure thatthere is absolute clarity and consistency docum€ntation of the process in an efficient manner
in bidding documents and qualification criteria is objective and quantifiable. Model Structure is given at Annexure 4.3.
a Employer/Authority shall ensure that bid notice is given adequate publicity.
a Bid evaluation shall be strictly an inhouse exercise of Employer/Authority
4,4,3.3 Goneral Protocol for Employer/Authority duing Construction Stage
without any outsourcing. Nolwlthstanding the role and responsibility of Conskuction Supervision ConsultanV
a Evaluation process shall have undeniable transparency and accountability. Independent Engineer/Authority's Engineer, Employer/Authority has to play a crucial role in
anrurlng quality of construction. The broad requirements are discussed below:
a There should be strong deterrent to conflict of interest.
o Employer/Authority shall ensure that evaluation process is fully documented.
(i) Employer/Authority shall ensure availability of minimum staffing both at plU
and HO level so that decisions arefastandjust. While itmay not be appropriate
a There should be a credible complaint and grievance redressal mechanism.
to exactly specify the details of personnel considering variability of size and
The above requirements should be inbuilt into Quality policy/Manual of the Employer/ complexity of project, additional and miscelleneous responsibilities etc. an
Authority. idea is given below for desirable strength at PIU level for handling average
size Droiects:
4.4.3 Construction
Designation of officer at PIU level Maximum number of prolects to
The objective of Quality Assurance Plan for the construction stage is clearly spelt out in be assigned
Clause No. 4.2 of this Section. QAP is a tool that ensures that construction of the project is
done in a manner such that quality standards of the project are duly achieved as evidenced Asst. Executive Engineer/Deputy 1 with no other responsibility
in outcome of quality control tests. lt covers both process and end control arid acts as a l\.4anager
precussor to cost and time control such that value for money is achieved Executive Engineer/ lvlanager/ 2 with no other responsibility/1 with
A QualityAssurance Plan for the Contractor shall typically cover but not limited to the following
Deputy General Manager other responsibilities
aspects: Supef intending Engineer/General 3 with other responsibilities
. Organisation structure of contractor's project implementation team including Manager
assignment of duties and responsibilities and internal chain of commandi
o Operational skills and training of workforce;
(ii) EmployeriAuthority shall have an independent evaluation and monitoring
system to ascertain quality control of project. It may be through a dedicated
r Performance standards of machinery;
cell at HO level, third party auditing or any other appropriate method but the
. Laboratory infrastructure, equipment and personnel; extent and contour of independent evaluation and monitoring system shall
. Calibration of equipments; be decided well in advance of commencement/appointed date.
a Document control; (iii) Employer/Authority shall install a robust mechanism for dissemination
. Methodology of working, test and inspection plan; of project information. Dissemination shall be multi modal to cater to the
a Control of materials including source selection; reach of the stakeholders and shall be continued on sustained basis upto
a Control of workmanship; completion of the project
a Plan for acceptance, non conformities, correction and rejection; (lv) Employer/Authority shall put in place a credible complaint and grievance
redressal mechanism through which complaintsigrievances of stakeholders
a Plan for adherance to safety, health and environmental considerations.
can be genuinely and timely addressed.
4.4.3.1 QAP for Contractor Thl lbova roqulremenls should be inbuilt into Quality Policy/Manual of the Emptoyer/
Model Structure is given at Annexure 4,2. Auihorlly.

4.4.3.2 Quality Assurance Mechanism for Construction Suoeruision Consultant/ 1,1,3,1 lnleractlon between QA & QC Personnel of Contractor and Engineer
I ndependent Enginee r/Authority s Engineer Pfopar Ind tlmoly hteraction between QAand QC personnel of Contractor including its project
The Construction Supervision ConsultanVlndependent Engineer/Authority's Engineer shall mlnagamant contractor, if engaged, and Engineer is very critical for achieving quality as well
work out a mechanism to be followed within its organisation and team so as to exercise la plogrctt ol work, Interaction involves both physical interaction as well as communication
t1
---- ,i(; lit) 1t2-2017
IRC:SP:112-2017

n l'rard copy and digital format. Contractor will evolve a mechanism for interaction as above
Annexure 4.1
and include the same in its QAP
MODEL QUALITY ASSURANCE PLAN FOR PROJECT PREPARATION
4.4.3.5 Pre-audit of QAP
QAP prepared by the Contractor is subject to review of Construction Supervision ConsultanV 1. Brief particulars of assignmenr
Independent Engineer/Authority's Engineer. Contractor may also engage a separate entjty
for pre-audit of the QAP before it is submitted to the Engineer for approval The general
o Name of Ctient including all unjts/offices associated with project preparation
points for pre-audivreview of QAP is given below: . Scope of assignment;

. QAP is prepared in sync with the Quality Policy of the Conrracror.

. Brief description of location, terrain, topography, climate, soclo_economic
characteristics of the project area;
a All the works, materials and finished products are covered.
. Stages of project preparation including allocated timeline for each staoe;
o There is clear task delineation
o Reference and applicable documents:
o l\4aterial/finished productprocurementmethodestabtished.
. Any other important point(s).
. l\4achinery selection estabtished in conformity with methodology and quality 2. euatity poticy
control.
o Laboratory infrastructure and testing processes established.
. Quality policy of the Consultant as per its own charter and reference to such
document
:1. Consultant's organization and responsibility matrix
n lr(;lorial chart of the organization of the Consultant responsible for prolecl preparatron
rrl.r(rwrth unit(s)/individuar(s) of consurtant's Ho who may checldvet the reports/designs/
(l!rw|t(ts shall be provided in eAp
l{r )|]sibility matrix for main tasks/group oftasks showing clearly the primary, secondary
'i;l)( and
lr'rllrry fcsponsibirity sharr be provided in eAp rhe primary responsibirity shaI mean actual
lr r l(,||rirnce of tasks such as survey, field data collection, design, drawing etc. Secondary
r rlrorrsibility includes guidance, supervision and checking with or without approvat In respect
ol l.lrr) lilsks being performed by personnel direcfly reporting to a particular personnet. tt
also
l||r lu(los opinion/vetting about a particular output by another pefsonnel/expert
which may
lr/rvo ir lx)aring on such output. Tertiary responsibility includes final approval of major
tasks
lrvolvlxl bility may lie with Team ader or senior expert(s)
lr l:r)nrirl ponsibility matrix hinge n understanding
ll;"l;;i;
of the
I 5HYl,."T:l[:ilJ::i:::3:iT[ffi1;l3T:i
'|
lrrrlly lrl(,rfaces of arr major tasks in the form of a frow chart before finarising responsibirity
tr tr rlr lr
4. Control of surveys
lJ|ll|llly ( r lr rli I is key to preparation of a sound and accurate project report.
'l eAp shall contain
llro [''][rwinl'(l{'lirils as regards to survey activities:
. I ist of the details of surveys to be conducted as per ToR:
. lisl of additional surveys, if any, required to be conducted for overall
|( )(lLrirement of project preparation;
. I irit of relevant IRc/ls/other Codes of practice/Guidelines/Manuals for each
rilltvoy to be conducted;

24 25
IRC:SP:112-2017
IRC:SPi112-2017

a Lrst of the equipments to be used for each survey;
o Formats for recording of data for each of the survey in accordance with the
respective Codes of Practice/Guidelines/l\,4anuals. All the formats shall be
enclosed to QAP;
Responsibility l\y'atrix of survey and supervision thereof among key and sub
professional,each survey wise, pursuant to para 3 of this Annexure;
Percentage of checking of data to be carried out by the key professional
during survey and post survey. each survey wise:
. Any other point(s) considered relevant.
Control of laboratory and field testing
QAP shall contain the following details as regards testing:
/. Control of data analysis and detailed design
IIIJ ft)lk)wing shall be provided in eAp regarding data analysis and detailed design.
. List of the details of analysis and designs to be carried out as per ToR:
. List of relevant IRC/BlS/other Codes of practice/Manuals/Guidelines for
each analysis/design:
. List of the software/programming to be used for different analysis and
destgns;
. Responsibility Matrix for analysis and design and supervision thereoF among
key and sub professional each case wise pursuant to para 3 of this Annexure;
. Procedure for numbering and storage of manuscripts;

List of the details of laboratory and field testing to be conducted as per ToR;
. Pfocedure for maintaining records ofcorrection and final clearance/aooroval
o by designated personnel of Consultant. Suitable formats shall be devised for
a List of additional testing, if any, required to be conducted for overall the purpose;
requirement of project preparation; . Control of revisions- The first formal issue of analysis/design sheet and also
List of relevant BIS/other Codes of Praciice/Guidelines/l\,4anuals for each drawings referred to jn para 7 of this Annexure shall be marked as RO and
tesi to be conducted; subsequent revisions, if any, shall be marked R1 , R2 etc. A sample format for
a List of the equipments and consumables to be used for each test; keeping a watch on the amendments is qiven below:
O List of the calibration requirements of the testing equipments; llov Section Revision DescriDtion
a Formats for recording of test data in accordance with the respective Codes
of Practice/Guidelines/lvlanuals. All the formats shall be enclosed to QAP:
Responsibility l\y'atrix for testing and supervision thereof among key and sub o List the procedure for identification and traceability of documentsi
professional, each test wise, pursuant to para 3 of this Annexure; . Any other point(s) considered relevant.
Percentage of testing to be witnessed by the key professional, each test . Control of safety, health and environment
wise; rl, rly, lrrri tltl) and environment are growing concerns in a road project during
: ii
both construction
o Any other point(s) considered relevant. rr r( l r )l x ,r: llton Prolect preparation must address concerns of safety, health and environment
6. Control of alignment fixation including siting of bridges rrrrr.rr l)rojo(I cycle. A set of action points to the effect must be included in eAp keeDino
Alignment tlxation is a key requirement and involves of technical, economic, environmental ',1r",:tltr:t)roj(xt features in view in line with Section 13 ofthe lvanual.
and social considerations and particularly expanse and depth of social considerations. ll. Control of drawings
Alignment needs to be linalised after careful evaluation of all these considerations and in due List the rules for deciding sizes of drawings. The drawings shall be of
consultation with all stakeholders. QAP shall contain following details specific to the project standard size as mentioned below:
in this reoard:
Sl. No Conventional Size Dimension
o Guidelines for widening scheme;
1 AO (840mm x 1188mm)
o Guidelines for deciding the requirement of a bypass and actual alignment of
2 (594mm x 840mm)
the bypass;
3 A2 (420mm x 594mm)
o Guidelines for realignment;
4: A3 (420mm x 297mm)
o Procedure for consultation with stakeholders and dissemination of information
5. (297mm x 21omm)
about alignment and other pOect related features;
Any other point(s) considered relevant. a I)oviso standard title block for drawings.
a I ir;l llro rules for incorporating notes on the body of drawings such as design
l); rr iiri/l)lrilosophy, design parameters, characteristics of selected materials.

26
27
IRC:SP:112-20'17
IRC:SP:112-2017

loading details, description of implementation scheme of design if any, etc.

Dimensions of all the lanes, curve radii
. Devise procedure for preparation, checking and approval of drawings with mentioned and across section cut and
assignment of responsibility among sub professional, key professional and shown separately
senior expert from HO ofthe Consultant pursuant to para 3 ofthisAnnexure. A
sample checklist for preparation, correction and approval ofjunction drawing
From (Place Name) To (place Name)
mentioned on all the arms
is given below. Similar checklist for other drawings shall be devised.
Traffic island at appropriate location with
st. Compliance
Particulars complete dimenslons of all elements
No.
Yes No NA to ltem (radius etc.)
marked "No"
A GENERAL Sufficient clearance and storage lane
at JUnction available for right turning
1 Drawing title corrected movements
2 Drawino number/date corrected All types of traffic signs boards at
3 Revision status given appropriate places on allthe arms ofthe
intersection drawings shown
4. Signature of all concerned
All features to be named (e.g. existing
5. Legend abbreviation and notes
road, main carriage way, service road,
JUNCTION ELEMENTS existing culvert and other details)
1. Scale of the drawings as per TOR
2. Grids and station points on the drawing Text and line styles should be same for
with value all the similar drawings
3. Check the centre line at the junction, CLIENT COMMENTS
whether it matches with related plan
drawrng
Check acceleration, deceleration and o List the procedure for identification and traceability of drawings
storage lane provided as per requirement
5. Tapering and additional lane is as per
design requirements
6. Turning radius is as per design
requrrement
7 Stop line, lane, edge, chevron markings
and over head gantry location are correct
8. Cross drainage structures and side
drain is tied up properly for smooth flow
of water and shown properly
9. Forexisting situation, the plan ofexisting
junction to be super imposed and shown
in up graded drawings
'10. Traffic flow markings are shown on all
the arms at appropriate locations

28 29
.qF

IRC:SP:'1'12-2017
IRC:SP:112-20'17

Annexure 4.2 . Works/items to be sub contracted in the project as a whole;

MODEL QUALITYASSURANCE PLAN FOR CONSTRUCTION o Plan as to how the works/items to be sub contracted will match the works
programme of the contractor for the whole project;
'1. Brief particulars of project a Plan as to how the role of QA&QC personnel of contractor/ project
. Name of Employer/Authority including all units/offices associated with project
management consultants shall be enforceable to the works/items to be sub
contracted.
imolementation:
. Name of the Independent Engineer/Authority's Engineer/Construction
B. Control of documentation and communication
Supervision Consultant; . Procedure for filing, indexing and maintainence of records in a manner that
. Name of Concessionaire and/or Contractor;
provides for ready access to documents and prevents loss, damage, or
. Brief description of location, terrain, topography, climate, socio-economic
deterioration:
characteristics of the project area; . RFD (Result Framework Document) by contractor (A results framework is
. Any other important point(s).
an explicit articulation (graphic display, matrix or summary) of the different
levels or chains of results expected from a particular intervention).
2. Scooe of civil works 0. Control of methodology
List the scope of civil works such as earthwork, pavement courses, structures, drainage and ( ir,nlrirctor is required to submit methodology
protection works, safety measures etc. Scope of works should indicate use of site and factory as per provision of agreement eAp shall
l||rllcnlo a plan of approach as to how approved methodology shall be followed diligenfly
manufactured materials in particular items.
rltIht0 L.xecution.
Applicable documents and references 10, Human resources and training
List all the applicable documents such as contract agreement, applicable manual, MoRT&H liklll, knowledge and expertise of conkactor's personnel responsible for various activities
Specifications, relevant IRC/BlS/other codes of practice. hllirlr irs planVmachinery operation and maintenance, laboratory/field testing etc. are
4. Quality policy '|xlruroly important to ensure quality of the project. QAp shall deal with contractor's plan
Contractor's own quality policy as per its own charter and reference to such document. Il l)rooramme to train its own personnel.
5, Contractor's organisation and structure 11. Control of materials including traceability and product identification
o Indicate organisational chart of the project implementation team of the (Jn I'will oontain two different protocols to be followed
by the Contractor to procure naturally
conlraclor. minerals and manufactured materials. There will be a separate protocol to control
'|ril.'|[l||{l
o Chart shallshow the QAand QC section ofthe contractor/ project management |lrlx Irrlorials at Contractor's plant site. The protocol will list the responsibility of Contractor's
consultants as applicable in more detail. koy Iotsorrnel and sub professional pursuant to para 6 of this Annexure as regards control of
a Chart shall show interface with top management of the contractor and IIrl'rirl$. The protocols will contain a faultless system for maintaning product identification
Independent Engineer/Authority's Engineer/Construction Supervision n n|| ll)k) l)rotocol is given below;
Consultant as aDDlicable. . Estimate material quantities with reference to drawings and specifications;
6. Responsibility matrix among the contractor's key personnel . Prepare requirement plan;
o All the major tasks in project implementation including pre-construction/ a Floatenquiries'enclosingspecifications;
preparatory works shall be identified a Assign the responsibility oftesting and obtaining approval among Contrctor's
o The role of QA&QC person nel of contractor/ project management consu ltants I)ersonnel:
as applicable during performance of different tasks shall be established. o Collect samples, test independently;
7. Control of sub-contracting o S(x)k/obtain approval ofthe source, if necessary;
Sub contracting is a reallty in almost all contracts though varying in nature and extent. a l,litcc order, receive materials, test samoles:
Sometimes sub contracting of a specialised nature of work is a genuine necessity While r Assign suitable identification number to each lovstack and maintain record of
finalising a sub contractor, qualification criteria as stipulated in contract agreement shall be lo same:
followed. QAP shall provide the following details as regards sub contracting:
. n llow for usage if test reports are satisfactory;
 ic lil, lt2 201 / IRC:SP'112-20'17

. Untested materials to be stacked at locations designated for the purpose; Annexure 4.3
. Where routine tests are not conforming to requirements, materials to be
segregated at locations designated for rejected matenals and quickly MODEL QUALITYASSURANCE MECHANISM FOR
removed from site: CONSTRUCTION SUPERVISION CONSULTANT/INDEPENDENT
o lf materials from a pariicular source continue to fail in the tests, discard the ENGINEERYAUTHORITY'S ENGINEER
source.
12. Control of machinery I Brief particulars of assignment:
o PTan for selection of machinery (number, type and capacity) keeping in view . Name of Employer/Authority including all units/offices associated with proiect
production rate; molementation:
o Plan for kaining of operaiors as per manufacturer's requirement; . Name of the Independent Engineer/Authority's Engineer/Construction
Supervision Consultant;
o Plan for calibration, routine checking and upkeep of machinery including all
relevant Darts resDonsible for different controls . Name of Concessionalre and/or Contractor:
13. Control of laboratory and field testing facility . Brief description of the scope of work of consultancy services;

a Plan for laboraiory infrastructure such as location, space size, personnel, . Any other important point(s)
equipments, accessories, consumables, general facilities commensurate ,' Applicable documents and references
with work requirements; Ii .l rll llrr irl)l)licable documents such as contract agreement, applicable manual, l\y'oRT&H
r Plan for calibration of equipments; ' ,t,", rl , ! rlro|ls relevant IRC/BlS/other Codes of Practice/Guidelines/l\.4anuals
a Plan for upkeep of equipments; I euality policy
a Plan for identification of samples and docurnentation of test results; ,l rl,' llri, oo|rjultant's own quality policy as per its own charter and reference to such
o Sample formats for collection of samples, recording of iest (field and
laboratory) observations and analysis/calculation of test results;
o Sample formais for statistical analysis;
4 Consultant's organization and structure
l|l'lr, .,i,' ,,rti /ational chart of the consultant's team with clear emphasis on eA and OC
o Sample formats for checklng of levels and profiles.
All the sample formats mentioned above shall be included in QAP
14. Control of corrective action
', Ilcsponsibility matrix among consultant,s personnel
'l|l llir l, |;ks of the consu ltancy services related to quality assurance and control. prepare
lr'.1 , ,
List the protocol for retesting and acceptance mechanism.
r',,t,,,ll,,r])rlrly rirtrix among key personnel, sub professionals and HO Support for qUality
15. Control of traffic management, work zone safety, health and environmenl | .,l, f ,! ! r(l (x)ntrol clearly showing primary, secondary and terttary responsibility.
Enforcement of traffic management, work zone safety, health and environmeni managernent lr (:() trol of documentation and communication
plans are often neglected QAPshall provide a protocol for enforcemeni of these plans
/ l'r()locol for acceptance, non conformance and rejection
16. Interaction between QA & OC Personnel of Contractor and Engineer
QAP will deta I the mechanism for inieraction between QA & QC Personnel of Contractor
including ts pfoject management consultant, if engaged, and Engineer to achieve quality of
works together with timely completion

32 33
 IRC:SP:1'12-2017
sEcTtoN 5
QUALITY REQUIREMENTS FOR FACTORY MANUFACTURED
MATERIALS, PRODUCTS AND SPECIALIZED ITEMS
5.1 lntroduction
The materials used in road construction can be broadly classified into three categories
i.e. natural materials such as soil, sand, gravel, stone etc., factory manufactured materials
such as steel, cement, bitumen etc. products and specialized items such as bridge bearing,
expansionjoint, tolling equipment, crash barrieretc Field laboratory is required to be equipped
for carrying out most of the tests specified for natural materials and factory manufactured
materials. However, the finished items are usually tested in manufacturer's own laboratory
or in a specialized laboratory.
5.1.1 Tentative list of factory manufactured materials used in road construction and
testing requirements for the same are indicated in Annexure 5.1. The tests, which are
normally carried out in field laboratory in respectofsuch materials, are also indicated therein.
5.'1.2 Tentative list of factory manufactured finished items used in road conshuction
and operation are indicated in Annexure 5.2 along with testing requirements for the same.
Normally, there is no facility in field laboratory to carry out such tests.
5.1.3 Reliability of factory manufactured materials and finished items specilled
I Annexure 5.1 & 5.2 in the absence of regular site testing has a lot of concerns which need to
be duly addressed through a combination of testing in manufacturer's/third party laboratory
and rigorous protocol to ensure adoption of correct practices by the manufacturers.
5.2 General Princioles
5.2.1 Quality of factory manufactured materials and finished items specified in
Annexure 5.1 & 5.2 hinges upon the manufacturer's commitment and implementation of a
rigorous protocol in a sustained manner in pursuance to ISO 9001-2015 or similar standard.
Three aspects are critical in this regard:
o Process approach
. Plan-Do-Check-Act (PDCA) cycle
a Evidence based decision makrng
5.2.1.1 ProcessApproach
A process is defined as a set of interrelated or interacting activities that use inputs to deliver
an intended result The process approach is a management strategy. When a firm/company
uses a process approach, it means that it manages and controls the processes that make up
its organization, the interactions between these processes, and the inputs and outputs that
tie these processes together
When this approach is applied to quality management, it means that the processes and
process interactions are managed by the firm/company as a coherent process-based quality
IRC:SP:'112-2017
ttnnltgomont system. A process-based quality management system (eMS) uses a process
Fpl)roach to manage and contror how its quarity poricy is impremented and how its ouaritv
otroctlvos are achieved. In a nutshell, a firm/company is required to identify the processes
lllnl llB QMS needs, to identify their sequence and interaction, to identify required inouts and
cxpo(itod outputs for each process, to identjfy process risks and opportunities. and io assign
rrrponslbllities and authorities for each process. lt also expects the firm/company to ident-ify
ll!o ntothods needed to manage, monito( measure, evaluate, and control each process and
k) pr()vldo the resources that each process needs
D,2,1,2 Plan-Do-Check-Act(?DCA) Cycte
Allrnr/company is required to (i) plan its process based elVS, (ii) operate tts process based
QMs, (lll) ovaluate its process based eN/S and (iv) finally improve its process based elvls.
A llnn/r:ompany is required to consistenfly foflow the steps (iii) and (iv) during its operation/
mrntifncturing.
D ?.1.:l Evidence based Decision Making
MIkltU (k)clsrons involves a degree of uncertainty, but ensuring that decisions are based on
lhr rlnly8ls and evaluation of data is more likely to produce the desired result. This orinciole
lt dkrotly applied to step 1,3 and 4 of PDCA cycle in managing and ensuring quality.
8,2,2 When reliance is made on the quality of a factory manufactured materiat or finished
llam, lt must be certified that the manufacturer is reasonabry comprying with the requirements
ahla(l In 5.2.1 above
in
t,l RosponsibilityofSupplier/Manufacturer
Thc rupllllor/manufacturer has the responsibility of formulating a sound quality management
phn (ONIP) In accordance with the principles set out in clause 5.2 above that meets the
lprolllontlon roquirements through systematic program of sampling, testing, and inspection.
OMP rhnll bs consistent with quality policy of the manufacturer. the qualitv manaoement
pltn rlrflll oover aspects such as particurars of certification of company by ldo or ariy ottrer
olgrnkrllon. testing facilities, accreditation of manufacturer's laboratory by NABL/equivalent
Intatntlk)nnl organisation, calibration process, eC personnel, acceptance mechanism,
doountrntflllon, third party testing and evaluation method. The supplier shall follow its
QMP dlllgrrntly. The supplier/manufacturer shalt furnish its quality management plan and
lootrfrh rol)orts of its in house testing and third party laboratory test reports to the purchaser
(lmployrr/ftuthorityicontractor). Annexure S.3 gives list of documents to be furnished bv
Itlppllar/nrnnufncturer. Annexure 5.3 is a minimum requirement only. lf any Code of practice/
oUldrlln rp(xlfies the detaits of documents to be provided by supplier/manufacturer for a
plltlouhr nlIl(|rhUitem, the same shall also be provided additionally. Requirements given
In Annlxurr 6.3 may be further improved by concessionaire/contraitor in its eAp foi any
apaolllo lH0lory monufactured material/finished item.
l,a RarponslbllityofConcessionaire/Contractor
lhl tt'rtrrprlk rrrrrlro/contractor will remain responsible for the ultimate quality of an item
l)fo(llr0crl trl 0 hclory manufactured material or a finished item itself. The contractor shall
lltnrsloro. nxnrr;ln0 lts checks pursuant to its own OAp for such materials.
ll{( ):SP:112 2017 IRC:SP 1112-2417

5.5 ResponsibiliiyofEngineer/ConsultanUEmployer/Authority Annexure 5.1

The responsibility of Engineer/Consultant is basically threefold. First, the Ouality Management -LIST OF FACTORY MANUFACTURED MATERIALS
Plan and other documents submitted by the supplier/ manutacturer shall be scrutinized at
length to find consistency of documents in accordance with quality policy of the manufacturer USED IN ROAD CONSTRUCTION
Second, the Engineer/Consultant is required to witness a certain percentage of in house tests
conducted by the supplier/manufacturer The Employer/Authority shall carry out witnessing ^{ | lrls is not an exhaustive list}
of tests, wherever Engineer/Consultant is not engaged for a particular project. Engineer/ Fac:tory Testing requirements
itl Test facility
ConsultanVEmployer/Authority shall get third party testing of certain manufactured materials/ manufibctured at field
Nrl Applicable
finished items in a laboratory of repute depending upon the volume of work, importance/ matterial Test
Code of Practice laboratory
unique nature of a particular finished item, inconsistency of manufacturer's test reports, fragile
I ly Ash Requlrement of IRC SP:58 lS:2720-Patl-2
results of the tests. Random sampling along with traceability of sample is a pre-requisite for
lst2720-Paft-4
third party testing Quality Assurance l\4echanism of Engineer/Consultant shall firm up the Grain Size Analysls
lSr2720-Part-5
details of tests to be witnessed by Engineer/Consultant and third party testing of certain Atierberg Limits
lS:2720-Part-B
t\,4 D D/O t\.4 C
manufactured rnaterials/ finished items to be carried out CBR
lSr2720-Part-13
lst27zO-Paft-15
lMo sture Content
5.6 New Materials cohesion (C)
lS:2720-Part-16
lS:2720-Patl-17
Several new materials are being developed from time to time which are not incorporated in AngLe of Shearing Resistance (q)
CoefficienI of Consolidation
N,4oRT&H Specifications for Road & Bridge Works. Such new materials are meant for use
Compression index
in pavement courses, concrete and various miscellaneous works to bring in economy in Permeab I ty
construction/enhancement of performance/protection of environment etc. . Whereas decision Coefficienl of Uniformity
as to use of such materials shall be taken as per provisions of Contract Agreement or based Requirement of 1S.3812 (Part t)
on judgement of Employer/Authority, following guidelines shall be followed to ensure that
pn
stated objectives are duly realized. Sllicon Dioxide
o All new materials proposed to be used should be fit for the intended purpose Magnesium Oxide
of the material or the work in which these are incorporated (e g strength' Sulphur Trioxide
Loss on lgnition
durability, volume stability, permeability, separation or filtration' visibility, Sod um Oxide lS:1727
reflectivity, impact resistance, etc as relevant), tested in reputed laboratories Silicon Dioxide, plus lS:4032
and in the field. Aluminium Oxide plus lron lS:12423 NO
Oxide lS:2724
The material should have a technology and production base that is capable
TotalChloride
of producing the required quantity with consistent and reproducible qualitr. Reactive Silica
Full responsibility of the manufacturer shall be guaranteed towards Fineness
performance of the material. Wet Sieving
Lime Reactivity
. The manufacturer's Quality Policy shall be submitted. Compressive Skength
The soecification limits of the material shall be informed for different quality Soundness
characteristics. Requirement of MoRT&H
Undertaking of the manufacturer about no adverse environmental impact Specifications
shall be furnished supported with test reports. S eveAnaysls S:1514 NO
Calcium Carbonate
Calcium Oxide

