QAP 31-01-2020 Silchar Project

QUALITY ASSURANCE PLAN
Name of Work: Strengthening of 2 lane with paved shoulder of NH-54 from

12th km to 40th km under Annual plan for the year 2018-19 under EPC mode
under PWD, NH Division, Silchar in the state of Assam
: EPC CONTRACTOR:
UCN Construction Company Pvt. Ltd.
Century Plaza, 3rd Floor, Ganeshguri
Assam, Pin-871005
CONTENTS
PAGE NO.
1. Purpose 1
2. Policy Statement 5
3. Project Organization (Flow Chart) 6
4. Project Organization (Duties and Responsibilities) 9
5. Project Control and Administration 11
6 Document Control 12
7. Control of Materials 18
8. Methodology of Working, Test and Inspection Plan 24
9. Calibration 34
10. Quality Audits 59
11. Safety 64
Appendix – I – List of Equipment to be provided in the site laboratory 65-66
Appendix – II – Quality Control Tests and acceptance criteria 67-94
Appendix –III – Quality Control Procedure
Appendix – IV – Design Quality Plan
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1. Purpose
Name of work: Strengthening of 2 lane with paved shoulder of NH-54 from 12th
km to 40th km under Annual plan for the year 2018-19 under EPC mode under
PWD, NH Division, Silchar in the state of Assam.
This project specific quality plan is prepared to systematize all activities
associated with planning, design, construction, quality control and quality
assurance and thus meet the requirements of contract between Ministry of Road
Transport & Highways and UCN Construction Company Pvt. Ltd. Century Plaza,
3rd Floor, Ganeshguri, Assam,
1.1. Scope
Contents of this document are applicable to all works to be carried out by UCN
Construction Company Pvt. Ltd. like, engineering, procurement, construction,
calibration, testing for the following activities
• Design works including preliminary survey and investigation
• Temporary works for crusher, hot mix plant, services detour, temporary detour,
etc.
• Construction of embankment/subgrade
• Dense bituminous macadam, Bituminous Concrete
• Road marking
• Road furniture
• Lighting
• The scope will be updated as required
1.2. Reference and Applicable Documents
The following documents are referred while preparing the project quality plan:
• Contract documents, specifications and drawings.
• General specifications for roads and bridges issued by MOST.
• Indian standard codes, as applicable.
• IRC - codes of practice as applicable.
1.3. Definitions
In the context of this document the following abbreviations, words or phrases
shall be taken to have the meanings assigned to them:
• Client --- Ministry of road transport & Highway (The Authority)
• Contractor --- UCN Construction Company Pvt. Ltd.
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• Authority’s Representative – Chief Engineer, P.W.D. NH Works, Assam,
Chandmari, Guwahati–3
• Authority’s Engineer: Chief Engineer, P.W.D. NH Works, Assam, Chandmari,
Guwahati–3
Sub-contractor - agencies/piece rate workers engaged by the Contractor for
carrying out temporary or permanent works under supervision or management of
the Contractor. List of subcontractors will be submitted separately as per
requirement for approval from the Authority.
Vendor - any person, agency, firm or company contracted to supply material or
provide service in connection with this project. List of vendors will be submitted
separately as per requirement for approval from the Authority.
Quality - the totality of features and characteristics of a product or service that
relies on its ability to satisfy stated or implied needs.
Quality Assurance - All those planned and systematic actions necessary to
provide adequate confidence that a product or service will satisfy given
requirement for quality.
Quality Control - Operational techniques or activities (e.g., inspection or test)
used to verify technical and quality requirements for services and or products.
Quality Audit - A systematic and independent examination to determine whether
quality activities and related results comply with planned arrangements and
whether these arrangements are implemented effectively and are suitable to
achieve objectives.
Quality Plan - A document setting out the specific practices, resources and
sequences of activities relevant to a particular product, service, contract or
project.
Procedures - A documented description of me method to be adopted in
performance of a given task and where applicable, accept or reject criteria for
that task.
Inspection - Activities, such as, measuring, examining, testing, gauging one or
more characteristics of a product or service and comparing these with specified
requirements.
Non-conformity - Non fulfillment of specified requirements,
Corrective Action - An activity the intention of which, is to return a non-conforming
item or action to a state or conformity. It also covers action taken to prevent
further recurrences of non-conformity.
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Concession - A formal approval by appropriate agency to authorize a deviation
from the specification or design which does not affect the final function of the
proposed specification or design.
Repair - The process of restoring a non-conforming characteristic to a condition
such that the item conforms to the original specified requirements, where such a
repair or restoration is acceptable.
Inspection - A documented procedure showing systematic inspection and tests
relating to a product and indicating the agreed inspection and hold points for the
interested parties.
Hold Point - A state in the production cycle where inspection and/or tests are
performed to determine the acceptability of the item for further processing.
Witness Point - A stage in the production cycle, when third party inspector,
contractor or company representative, witness any inspection or test to determine
the acceptability of an item for further processing.
Calibration - A comparison of two instruments, measuring devices or gauges
(gauges in this sense will include manufacturing jigs and fixtures) one of which is
of known accuracy and where applicable, traceable to an internationally
recognized standard.
Non-Destructive Examination - The means by which the integrity or conformity of
an item has to be assessed without resorting to destructive analytical procedures.
1.4 Class of Quality Assurance: This Quality Assurance plan is prepared
based on Q-3 class of quality assurance which is applicable to projects as
following situations:
a. National Highway and State Highway
b. Coastal Roads
c. Road in High Altitude.
d. Roads in High rainfall areas (average over 2000mm)
e. Large size projects on major District Roads.
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POLICY STATEMENT
2. Quality Policy
Name of work: Strengthening of 2 lane with paved shoulder of NH-54 from 12th
PWD, NH Division, Silchar in the state of Assam It is the policy of UCN
Construction Company Pvt. Ltd. to clearly define and meet quality requirements
and to actively promote continuous improvements in all aspects of the works. Our
quality objectives are:
• Consistently achieve compliance with all contractual and environmental
requirements.
• Achieve customer satisfaction.
• Implement departmental procedures consistent with the international standard
requirements.
• To continually evaluate the quality system, seeking further improvements
through regular assessment and review.
Authorised Signatory Date:
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3. PROJECT ORGANISATION
3.1 Various activities on this EPC project can be classified under four groups.
(1) Design
(2) Construction
(3) Manufacturing
(4) Operation and Maintenance
3.2 In design activity, the contractor appoints a Design Director as per Clause 10.
1.1 (b) who will head the Contractor’s design unit and shall be responsible for
surveys, investigations, collection of data, and preparation of preliminary and
detailed designs.
The Contractor shall appoint a proof check consultant (the “Proof
Consultant”) after proposing to the Authority a panel of three names of
qualified and experienced firms from whom the Authority may choose one to
be the Proof Consultant. Provided, however, that if the panel is not
acceptable to the Authority and the reasons for the same are furnished to the
Contractor, the Contactor shall propose to the Authority a revised panel of
three names from the firms empaneled as proof consultants by the [Ministry
of Road Transport and Highways] for obtaining the consent of the Authority.
The Contractor shall also obtain the consent of the Authority for two key
personnel of the Proof Consultant who shall have adequate experience and
qualifications in highways and bridges respectively. The Authority shall,
within 15 (fifteen) days of receiving a proposal from the Contractor
hereunder, convey its decision, with reasons, to the Contractor, and if no
such decision is conveyed within the said period, the Contractor may
proceed with engaging of the Proof Consultant.
The Proof Consultant shall:
(a) evolve a systems approach with the Design Director to minimize the time
required for final designs and construction drawings; and
(b) proof check the detailed calculations, drawings and designs, which have
been approved by the Design Director.
Works shall be executed in accordance with the Drawings provided by the
Contractor in accordance with the provisions of this Clause 10.2 of the
Contract agreement and the observations of the Authority’s Engineer thereon
as communicated pursuant to the provisions of Clause 10.2.4 (d) of the CA.
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3.3 Under the construction activity, The Contractor shall construct the Project
Highway as specified in Schedule-B and Schedule-C, and in conformity with the
Specifications and Standards set forth in Schedule-D of the contract agreement.
The Contractor shall construct the Project Highway in accordance with the
Project Completion Schedule set forth in Schedule-J.
3.4 Manufacturing activities fall under the following two categories. '
The first category consists of factory manufactured item for general use,
like, aggregates, cement, bitumen/bitumen products, reinforcement, etc. Quality
assurance for manufacture of these items need not be covered under the Quality
Assurance Manual for Roads.
However, the requirements of quality system pertaining to the
specifications of quality, testing and acceptance procedure, procurement,
storage, traceability and such other relevant items, which are to be carried out by
owner/designer/contractor, should be covered therein.
The second category of manufactured items cover chain link fencing, road
markers, lane dividers, lighting masts, energy absorbing terminals, road signs,
etc. manufactured by specialist suppliers and are purchased for use as finished
products by the contractor. The quality assurance manual should cover the
quality assurance of such items.
3.5 Based on the activities involved in the EPC contract agreement, the
contractor proposes the following organization structure for the execution of the
project. A separate QAP manual (or Maintenance Manual) as per clause 10.7 of
the Contract agreement will be submitted for Operation and Maintenance on
declaration of the commercial operation date of the project.
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ORGANISATION OF THE CONTRACTOR FOR CONSTRUCTION WORKS
MANAGEMENT
Management Representative
(HO-QA Cell Implementation of Project Manager
Quality Policy and Review
Quality Audit Project Engineer
HR & Safety Construction Plant and Design Director, Q A Engineer

Engineer Engineer Equipment Proof Consultant
Engineer and Safety
Consultant
Planning Material Engineer Special Agencies

Engineer like Quality
Survey,
Environment etc.
Notes:
(1) The organigram indicates levels of responsibility in four rows. The lines of reporting for execution of work and responsibility for quality are shown by full lines and arrowheads. Working
level interactions are indicated by dotted lines. The decisions concerning relative priorities, and about differences
between equal levels are to be taken at higher level of responsibility.
(2) the responsibilities shown in each box has separate group of personnel with group head.
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4. DUTIES AND RESPONSIBILITIES
4.1 Duties and Responsibilities: The Duties and responsibilities of various levels of
the organigram are as follows:
4.1.1 Management, Project Manager and Management’s Representative:
(i) Management of the Quality Policy
(ii) Qualified and experienced technical work force and deployment of trained
supervisors/workmen in adequate strength.
(iii) Preparation of Quality Assurance Manual including provision for quality
audit.
(iv) Mobilization of adequate resources including suitable plant and equipment.
(v) Continuous planning, review and corrective action
(vi) Adequate financial input including cash-flow and fund management.
(vii) Prequalification of sub-contractors/suppliers.
4.1.2 Project Manager
• Reports to Senior Management.
• Liaison with other associated agencies or departments as applicable.
• Implements the project quality plan.
• Ensures harmonious interfaces between all sections in the organization. '
• Responsible for quality, process and cost.
4.1.3 Project Engineer: The Quality Control of the project is headed by the Project
Engineer. His roles and responsibilities include:
• Responsible for checking that the project is executed to the approved quality
standard as specified in quality plan
• Responsible for checking any abnormality from inspection report to carry out
rectification or give alternative solution.
• To ensure that further processing of non-conforming area is withheld till the
conformity is rectified.
• To highlight reasons of any failure in maintaining quality on work site
• To ensure that recurrence of nonconformity is prevented through an efficient
control system
• Responsible to control quality related activities of all working agencies (Sub
Contractor) engaged on site.
• To check record of certificates for consumables used.
• To keep records of all deviations.
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• To ensure that only calibrated Tools and Machines are being used in construction
site for measuring and testing.
• To review quality plan and work instruction.
• To ensure that policies, objectives and procedures are clearly followed.
The duties among the staff below the Project Engineer could be generally on the following
functional lines:
(a) Planning Engineer: The main responsibility of the planning engineer include
• Reports to the project/construction manager.
• Prepares construction program, monitors and reports to the management.
• Indents materials, plant, labor.
• Draws weekly and monthly plans.
• Handles contract documentation (Letters, drawings, etc.)
• Vendor qualification.
• Contract closing.
(b) Materials Engineer: In-charge of material management including procurement and
quality control aspects, viz., inspection, field sampling and testing.
(c) Construction Engineer: In-charge of various construction activities and responsible
for following approved working methods, drawings and specifications.
(d) Plant, Equipment and Instrumentation Engineer: In-charge of deployment,
operation, maintenance of various mechanical and electrical plant and equipment as well
as instrumentation needed at site for construction.
(e) Design Director: Responsible for initial investigation and Submission of Design. The
design director heads the design unit of the contractor.
(f) Safety Engineer: Responsible for preparation and implementation of safety systems
within the construction site in addition to ensuring safety of Public/Traffic using part of the
roadway under construction.
(g) Survey Engineer: Responsible for all topographic, land surveys and setting out of
works as per drawings.
(h) Quality Assurance Engineer: Responsible for all aspects of preparation, review,
acceptance of quality plan and operation of the same at site. He is also in-charge of
quality related records and documents.
(i) Quality Audit: Independent team reporting to management.
5. Project Control and Administration
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This project will be administered by the project/construction manager and will conduct the
following procedures as below:
5.1. Contract Review
Contract review will be done by the project manager/construction manager at monthly
intervals.
The review will comprise the following:
(a) Design
(b) Reference standards, method statements and work procedures
(c) Construction time actual Vs. planned
(d) Resource leveling
(e) Cost Review
(f) Quality Review
All reviews will be done with a view to meet contract requirements. Review proceedings
will be documented, informed to senior management by copies of proceedings. Originals
will be filed in Planning Engineers office in files of green colour coding. (The site is free to
choose the color coding).
5.2. Variations - Contract Variations Raised by Client or Contractor will be reviewed to
assess its impact on
(a) Schedule
(b) Cost
(c) Resources
Variations will be documented, variation compensations will be discussed and agreed. All
documentation will be processed by the Planning Engineer, distributed to senior
management delegated to authorize such acts. Originals will be filed in the planning
section in files of yellow colour coding.
5.3. Project Planning and Scheduling
Scheduling and planning will be achieved by computer-based programs. This exercise
will be done at monthly frequencies.
The exercise will review progress, cost, plant, resources etc. against planned and
document remedial measures to overcome any deficiency.
All documentation of this procedure will be maintained by the planning section, copied to
senior management. Originals will be retained in planning section in blue colour coded
files
Monthly reporting of the above reviews will be sent to senior management/clients as
applicable.
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The Monthly progress reports will be Submitted to the client in approved format of
MORT&H.
6. DOCUMENT CONTROL
6.1 Control of Data and Documentation

6.1.1 Road related documents
Drawings, specifications, work instructions and other road related documents shall be
maintained as described below to ensure that only the latest approved documents are
used for the construction of each part of the work, which covers both the temporary and
the permanent works:
(a) The issuing authority will maintain the registers of drawings/documents giving
information about reference number, revision reference, title/date of issue, to whom
issued, number of copies issued, status of issue, date of approval, purpose of issue, etc.
(Superseded drawings/documents shall be so super scribed boldly across the heading
block).
(b) Receiving officer to whom documents are issued at site will maintain similar record.
(c) Maintenance and accessibility of site instructions book/order with both issuing party
and to whom issued.
(d) Maintenance and accessibility of registers of correspondence files.
(e) Daily diary of work.
(f) List of registers on site.
6.1.2. Quality related records and documents