36 37
IRC:SP 1112-2017
IRC.SP:112-2017

Factory Testing requirement! Test facility Testing requirements

st. Test facility
manufactured Applicable at field nufactured
No Test Applicable at field
material Code of Practice Iaboratory material
Code oI Practice laboratory
3 Ordinary Requirement of lS:269 lS:4031-Part-1
Podland lS 4031 Part-2
PhysicalTests
Cement lSi4031 Part-3
Consistency
lS:4031-Part-4
Setting Time
lS:4031-Pad-5
Fineness(Blalne s a r dry
lS:4031 Part-6
se vrng)
S:4031-Part-11
Soundness
Density ll,rtnd Ha
laroen ng
Compress ve Strength i Cemenl
Physical lS:4031-Pad-1
ChemicalTests Consisiency lS:4031-Part 2
Ltme Setting Time lS:403'1-Part 3
Soluble S lca Fineness(B a ne's air, dry lS:4031-Part 4
Alumina seiving) lSi4031-Part 5
lron Oxide Soundness 1S.403'1-Part 6
Total Sulpher Conlent S:4032, Density lS:4031-Parl-11
NO
Tricalcium Alurninate S:12423-1988 Compressive Skength
I\,4agnesia
Loss on lgnition Chemical
Chlorde Content Lrne
Insolub e ResidLre Silca
Alkali Alum na
lron Oxide
PPC Requirernent of S:1489 Total Sulpher Content 1S14032, lS:12423 NO
Physical S:4031'Part-1 TricaJcium Alurninate
Cons slency Sr4031 Part-2 Magnesia
Setting Trne S:4031 Pad-3 Totalloss on lgnition
Fineness (Blaine s air, Dry S:4031-Part 4 TotalChtoride Content
Seiving) S:4031-Part 5 Insoluble Residue
Soundness S:4031-Part 6 Requirernent of lS:73
Density S:4031-Paft 10
Compressive Skength S 4031-Part 11 Penetration al25'C, 100 g,5 s,0 1 mm
Drying Shr nkage Abso ute Viscosity at 60'C, poises
Kinematic Viscosity at 135"C, cst,
Ghemical Flash Point (Cleveiand open cup),.C
Su lpheric An hyd nde So ubllity in Trichloroethylene, per cent,
I\,4agnesia lS:4032, S.12423 NO Softening Point (R&B), "C
Loss on lgniton Tesis on Residue from rolling
Insoluble Residue th n film Oven Test:
5 PSC Requirement of 1S 455 a) Vlscosity Ratio at 60"C
Physical lS:4031 Part-1 b) Duclility at 25'C, cm
Consistency lS:4031-Part-2
Setting Time lS:4031-Part-3
Fineness(Blaine's air, dry lS:4031-Part-4
seiving) lS:4031-Pa.t-5
Soundness lS:4031-Pa.1-6
Density lS:4031-Pai(-11
Compressive Strenglh
IRC:SP:'112-2017 IRC:SP:112-2017

Testing requirements
T€8t facility
at field
Iaboratory
Modified Bitumen Requirement of IRC:SP:53 Modlfled Bltumen Requirement of l\TORTH
Penetration at 25'C 0.1 mm 100 gm, lmulllon for lvlicro Specific€tion
5 sec lS:1203 turtrclng
Residue on 600 micron lS sieve
Sofrening point (R&B)'C lS:1205
Viscosity by Say Bolt Furol
Ductility at 27'C lS:1208
Fraass Breaking Point 'C lS:9381 Viscometer
Flash Point CoC 'C lS:1209 Coagulation of Emulsion lS:8887
Elastic recovery of halfthread in lS:1206-Part 2 Storage Stiability lSr1203
Ductilometer at '15'C per cent lS:15462-A Padcle Charge lS:1208
Separation difierence in Annex-1,2,3 & 4 of lS:1205
Tesl on Residue
softening point, R&B Method in 'C IRC:SP:53 IS:'15462
Viscosity at 150'C Flash Point, COC lS:9382 Residue by evaporalion lS:1216
Thin film oven test on residue Penetration at 25"C/ 1 00 gm/5 secs
a) Loss in lvass Ductility at 27'C cm
b) Increase in Softening Point Softening point 'C
c) Reduction in penetration of Elastic recovery
Residue at 25'C , porcent(ls 1203) Solubility in trichloroethylene
d) Elastic recovery of half thread in
St pplng Agenl
ductilometer at 25'C
Cationic Bitumen Reouirement of 1Sr8887. ASTM:D-2397
Emulsion Appearance
Mscosity by Saybolt Furol
Odour
Viscometer, seconds Specific Gravity 27'C
Storage Stability Pour Poinl 'C
Particle Charge Test ASTM: D-244 Flash Point '(COC)
ASTM: D-6933 Water Content per cent Vol.
Cement Mixing Stability
ASTM: D-6935 Solubilfty in diesel oil (HDO or LDO) in
Distillation the ratio of2:98 at 50"C lSt1202
ASTM: D-6997
Residue on 600 micron lS Total base value mg KOH/g lS:1,{48
Annex-B, D, E, G,
Nitrogen Content per cent Wt. ASTM: D-664
Sieve, percentage by mass H and J of lS: 8887
Stripping value with bitumen containing lSr6241
Penetration Ductility ASTI\4: D-3625
'1 per cent Wt. anti stripping compound at
Solublity in Tdchloroethylene 40"C 24 hou.s
Miscibility with water Under waler coating t€st
Residue by evaporation Thermal stability at 163'C 5 hours
Boiling Water Test per cent coating
Requirement of lS:217 Retained L4arshall Stability per cent
Kin€matic viscosity at 60'C Requirements of IVIORTH Specif cations
lS:1206-Part-3
Flash point Pensky Nrortens Closed lS:'1209
Type 'C Maximum fibre length
lS:12'13
Distillate volume per cent of total distillate Ash Content
upto 360'C OilAbsorption
iroisturo Content

40 41
IRC:SP:1'12-20'17
IRC:SP:112-2017

Factory Tesling requirements Test facility

st. F!ctory Testing iequirerhents
No.
manufactured Applicable at field lt, m0nufactur0d
Test facility
material laboratory 1{0. at field
Code of Praclice matorlal
al Test I code
Appticabte
'14 ] of practice laboratory
Silica Fume Requirement of lS:15388
ll lltllr:hrifllSt6el ReqLrireme tS:11SB7,lS:1977,
Physical lS:8500 & I 62
Specific Surface
PHYSICAL
Pozz Activity Index
Tensile Strength (N/mm,)
45 N,,licron Relained lS:1608
Bend Test
Bulk Density ASTM Cr'1240 No lS:1599
lmpact Test
Chemical Flattening Test lS:1757
lS:2328 No
Silicon Dioxide
IVoisture Content
CHEMICAL
Carbon (%)
Loss in lgnition
Alkalis as NarO Sulphur (%)
1Sr11587
Phosphorus (%)
15 CementAdmixture Requirement of lS:9103 Sulph'rr (%)
Phosphorus (%)
Dry l\,,laterial Content
Ash Content lS:6925
lSr9103 (Annex E)
NO ll l'lr lJlroBolng Requifements of tS: 14268
pn tlftlStrndg
Nominal Diameke
Water Soluble Chlonde
Relative densrty
NomrnalArea

Jornt Ceiling Penetration ASTI\,4:D-532g-Sec 6

-
Nominall\,,lass ts 14268 No
Proof Load ts f608
Compound ASTM:D-532g-Sec 8 Breaking Strength of Strand
Bond ASTI\,4:D-532g-Sec 9 % Elongation
Resilience AST[1:D-5329
Sec 12 l0 Itllrk)r t|ondo d Requirements of tSt13620
llnrxy O(xllod
17 Reinforcing Steel Requrrement of lS:1786 & lS:2062 Coating Thickness
llrcl
Chemical Resistance
Physical
Corrosion Tesl
Unit Weighl (kg/m) lSr1786
Adhesion NO
Yield Strenglh (0 2% proof stress) lS:6885
Bond Strenglh to Concrete
(N/mm'z)
Abrasion Resistance
Ultimate Tensile Strength (N/mm'?) lS:1608
lmpact Test
% Elongation
NO Hardness Test
Bend & Re- bend test

Chemical
lr lhl lorr slool Requirements of lS:6603, tSt69.l1
Carbon (%) Chemical composilion
Sulphur {%) Tilanium
lS:228
Phosphorus (%) Niobium
Sulphur (%) + [rolybdenum
lS:1608
Phosphorus(%) Copper
lS:1599
No
Mechanical property lS:'1500
Tensile test lS:1501 (Pt.-1)
Bend test lS:1586
Hatdness lS:1499
Charpy impact iest lS:6603
Dimensional tolerances

42
43
IRC:8P:112-2017 IRC:SP:112-2017

Testing r€quirements Test faclllty Factory Testlng requirements

atfleld mtnufaclured Applicable
labolatory matorial
Code of Practlce
Requirements of lS:1'161 olaal Forgings Requirement of lSt1875

Mechanical Test tensr|e test IS:1608

Tensile Test Hardness Test lS:1500
Flattening T6st Retest lS:1599
Bend Test bend test lS:4748
Retest Grain Size lS:11371
Macro structure lS:10138
Chemical analysls test lS:'l161 lJltrasonic Test lSr4075
Hot-dip Zinc Coating [ragnetic Particle Tost lS:3739
Tolerance Blue Fracture Test lS:4075
Siz€s and Properties Dimensional Tolerance ts..228
Steel & Supply Macro streak flaw t€st
Manufactudng Process ChemicalAnalysis
HFW It.l Nut Bolt Requirements of lS:1364 and lS:1367 lS:1364
HFS W||hlrs lSOt724
ERW/HRIW Dimenslons & Mechanical
ISO:965-1
Properties
Prefered Threads ISO:898-1
ISO:4759-1
Quality of zinc Non Prefened Thaead
ISO:4042
Galvanizing lSr4736 Tolerance
Property Class ISO:10683
Basic Metalfor Tubes lSr2629
lS:1367 (Pt.-17)
lrass of Zinc Coating lS:4736 ProductGrade.
ISO:3269
Freedom from defect lS:6745 Finbh and or Coating
Free Bore Test lS:2629 For Electropl€ting
Uniformity of Galvanized Coating lS:4736 For non electrolytically
Adh€sion Test lS:2633 Applied Zinc Flake Coating
Sampling & Preparation of lS:2629
lS:4736 Plain washer
Test Specimen
Hole Diameter
Re Test
Outside Di€meter
Requirement of lS:1030 Hardness Test
Tensile Test lS:'1608 Requirements of
Brindell Hardness Test lS:1500 l\4ORT&H Specific€tions
lmpact Test lS:1757
lS:1599 mechanical properties of ACi,
Bend Test
lSt228 Peel off strength with Reko-reflective ASTM:D-903
Chemical Analysis
lS:1030 Sheeting (Drum Peel Test) ASTM:E-8
Chemical Composition
lS:2595 Tensile Strength ASTMr393
Non Destauctive Test
lSr3658 0.2% Proof Stress ASTI\4r732
Hydraulic Test
Elongation
Radiographic Test lS:3703
Flexural Strength
Liquid Penetrant Flaw Detection
FlexuralModulus
Magentic pafiicle flaw Detection
Shear Strength with punch Shear Test
Properties of Aluminium Skin
Tensil€ Strength(Rm)
Modulus of Elaslicity
Elongation
0.2% Proof Stress

44
IRCtSP:1 12-2017
IRCTSP:112-2017

Factory Testing requirements Test facility

9t. Factory Testing requirements
No.
manufactuted
Applicable at field lt. anutactured
Test facility
material Test laboratory NO, Applicable at field
Code of Practice material Test
laboratory
n Retro-Reflective Tensile Shength
Luminous Coefficient
Code of Practice
Sign Board & % Elongalion
Sheetrng Aluminium No- Pick UpTime
Heat Stability ASTN4:B-209M No Resistance to Wear
Crackrng Resistance Gradation of class Beads
Retro Sheeting tl rr{trn Clay Bricks Requirements of lS:'1077
29 Ordinary Road Requirement of lS:164 Compressive Strength lS:3495 (Pt -1)
Marking Paint WaterAbsorption Yes
Durability lS:3495 (Pt -2)
Drying time on Bttuminous Efflorescence IS:3495 (Pt.-3)
Surface t4 lhIn Pipe (NP-4) Requremenis of lS:458
Surface Dry
Compressive Strength lS:516
Hard Dry
Splittrng tensile Strength lS:5816
Consistency
Hydrostatic Test lS:3597
Finish
Three Edge Bearing Test lS:3597
Application S:164 NO
Permeability Test lS:3597
Colour s 101 NO
Working Pressure lS:458
Wet Capacity
Site Test Pressure
Resistance to Bleeding
Surge (Water Hammer)
Recoating Property
Pressure
Resistance to Wear
Design & Slrength Test
Resrdue on Sieve
Spigot & Socket Dimension Test
Flash point
Keeping properties
ln Hlxlrl lllng lJuct Workabiljty
Transverse Load Rating Test
30 Thermo Plaslic Luminance
MSHTO: M-249 Tension Load Test
Road Marking Drying Time
I\,4ORTH Water Loss Test lS:'1343
Paint Skid Resistance NO
Specifications Bond Tesl
Crackrng Resistance at low
BS:604 NO Compresston Test for the
Temperatute
AST[,4 rD-36 Loss ofWallThickness
Softening Point
Flow Resistance AASHTO: iM"249 IN )flr0o for Requirements of lS:1343 lS:1343
Yellowness lndex AASHTO: N,4-249 lrrn l; Ilosstng
Static Load Test with Tendon Anchorage
31 Reflectorising Gradation BS:6088 Assembly Dynamic Load Test with NO
Glass Beads Roundness BS:6088 Tendon Anchorage Assembly Load
Refractive lndex BS:3262 (Pt.-1) Transport Tesl
NO
Free Flowing Properties MORTH tt t )hqrlrl(xrlRosistanl Requkements of draft
Specifications rnft)lrivo Paint RDSO Specificatron No
Cold Applied Requirements of MORT&H Specifications MORT&H Spec M & C/PCN/f23-tl
Refleclive Paint 1475
ASTI\.,1: D- Drying time
Binder NO
Titanium Dioxide AST[.4: D-7'l 1 Consrstency lS:101
Calcium Carbonate & lnterfiller ASTI\4rD-968 Dry Thickness and Rate of
Yellow Pigment ASTMTD-1737 Consumption
Density AST[,1rD- 1647
BS:6044 No
Drying Time
Sand Abraston Test BS:EN-1436- 1998
Elongation (Unbeated Dry Film) ASTM:D-71'l
Water Resistance ASTt\r-D-4060
Skid Resistance ASTM:D-968
Retro-Reflective Property BS:60B8

46
47
lRCrSPill2-2017
IRC:SP:112-2017

Factory Testing requirements Test tacility

st. Factoay
manufactured at field
d. manufactured
No. Applicable
mat6rial Test laboratory No.
mateaial
Applicable
Code oI Practice
Code of Practice
38 Epoxy Based Paint Requirements of lS:14589 42 I M""ha"i"=tty Wo*" Mechanical paoperties
Consistency Tensile Strength of wire for double
Drying Time twisted
Finish Physical properti6s
Colour Zinc Coating
Volatile l\4atter M€ss Zinc Coating lS:280
Pigment Content Adhesion of Zinc Coating lS:4826
Volume Solids lS:101 NO PVC for coating lS:4826
Dry Film Thickness Specific Gravity lS:13360
Flash Point Tensile Strength
Protection against corosion Hardness Test
Resistance to Salt Spray Resistanc€ of PVC Coating to sodium
Effect ofwelding Chloride
Keeping quality Salt spray Exposure
POt t|te
Latox Acrylic Polymer Appearance l\4elting point
39 Grease Requirernents of lSt508 glass-transition Temperature
Kinematic Mscosity in CST Specific Gravity
lS:1448 (Pt -25) Water Solubility
Flash Point lS:1448 (Pt.-69)
Penetration Test Flammability Limlt
lS:1448 (Pt.-60) Autoignition Temp.
Graphite Content Acrylic Polymef
lS:1448 (Pt.-58) Explosive Properties
Drop Point Latex WB-111
lS:1448 (Pt.-52) Reactivity
Copper Strip Corosion lS:1448 (Pt.-51)
NO
Water Content Particle size Distribution
lS:1,148 (Pt.40) Purity of Chemical
F.eeAcidity lS:1,148 (Pt.-53)
FreeAlkalinity Maximum weight % of
lS:1,148 (Pt.-62) Residual lmpurities
Heat Stability lS:1448
Low Temperalure Pumping Properties Acryllc Elastomeric Requirements of NIORT&H Specifications
Glycerine Conlent Cortlng
Specific Gravity
40 Mild Steel Requirements of lS:432 (Pt.-1) Solid Content
Ultra Violet Resistance lSr345
Chemical Colhposition lSr226
lR-spectrum lS:345
I\4echanical Properties of Bars l5:432 (Pt.-1) NO
Adhesion with Concrete ASTM:c-53/
Tensile test lS:1608
Dry Film Thicknoss DTNEN-150-105
Bend test lS:1599
Coverage lR-spectrometer
41 Epoxy Requirements of MORTH SDecifications Physic€l Properties standard
Diffusion Resistance against ASTM: D-4541-
Viscosity
Carbon Dioxide 02lDtN 500014
Pot Life Test in Minute Diff usion Resislance against I\,,IORT&H
Bond Test I\4ORT&H Water Vapour Specific€tions
Shear Test No
Specifications Water Proofing DlNr 53122-P-1
Core Test Characteristics DlNr 52615
Test for Injection Equipment
Re-coatAbility
Pressure Test
Ratio Test

48 49
IRC:SP:112-2017
IRC:SP:112-2017

Factory Testing requiaements

st. Test facility Annexure 5.2
manufactured
No Applicable at field
material laboratoJy TENTATIVE LIST OF FACTORY MANUFACTURED
Code of Paactice FINISHED ITEMS
45 Soil Rejnforcing Requirements of USED IN ROAD CONSTRUCTION
MORT&H SpeciUcatrons
Ultimate Tensile Strength ISO:'10319 Factory Testing requirements
Pull-out Resislance in Soil ASTN,: D-6706
ll, manutactured
No.
Coefficient of Interaction between AST[,,]: D-5321 flnlghed iterh
Reinforced fill Soil and Geo grid lS:13326 (Pt-1)
MSHTO: T-288 ,Jolnl Filler Board
Determtning lhe Coefficient of Requirements of tS: 1B-8@l
soil and Geo Synthetic Fdction MSHTO: T-289 NO
R sistance to handljng
by Direct Shear method ASTM. D-4327 lS:f0566
Electrochemical Properties ASTM: D4327 lS:10566
Compression
for Reinforced Fills with Extrusion
lS:10566
Steel Reinforcement lS:10566
WaterAbsorptron
Resisttvity lS:'10566
Density
pH IS:10566
Brtumen Contenl
Chlorides Sulphates lS:10566
Wealhering
46 SoilNailing lS:10566
Requirements of l\y'ORTH lS:1786 Penetration of re-coveted
Specifications lS:9012 Bitumen
Steel I\4ORT&H ll rr Formed Requrirements of ASTM:b-628
Grout Mix Speciilcations J(t lSoals
NO ASTMTD-412
Field Pull Out Testrng Elongation at break
Verification Test AST[4:D-2240
Hardness, Type A Durometer
ProofTest ASTM:D-573
Oven aging, 7Oh at 1OO"C
Creep Test ASTM:D-471
Tensile Strength Loss
ASTI,rD-1149
Elongation Loss
AST[,4:D-2240
Hardness Change Type A
ASTII:D-9.2D-2628
Durometer
ASTM:D-9 3D-2628
Oil swell, ASTM orl 3, 7Oh at .100.
Weight Change
Ozone Resistance 20 %
strain, 300 pphm in a|l, 7Oh at
40' c
Low Temperature stiffenino,
7 days at -fO.C Hardness;hanqe
Type A Durometer

Lowet temperature rec verv,

22h at-29'C, EO% defl di;n

Compression, Deflection, at
80% of normatwidth (min)

50
5't
 lRCrSPrll2-2017
IRC:SP:'l'12-2017

Testing requirements Test

facility Test
at site facility
Applicable at site
laboratory
Code of Practice
Geo Synthetics Genoral laboratory
Prefabricated
width
V€rtic€l Drain
Thickness
Tensile strength '1. Composite drain
Elongation at break ASTM:D-5199
width
Discharge Capacity ASTM:D-4595
Thickness ASTM:D-5199
i= '1.0 at. 300 kPa pressure ASTM:D4716
Tensile Strength ASTI\4: D-4595
ASTI\4:D-5261
Filterlraterial Elongation at break ASTM:D4716
Composite Drain ASTI\4: D4632
(Polyster/Polypropylene) Discharge Capacity
ASTI\4: D4533
Mass per unit area i= 1.0 at. 300 kPa pressure
ASTN4: D-4491
Tensile Strength 2- Corc
ASTN4:D4751
Elongation at Break Material
Trapezoid Tea. Strength Configuration
Permeability 3. Fllter
Apparent opening size Material
Skucture
Perforated/ Tubings & Fittings
llass per unit Area AST|\4 D 5261
lmperforated Pipes Conugated Polyethylene (PE) ASTMTF-405 Tensile Strength ASTM D 4632
(PVc) tubing and fittings 3-6 in
Elongation at Break ASTM D 4632
Corrugated Polyethylene (PE) ASTMTF-667
Trapezoid Tear Strength AST|\4 D 4533
tubing and fittings 8-24 in
Permeability ASTM D 4491
Corrugatod Polyethylene (PE) MSHTO:l\4-252
Apparent opening size ASTM D 4751
drainage pipe 3-10 in
Corrugated Polyethylene (PE) ASSHTO: l\4-294 WaterAbsorption & Bulk Density lS:13630(Pt-2)
drainage pipe '12-60 in lS:13630(Pt-3)
AST[4: D-3034 Moisture Expansion using
Dualwall High Density lS:13630(Pt-4)
Boiling water -Unglazed l'iles
polyethylene (HDPE) pipe lS:13630(Pt-5)
Linear Th€rmal Expansion
and fittings 3-6 in ls:13630(Pt-6)
ASTI\4: F-949 Resistance to Thermal Shock
Dualwall High Density lS:13630(Pt-7)
ASTM:D-2729 llodulus of Rupture and
polyethylene (HDPE) pipe lS:13630(Pl8)
t Breaking Strength
and fittings 8-24 in 1Sr13630(Pt-g)
Chomical Resistance
Conugated Polyvinyl lS:13630(Pt10)
I Unglazed liles
Chlodde (PVC) pipe and lS:13630(Pt-'l'l )
Chemical Resistance Glazed
fittings 1Sr13630(Pt-12)
tes
Polyvinyl Chloride (PVC) lS:13630(Pt-13)
Crazing Resistance Glazed Tile
dual wall sewer pipe and lS:13630(Pt-14)
Frost Resistan@
fittings lSr'13630(Pt-15)
Resistance of Surface
PolWinyl Chloride (PVC)
Abrasion clazed llles
sewer pipe
Resistance to Deep Abrasion
L,nglazed ljles
Scratch Hardnoss of surface
according to [4OHS
lmpact Resistance by
Measurement of Coefficient of
Restitution
Sampling and basis for
acceplance

52
IRC:SP:112-2017
IRC:SP:1 12-2017

Factory Testing requirements Test Testing requirements

st. Factory Test
manufaclured tacility manufactured
anufacture(
No. Applicable facility
finished item at site flnlshed
nlshed item Test Applicable at site
Code of Practice laboratory Code ot Practice
laboratory
7 Reflective Load Tesl ASTM:D4280 NO rrclo
Rolnforcec Requrrements of MORT&H lS:2062
Pavemenl
IVarkers
Coefficient Luminance ASTN4:E -809 Elnotom€n
Jt)lnls
)m€nc - Specifications lS:1030
BS:873 (Pt.-a) lRCrB3 (Pt.ll)
[,,lild Steel for Reinforcing
Lenses of l/ethyl ASTIV:D 788 lS:3400 (Pt.-l)
Nlethecrylate lS:3400 (Pt.-ll)
lS:3400 (Pt.JV) No
Plates
Solar Powered Load Test ASTMrD4280 No Elastomer lS:3400 (Pt.-X)
I Road Markers Water Resistance lS:12063 Laminates l5:3400 (Pt -XlV)
Dimensionaltolerance lS:3400 (Pt.-XX)
lS:226
I Road Delineators Requirements of IRC:79
Clrrolo Requirements of |\rORT&H
Physical Dimension Test NO
ItlrlD/Mlodular Specifications
6klp Srool
10 I\,4etal Beam Requirements of l5:5986, lS:4759 Edge Beam E Central DlNr17100
J(,Irl.
Crash Bariers Beam/Lamella AST[4:A-36
'W Beam, Post, Spacer NO
Anchorage AST[4:A-588
Thickness
Chloroprene Seal lS:2062
Yield strength, N/mm,
Hardness ASTM:D-2240
Ultimate Strength N/mm,
Elongation % Tensile Strength ASTI\4: D-41 2
lS:1367(Pt -Xlll) ASTM:D-624
Elongation at Fractu.e DlNr53504
Sulphur % NO
Phosphorus % Tear Propagation Shength DIN:53505
Silicon % Longitudinal transverse DlNr53507
lvlanganese % Shock Elasticity DlNr53512
Carbon Equivalent % Abrasion DIN:53516
Zinc Coating Resrdual Compression Strain DIN:53517
ASTM:D-395
11 Wre Rope Conformance with the requkements AS/NZS 3845 NO Ageing in Hot air DlNr53508
Crash Bafiier ofAushalian Standard Road Safety Ageing in Ozone DlNr53509
Barrier Systems Swelllng Behaviour in Oil DIN:5352,l
Cold Hardening Point ASTIV:D-1043
Satisfactory crash testing at least Plug Requiremenls of NIORT&H
Test Level 4 including the 4-1'l NCHRP Report 350
Specifications
test designation, or other accepted Binder
equivalent procedures Softening pornt
Traffic Cones Crash Test BS 873 Cone Penetralion at 25. C. BS:2499
NO
BS EN-i3422 OlMM ASTM:D-'1190
Flow Resistance at 70.C. 05 Hrs MORTH Specifications
13 Trafflc Attenuator Crash Test NCHRP Report 350 No Extension Test
14 Safe healing Temperature, 210. lS:2062
Frller Joints Requirements of lS:1838 (Pt.-3)
No
Resistance to Handling ts 10566 Aggregate
Recovery 10566 Grading Requirement
Compression 10566 Polished Stone Value
Extrusion 10566 NO Aggregate Abfasion Vatue I
WaterAbsorption 10566 Aggregate tmpact Vatue )
Density ts 10566 Aggrogate Crush vatue t
Weathering Closure plate
Foam caulking/Backer road

54 55
IRC:SP:112-2017
IRCiSP:1f2-2017

Testing requirements Test

Factory
st. facility
manutactuted Applicable
No. at site
tinished item Code of Paactice laboratory
'18 Compression Requiremenls of IVORT&H lS:2062
SealJo nt Speciflcations ASTIV:D-2240
ASTM:D-412
Steellor Nosing and
ASTN,4:D-624
Anchorage
DIN:53504
Chloroprene Seal
DIN:53505
Closed Cell Foam Seal
DIN:53507
DIN:53512
DIN:535'16
DIN:53517
NO
ASTM:D-395
DIN:53508
DIN:53509
DIN:53521
ASTM:D-1043
ASTM:D-3575
l5:3400 (Pt -XlV)
AST[r:D-797
lS:3400 (Pt -XXll)
AST[.4:D-3677