For quality assurance of work, it is essential to document each and every
operation and activity connected with the work and maintain the record of inspections,
approvals/non-approvals and other statistical day-to-day information about the progress
of work. These are normally recorded in the standard forms (to be specially evolved for
each activity) and they constitute an important component of the Quality Assurance
Manual. Each activity or operation could be broadly categorized as under:
(a) Method Statement
The method statements give detailed proposals of the constructing agency which
are approved by the 'Engineer' (owner's Engineer-in-charge of the project). These
method statements are written in form of various steps in a particular sequence
supplemented by suitable sketches to be self-explanatory. No change shall be carried
out from the procedures prescribed in the method statements without first obtaining
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approvals to such change from the 'Engineer'. The method statement has been
submitted as a separate document along with the QAP.
(b) Inspection Proforma of Request for inspection (RFI)
These are used for the purpose of seeking approvals from the 'Engineer' or his
representative before commencing every operation, such as, pour cards for concrete,
approval to reinforcement, approval to formwork, approval to setting out, approval to
earthworks, approval to asphalting, etc. These are usually supplemented by standard
check-list which have to be verified by the 'Engineer' and after he is satisfied about the
various points the approval is then accorded on that form.
(c) Test Results
This set of proforma is meant for recording the results of day-to-day tests carried
out in accordance with the requirements or specifications. The proforma will be
maintained in two forms; one is loose leaf system for recording the various observations
during each test and second is for recording the summary of test results in a register
form to facilitate later analysis.
(d) Daily Diary of Work and Quantity Records
Elaborate registers are required to be maintained at site to record the day-to-day
operations, activities and events taking place at the site of work, such as, equipment
deployed, manpower deployed, activities carried out, different types of materials
consumed, detailed observations of the 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 investigating any unusual
observations, which come to notice afterwards.
(e) Non-conforming Products
Detailed statements will be prepared describing the procedures to be followed as
soon as any result not conforming to the requirements (or unusually better results) is
obtained. Such statements deal with the (i) procedures to be adopted for rectification of
the particular component where such result have been noticed, (ii) the long-term
corrective action, and (iii) immediate preventive actions in other similarly affected
activities till the long-term corrective actions are implemented.
(f) Quality Audit
A separate set of proforma with detailed instructions are laid down for facilitating
the audit of the quality assurance by an independent unit at periodical intervals.
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6.1 (a) Drawing Register- Illustration
(Maintained at Planning Office, updated for each drawing receipt, Copied at Monthly Intervals to Section
Engineers)
Name of Project: Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under
Annual plan for the year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of
Assam..
Sl. Revision Date
Title Remarks
No. 0 1 2 3 4
(1) Longitudinal Profile 15/2 20/9 15/12
(2) Cross-Sections CH 140-155 20/2
Architectural Details Minor

(3) 15/8 20/10
Bridge 104
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6.1. (b) Master Filling System-Illustration
(To be displayed on table tops of Project Manager-Planning, Secretary and Section Heads)
Annual plan for the year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam.
Yellow Green
File
Title File Ref. Title
Ref.
1.00 Incoming mail Register 3.00 Progress report to clients
1.01 Outgoing mail Register 3.01 Legal Matters
1.02 Telephone/Telex/Fax 3.02 Taxes
1.03 E-mail 3.03 Government Matters
1.04 Wireless 3.04 Cleaning and Screening
1.05 Office equipment
1.06 Quotations
1.07 Drawing register
Red Orange
2.00 4.00 Materials-General
2.01 4.01 Tests in-house
2.02 4.02 Tests Third party
2.03 4.03 Reinforcement
4.04 Aggregates
4.05 Concrete
4.06 Bitumen
This is to be expanded to suit project needs
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7. CONTROL ON MATERIALS
Project execution requires use of construction materials of natural origin and
manufactured items Materials for use in permanent/temporary works should conform to
the contract specifications in both the cases. The steps that will be adopted for control of
these materials is represented by flow charts for each
of the above category. The procedure for material procurement will be as per flow chart.
7.1 Construction Materials of Natural Origin
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7.2 Flow Chart for Procurement of Manufactured Items
19
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7.4 Procedure for control of Materials-refer Tables 7.1 to 7.3
Sl. No Activity Action by Check By Remarks

(1) Estimate material Section Planning All quantities in
questions Engineers Engineer respective material files
with reference to Drgs section 3 of system
And spects
(2) Prepare requirement plan Section Planning Record in formats made
Engineers Engineer for this purpose,
(3) Float enquires enclosing Purchase Planning

specifications officer Engineer
(4) Collect samples, test Planning QA

independently Engineer/
QCE
(5) Approve secure QCE Some contracts require
source approval by
consultants.
(6) Place order, receive Purchase QCE Store to stack untested
materials, sample, test officer/ material at locations
stores designated for the
purpose
(7) Receive test reports, if QCE QA QCE to inform stores on
within spects, approve for standard formats.
usage
(8) If routine tests not QCE QA

conforming, inform stores
in writing segregate this
material Rejected material to be
highlighted in front of
(9) If source fails consistently QCE QA locations by flags and
discard removed to location out
of bounds for staff or
(10) Quality another source Planning QA labour
vides steps 4:5 Engineer
QCE
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7.4 (a) Material Receipt not –Illustration
(To be initiated by stores, copy to planning and quality control Engineer
DATE:
Material Description 20 mm aggregate
Vehicle No. Delivery Challan No. ECC SOL1265
Source: - Unloaded and stored at
Tests Certificates, if any Source tested by QCE
Material identification boards inspected / Not inspected / Approved

for use/ rejected place boards
(Tick as applicable)
Purchase order No. ______________
Remarks: __________________________________
STORE KEEPAR
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7.4 (b) Internal Test Reports – Illustration
(To be initiated by QCE, copy to stores, planning and the user section)
DATE:
Name of Project: Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to
40th km under Annual plan for the year 2018-19 under EPC mode under PWD, NH
Division, Silchar in the state of Assam.
(1) Material Description: Reinforcement dia 32 mm high yield
(2) Sampled from: SAIL yard stack No. 35 test No. 2695V
(3) DC Reference: Nil
(4) Tests meeting/Not meeting specs: Yield is 385 mpa against 415 required
(5) Instruction to store Do not lift the material from SAIL yard
(a) issue for use
(b) Hold till further instructions
(c) Remove from store yard
• Tick as applicable strike items not applicable
QC ENGINEER
Copy to stores, purchase, planning
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8. METHODOLOGY OF WORKING, TEST AND INSPECTION PLAN
8.1 Methods Statement
Prior to the commencement of important item of work and activity the Contractor is
required to submit for approval by the Authority’s Engineer a “Methods Statement”, which
describes the methodology as to how he (the Contractor) plans to carry out that item of
work/activity in accordance with the Specifications. The Methods Statements shall be
developed to a degree of detail depending upon:
(a) The intricacy of operations for carrying out the proposed construction activity; and
(b) The extent to which the methodology is detailed out in the Specifications.
The Methods Statement shall describe the equipment to the deployed
(size/number/capacity), the sequence of operations, field trials if any are involved, design
of mixes, job-mix-formulae, temporary works erection and launching, traffic management
plan, safety precautions, environmental protection measures etc.
The Methods to be furnished by the Contractor in respect of each major activity
shall be step-wise sequencing of tasks, and should be detailed and meaningful. The
Engineer shall either straightway give his consent or ask for modification before
acceptance. The following lists out some important activities, and details out what would
be expected.
(a) Major Earthwork Operations
(i) Tests for borrow area soils
(ii) Type and number of excavation plant and transportation machinery and their
anticipated outputs
(iii) Method of working in cut and fill sections
(iv) Type and number of spreading plant for filling and anticipated outputs (v) Type and
number of compaction plant and anticipated outputs
(vi) Testing and layer approval
(vii) Method of working for site clearance and dealing with trees and vegetation
(viii) Setting out and control of levels and batters
(ix) Details of disposal areas for unsuitable material
(x) Details of suitable borrow areas for imported fill
(b) Bridge Works
(i) Details of all temporary works for construction of substructure and superstructure
(ii) Details of piling or well-sinking or open foundation, bed protection method
(iii) Details of proposed formwork and false work requirements (iv) Reinforcement and
duct fixing and cables
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(v) Concreting and curing including compaction, machinery deployment (vi) Stressing,
anchorage and grouting
(vii) Manufacture of bearings, their testing and installation
(viii) Expansion joints
(ix) Parapet rail fabrication and fixing
(x) Back-filling
(c) Fixing of PTFE cum POT Bearing
(i) Manufacturer of the bearings
(ii) Date of supply of the bearings
(iii) Expected date of installation
(iv) Precise sequence of operations such as preparation of pockets, placements of
sleeves, placement and aligning of bearing, grouting, tightening of bolts etc.
(v) Likely difficulties which may be faced and corrective measures
(vi) Location where the bearing was tested
(vii) Manufacturer’s warrantee period
(d) Pavement Works
For flexible and/rigid pavement construction including subbase, road base, DBM and
asphaltic layers or DLC and pavement concrete
(i) Proposed method of working e.g., preparation of surface, control of levels etc.
(ii) Type and number of laying plant and anticipated outputs
(iii) Type and number of compaction plant and anticipated outputs
(iv) Layer Approvals
(v) Curing arrangements
(e) Environmental Safeguards
The measures to be taken by the Contractor shall be addressed to the prevention of any
damage or pollution to the environment at the site and adjoining areas, viz.:
(i) Restoration of quarry areas and plantation
(ii) Disposal of waste materials and construction equipment on completion of works
(iii) Air dust and noise pollution from construction activities
(iv) Labour camp
(v) Effluent treatment and waste disposal
(vi) Social disturbance caused by the presence of the temporary labour force
(vii) Effects on navigational and water flow at bridge crossings
(f) Temporary Traffic Diversions and Traffic Crossings
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(i) Details of any temporary traffic diversions that may be required in order to execute the
works safely
(ii) Proposed length of diversion
(iii) Duration of operation of diversion
(iv) Constructional details of diversion including signage
(v) Details of proposed traffic management, including liaison with the police and
concerned authorities
(g) Concrete Production and Transport
Detail proposed set-up for the production and transport of concrete
(i) Location and layout of batching plants
(ii) Details of plant size, type and estimated outputs
(iii) Details of cement storage and handling
(iv) Details of aggregate stockpiles and storage capacities
(v) Details of water supply and chilling arrangements
(vi) Details of proposed transport of concrete
(h) Asphaltic Concrete Production and Transport
Detail proposed set-up for the production and transport of asphaltic and bitumen paving
products
(i) Location and layout of asphalt plant
(ii) Details of plant size, type and estimated outputs
(iii) Details of aggregate stockpiles, handling etc.
(iv) Details of bitumen storage, heating facilities etc.
(v) Details of proposed transport of mixed materials
(vi) Dust nuisance.
(i) Quarrying and Crushing Operations
Detail proposed set-up for production of aggregates and other stone products to be
incorporated in the works:
(i) Location of proposed quarry
(ii) Details of proposed method of operation of quarry i.e., development and operation of
quarry face, outputs etc.
(iii) Details of proposed plant installations giving type and size of main items and layout of
crushing operations showing production flow through to final products.
(j) Control and Administration Systems
This will give details of following
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(i) Codes of Practice to be used for the design of temporary or permanent works for
which the contractor is responsible, and copies of codes that will be kept in the site
library
(ii) Inventory of standard specifications covering every element of the works and copies
of which will be held in the site library
(iii) Drawing management system
(iv) Establishment and checking procedures for main survey and bench marks
(v) Routine for checking and calibration of surveying instruments
(vi) Layout of laboratory and inventory of materials testing equipment
(vii) Statutory laws, acts and regulations that relate to any operations that will be
performed, specifically relating to control and use of explosives and detonators, operation
of machinery, health and safety on site, environmental safeguards etc.
(viii) Fire prevention and fighting measures
(ix) Safety measures
(x) First aid facilities and procedures to be adopted in the event of accidents to personnel
(xi) Measurements before covering
8.2 Performance of Quality Control on materials
8.2.1 Testing Facilities
Before the Contractor initiates earthworks, asphalt paving, concrete works etc.,
the corresponding test facilities must be available, i.e.
(a) Laboratories must be built and equipped; (b) Laboratory equipment must be
procured and tested; (c) Test forms must be prepared; and (d) Laboratory technicians
must be employed and trained.
An illustrative list of minimum equipment needed for the site laboratory is enclosed
at Appendix-I. The Contractor may also get the tests carried out in recognized testing
laboratories outside for tests of a special nature not covered by the equipment indicated
in Table 8.2. Such testing must be preceded by approval of the Engineer. The testing
equipment must be regularly serviced as recommended by the suppliers. A calibration
chart must be available for each equipment. Forms for laboratory testing are given in
Appendix II.
8.2.2 Test Specification
Specification usually describe test methods by referring to standard methods issued by
Ministry of Shipping, Road Transport & Highways (MOSRTH), the American Standards
for Testing Materials (ASTM), the American Association of State Highway and
27
Transportation Officials (AASHTO), the British Standards (BS) and the Bureau of Indian
Standards (BIS).
8.2.3 Testing Frequency
The frequency of technical control is usually laid down by the Consultants at the
beginning of a project and is generally related to the specifications. A testing plan giving
the testing frequency, standards, acceptance criteria and agency responsible for the
tests must be prepared by the Contractor and got approved by the Engineer. Appendix II
gives the Quality Control Tests and Acceptance Criteria, assembled from IRC and
MOSRTH documents.
8.2.4 Method Control
Method control is carried out according to the type of work. Where the work method is
of considerable importance and requires constant supervision to achieve the quality, or
where in some case, the quality is difficult to improve on, there should always be a field
engineer on the site. Examples are the ramming of piles, the laying of asphalt, and
concreting etc. Where work methods are of less importance or quality is constantly being
achieved by the contractor, there may be no need for continuous surveillance. Examples
are excavation and compaction of soil.
8.2.5 End-result Control
The frequency of end-result control depends on the quality parameters that are to be
checked. Parameters which can vary considerably are continuously controlled. As
regards regulating laboratory tests the specification usually determines the number of
tests. When the works are started and in cases where difficulties as regards compliance
with quality requirements are encountered, laboratory testing will normally be intensified.
8.2.6 Quality Parameters
Quality parameters which are usually more or less constant, e.g. the Los Angeles
Strength of stone materials from the same quarry, are only controlled occasionally. The
same applies to parameters which can be checked fairly well with the naked eye, e.g. the
particle form of crushed stone. As regards the quality of manufactured materials
produced by using advanced technology, e.g. steel and bitumen, one usually trusts the
manufacturer`s certificates, but when in doubt carry out additional tests.
8.2.7 Reporting of Test Results
The test results must be recorded systematically in a register, which must be
signed by the testing authority and the representative of the Engineer, if present during
the tests. Form V-6 gives the format for daily tests on highway works.
28
8.2.8 Interpretation of Test Results
The test results should be plotted on a graph sheet showing the dates/sample
numbers on the x-axis and the test values on the yaxis. The statistical “warning limits”
and “action limits” should be indicated on these graphs. When any test results falls
outside the “warning limits”, the cause should be investigated and suitable corrective
action taken. When any test result falls outside the “action limits”, the process should be
stopped, and a thorough investigation made into the entire process, and the cause for
faulty performance determined. Suitable remedial action should be immediately taken
and the process brought under control.
8.2.9 Statistical Quality Control
Quality control based individual tests do not ensure well defined qualities of a
product. One has therefore, for many years in the industry, used statistical methods
where works and supplies are approved or rejected after an evaluation of the average
and standard deviation of a number of test results. Similar methods are gradually
gaining way in the road construction sector, and today it is not unusual to use statistical
methods for the quality control. The IRC Handbook on Quality Control (SP-11) may be
consulted for guidance. The use of Control Charts for establishing the trend line, and the
time when corrective steps are to be taken is recommended.
8.3 APPROVAL OF QUARRIES, BURROW AREAS AND MATERIALS
The Contractor is to obtain approval from the Material Engineer through the
Resident Engineer for each Quarry and Borrow Area to be used in the project prior to
commencement of quarrying and/or borrow area excavation activities. The primary
considerations to be considered by the Engineer in granting approval are: • The
proposed materials meet specification requirements • The Contractor has legal approval
by the owner to excavate/remove materials from the proposed quarry/borrow area • The
Contractor submits an acceptable “Environmental Management Plan” for development;
use and closing down of the proposed quarry/borrow area, together with any other
approvals or documents that may be required from the Ministry of Environment and
Forests or other concerned authorities.
The steps to be followed for approval of each Quarry/Borrow Area are:
(a) The Contractor is to complete the “Materials Sources Data” form giving details
regarding size, location, orientation and access for the proposed quarry/borrow area
(rough map to be drawn). Also, to be included are the list of materials to be sourced for
the project works (e.g. embankment, GSB, WMM etc.), and the estimated quantities for
these materials.
29
(b) The results of laboratory tests conducted on the materials jointly sampled with the
Consultant’s Material Engineer (or his designated representative) are to be summarized
on the approval form, and complete copies of all tests are to be attached to the form.
(c) The Contractor is to attach to the completed “Materials Sources Data” form, a letter,
or some other form of written acknowledgement, that indicates that the owner of the
quarry/borrow area agrees to the Contractor removing the proposed types and quantities
of materials indicated in the form.
(d) The Contractor attaches to the completed “Material Sources Data” form, his
proposed “Environmental Management Plan” for development, use and closing down of
the proposed quarry/ borrow area. Photographs of the sources site, including access
roads, etc. should be included with the proposal so that the base line conditions of the
Quarry/Borrow Area to be clearly established.
(e) Following receipt of the proposal for approval of quarry(ies)/borrow area(s), the
Resident Engineer is to dispatch a team consisting of the Environmental Officer and
Materials Engineer to inspect the proposed site, who will then report on their findings to
the Resident Engineer.
(f) Based on the Contractor’s proposal, and on the site inspection team’s comments, the
Authority’s Engineer will reply to the Contractor in accordance with the one of the
following:
(i) The Quarry/Borrow Area is approved as proposed.
(ii) The proposed Quarry/Borrow Area is approved subject to one or more required
changes/additions etc. (to be detailed by the Authority’s Engineer) (iii) The contractor is
requested to revise and re-submit all or part of the proposal submittal, giving details of
required changes, additional requirements etc.
(iv) The proposed Quarry/Borrow Area is rejected.
8.4 APPROVAL OF MATERIALS
8.4.1 General
All materials proposed by the contractor to be used in the project works are to be
approved first. In general, there are four types of materials to be approved.
(a) Natural Materials – materials with little or no processing except for perhaps screening
for oversize and removal of unsuitable particles, etc. An example of this is soil
embankment materials.
(b) Processed Materials – materials that require significant processing, including
removal of unsuitable particles, crushing, screening and perhaps, blending of sizes.
30
These materials are homogeneous, but with specified gradations. An example of this is
Wet Mixed Macadam Base Course.
(c) Manufactured Materials – especially homogeneous construction materials, like
Portland cement and bitumen, that are used for blending with natural materials (generally
soil or aggregate) to obtain a pavement mix.
(d) Designed Materials- materials that involve the mixture, to specific proportions of two
or more different, natural, processed or manufactured materials to obtain a modified
material giving a set of desired specific properties.
Approval of each of the above material types is required, however the requirements for
obtaining approval of materials for each type differs slightly.
8.4.1 Approval of Natural Materials
Natural materials are mined (i.e., excavated) and hence the first step, following
assurance that the material(s) is acceptable for its intended purpose, is to obtain
approval for the Borrow Area or Quarry.
Approval of the material for construction is then obtained by submittal of test results for
all tests required by the Specifications (i.e., to prove that the material meets all minimum
properties required), and, in some cases, by construction of trial sections to prove that
this material can be placed in the field so as to attain minimum required field properties
(e.g. to meet minimum density, etc.)
8.4.2 Approval of Processed Materials
Approval of processed materials follows that noted above for “natural” materials, except
that usually the specifications are tighter (e.g. the material may also have to meet
stringent gradation limits), and a greater variety of tests (and production/storage)
conditions are required to be met.
8.4.3 Approval of Manufactured Materials
Approval of manufactured materials, based on specific Specifications requirements, is
generally given in two stages.
(a) Initial Approval – given prior to receipt of the materials based on submittal of
appropriate testing results confirmed by the manufacturer (note that claims by
manufactures, or tests etc. by distributors, etc. are not to be accepted).
(b) Final Approval – given based on initial approval plus positive results being obtained
for all “acceptance” tests required by the Specifications, or as directed by the Engineer.
The Quality Assurance System and plan of the manufacturer shall also be examined
before approval.
8.4.4 Approval of Designed Materials
31
Approval of “designed” materials for the project concerns those mix designs for Cement
Concrete (for concrete pavements, box culverts, bridges etc) and Asphaltic Concrete
(flexible pavement materials including bituminous macadam, dense bituminous
macadam, bituminous concrete, mixed seal surfacing, semi dense bituminous concrete
and seal coat). Due to the complexity of these “mixed” materials, and the plants for
producing the range of materials sizes, final approval is deferred until completion of the
following steps:
(a) Approval of sources (generally quarries) for each of the processed material
constituents to be included in the final mix design.
(b) Approval of each of the individual processed materials and manufactured materials to
be included in the final mix design.
(c) Tentative approval of a laboratory-based mix design, based on a mixture of approved
materials so that the mixture meets all Specifications requirements.
(d) Tentative approval of a plant mix design, based on proportioning of aggregate bins
materials and manufactured materials to closely approximate the proportioning of
material types/sizes finalized for the laboratory-based mix design (i.e. and so that the
mixture still meets the minimum Specifications requirements). (e) Conduct trial section of
works (off the project site) using the tentatively approved plant mix design and placing
the mixture in accordance with a previously approved construction methodology that
conforms to Specifications requirements.
(f) Based on successful laying of the mixture in accordance to the approved
Methodology, conformance of the placed mixture to required placing temperatures, levels
and finish, etc. and conformance to quality control requirements as verified by successful
testing in accordance with the Specifications, the Material Engineer is to give final
approval of the mix design based on the plant mix proportions.
8.5 SAMPLING OF MATERIALS
8.5.1 Sampling Requirements
All construction materials to be used in the permanent works are to be sampled jointly by
the Consultant and Contractor prior to commencement of the Works. This includes
sampling for materials to be tested for proposing approval of the material source as well
as sampling of materials for approval of the individual construction materials. In both
cases, and for each instance, the Contractor will give notification of a request for such
sampling to the Authority’s Engineer in advance (minimum 48 hours) by way of the
Inspection Request Form (IRF). All assistance (e.g. sampling instruments and
equipment, sample bags, and labour etc.) that is required for carrying out the sampling
32
activities will be provided by the Contractor. For sampling activities, the Authority’s
Engineer is to be represented by the Material Engineer or his appointee.
8.5.2 Sampling Guidelines
All sampling is to be carried out in accordance with instructions to be given by the
Consultant. Sampling procedures are to follow recognized guidelines of good
engineering practice. These include:
(a) Obtaining samples from at least three areas.
(b) Ensuring that the sampled materials and locations are “typical” for the material to be
tested.
(c) Ensuring that all overburden etc. is removed within the stockpiles rather than from the
surface (top, side or base of the stockpile) in order to avoid the collection of segregated
materials.
(d) Ensure that sufficient quantities are sampled to enable all tests to the conducted, plus
additional material, to be stored for subsequent testing if required.
(e) Ensure that each sample bag is marked/labeled both inside and outside, giving the
sample number, material type, sample location, date and number of the bag, as well as
any additional information instructed by the Material Engineer or his appointee.
8.5.3 Preparation and Storage of Samples
Samples collected are reduced and prepared as per standard methods (Indian
Standards), with an additional sufficient quantity retained in appropriately sealed bag(s)
or container(s) and separately kept in the sample storage room of the laboratory for
additional testing and/or future reference as required. Concrete samples in particular are
to be carefully cured and kept in the curing tank of the laboratory. Access to stored
samples is under the strict direct control of the Consultant’s Material Engineer. Details of
all samples stored are to be kept in a register to be administered by the Material
Engineer.
8.5.4 Field Testing Laboratory
The Field-Testing Laboratory, including all furniture, testing equipment and apparatus as
required by the Specifications is to be provided and maintained by the Contractor
together with the provision of all necessary utilities (e.g. electricity, water, sewerage and
drainage). The design and layout of the laboratory is to be approved by the Resident
Engineer based on recommendations by the Material Engineer. It is the responsibility of
the Contractor to ensure that the laboratory is proficiently guarded at all times of the day
and night (i.e. to control access and maintain security), is cleaned daily and is properly
maintained. Testing equipment and apparatus are to be initially approved, and
33
subsequently periodically checked, by the Authority’s Engineer to assure proper
operation, accuracy, correct calibration and complete conformance to all Specifications
requirements. Likewise, all testing procedures detailed in the Specifications and
procedures instructed by the Material Engineer as part of his Quality Control and Quality
Assurance Plan are to be strictly adhered to by the Contractor. The Authority’s Engineer
is to supervise, monitor and check all aspects of the testing procedures, including sample
storage, preparation, testing and analysis and reporting of testing results. All relevant
material testing details related to sample preparation, testing and analysis of results are
to the recorded on the relevant standard testing form(s) given in Appendix II.
8.5.5 Acceptance Testing
8.5.5.1 General
All materials included in the construction works for which quality control tests are
specified, and for which approval by the Engineer has been previously given, are to be
inspected and checked for acceptability in accordance with the Specifications
requirements.
Any of the completed construction works in which unapproved and/or untested
and/or unaccepted materials are incorporated without approval or written permission
from the consultant are deemed performed at the Contractor’s risk and are considered as
unacceptable and unauthorized.
8.5.5.2 Routine Acceptance Tests 1111
All sampling and quality control testing, as well as check tests to verify quality of
materials, are to be conducted by the Contractor at his own expense under the direct
supervision of the Consultant. The kind(s) of test(s) and frequency of testing should
conform to the Minimum Quality Control Testing Requirements of the MOSRTH
Specifications. Sampling and Testing should be in accordance with the relevant IS
methods. Tests are to be reported on proper forms, samples of which are shown in
Appendix II.
9.CALIBRATION
Equipment are to be calibrated prior to use at the frequencies noted:
Sl. No. Instrument Frequency Calibration at
(1) Auto levels Monthly Site
(2) Theodolites Monthly Site
(3) Total Stations 6 Months Manufacturers Works
(4) Weigh batchers 6 Months Site
34
(5) Batching plants 6 Months Site
(6) Pugmill 6 Months Site -.,
(7) Cube Testing Machine Yearly Site
(8) Compressive strength 6 Months Site
test machine
(9) Load Proving Ring 6 months Site
For CBR Test
(10) Rapid Moisture Meter Monthly Site
(11) All Electronic Weight
Balance Monthly Site
The records of calibration of equipment are to be maintained as per
the following format:
Name of Work: Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km
under Annual plan for the year 2018-19 under EPC mode under PWD, NH Division, Silchar in the
state of Assam.
Name of Contractor: M/S Dhar Construction Company (Partner)
DATE CALIBRATED&
DATE OF INSPECTION
PERSON CERTIFYING DATA OF NEXT RESULT OF
ITEM &PERSON APPROVING
(FOR VENDOR OR CALIBRATION INSPECTION
(FOR DEPARTMENT)
CONTRACTOR)
35
CALIBRATION CHART OF BATCHING PLANT FOR
AGGREGATE GUAGE
state of Assam.
CALIBRATED DATE: -
LOAD DIAL GAUGE READINGS

APPLIED
TRIAL -1 TRIAL -2 TRIAL -3
(KG) AVERAGE
LOADING UNLOADING LOADING UNLOADING LOADING UNLOADING
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
REMARKS
CLIENT'S REPRESENTATIVE CONTRACTOR'S REPRESENTATIVE
36
WATER METER
state of Assam.
CALIBRATED DATE: -
TRIAL-1 TRIAL-2 TRIAL-3
SL. METER WATER METER WATER METER WATER
AVERAGE
NO. READING MEASURED READING MEASURED READING MEASURED
(LTRS) (LTRS) (LTRS) (LTRS) (LTRS) (LTRS)
1 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
9 90 90 90
10 100 100 100
11 110 110 110
12 120 120 120
13 130 130 130
14 140 140 140
15 150 150 150
REMARKS
37
CEMENT GUAGE
CALIBRATED DATE: -
state of Assam.
LOAD DIAL-GAUGE READINGS

APPLIED
TRIAL-1 TRIAL-2 TRIAL-3
(KG) AVERAGE
LOADING UNLOADING LOADING UNLOADING LOADING UNLOADING
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
REMARKS
38
CALIBRATION REPORT
(Cube Testing Machine)
state of Assam.
DATE OF CALIBRATION TEMP.