SteelBearing Requirementsof lRC 83-20 14 (Pt. l)

Raw Material lSr1030

a) N.,lild Steel lS:2062
b) Forged Steel lS:1875
c) High Tensile Steel lS:2004
lS:961
d) Stainless Stee
lS:6603
e) Cast Steel
lS:7666 NO
Test on welding Dry IS:1024
penetration test IS:814
Test on dimensions lS:919
Ultrasoni6 Testing lS:3073
Load test lS:9565
ChemicalTest IRC:83 (Pt.l)
20 Spherical/ Requirementsof lRC.83-2014(Pt. lV) IRC:83-201a (Pt.-lV)
Cylindrical Bearing
Raw lvlaterial
a) Cast Steel
b) Rolled Steel
c) Forged Steel
d) Stainless Steel
e) Duplex Steel NO

g) UHMWPE
h) cMl
i) cr\r 2
j) Lubricant
k) AnchoringArrangement

56
IRC:SP:112-2017
IRC:SP:112-2017

Testing requirements Test

Factory
8t.
ma ufaclu red
facility Annexure 5,3
No.
n Applicable at site
finished item Code of Practice LIST OF DOCUMENTS TO BE FURNISHED BY
laboratory
Requirements of IRC 83 lS:'1030 SUPPLIERYMANUFACTURER
PIN & Mettalic (Pt -|||) lS:2062
Guide
Bearings
Test on Raw Mate.ial
lS:961
lS:'1875
L Quality Policy of the Manufacturer
a) Mild steel
b) High Tensile Steel
lS:6911
BS:3784
L Quality Management ptan (eMp)
c) Cast Steel BS:5350:(Part C9)
d) Forged Steel IRC:83 (Part lll) Jf.f OUn of the supplier/manufacturer is expected to give accurate information about the
fbllowlng espects but not rimited to it in so fir it ,"rit"" ioln" plrticurar manufactured
lS:410
e) Stainless Steel
f) PTFE ISO:1183
".
llllltrlrl/flnlshed item being sourced from it However, in u.p""t rs not covered,
g) Adhesive ISO:'1133 """" "orJ
lgtolllc lnformation mav be cated by concessionairelconio"toJi-ngin""r/consurtanv
h) Elastomer
ISO:572-2 lnployor/Authority from ihe supptier/manufacturer
lS:1363
i) Internal Seal
lS:1364 a Raw materials sourcing
j) Poly Oxy Methylene
Sealing Chain
lS:1365 . and finished product (The
lS:2269
k) Fasteners lS:3138
f manufacturing process of the
lS:6761 with manufacturing process of
Test on Corrosion protection
Test on Casting lS:6639 respective raw material manufacturers. For
lS:1367
Test on welding any
lS:42'18
Test on Bearing ting,
lS:2016
Overall dimension
lS:6610
Surface Finish a
Load Test lS:9954
Friction Test lS:8'16 a Laboratoryaccredltatron
lS:9595
Rotation Test
lS:814 o Calibration process
Atst 3161 a Personnel
lS:2004
a Details of sub contractors e.g. fabricators, galvanizers, and patnters
etc.
a Reference to applicable B|S/lnternational Code of practice
a Acceptancel\y'echanism
a Documentation system (internal as well as external) e.g.
accurate
utding, cuttins, dri ins, processins ind tesfins
t, ::T:Tl:il"l_-gf
Operations in case of.T
bearing to shop personnel
a Thlrd party testing
a Traceability of materials, processes and testino
a Evaluation method

Copy of Certification by ISO or any other organization

Plaor rnd Poriod of manufacturing
thlpm.nulot ldentification Number and tndividuat product ldentification
t, Numbar wherevor applicable
I llltnufrcluror'8 Certificate about compliance to eMp Shipmenulot wise

58
59
 lltC:SP:112-2017 IRC:SP:112-2017

- 7. Certified Laboratory Test Reports Shipmenulot wise SECTION 6

The test results shall include the following:
. Test reports from raw material manufacturers and sub contractors
FIELD LABORATORY SET UP
. Test reports of material/flnished item including destructive testing, acceptance
testing etc ll I Introduction
l l|l,rltlV Oor rol requires testing of materials, processes
at. As.built Shop Drawings and Installation Drawings (showing prope ,rt r,,,'t(;o. truclion. Adequate numberoffield laboratories
and workmanship in various stages
orientation) wherever applicable shall be set up bythe Contraitor
rrr llr, r)rol(x)t slte by installing the equipments suggested
in section 100 of the MoRTH
'rl|'rr llr{.;rlrons for Road and Bridge Works. The numOer and ize of taboratories depend
Ur ll.ri' i r:;l; rl)lishment and oraganisatjon structure at site. lt als
depends on the location of
, I rr,l! ,r r,, (:(rtcrete batching plant, wet mix plant,
hot mix plant and ihe camp office. lf all are
lrx llr() same place, one single laboratory with the facilities
'rl,xl.r|| to test all the construction
rr'|rr"rrrrr:' rilrirI be estabrished in the camp site rf the prants are
rocated in different rocations.

t|'r lIlr I rtri of indtVidUal plants.

|
' tr

lr'rx'r'rlly, tl is Contractor's obligation to establish the test laborat

ries but where a project
lrx.lrrlrr, (lllloronl packages, the Employer/Authority may choos
to establish
a Central
| ,rlx'rlr.ry.l ir convenient location, where the Engineer may also be abte
to conduct tests
rrll iylr',1 r)l laterials and mixes.
'rtr
A, Oltoctive
I lrtl'l I r rlr n rt{ )ry is t e real bastion of quality control. Infrastructure and
equipments of Field
I rrr'.,rrli'rv |l:ry criti al role in quality control and, in fact, is
a cornerstone in the process of
,lil,rlllV,r,,,,Url|||(:o The objectives ofan ideal Fjeld Laboratory
can therefore, be summarized

r) t y out pla is such that it accommodates the equipments in proper

|lrirnner and
rovideS good and efficient wOrktng envirOnment.
) tn tcoded eq u ipments and accessories are available
and properly maintained
t) hrtonded consumables are available and properly stored.
tv) l)( x jl tmentation management system is efficient.

I| (lo rrrfll Features

al I lllx,t,t Itthoratoty
l||lrrrxlt u,,o ttrr',r,/,. Dackaoino fleld organization structure and geographtca spread
rrl llrrr lrrr,1rr | ',trr,. r rr' can bJa-cenkal/main laboratory
for each package. Furth r, plant
l'.lnrtrt','"' r ,rrr lrrr rr:rt;rblished if they are located in diffe;ent cations than the main camp
rl||. lr[r1r 11111111111p111:i i rt t
oach pranIaboratory wil be specific the prant estabrished atthat
hx lh'|l l l n lltl r, nty / f
.
tployer may choose to establish a central laboratory, forconducting
||rrttr l tlr I lr tl I i , || |r r:| |Ii( ; I I tests

60 6l
 IRCiSP:112-2017
IRC:SP:112-2017
6.3.2 Lay out of Laboratory
The layout of the laboratory depends on the test facilities required at that location. Test
facilities can be divided in to three principal sections namely, soil and aggregate testing Its of various tests shall be included in the
section, concrete section, asphalt section. be made available in the central/main &
entered in suitable registers and/or forms
Plant laboratories will have a concrete section for concrele batching plant and aggregate and
asphalt section for wet mix macadom and hot mix plants. However, the facilities required for
.All RFts, if
I the etrieved
mix designs need not be established at the plant laboratory Depending on the Contractor's
plans for establishing the plants and their relative positioning with the field laboratories, the
snou inked to
be stored in an orderly manner in the safe
placement of facilities may be optimized.
copy of the records shall be maintained in
Considering that a field laboratory is established for each package and plant laboratory is I
established at the plant site, suggestive lay outs are furnished in Annexure 6.1 of this Section.

6.3.3 List of Equipment &Accessodes

The list of equipment and various accessories in each laboratory depends on the type of
laboratory and the test facilities envisaged or planned by the Contractor at that location. With
the same assumptions used for deciding the layout of various laboratories presented in para
6.3. 1, a comprehensive list of equipment in each laboratory and the suggested inventory of
consumables are furnished in Annexure 6.2 and Annexure 6.3 of this Section, respectively.
As such, this list shall be consistent with section '100 of N/ORTH Specifications for Road and
Bridge Works. However, it may vary depending on the actual test facility envisaged at that
location subject to approval of Engineer

6.3.4 Man Power

Deployment of manpower depends on the size of the laboratory the test facilities planned
and the volume of work involved. The central/main laboratory shall be headed by euality
Control/Asst. Quality Control Engineer The qualification and experience shall be as per the
requirements of Section 3 of this N4anual. Each plant laboratory shall be manned by afleast d and wellmaintained with properwatersupply
one lab technician. apparatus requiring temperature controlled
ned rooms. The tests that use infammable
6.3.5 Codes of Practice
L! USs
Irurrr"ucs snar De conoucled tn separate room having adequate ventillation / windows.
aIIltne

All the tests shall be conducted as per relevanl Indian Standard Codes of practice, which lhtcAuipment provided in thecentral/main as wellas the plant laboratories
have been mentioned in Section 900 and other sections of MORTH Specifications for Road shall be checked
and Bridge Works. In the absence of Indian Standards for any test, reference may be drawn T,il:""lltl^f:llfglif:
lll the equipment"crion
ins and servins the inrended puipos.. io;;;;;;i;,", rnuinrenance
from any other appropriate international code of practice such as BS, ASTN.4 etc. A list
sha' b; carried i
out at fixed interu"is ,"rn; ;-,.-n#ij","J':"#;
when the equipment warrants r"p"i. or i'r"int"n"nce.
suggested codes ofpractice for various tests to be conducted on naturally occurring materia ll.g-ti.:111"-":::"d
lll_atruring equipments sha be carried out as per specified ii"qr"nJy o.,i,"n"u",
caribration
in original/crushed form is given in Section 8 whereas the same for factory manufa tn"
time. arine equipmeni sliin iile raoo.ato.v snarr
materials/finished oroducts is furnished in Section 5. lllgll*i::1",_",:l:.1lllT ll ry timits. eny inspectio;,
worklng condition within the toterabte
;;;;";;;;;i# ilii;;
wear and tear and requires caritiation.riore rrequentry
6.3.6 Test Procedures T..i:j:::::3::n^1:€xcessive
Test procedures shall be drawn from the suggested Codes of Practice in para 6.3.5 ab
and included in the Quality Assurance Plan. Further, all the procedures shall be converted i

to brief work instructions and displayed near the individual test facility. yaarr. also may be considered for repracement unless
it is certineo ov tne accredited
lillorlod to be fit for use.

63

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IRC:SP:112-2017 IRC:SP:112-2017

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64 65
IRC:SP:112-2017
tRC:Sp:112_2017

Annexure 6.2 iii.CBR plunger with set ement dial gauge

LIST OF EQUIPMENTS FOR CENTRAL/MAIN LABORATORY iv surciarge weight 147 mm dia 2.5 kg wt.
spacers disc 148 mm dia47.7
mm ht. with handle
'1. Soil Testing Equipment v perforated plate (Brass)
a. Weigh Balances vi. Soaking tank for accommodating CBR
moulds
i. 5 -20 kg capacity Electronic type _ Accuracy 1 gm vii, Proving dngs capacity of 1OkN, 20 kN,2SkN and
3OkN.
ii. 500 gm capacity Electronic type _Accuracy 0.01 gm viii. Dial gauges 25 mm travel_ O.01 mm/division
iii. Electronic 5 kg capacity Accuracy 0.5 gm
p. Dynamic cone penetration test equtpment
iv Chemical Batance 100 gm capacity accuracy O.OO1 gm q. Nuclear moisture density meter or equtvalent
b. Oven-electrically operated, thermostatically controlled (including r Speedy moisture meter complete with chemicals
thermometer), stainless steel interior from O"C to 220.C s. Rifle Box
c. lS Sieves: 200 mm internal dia (brass frame and steel/or brass wire cloth t. Differential Free Swell Index as per
lS: 2720 (pan 40)
mesh) consisting of sieve sets of required sieve sizes complete with lid. u Hydrometer & Hydrometerjar
d. Sieve shaker capable of shaking 20omm dia sieves_ electrically ooerated
Aggregate Testing Equipment
with time switch.
e. Stop watches 1/5 sec. Accuracy a. Sieves: as per 15:460
f. Glass ware compressing beakers, pipettes, dishes, measuring cyljnders i IS sieves of required sizes (450 mm lnternal
dia) sets as per BIS
(100 to 1000 cc) comptete with lid and pan
g. Enameltrays
i.
ii.
iii.
600mmx450mmx5mm
450 mm x 300 mm x 40 mm
300 mm x 250 mm x 40 mm
, Internal dia (brass frame and steel/or

;Jil:ft.1":'Jil"#;ffi5:ilffifl;i:1":i
ith time swit
brass wire cloth

h. c. Enamel trays
Liquid Limit device with ASTI\,4 grooving tools as per lS:2720(part 5)
i. Sampling pipettes fitted with pressure and suction inlets, 1O ml. capacity.
r.600 mm x 450 mm x 50 Inm

j. Compaction apparatus (proctor) as per lS:2720 (part 7) complete with collar,

ii.
450 mm x 3OO mm x 40 mm
base plate and hammer and all other accessories.
iii.
300 mm x 2S0 mm x 40 rnm
k. N4odified AASHTO compaction apparatus as per lS:2720 (part 8) or heavy
iv.
Circular plates of 250 mm ora
compaction d. Flakiness and Elongation index resr
apparatus
L Sand pouring cylinder with conical funnel and tap and complete as per e. Aggregate impact test apparatus as per 15:2386
(part 4)
lS:2720 (Pan 28)including modern equipment. f. Los-Angeles abrasion test apparatus
as per 15:23g6 (part 4)
m. Natural sand passes through 1 mm and retained on 600 mm as per lS:2720 g. Apparatus for determination of speciflc gravity
of fine and coarse aggregate
Pat128. as per tS;2386(part 3)
n. Sampling tins with lids 1OO mm dia x 75 mm ht y. kg capacity and s per 15:2386 part 3 for checking bulk
miscellaneous items like moisture tins with lid SO gm etc. d.
o Lat CBR testing equipment for conducting CBR testing, load frame with ,5.k9 and
.10.0
kg sensitive to O.1om
s_Tonne capacity, electrically operated wlth speed contiol as per lS:2720
Cement and Cement Concrete Testing
(Pan '16) and consisting of following Equipment
i. CBR moulds '150 mm dia -.175 mm ht a. High frequency mortar cube vibrator for
cement testino
ii. Tripod stands for hotding dial gauge i Cement motor moulds (70.6 mm W
x 70.6 mm L x 70.6 mm H)

67
IRC:SP:112-2017
tRC:Sp:112-2017

Vicat needle apparatus for setting time with plungers as per lS;269
b. o.
9lg:: rirg compressing beakers, pipettes, dishes, measuring cylinders
c. Soundness testing apparatus for cement (Le Chattlieo (100 to 1000 cc and metallic thermometers range up to 3OO.c.)
d. Weigh Balances p. Hot plates 200 mm dia (1500 watt)
i. 5 -20 kg capacity electronic type - accuracy 1 gm q. Oven-electrically operated, thermostatically controlled(includrng
ii 500 gm capacity electronic type - accuracy 0 01 gm thermometer), stainless steel interior from 0.C to 220.C
iii. Electronic 5 kg capacity accuracy 0.5 gm t Cannon Manning Viscometer for determination of Absolute viscosity and
iv. 50 kg capacity electronic type - accuracy 2 gm Cannon Fenske Viscometer for determination of Kinematic viscosity.
e. Concrete mixer power driven, 1 cft capacity s. Marshall stability test apparatus as perASTM-D6927 with 25 KN and
SO KN
proving ring and automatic compactor and mould for marshall
f. Moulds and modified
l\,4arshall test.
i. 150 mm x 300 mm ht. cylinder with capping component along with the
t. Core cutting machine suitable for up to 1SO mm dia core.
capping set.
ii. Cube 150 mm and 100 mm (each size) L Sub-Soil Testing Equipment
s. Appartus for slump test Direct.shear test apparatus having 12 variable speed and 2 KN proving
flng
h. Variable frequency and amplitude vibrating table size 1m x 1m as per the with all the accessories given in lS:2720 part 13.
relevant British standard b. Weigh Balances
i. Compression and Flexural strength testing machine of 2000 KN capacity i. Electronic 5 kg capacity accuracy 0.5 gm
with additional dial for flexural testing
j. Core cutting machine with 1ocm dia. diamond cutting edge
ii. 500 gm capacity electronic type accuracy 0 01 gm
c. Oven-elechically operated, thermostatically controlled (including
k. Lechatelier flask thermometer), stainless steel interior from O"C to 220 .C
4. Bitumen Testing Equipment d. Sieves: as per lS:460 lS sjeve 2OO mm internal dia (brass frame and steeu
a. Constant temperature bath for accommodating bitumen test specimen, or brass wire cloth mesh) consisting of sieve sets of required sieve sizes
complete with lid and pan.
electrically operated and thermostatically controlled (to accommodate
minimum six sDecimens) Liquid limit device with ASTN4 grooving tools as per lS:2720(part 5)
o. Penetrometer automatic type, including adjustable weight arrangement and f. Sampling pipettes fitted with pressure and suction inlets, 1O ml. Caoacitv.
needles as per IS:1203 s. Sampling tins with tids (100 mm dia x 75 mm ht.) of 50ogm capacity and
c. Bitumen laboratory mixer including required accessories (20 ltrs.) miscellaneous items like moisture tins with lid 50 qm etc.
d. Ductility meter
e. Furol Viscometer
t. Softening Point Test Apparatus (Ring and Ball app)
Digital thermometer
Rifle box
Thin film oven test aoDaratus for modified binder either with PMB or CMRB
Mastic Asphalt hardness testing equipment
Sand equivalent test apparatus
Thermomelers
Gas Stove and Cylinder
Soxhlet extraction or centrifuge type apparatus complete with extractio
thimbles with solvent and filter paper

68
69
IRC;SP:1'12-2017
IRC:SP:'1't2-20'17

LIST OF EQUIPMENTS FOR PLANT LABORATORY o. Glassware compressing beakers, pipettes, dishes, measuring cylinders
(100 to 1000 cc and metallic thermometers range up to 300"C)
1. Wet Mix Plant p. Hot plates 200 mm dia (1500 watt)
a. Sieves: as per 15:460 Oven-electrically operated, thermostatically controlled (includrng
i. lS sieves of required sizes (450 mm internal dia) sets as per
BIS
thermometer), stainless steel interior from 0.C to 220.C
complete with ljd and oan
Concrete Batching Plant
ii. lS sieve 200 mm internal dia. (brass frame and steel/or
brass wire cloth a. Moulds
mesh) consisting of sieve sets of required sieve sizes
comflte with lid i. 150 mm x 300 mm ht. cylinder with capping component along with the
ano pan.
b. Sieve shaker capable of shaking 200 mm and 450 capping set.
operated with time switch.
mm dia sieves_etectrically
ii. Cube 150 mm and 100 mm (each size)
c. Apparatus for testing Aggregate lmpact Value (AIV), Soundness, b. Apparatus for slump test
Ftakiness
& Elongation lndex, Stone polishing Value. c. High frequency mortar cube vibrator for cement testing
Hot Mix Plant i. Cement motor moulds (70.6 mm W x 70.6 mm L x 70.6 mm H)
d. Vicat needle apparatus for setting time with plungers as per 15:269-1967
a. Sieves: as per lS:1460
e. Soundness testing apparatus for cement(Le Chatdier)
i. lS sieves 450 mm internal dia. of sieve sets as per BIS
of requrred I Weigh Balances
sreve sizes complete with lid and pan
ii. lS sieve 200 mm internal dia. (brass frame and steel/or
i. 5 -20 kg capacity Electronic type -Accuracy 1 gm

mesh) consisting ofsieve sets of required sieve sizes

brass wire cloth ii. 500 gm capacity Electronic type -Accuracy 0.01 gm
b. Sieve shakercapable ofshaking 2OO mm and 450 mm
complete with lid iii. Electronic 5 kg capacjty -Accuracy 0.5 gm
operated with time swltch
dia. sieves_ electrically iv. 50 kg capacity Electronic type - Accuracy 2 gm
c. Aggregate lmpact Value (AlV), Soundness, Crushing g. Variable frequency and amplitude vibrating table size .l m x 1 m as per the
Value, Flakjness & relevant Brltish standard
Elongation lndex, polished Stone Value.
d. Oven-elechically operated, thermostatically controlled (inctuding h. Compression and Flexural strength testing machine of 20OO KN capacity
thermometer), stainless steel interi )r from O.C 6 220.C with additional dial for flexural lestino
e Constant temperature bath for accommodating bitumen test i. Lechatelier flask
- specimen,
electrically operated, and thermostatically coitrotteJ
lto u""o'i,rnoo"r"
minimum six specimens).
f. Penetrometer automatic type, including adjustable
weight arrangemenr and
needles as per lS:1203.
s Furol Viscometer
n Softening point(Ring and Ball app)
Distant reading thermometer
.
l. Mastic Asphalt Hardness testing equrpment
k. Sand Equivalent test apparatus
L Thermometers
m. Gas Stove and Cylinder
n. Soxhlet extraction or centrifuge type apparatus complete
with extraction
thimbles with solvent and fllter paper

70
IRC:SP:112-2017 IRC:SP:112-2017

Annexure 6.3 SECTION 7

SUGGESTED INVENTORY OF CONSUMABLES CALIBRATION OF INSPECTION, MEASURING AND

TESTING EQUIPMENT
1. Soil Testing
Distilled water, Filter Paper, Sodium hexameta phosphate and Sodium carbonate'
Kerosene, 7.1 Introduclion
l,4ost of the equipment listed in Section 6 of this Manual contain/involve use of measuring
2. Aggregate Testing
devices namely proving rings, extension meters, dialgauges, temperature gauges, load cells,
Sodium Sulphate, Magnesium Sulphate, weighing pads /scales etc. which measure the values of various test oarameters.
Cement Testing The accuracy of the equipmenvmeasuring devices degrade over time. This is typically
Cement, Admixtures, Distilled water, caused by normal wear and tear. However, changes in accuracy can also be caused by
electric or mechanical shock or a hazardous working environment. Depending on the type
4. Bitumen Testing of the instrument and the environment in which it is being used, it may degrade very quickly
Bitumen, Benzene, gas cylinder, filter paper, or over a long period of time. The bottom line is that, calibration restores the accuracy of a
measuring device as prescribed by the manufacturer and thereby reliability of the material/
Concrete Testing mix/finished product in terms of quality is ensured.
Nil To ensure valid results, the measuring equipment shall be calibrated or verified prior to use
and also at specific intervals normally as specified by the equipment manufacturer, against
6. Sub-Soil Testing measurement stadards traceable to national or international measurement stadards, and
Distilled water, Filter Paper, Sodium hexameta phosphate and Sodium carbonate' where such standards do not exist, the basis for calibration or verification needs to be
Kerosene documented

7.2 Objective
Calibration is a comparison between a known measurement (the standard) and the
measurement using the instrument to be calibrated.
Primary objective of calibration is to check and ensure that the measurements made by
the IMT equipment has the same accuracy as specified by the equipment manufacturer. In
practice, calibration also includes repair of the device. A report is provided by the calibration
expert, which shows the error in the measurements with the measurino device before and
after the calibration
Hidden costs and risks associated with the un-calibrated measurino device could be
much higher than the cost of calibration Therefore, it is absolutely esaen al that the IMT
equipmenUmeasuring devices are calibfated regularly, to ensure that errors associated with
the measurements are in the acceptable range.

7.3 Scooe
All the IMT equipment, which is used for inspection, measuring and testing during project
preparation, conskuction and operation & maintenance fall within the purview of calibration.
Besides production units such as Hot Mix Plant, Wet Mix Plant, Batching plant, Crusher etc.
also need to be calibrated Further, the measuring devices of laying units such as asphalt
paver, concrete paver need to be calibrated. Calibration of the machine Oarts does not fall

72 73
 IRC:SP:112-2017

IRC:S p: .t
1 2-20.t 7
needs lo ensure that the plant,
we maintained and calibrated 7-4 Type of Catibration
stages of project Development,
uent/routine inspection and verification
specified in the codes of practice for
7.3.1 project preparation and project
Development re found to be deviating from the codal

a.

proving rings, ex
balances, the us
gauge readings and the actu
prior tocarryi or c. Replace _ for example, whe
appropriate means. to the requirements, the sie
The Design Consultants shall use standard sieve conforming to the natio
and approved equipment for carrytng out various not conform to the requlred s
studies and welt established laboratories for carting
out G?"t;. AIt ;"tMT equipment or scale fade away, they
being used in the assignment sha, be catibrated
as p"", th"'6;;;;il of this section. neither be adjusted nor ca
7.3.2 Construction 7.4.1 Calibrations and checks.to be c€rried out
on IMT equipmenumeasuring devices
to carry out various tests in the field can be classified into four categories:
IMT equipment required to carry out a. the item
whi.h ra^"i' the requi "i",tii
ired.This slble but
b. physical check _ which
may be performed by the comperent staff
usrng appropriatery caribrated equipment in_house,
to i documenieo procedure
c. Inhouse calibration _ which m
7.3,3 Operation & Maintenance
During the operation & Maintenance, to carry out maintenance
an
and repair works as a part of routine
order to verify compliance
sc
to the requirements of maintenance
Contractor/Engineer have d. External calibration-_ which, is carried out
ically. Various materials/ by the laborarory accredited by
mi NABL for the measurement concerned
uni f_ ;J;h NABL has issued
,n ,MT equipment specified
calibration.
certificate.

7:"-:7 ll\4T equipment may be used in various

stages of the project but, the catibration
requirements, calibration procedure, frequency
and tne acceptaUifity criterra continue to be
same.

74
75
IRC:SP:112-2017 IRC:SP:112-2017

The IMT equipment which can be calibrated with inhouse facilities shall be identified and status ofcalibration and the caribration certificate shafl be disprayed near the respective rMT
suitable methodologies shall be drawn for the approval of the Competent Authority. equrpment.

7.5 Requirements for Calibration 7,8 Recall Procedures

In order to carry out the calibration, it is necessary to have the required Master Calibrating soon afrer recalibration of the IMT equipment, it sha be verified whether there is any major
Devices, ambient conditions and trained man power. Master Calibrating Device is the difference in the old and new calibrations, and if they wourd affect the readings taken in the
past. Any borderline results deduced from the readings of the equipment
instrument having capacity higher than the instrumenU equipment to be calibrated and whose under reference
measurements are already verified and certified by authenticated master calibration, whose in the past 3-6 months may be verified against the new calibration. lf there is any point
of
details are traceable. concern, then the corresponding elements or components may be identified for cairying
out
suitable confirmatory tests in field. on review of the field tedts and on verification ofiheir
Typically, the accuracy of the standard should be ten times the accurate of the measuring compliance with the specific€tions and standards, if necessary suitable action will be iniated
device being tested. However, accuracy ratio of 3:1 is acceptable by most standards as per the requiremenis of section 11 0f this Manual. To this extent, it is recommended that
organizations. the agency shall maintain a separate record of all the bordedine cases in a separate rocation
so that positive recall procedures can be easily applied, when found necessary.
7,6 Frequency of Calibration
As a general rule, the IMT equipmenUmeasuring devices shall be calibrated at the frequency
specified by the manufacturers of the specific equipment. In some of the cases, frequency
depends on the use and wear and tear of the equipment. For example, the Bump Integrator
may have to be calibrated after running a specific distance (km). Calibration shall also be
done invariably after repair or mechanical maintenance of the equipment
For each ofthe measuring and testing equipment the manufacturer specifies the time interval
for its calibratlon. In addition to manufacturers' recommendations, depending upon the usage
wear and tear that takes place to the instrumenuequipment and the limitations on master
calibrating unit, certain interval shall be fixed for individual equipmenuinstruments Details
of calibration requirements and intervals are listed in Annexure 7.'1. Wherever time interval
for calibration specified by the manufacturer is smaller than the time interval indicated in the
Annexure 7.1, the manufacturer's recommendation shall be followed.