GAUGE NO CAPACITY
EQUIPMENT MODEL
FORCE MEASURING DEVICE SL.NO.
CERTIFIED BY PLACE
REF.
ACTUAL
DEFLECTION IN DIAL AVERAGE
LOAD INDICATED LOAD
SL.NO. GAUGE IN PROVING OF THREE
APPLIED ON GAUGE ERROR
RING READING
KN
1
10
NOTE: To obtain Correct result (+) error to be subtracted negative (-) error to be added to the
indicated
Load readings on machine gauges.
CLIENT’S REPRESENTATIVE CONTRACTOR’S REPRESENTATIVE
39
10. PROFORMA FOR INSPECTION
DATA SHEET FOR SIEVE ANAL YSIS -AGGREGATE
under Annual plan for the year 2018-19 under EPC mode under PWD, NH Division, Silchar in
the state of Assam.
SAMPL : DATA OF SAMPLING :
QUANTITY OF AGGREGATE : MATHOD OF TEST :
SOURCE : DATA OF TESTING :
TO BE USED IN STRUCTURE : SAMPLING & TESTED BY:
WEIGHT OF SAMPLE :
IS SIEVE CUMULATIVE %CUMULATIVE ACCEPTABLE

MASS RETAINED
NO MASS RETAINED RETAINED LIMIT
REMARKS:
Note
Piot a Grain Size Distribution Curve
Signed Signed
Date Date
For Contractor For Contractor
Name Name
40
FORMWORK INSPECTION CHEKLIST
state of Assam.
LOCATION: Assam, Silchar. DATED:
CONTRCTORS INSPECTION REQUEST NO. YES NO
CONTRACTORS DRG OR SKECTCH NO.
1. Formwork design/drawing/sketch approved
including de-shuttering arrangement
2. Trial panel approved correct
3. Formwork alignment correct
4. Formwork levels correct, including screeds
5. Formwork dimension spacing correct
6. Formwork member spacing correct
7. Formwork member material quality acceptable
8. Falsework member sizes correct
9. False member spacing correct
10. Falsework member material quality acceptable
11. Gaps between primary and secondary members closed /wedged
12. Face boarding/Plywood/Metal thickness correct
13. Joints between panels closed (No gaps)
14. Joints between panels flush (No steps/lips)
15. Panel flatness acceptable
16. Gaps between panels secondary member and face panels closed
17. Tie rod material and sizes correct
18. Tie rod spacing correct
19. Tie rods tight face cones flush
20. Spacers between shutter surface tightly fitting
21. Box cuts, cast-in items, ducts fixed correct, security
22. Prestressing sheeting and vents, alignment and spacing of
supports acceptable
23. Empty sheathing secured against flotation
24. Prestressing anchorage position and fixing acceptable
25. Chamfers/filets sizes, straightness, fixing acceptable
41
26. Formwork clean
27. Formwork release oil material approved
28. Formwork release oil applied correctly
29. Construction joint preparation satisfactory
30. Constriction/expansion joint preparation satisfactory
31.Safe access constructed
32. Adequate work space provided for labour equipment
33.Shutter vibrators (if required) location and fixing arrangement approved
Inspected by : Name Signed Date

(for Contractor)
Approved by : Name Signed Date

(for Department)
42
REINFORCEMENT INSPECTION CHECK LIST
state of Assam.
LOCATION DATED:
CONTRCTORS INSPECTION REQUEST NO.
REF DRG NO.:
YES NO
1. Working drawing checked and approved
2. Latest revision being used
3. Bar schedules approved
4. Reinforcing steel material approved
5. Bar bending and cutting satisfactory
6. Corrosion treatment of bars, if required, satisfactory
7. Bar sizes correct
8. Bar spacing correct
9. Bar lap lengths correct
10. Bar laps at correct locations
11. Bar tied as specified
12. Bar assembly rigid and adequately supported

(including spacers/chair supports
13. Cover to bottom bars correct

14. Cover to side bars correct
15. Cover to top bars correct
16.Cover blocks approved including fixing
Inspected by : Name Signature Date
(for Contractor)
Approved by : Name Signature Date
(for Department)
43
INSPECTION CHECK LIST BEFORE APPROVAL TO CONCREAT
state of Assam.
LOCATION DATED:
CONTRCTORS INSPECTION REQUEST NO. YES/NO
1. Method statement approved

2. Batching plant mixers in working order (Separate dispenser for admixture, if required
available
3. Standby batcher in working order
4. Water. Sand coarse aggregate, cement, admixture, cement approved
5. Water. Sand coarse aggregate, cement, admixture, cement stock sufficient
6. Concreate conveying arrangement (including transited mixers) available in working
condition and of sufficient capacity
7. Formwork approved
8. Reinforcement approved
9. Presenting sheathing approved
10. Concreating equipment in working order
11. Standby crane, vibrators present
12. Tremie working order (for under water work)
13. Concreate gang present, including carpenter, steel fixer, mechanics and electricians
14 Access provides
15. Safety arrangements adequate
16. Lighting provided
17. Communications between various points provided
18. Arrangements for arranging suspension/stoppage of concreate provided
19. Curing arrangements made
20. Laboratory notified
Inspected by : Name Signature Date
(for Contractor)
Approved by : Name Signature Date
(for Department)
44
CONCREATE DELIVERY AND POUR RECORD
state of Assam.
1. CONREATE BATCHING DELIVERY TICKET NO.
Location of Pour : Date
Concreate Grade : Mix Temp
W/C Ratio : Slump
Cement contents : No. of cubes taken
Max Aggregate size :
Admixture (type & Dosage) :
Batching started, Hrs : Batching finishing, Rs
Quantity Batched : Truck No.
2. TRUCK ARRIVED ON SITE Hrs
Stump test result(s) : mm at
Discharge started : Hrs
No. of site cubes taken : Hrs
Place where cubes taken : Hrs
Placement temperature of concreate: Hrs
Ambient Temp. :
Weather condition :
Inspected by : Name Signed Date

(for Contractor)
Approved by : Name Signed Date

(for Department)
45
POST CONCRETING INSPECTION
Note: Post concreting inspection shall be carried at various stages, such as after stripping of side Shuttering
each stage of presenting, decentering and/or as designers’ stipulation.
Location Stage of inspection
Date of Pour Date of inspection
Specified Class
S or NS’
Type of Remarks
Observation
S or NS’
1 Position/Dimensions of the
member
2 Surface Defects (honey
combing/sand streaks/air
bubbles/cold joints)
3 Class of Finish
4 Creaks
5 Any other Defect
6 Non-conformance report no
Remarks: In case of NS report in item (1) to (5),it should be examined by competent authority before Approval or
non-approval. If required, a separate non-conformance report (including sketches, photographs, etc.) shall be
prepared for further action.
*S= Satisfaction, NS= Satisfactory
Name Signature Date

Inspected by
(For Contractor)
Name Signature Date

Approved by
(For Department)
Approval/ non Name Signature Date

approval by
(For Department
46
AGGREGATE IMPACT VALUE- AIV
IS: 2386 (PART-IV)
state of Assam.
LOCATION/SECTION OF LAB: SOURCE OF MATERIAL:
SAMPLE LOCATION: DATE OF TESTING:
PARPOSE OF USE:
SAMPLE SIZE: 12.5 mm Passing & 10 mm retained
Determinations
Description Symbol Unit
1 2 3
Weight of aggregate (Dry)
passing through IS Sieve 12.5 W1 g
mm & retained on 10 mm
Weight of fraction retained on W2
g
2.36 mm IS sieve
Weight of fraction passing W3 = W1 – W2
g
through 2.36 mm IS sieve
Ww = W1 – (W2+ W3) W4
(if W4>1g, discard and %
carryout fresh test)
Aggregate Impact value (W3 / W1)*100 %
Average Aggregate Impact
value
REMARKS:
Prepared by Checked by Approved by
47
FIELD DENSITY TEST
CORE CUTTER METHOD
state of Assam.
LOCATION : TESTED BY :
MATERIAL : DATE :
Reduced level :
Bulk Density : gm/CC
No. CHAINAGE. Unit 1 2 3 4 5 6
1 Mass of mould + Gms
Compacted soil
2. Mass of mould Gms
3. Mass of Compacted soil Gms
(2-1)
4. Volume of Mould Gms
5. Wet Density of soil (3/4) Gms/CC
6. Wt Wet soil + Gms

7. Wt Dry soil + Gms/CC
8. Wt water (6) - (7) Gms
9. Moisture cement %
(8)/(7)x100
10. Field dry density of soil %
(5)/1+(9)/100
Degree of compaction
(10/MDDX100)
Average degree of Compaction :
Standerd Deviation :
REMARKS:
CLIENT’S REPRESENTATIVE
CONTRATOR’SREPRESENTATIVE
48
FLAKINESS INDEX TEST
Name of Work: Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th
km under Annual plan for the year 2018-19 under EPC mode under PWD, NH Division,
Silchar in the state of Assam.
Location Tested By
Material Date
2
1 3 4
Wt.
Sieve Range Total Weight Wt. Flakiness
Aggregate
(mm) of Aggregates Aggregate Index (%)
retained
(Gms) passing (Gms) (Gms)
(Gms)
63-50
50-40
40-31.5
31.5-25
25-20
20-16
16-12.50
12.50-10
10-6.3
Remarks Average %
CLIENT’S
REPRESENTANTIVE CONTRACTOR’S REPRESENTATIVE
49
ATTERBERG LIMIT
LOCATION: TESTED BY
SOURCE: DATE:
MATERIAL: SAMPLE NO.
LIQUID LIMIT PLASTIC LIMIT
(LL) (PL)
DETERMINATION Unit 1 2 3 4 1 2 3
No. of Blows / Penetration in mm Gms
CONTAINER NO.
1. Wt. Container+Wet Soil
2. Wt. of Container + Dry Soil Gms
3. Wt. of Water (1-2) Gms
4. Wt. of Container Gms
5. Wt. of Dry Soil (2-4) Gms/
CC
6. Moisture Content (w) 3/5*100 %
Moisture Content (%)
No. of Blows
LL %
PL %
Plasticity Index (PI) %
Remarks
50
COMPACTION TEST
MODIFIED PROCTOR
LOCATION: TESTED BY
SOURCE: DATE:
MATERIAL: SAMPLE NO.
WET DENSITY
DETERMINATION Unit 1 2 3 4 5 6
1. Wt. of Mould + Compacted Soil Gms
2. Wt. of Mould Gms
3. Wt. of Compacted Soil (1-2) Gms
4. Volume of Mould Gms
5. Wt. Density (3/4) Gms/CC
6. Moisture Content (w) %
7. Dry Density (5/1+W)/100 Gms/CC
Dry Density (Gms/CC)
Moisture Content (%)
MAXIMUM DRY DENSITY (MMD): Gms/CC

Optimum Moisture Content (OMC) %
Remarks
51
Field Density Test
By Sand Replacement Method
LOCATION: TESTED BY
SOURCE:
MATERIAL:
RL (O) Bulk Density: Gm/CC
Layer Thickness: mm OMC % (14) MDD
Gm/CC
SAMPLE NO. Unit 1 2 3 4 5 6
1. Wt. of sand before Pouring Gms
2. Wt. of sand after Pouring Gms
3. Wt. of sand in Hole Cone Gms
(1-2)
4. Wt. of sand in Cone Gms
5. Wt. of sand in Hole (3-4) Gms
6. Vol. of Hole (5/O) Gms
7. Wt. Wet soil from hole Gms
8. Wet density of Soil (7/6) Gms/CC
Moisture Determination
9. Wt. of wet soil Gms
10. Wt. of Dry soil %
11. Wt. of Water (9-10)
12. Moisture Content
(11/10*100)
13. Field Dry Density Gm/CC
DEGREE OF COMPACTION
(13/14*100)
REMARKS: AVERAGE DEGREE OF
COMPACTION: %
CLIENT’S REPRESENTATIVE CONTRACTOR’S

REPRESENTATIVE
52
c
53
BITUMEN EXTRACTION
LOCATION DATE SAMPLED DATE TESTED
1. Wt. in Sample + Bowl Gms
2. Wt. of Bowl Gms
3. Wt. in Sample Gms
4. Wt. of Filter paper before Gms
extension
5. Wt. of filter paper after Gms
extraction
6. Wt. of filter on filter paper Gms
7. Wt. of aggregate + bowl Gms
after extraction
8. Wt. of washed (7-2+6) Gms
aggregate
9. Wt. of bitumen (3-8) Gms
10. Binder content (9/3) %
REMARKS
54
MARSHAL TEST
MATERIAL DESCRIPTION: D.B.M. / B.C.
state of Assam.
Density Determination Marshal JMF dens
1. Wt. in Air Gms
2. Wt. in Air SSD Gms
3. Wt. in Water Gms
4. Volume Gms
5. Density Gms/CC
6. Air Voids in Mix 3-5%
7. VMA 8-22%
8. Stability 820 Kg
9. Flow 2-4 mm
REMARKS
55
CORE TEST
MATERIAL DESCRIPTION: D.B.M. / A.C.
state of Assam.
Density Determination Core JMF dens
1. Core no.
2. Core Chainage
3. Core Thickness mm
4. Wt. in Air Gms
5. Wt. in Water Gms
6. Volume Gms
7. Density Gms/CC
8. Compaction (Core) %
REMARKS

REPRESENTATIVE
56
GRADATION/BC
Material Description: AC
Name of Work: Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under
WT. % % CUMULATIVE PASSING

IS %
RETAINED CUMULATIVE DESIGN
SIEVE RETAINED ACTUAL LIMIT
GMS RETAINED SAMPLE
26.5 100 100
19.0 100 90-
9.50 71.2 100
4.75 45.0 56-80
2.36 34.1 35-65
0.30 11 23-49
0.075 32 5-19
2-8
100
90
80
70
% of Passing
60
50
40
30
20
10
0
0.075 0.3 2.36 12.5 26.5 37.5
SIEVE SIZE

REPRESENTATIVE
57
GRADATION/DBM
Material Description: DBM
WT. % CUMULATIVE PASSING
IS % % CUMULATIVE
RETAINED DESIGN
SIEVE RETAINED RETAINED ACTUAL LIMIT
GMS SAMPLE
37.5 100 100
26.5 100 90-100
12.50 64.1 56-80
4.75 39.1 29-59
2.36 29.7 19-45
0.30 9.6 5-17
0.075 2.5 1-7
100
90
80
70
60
% of Passing
50
40
30
20
10
0
0.075 0.3 2.36 12.5 26.5 37.5
SIEVE SIZE
58
10. QUALITY AUDITS
59
10.1 Audit Notification
To:
CC:
This notification is to advise you that an Audit has been scheduled to take place
in your Company/ Department / Area as detailed below. Please acknowledge
receipt of this notification by signing and returning a copy to this form to the
QM-Department as soon as possible.
AUDIT DETAILS:
Audit Number:
Date Planned:
Time:
General Agenda:
Documents to be audited:
The Audit Team will be:
The following personnel will be required to be available during the Audit:
Approved Management Representative Received by (Title)
Signed: Signed:
Date: Date:
60
10.2 Audit Checklist
Area Audited: Audit Auditor: Approved QA-Manager:
No.:
Checklist Activity Compliance Comments
*Complete Activity Compliance column with one of the following:
*Acceptable* Not acceptable* *Not Applicable* *See Comments*
61
10.3 Audit Report
Date of Audit:
Previous Audit Report:
Audit Team:
Persons Contacted
Audit Scope and Objective:
Audit Summary:
Category: 1 2 3 4 5 6
NCR’s Issued:
Observation Issued:
Auditor: Management Representative:
Signature: Signature:
Date: Date:
62
11. SAFETY
The project safety plan to be prepared separately by the Safety Engineer will cover
safety
procedures associated with road works for the following:
• Detours
• Signing and lighting temporary
• Working close to HT & LT cables
• Working close to High Pressure Water/Gas mains
• Working close to canals/rivers
• High embankment construction
- • Working during poor visibility conditions
• Removal of obstructions to traffic
• Safety procedures at quarries, crushers and other plant
• Safety procedures for decanting bitumen
• Safety procedures for handling hot mix, paving operations, etc.
Safety Organization
The project safety team will comprise of the Safety Engineer and staff trained for works
of such magnitude with access to equipment like rescue vehicles, first aid, water bowser
etc.* The proposed safety plan will cover in detail such facilities.
63
APPENDIX I
List of Equipment to be provided in Site Laboratory
General
(i) Oven-electrically operated, thermostatically controlled, range
upto 200°C sensitivity 1°C 1 No.
(ii) Platform balance 300 kg capacity 1 No.
(iii) Balance 20 kg capacity-self indicating types 1 No.
(iv) Electronic Balance 5 kg capacity accuracy 0.5 gm 2 Nos.
(v) Water bath-electrically operated and thermostatically
controlled with adjustable shelves, sensitivity 1°C. 1 No.
(vi) Thermometers:
Mercury-in-glass thermometer range 0°C to 25°C 4 Nos.
Mercury-in-steel thermometer with 30 cm stem, range upto
300°C 1 No.
(vii) Kerosene or gas stove or electric hot plate 1 No.
(viii) Glasswares, spatulas, wire gauzes, steel scales, measuring
tape, casseroles, karahis, enameled trays of assorted sizes,
pestle-mortar, porcelain dishes, gunny bags, plastic bags,
chemicals, digging tools like pickaxes, shovels etc As required
(ix) Set of IS sieve with lid and pan: 450mm diameter
63 mm, 53 mm, 37.5 mm, 26.5 mm, 13.2 mm, 9.5 mm, 6.7
mm and 4.75 mm size 1 Set
2.36 mm, 2.0 mm, 1.18 mm, 600 micron, 425 micron, 300
micron, 150 micron and 75 micron 2 Sets
(x) Water testing kit 1 Set
(xi) First aid box 1 Set
For soils and aggregates
(i) Riffle Box 1 No.
(ii) Atterberg Limits (liquid and plastic limits) determination
Apparatus 1 Set
(iii) Compaction Test Equipment both 2.5 kg and 4.5 kg rammers
(Light and Heavy compactive efforts) 1 Set
(iv) Dry Bulk Density Test apparatus (sand pouring cylinder, tray,
can etc.) complete 1 Set
64
(v) Speedy Moisture Meter complete with chemicals 1 Set
(vi) Post-hole Auger with extensions 1 Set
(vii) Core cutter apparatus 10 cm dia, 10/15 cm height, complete
with dolly, rammer etc. 1 Set
(viii) Aggregate Impact Value Test apparatus/Los Angeles Abrasion
Test apparatus 1 Set
(ix) Flakiness and Elongation Test Gauges 1 Set
(x) Standard measures of 30, 15 and 3 litres capacity along with
standard tamping rod 1 Set
(xi) California Bearing Ratio test Apparatus 1 Set
(xii) Unconfined compression test apparatus 1 Set
For Bitumen and Bituminous Mixes
(i) Penetrometer with standard needles 1 Set
(ii) Riffle box – small size 1 No.
(iii) Centrifuge type bitumen extractor, hand operated, complete
with petrol/commercial benzene. 1 Set
(iv) Marshall stability test apparatus, complete with all accessories 1 Set
(v) Field density bottle along with cutting, tray, chisel, hammer
and standard sand 2 Nos.
(vi) 3 m straight edge 1 Set
(vii) Camber board 1 No.
(viii) Core cutting machine with 10 cm dia diamond cutting edge 1 Set
(ix) Vacuum pump and 3 specific gravity bottles 1 Set
For Cement and Cement Concrete
(i) Vicat apparatus for testing setting times 1 Set
(ii) Slump testing apparatus 4 Sets
(iii) Compression and Flexural strength testing machine of 200
tonne capacity with additional dial for flexural testing 1 No.
(iv) Needle Vibrator 2 Nos.
(v) Air Meter 1 No.
(vi) Vibrating hammer for vibrating dry mix as for Dry Lean
Cement concrete sub-base 1 No.
(vii) Core cutter apparatus 150 mm dia 1 Set
65
APPENDIX II
Quality Control Tests and Acceptance Criteria
Acceptance criteria for Horizontal alignment and surface levels for Subgrade, GSB, WMM, DBM and BC:-
Horizontal Alignment: Horizontal alignments shall be reckoned with respect to the center line of the carriageway as shown on the
drawings. The edges of the carriageway as constructed shall be correct within a tolerance of + 10 mm there from. The corresponding
tolerance for edges of the roadway and lower layers of pavement shall be + 25 mm.
Surface Levels: The levels of the subgrade and different pavement courses as constructed, shall not vary from those calculated with
reference to the longitudinal and cross-profile of the road shown on the drawings or as directed by the Engineer beyond the tolerances
mentioned in Table 900-1 of MoRT&H (5th Rev).
66
INSPECTION AND TEST PLAN FOR EARTHWORK
REFERENCE
CLAUSE FROM
ACCEPTANCE INSPECTION SAMPLE INSPECTION MORTH/
PRODUCT TEST STAGE CHARACTERISTIC
CRITERIA FREQUENCY SIZE METHOD SUPPLEMENTARY
TECHNICAL
SPECIFICATION
Should not be OL,OI,OH 4.75mm -

Gradation Lab test Grain size 2 test for 3000m3 As per IS 2720 pt.4 MORTH 903.2.1
or pt class 75mic
Embankment upto Not less than 15.2 MORTH Table 300

Lab test 2 test for 3000m3 20mm down As per IS 2720 pt 8
3m height Kn/Cum -I
MDD Embankment
Not less than 16.0 MORTH Table 300
Lab test exceeding 3m 2 test for 3000m3 20mm down As per IS 2720 pt 8
Kn/Cum -I
height
Technical
Not more than 50% for LL 425 mic
LL & PL Lab test LL Value 2 test for 3000m3 As per IS 2720 pt 5 Specifications
And 25% for PI down
CL.305.2.1.1
Technical
425mic
PI Lab test PI Value Not more than 50% 2 test for 3000m3 As per IS 2720 pt 5 Specifications
down
CL.305.2.1.2
Embankment Deleterious Sulphate Content Not more than 0.5% by As required by the MORTH CL.
Lab test As per IS 2720 pt 27
Content (So3) mass Engineer 903.2.1
Field Density shall not be One set per 1000m2 of
less than each compacted area
95%(Upto 6m heigth) of with minimum number
the Maximum Dry of 6 tests in one set of
Density. measurement
The acceptance Criteria If considerable
Field Field Degree of MORTH CL.
shall be that the Mean variations are observed As per IS 2720 pt 28
Density test Compaction 903.2.2
Field Density is not less between individual
than 95% plus(1.65 - Density results, the
1.65/No of samples 0.5 ) minimum number of test
times the Standard in one set of
Deviation measurements shall be
increased to 10.
67
INSPECTION AND TEST PLAN FOR EARTHWORK
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Moisture Technical
Field Moisture Content Plus 1 or Minus 2 percent 2 - 3 tests per 250M3 of As per IS 2720 pt 2
Content Specifications
test test of OMC loose Soil & pt 8
test CL.305.3.5
Free
As required by the MORTH CL.
Swelling Lab test Free Swelling Index Not more than 50% As per IS 2720 pt 40
Engineer 305.2.1.2
Index
INSPECTION AND TEST PLAN FOR SUBGRADE CONSTRUCTION
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Should not be
4.75mm - As per IS 2720
Gradation Lab test Grain size OL,OI,OH or pt 2 test for 3000m3 MORTH 903.2.1
75mic pt.4
class
Not less than 17.5 As per IS 2720 pt
MDD Lab test MDD 2 test for 3000m3 20mm down MORTH Table 300 - I
Kn/Cum 8
Subgrade
Technical
As per IS 2720 pt
LL & PL Lab test LL Value Not more than 40 2 test for 3000m3 425mic down Specifications
5
CL.305.2.1.1
Technical
As per IS 2720 pt
PI Lab test PI Value Not more than 15 2 test for 3000m3 425mic down Specifications
5
CL.305.2.1.2
68
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
1 test for 3000m3 or Technical

As per IS 2720 pt
CBR Lab test CBR Value Not less than 10 closer as required 20mm down Specifications
8
by the Engineer CL.305.2.2.2
Deleterious Sulphate Not more than As required by the As per IS 2720 pt
Lab test MORTH CL. 903.2.1
Content Content(So3) 0.5% by mass Engineer 27
1 test for 3000m3 or Technical

As per IS 2720 pt
CBR Lab test CBR Value Not less than 10 closer as required 20mm down Specifications
8
by the Engineer CL.305.2.2.2
Field Density shall
not be less than
97% of the
Maximum Dry
Density.
Subgrade and One set per 500m2
Field Dry The acceptance
Shoulder(earthen) of each compacted
Density of Criteria shall be
Degree of area with minimum As per 2720 Part
each Field test that the Mean Field MORTH CL. 903.2.2
Compaction number of 10 tests 28
compacted Density is not less
in one set of
layer than 97% plus(1.65
measurement
- 1.65/No of
samples 0.5 ) times
the Standard
Deviation
Moisture
Content Technical
Moisture Content Plus 1 or Minus 2 2 - 3 test per 250M3 As per IS 2720 pt
Subgrade test just Field test Specifications
test percent of OMC of loose soil 2 & pt 8
before CL.305.3.5
compaction
69
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Free
As required by the As per IS 2720 pt
Swelling Lab test Free Swelling Index Not more than 50% MORTH CL. 305.2.1.2
Engineer 40
Index
INSPECTION AND TEST PLAN FOR GSB

REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Sieve Size MORTH Table 75mm- As per IS 2386
Gradation Lab Test Size of aggregate 1 test per 400m3
400-1 75mic pt.1
75mm 100
53mm 80-100
26.5mm 55-90
GSB 9.5mm 35 - 65 MORTH Table 400-I
4.75mm 25-55
2.36mm 20-40
0.425mm 10-15
.075mm <5
70
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Natural
Plus 1 or Minus 2 percent As per IS 2720 pt MORTH Table 900-
Moisture Field test Moisture Content One test per 400m3
of OMC 2 3
Content
Moisture
Content Plus 1 or Minus 2 percent As per IS 2720 pt MORTH Table 900-
Field test Moisture Content One test per 400m3
prior to of OMC 2 3
compaction
One test per 1000m3
CBR test to at least or closer as
Technical
be conducted and when required by 22.4mm
CBR CBR Value Not less than 30 As per 2720 pt 16 Specification Sub-
prior to actual Engineer shall be down
Clause 401.3
execution conducted prior to
laying and spreading
425 mic As per IS 2720 pt MORTH Table 400-
Liquid Limit Lab test LL Value Not more than 25 1 test per 400m3
down 5 2 Note
Plasticity 425 mic As per IS 2720 pt MORTH Table 400-
Lab test PI Value Not more than 6 1 test per 400m3
Index down 5 2 Note
Technical
Water As required by the
Lab test WA Not more than 2% As per 2386 pt.3 Specification
Absorption Engineer
401.2.2
The average loss of
weight of coarse
aggregate after 5 cycles
shall not exceed 12% Technical
As required by As per 2386 para
Soundness Lab test Soundness when tested with Sodium Specification Clause
Engineer 5 & IS: 383
Sulphate and 18% when 401.2.2
tested with magnesium
Sulphate as specified in
IS 383
71
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
The material shall have a

10% Fines Value of 50KN
10% Fines or more for sample in As required by
Lab test 10% Fines Value MORTH CL.401.2.2
Value Soaked Condition when Engineer BIS 812 pt 111
tested in compliance with
BS 812 Part 3
Field Density shall not be
less than 98% of the
Maximum Dry Density.
The acceptance Criteria One set per 500m2 of
shall be that the Mean each compacted area
Field Degree of As per IS 2720 pt
GSB Field test Field Density is not less with minimum number MORTH CL. 903.2.2
Density Compaction 28
than 98% plus(1.65 - of 10 tests in one set
1.65/No of samples 0.5 ) of measurement
times the Standard
Deviation
72
INSPECTION AND TEST PLAN FOR WMM
REFERENCE CLAUSE
FROM MORTH/
INSPECTION INSPECTION
PRODUCT TEST STAGE CHARACTERISTIC ACCEPTANCE CRITERIA SAMPLE SIZE SUPPLEMENTARY
FREQUENCY METHOD
TECHNICAL
SPECIFICATION
Sieve size MORTH

Table 400-11
53mm 100
45mm 95-100
Lab 22.4mm 60-80 1 test per 200m3
Gradation Size of aggregate MORTH Table 400-11
test 11.2mm 40-60 of aggregate
4.75mm 25-40
2.36mm 15-30
.600mm 8-22
.075mm 0- 8
WMM Lab 1 test per 200m3 As per IS MORTH CL.406.2.1.2
PI Value PI Value Not more than 6 425 mic. Down
test of aggregate 2720 pt 5 and MORTH Table 900-3
Lab 1 test per 500m3 As per IS Technical Specification

FI & EI FI & EI Value Not more than 30% 50mm - 6.3mm
test of aggregate 2386 pt 1 Sub Clause 406.2.1.1
Lab 1 test per 1000m3 12.5mm - As per IS

A.I.V Impact Value Not more than 30% MORTH Table 400 -10
test of aggregate 10.0mm 2386 pt 4
As required by
the Engineer
Water Lab crushed As per 2386
WA Not more than 2% suject to minimum MORTH CL.406.2.1.1
Absorption test aggregate pt. 5
of one test per
day
73
INSPECTION AND TEST PLAN FOR WMM
REFERENCE CLAUSE
FROM MORTH/
INSPECTION INSPECTION
PRODUCT TEST STAGE CHARACTERISTIC ACCEPTANCE CRITERIA SAMPLE SIZE SUPPLEMENTARY
FREQUENCY METHOD
TECHNICAL
SPECIFICATION
The average loss of weight of

coarse aggregate after 5 cycles Before approving
As per 2386
Lab shall not exceed 12 % when tested the aggregates Technical Specification
Soundness Soundness para 5 & IS:
test with Sodium Sulphate and 18% and every month 406.2.1.1
383
when tested with Magnesium subsequently
Sulphate as specified in IS 383
As required by
Los
the Engineer Technical Specification
Angeles Lab As per 2386
L.A. Value Not more than 40% suject to minimum 40mm down Table 400 -10
Abrasion test pt 4
of one test per (CL.406.2.1.1)
Value
day
Field Density shall not be less than One set per
98% of the Maximum Dry Density. 500m2 of each
The acceptance Criteria shall be compacted area As per IS
Field Field Degree of that the Mean Field Density is not with minimum 2720 pt 28
number of 10 MORTH CL. 903.2.2
Density test compaction less than 98% plus(1.65 - 1.65/No with big
of samples 0.5) times the Standard tests in one set of cylinder
Deviation measurement
74
INSPECTION AND TEST PLAN FOR DENSE BITUMINOUS MACADAM
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Cleanliness Grain size

Max 5% passing
analysis (Coarse Lab test As per IS 2386 Part I MORTH Table 500-3
0.075mm Sieve
aggregate) individual
MORTH Table 900-4