7.7 CalibrationRecords
Calibration records shall be maintained and associated with a unique identifier of each piece
of eouioment. These records shall include:
. ldentity of item of equipment
a Name of the manufacturer
r Serial number
. Date of calibration
o Current location
a Manufacturer'sinstructions
. Reference standard, and reference used for calibration
. Copies of all reports, results of calibration and certificate of calibration
. Maintenance plan and due date of next calibration
. ldentity ofthe individual performing the calibration

76 77
IRC:SP:112-2017 IRC:SP:112-2017

t
t(, sEcTtoN I
x(, -= t-6 ,2 INSPECTION AND TESTING
;t
FO)
JE
oo
,9
6X J
() <E
zu >z zt
CD

z 8.'l Introduction
o Inspection and Testing is an integral part of the construction activities. All the materials being
d
I :g 6
E
incorporated in the product, all the processes being followed and allthe finished products will
p E9 a) be subjected to inspection and testing to ensure conformity of the product with the standards
q6
=:?
EEg - and specifications. The Contractor shall submit the QualityAssurance plan at commencement
d
66 A <dl <i5 6 lll and carry out quality control during the currency of contract through inspection and testing at
various hold ooints soecified therein.
o E1;
zl! ii
qo d 8.2 Objective
f J tL!
o
IIJ
LIJ

€.9 E o)
The primary objective of inspection and testing at various stages is to ensure that the all the
materials being incorporated in the product and the end product fulfill the quality requirements
u
lt
qF
oE
.E
of the MORTH Specifications for Road and Bridge Works. Contractor is responsible for the
Ft
c! ".9 -h g=*
oiJ6 E Quality Assurance and Quality Control i.e planning and conducting the inspection and testing
o
F
=d
E:!i activities. Other entities will perform their roles as envisaged in the contract agreement.
.t
zIIJ -F- F".}E .E;: 8; 8.3 Scope
o
El:e F The current section specifies the inspection and testing requirements during project
l=! co
cf o; TE preparation, construction and operation & maintenance. lt covers the stages of inspection,
.E codes, test procedures to be followed, documenlation and records to be maintained.
o (,o 339 6 ij
Fq)
IJJ
d Yz qx
€ur h R odB 4.4 Project Preparation
z
IF iitr 66 ;3p.: o E5 E
During the project preparation, the Design Consultants need to carry out various surveys
and investigations including pavement investigations, sub-soil investigations, material
.9 investigations etc. as per the Manual for Surveys, Investigation and preparation of Road
t 1'>
,"
Projects IRC:SP:1g. Inspection and Testing requirements will be as per the Terms of
dl F;E Reference (TOR) ofthe consultancy contract. When the TOR is silent about the frequency of
F6t 6,
e
E s9 - --E
= .9 :?g testing, the same shall be as per good industry practice. Various tests to be conducted and
o u,l q @= i LxP the performance and acceptance criteria are given in Table 8.1.
HT E T.; E6rg E9\
h ;i .jc = =>r
= F6d69 Table 8.1
o E>>d >o(/)o i3g o) d b-3 rgc) s. Test Applicable Code of Acceptance Criteria
No. Practice
.g
a
0
A Pavement investigations
ol Visual Condition Survey IRC:81
1 IRC:8'l
(J
>6i 6d, >6i 2 Bump Integrator
-.9 P.; ., .9 IRC:SP:16; lS:3073 IRC:SP:16; lS:3073
=
io |:>E ,= ,E o- 3 BBD IRC:8'l IRC:81
4 FWD IRC:1'15 IRC:'115
ui2

78 79
IRC:SP:112-2017 IRC:SP:112-2017

s. Test Applicable Code of AcceDtance Criteria s. Test Applicable Code of Acceptance Criteria
No. Practice No. Practice
Subgrade Strength lS:2720, Part-16 IRC:37 & CA I Ten percent Fines value & lS:2386, Part-4 MORTH Specifications for
Crushing value Road & Bridge Works Section
6 Pavement Composition ASTtVt C 1741 174M &
400
lVlS 23 Manual
Cement
B Sub.Soil Investigations
1 Collection of UDS lS:1892 & 2132 MORTH Specifications for I Consistency lS:4031, Part-4 MORTH Specifications for
Road & Bridge Works Road & Bridge Works Section
2 Standafd Penetration Test lS:2'131 2 Setting Time lS:4031, Part-s
1000
3 T axialTest lS:2720, Pad-'l'l & Part -'13 3 Compressive Strength lS:4031, Part-6

4 UCS lSt272O, Pai-lo 4 Fineness lS:403'1, Part-1

5 Consistency limits lS:2720, Part-s 5 Soundness l5:403'1, Part-3

6 Classification of Soils lS:1498 F Bitumen
7 Silt factor lS:2720, Part4 & IRC:78 1 Penetration lS:'1203 lS:73
I Direct Shear Test lst2720-13 2 Softening Point lS:'1205
c BorrowAreas (Soil) 3 Ductility lS:1208
1 Sieve Analysis lS:2720, Paft-4 IVIORTH Specifications for 4 Viscosity lS:1206 (Part ll & lll)
Road & Bridge Works
2 Atterberg's Limits lS:2720, Patt-' Speciflc Gravity lS:1202
3 Compaction Test lSt272O, Patl-7 & I Concrete Mix Design
CBR lS:2720, Part-16 1 Sampling lS:10262 IVIORTH Speciflcations for
5 Free Swell index lS:2720 , Patl-Ao Road & Bridge Works Section
2 Mix Design lS:10262
1700
D Quarries (Aggregate) IRC:SP:23 & IRC:112
Sieve Analysis lS:2386, Part-2 MORTH Specifications for 3 Workability lS:1199
Road & Bridge Works Section
2 lmpact Value lS:2386, Part-4 or 4 Compressive Strength lS:5'16
'1000
lS:5640, Part-4
5 Flexible Strength lS:516
3 Abrasion Value lS:2386, Part-4
G Asphalt Mix Design
4 Soundness lS:2386, Part-s
1 Mix Design MS-2 I\TORTH Specifications for
Stripping Value lS:6241 MORTH Specifications for Road & Bridge Works Section
,Road & Bridge Works Section 2 Stability testing
500
500 3 Void Analysis
6 Water absorption lS:2386, Part-3 MORTH Specifications RE Wall
for Road & Bridge Works
Sections: 400, 500, 600 &
'| Fitl IS:2720, Part-13, Part-4 & MORTH Specifications for
Pan-o Road & Bridge Works Section
1000
3100
7 Polished Stone Value BS 812 Part-114 MORTH Specitications for
Road & Bridge Works Section Note: Lafesl vers/ons of the codes indicated above shall be used.
500
8.5 Construction
I Sand Equivalent value lSt272O, Patl-31 MORTH Specifications for
Road & Bridge Works Section All the tests prescribed in NiIORTH Specifications for Road & Bridge Works shall be conducted
500 at various stages and frequencies stipulated therein, during the construction stage. Besides

80 81

IRC:SP: l l2-2017
additional tests shall be conducted for factory manufactured materials, products and
specialized items as per Section 5 of this Manual. Requirement and procedure of testing
during different stages of construction are given below:
8.5.1 ApprovalofSources
The Contractor will identify the sources of raw materials viz, soil, morrum, sand, fly ash,
quarry stone etc. and thoroughly inspect the sources for adequacy of quantity, quality and
consistency including the history of usage of the material from the quarry' details of the
projects wirere the material was used and the problems observed if any Subsequently,
bontractor shall collect the samples and subject them to the prescribed tests to verify their
conformity with the requirements. The proposed sources of manufactured materials viz,
Cement. Steel, Bitumen, Emulsions, Admixtures etc. also shall be subjected to tests as
detailed in section 5 of this lvlanual at the site laboratories or third party labortories as
applicable. The Contractor shall submit the test results along with the location and layout
oi ihe bonow pit or quarry and the locations of the samples and the depth of collection For
manufactured materials the test results shall be submitted along with the further details as
specified in section 5 of this Manual. The Engineer will determine the necessity of further
tests at the site laboratory or elsewhere and communciate the approval for the sources'
Unless the aoproval is received, the Contractor shall not procure the material Engineer
shall communciate his approval expeditiously to avoid delay in procurment of the material'
The contractor shall plan the activities carefully so that approval of the sources is done well
ahead of the actual construction.
8.5.2 Testing of Sources of Materials
The contractor shall subject allthe raw materials and the manufactured materials to testing
as oer the procedures and frequencies stipulated in Section 900 for road works and other
applicable sections for bridges and structures of MORTH Specifications for Road & Bridge
Works.
For soil and moorum materials, adequate number of samples shall be collected from the
borrow areas so that the entire borrow pit is representated in both area and depth lf the
Contractor intends to collect samples from a deeper level, samples shall suitably cover the
entire depth. After mapping the densities, consistency and strength properties of the material,
the borrow area will be segragated based on their properties and an average density value is
determined for different parts for the purpose of verifying the degree of compaction achieved
in the field. lf there is any considerable variation in the densities or visible change in the
quality of material, the material in the borrow pits will be retested and the reference density
is revalidated.
Samples ofaggregates shall be collected from stock piles in the stacking area or the crushers'
Sample size depends on the quantity of stock pile and the guidelines given in lS:383 and
ls:2i86 for condcting various tests. All manufactured materlals Viz., cement, steel and
bitumen procured from pre-approved sources shall be tested prior to use. Manufacturer's
Test certiflcates and other details specified in section 5 of this Manual pertaining to the lot
received shall be submitted by the Contractor for reference. In addition, the Engineer shall
determine the tests to be conducted at the site laboratory and the 3d party laboratory as
82
IRC:SP:112-2017
relevant, as per the Qulaity Assuarnce Plan approved for the project. Only after obtaining
the approval of the Engineer, the materials shall be incorporated in the works, as concrete
elements and bituminous courses are irreversible in nature and if any test fails, it is difficult
to rectify.
8.5.3 ln-Process lnspection & Testing
It is advisable that test sections are prepared using any material or mix being incorporated
in the pavement, sub-grade and filling and all the parameters are verified. This will not only
be useful in optimising the compaction effort i.e the number passes, rolling pattern, overlaps,
speed etc. but also to train the team in verification of process parameters viz., temperature,
moisture, line, level etc. The compaction-factor can be determined for a specific borrow area
or the mix so that loose material can be accordingly laid in a manner that the desired levels
are achieved at the required degree of compaction.
Test sections also ensure that the performance ofthe plant and equipment used for producing
the mix and laying the mix is verified and confirmed with the requirments of the specifications.
l\,4aterial shall be collected from the cold bins/hot bins of the WMP/HMP/Concrete Batching
Plant etc. to verify the calibration of the motors/load cells and tested for conformance to the
mix proportions envisaged in the design. The mix finally delivered in the hopper shall be
collected and verified for the proportions and respeclive properties of the ingradients and
mixes.
The performance of the paver or grader etc., in producing the desired workmanship and
finished properties shall be verified in the field and suitable corrections shall be made to the
eq uipment/ processes. The plant or equipment, which is unable to produce the desirable
quality at site shall be removed and replaced with the approved equipment as per Contract.
All the ingredients of the concrete, GSB, WMM and Asphalt courses shall be tested on a
day to day basis at various stages including in stock piles, bins, dry mix, final mix loaded in
the truck and at fleld as applicable and relevant. This will clearly isolate the deficiency and
provide insignts in to the reasons for variation in quality.
Samples shall be collected from the pavement layers prior to compaction and routine tests
shall be conducted to verify the reference density and other properties if necessary. These
control tests will explain the variation in the degree of compaction if compaction is done
under controlled conditions, duly verifying all the process parameters. The results of the
control tests shall be documented and monitored.
Generally, the reference values shall be those obtained during the mix design process. But,
if necessary and found advisable, the reference densities may be obtained on a day to day
basis from the material actually laid at site.
Process parameters viz., moisture, temperature, line and level shall be checked prior to
compacting the layers so that the end product fulfills the requirements of the specifications.
Record of such inspection and verification shall be maintained in relevant check lists and
formats.
For concrete works various pre-concrete and post-concrete checks shall be made as per the
provisions ofapplicable codes and good industry practice. lt shall be ensured that the staging
IRC:SP:112-2017
IRC:SP:112-2017

conforms to pre-approved designs and all the joints are tight and safe. Further, the shuttering
to be rectified. GeneraIy, the contract specifies a definite time period of rectification
shall be as per the lines and levels given in the drawings and the joints are sealed to prevent for each
type of diskess. Accordingly, the Contractor shall prepare a maintenance programme
leakage. lt shall also be ensured that chairs and cover blocks are placed to achieve the and
carry out the rectification accordingly.
spacing of reinforcement and the concrete cover respectively. All the arrangements shall be
verified against the checklists provided in the QAP. Engineer shall inspect the works at all the 3 stages i.e. before, during
and after rectification
and.verify compliance to the requirements of th; Specifications. Th6 requirements
Reinforced Earth Walls require thorough inspection during the erection of panels itself as of sub_
section 8.5. f this r\y'anuar shafl appry mutatis mutandis to the various Inspection
correction of the deficiency after construction is extremely difficult. Horizontal and vertical and test
requirement during O&M.
alignment shall be checked at each stage by appropriate means i.e total station and plumb
I
bob. The c, and density of the reinforced soil fill should be checked regularly. Further, the Any other tests or surveys required during O&M viz., visual condition surveys, BBD/FWD
grids or the strips should be protected from exposure to fire, sun etc. as per the manufacturer,s and roughness tests shall be carried out in iccordance with relevant codes
and conformance
specifications and kept adequately covered. Adequate earth cushion should be ensured to to the requirements of the agreement shall be verified and ensured. Any non_conformance
prevent damage of the grids while compacting. Low capacity compactors should be used shall be processed as per Section 11 of this Manual.
while compacting near the panels. Casting, storing and erection of friction crash barriers
should be done with adequate care to ensure a good finish. lt is emphasized that adequate 8-7 Third Party testing .

care should be taken at each step during the construction itself. some of the tests may have to be conducted in the third party raboratories in case of speciar
tests and also if the Contractor does not h
8.5.4 Final lnspection & Testing out the tests, which include special tests on
It is important that the final product conforms to the requirements of the speciflcation and Geogrid, other forms of soil reinforcement, R
standards and the same is verified prior to taking up the next component. some cases the Employer/Authority or the E
external laboratories, even though the Contractor has the test facility at
In case of road works, each layer shall be inspected and put to tests as required by site. Such cases may
also include extensive and poorly explained ailure of structural an; pavement
Section 900 of MORTH Speciflcations for Road and Bridge Works. lnitially, the layer etements.
shall be visually inspected for its workmanship, uniformity in texture, undulations, roller Sampling shall be carried out joinfly by the parties including the Authority, Contractor
and the
marks, segregation, pumping etc. All the cross sectional elements including the width of trngrneer and the samptes shall be carefully numbered for unique identification
and packed
the carriageway, paved shoulder, earthen shoulder, toe width, camber, side slope, surface for despatch. lfthe raboratory alows, the tests shal arso be conducted in the presence
parties who sampred the materiars. The externar raboratories
ofthe
regularity shall be measured and verified. Any defects shall be corrected prior to taking up shafl furfiI the iequirements of
final testing. Levels, thickness and degree of compaction of the layer shall be checked at Section 5 and 6 of this Manual.
prescribed spacing and intervals and checked whetherthey are within the specified tolerances.
Any nonconformance shall be identified and corrected before proceeding to the next stage. 8.8 Sampting
NCRS shall be issued in case of any irreversible processes and the required corrective and Sampling of the materials should be done with utmost care as the right product
may fail on
preventive actions shall be initiated and disposed as per the provisions of Section 1i ofthis account ofpreparing and / orlesting a wrong sample and vice versa. M-oreover,
the consituent
l\4anual. materials of road are of heterogeneous quality and further subjected to heterogeneous
processes. Hence, sampling done at adjacent locations may
All concrete works shall be inspected after the removal of the false work, staging, shuttering . siill yield different results.
and inspected for undulations, segregation, bleeding etc. and suitable rectification shall be Hence, statistical procedures shall be applied for sampling and testing as per
Section 10 of
carried out, if necessary. All elements shall be verified for lines, levels, dimensions and surface this lvianual.
regularity for confofmity lo the tolerances. lt shall also be verifled if the concrete fulfills the
other acceptance criteria of compressive and / or flexural strength which is generally verifled
8.8.1 Sampling of Quarries
by casting cubes, beams, cylinders etc. as required during the casting of concrete. In case While sampling the stone quarries, the entire quarry shall be visually inspected for
its
of any shortfall in strength properties, NCR shall be issued and cores shalt be collected from homogenity of surface, quarity and the quarity and eitent of over burden. Representative
the respective components to verify the corresponding properties and the required corrective sample shall be carefufly serected for conducting various tests. rf the quarry is being
used
and preventive actions as necessary, shall be initiated and disposed as per the provisions of in any oJ the crushers, crushed aggregared shil arso be coflected from tne crushers for
Section 'll of this Manual. approval of the source.

8.6 Operation & Maintenance 8.8-2 Sampling of Borrow pits

During the O&l\,4 stage, the Contractor shall carry out rountine inspection of the highway at the The extent of the borrow pit shafl be identified and marked for derineating the area in to
time and intervals specified in the contract agreement and identifythe defects and deficiencies various sections of atleast 25 m X 25 m. Samples shall be collected from each
such section
 IRC:Spil,'2_2017

5:'mH[?J;i::1,3:,",i:t .Jt"ylil",3j:Ji#
ffffi: ;t1 ffffi"l:i[,#3.,:,[TiJ:;
IRC:Sp:1.12-20.17

Annexure g.1
SAMPLE FORMATS
st.
Descripti,on-

ffi
No
FormatlD-
1

2
A-1
3 f(einforcement Inso-Jii.iilf, B-1
4
B-2
5
o-J
6
B-4
7
o-c
8
c,1

8.8.5 Sampling on layers 10

11
H c-3

14
c-7 & c_8
IC
c-9
c-10
17
18 c-12 & c-.13
8.9 General Guideline
19
c-14
for Inspection & Testing 20 q g gregare tmpa ct
VajlElnnr-
2'l
22
23
:l:l!ary::or Fi're AG;GG c-'18
24 rerenous Materiat and dEiiiiliii., c-19
25 tol c-20
26 s". c-2,1
27 DP€ c-22
28
86

87
 IRC:SP:'112-2017

st. IRC:SP:1.12-2017
Description
No Format lD st.
;;;;=.-. vervr rPl|(r|l
29 ruTo Flnes Value Test No Format lD
30
31
ffi - c-26
58
59
"ffi E-3
60 E4
33 c-28 6'l
34 c-29 62 F-'l
-
35 c-30 63 Cement Register
36
37
ffi 64 ConsumptionolSsJne-f,l EnJ;;;E;;,-- vvorKs ( theoretical and
t--J
F-4
c-33 65
38 Penetration Vatue of BituiEn
-- c-34 66 l--C
39
40 67

41 c-36 68
F-8
42
vv, rtEr ravrng Mrxtures centrifuge
Method BC/b-BNTBM rL
c-38 70 F-9
43 71 F-10
44 c-39 72 F-11

45 c-40 73 F-12
'roforma for ResuttlnliJ"ilF
46 c-41 r-- lJ
47 B c-42
48 - c-43
49 D' c-44
50
c-46
51 rallin g Weight D-fl
eit6mer;
c-47
53 D-'1

54
55 D-3

56 D-4
57 E-1
IRC:SP:112-2017 IRCtSP 112-2017

Category B: Inspection proforma B_1

E!, aa
G
9=P vi FORMWORK INSPECTION CHECK LIST
;
c)
3< :*
_o ;s LOCATION:
'i 'o oX
DATED:
8- _99 CONTRACTOR'S INSPECTION REQUEST NO.
J 6e CONTRACTORS DRG OR SKETCH NO
C' =v
t P -.E
(D S.
E< o NO.
DESCRIPTION NO N.A.
o :o BP
io t o 6h' !Ltl
1 Formwork design/drawing/sketch approved includ jng
E =I o* de-shuttering arrangements
I ;; 60
o
(! ;":
6+ :
I
o
q
)2)
.=.8
He
'6d
2
3
Trial panel approved(if required)
Formwork alignment correct
LrJ
.it ; -E 4 Formwork levels correct, including screeds
J >9 >' >r Lv OO 5 Formwork dimensions correct
o ;i::t
=:9 ; _H._98
uJ
I() o i;< I 6 € <l 6 Formwork member spacing correct
9 'E F-o 7 Formwork member material quality acceptable
at, -: tt ! io 8 False wo|k member sizes correct
o "i !=
t ==
.E >, .=
o
zuJ EP
x6
iE
".w
9 False work member spacing correct
: J N::
fg o.b< E g t EE '10

'11
False work member material quality acceptable
Gaps between primary and secondary members closed/
ITJ !E (/) o o! weogeo
d
t! c9 ! I (DO
EE o ; x =f Face boarding/plywood/metal thickness correct
F xH )! >-:
o
UJ
XE
';F ij(! E +i 13 Joints between panels closed (no gaps)
F o 6C : :: 14 Joints between panels flush(no steps/lips)
e> - = =ii Panel flatness acceptable
;.!! ; o- tr o Gaps between secondary members and face panels closed
4E .^tr o E t9(/) 16
6 E aO f!r FE
x c ; : Hc Tie rod material and sizes correct
17
-F
3 r* u "=
-.9o:bE
X=* E9 d 99
6p E i;
18 Tie rod spacing correct
6 E 6 -:: 96 P E -1.9 19 Tie rods tight, face cones flush
o 0- co(r> 20 Spacers between shutter surface tighfly fitting
;= ii p
tr -;
G' -.ot 6 id
a 6 @ 6 _e
.!^
6-
21 Box outs, cast-in items, ducts fixed correct. securelv
Eq 9; b{
::;>ru
o
22 Pre-stressing, sheathing and vents, alignments and spacing
i !,t x.c P- ex
'=+ of supports acceptable
A
;!; = o = ::i
<9 < > F E o-.
23 Empty sheathing secured against floatation

o6
oo
9O
o,3
24 Pre-stressing anchorage positions and flxing acceptable

90 91
IRCTSP:112-2017 tRC:Sp:1i2-2017

s. Category B: Inspection proforma B_2

DESCRIPTION YES NO N.A.
NO.
REINFORCEMENT INSPECTION CHECKLIST
25 Chamfers/fillets sizes, straightness, fixing acceptable
26 Form work clean LOCATION: DATED:
27 Form work release oil material aoDroved
CONTRACTORS INSPECTION REQUEST NO.:
28 Form work release oil applied correctly
REF DRG NO,:
29 Construction joint preparation satisfactory
S. No. DESCRIPTION YES
30 Contraction/expansion joint preparation satisfactory NO N.A.
Working drawing checked & approved
Safe access constructed
2 Latest revision being used
32 Adequate workspace provided for labour, equipment
3 Bar schedules approved
33 Shuttervibrators (if required) location and fixing arrangements
aooroved Reinforcing steel material aporoved
5 Bar bending & cutting satisfactory
6 Corrosion treatment of bars if fequired, satisfactory
7 Bar sizes @rrect
I Bar spacing correct
Inspected by: Name: Signedl Date: I Bar lap lengths correct
(For Contractor) 10 Bar laps at correct locations
'11
Bar tied as specifled
Bar assembly rigid and adequately supported (including
spacers/chair supports)
13 Cover to bottom bars correct
Approved by: Name: Signed: Date:
14 Cover to side bars correct
(For Engineer)
Cover to top bars corect
'16 Cover blocks approved inctuding lixing

Inspected by: Name: Signed: Date:

(For Contractor)

Approved by: Name: Signed: Date:

(For Engineer)

92 93
IRC:SP:112-2017 IRC:SP:112-2017

Category B: InsPection Proforma B€ Category B: Inspection Proforma 84

INSPECTION CHECKLIST BEFORE APPROVAL TO CONCRETE PROFORMA FOR CONCRETE DELIVERYAND POUR RECORD

DATED: 1. CONCRETE BATCHING DELIVERY TICKET NO:

LOCATION:
CONTRACTOR'S INSPECTION REQUEST NO.: Location of pour Date
Concrete grade Mix Temp
Method statement approved W/C ratlo Slump
Batching plant mixtures in working order (separate dispenser Cement contents No. of cubes taken
for admixture, if required, available) Max. Aggregate size
Stand-by batcher in working order Admixture
Water, sand, coarse aggregate, admixture, cement stock (Type and dosage)
Batching started, Hrs Batching finished, Hrs
Water, sand, coarse aggregate, admixture, cement stock
Quantity batched, Cum Truck no
Concreteconveying arrangement(including transitmixtures)
available in working condition and of sufficient capacity TRUCK ARRIVED ON SITE
Formwork approved Slump test result(S) Hrs
Discharge started mm at Hrs
Fre-stressing sheathing approved
Concreting equipment in working order
Placement completed Hrs
Stand-by crane, vibrators Present No of site cubes taken Hrs
tromie in wo*ing order (for under water work)
Place where cubes taken Hrs
Concrete gang present, including carpenter, steel fixer,
mechanics and electricians Placement temperature of
concrete
Safety arrangements adequate Ambient temp
Lighting provided
Weather condition
Communications between various points provided
Arrangements for arranging suspension/stoppage of

Curing arrangements made

Laboratory notified !nspected by: Name: Signed: Date:
(For Contractor)

Inspected by: Name: Signed: Date:

(For Conkactor)
Approved by: Name: Signed: Date:
(For Engineer)

Approved by: Name: Signed: Date:

(For Engineer)

94
IRC:SP:'112-2017
IRC:Sp:112_20i 7

Category B: Inspection Proforma B-5

Category C: Testing proforma C_1
POST CONCRETING INSPECTION GRAIN StZE ANALySts (tS:2720 PART-4)
Note: Post concreting inspection shall be carried at various stages such as after stripping of Lab location :
side shuttering, each stage of pre-stressing, decentring and/or as per designer stipulation. Sampled
Location/Chainage
Location
Date of Testing :
Weight of Sampte Taken
Wt. of Sample retained on
Date of pour Stage of Inspection :
0.075mm Sieve :

Specified class Date of inspection : Empty weight of Container(g)(W,):

Wt of Water (W4=W,-W3) :
S or NS. Wt. Container + Wet Soil
(s)(W,) :
Type of remark
S. No Observalion Wt. of Container+dry :
(S or NS.) l\.4oisture Content
Position/Drmensions of member Alignment SorNS soit(sxw3) : (wr/(w3)-(w,)).100
Levets SorNS l.S Sieve Weight of Cumulative Cumulative
Dimensions SorNS Designation Soil retained
Cumulative
Wt. of Soil Percentage Percentage
2 Surface defects (honey combing/sand No defects (Note type and extent (mm) (s) Results
retained (g) retained (%) Passing (7o)
streaks/air bubbles/cold joints) Minor defects of defect)
100.000
l\,4ajor defects
75 000
3 Class of finish SorNS
60 000
4 Cracks No cracks Date first observed
cracks 40.000 Gravel =
Nature of cracks: 19.000
5 Any other defect
10.000
6 Non-conformance report no Report no /
Not applicable
4.750
2 000
Remarks:
1.180 Sand =
In 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, o 425
etc ,) shall be prepafed for further action 0 075
*S Satisfactory,
= NS = Not satisfactory Pan Silt & Clay =

Inspected by: Name: Signed: Date:

(For Contractor)

Approved by: Name: Signed: Date:

(For Engineer)

96
97
I RC: S P:'1 '1 2-20'l 7
tRC:Sp:112_2017
Grain size distribution curve
Category C: Testing proforma C.2

100 DETERMINATION OF PARTICLE SIZE BY

90
HYDROMETER METHOD (tS:2720 PART4)

!80 a) Percentage otsoitpassrng 75m tS Sieve:

'6 b)MassofsampletakenforsedimenlationHeightoflhebulb(h):
3-70 Analysis: volume ofthe Hydrometer ml
60 (vh)J:
-a c) specific Graviiy (G): cross sectionatarea ofthe
.E C0 Cytinder (A) i Sq cm
d) Meniscus Correction (cm):
constant = (1/2(h_(vh/A))
6-"

J.l=

Diameter in (mm)

Remarks:

Type of soil:

Prepared by checked by Approved by

Prepared by checked by

98
99
IRCTSP:'112-2017
IRC:SP:'112-2017

Category C: Testing proforma C-3 Category C; Testing proforma C4

LIQUID LIMIT AND PLASTIC LIMIT (ts:2720 pARr-S) FREE SWELL INDEX (FSl) (ts:2720 PART-4o)
Lab location : Sampled Section/Lab location : Sampled Location/Chainage :
Location/Chainage
Date of Testing : Weight of Sample Date of Testing : Weight of Sample Taken
Taken
s.
Llquld Limit: samp ing samplo {s) Soil ofSollin
2 3 5 2 3

wt or empty Containe(s)
wr or container + wetsoi (S)

Wt orContainer+ drysot(s)

T€st Results

Liquid Lirr|it (LL%):

Plastic Limit (PL%) :

{Av€rage Value)
Prepared by checked by Approved by

Plaslicity Index:

(LL-PL)

Prepared by Checked by Approved by

 IRC:SP:112-20'17
lRC:SP:112-2017

Category C: Testing Proforma C-5 Category C: Testing proforma C6

COMPACTION TEST (ls:2720 PART-8)

SOIL SPECIFIC GRAVITY TEST (ls:2720 PARrllull)
Sampled Location
section/Location of Lab : Date of Sampling
Source of Sample

Location/Chainage : Source of Material Date of testing

Volume of Mould
Date ofTesting : Sample code/No
Type of Compaction
s. Description Trial t Trial 2 Trial 3 | Average
No.