Quality of Binder Number of samples
Lab test Quality of binder As per IS 73 IS 73 and Technical
Grade 60-70 per lot
Specification CL. 507
1 test per 50m3 of MORTH Table 900-4
aggregate subject to 12.5mm - IS 2386 Part and Technical
Aggregate Impact Value Lab test Impact value Max 27%
minimum of one test 10mm IV Specifications Table
per day. 500-8
Los Angeles Abrasion aggregate subject to IS 2386 Part and Technical
Lab test L.A. Value Max 35% 20mm down
Value minimum of one test IV Specifications Table
per day. 500-8
Flakiness and Elongation aggregate subject to IS 2386 Part and Technical
DBM Lab test FI & EI Value Max 30%
Index minimum of one test IV Specifications Table
per day. 500-8
Initially for source
approval one set of 5
representatives’
specimens for each
source of supply MORTH Table 900-4
Percentage of Minimum retained (Outside and Technical
Stripping Value Lab test IS 6241
coating coating 95% Laboratory). Specifications Table
Subsequently when 500-8
warranted by
changes in the
quality of
aggregates. For
75
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
everyday work one
test per 50M3 of
aggregate subject to
minimum
As required by the
Sand equivalent test Lab test MORTH Table 900-4
Engineer
When gravel is used
Percentage of fractured Percentage of
Lab test , one test per 50M3 MORTH Table 900-4
faces fractured faces
of aggregate
One test for each
source and
Plasticity Index Lab test P.I. Value whenever there is MORTH Table 900-4
change in the quality
of aggregate.
One test for each
MORTH Table 900-4
source and
IS 2386 Part and Technical
Water Absorption Lab test W.A. Max 2% whenever there is
III Specifications Table
500-8
of aggregate.
Grading 2
Nominal
25mm One set of tests on
agg. Size
Layer individual
50-75mm constituents and
thickness MORTH Table 900-4
Cumulative% by mixed aggregate
IS Sieve and Technical
DBM Mix Grading weight of total agg. from the dryer for IS 2386 Part I
(mm) Specifications Table
Passing each400 tonnes of
500-8
mix subject to a
37.5 100
minimum of two tests
26.5 90 - 100 per plant per day
19 71 - 95
13.2 56 - 80
76
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
4.75 38 - 54
2.36 28 - 42
0.3 7 - 21
0.075 2-8
Bitumen
content%
Min 4.0
by mass of
total mix
Bitumen
60-70
grade (pen)
The average loss
of weight of
coarse
aggregates after
5 cycles shall not
One test for each
exceed 12% MORTH Table 900-4
source and
when tested with IS 2386 Part and Technical
Soundness Lab test whenever there is 20mm down
Sodium Sulphate V Specifications Table
and 18% when 500-8
of aggregate.
tested with
Magnesium
Sulphate as
specified in IS
383
77
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
For each 400 tonnes
of mix produced, a
set of 3 Marshall
specimens to be
prepared and tested
Stability of Mix Lab test for stability, flow MORTH Table 900-4
value, density and
void content subject
to a minimum of two
sets being tested per
plant per day
The water Initially one set of 3
sensivity test is representatives’
only required if specimens for each
Water sensitivity of mix
the minimum source of supply.
(Retained Tensile Lab test MORTH Table 900-4
retained coating Subsequently when
Strength)
in the stripping warranted by
test is less than changes in the
95% quality of aggregates
Control of temperature of
binder in boiler, At reqular close
aggregate in the dryer Field test interval, as required MORTH Table 900-4
and mix at the time of by the Engineer
laying and rolling
DBM
One test fo each 400
tonnes of mix subject
Control of Binder content
Lab test to a minimum of two MORTH Table 900-4
and grading of the mix
tests per day per
plant
78
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
At reqular close
Bitumen Mixing Field test 150oC to 165oC interval, as required MORTHTable 500-5
by the Engineer
At reqular close
Aggregate Mixing Field test 150oC to 170oC interval, as required MORTHTable 500-5
by the Engineer
At reqular close
Mixed Material Field test 165oC Maximum interval, as required MORTHTable 500-5
by the Engineer
At reqular close
Rolling Field test 90oC Minimum interval, as required MORTHTable 500-5
by the Engineer
125oC Minimum At reqular close
MORTHT able 500-5
Laying Field test and not exceed interval, as required
IRC 94
1600. by the Engineer
Density of compacted One test per 250M2

Field test Compaction MORTH Table 900-4
layer area
Regular control
through checks on
Rate of spread of
Field test Spread the weight of mixed MORTH Table 900-4
materials
material and layer
thickness
Technical
Filler Material Specifications Cl No.
507.2.4
79
INSPECTION AND TEST PLAN FOR BITUMINOUS CONCRETE
REFERENCE
CLAUSE FROM
INSPECTION SAMPLE INSPECTION MORTH/
PRODUCT TEST STAGE CHARACTERISTIC ACCEPTANCE CRITERIA
FREQUENCY SIZE METHOD SUPPLEMENTARY
TECHNICAL
SPECIFICATION
Cleanliness
Grain size
Max 5% passing 0.075mm MORTH Table 500-
analysis (Coarse Lab test IS 2386 Part I
Sieve 17
aggregate)
individual
Number of samples per
Quality of Binder Lab test Quality of binder MORTH 900-4
lot and test as per IS 73
1 test per 350m3 of

aggregate for each
Flakiness and MORTH Table 500-
Lab test FI & EI Value Max 30% (Combined)2 source and whenever IS 2386 Part I
Elongation Index 17
there is change in the
quality of aggregate.
BITUMINOUS 1 test per 350m3 of
CONCRETE aggregate for each
Los Angeles IS 2386 Part MORTH Table 500-
Lab test L.A. Value Max 30% source and whenever
Abrasion Value IV 17
1 test per 350m3 of
aggregate for each
Aggregate 12.5mm IS 2386 Part MORTH Table 500-
Lab test Impact value Max 24% source and whenever
Impact Value to 10mm IV 17
One test for each source
Water and whenever there is IS 2386 Part MORTH Table 500-
Lab test W.A. Max 2%
Absorption change in the quality of III 17
aggregate.
80
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
The average loss of weight
of coarse aggregates after 5
cycles shall not exceed One test for each source
Sodium Sulphate
12% when tested with and whenever there is IS 2386 Part MORTH Table 500-
Soundness Lab test Magnesium
Sodium Sulphate and 18% change in the quality of V 17
Sulphate
when tested with aggregate.
Magnesium Sulphate as
specified in IS 383
Initially one set of 3

Coating and representatives’
Stripping of specimens for each
Percentage of Minimum retained coating MORTH Table 500-
Bitumen Lab test source of supply. IS 6241
coating 95% 17
Aggregate Subsequently when
Mixtures warranted by changes in
the quality of aggregates
Mix Designation
Grading I Grading II
Nominal agg. Size
BITUMINOUS
19mm 13mm
CONCRETE
Layer thickness 50-
65mm 30-45mm One test for individual
IS Sieve (mm) constituent and mixed
Composition of
Cumulative% by wt.of total aggregate from dryer for
Grading Lab test Bituminous MORTH 500 - 18
Agg. passing each 400T of mix subject
Concrete
45 to minimum of two test
per day per plant.
37.5
26.5 100
19 79 -100
81
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
100
13.2 59 - 79
79 -100
4.75 35-55
53-71
2.36 28-44
42-58
1.18 20-34
34-48
0.6 15-27
26-38
0.300 10-20
18-28
0.15 5-13
12-20
0.075 2-8
4-10
Initially one set of 3
The water sensivity test is
representatives’
only required if the
specimens for each
Water sensitivity minimum retained coating in
source of supply. MORTH 900-4
of Mix the stripping test is less
Subsequently when
than 95% & it should be at
warranted by changes in
least 80%
the quality of aggregates
Percentage of When gravel is used ,
fractured faces one test per 50M3 of MORTH 900-4
for gravel aggregate
82
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Control of
temperature of
binder and
aggregate for
At regular interval MORTH 900-4
mixing and of
the mix at the
time of laying
and rolling
Bitumen Number of samples per MORTH Table 500-
Lab test Penetration 65
Penetration lot and tests as per IS 73 18
Bitumen MORTH Table 500-
Field test 1500C - 1650C At regular close interval
Mixing(oC) 5
Aggregate MORTH Table 500-
Field test 1500C - 1700C At regular close interval
mixing (oC) 5
BITUMINOUS
CONCRETE Field test
Mixed MORTH Table 500-
and Lab 165oC Maximum At regular close interval
Material(oC) 5
test
MORTH Table 500-
Rolling (oC) Field test 900C minimum At regular close interval
5
MORTH Table 500-
Laying (oC) Field test 125oC Minimum At regular close interval
5
One set for each 400 T of
Binder Content
5.0 - 6.0 (Grading I) 5.0 - mix subject to minimum MORTH Table 500-
and aggregate Lab test
7.0 (Grading 2) of two tests per day per 18
grading
plant
Rate of spread
MORTH Table 900
of mixed Field test After every 5th truck load
-4
material
83
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Density of MORTH Table 900

Field test Compaction One test per 700m2 area
compacted layer -4
INSPECTION AND TEST PLAN FOR PRIME - TACK COAT

REFERENCE CLAUSE
FROM MORTH/
ACCEPTANCE INSPECTION
PRODUCT TEST STAGE CHARACTERISTIC INSPECTION METHOD SUPPLEMENTARY
CRITERIA FREQUENCY
TECHNICAL
SPECIFICATION
Quality of Binder As per IS 73, IS 217, MORTH Table 900-4 and

PRIME Number of samples per
(Bitumen Lab test Quantity of binder IS 8887 whichever is As per IS 8887 Technical Specification
COAT lot
Emulsion) applicable CL. 502
Binder
Field test Binder temperature 1650C At regular close interval MORTH Table 900-4
temperature
MORTH Table 900-4 and

Rate of spread of As per MORTH Cl.
Field test Quantity of Binder 9.0 kg/10 m2 Three test per day As per MORTH Cl.
binder 502.4.3
502.4.3
Quality of Binder As per IS 73, IS217,

Number of samples per
Tack Coat (Bitumen Lab test Quantity of Binder IS 8887 whichever is As per IS 8887 MORTH Table 900-4
lot
Emulsion) applicable
84
INSPECTION AND TEST PLAN FOR PRIME - TACK COAT
REFERENCE CLAUSE
FROM MORTH/
ACCEPTANCE INSPECTION
PRODUCT TEST STAGE CHARACTERISTIC INSPECTION METHOD SUPPLEMENTARY
CRITERIA FREQUENCY
TECHNICAL
SPECIFICATION
Binder
temperature for Field test At regular close intervals MORTH Table 900-4
application
Tray method as given in MORTH Table 900-4 and
2.5kg /10m2 on Dry
Appendix V of IRC Special Technical Specification
Rate of spread of & hungry surface
Field test Quantity of Binder Three test per day Publication No.11
Binder and 2kg/ 10m2 on
Bituminous surface
Spreading
Field test 20oC - 70oC MORTH CL.503.4.3
Temperature
INSPECTION AND TEST PLAN FOR BITUMEN

REFERENCE CLAUSE
FROM MORTH/
ACCEPTANCE INSPECTION INSPECTION
PRODUCT TEST STAGE CHARACTERISTIC SAMPLE SIZE SUPPLEMENTARY
CRITERIA FREQUENCY METHOD
TECHNICAL
SPECIFICATION
One test per 50
60-70 for S-65 tones or as
PENETRATION Lab test Penetration value As per cup As per IS 1203
grade required by the
Engineer
One test per 50
Temp at which
Bitumen SOFTENING tones or as
Lab test point Bitumen 40oC - 550C As per Mould As per IS 1205
POINT required by the
soften
Engineer
As required by
DUCTILITY Lab test Ductility value Minimum 75 cm As per Mould As per IS 1208
the Engineer
85
FLASH AND FIRE Temp. at which As required by
Lab test As per IS 73 As per IS 1209
POINT point Bitumen burn the Engineer
SPECIFIC As required by
Lab test As per IS 73 As per IS 73
GRAVITY TEST the Engineer
LOSS ON As required by
Lab test As per IS 73 AS per IS 1212
HEATING TEST the Engineer
INSPECTION AND TEST PLAN FOR CONCRETE

REFERENCE CLAUSE
FROM MORTH/
ACCEPTANCE INSPECTION SAMPLE INSPECTION
PRODUCT TEST STAGE CHARACTERISTIC SUPPLEMENTARY
CRITERIA FREQUENCY SIZE METHOD
TECHNICAL
SPECIFICATION
Minimum 5 trials mix

for each grade and
Mix design Lab test Cement content/m3 As per IS 10262 20mm down IS 10262
as required by
Engineer
As required by
Engineer subject to
Workability Field test Slump Value 60 + 35mm IS 1199
minimum of two
CONCRETE tests per day of work
(STRUCTURE) Minimum of two test
Gradation of Lab/Field As per IS 383 latest per day or as MORTH & Technical
Gradation IS 2386 Part I
Sand test revision required by the Specifications CL.1008
Engineer
Minimum of two test
Gradation of
Lab/Field As per IS 383 latest per day or as MORTH & Technical
Coarse Gradation IS 2386 Part I
test revision required by the Specifications CL.1007
aggregate
Engineer
86
INSPECTION AND TEST PLAN FOR CONCRETE
REFERENCE CLAUSE
FROM MORTH/
ACCEPTANCE INSPECTION SAMPLE INSPECTION
PRODUCT TEST STAGE CHARACTERISTIC SUPPLEMENTARY
CRITERIA FREQUENCY SIZE METHOD
TECHNICAL
SPECIFICATION
Minimum of two test

Silt Content of Lab/Field per day or as MORTH & Technical
Not more than 4 % IS 2386 Part I
Sand test required by the Specifications CL.1008
Engineer
5 tests of the source
approval (Outside
12.5mm to MORTH & Technical
A.I.V Lab test Not more than 45% Laboratory) and as IS 2386 pt 4
10mm Specifications CL.1007
required by the
Engineer
Flakiness of
As required by MORTH & Technical
Coarse Lab test Not more than 35% IS 2386 pt 1
Engineer Specifications CL.1007
aggregate
a) The mean
strength
determined from
any group of four
consecutive
samples should
1m3 - 5m3 = 1 set
exceed the
6m3 - 15m3 = 2 set
specified
16m3 - 30m3 = 3 set
Cube casting and Lab/Field Cube casting and characteristic MORTH CL.1716.2.4
31m3 - 50m3 = 4 set As per IS 516
strength test strength of cubes compressive MORTH CL. 1716.2.5
with a minimum of
strength.
one set of three
b) Strength of any
cubes per day
sample is not less
than the specified
characteristic
compressive
strength minus 3
Mpa.
87
INSPECTION AND TEST PLAN FOR CEMENT
REFERENCE
CLAUSE FROM
TECHNICAL
SPECIFICATION
Fineness Lab test % of fineness Maximum 10% As per IS 4031
As per Vicat
One test per 50 Mould
Initial setting time Lab test Initial setting time Minimum 30 minutes MT or as required As per IS 4031
CEMENT by the Engineer

Final setting time Lab test Final setting time Maximum 600 minutes As per IS 4031
Soundness Lab test Soundness Maximum 10mm As per IS 4031