Wt. of Density Bottle with Lid (W,)

Wt. of Mould + Soil
2 Wt. Density Bottle + soil (W,)

3 Wt. Density Bottle + Soil + Water (W3)

Wt. Density Bottle + Water (W.) Container No.

Weight of Soil (w,-W1)

6 Speclfic Gravity (G)= W5/OV1-W1) -(W3-W,) Wt. of C + Wet Soil

Remarks: wt. of c + Dry soil

wt. of wet soil
Wt. of Dry Soil
Wt. of Moisture

2.24
6 2.20

prepared by checked by . Approved by E 2.10

9 2.05
> 2,fl)

F 1.90
i 1,85
; 1.80
61.75
5678 91011 12131415161',718
Moisture conlenl (%)

Prepared by Chocked by APProved bY

102
IRC:SP:112-20'17
IRC:SP:112-20i 7
t-
()
o
3s
E
3 o
o
a0
t.l)

.0, o

e )z
o e q'9 Er
o IF o EE
G IF
E
93 ol 4E
o lo
ert9
elE i^

.tl
tAl
=i ;o
<l
<l E6 ql
!t, I
N5
J t--
fl
ol
uJI ct o
tl 9g
gE o
F E
vtl gl
88 RPePo
E
E
9rl o xl -i6vx
tl : (€))peol f
ml
o

3
o
E
t0
€
o c
';E
9! G
tl
E E
4'l E
n I o
.9
P
d
(., FFFEESEEHceF" !l g
p (€)) peo.t
6
63 il t E
o-
IRC:SP:112-2017
IRC:SPr1'12-2017

Category C: Testing proforma C-8

C B R TEST (ts:2720 PART-16) $"

Lab
Section/Location of I Surcharge Wt. :B
Loc€tion of Sample : O.N,,|.C/N.M.C (%) o
Type of Test : Un-Soaked/Soaked |\,.D.D/F.D.D (g/cc)
Date of Moulding : 97olo OF [/.0.D (g/cc)
Dale of Testing : Type of Compaction
P p aE
69r

C.B.R. Compaction :.
(, s -t :i
No. of Blows
Mould No
't0 30 t
o 8 i=j
Moisture Determination o -e
!r P IxE
Wt. of lrould (g) -E ii -
Wt of Mould + Soil (g) 6B
#r- E2eE
-
gi It ;d
Wt. of Soil (g) rf E',g:?i-
Volume of the mould (cc)
Bulk density (gicc) f +g*;s
d==:q
E

add6-d
Container No. F- ;.!!b<'
Wt of Container (g)
q-,1

g F33gF
wt of c + wet soit(g)
F
CFFii
bbr E:
;6
wt. of c + Dry soit (s)
N4oisture Content (%)
at,
IJJ
g;;!F
F
Dry density (g/cc) u !
TEST RESULTS: ;b
UJ
CBRGraph 7
On Remoulded and 100.0 E

Un-Soaked/ Soaked Sample ?l 8S i,

- 80.0 6t
No of Blows Dry density cBR (%) 6 -^^ uJI I Ee
(g/cc) E
; 40.o
El
10
- 20.0
ol o
r€
30
0.0
b
65 1_70 180 190 2.OO 2aO 2.20 t
p ^?
;g
i5

Dry density(e/cc)
? E5a e Er
CBR Value @ 97% of MDD = "..,99Y R

EI EdY
Remarks:
9t .9
5 gE g; 8,5<
= E

E
I F
S> e E SETS]
!-t E I
-5
EEF
:iE9€:H Y
xoE!!l
n9:
b;9
ii!935E
E E il q o I
+€ a
Cesd
al

Prepared by Checked by Approved by J$sg3:i

-=. ai2

107
IRCiSP:112-20'17
IRC:SP:112-2017

Category C: Testing proforma C-10

TRfAXIAL SHEAR TEST ns.:2720 pARr-'t':, tst272o pARr-i2, AsrM_D 718i)

g
Section/Lab Location : Sample Dia : 38cm
g Sample Type & Location: Sample Height (l) :
6 7.6 cm
Type of Test (UU/CD/CU): UU proving Ring Constant I kg/div
g Depth of Sample: Votume of moutd : 86..19 cc

I ^t Date ofTestingl
Hb
g
Provlng RIng R..dtngs
(dlv) @c.ttPE$uro (s3)
i
E
z t,0 t5 1.5
I :ts (1io)l
0.5

1 2 1 9 12 13

00

P 5

12
i
=

20

12

13 24

E 15 2A
i! €
E

E
q.)
= s 32
6 '6
q
-9

E
z
E

108
lRCi9P:112-2017
IRC:SP:112-20.17

3.00
=.

27 I o.so
2A
- o.oo
4.O 5.0 60 70

53

31
Test Results from graph:

'1 Cohesion 'c': kg/cm,

2 Angle of internal friction,F': oegrees
Remarks:

38

39

42 a2
Prepared
Checked
Approv€d

33

46

92

9a

51
IRC:SP:1'12-20'l7 IRC:SP:1'12-20'l7

Category C: Testing proforma C-ll

I Vs Dlolguoge reodlng

CONSOLIDATION TEST (ls: 2720 (PART-15)

Section/Lab :
Location Sample Dia
Sample Type and No : Height
Sampling Date : Sampling Date
Testing Date :
()3
Time in Min. \it Dial Gauge Readings in (mm) for Diff.
(r) Pressures kg/cm'? * 2.3

0 0 0.5 1 1.5 2
o.25 05 012 3 4 5 6 ? 8 910111213141516171A1920272223242526272A293031323334353637333940

2.25 1.5
Remarks:
4 2
6.25 2.5
I 3
12.25 3.5
16 4
Prepared by Checked Approved
20.25
25 5
36 6
49 7
64 I
100 10
144
196 14
225 15
252 15.9
1440 37.9

1't2
IRC:SP:112-2017
IRC:SP:112-20i 7

Category C: Testing proforma C-12

Category C: Testing proforma C-13
SOIL PERMIABILITY TEST -CONSTANT HEAD METHOD SOIL PERMIABILITY TEST -VARIABLE HEAD METHOD
(lS:2720 PART-17)
(lS:2720 PART-17)
Lab location : Sampled Location/Chainage Section Lab location : SampledLocation/Chainage
Date of Testing : :
Weight of Sampte Taken Testing
Date of : Weight of Sample Taken
NMC or OMC : :
Depth NMCoTOMC : Depth
Diameter of mould(D) :
:
FDD or MDD Diameter of :
mould(D) FDD or MDD
Length of mould (L) : Dia of Stand pipe (d) Length of mould (L) : Dia of Stand pipe (d)
Area of mould(A) : Area of stand pipe (a) Area of mould(A) : Area of stand pipe (a)
s. Head (h) Time (t) Quantity of Avg. Quantity Coefficient of Initial Head Final Head IniiialTime Final Time Net Time Coefficient
No water (ml) of water permeability No (hl) (h2) (rr) (t2) (t) ot
(ml) (K) permeability
(K)

Calculation:

Remarks:

Remarks:

PrepaJed by Checked by Approved by

PrePared bY checked by Approved by
IRC:SP:1'12-2017
IRC:SP:'112-2017

Category C: Testing proforma C-i4 Category C; Testing proforma C-l5

SWELL PRESSURE TEST BY CONSTANT VOLUME METHOD UNCONFINED COMPRESSIVE STRENGTH
(lS:2720 PART-41|
(tS:2720 PART-I0)
Lab location : Sampled Locaton/Chainage : Section/Location of Lab: Date of Testing
Date ofTesting : Taken
Weight of Sample : Inltial Height of Sample : Rate of Skain
Proving Ring Constant : Kg/Div. Initial Dia. of Sample : Sample Code
Area of Specimen : Sq.cm OMC o/o : MDD(g/cc)
Dry density: Wt. of
Contalner
Strain dial Swell + Wel Soll
Gauge pressure in
Reading Kg/cm,
before
Adiustment

Stress Dial cauge Readings (div.)

PrePared bY checked by Approved by

116
1',t7
IRC:SP:112-2017 IRC:SP:112-2017

Skaln Dlal Stress DialGauge Readings (div.) Category C: Testing proforma C-16
st. Gauge
No. Readlng Sample 1 Sample 2 Sample 3
(mm) AGGREGATE IMPACT VALUE
lS: 2386 (PARTIV)
't7 3.2
18 3.4 Lab :
Location/Secion of Source of Matorial
Sample Location : Oate of testlng
19 3.6
Purpose of Use :
20 38
Sample size | 12.5 mm Passing & l0 mm retained
21 4.O
Determinalions
22 4.2 Description Symbol unit
1
23 4.4
Weightof aggregate(dry) passing through I
24 4.6 lS Sieve12.5 mm & retained on '10 mm
25 4.8 Weight of fraction retained on 2.36 mm s
lS sieve
26 5.0
Weight oI fraction passing through
27 2.36 mm lS sieve
2a 5.4
%
5.6 (if W4>19, discard and carryout fresh test)
30 5.8 Aggregate lmpact value (w3/vv1)"100 %
Average Aggregate lmpact value
Remarks:
Remarks:

Pr€pared by Checked by Approved by

Prepared by Checked bY APProvod bY

118 119
IRCTSP;112.20'17
IRC:SP:112-20'17

Category C: Testing proforma C-12

Category C: Testing proforma C-18
FLAKINESS INDEXAND ELONGATION INDEX INDIVIDUAL GRADATION OF COARSE AGGREGATE
(lS:2386 PARTJ)
(lS:383)
Lab:
Section/Location of purpose of Use
Sampling location' :
Date ofSampling :
Date of Sampling
:
Location/chainage
Soutce of Mateflar
Source of Materials : Date of Testing
i

Date ofTesting I
Type of Material : Total u,
r^1.r M. of ^^_-,^ ,_\
^+ sampte (g) :

Sp€citi€d % ot pa$tng
Total Welght ot Weighl ot Welght of
Aggregate taken (g) Aggregate passlng Aggregat
through Thlckness retaln€d on
gauge (g) length g.uge
after ratained on
Thlckness gauge
(s)

Preparod by Ch€cked by Approved by

Flakln€ss Index (C/A) = Ebngation Inder (D/B) =
Comblned Flakine$ and Elongation Indices ((C/A) + D/B)) X i00
= =

Prepared by checked by Approved by

120
IRC:SP:112-2017 IRC:SP:112-2017

category C: Testing proforma C-19 Category C: Testing proforma C-20

SIEVE ANALYSIS OF FINE AGGREGATE

Lab :
Location of Date of Sampling DELETERIOUS MATERIALS AND ORGANIC IMPURITIES
(lS:2386 PART-|t)
Location/Chainage : Source of Material
Lab
Section/Location of : purpose of Use
Date of Testing : Total M. of sample (g) Location/Chainage : Date of Sampling
lS Sieve Size Wt; of Cum.Wt. ot Cum. % of Percentage Weight of Passing
(lnm) Material Matorlal Ret. Materlal Source of material : Date oftesting
Retained {gm, Retained Specifi calion Limlts (1 000-2)
€mJ Description of material :
zoNE-l zoNE-tl zoNE- l

10.00 100 100 '100

s. No DETERMINATION NO. 1 AVERAGE
4.75 90-100 90-100 90-100

60-95 75-100 85-100

1 Total weight of sample (W) g
1.18 30-70 55-90 75- 100
2 Total weight of sample after
0.60 15-34 35-59 60-79 removing clay lumps (R) g
0.30 8-30 1240 3 Percentage of clay (%);
(L=(W-R)/(w)x100)
0.15 0-10 0-10 0-10
Remarks:
FINENESS MODULUS

PJepared by Checked by App.oved by

Remarks:

Prepared by Checked by Approved by

122
IRC;SP:112-2017 IRC:SP 1112-2017

Category C: Testing Proforma C-21 Category C: Testing proforma C-22

POINT LOAD TEST (ls:E764) SOUNDNESS TEST BY USING SODIUM SULPHATE

(lS:2386 (PART-V)
Section/Location of Laboratory Lab
Location of : Date of Sampling
Location : Bore Hole No
Location/Chainage : Source of Material
Sample No : Depth .
Type of material Tested by
Date of Sampling : Date of Testing
Date ofTesting : proposede Use

COARSE AGGREGATE
Ave. Height ofthe specimen (H) mm Passing Retained Grading Weight Weight Percenlage Weightod
sieve size sieve of of Test of T€sl Passing Av6rage
Ave. Dia. of Specimen (D)mm size Orignal Fraction Fraction Finor Sieve (Corected
Sample Before Test After Test Aft€r Test P€rcent
Area of the specimen (A) mm'? Percenl (sm) (sn) (Actual Loss)
Percentage
Failure Load (P) kN
Loss)
Standard Core Diameter (mm) 63mm 40mm
40mm
Point Load Strength Index kg/cm'?
ls=P/(sqrt(D1sXD) 20mm 1omm

Uniaxial Compressive Strength Vm'? 10mm 4.75mm

oc= 22x1"(50) Total
Average Value neglecting Highest and
Lowest values Passing Retained Gradlng Welght Weight Peacentage Welghtod
sieve size of of Test of Test Passing Average
stze Orignal Fraction Fraclion Finer Siave (Corrected
Sample Before Test After Test After Tesl Percent
Percent (sm) (gm) (Actual Loss)
Percentage
Loss)
600 mic 300mic
1 .'18 mm 600mic
2.36mm 1.18mm
Prepar€d by Checked bY APproved bY 4.75'!'l, n 2.36mm
1omm 4.75mm
Total
Remarks:

Prepared by Checked by Approved by

124 125
IRC:8Pi112.2017
tRC:Sp:1,12_2017

Category C: Testing proforma C-23

Category C: Testing proforma C-24
SPECIFIC GRAVIry & WATER ABSORPTION OF FINE AGGREGATES
SPECIFIC GMVITY & WATER AESORFTION OF
lS:2386 (PARTntt)
COARSE AGGREGATES
Section/Location of Lab : lS:2386 (PART-|l
Source : Date of sampling Type of Sample
: (Rock sampte/ Aggregate)
Location : Date of testing
Co-ordinate/Chainage
Proposed Use
Date of Sampling
BY PYCNOMETER METHOD

Before Soaking
Pycnometer Bottle Number
Weight of sampte in air (W)g
Weight of SSD Sampte (W1) (g) Weight of sampte in water (WJg-
Weight of Pycnometer botfle + water + Sampte(W,) (S) Volume of Specimen (V = W, U,f cc
-
After Soaking
Weight of Pycnometer botfle + water (W3) (g)
Weight of SSD sampte in w-ter
1W$
Weight of oven dry sampte (W4) (g) S.S.D weight of sampte (WJ
Bulk Specific cravity = W4(W1- (W, Volume of specimenT=(W.4) G
- W3))
Bulk Density of sample
Apparent Specific cravity = W4/W4- W,-W3)
Weight of oven dried5ampte (WJg-
WaterAbsorption = (Wr - W4) / W4. 100 Moisture Content (w)%
Average Specifi c cravity Dry density yd= yb/i +(w/100)
Speciflc Gravity of sampte 1G)
Average Water absorption (%)
Apparent Specifi c aEvity@)

Void ratio (e)

Porosity = (e/'l+e)"100

Prepa.ed by Checked by Approved by

Prepared by Checked by Approved by

IRC:SP:1'12-2017 IRC:SP:112-2017

Category C: Testing proforma C-25 Category C: Testing proforma C-26

10% FINES VALUE TEST UNIAXIAL COMPRESSION STRENGTH TEST

(BS: 812 PART"lll) (lS:9143-1979)

Lab
Location of : Date of sampling
Section Location ol Lab :

Location :
Location/Chainage : Source of Material BH No. : Depth(m)
Date ofTesting : Proposed use Piece No
sample Dia. ofsample H6ight of Area (m'?) Load al Compresaion
Proposed Use No: (D) m Sample (H) m Failure (kN) Str6ngth
(kN/m'z)
Trial No
Determination
1 2 3 2
Weight of Saturated surface dry Sample passing 3
lS Sieve '14 mm and retained on lS Sieve 1omm (A) g
Corhpr€ssion strength
Oven dried weight of fraction retained on lS Sieve (um')
2.36 mm after the test (g) Young's Modulus (lS:7317-1974)

Oven dried weight of fraction passing lS Sieve Oia. ofsample (m) : Helghtof. . Area (m,)
2.36 mm after the test (B) g sampre(m,

The Maximum force 'X' (Tonne) S. No. Dial Deformalion Straln Load Dial Stless
(AD
Gauge (AV0'1000) Reading (kN) (kN/m'z)
Y = % of material passing lS Sieve 2.36 mm at the (mm,
maximum force (B/A X'100) reading
0 0
10 % Fines Value (TFV) = 14)V (Y+4) (kN)
1 '10
Average Value of '10 % Fines Value (kN) 2 20
Remarks: 3 30
4 40
5 50
6 60
7 70
8 80

Prepared by Checked by I 90
Approved by
10 100
11 110
Remarks:

Prepared by Checked by Approved by

128 't29
IRC:SP:1'12-20'17
IRC:SP:112-2017

Category C: Testing proforma C-27

Category C: Testing proforma C-2g
FINENESS OF CEMENT NORMAL CONSISTENcY.F
(lS:4031 PART-I) cE]T,I ET.IT
(lS:4031 PART-V)
Lab
Section/Location oi : Section/Location of Lab
Description of cement : Date of Sampling Description of cement : Date ofSampling :
Week No. : Date of testing Week No. . Date oftesting :

OBSERVATIONS: Temperature ("C) :28"C

SPECIFIED
NORMAL CONSISTENCY
S. No. DESCRIPTION AVERAGE LIMITS AS
1 2 3
(%l PER Weight of Weight of Plunger Time taken Consisiency of
lS: 8112 Cement taken water taken (9) penetration from adding Cement (%)
1 Wt. of Sample taken (Wj) gm (s) trom bottom of of waler to
Mould (mm) Cement (min)
2 Wt. of residue on 90p sieve (Wr) gm Max. 10%
3 Fineness (o/o) (Wz/W,) X100
Remark6:

Prepared by Checked by Approved by

Prepared by Checked by Approved by

130
IRC: S P:'1 '1 2-201 7 IRC:SP:112-2017

Category C: Testing proforma C-29 Category C: Testing proforma C-30

INITIALAND FINAL SETTING TIME OF CEMENT SOUNDNESS OF CEMENT BY LE-CHATELIER METHOD

(lS:4031 PARTill)
(lS:4031 PART-V)
Lab
Section/ Location of :
Location of Lab :
Description ofcement : Sample Code
Descriptlon of cement :

Week No. : Date of Sampling : Week No : Date oftesting

Temperature ('C):28"C Date of testing Temperature ("C) : 280C Date of testing

A) INITIAL SETTING TIME
Quantity of WaterAdded Quantity of Cement
Weight of Cement taken (g) : (0.78*Standard Consistency) : Added
Weight of water added = 0.85 of Normal Consistency:
SOUNDNESS OF CEMENT
A) INITIAL SETTING TIME B) FINAL SETTING TIME
s. lnitialDistance Distance Between Distance Between Soundness of cement
s. Time of Needle lnitial s. Time of Needle Final No. Between lndicalors lndicators after 24 lndicatoas after (1,-L)-(mm)
No, water added penetration Setting Time No. water penetration Setting (1,) hrs of submerslon in subme.sion in boiling
(mm) (min) added (mm) Time (min) watet at 27+2oc(L2l watea foa three
hours(L,)
'1

2 2
2
3 3
4 3
4

5 5 4

Initial Setting time: Final Setting tim€: 5

Acceotance Criteria: Remarks:

InitialSettinglime : >30min
Final Setting Time : s 600min

Remarks:

Prepared by Checked by Approved by

Prepared by Checked by Approved bY

133
IRC:SP:112-2017 IRC:SP:112-2017

Category c: Testing proforma C-31 Category C: Testing proforma C-32

SPECIFIC GRAVITY OF CEMENT COMPRESSIVE STRENGTH OF MORTAR CUBES

(AS PER 15:516)
(lS:4031)
Lab
Section/Location of :

Lab
Section/Location of :
Description of cement : Date of Casting
Name/ Brand of cement : Date of Sampling
Week No. : Date of testing
Grade of Cement : Date of testing
Size of Mortar Cube : Grade of Cement
Week No. :
st. Age in Days Weight Density Load at Compressive Avorago
Trial No. No (s) (g/cc) Failure (kN) Strength of Comproaalvo
Determination lndividual Strength (t _)
2 Average Sample (fr) in in (N/mmz)
(N/mm?)
Weight of bottle (wj)

Weight of bottle with sample (wr)

Weight of bottle with sample and kerosene (w3)

Weight of bottle with water (w4)

Weight of bottle with kerosene (ws)

Specific Gravity of Kerosene(w6)

=(ws-w1)/(w4-w1)
Specific Gravity of Sample=
(wr-w1 ) *w6/(wr-w1 )-(w3-w5)

Remarks:

l* : Characteristic Compressive Strength of Cement

Remarks:

Prepared by checked bY ApProved bY

Prepared by Checked by Approvod by

134
IRC:SP:112-2017

tRC:SP:112-2017
Category C: Testing proforma C_33
coMPREsstvEs@ Category C: Testing proforma
C_34
_ (tS:516)
PENErRAroElHvAL,S-,1E;I_B[yMEN
Section/Location of Lab
Grade of Concrete
Location of Lab
Oate of Casting
Water-cement Ral|o Date ofSampling
Oate of testing Loc€tion/Chainage
Description of Cement Source of Material
Structure location Date of Testing
Size of Concrete Cube Sanple Code/No
Bitumen grade
Part ot Structurc Proposed Use
Dial Reading (O.l mm)

f*,Char""teti"@

136
137
IRCTSP:112-2017 IRC:SP:'112-2017

category C: Testing proforma c-35 Category C: Testing proforma C-36

BITUMEN SPECIFIG GRAVITY

(lS:1202-1978) DETERMINATION OF SOFTENING POINT
(lS:1205-1978)
Source of Material : Date of Sampling
Section/Location ofLab :

Location : Date of Testing Source of lvlaterial : Date of Sampling

Bitumen Grade : Date of Testing ..

Proposed Use
Apparatus Used : Ring and BallApparatus

Period of Cooling at : 30"C period of Cooling in Water bath

Weight of Pycnometer (Wj) g
Weight of Pycnometer + Sample (Wr)
Weight of Pycnometer + Sample + Water (W3) g
Weight of Pycnometer + Water (W")g
Weight of Sample (W, - W1) g
Specific Gravity of Sample =
(w, -w1yw4 -w1) - (w3 -w')
@ S"C
Room Temperature (min) Temperature (min)
Rate of Heating : 5"C r 0.5"C
I Time (min) Temperature of water Time (min) T6mperature of water
bath "C bath .C
I 7
2 8
3 I
4 '10

5 11

6
Description Bill No. 1 Bitl No. Mean Value of
Sofrening Point
Temperature at which
sample touches the
bottom plate ('C)
Remarks:

Prepared by Checked bY APP.oved bY

Propared by Chocked by Approved by

138
IRC;SP:112-2017
tRC:S p: 1 1 2_20.i 7

Category C: Testing proforma C-37

Category C: Testing proforma C-38
DETERMINATION OF VISCOSITY
(lS:1206-1978)
GRADATIONAGGREGATE@
MIXTURES CENTRIFUGE METHOD BC /DBM/ BM
Section/Location of Lab :
IRC:SP:11
Source Section/Location of Lab
: Date of Sampling :

Sample Location :
Date ofsampling : Date of Location
Date of Testing :
Date of Testing : Layer
Bitumen Grade :
BINDER CONTENT TEST
Observations
Pouring Temperature,'C

Test Temperature, "C

Initialweighl of fitter paper
Size of Orifice (mm) Weight of Aggregate after
Viscosity in (sec)
Weight of filter paper after
Viscosity in (Cst) extraction with fine materials
lncreased weight of filter
(Note 1: 1 sec = 400 Cst for 10 mm Orifice)
(Note 2 : '1 sec = 13.2 Cst for 4 mm Orifice) Weight of Binder

Remarks: Binder Content (BC)

= W5M1X100

GRADATIONOFAGGREG@
(DBM - MoRT&H Tabte 500_1o)a(BM
Sievs
_ nrronran raur" iooji-
Prepared by Ch€cked by Approved by size
(mm)

Prepared by Checkedlby Approved by

't40
141
lRCrSPrl l2-2017
IRC:SP:112-2017

Category C: Testing proforma C-39 o

Y
o
FLASH AND FIRE POINT TEST o
(tS:i209_1978)
Section/Location of Lab : o
Source : Date of sampling o
Location : Date of testino
e
Proposed Use : o
'1. Bitumen grade/ Cutback type & grade:
e
o
2. Type of equipment: Closed cup/ Open cup
(J f
.!
Rate of heatino
I
Time, minutes (t, .!
1 2 4 a 6 7 8 '10 11 12
!
f
o
.I
Temperature,'C at,
UJA ,!
EP at

F=
Ol .!
Test property !.u o
Test Number Mean
value JF SF
1
>th
L Flash point
=<
o
2. Fire point
t
3. Mean value
=
Remarks:

db);
Prepared by Checked by Approved by

142
't43
IRCTSP:'112-2017 IRCiSP:112-2017

s
to
tt

-z
s
o
=

:x
>.
o
uJ

., 5 t (cc/uB) AItSNfc
t l (%)€rA

,o
J

o
e.

= o =
lt'

z
z

ot
o o
;<

qt

I o
E

a q,

(e)),]\l|lr€vIS
=
6
144
 I RC:S P: 1 1 2-20'l 7
lRc:SP:112-2017

T
J
E
'6 o
o
@

s ..,
o
u,.l
q)

b (t)
Lil
En F
o LIJ
F
o
o o o
c) tl tl tl
= o)
E
tt,
Ic' .ls
z
s F
tt o
N
q rlt .9 o s u,l ;L!
E
€
o
o
I a o l*
t+
B
uJ
d =
(tt t! o o t> o
o (lt <t)
E s uJ

e
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147
IRC:SP:112-2017 IRC:SP:'l'12-20'17

Category C: Testing proforma C42 Y

o
FIELD DENSITY TEST BY CORE CUTTER METHOD
I
Reduced level : Layer No. MDD = gm/cc o
Bulk Density: gm/cc Layer Thickness OMC = % I
CI
6
P
4 c cn
No. CHAINAGE Unit 1 3
ql
1 Mass of mould+ComDacted soil Gms
.(, o
2 Mass of mould Gms
o
3 Mass of compacted soil (2-1) Gms t
Volume of mould
o
5 Wet Density of soil (3/4) GmsicC (J
Moisture Determination u,l

6 Wt. Wet soil Gms

t
fah
7 Wt. Dry soil Gms o
8 wt. water (6)-(7) Gms
o
t0
9 Moisture content (8)/(7)xl00 % z RF
10 Field Dry density of soil Gms/CC tr
(5y1+(9y100
o
uJ

Degree of compaction (10/MDD x 100) ./" tt

ut
OE ! o
Average degree of Compaction ZO
=
!J
Standard Deviation o
z 6
REMARKS: .9
E
E o
-z dt
uJ
o ]

a
E
z
Prepared by Checked by Approved by o
J

(eHU/SH']J
J
g
.s .q I
aa E
zo
148
IRC:SP:112-20'17
tRC:Sp:1.t2_2017

Category C: Testing proforma C44

Category C: Testing proforma C-45
PAVEMENT ROUGHNESS SURVEY USING BUMP INTEGRATOR DYNAMIC CONE PENETROMETER TEST
Name of the Project : (PAVEMENT DC
No. of Lanes Date :

Climatic Condition : Vehicle Speed :32 i 0.5 km per hr.

Carriageway Surface : Tyre pressure: 30 psi

Angle of Cone Used in Test
Bump Integraior Roadhg
chalnase(km)
(No. of Bumps In cm)
(Ulln hm/km)
(m)
LHS RHS
Dynomlc Cone Penehometer Tesl
Tdal-'l Tda13 Resulli
0 510 15 20 2J lO 35 40

Soecifications: Vehicle operaling speed shall be 32 +/- 0.5 kmph and tyre pGssurc sha be 2. t kg/cm, or 3otb/sq.in I roo

Observed Roughness or Ul (mm/Km) = Bl Counter Reading (Cm) X 10 X Distance Reading per Km/ Distanc€ Counter
Reading in Test Length
Calibration EquatDn from CRRI: = 1.1529 (X) + 3.01881; where Y is Catibrated roughness in mm/km and X is the ! 400
observed roughness wilhARUR (No. STECO-g4) in mm/km
Remarks
cumulqtlve No ot Stow!

Rate of Penetration per Blow in mm for '1.ilaver

=
Rate of Penetration per Blow in mm lor 2nd laver
=
CBR From Corelation Curves for 60-degree cone (%):
Prepared by Ch€cked by Approved by For 1d layer

Prepared by Checked by Approved by

151
IRC:SPrl'12-2017 IRC:SP:112-20'17

Category C: Testing proforma C.46 F.

T
o
DETERMINATION OF DRY DENSITY OF SOIL IN-PLACE .g
g aperEqns
(SAND REPLACEMENT METHOD) .o
Y

AS PER lS:2720-PART 29
Source/Location of Lab:
;?
Material Source Defails .9E
1 Bofiow area Name/ Pit No /Any other Reference Date:
.o P E

2 Optimum Moisture Content (OMC) % | [IDD. (g/cc):

Pre-Test Data
B E
'l Chainage of Stietch (From Km - To Km) o
|'t 3
2 Layer No:
o =
3 Bulk Density of Sand, g. (g/cc) tr i9
lrJ i
4 Weight of sand in Cone w3(grams from lab) F
Field Density Oete.mination uJ
sl.
No.
Description Unit Observations at Pit Location t
=
o
o)

Chainage & Pit loc€tion s

F
C)
git 00st

2 WeEht of wet soil frcm hole W s 14?

3 Weight of sand wilh cylinder before pou ng (W,) s |!9
ul 't (E-Cv 009r
Weight of sand wth cylinder after pounng (W,) s
5 Weight of sand in hole (W"=W,-W,-W3) s ^ro
q/9" o0zl
6
7
Volume of lhe hole V =
Bulk Density of Soil 9b",, = (W /)
s TE
IJJ
Moisture Content Determinalion !.9 006
Container No,
=
(9 iE
2 Weight of Contarner (Wa) gms z
3 Wt of Contiainer + wetsoil(W5) sms
J ze 009
J !E
Weighl ofContainer + dry Soil (W6) gms
l!
5 Moisture Conlent'w' = (Ws-W6y(w6-Wa) xl00 % 00€
Test Results o
1 Dry Density gd= gb"k/(1+w/100)
2 Perceniage Compaction= (g/MDD) x 100
>!=
oo 0

3 Mean Densily (g/cc)

=-9
Pq n
4 Compaction Density Required (g/cc) (97% of MDD)
5 Slandard Deviaiion, SD
> vot ;6
6 Acceptance C teria {Mean Requjred Compaclion+
[1.65- (1 65/(No of Samples)o5] x SD]
od9 e6euteqC

Rema.ks -I
!

Prepared by Checked by Approved by zi 'oN ts E

o-

152
 IRC:SP:'112-2017
IRC:SP;112-2017
Category D: Calibration Proforma D-2
Category D: Calibration Proforma D-l

GUAGE
CALIBRATION CHART OF BATCHING FORAGGREGATE CALIBRATION CHART OF BATCHING PLANT FOR WATER METER
CALIBRATED DATE: CALIBRATED DATE:
sL. TRIAL.l TRIAL.2 TRAIL-3 AVEMGE
DIALGUAGE READINGS
NO.
['IETRE WATER METRE WATER METRE WATER
READING MEASURED READING MEASURED READING MEASURED
(LTRS) (LTRS) (LrRs) (LTRS) (LrRS) (LTRS)

10 10 10

2 20 20 20

3 30 30 30

4 40 40 40

5 50 50 50

6 60 60 60

7 70 70 70

8 80 80 80

I 90 90 90

10 100 100 100

11 110 110 110

12 120 120 120

13 130 130 130

14 '140 140 140

150 '150
15 150

REMARKS:

For Contractor For Engineor

For Engineer

155
't54
IRC:SP:'112-2017 IRC:SP:'l'l2-2017

Category D: Calibration Pioforma D-3 Category D: Calibration Proforma D4

CALIBRATION CHART OF BATCHING FOR CEMENT GUAGE CALIBRATION REPORT

CALIBRATED DATE: (CUBE TESTING MACHINE)
DIAL GUAGE READINGS DATE OF CALIBRATION : TEN,IP :

LOAD
APPLIED
TRIAL.'I TRIAL.2 TRAIL.3 AVERAGE
GAUGE NO.: CAPACITY:
LOADING UNLOADING LOADING UNLOADING LOADING UNLOADING
(KG)
EQUIPMENT: MODEL:
0
FORCE MEASURING DEVICE: SL. NO. :
50
100 CERTIFIED BY: PLACE:
'150
REF :
200
sL. DEFLECTION IN DIAL GAUGE ACTUAL LOAD AVERAGE OF INDICATED LOAD
250 NO. IN PROVING RING APPLIED THREE READING IN GAUGE ERROR
300 1
350
2
400
3
450
500
550
5
600 6
650 7
700 8
750 9
800 10
850
900 NOTE: To obtain correct result positive (+) error to be subtracted, negative C) error to be
950 added to the indicated load readings on machine gauges.
1000
1050
1100
1150
For Contlaclor For Engineel

REMARKS:

For contractor For Engineer

156 157
 -

IRC:S P:'1 '1 2-201 7

IRC:SP:112-2017

Category E: Surveillance Proforma E-2

Category E: Surveillance Proforma E-l
PRODUCTS QUALITY SURVEILLANCE FORM
MATERIAL QUALITY SU RVEILLANCE FORM
NAME OF PRODUCT:
Contractor Contract No

Inspecting Agency Contraclor Conkact to

IVanufacluret/supplier/
Source
Manufacturer/supplier/ Purchase order Inspecling Agency
Source

Delivery Distinguishing Dale of IVFR

Inspection Delivery challan Distinguishing mark Date of manufacture
C€rlificate challan Mark /supply
certiflcate /supply

Drawing Nos. Tender specification clause

Shippiog storage and olher Remarks (Satisf actory/Not satisfaclory)

TEST RECORD Shipping storage and other Remarks

Acceptance
Sl. No Test Method of tesi Obtained value Remaaks sl. no Test Method of test Acceplance Obtained value Remarks
range
range

Remarks:

Name: Signed: Datei

Inspected by:
(For QA Engineer) Inspected by: Name: Signed: Date:
(For QA Engineer)

In presence of: Name: Signed: Date:

(For Contractor) In presence of: Name: Signed: Date:
(For Contractor)

159
158
 IRC:SP:112-2017
IRC:SP:112-20'17

Category E: Surveillance Proforma E-3 Category E: Surveillance Proforma E4

SURVEILLANCE FORM FOR PRE-CONCRETING OPERATIONS OUALITY SURVEILLANCE FORM FOR WORKMANSHIP OF CONCRETE

CONTRACT NO. CONTRACTOR CONTRACT NO,

CONTMCTOR
LOCATION ELEMENTS OF IDENTIFICATION NO. LOCATION
ELEMENTS OF STRUCTURE IDENTIFICATION NO.
STRUCTURE
SURVEILLANCE OBSERVATIONS
SURVEILLANCE OBSERVATIONS
The following items should be obseNed during concrete pour by the QAsurveillance team.
WORK DESCRIPTION
(1) Mixing of concrete
Line, level and
Dimension as per Drg a Check lhe concrete class and lhe respectiv€ mix design already approved

Availability of adequate
a Check the condition of aggregates to be used.

Approved material a Check the weighing and water dispensing methods adopted during the mlxing.

o Check that the mixer machine has been cleaned properly

Placing of rcinforcement
(lncluding supports/spacers etc.) . Check that the required mixing time is allowed.

Formworks and scaffolding t2l Transportation/conveyance (as specified, but generally to cover following)
as per drawing a Check ifthe equipmenl is in proper working order'

Box outs/embedded Parts, if any . Check ifthe specified methods are being followed.

Cleaning offorms a Check ifthe stipulated time limits are observed

Afiangements of Plant
& equipment
a Check if the non-conforming wet concrete is being rejected and disposed off.

(3) Placing of concrete

Walkwayfor pouring and inspections Check that:

Safety arrangements a The concrete is not segregated during pour. The height ofdropping is controlled

a The concrete is poured in layers.

10 Curing arrangement
a The vibratorc are being applied systematically lo compact uniformly and adequately' avoiding
overvibtation,

a The concrete is not being pulled or pushed. Pouring is being done lose to the final position.

a The cold joints are not alloyed to be developed

a The underwater concrete is being poured only by hemies or pipeline

Name: Signed: Date:
Inspected by:
a The foms are not getting displaced or deformed during the concrete pour and vibrating.
(For OA Engineer)
a No cement sturry is getting lost. Suitable numberc of carpenters are present to watch and repair
Name: Signed: Date: formwork dudng pour, if required.
In presence of:
(For Cont.actor)
a The concrete is being poured within the allowable time limits from the time of batching

a The concrete cubes are taken as required,

'161
160
IRC:SPr112-2017 IRC:S P: I '1 2-20 1 7

a The cuing arrangements are satisfactory' Category E: Surveillance Proforma E-5

The equipment is in working condition.
SURVEILLANCE FORM FOR PAVEMENT LAYERS
a The equipment is cleaned Propedy
SU RVEILLANCE OBSERVATIONS
a The quality ofwet concrete is as per specifications (slump' homogenous mix etc )
PAVEMENT LAYER LAYER NO./REQUIRED LEVEL LOCATION
a Continuous supply of concrete is assured
DESIGNATION

Materials/wolkmanship

Earth works/Granular sub.base Wet mix macadam Asphalt

Signed: Date: 1.
Inspected by: Name: '1. Check material is from Conforms to job mix formula 1. Conforms to job mix formula
(For QA Engineer) approveo ootrow 2. Faee from deletorious 2. Free from deleteaious
2. Free from roots and other materials matorials
Signed: Date: perishable material
In pres€nce ofl Name: 3. Spread layer thickness is 3. Spread layer thickness is
(For ContJactor) 3. Grading is acceptable acceptable acceptable
4. Spread layerthickness is 4. Ivloisture is near optimum 4. Temperature at break down
acceptable prioa to compaction rolling is within specs
5. Ivoisture is near optimum 5. No segregation during 5. No segaegation during
prior to compaction fianspon ranspon
6 Lines/levels are within 6. No segregation during paving 6. No segregation during paving
tolerance
7. Lines and levels wilhin 7. Lines and levels within
Equipments lolerance rcrerance

Check Equipments Equipments

'1. Adequate for the work Check
Check
2. In condition 'l 1. Adequate fof the work
Adequale for the work
2. In condition
2 In condition

Inspected by: Name: Signed: Date:

(For OA Engineer)

In presence of: Name: Signed: Dale:

(For Contractor)

't62 163
IRC:SP:112-2017 IRC:SP:112-2017

Category F: Proforma for Registers and Records F-1 Category F: Proforma for Registers and Records F-2

PARTICULARS OF WORK REGISTER OF DRAWINGS

Name of work
Nameofwo* :

Name ofcontractor :

Name of contractor 1. Recelpt of d.awings

Address of contractor st. Drawlng Revlsion Brlsftitle lssued Date of No, of StatG ot Further Slgnature
No No./ Dato No by/ receipl orgs actlon and date
Contract agreement no. (source)

Contract amount

Applicable schedule of rates

Period of Completion

Date of Work order

Stipulated date of completion

2. lssue of drawings
Actual date of starting of work
st. D.awing R€vision Brief titl€ Sl.no of lssusd to Status Drs Signatur€
Extensions No No./ Dat6 No ngceipt ot drgs SUpeasedes
reglslsr Drg no (lt
(1)
any)

INCUMBANCY

Period
Sl. No Designation" Name
From To

For Contractor For Engineer

Name : Namg :

*Departmentat officers' designations covering allofficeG having execution responsibilities forthe project
Signed :
Signed :

For Engineer Date: Date:

For Contractor

Name : Name :

Signed : Signed :

Date: Date:

164 165
 IRC:SP:112-20'17
IRC:SP:112-20'17

Category F: Proforma for Registers and Records F-3 1

tt E
o
CEMENT REGISTER Y ]
o
t) 5EF .9

to-) o oG
1. Weekly Receipt lssue (For week from d ET
.E
I
g
Name of Work
9o
.gY
o EE',
:
Ptr
do t Fd.gE
Name of Contractor:

Closing Balance at the Site of Work from

b=
(!=
Ei E8
(-t it
Previous week-Dags. Lo
*E o o
o
.R
Closing balance
.Y IIJ
at the end of day ILF
E-= fiPE
r Ir
(b.gs/MT) xiio)
'ii 2A 5:F EZ6
C HP o.0
E E9
e Eo E

oa
ZJ ' E
of; e o
F=
Zu
ulE o I
=9
ulg
oF
E
o o oG
(1,
E- o
o F o o
zr^o
For Engineer
For Contractor =f
FO
o-= =
Ec
Name :
Name :
=b
fo
o....E
(lt o
z9 o
o '
Signed:
Signed :
OE
C': zo =
o
Date:
Date: o
66
lE>.
bF* g
6 zo
E
t!
=66
bb3 tri
oo d9E
zz> d)
:HEr
EZtn
166 167
IRC:S P: 1 1 2-20'l 7
tRC:Sp:1.12-2017

Category F: Proforma for Registers and Records F-5 Category F: proforma for Registers and Records
F_6
REGORDS OF CALIBRATION OF EQUIPMENT DAILY PROGRESS REPORT

Name of Work : Name of Work :

Name of Contractqr : Name of Contractor :

ITEM DATE *DATE OF NEXT DATE OF RESULT OF

CALIBRATED CALIBRATION INSPECTION INSPECTIONS
& PERSON & PERSON
CERTIFYING(FOR APPROVING (FOR
VENDOR OR DEPARTMENT)
CONTRACTOR}

For Contractor
For Engineer

Name :
"Frequency ofcalibration for different equipment to be specified in advance. N6me :

Signed:
For Contractor For Engineer Slgned :

Datel
Name : Name : Datol

Signed I Signed :

Dale: uate:

168 '| 69
IRC:SP:1'12-2017 IRC:SP:'l'12-20'17

Category F: Proforma for Registers and Records F-7 Category F: Proforma for Registers and Records F-8

REGISTER OF INSPECTION NOTES REGISTER OF OBSERVATIONS MEMOS TSSUED

FROM THE QUALITY CONTROL CELL
Name of Work :

Name of Work :
Name of Contractor :

Name of Contractor :
No. of No. and Signature Number Signature Remarks
Inspection date under by & date of oy
which compllance
Nots 9d
tz E 3Hr E
submitted
;t.! ,
dP E 'te .9t
E
6E i6

For Conkactor For Engineer

For Engineer

Name : Name :
Name :

Signed : Signed :

Signed :

Date: Date:
Date:

170 171
IRC:SP:112-20'17 IRC:SP:112-2017

Category F: Proforma for Registers and Records F-9 Category F: Proforma for Registers and Records F-i0

BITUMEN REGISTER RECORD OF PRESTRESSING WORK

1. Weekly Receipvlssue (For week from to) 1 Name ofwork : 5. Name and number of component

2 Name of contractor : 6. Date of Casting:

Name of Work :

3. Span length :

Name of Contractor : (indicate avg cube skength at 7 and 7. Gauge pressure not to exceed :
28 days as per design)
Closing Balance at site of work :

Previous week
4. Span number :
l\.4TlPacks

Dale Quantity Received Source Quantity Purpose Closing Balance

used MT at the end of day
MT Grade (Packs/MT) Date of pre- No. of cable Side.
stressing
pair of wires Gauge lniiial Locking Slip Final
Reading extension in plessure observed in Extension
mm mm
1 3(D 3(iD 3(iiD 3(iv) 3(v)

Sid€.............. Calculated
Guage extension in mm
lnitial Slip Total final
reading Locking Final for an initial pull
extension observed in extension in mm
ptessure Extension per cable/wire/
in mm mm pair of wire
4(D 4(iD 4(iii) 4(iv) 4(v)

Theoretical Progresslve Signatures

Total Losses or galn Slip observed,
Extension
Extension in
Loss or gain
if any, afrer 10 Remarks
required in Extension in EE

7 8 9 10 11 12li) 12liil 12(iiD

For Contractor For Engineer

For Contractor For Engineer

Name : Name :

Name ' Name .

Srgned I Signed :

Signed :
Date:

Date: Date:

172 173
lRc:SP:112-20'17 IRC:SP:112-2017

Caiegory F: Proforma for Registers and Records F-ll Category F: Proforma for Registers and Records F-12

GROUTING RECORD PROFORMA FOR RESULT ANALYS|S (CEMENT)

Name of the work Name of work

Name of Conhactor Cable No I
Name of contractor
Span No. Dateofcrouting:
Date of Cable Installation
Type of Cement Grade ofCement :

Type of Cement OPC/IlSOPC S. No. Consignment No./Date Sample Results of Results of Rosults of
Week & Year of Manufacture of oPC/llSOPC Reference No./ Chemical Test physical iest sp6clal t€sts,
Date C3A, Etc. (Fineness, lf any
W/C Ratio
Strength €tc.)
Name &Amount of admixture
used, if any
Temp Mixing Water Grout

llme Start Frnrsn

Equipment Grout l\rixe. Grout Pump

No. of samples
Cable Duct Diameter Length Mean
Regrouting Standard Devialion
Volume of Grout in liters
Range
Grouting pressure
Remarks:
Cement consumption
Theoretical Actual

Ple-grouting checksl
For Contractor
Free of blockage lnlet Yes/No Outlet : Yes/No For Engineer

Yes/No Cable duct : Yes/No

Name : Name :

Leakage observed Yes/No Sealed I Yes/No

lf cable duct blockedr Remedial measures Signed: Signed I

Grouting observations :

Date: Date:
Passage of grout through vents Yes/No

Passage ofgrout through outlet Yes/No

Any equipment failure Post grouting checks

Probing by stiff wire
Remarks
Signatures of officers present
during grouting

For Conhactor For Engineer

Name : Name :

Signed : Date: Signed: Date:

174 175
IRC:SP:112-2017 IRC:S P:'1 'l 2-201 7

Category F: Proforma for Registers and Records F-'13 sEcTroN I

PROFORMA FOR RESULT ANALYSTS (CONCRETE)
DOCUMENTATION AND COMMUNICATION
Name of work
9.1 Introduction
Name of contractor
During implementation and upon completibn ofa road poect, several documents are required
Type of Cement Grade of Cement to be prepared. Communication among Authority/Employer, Engineer and Concessionaire/
Contractor is a part of operational requirements of a Contract. The interaction takes olaces
st. Sample Ref No. Structure Wet Concrete Hardened Concrete Propeft ies on issues like project execution, progress reporting, quality of works, invoicing, revised
No. Element properties Strength at age in days plans, change of scope, statutory and regulatory requirements as per Contract and any other
requirements of Authority/Employer, Engineer and Concessionaire/Contractor.
Temp Slump 3 days 7 days 28 days
9.2 General Principles of Documentation and Communication

9.2-1 Overuiew of documentation

Documentation is involved in the process of planning, design, reviews, procurement, storage
& issue of materials, plant and machinery operations, changes, amendments, approvals,
subcontracting, payment, accounting and control of obsolete documents. lt also includes
No. of sample methods of controlling records, which are generated as a part of euality Management
Ivlean Standard
Deviation
System during project implementation. All the stakeholders shall ensure that the documents
Range are legible, readily available and retrievable at alter date.
Comments
9.2.2 OveNiew of communication practices
Communication practices should be such that there js quick and objective interacton among
For Conhactor For Engineer all stake-holders for the day-to-day needs. For this purpose, e-tools may be the preferred
option for the communication. The internal and external communication needs are reouired
Name : Name I to be identifled with respect to what will be communicated, when, with whom and how- related
to all aspects of project implementation including total quality management of the project.
Signed I Signed:
9.2.3 Requirement of Digital Technology in documentation
Date: Date: Document digitization is the process of converting manual documents into digital formats.
In the process of document digitization, any type of document like text, images and videos
are digitized and converted into digital formats such as .txt, .html, .xml, .pdf, .doc, .xls, .gif,
jpeg or .tif. Some of the advantages of digitization are perpetual preservation of vulnerable
physical documents, quick and easy retrieval, easy access and easy to share.
All original records must be examined for their digitization suitability prior to the digitization
process. This process will determine the extent of preparation required and ensure that
successful images are obtained from the digitization process

9.2.4 Requirement of E-Tools in communication

E-Tools orelectronictools implythe application of modern ICT(lnformation and Communication
Technology) tools to automate ce(ain tasks. E-Tools is a generic term, which covers usage
of a combination of computer hardware, software, communication tools and technolooies for

176 177
IRC:SP:'112-2017
a specific purpose or application. Key beneflts of E-Tools are:
. Better quality, speed and effective flow of information.
a lmproved accuracy and consistency of documentation.
a Paperless interaction - environment friendly.
. Builds transparency and accountability at all levels.
E-Tools should be oreferred and used for communication as far as possible.
9.3 Guidelines for establishing mechanism for documentation
9.3.1 Proiectpreparation
During the course of DPR preparation, several discussions are made at site as well as office,
which impact different aspects of the project. Both Authority and Consultant shall maintain
records of all such discussions/meetings and related communication held for finalization
of the alignment and various provisions/components of the project in a systematic and
chronological manner All volumes/parts forming part of DPR shall have proper index and
the main report shall contain consolidated index of all volumes/parts All revisions to DPRy
any particular part of it shall be properly identified and a table inserted in the main report
chronicling each revision. The soft and hard copies of various reports (like DPRs, Feasibility
Reports, lA plans) submitted by the Consultant shall be maintained at the site office of
Authority.
9.3.2 Construction
(i) Drawings, Specifications, Work related documents: The issuing authority
should maintain the records of drawings/documents giving information about
reference numbe( revision, reference, title, date of issue, to whom issued'
number of copies issued, status of issue, date of approval, purpose of issue
etc. Receiving ofllcer to whom documents are issued at site should maintain
similar record.
(ii) Inspection Proforma: These are used for the purpose of seeking approvals
from the 'Engineer or his representative' before commencing any operation,
such as, pour cards for concrete, approval to reinforcement' approval to
formwork, approval to setting out, approval to pre-stressing' approval to
grouting, etc. These are usually supplemented by standard checklists which
have to be verified by the 'Engineer'and after he is satisfied about contents,
approval is then accorded on that form.
(iii) Test Results: The results of day-to-day tests carried out in accordance with
the requirements or specifications should be recorded in the prescribed
Proforma. The Proforma are usually maintained in two forms - one for
recording the observations during each test and calculation of quality
characteristics. The second is for recording the summary of test results to
facilitate later analysis.
(iv) Method Statements: The method statements give a detailed proposal
of the constructing agency for carrying out each and every activity in the
178
IRC:SP:112-2017
Project. These are written in form of various steps in a particular sequence
supplemented by suitable sketches to be self-explanatory. These method
statements shall be approved by Engineer prior to implementation.
Daily Dairy of Work and Quantity Records: Records are required to be
maintained at site for the day-to-day operations, actlvities and events taking
place at the site ofwork, such as equipment deployed, manpower deployed,
activities carried out, different types of materials consumed, detailed
observations ofthe activities at site (foundation strata, tilts, shifts, etc.), visits
by senior level engineers and follow-up of their instructions. These records
will enable preparation of the completion report as well as investigation of
any unusual observations, which come to notice afteMard.
(v) Non-conforming Products: Detailed statements have to be prepared
describing the procedures to befollowed as soon as any result notconforming
to the requirements is obtained. Such statements include the (a) procedures
to be adopted for rectiflcation ofa particular component where such result has
been noticed, (b) the long term corrective action, (c) immediate preventive
action in other similarly affected activities till the long term corrective
actions are implemented and (d) dismantling/removal/disposal of unsuitable
components/materials.
For the quality of the finished work, it is necessary for the materials and
workmanship to fully comply with the work requirement.
Special situations may, however, arise where non-conformance may only
be known after sometime e.9., strength of concrete 28 days after casting.
Separate recall procedures should be laid out for dealing with such non-
conforming situations.
(vii) Quality Audit Records: The audit programme shall assign qualified
personnel to perform such audits and define the frequency and procedure
of audit. The method of reporting the findings and recommendations and the
means for corrective actions shall be documented.
(viii) Mechanism shallalso be developed for recording and maintaining documents
with regards to other aspects of construction such as procurement, storage
and issue of materials, operation ofplantand machinery payment, accounting,
approvals, tratfic diversion, safety and environmental safeguards measures
etc.
9.3.3 After Construction
a) The As-built drawings/plans:
The conditions of Contracvconcession Agreement provide all information
and the required content of "As-built Drawings", and responsibilities for their
preparation. lt is the Contractor's/Concessionaire's responsibility to prepare
the As-built Drawings. The Engineer must supervise, monitor, and check
the preparation of the As-built Drawings. The preparation of these drawings
must be performed during the course of the works and must not be left until
179
lRc:SP:112-2017 IRC:SP:112-2017

"substantial completion" to commence. As the works are completed they are (tt
to be surveyed / measured and the drawings prepared. ID Eg -8;
b) Final Completion report Eq
Although final documentation is to be submitted on completion of a section /
o at F€ a::
mile stone and/or at the end of Contract, they have to be prepared as work
=Y F;.6
progresses, and finalized when works near completion.