Compressive Strength of Mortar As per grade of 70.6mm cube
Lab test As per IS 4031
Strength cubes Cement mould
Chemical As per grade of As required by
Lab test Chemical composition
Composition Cement the Engineer
88
INSPECTION AND TEST PLAN FOR WATER
REFERENCE
CLAUSE FROM
INSPECTION INSPECTION MORTH/
FREQUENCY METHOD SUPPLEMENTARY
TECHNICAL
SPECIFICATION
Organic Max. 200Mg/lit
Inorganic max. 3000 Mg/lit
Sulphate (SO4) Max. 500 Mg/lit

As required by
WATER Lab test Solid Content N.A. As per IS 3025
Engineer
Chloride (CL) Max.500Mg/lit
Suspended matter Max.2000Mg/lit
pH Value Not less than 6
89
QUALITY CONTROL PROCEDURE
Name of Work: Strengthening of 2 lane with paved shoulder of NH-54 from 12th
: EPC CONTRACTOR:
Century Plaza, 3rd Floor, Ganeshguri
Assam, Pin-871005
QUALITY CONTROL PROCEDURE
APPENDIX-III
INTRODUCTORY PART
Quality Control Procedure is presented in mainly following categories i.e. SOIL,

AGGREGATE/ CONCRETE, CEMENT AND BITUMEN.
1 SOIL 1. A MDD & OMC

1. B LL, PL & PI
1. C CBR (4 Days Soaked)
1. D FSI
1. E FDD
1. F SIEVE ANALYSIS
2 AGGREGATE / CONCRETE 2. A GRADATION

2. B IMPACT
2. C ABRASION
2. D SPECIFIC GRAVITY & WATER
ABSORPTION
2. E SILT CONTENT
2. F CRUSHING VALUE
2. G SHAPE TEST
2. H AGGREGATE ALKALI REACTIVITY
2. I SOUNDNESS
2. J CONCRETE CUBE CASTING
2. K SLUMP TEST
3. CEMENT 3. A.1 IS & FS TIME

3. A.2 CONSISTENCY
3. A.3 SOUNDNESS
3. A.4 FINENESS
4. BITUMEN 4. A PENETRATION
4. B SOFTENING POINT
4. C FLASH & FIRE POINT
4. D DUCTILITY
4. E SPECIFIC GRAVITY OF BITUMEN
4. F BITUMEN EXTRACTION
4. G STRIPPING VALUE
4. H MARSHALL STABILITY TEST
4. HUME PIPE
5. TESTING FORMATS
PART - I
SOIL
1
1. A NAME OF TEST : MDD & OMC
DEFINITION : Compaction is a process by which the soil particles

are artificially rearranged and packed together into a closer
state of contact by mechanical means in order to decrease
the porosity of the soil and thus increase its dry density.
SCOPE : The object of the test is to determine the relationship

between water content and dry density of the soil using
Standard Proctor or Modified Proctor and then to determine
the optimum water content and the corresponding maximum
dry density for the soil.
APPARATUS REQ. : Proctor mould, Proctor rammer, Steel Straight Edge,

Mixing Pan, Spoon, Trowel, Spatula, Sample Extruder,
Measuring Cylinder of glass 100ml capacity,
Thermostatically controlled oven to maintain temperature
between 105 to 110 0C
TEST PROCEDURE : Representative sample of 7kg passing 19mm IS

Sieve was collected and mixed thoroughly. Take the empty
weight of mould with base to the nearest 1gm accuracy. Mix
the soil and compact in five equal layers, each layer being
given 25 blows from the rammer weighing 4.89kg for 1000cc
mould. If however 2250cc mould is used about 5kg of
sample should be used and compacted in five layers by
giving 56 blows in each layer from the rammer weighing
4.89kg. The blows should be uniformly distributed over the
surface of each layer. Remove the collar and cut the excess
soil with the help of straight edge clean and weigh to the
nearest 1gm. Eject out the soil from the mould cut it in the
middle and keep a representative soil specimen for water
content determination. Calculate the corresponding Dry
density for the moisture content and repeat the procedure to
arrive at five points. Then plot a graph between moisture
2
content and dry density in normal graph and note the point
of Maximum Dry Density & Optimum Moisture Content.
OBSERVATION : AS PER ANNEXURE ENCLOSED
LIMITS : As per MORT & H

Embankment Up to 3m height > 1.52 gm/cc
Embankment more than 6m height > 1.60 gm/cc
Subgrade > 1.75 gm/cc
3
1. B NAME OF TEST : LL, PL & PI
DEFINITION : LIQUID LIMIT - It is defined as the minimum water

content at which the soil is still in the liquid state but has a
small shearing strength against flowing which can be
measured by standard available means.
PLASTIC LIMIT - It is defined as the minimum water
content at which a soil will just begin to crumble when rolled
into a thread approximately 3mm in diameter.
PLASTIC INDEX - It is defined as the numerical
difference between the liquid limit and plastic limit of soil.
SCOPE : To determine the Index properties of soil and their

classification.
APPARATUS REQ. : Liquid Limit device (Cassagrandes Apparatus / Cone

Penetrometer), Porcelain dish about 12cm in diameter,
Flexible spatula, Balance, thermostatically controlled oven to
maintain temperature between 105 to 110 0C, 425micron
sieve, 3mm rod and desiccator.
TEST PROCEDURE : Liquid Limit –

About 120gms of soil sample passing through 425mic. IS
Sieve is collected and mixed thoroughly with distilled water
in the evaporating dish till the uniform paste is formed. With
the help of spatula place it in the centre of the cup so that it
is almost half filled. With the help of grooving tool the paste
in the cup is divided along the cup diameter. The cup was
allowed to fall at the rate of 2 per sec. Until the two parts of
soil come in contact with the bottom of the groove along a
distance of 10mm. A representative soil sample collected for
the determination of moisture content. The test was
repeated 3 to 4 times to get the no. of blows in the range of
15 to 35. A semi log graph plotted between no. of blows and
4
moisture content and moisture content corresponding to 25
blows were noted as Liquid Limit of the soil.
Plastic Limit –
About 20gms of soil passing through 425mic. Were
collected and mixed with distilled water. Prepare a ball and
roll it with a pressure sufficient to make thread of 3mm dia
throughout. When the diameter of the thread was decreased
to 3mm the specimen is kneaded together and rolled out
again. Continue the process until the thread just crumbles at
3mm diameter. The moisture content of the crumbed portion
were determined and represented as Plastic Limit of the soil.

LIMITS : LL < 70% and PI < 45%
5
1. C NAME OF TEST : CBR (4 Days Soaked)
DEFINITION : This is a penetration test developed by the California
Division of Highways as a method for evaluating the stability
of soil subgrade and other flexible materials.
SCOPE : The CBR test is essentially an arbitrary strength test.
The test is meant for soils and is also carried out on sub-
base and granular base course materials.
APPARATUS REQ. : CBR M/c, CBR mould, standard rammer, 19mm IS
Sieve, Electronic weighing balance, plunger 50mm in dia,
spacer disc, brass perforated plate annular weights of 2.5kg
& filter paper
PROCEDURE : The air-dried sample was collected in an enamel tray
and was compacted to 97% of the MDD of the sample. The
representative sample was kept for determining the moisture
content of the sample and was allowed to soak in water. The
dial gauge was placed on the mould in the top and initial
reading was noted. For each day the soaking in the mould
was noted. The initial and final reading of the dial gauge
gives the % swelling in the soil. The mould was removed
from the tank and kept outside in slanting for 15 min. to
drain out. The mould was positioned on the m/c for testing
and started. The plunger was positioned and proving ring &
dial gauge reading were made zero. The plunger was
allowed to penetrate @ 1.25mmpermin. and proving ring
readings corresponding to different levels of penetration
depth were noted. The graph was plotted between the
penetration depth and proving ring readings and value at
2.5mm and 5mm penetration were noted and calculated for
CBR value. The higher value will be represented as CBR
Value, if CBR value of 5mm penetration is more than 2.5mm
penetration, then the test is to be repeated. If in the repeat
test also the same results persist then the 5mm penetration
value will be presented as CBR VALUE of the soil.
LIMITS : Should be more than 7%
6
1. D NAME OF TEST : FSI (Free Swell Index)
DEFINITION : It is the swelling of the soil observed when placed

under standard test conditions.
SCOPE : This helps to identify the potential of a soil to swell

which might need further detailed investigation regarding
swelling and swelling pressures under different field
conditions.
APPARATUS REQ. : High precision Balance 600gms cap. 425 mic. IS

Sieve, 100ml glass cylinder.
PROCEDURE : About 10gms of oven dried sample shall be poured

in each of the two glass graduated cylinders of 100 ml
capacity each. One filled with distilled water and the one
with kerosene and kept undisturbed for 24 hrs. The volume
will be compared with sample left in kerosene as standard to
that of water, kerosene being a non-polar liquid does not
cause swelling of the soil. The result will be represented as
%.
LIMITS : Should not be more than 50%
7
1. E Name of Test : Field Dry Density
Field Dry density of soil and GSB can be determined, with sand replacement method.
Difference between the process of FDD test for Soil, GSB and Bedding material for pipe
Bedding material GSB/Soil
Small pouring cylinder method: - Large pouring cylinder method: -
(1) The method is applicable to (1) This method is applicable to GSB

layers not exceeding 150mm in because of consists of gravel or
thickness. stone. It can also used for soil
compaction test upto 250mm thick
(2) Height of the sand pouring
cylinder is 380mm with internal dia. (2) Height of sand pouring cylinder
115mm is 610mm with internal dia 215mm
(3) Calibrating container with an (3) Calibrating container with

internal dia 100mm and in internal internal dia 200mm and internal depth
depth of 150mm 250mm
(4) 300mm square, 40mm deep (4) 450mm square, 50mm deep with
calibrating container with internal dia a 200mm dia hole in the centre tray.
200mm and internal depth 250mm
APPARATUS: Common for all i.e. Soil, GSB and bedding material tests are:
(i) Moisture meter
(ii) Metal Container
(iii) Weight Balance
(iv) Tools for excavating holes i.e. scraper, screwdriver, painted-steel rod
(v) Clean, uniformly graded 1.00mm passing and 600micron retained sand. It is generally
standard sand grade I, grade II and grade III.
8
PROCEDURE:
DETERMINATION OF SAND DENSITY:
(1) Sand cylinder is filled with the sand up to certain weight and record the same say
W1
(2) Sand cylinder along with sand must be placed over a glass plate on a leveled
surface.
(3) Now sand is allowed to run out from the sand cylinder over the glass plate by
opening the shutter of sand pouring cylinder. When no further movement of sand
takes place in the cylinder the shutter shall be closed and the cylinder removed
carefully and wet again and record the said weight say W2
Weight of sand in the cone Wc = W1 – W2
(4) Repeat the procedure (1) Then Place the sand pouring cylinder over the
calibrating Container and allow the sand to run out from the sand pouring cylinder
by opening the shutter of sand pouring cylinder. When no further movement of
sand takes place in the cylinder the shutter shall be closed and the cylinder
removed carefully and weihed again and record the said weight say W3
Sand in the calibrating container = W1 – W3 – Wc
Volume(v) of the calibrating container can be measured by taking the

measurement.
Now density of the sand = W1 – W3 - Wc
Density of soil
1) Sand cylinder is filled with the sand upto the certain weight
and record the same, say W1
2) Tray is placed at the position where density is required
3) At boundary of the tray nail is fixed, so that the tray is not

displaced
9
4) With the help of excavating tool soil is dug upto the
compacted thickness that is 250mm(Maximum) inside the
circular opening portion of the tray
5) Weight of the soil is taken, say WS
6) After removing the tray sand cylinder is filled with sand W1

weight is placed centrally over the hole and allow the sand to
run out from the sand cylinder to the excavated hole by
opening the shutter of sand pouring cylinder. When no further
movement of sand takes place in the cylinder the shutter shall
be closed and cylinder removed carefully and weighed again.
Say this weight is Wf.
CALCULATION
Weight of the sand in the hole = W1-Wf-Wc
Where Wc = Weight of sand in the cone which was previously check
W1-Wf-Wc
Volume of hole (Vh) = CC
Density of sand
Acceptance criteria
Refer MOST Section 900 Clause 903.2.2
The acceptance condition of FDD
Mean density is not less than 1.65 - 1.65 times the standard
deviation (Number of samples)0.5
Standard Deviation: j
J= E(X – X’)2
n–1
Where x = Any value in the set

n = no of samples
x’ = arithmetic mean of the density
10
APPLICABILITY:
For a large stretch of road where density is required to be determined it may not be
possible to achieve the specified percentage of compaction at all locations. Standard
deviation application may give the good result.
1. F Name of Test : Sieve Analysis

As Per Specifications
11
PART - II
AGGREGATES
12
2. A NAME OF TEST : GRADATION TEST
DEFINITION : Gradation test is defined as the percentage weight

passing of aggregate in each sieve to be confirmed with the
gradation limits given in the specification.
SCOPE : This test gives the grading of the aggregate to be

matched with IS 383-1970.
APPARATUS REQ. : IS Sieve set, weighing balance.
PROCEDURE : About 5 to 10 kg of sample taken for coarse

aggregate and 1 kg taken for fine aggregate for gradation
check. The sieve were arranged from big to small size as
per the grading required and charred in clockwise, anti-
clockwise, forward & backward movement till no aggregate
is passing through the openings. The weight retained on
each sieve is noted and percentage of each sieve passing is
calculated.
LIMITS : As per IS 383 table-4 for fine aggregates & table-2

for coarse aggregate.
13
2. B NAME OF TEST : IMPACT TEST
DEFINITION : To evaluate the toughness of stones or resistance of

the aggregate to fracture under repeated impacts is called
Impact Test.
SCOPE : The aggregate Impact value indicates a relative

measure of resistance of aggregate to Impact.
APPARATUS REQ. : Impact Tester, 2.36mm, 10mm & 12.5mm IS Sieve,

High precision balance 600gms capacity.
PROCEDURE : Aggregate specimen passing 12.5mm sieve and

retained on 10mm sieve is filled in the cylindrical measure in
three layers by tamping each layer by 25 blows. The sample
is transferred from the measure to the cup of aggregate
impact testing machine and compacted by tamping 25
times. The hammer is raised to a height of 38cms above the
upper surface of the aggregate in the cup and is allowed to
fall freely on the specimen. After subjecting the test
specimen to 15 blows, the crushed aggregate is sieved on
2.36mm sieve. The aggregate impact is expressed as the
percentage of the fine formed in terms of the total weight of
the sample.
LIMIT : 1. For Concrete other than wearing course AIV< 45%

2. For WMM & Bituminous Macadam AIV< 30%
3. For DBM & SDBC AIV< 27%
4. For Bituminous Concrete AIV< 24%
14
2. C NAME OF TEST : ABRASION TEST
DEFINITION : Due to movement of traffic the aggregates used in

the surface course are subject to wearing action at the top.
Hence they should be hard enough to resist the abrasion
due to traffic.
SCOPE : This test is carried out to test the hardness

properties of stones and to decide whether they are suitable
for the different road construction works.
APPARATUS REQ. : Los Angeles abrasion testing m/c, IS Sieve set,