9.3.4 Operation i5r isr

Records of all the maintenance activities carried out during Operation Period should be Ee 3 ; Buj
prepared by the Contractor and checked by the Engineer. A copy of such records should be
c E{ 3*e E
maintained at site office ofAuthority. E
g 8E9 'i€eE
9.4 Guidelines for security/authentication of documents
The documents need to be authenticated by Engineer. The authenticated documents should v,
be kept under the safe custody of site offlce ofAuthority after completion of the work. t z
=
o
9.5 Sample formats for communication lJ-
z
9.5.1 Request for lnspection Form (RFI) o
F
The Concessionaire/Contractor shall submit Request for lnspection Form (RFl) to the o
uJ
Engineer in advance. Asample of the RFI is given in Annexure 9.1. o.
at P€
9.5.2 Forms for Repofts and Recotds
<3
Samole forms for ReDorts and Records are ln Annexure 9.2. d
=
o
lt
F
o
IIJ
fF
o.i
uJx
E6
F
I
o

(J o

z >*
o o qd
o a 5/i-
o ;; .: q)
6 E 6 .. F 5
3(LEEr
(t,
(! (-) rt E 3.E,fr
E<ZOU)O
180 181
 IRC:SP:112-2017
IRC:SP:112-2017

Annexure 9,2 FORM -2

FORM -1
DRAWING ISSUE FORM DAILY REPORT
Sheet No. of DATEI
Weather ----,-A.[I_
PAGE:
OATE OF ISSUE
--__--___--__ PM
BILL NO,

DRAWING TITLE
DRAWNG REVISION NO,
ACTIVITIES (ttem No., descriprion, tocaiidns, qu-nt[iii6il,GGJ

MANPowER (Engineers, foremEn, diilGi-iaborers, operators,-thErsj

NO OF DRAWINGS ISSUED TO:

EQUIPTTENT (Type, No. workingtdl4

PURPOSE OF ISSUE PROBLEMS/|SSUES E NCOU t,tiEREOldisru roances, accidents. etc.i

ReMAnxs (tnspecting o@
Attached drawings have been checked and agreed
with above list
lssued by: Receipt Acknowtedged

FOR EPC CONTRACTOR FOR CONCESSIONAIRE FOR ENGINEER

(lfapplicable) (lf applicablo)
Name : Name : Name :
Designation: Designation Designation
Signature : Signature : Signature:
Date:
Date
182
183
IRC:SP:112-2017
IRC:SPr1'12-20'17

FORM -3
sEcTtoN 10
INSPECTION REPORT FOR MECHANICAL PLANT /MACHINERY
STATISTICAL ANALYSIS
Contractor Package No

Inspection Date Time 'lo.'l Introduction

Plant Machine Type Model No. 10.1.1 History of Statistical Quatity Contrcl

Manufacturer
Description
Overall Appearance
Tyres/Drums/Tracks
Steering Brakes
Operator/Understanding/Training
Environmental Condition
Spec. Clause No.
Specification
requirement
Manufacturer date
General Conditions
Condition
O.K./Poor/Not O.K.
Specifi cation Requirements
Description Rating
O.K./Poor/Not O.K.
Prior to second decade of 20h century industrial quality control meant inspection of products
and removing defective ones. Dr. Shewhart started the process Control whlle workino in
Western Electric Company jn the year 1924 and further developed it when he moved to Eell
Laboratories. A physicist, engineer and statistician by profession, Dr. Shewhart is also called
RemarkslDefects father of Statistical Process Control.
Shewhart framed the problem in terms of assignable-cause and chance-cause varjation and
introduced the control chart as a toolfor distinguishing between the two. shewhart stressed
that bringing a production process into a state of statistical control, where there is onlv
chance-cause variation, and keeping it in control, is necessary to predict future output and to
manage a process economically.
The next leap in quality controlwas Total euality Management, which was developed in post
war Japan under the aegis of William Edwards Deming a prot6g6e of Shewhart. Apart from
his statistical prowess,it was Deming's philosophy to manage a,,system" to achieve a high
quality product or service that resulted in the grand success of Japanese manufacturing
industry Deming's chain reaction is given below:
Remarks/Defects Cost decrease because
of less rework, fewer
lmprove Quality Productivity
mistakes and delays, improves
snags, etc

Capture the
market with better Provide jobs
Final R€commendalions: quality and lower Stay in business and more
pflces jobs

The next step foMard in quality management is six-sigma (60). A six sigma process is one
in which 99.99966% of all opportunities to produce some feature of a part are statisticallv
FOR EPC CONTRACTOR FOR CONCESSIONAIRE FOR ENGINEER
(lf applicable) (lf applicable)
expected to be free of defects (3.4 defective features per million opportunities). lntroduced
by Bill Smith while working at Motorola in 1986, it was substantia y developed by Jack Welch
Name Name Name :
: :
at General Electric in 1995.
Designation: Designation Designation
The fundamental concept of six sigma process is that upper and lower specification limits
Signature I Signature I Signalure :
(marked USL and LSL) are kept at a distance of 60 from the mean. Because ofthe proDerties
Date: Date uate of the normal distribution, values lying that far away from the mean are extremely unlikely:
approximately 1 in a billion too low, and the same too high. Even if the mean were to move
't84
185
lRCrSPrl l2-20'17
right or left by 1.5o at some point in the future, there is still a good safety cushion. This is
why Six Sigma aims to have processes where the mean is at least 60 away from the nearest
specification limit.
Speciflc managementtools are employed in allthe 3 methods mentioned above by monitoring
certain statistical parameters in different stages of manufacturing.
1O.1.2 Variability is a reality in road construction like any other manufacturing process. lt
is like a settled order ofthe nature. Variability occurs in materials and processes used for road
construction. lt also occurs in different stages of road construction, has different dimensions
and impact on quality of various components of road and bridge works in different manners.
Limiting the variability is a prime objective of QA Plan but variability does exist and needs
to be duly accounted for while evaluating quality of a component of road and bridge works
for the purpose of its acceptance. Adding to the variability of materials and processes, there
is also considerable variation in the process of sampling of materials carried out for testing
and actual testing of materials resulting in measurement errors. Under such circumstances,
statistical analysis helps in taking informed decisions about acceptance.While the guidelines
stated elsewhere in this lvlanual shall be followed to achieve desired quality, the quality
control test results of certain materials/layersicomponents as specified in Section '11 of this
Manual shall be subjected to statistical analysis as stated in this Section for the purpose of
acceptance of the particular material/layer/component. Essentially, statistical quality control
for road and brldge works relates to statistical Lot inspection of an item of work and its
acceDtance.
1O.2 Glossary of Terms
Before proceeding with a particular method of analysis, it is necessary to understand various
terms associated with statistical analysis. Whereas some of the terms are common to all
methods, some are unique to a particular method. The standard definitions as oiven in
different international codes of practice, literature are given below:
Quality Characteristics: Quality Characteristics are parameters/properties, measured
values of which define the quality of a product i.e. material/layer/component with reference to
its functionality, reliability, usability, efliciency, maintainability, and portability.
Attributes: Characteristics that are measured as either "acceptable" or "not acceptable" are
called Attributes. Thus Attributes have only discrete, binary or integer values.
Variables: Characteristics that are measured on a continuous scale are called Variables.
Population: Population is a set of similar items or events, which is of interest for some
question or exoeriment in statistics.
Lot: In statistical quality control for road & bridge works, Lot represents population. For
example it may be a section of a particular layer of pavement made from same type of
materials and constructed on the same day.
Sample: Sample is a set ofdata collected and/or selected from a Lot by a defined procedure.
The elements of a Sample are known as sample points, sampling units or observations.
186
IRC:SP:112-20'17
Sample Space: In probability theory, the Sample Space of an experiment or random trial is
the set of all possible outcomes or results of that experiment.
Random Sampling: Random Sample is a subset of a statistical population (Lot) in which
each member of the subset has an equal probability of being chosen. A simple Random
Sample is meant to be an unbiased represenlation of the Lot. The process of selecting a
random sample is called Random Sampling.
Mean: Mean refer to a measure of the central tendency either of a probability Distribution or
of the Random Variable characterized by that distribution.
Variance: Variance measures how far a set of numbers is spread out. The variance of a
Random VariableX is the expected value of the squared deviation from the Mean.
Standard Deviation; Standard Deviation (SD, also represented by the creek letter sigma
o or s) is a measure that is used to quantify the amount of variation or dispersion of a set of
data values. The standard Deviation of a Random variable, statisticar population, data set,
or Probability Distribution is the square root of its Variance.
continuous Probability Distribution: A probability Distribution is a statistical function that
describes all the possible values and likelihoods that a Random variable can take within a
given range. lf a Random Variable is a Continuous Variable, its probability Distribution is
called a continuous Probability Distribution. The equation used to describe a continuous
Probability Dislribution is caled a probability density function (pdf). Al probabirity density
functions satisfy the conditions i.e. (i) The Random Variable y is a function of x: that is. y
=
f(x)' (ii) The value of Y is greater than or equal to zero for all values of x and (iii) The total
area under the curve of the function is equal to one.
Normal Distribution: The Normal Distribution is a probability Distribution that associates the
normal Random variabre xwith acumurative probabirity. phy;ical quantities thar are expected
to be the sum of many independent processes (such as measurement errors) often have
distributions that are nearly normal. The probability Density of the Normal Distribution is
given by:
f('lp,o,)= olf+Z1r "-'#'
Where:
is mean or expectation of the distribution
/./
o is standard deviation
02 is variance
Normal Distribution curve is flatter if variation of data from mean is more and vice versa.
Standard Normal Distribution is the simplest case where l\4ean is o and standard Deviation
is 1.
specification Limit(s): The rimiting value(s) placed on a euality characteristic around a
nominal or target value of the characteristic that may be either an individual upper or lower
specification limit, USL or LSL, called a single specification limit; or USL and LSL together,
called double specification limits. specification Limits set forth in N/oRT&H sDeciflcations
187
 IRC:SP:'112-2017 IRCiSP:112-2017

gj::9.",1j^P1d_s_9,ry:1: :l iL"pqtb"!te-code of practice in respect of additionat euatity 10.3.2 Salient Aspects of Sampling
unaracte'strcs mentioned in the Section S ofthis l\ilanual are to be
considered forthe purpose Following are the important aspects of sampling:
of acceptance.
Sampling plan has to be prepared for each Quality Characteristic.
Quality Measure: Quarity Measure is a toor used in statisticar acceptance of a materiar/
rayedcom a The purpose of acceptance sampling is to sentence Lots i.e. not to precisely

ffi:iffi:
Characteristic. There are several oualitv
estimate the Lot quality.
The most effective use of acceptance sampling is not to "inspect quallty into
"." ":y:,Jli'J';",,JifliJ;i:?:f?:A1xyl;
recent years because they simultaneously measure both the average level and the variability the product," but rather as an audit tool to ensure that the outout of a Drocess
in a statistically etficient way. conforms to reouirements.
Percentage Within Limit (pWL): pWL is th When testing is destructive, there is no substitute for sampling.
beneath the USL, or between the LSL and U Acceptance sampling often greatly reduces the amount of inspection/testing
area underthe normalcurve bounded bv error.
Mean and the Population/Sample Stand a There are risks of accepting "bad" Lots and rejecting "good" Lots.
Percentage Defective (pD): 1OO-PWL a Acceptance sampling requires rigorous planning and documentation of tne
acceptance-sampling procedure.
Average Absorute Deviation: The AverageAbsorute Deviation (or Mean
Absorute Deviation) Variables acceptance-sampling plans assume that the distribution of tne
of a data set is the average of the absoluie deviations from a cLntraifoint,
usually Mean. lt Quality Characteristic is nearly normal. Any substantial departure of the
rs a summary statistic of statistical dispersion or variability.
distribution of the Quality Characteristic from being normal, adversely
Moving Average: Moving Average (rolling average or running average) is impacts reliability of the analysis.
a calculation to
analyze data points by creating series of averages of differentiubsetJof
the full data set. lt
is also called a moving mean or rolling mean and is a type of flnite
impulse response filter 10.3.3 Lot Selection
conformar Index: conformar rndex is a measure of the dispersion ot a series Lot selection is very important so that statistical analysis of samples presents good
of resurts
around a target or specified value, expressed as the square root of approximation ofthe Quality Characteristics ofthe Lot. The following criteria shall be followed
the quantity obtained by
summing the squares of the deviations from the target value and in Lot selection for road works:
dividing by tire number of
observations. The standard deviation is a measure bf precision, but The Lot must be deflned before testing commences.
the Cl is a measure of
exactness (accuracy) or degree of conformance with the target.
The Lot may be of any size, but is restricted to a single day's production.
Prodr.rcer's Riskr Probability of the sampling and decision plan resutting
in work of a a The Lot must be homogeneous with only random variation in characteristics
satisfactory quality being rejected.
such as density, moislure content, thickness, colour and finish.
Consumer's Risk: probability of the sampling and decision plan resulting
unsatisfactory quality being accepted.
in work of an 10.3.4 Random Sampling

Operating Characteristic Curve: A curve corresponding to a particular pD. Random Sampling gives us a way to study Population characteristics without systematic
The producer bias. Random Sampling is not arbitrary sampling but there are definsd ways to do it. In simple
may.increase the probability of his work being accepteO by reducing pD.
the Conversely Random Sampling each possible Sample has equal probability of being drawn. Number of
any increase in PD will increase the probability of rejection. The rel;tionship
between the Samples to be taken from each Lot is specified in MoRT&H Soecifications and to be followed
probability of acceptance and pD for a particular quality
control scheme is referred to as its although statistical tools are available to determins sampla size for different conditions. The
OC curve.
samples are collected in a relatively homogeneous set of conditions over time/space, which
10.3 Sampling and Testing helps to separate "signal" from "noiss".
'10'3.1 statisticar quarity contror for road works invorves statisticar Lot inspection and 10.4 Fundamental Principles of Statistical Analysis
acceptance or otheMise of the Lot but not rigorous stat
industriai quality control. Like statistical analysii for any ot
in The Bell-shaped normal probability distribution curve is symmetrical about the vertical axis.
for The intersection point of the vertical axis with the horizontal line asymptotic to the curve or
road works dealwith samples lo draw inference about euaj
on the mid- point represents the mean ('p'). The area of the curve is equal to unity representing
(Lot).
probability of 1 Any value (x) of the variable can lie to the teft (negative side) or ight (positive

188 '189
 IRC:SP:112-2017
IRC:SP:112-2017

side)ofthe mean and its distance from the mean in terms of standard deviation (o) represents Area=0.8413
the deviation from the mean (e.9. 1,2 or 3o'). No deviation beyond 30 on eitherside is possible.
The area of the curve bounded by two ordinates, representing two values, and the curve
indicates the probability of the values lying between the two points (e.g. -1.60 and +1.650). Area in tail (1-
The area left in either ofthe tails beyond any ordinate indicates the probability of the variable 0.8413)=0.1s87
not having a value that is greaterthan that value (if the ordinate is on the positive side) or less
than that value (if the ordinate is on the negative side).
Normal distribution is represented by two parameters, mean and standard deviationu and o
for population orx and s for samples. Larger the value ofstandard deviation (as in the case of
population) flatter is the curve and smaller is its value (as in the case ofsamples), the sharper
it is. (See the llgure below).
1.0 z=(x-p)/a
Nonal Distribution (sample mean): i,s

The Table below presents a compiration drawn from the standard statistical rabres of the
Normal Distribution (Population): areas under the curve and the tail for various Z and their interpretation.
z= (\_rlto Area under Area under Probability Probability Interpretation
Any value X the Curve the tail excluding of x not of x lying
for difierent beyon d x= both tails exceeclng oeMeen
z (A) l+l-Zo A-B= C its pesent the two
(1-A)=B tails (%)
Area in the tail Ax 1/100 Cxli 100
0.8413 0.1587 0.6826 84.13 68.26 84 % probability that x will
not exceed mean plus o,
16% probability that it
can go as low as !- o and
Normal Distribution Curve for population and Sample mean 68% probability that it witl
lie between p +/-o
Z statistic given by (x-Uyo is an indication of the deviation of the value of the variable from
the mean. The areas bound by the ordinate at any X corresponding to the Z (or vice versa) +l64 0 9495 0.0505 0.8990 94.95 89.90 95 % probability that x
are tabulated in standard Statistical Tables. For example, for Z=1, the area is 0.8413, which willnot exceed mean plus
means the remaining area in the tail is 0.1597. The interpretation is that there is 84.13 per 1.64o,5%probability
cent probability that the given value of the variable will not be exceeded and 15.87 per cent that it can go as low
probability that it will be. lf Z is equal to -1, by symmetry it can be said that there is 84.13 as p-'1.64 o and 90o/o
probability that it will lis
per cent probability that the given value X will not fall below that yalue and 15.87 Der cent between p +/- 1.64 o
probability that it will. lf the areas in the two tails is deducted from 1, it wi give the probabitity +1.96 0 9750 0.0250 0.9500 97 50 95.00 97.50 % probability that x
of the values lying between Z=+1 and -1, which in this case is 6g.26 Der cent. willnot exceed mean plus
1.960, 2 5 % probabillty
ln statistical quality control, the objective is to predict with a certain level of confidence the
that it can go as low
probability of a value of the desired variable (a) being exceeded or falling below this value, as p-1.96 o and 95 %
or (b) the value lying within a certain range. This confidence level in Statistics is called probability that it wlll lle
'Confidence Interval'. The probability of non-occurrence of any event, as explained above between p +^ 1.96 ol
is equal to the area in the tail and that is called the 'significance level'in statistics. Two sets
of values of Z, (+/-) 1 .65 anO (+l) 1 .96 are of special importance as these relate to 95 Der
cent and 97.5 per cent Confidence Interval of any value of variable being exceeded or falLing
below that value (ref (a) above), which is the main concern in quality control.

190 '191
IRC:SP:112-2017 IRC:SP:112-2017

+2 o.9772 o o22a 0.9544 97 72 95 44 97.7 % probability that x SECTION 11

will notexceed mean plus
20, 2.23V6p t ob abilit that

it can go as low as !-2 ACCEPTANCE/NON CON FORMANCE/RECTIFICATION

o and 95.4% probability
that it will lie between p
+l-2o 11.1 lntroduction
+3 0.9998 0.0002 0 9996 99 98 99 96 100 % probability that x Any material/producvspecialized item received/manufactured at site and any work carried out
will notexceed mean plus
at site has to be finally either accepted for the work or rejected. Rejected work may however
30, 0.02 % probabilitythat
it can go as low as p-3o
be reworked to meet acceptance process. The acceptance process typically comprises of
and 100% probability that the following steps:
itwill lie between p +^ 3 o i) ldentification of Attribute as well as Variable Quality Characteristics for
The discussion so far has been on population mean and standard deviation, which refers to acceDtance
the 'lot' in this document. Samples are drawn from the lot and tested. A number of tests (say ii) Selection of Lot
6 or 8) are carried out on each set of sample and every set will throw up a sample mean and iii) Sampling
the sample standard deviation. How to predict the lot from these tests is the question. This iv) Testing
problem is solved in three steps, viz.
v) Statistical Analysis, if applicable
(i) Each test, if carried out with uniform procedure, equipment and personnel,
vi) AcceptanceiRejection
i.e. without any bias in the testing procedure, can be considered to follow a
normal distribution with the sample mean (x) and sample standard deviation 'l'1.1.1 The Quality Characteiistics of different materials/finished products/items of work
(s). At 95 per cent Confidence interval, it can be said that no test value can are given in different Sections of MoRT&H Specifications for Road & Bridge Works whereas
fall below 1.65 s some additional Quality Characteristics of factory manufactured materials; products and
specialized items are detailed in Section 5 of this lvlanual.
(i) It is an established statistical principle that the samples follow normal
distribution with samole mean and standard deviation of s/Vn. This woura 11-1.2 Guidelines for Lot selection is described in Section 10 of this lvlanual lt is also
mean that the lowest value obtained by (i) above (mean -1.65s) can further prescribed in MoRT&H Specifications for Road & Bridge Works (Section 900 for road works
go down by 1 .65s4/n. and respective sections for structures).
(ii) Thus at 95 per cent Confldence Interval the total deviation possible from 11.'1.3 Sample size is prescribed in MoRT&H Specifications for Road & Bridge Works
the sample mean is (1.65-1 .65/!n) times s. In other words, if this quantity is (Section 900 for road works and respective sections for structures). Guidelines for Random
subtracted from the sample mean, the value obtained should be more than Sampling are described in Section 10 of this Manual. Further sampling method prescribed in
the value specified for quality. respective applicable BIS/lnternational Codes of Practice for different Quality characteristics
Explanation: lf Specification requirement is compaction to 98 per cent of different materials/works shall be strictly followed.
density and the mean of 4 tests in a set of sample comes to 99 per cent with 11-'l-4 Applicable test methods for Quality Characteristics of different materials/works
standard deviation of 3, the predicted lot density will be 99 -1.65 (1- 1/14) 3, are prescribed in MoRT&H Specifications for Road & Bridge Works whereas additional
i.e. 97.525, which is less than 98 and hence unacceptable. However, if the Quality Characteristics for factory manufactured materials, products and specialized items
variability in the tests is low and s is equal to 1.5 the predicted density would are detailed in Section 5 of this Manual.
be 98.089 and the samole would Dass.
11.1.5 General aspects of Statistical Analysis are given in Section 10 of this lvanual.
Applicability of Statistical Analysis to various Quality Characteristics of different materials/
works is given in following paragraph.
11.1.6 General principles Acceptance/Rejection are detailed in subsequent
of
paragraphs, which shall be followed in conjunction with applicable provisions of l\4oRT&H
Speciflcations for Road & Bridge Works.

't92 '193
IRC:SP:112-2017
I RC:S P: 1 1 2-20'1 7

1'1,2 AcceptanceCriteria 11.2.2.2 Acceptance of additionalQualityCharacteristicsforfactory manufactured materials,

Once the test result on lhe sample of a particular material/product/work is obtained for
a particular Quality Characteristic, the following procedure shall be followed to check its
acceptance or otherwise. Wherever multipile Quality Characteristics are specified in l\.4oRT&H
Specifications for Road & Bridge Works/Section 5 of this Manual for a particular material/
producvwork, acceptance against each Quality Characteristic shall be established for final
acceptance of the material/work.
products and specialized items as detailed in Section 5 of this Manual is established if the
value of the test result is more than the specified value/less than the specified value/within
tolerance limits of the specified value as applicable to the given Quality Characteristic based
on relevant Code of Practice.
11.3 Failure to meet acceptance criteria

11.2.1 In respect of the following materials/works, statistical analysis procedure given in Whenever, a material/work does not pass acceptance criteria pursuant to Clause 11.2 ofthis
Section 10 of this l\4anual shall be applied for the euality Characteristics mentioned against Section for allthe applicable Quality Characteristic(s) as per MoRT&H Specifications for Road
such materials/works. & Bridge Works and additional Quality Characteristics for factory manufactured materials,
products and specialized items as detailed in Section 5 of this Manual, the following options
Sample are available:
sl Quality
No.
M ate ria l/wo rk Lot Size Size i) Item reworked to meel acceotance criteria: The Concessionaire/Contractor
Characteristic(s)
(nos.) may rework the materialiwork to alter/enhance its oroDerties so that the
1 Earthwork for Compaction (Field 3000 sqm but Iimited to 10 reworked item meets acceptance criteria. For example an aggregate
Embankment Density) single day's production stockpile failing gradation requirement for a particular work may be mixed
2 Sub-Grade, Lime
with aggregates of suitable size so that the blended aggregates meet
Compaction (Field 2000 sqm but limited to 10 final gradation requirements or a compacted granular base layer failing
Treated Soil for Sub- Density) single day's production compaction requirement may be loosened, mixed with additional water and
Grade/Sub-Base
re-compacted to required density. This option may not be applicable to all
3 Cement Treated Soil/ Compaction (Field 2000 sqm but limited to '10 Quality Characteristics ofa particular material/work orallthe materials/works.
Cement-Fly Ash Density) single day's production The details of materials/works to be reworked forfailing in acceptance criteria
Treated Sub-Base/ of specific Quality Characteristic(s) shall be provided in Quality Assurance
Base Plan of the Concessionaire/Contractor along with procedure for reworking.
In case of Quality Characteristic(s) of a particular material/work not included
4 Granular Sub Base Compaction (Field 2000 sqm but limited to 5
Density)
in QAP, reworking can only be done by the Concessionaire/Contractor
single day's production
with speciflc approval of Conslruction Supervision Consultanvlndeoendent
5 Wet Mix Macadam Sub Compaction (Field 2000 sqm but limited to 6 Engineer/Authority's Engineer along with procedure/methodology thereof.
Base/Base Density) single day's production t) Accepted with reduced pay factor: This option can be exercised only if
6 DBIVI & BC Compaction (Field 3000 sqm but limited to 4 specifically provided for in conditions of contract following the procedure
Density) single day's production specified therein.
400 MT but limited to iii) Re-graded for alternate use: This option can be €x€rcised only if specifically
3
single day's,production
provided for in conditions of contract following the procedure specified
therein. For example a material rejected for main carriageway may be utilized
1'1.2.2 ln respect of the other Quality Characteristic(s) of the materials/works listed in in service road after necessary correction in properties if allowed in contract.
Clause 11.2.1 than those mentioned there in and materials/products/works not listed in iv) Rejected and replaced: A material/work failing to meet acceptance criteria
Clause '11 .2.1 , acceptance is established if the value of the test results of the samDle is more shall be rejected and replaced if none of the options mentioned at i, ii & iii are
than the specified value/less than the specified value/within tolerance limits of the soecified applicable or if the reworksd material still fails to meet acceotance criteria
value as applicable to the given Quality Characteristic based on MoRT&H Speciflcations for
Applicability of a particular option to a particular material/work other than option i & iv shall be
Road & Bridge Works.
in accordance with conditions of contract if it is sDecificallv mentioned therein.
11.2.2.1 ln respect of Quality Characteristic(s) of the materials/works listed in Clause
11.2.1, acceptance is established if the mean value of all the test results of the samDle is 11.4 Protocol for dealing with non-conformance works
more than the specified value/tess than the specified value r (r.ss tne Whenever a materiali work is found to fail acceptance criteria, Construction Supervision
standard deviation (more & + if it is LSL and less & - if it is USL). -=fr*-)times Consultanvlndependent Engineer/Authority's Engineer will notify the Concessionaire/

194 195
IRC;SP:1'12-2017 IRC:SP:112-2017

Contractor of the non-conformance. Following the notice, the Concessionaire/Contractor and Annexure 11.1
Construction Supervision ConsultanUlndependent Engineer/Authority's Engineer shall follow
the orotocol as detailed below: STANDARD FORMAT FOR ACCEPTANCE/REJECTION
11.4.1 A log shall be maintained for all the NCRS. Project Name:
'11.4.2 lf the QAP indicates a plan for rectification of the particular nonconformance, Employer/ Authority:
Concessionaire/Contractor may indicate within 2 working days from the date of receipt of
non-conformance notice, its intentfor rectification to the Supervision ConsultanUlndependent lE/AE/Supervision Consultant:
Engineer/Authority's Engineer along with plan of action and time schedule for carrying out
the rectification work. Concessionaire:
11.4.2.1 Concessionaire/Contractor will complete the physical rectification works within '10
Contractor:
days from the date of receipt of non-conformance notice after which the material/work will be
subjected to acceptance tests as per Clause 11.2 ofthis Section. Date of execution/compietion :

11.4.2.2 lnaclion on the part of the Concessionaire/Contractor pursuant to Clause 11.4.2 RFI No.
& 11.4.2.1 of this Section or failure of the material/work to meet acceDtance criteria after
rectification shall make the material/work liable for rejection unless otheMise agreed to by Date:
the Engineer before the dateline.
Inspected by:
11,4.3 lfthe QAP does not indicate a plan for rectification ofthe particular nonconformance,
Concessionaire/Contractor may still indicate within 5 working days from the date of receipt of Witnessed by (Name, Designation, signature):
non-conformance notice, its intent for rectification along with methodology, plan of action and
time schedule for carrying out the rectification work. Accepted/Rejection. (comments, if any)
11.4.3.1 Engineer shall within 5 working days from the date of receipt of the proposal from
Name, Designation, signature, Date
the Concessionaire/Contractor shall either accepvreject the proposal with reasons recorded
in writing. copy
11.4.3.2 Concessionaire/Contractor will complete the physical rectification works within '1. FilelE/AE/SupervisionConsultant
10 days from the date of approval of the Supervision Consultanvlndependent Engineer/ 2. Concesslonaire/Contractor
Authority's Engineer after which the material/work will be subjected to acceptance tests as
Der Clause 1 1.2 of this Section.
3. Employer/Authority

11.4.3.3 Rejection of the proposal of the Concessionaire/Contractor by the Engineer or Standard Format for NGR
inaction on the part of the Concessionaire/Contractor pursuant to Clause 11.4.3.2 of this
Project Name:
Section or failure of the inaterial/work to meet acceDtance criteria after rectification shall
make the material/work liable for rejection unless otherwise agreed to by the Engineer before Employer /Authority
the dateline. lE/AE/Supervision Consultant

'11.4.4 All the actions taken by all the parties in relation to non-conformance works shall Concessionaire
be properly documented. Contaactor

11.5 Standard Formats Non Conformance ReDort

Inspected by: Report
Standard formats for following actions by the Construction Supervision Consultanu
Independent Engineer/Authority's Engineer are given in Annexure 11,1: (NcR)
i) Acceptance/Rejection
No.

iD NCR
RFI No. :

Conformance: I
Date I

iii) Acceptance on compliance to NCR

Non Location: Details:

196 197
 IRC:SP:'l'12-20.17

IRC:SP:112-2017
oetarted Description or N-n-ii6fiiii-
Name & Signalure NCR lssued by (Name / Designation)
NCR Category

Recommended RemedElliiii
RemedialAction Taken :

lssued Oy Name/ Oei;gnadon-TGignatuE

Completion Target Date: Witnessed by lE and Concessionaire (Name/ D"signation I Signiiie; Comptetion DiG
Copy 1-File IEiAE/Supervision Consuttahr
3.Client
Category:
1 - File lE/AE/Supervision Consultant: 2. Concessionaire 3. Ctient: 1. Safety Arrangements Minor /Major
2. Defeclive Concrete works Minor/Major
1. Satety Arrangements
3. Defective Road Works Minor/Majo,
2, Detective Concrete works Minor /Major 4. Tests not conducted as specified Minor/Major
3. Defective Road Works Minor /Major 5. Check lists and records not authenticated Minor /Majoj
4. Tests not conducted as specified Minor /Major 6. Non.compliance with specifications and Major
standards
Minor /Maior
5. Check lists and records not authenticated 7. Non.coInpliance with Recommendations
Minor/Maiot
6. Non-compliance with specifications and standards 8. Product nol to acceptable standards Major
Major
7. Non.compliancewith Recommendations (Requi.es rejection). Ma.io.
Major
8. Product not to acceptable stahdards. (Requires
rejection).

Slahdard Format for Acceptance

on Comptiance to NCR
Project Name :

lE/AE/Supervision Consultanl
Concessionaire
Conlractor

Corective Action Ta kdiepdrt-

Inspected by :
Ref. Report (NCR) No.

Non Conformancel

Deta ited Description of N-n=to-i6rm-iii-

199

IRC:SP:1'l2-2017
SECTION 12
THIRD PARTY QUALITY AUDIT
12.1 Audit- Objectives and Principles
Audlf is defined in ISO 9000-2005 as "Systematic, independent and documented process for
obtaining audit evidence and evaluating it objectively to determine the extent to which audit
criteria are fulfilled". Audit criteria and audit evidence are defined as follows:
Audit criteria: Set of policies, procedures or requirements used as a reference against which
audit evidence is compared.
Audit evidence: Records, statements of fact or other information, which are relevant to the
audit criteria and verifiable.
The principles of auditing should ensure thatan auditisan effective and reliable toolin support
of management policies and controls, by providing information on which an organization can
act in orderto improve its performance. The principles as outlined in ISO 19011:2011 include
the following:
. Integrity
. Fair presentation
o Due professional care
. Confidentiality
. Independence
. Evidence-basedapproach
Scope ofAudit is wide and varied. lt applies to several management systems of an organization
either individually or jointly. Audit is broadly classified into 3 types i.e. First Party Audit (the
organization audits its own systems to measure the strengths and weaknesses of the
managemenl system against the system requirements), Second Party Audit (the customer
or client audits the facilities of the organization with which it has a contract to supply goods
and services) and Third PartyAudit (carried out by an independent organization generally for
the purpose of certification). Whereas the First PartyAudit is an internal process, the Second
Party Audit and Third Party Audit are external.
12.2
Third Party Quality Audit of Road Projects- General Overview
Whereas quality audit applies to severalmanagement systems ofa Concessionaire/Contractor
organization in implementation of a pOect, third party quality audit is generally carried out
by an organization independent of the project implementation agencies i.e. Concessionaire/
Contractor, Supervision ConsultanUlE/AE and Employer/Authority. A Third Party Quality Audit
is a review by an independent entity (a separate firm/group of experts) of how well the key
areas of a project quality plan is being followed and whether it's efiective in getting the quality
results originally envisaged. lt is a value addition to the project and not just fault finding
with the contractor. Normally audit scope covers safety adherence, occupational health and
environmental compliance of the project apart from quality of works.
IRCiSP:112-2017
12.3 Selection of Projects for Third Party Quality Audit
Employer/Authority shall take a decision on case-to-case basis for Third Party Quallty Audlt
of a road project depending upon its size and complexity. However, projects fulfilling any or
all of the following criteria may be considered for Third Party Quality Audit:
i) Projects costing more than Rs. l ooo crore (cost of civil works at 2016 pricss)
ii) Projects involving tunnel
iii) Projects involving at least one bridge having individual span length more
than 1Oom or total bridge/viaduct length more than 2000m
iv) Projects involving cable stay/suspension cableiany other innovative bridge
deslgn
12.4 Scope of Third Party Quality Audit
Scope of Third Party Audit for a typical road project is given in Annexure 12.1 Scope may
be modified considering complexity and special features of a particular project lf road safety
auditor is engaged for a project, scope of Third Party Audit shall be suitably modified to
exclude safety related issues. Third Party Quality Audit shall cover physical verification of all
major items ofwork. lnception Report shall list all such items The Quality Characteristics of
a particular item of work and sample size for physical verification shall also be ldentifled in
Inception Report.
12.5 Audit Team
Typical composition of the TPA team and qualification and experience of the TPA team
members is given in Annexure 12.1. Depending upon size and complexity of the project,
composition of the team and qualiflcation and experience of the members may be modified'
Two requirements which are critical for meeting objective of Third Party Audit are (i) integrity
of the team members and (ii) independence of the team. The bid documents for selection
of consultant for TPA shall make adequate provision to prevent the experts with doubtful
integrity from being selected. Further to ensure independence of audit team from any
undesirable influence of the representative of [Employer/Authority] in charge of a particular
project, selection of the consultant for TPA and administration of its contract shall be done by
a special cell or Hqs of the EmployeriAuthority
12.6 National Level Project Monitor
MoRT&H has empanellediin the process of empanelment of some retired Govt. officers in
the rank of Superintending Engineer and above as National Level Project Monitor (NLPN'4) to
examinee issues such as inferior quality works, delay in completion, inadequate provisions
in the project & poor services by the concessionaire and suggest remedial actions for them'
Although exact scope of services of NLPMS shall be as per relevant guidelines/circular of
[,4oRT&H, the aspects related to Quality Control shall be similar to what prescribed in this
Section for Third Party Audit.
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lRCtsPill2-2017
Annexure 12.1
STANDARD TERMS OF REFERENCE FOR THIRD PARry
QUALITYAUDIT OF HIGHWAY PROJECTS
1. Brief overview of the Project
(Give brief features of the pOect such as location, terrain, scope, cost, mode of contract,
particulars of Employer/Authority, Concessionaire/Conkactor, lE/AE)
2. The Consultancy Services ("The Services") include conducting Third party Audit
as outlined hereafter. [Employer/Authority] intends that periodic euality Auditing are carried
out by a third-party to enable the Employer/Authority assess crjtically the in-place quality of
the project. Third Party QualityAudit is required to be carrjed out once every six months over
a period of.....months. The audit will be comprehensive, and include examination of the
quality ofworks executed and services carried out, compliance of road and bridge works with
the technical specifications and standards described in the contract documents, comoliance
ofsocial and environmental safeguards, compliance of safety requirements and furnishing of
recommendations for improvements in quality ofthe project and project implementation as a
whole.
3. Employer/Authority invites bid offers from consulting firms hereinafter to be called
Third Party Auditor (TPA) to assist it in auditing quatity of the project. The TpA sha inctude a
team ofqualitied and experienced technical and other experts to be able to satisfactorily fulllll
the objectives of the Audit.
4. Project Familiarization
The TPA should clearly understand the scope and complexities of the project by studying all
contract documents including drawings, specifications, materials reports and conditions of
contract. The TPA shall visit the project site to acquaint himself with the ground conditions.
A report in the nature of a Project Familiarization shall be submitted within 2 months of
commencing the assignment.
5. Scope ofthe Consultancy Services
5.1 The objectives ofthe Consultancy Services are to:
(i)
Verify if the quality of the Works are consistent with contract conditions
as well as technical specifications including compliance to the social and
environmental safeguards, occupational health and safety requirements
by independent assessment / audit of quality of works at various stages of
construction: and.
(ii)
ldentify and recommend improvements to achieve the quality.
5.2 Tasks to be performed by the TPA
The TPAwill undertake the following tasks but not limited to it. TpA may suggest improvement
over the seryices mentioned here below without any additional burden to Employer/Authority.
202
IRC:SP:1'12-20'17
5.2-1 Task 1: Technical Examination of Works
a) The TPA shall verify the adequacy of the Contractor's field laboratories,
plant, equipment and personnel and general fitness for purpose of such
inputs, including the accuracy/calibration of testing equipment used for
measurement.
b) The TPA shall review the Contractor's working practices e.g. material receipt'
storing, consumption procedures, material testing, construction methods,
and documentation system to assess whether sound practices are being
employed to achieve quality.
The TPA shall review degree of quality control exercised during the
construction by the Contractor (tests, numbers, frequency, approach'
timing etc.) and documentation (QC registers, test reports' observations of
supervisory staff, compliance etc) to assess whether the same is compliant
to technical specillcations.
d) The TPA shall review Contractor's plan and actual practices with respect to
social and environmental safeguards, safety measures, working conditions,
and employment legislation as stipulated under the contract and relevant
national and state laws/regulations.
The TPAshallverifywhetherthe quality of Works is in accordance with contract
sDecifications. This verification is to be implemented through independent
materials testing of at least 75% BOO items using a sample size, which
needs to be approved by the Employer/Authority Verification shall include
surface profile in case of different layers of roadway and deviations from
dimensions in case of embankment, pavement and structures. The TPAshall
verify actual implementation of EMP and carry out safety audit (both design
and construction stage).
The TPA shall prepare lnspection Test Plans (lTPs), to be agreed with the
Employer/Authority that set down the timetable and method fof performing
field inspections The formats to be used in this assessment shall be provided
in the Inception Report.
quality
s) The TPA shall audit and assess the Supervision Consultant's/lE/AE
control oractices and documentation thereof.
n) The TPAshall undertake follow up visits on a sample basis with prior intimation
and approval of the Employer/Authority to verify actual compliance with
previously identified quality enhancement measures and recommendations.
5.2.2 Task 2: Training
The TPA shall provide on the job training to PIU staff on quality control procedures, safety
and environmental management etc.
o, The above assessments/information should be presented to the Employer/
Authority as a summary report biannually highlighting the following:
i) Oualitv enhancement measures
203
IRC:SP:112-20'17
IRC:SP:112-2017

ii) Clear recommendation, if any Work is to be rejected/regraded for use

'11. Deliverables and Payment Schedule
6.'l The Final Audit should commence at least six weeks before issuance of the The payment schedule will be based on the outputs delivered as shown in the following Table:
Substantial Completion Certificate/provisional COD is due.
st. Deliverable Schedule of Payment Remarks
7. Confidentiality No. Submission from Schedule (in
The TPA by virtue of their scope of work wi come in contact with severar confidential the start date % to the total
documents and their recommendations may have financial and legal implications. lt is, Value)
therefore, essential that the TpA and its experts wi exhibit and enaure highest sense of 1 Inception Report Three weeks NI A mobilization
probity and integrity apart from knowledge and experience and maintain
strict confidentialitv.
from date of advance of 10 per
commencement of cent will be provided
8. Time frame services on request of
The TPA consultancy services wiI be for .......months. The expected date of commencement TPA against Bank
of Services is....... Guaranlee

9. Organization
2 Six monthly Audit Within 14 days 70% equally In case of extension
Reports from the date of distributed among ofcontract period,
The TPA should have the capability to carry out the job on its own strengths (in terms of completion of audit total half yearly each half yearly
skilled manpower, equipment, technical skills etc.) with adequate logistrcat support at the payment to be
project location. To ensure that rpA objective is duly carried out, the organization suitably adjusted
should
have carried out at least lwo assignments of similar nature in the last 3 years. 3 Draft Final Audit Within 14 days 15%
10. Reporting Requirements
Report from the date of
completion of audit
The TPA shall furnish its reports in soft and 3 hard copies. The TpAshall submit the followino
FinalAudit Report Within 21 days 15%
documents in pursuance of its services:
from the date of
i) lnception Report (lR) containing the approach, methodology, audiVmonitonng compliance of draft
formats, etc. The report should contain a flow chart indicating the inputs / Final Audit Report
outputs by stages and type of work. The tR sha be submitted within 3 (three) findings bythe
weeks from the date of commencing the services. The TpA shall make a Concessionaire/
presentation to the Employer/Authority and modify the contents, ifsuggested Contractor
by Employer/Authority. 12. List of Key Experts
iD Six monthlyAudit Report and drafr FinalAudit Report within 14 davs from the List of Key Experts required in the TPA team are given below along with their indicative man
date of completion of audit month for a 30 months period contract. The requirement may be modified for a particular
iD FinalAudit Report within 21 days from the date of compliance of draft Final contract keeping in view contract period, size and complexity of contract.
Audit Report findings by the Concessionaire/Contractor Position Number Period of
iv) TPA shall make a presentation to the Employer/Authority in presence of deployment
(months)
Concessionaire/Contractor and Supervision ConsultanVlE/AE.
Team Leader cum Sr. Highway Engineer 10
Senior Bridge / Structural Engineer 3
Senior l\.4aterial Engineer cum Pavement Specialist 3
Environmental Specialist 2
Road Safety Expert 2

204 205
IRC:SP:112-2017
13. Qualification / Experience ofthe Key Experls
These are senior positions calling for a very high level of probity in quality auditing. The
qualification and experience requirement of key experts is given below:
Team Leader Cum Senior Highway Engineer:
The expert should be a graduate civil engineer preferably with master degree in construction
managemenvtransportation/highway engineering. Sound knowledge in construction and
quality management practices is preferred. The overall experience should be more than 15
years in highway construction He should have experience in third party quality auditing of
at least t highway project of Rs. 200 crores magnitude at 20'16 prices. Experience in having
established Quality Control, Quality l\y'anagement Systems in large sized highway projects will
be essential.Agood understanding ofthe contractual relationships between Concessionaire/
Contractors, Supervision Consultants/lE/AE and Employer/Authority is necessary
Senior Bridge / Structural Engineer:
The expert should be a graduate civil engineer with master degree in structural/bridge
engineering with 10 years of post- qualification experience in bridge construction/rehabilitation.
Experience in quality control and quality assurance of bridge construction aspects such as
foundation, formwork, launching, specialized components such as bearings, expansion joints
etc. is essential.
Senior Material Engineer cum Pavement Specialist:
The expert should be a graduate civil engineer. He should have minimum 10 years of post-
qualification experience in quality control/quality assurance. He should have thorough
knowledge of relevant codes of practice for testing of different materialsifinished products,
testing apparatus, calibration, sampling, testing, recording test observations in proper formats
and determination of test results. He should have good knowledge in pavement construction
orocess, compaction, proflle and pavement performance.
Environmental SPecialist
The Environmental Expert must possess degree in environmental engineering/science
or master degree in natural science. He should be familiar with national environmental
regulations and guidelines of Ministry of Environment & Foresls and Climate Change, Govt.
of India. He must have at least 5 years of relevant experience, with minimum 3 years of
experience in highwayi linear projects in India
Road Safety Expen
The Road safety Expert must have a degree in civil engineering. He must have either post
graduation in trafficltransportation engineering or a certified road safety auditor course. He
must have 1O years of experience in highway projects involving highway geometrics design,
traffic studies, road safety analysis intersection layout and design. He must have done road
safety audit of at least 3 road projects involving deslgn stage, constfuction stage as well as
operation stage and should have reviewed and audited the road safety matters.
206
IRC:SP:112-2017
14- Duties ofthe Key Experts
The duties of the key experts are broadly mentioned as follows:
Team Leader Cum Senior Highway Engineer:
Team Leader will remain overall charge of planning the activities, checking adequacy of
Quality Assurance Plan of Contractor, determining sample sizes of different items, monitoring
of activities of other key experts, scrutiny of test results produced by other key experts,
preparation of reports and presentation before the Employer/Authority. As senior highway
engineer, he will also personally remain responsible to check geometrics, verify all survey
records, checksurface profile and all other aspects not covered by other key experts.
Senior Bridge / Structural Engineer:
His duties will involve verifying working drawings of bridges/RoBs/flyovers and culverts with
respect to contract drawings/schedules, verifying the as built features of foundation with
reference to working drawings and actual bearing capacity of soil, verifying pre-stressing
schedule, checking dimensions, checking the adequacy of form-work etc.
Senior Material Engineer cum Pavement Specialist:
Senior Material Engineer will check adequacy of Quality Assurance Plan of the Contractor,
adequacy of site laboratory, ability and expertise of quality control personnel, calibration
details of equipment, testing records etc. He will also carry out physical tests on samples
including destructive and nondestructive tests on completed works.
Environmental SDecialist
Environmental Expert will review the records related to fulfillment of Environmental
l\y'anagement Plan of the project, will carry out review as per the environmental regulations/
conditions to environmental clearance and forest land diversion relevanl to the project. He
will also make sample check of above compliances and those relating to social safeguards.
Road Safety Expert
Road Safety Expertwillcarry out safety auditof sample critical components based on accident
records/blacklists.
15. Data, services, and facilities to be provided by Employer/Authority:
Apart from quality control and quality assistance records maintained by the Contractor
and Engineer, copies of the civil works contract agreements and contract agreement with
Suoervision ConsultanvlE/AE will be made available to the TPA.
207
 IRCiSP:112-2017
sEcTtoN 13
SAFEry HEALTH AND ENVIRONMENT
13.1 Introduction
Road construction has signiflcant impacts on nearby communities, their health and safety
as
wellas the natural environment. people and properties may be in the direct path ofroad works
and affected in a majorway. Peopre may arso be indirecfly affected by construction, through
the
disruption of livelihood, ross of accustomed traver paths and community rinkages, incriases
in noise and pollution, and more road accidents. Disturbances to the naturai environment
may include soil erosion, changes to streams and underground water, and interference with
natural habitats and prant life. euality in safety, Hearth and Environment at work praces is
therefore of paramount importance to the nearby communities, road users and construction
workers during construction stage. These factors also impact nearby communities and road
users post construction. Therefore, a set of guidelines has been given in this section to
ensure quality in safety, Hearth and Environment at work places. lt is further established that
better care for safety, Health and Environment at work places automatically enhances quality
in road construction.
'13.2 Transportation Planning & Health
Transportation planning can affect human health, either positively or negatively, in several
ways. For example:
Safety: Motorvehicle crashes area leading cause ofdeath. Effective safetv measures
and responsible behaviors by all road users can reduce the number of
fatalities and injuries. This is particularly important for vulnerable road users
like pedestrians, bicyclists, children, differenfly abled persons and senror
citizens.
Ai Quality: Transportation planning that reduces vehicle emissions improves air quality
for everyone. On the other hand improper planning and or implementation
during construction stage deteriorales air quality during construction/
operation stage.
Noise; Alternatives can be designed to reduce noise and thereby prevent or reduce
adverse health effects like hearing loss, sleep disturbances, cardiovascular
problems, performance reduction, annoyance responses, ano aoverse
social behavior - all of which are associated with exposure to varying levels
of noise.
Transportation Planning and designing should take into account the above considerations
for better health of society. Some of the aspects are also relevant during construction
stage.
13.3 Safety, Health & Environmental Safeguards During Construction
Following are a set of suggestive actions for the Contractor during construction stage to
safeguard safety, health and environment:
208
IRC:SP:112-2017
13.3.1 General
The contractor which includes its Sub-Contractors and any other agency/person engaged
by it shall be deemed to have acquainted himself with the requirements of all the prevalent
statutes, ordinances by laws, rules, regulation or their instruments having the force of law
in India including without limitation those relating to protection of the environment, health
and safety, importation of labour, demolition of houses, protection of environment and
procurement, transportation, storage and use of explosives, etc.
13.3.2 SiteRequirements
r) The co ntractor will not carry out any work on the site otherthan that necessary
for the completion of the contract.
ii) The contractor will provide and maintain barriers fencing and lighting around
the site and wherever necessary for the safety, security and convenience
of the public including traffic on road and as otheMise needed to sult his
working methods and timings.
iii) The contractor will provide and maintain all necessary temporary buildings
including, office sheds, stores, storage areas, explosive magazines and
water storage tanks without limitation.
iv) Contractor will be responsible for the provision and maintenance of all site
services necessary for the execution of the works including, provision of
electricity, water, and site communication facilities.
v) Contractor will maintain the site in safe, clean, tidy and sanitary condition.
Contractorwill also be responsible for cleaning allgeneral rubbish and waste
from whatever source generated during execution of the works.
13.3.3 Safety and Health
i) Near towns, villages and all frequented places, trenches and foundation pits
shall be securely fenced, provided with proper caution signs and marked
with lights at night to avoid accidents. The contractor shall take adequate
protective measures to see that the excavation operations do not affect or
damage adjoining structures. For safety precautions' guidance may be taken
from lS: 3764.
ii) The contractor shall not use or generate any materials in the works, which
are hazardous to the health of persons, animals or vegetation
iii) The contractor will take all measures necessary to safeguard the safety'
health and welfare of all persons entitled to be on site and will ensure that
works are carried out in a safe and efficienl manner.
iv) The contractor will provide, and ensure the utilization ofappropriate personal
protection equipment for allworkmen and staffemployed directly or indirectly
by the contractor. Such equipment will include but not be limitsd to the
safety helmets, goggles and other eye protectors, hearing protectors, safety
harnesses, safety equipment for working over water, rescue equipm€nt' fire
209
IRC:SP:1'12-2017
IRC:SP:112-2017

u) exfinguishers and firsf3id equipment.

locations at site will I
The personnel worKrng at vutnerable
"""'Tiiei;,F;:#il1,:ffi.1",#:::;,":;;
he site where work is in progress
and ensure thai
xt) Wherever traffic diversions, warning signs, traffic control signals, barriers
and the like are required, the contractor will install them to the satisfaction of
Employer/Authority prior to commencing the work, in that area.
xiii) Contractor will install asphalt plants and other machineries away from the
ano matntained in a hygienic condition.
populated areas as per laid down regulations.
13.3.4 protection of Environment
j) The contractor will take all nece
13.3.5 Traffic Safety and Contrcl in Works Zone
rha ay6^,,1i^^
rher the
that __, and "---v w s.v
:""?,y-reasures and precautions
v'euauuurrs alro
and ensure All traffic safety and control measures shall be pursuant to IRC:Sp:55.
^..,^..works
execution ofthe a'lr associated operations on site
D
ere carried
are rarria.t out
^,,r in ^^- __a
i- con ..,
rmitv with !
rrc ur
or urrsrte
offsite ii) The Contractor shall take all necessary measures for the safety of traffic
ra.flrirahahlcin^r,i,,^^.L_-- .;tatutory and regulatory environmental
requirements inctuding tno"j pru."rib;Jin
iilp during construction and provide, erect and maintain such barricades,
ii) including signs, marking, flags, lights and flagmen as may be required by the
]l:,::::r::"r.*'1,
or l"ke a measures.and precautions to avoid any nujsance
otsturbance to inhabitants Engineer for the informalion and protection of traffic approaching or passing
arising from the execution of works.
through the section of the project road under improvement. Before taking up
iiD All liquid waste products arisino on t h::it""
will be collected and disposed
of at a t.r,ri^n ^i_-
or off the s-ites,;; ;';;;;;, ;;;fi any construction, an agreed phased programme for the diversion of traflic or
:H:":"*T:L
nuisance nor pollution. ;:fr:,;::;:: closure of traffic on the highway shall be drawn up in consultation with tne
EmployeriAuthority.
rv)
existing water bodies and drarns iii) At the points where traffic is to deviate from its normal path (whether on
and free from any contaminahon. temporary diversion or part width of the carriageway) the lane width path for
v)
system traffic shall be cleady marked with the aid of pavement markings, painted
scnarge drums ora similar device to the directions ofthe lE/AE/Supervision Consultant.
rk on its At night, the passage shall be delineated with suitable light source.

vi) Th^e contractor wifl arrange afl the equipment

iv) One-way traffic operation shall be established whenever the traffic is to be
in good condition to minimrze passed over part ofthe carriageway inadequate fortwo-lane traffic. This shall
oust, gaseous or other air_borne emtsstons
and carry out the works in such be done with the help of temporary traffic signals or flagmen kept positioned
mpact on air. on opposite sides during all hours. For regulation of traffic, the flagmen shall
vii) be equipped wilh red and green flags and lanterns / lights.
v) On both sides, suitable regulatory / warnings signs as approved by the lEi
AE/Supervision Consultant shall be installed for the guidance of road users.
On each approach, at least two signs shall be put up, one close to the point
where transition of carriageway begins and the other j2O m away.
measures to ensure that the operation vi) Signs, lights, barriers and other tratfic control devices, as well as the riding
ndition processes on and off the site surface of diversion shall be maintained in a salisfactorv condition till such
r.excessive noise, taking into account time they are required as directed by the Engineer. The'temporary traveled
nts_ way shall be kept free of dust by frequent applications of water, if necessary
ix) The contractor will take necessar! measures
equipment in good condition. 'r
to maintain all plant and 13.4 Quality Process to take care of Safety & Environment
x) Quality assurance planning should duly consider the nuances of safety and environment
Hj"",1",*^:::."^lPl ?j,tf" y9rt" requires temporary crosure of road
to aspects of the poect and make due provision for ensuring safety of all stakeholders and
:",fl:Ji:,f
s,ubject i:,^":i yll p..ld" ""o,"i"Li" i"i.'p",il
to the approval of the Employe/Authority.
A;; ;#:lJ: preserving environment. Similarly during actual quality control exercises, due attention shall
xt) Where the execution of the works re be given to ensure that construction zone safetv requirements are not violated.
single lane operation on public
road the .:.)nrr,^r^r ,^,i[ ^.^.,,!^ ^-_ _]!y'r,":
.:'.1,1"'i:,"::[T:"i"y,1,
sisns and traffic controt 11::l],: r1l :lr:i;ii;"#;#ffi;:1,11?l;
saii;iil;;il;iffi;;hffi:;ll:
sisnats to the

2't0
21'l
(The Official amendments to this document would be published by
the IRC in its periodical, 'Indian Highways' which shall be
considered as effective and as part ofthe code/guidelines/manual,
etc. from the date specilied therein)