Electronic weighing balance,
PROCEDURE : About 5 to 10kg (depending on the gradation) of the

aggregate specimen is placed in the machine along with the
abrasive charges. The machine is rotated at a speed of 30to
33rpm for the specified number of revolutions. The abraded
aggregate is then sieved on 1.7mm IS Sieve, and weight of
the powdered aggregate passing this sieve is found. The
results of the abrasion test is expressed as percentage wear
or the percentage passing 1.7mm sieve expressed in terms
of the original weight of the sample.
LIMITS : 1. For Concrete other than wearing course LAV < 50%
2. For WMM & Bituminous Macadam LAV < 40%
3. For DBM & SDBC LAV < 35%
4. For Bituminous Concrete LAV < 30%
15
2. D NAME OF TEST : Specific Gravity and water absorption test
DEFINITION : Specific Gravity is the weight of dry aggregate by

weight of equal volume of water. Water absorption is
expressed as the percentage water absorbed in terms of
oven dried weight of the aggregates.
SCOPE : The specific gravity of an aggregate is considered to

a measure of the quality or strength of the material. Stones
having low specific gravity values are generally weaker than
those having higher values.
APPARATUS REQ. : Pycnometer 1000ml capacity, Wire basket, weighing

balance, thermostatically controlled oven maintaining
constant temperature of 105 - 110 0C.
PROCEDURE : Initially weight of pycnometer filled with water is

weighed as W2, and then the water was replaced by
aggregate sample completely filled. This weight i.e. weight
of sample, water and pycnometer is weighed as W1. The
sample was kept undisturbed for 24hrs to mature and weight
of saturated surface dry sample was taken as W3 in gms.
Then the aggregates were collected and placed in an oven
at 105 to 110 0C for drying. The weight of oven dried
sample was noted as W4 in gms.
Specific Gravity is calculated as weight of oven dried sample
to the weight of saturated surface dry aggregate minus the
weight of water.
Water absorption is calculated as wt. Of water divided by the
oven dried weight of sample.
LIMIT : As per IS / MORT & H Water Absorption < 2%
16
2. E NAME OF TEST : SILT CONTENT
DEFINITION : Weight of Fines passing 75 micron IS sieve is

defined as silt content of the material.
SCOPE : Depending upon the silt content the use of fines for
the concrete work is decided. For uncrushed material this
should not be more than 3% by weight.
APPARATUS REQ. : IS sieve 75 micron, weighing balance & oven.
PROCEDURE : About 500 gms of fine aggregate were weighed and

washed in distilled water thoroughly till clean water flows
out. The collect the fines retained on the sieve with utmost
care and keep in an oven at 105 to 110 0C for drying. Take
the weight of dried fine aggregates to the nearest 1gm
accuracy and be reported as % of total weight. This will be
the silt content by weight.
LIMIT : For uncrushed material < 3% & for crushed material <15%
17
2. F NAME OF TEST : CRUSHING VALUE
DEFINITION : Aggregate crushing value provides a relative measure of

resistance to crushing under gradually applied compressive
load.
SCOPE : It gives the strength of aggregate and suitability of the

aggregate to be used in the wearing courses.
APPARATUS REQ. : CTM, Steel cylinder 15.2cm dia with a base plate and
plunger, cylindrical measure of dia 11.5cms and height
18cms, tamping rod and sieve.
PROCEDURE : Dry aggregate passing 12.5mm sieve and retained on

10mm sieve is filled in the cylindrical measure in three equal
layers, each layer being tamped 25 times by the tamper.
The plunger is placed on the top of the specimen and a load
of 40 tons is applied @ 4 tons per minute by CTM. The
crushed aggregate is removed and sieved on 2.36mm sieve.
The aggregate crushing value is the percentage of the
crushed material passing 2.36mm sieve in terms of the
original weight of the specimen.
LIMIT : 1. For Concrete other than wearing course < 45%

2. For Concrete in wearing course <30%
18
2. G NAME OF TEST : SHAPE TEST
DEFINITION : Flakiness Index - FI is the percentage by weight of

aggregate particles whose least dimension or thickness is
less than three fifth or 0.6 of their mean dimensions.
Elongation Index - EI is the percentage by weight of
particles whose greatest dimension or length is greater than
one and four fifth or 1.8 times their mean dimension.
SCOPE : Useful in determining the Index properties of Aggregate.
APPARATUS REQ. : Flakiness gauge, Elongation gauge, IS Sieve set, Weighing
balance.
PROCEDURE : FI - Sample of aggregate to be tested is sieved through a
set of sieves and separated into specified size ranges. The
width of the appropriate slot would be 0.6 of the average of
the size. The flaky materials passing the appropriate slot
from each size range of test aggregate are added up. The
flakiness index is the percentage of flaky material the width
of which is less than 0.6 of the mean dimensions.
EI - The aggregate from each of the size range is
individually passed through the appropriate gauge of the
length gauge with the longest side in order to separate the
elongated particles. The gauge length would be 1.8 times
the mean size of the aggregate. The portion of the
elongated aggregate having length greater than the
specified gauge from each size range is weighed and the
total weight of the elongated stones, is expressed as a
percentage of the total weight of the sample, to get the
elongation index.
LIMITS : 1. For Concrete, Flakiness Index < 35%
2. For WMM & all Bituminous works,
Combined FI & EI < 30%
19
2. H Name of Test : ALKALI AGGREGATE REACTIVITY
1. Weigh three representative 25.00±0.05 g portions of the dry 300-micron test

sample prepared in accordance with Clause 3.5 of IS : 2386 (Part VII) – 1963.
2. Place one portion in each of three of the reaction containers and add by means of
a pipette or burette 25ml of the 1.000 N caustic soda solution.
3. To a fourth reaction container, by means of a pipette or burette, add 25 ml of the
same caustic soda solution to serve as a blank. Seal the four containers and
gently swirl them to liberate trapped air.
4. Immediately after the containers have been sealed, place them in liquid bath
maintained at 80 ±1.0˚C. After 24±1/4 h remove the container from the bath and
cool them under flowing water for 15±2 minutes to below 30˚C.
5. After the containers have been cooled, open them and filter the solution from the
aggregate residue. Use a porcelain Gooch crucible with a disc of rapid, low- ash
filter paper cut to fit the bottom of the crucible, setting the crucible in a rubber
crucible holder in a funnel. Place a dry test tube, of 30 to 50 ml capacity, in the
filter flask to collect the filtrate, and seat the funnel in the neck of the filter flask.
With the aspirator in operation or the vacuum line open, decant a small quantity of
the solution onto the filter paper so it will seat properly in the crucible. Without
stirring the contents of the container, decant he remaining free liquid into the
crucible. When the decantation of the liquid has been completed, discontinue the
vacuum and transfer the solid remaining in the container to the crucible and pack
in place with the aid of a stainless steel spatula. Then apply and adjust the vacuum
to approximately 375 mm of mercury. Continue the filtration until further filtration
yields filtrate at the approximate rate of one drop every 10 seconds; reserve the
filtrate for further tests. Record the total amount of time during which the vacuum is
applied as the filtration time; every effort shall be made to achieve an equal
filtration time for all samples in a set, by uniformity of procedure in the assembly of
the filtration apparatus and the packing of the solids in the crucible.
6. Filter the blank according to the procedure described above. Apply the vacuum for
a length of time equal to the average filtration time for three specimens.
7. Immediately following the completion of filtration, stir the filtrate to assume
homogeneity, then take an aliquot of 10ml of the filtrate and dilute with water to
200 ml in a volumetric flask. Reserve this diluted solution for the determination of
dissolved silica and reduction in alkalinity.
20
NOTE - If the diluted filtrate is not to analyzed within 4 hr. following completion of the
filtration, transfer the solution to a clean, dry polyethylene container and close the
container by means of a stopper or tight- fitting cap or lid.
2. I Name of Test : Soundness

Prepare the solution of Sodium Sulphate or Magnesium Sulphate with water as per IS
2386 pt 5.
Sieve the aggregates as per IS specifications.
Follow The Procedure as Per IS 2386 pt-5 as per Specification.
RESULTS-
The Results Should be Reported giving the Following Particulars;
(a) Type of Solution Used for the test.
(b) Weight of each Fraction of Sample before test.
(c) Material From each fraction of the sample finer
than the sieve on which the fraction was retained
before test expressed as a Percentage by wt of
the fraction.
(d) Weighted average calculated from the Percentage
loss for each fraction based on the grading of
the sample as received from examination.
(e) In the case of particles coarser than 20mm size
before the test .the number of Particles in
each fractions before the test and the number of
Particles affected . classified as to the number
disintegrating , splitting crumbling cracking , Flaking
etc.
21
PART - III
CONCRETE
22
3. A.1 NAME OF TEST : INITIAL AND FINAL SETTING TIME
DEFINITION : Initial Setting Time - It is the time elapsed for leaving

an impression with ring to the time of adding water.
Final Setting Time - It is the time elapsed for leaving
an impression of the tip of the ring only to the time of adding
water to cement.
SCOPE : Required for the determination of properties of cement.
APPARATUS REQ. : Vicat’s apparatus, porcelain dish, high precision balance.
PROCEDURE : About 400 gms of cement weighed and water added to it

approximately 0.85 P where P is the consistency of cement
of the same batch. The cement paste is mixed thoroughly to
get a uniform paste and the mould was prepared. The
arrangement was kept below the vicats apparatus needle for
penetration. The needle was allowed to fall freely on the
mould and the readings were noted. The time taken to
penetrate the needle about5 - 7mm from bottom is noted as
Initial Setting Time. Then the needle changed and fitted the
Final setting time needle which is having a round shape at
the tip. This is the time taken to keep an impression of the
circular ring on the mould.
OBSERVATION : AS PER ANNUXURE ENCLOSED
LIMITS : Initial Setting Time > 30min.

Final Setting Time < 600min.
23
3. A.2 NAME OF TEST : CONSISTENCY TEST
DEFINITION : It is the amount of water required to prepare a cement

paste which will allow the needle to penetrate 5 to 7mm from
bottom.
SCOPE : To determine the properties of cement.
APPARATUS REQ. : Vicats apparatus, porcelain dish, high precision balance.
PROCEDURE : 400gms of cement weighed and collected in a

porcelain dish and approximately 25% of water added
initially to prepare the mix. The mixing was done till
uniformity of the paste achieved and mould filled with
tamping to remove air bubbles any inside within the
timeframe of 5minutes. Immediately after the preparation of
mould the arrangement was kept under the penetration
needle and allowed to penetrate. Note the reading on the
gauge if it is in the range of 5 to 7mm from bottom then the
% of water added will be represented as consistency of the
cement.
LIMITS : Consistency of the Cement should be less than or

equal to 30.
24
3. A.3 NAME OF TEST : SOUNDNESS TEST
DEFINITION : Soundness is defined as the deformation or cracks

or any surface failure observed when the mould was heated
to a temperature of 100 0C for three hours.
SCOPE : This test is useful in determining the swelling of

cement while heating.
APPARATUS REQ. : Le-chatliers apparatus, water bath with temperature

range of 0-120 0 C, Weighing Balance.
PROCEDURE : About 400 gms of cement weighed and water added

at 0.72 times P where P is the consistency of cement. The
moulds were filled after mixing the cement uniformly. Then
they were kept in water bath maintained at constant
temperature of 30 0C for 24 hrs. Initial readings of the tip
were noted with the help of gauge and the moulds were kept
in water bath at 100 0C for three hours. Then the final
reading of the tip is noted. The difference is reported as the
soundness of the cement.
LIMIT : Should not be more than 10mm
25
3. A.4 NAME OF TEST : FINENESS TEST
DEFINITION : Fineness of the cement is defined as the percentage

passing 90 micron sieve.
SCOPE : The fineness of the cement affects the strength as

well as the setting time of the concrete.
APPARATUS REQ. : 90mic. IS Sieve, high precision balance.
PROCEDURE : Initially 500 gms of cement weighed and sieved

through 90 micron sieve by rotating clockwise and anti
clockwise and with jarring. The weight of cement retained on
the sieve is collected in a pan and weighed. Then the
percentage passing the 90 micron sieve is calculated and
reported as fineness of the cement.
LIMIT : Should not be more than 10%
26
3.B.1 Name of Test : SLUMP TEST OF CONCRETE
APPARATUS:
i) Slump Cone: Having 20cm dia. at bottom, 10cm dia. at top and 30cm height.
ii) Tamping rod
iii) Trowel.
PROCEDURE:
I) The slump cone shall be kept on a horizontal surface.
II) The concrete shall be poured in to the cone in 4 layers, each layer should be
provided with 25 strokes by the tamping rod. After the top layer has been
completed, the surface of the top layer shall be finished level using a trowel.
III) Immediately after this, the cone shall be taken out slowly from its base.
IV) Then the slump value shall be measured by using a steel scale (the other side of
the tamping rod is used for that).
V) The difference between the height of the cone & the subsided concrete after
removal of the cone is known as Slump Value. Slump Value is measured in mm.
NOTE:-
a) Plain Cement Concrete – 25mm.
b) RCC structures for column, footing – 40 to 50mm.
c) RCC structures with fair degree of congestion of steel i.e. box culvert, slab
– 50 to 75mm.
27
3. B.2 Name of Test : METHOD OF CONCRETE CUBE CASTING AT SITE
I) The Interior surfaces of the assembled mould shall be thinly coated with mould oil
to prevent adhesion of the concrete.
II) The mould should be cubical in shape and should have 15cm x 15cm x 15cm x
interior dimensions. The angle of internal faces should be 900+0.50
III) The concrete shall be filled into the mould in three layers having approximately
5cm depth, each layer should be provided with 35j strokes of the tamping rod.
After the top layer has been completed, the surface of the top layer shall be
finished level using the trowel.
IV) On the top surface of each cube, the grade of concrete, date of casting, location
etc. should be written along with the signature of the concerned Engineer.
28
PART - IV
BITUMEN
29
4. A NAME OF TEST : PENETRATION TEST
DEFINITION : It is the hardness or softness of bitumen by

measuring the depth in tenth of a millimeter to which a
standard loaded needle will penetrate vertically in five
seconds.
SCOPE : Useful in determining the grade of bitumen.
APPARATUS REQ. : Bitumen penetrometer, water bath thermostatically
controlled, Heater, Benzene.
PROCEDURE : The sample material is thoroughly stirred to make it
homogeneous and free from air bubbles and water.
The sample is then poured into the container to a depth
atleast 15mm more than the expected penetration and
placed in a temperature controlled water bath at a temp. of
25 OC for a period of one hour.
The sample is placed under the needle of the penetrometer
and is now arranged to make contact with the sample
surface. Zero reading of the penetrometer dial is taken
before releasing the needle.
The needle is released for 5 sec. And the final reading is
taken on the dial. Atleast three measurements are made on
this sample by testing at distance of not less than 10mm
apart.
After each test the needle is disengaged and wiped with
benzene and carefully dried.
The depth of penetration is reported in hundredth of a
centimeter, and the mean value of three consistent
measurements is reported as the penetration value.
LIMITS : Penetration grade Repeatability
0 – 80 4%
80 – 225 5%
Above 225 7%
30
4. B NAME OF TEST : SOFTENING POINT
DEFINITION : It is the temperature at which the substance attains a

particular degree of softening under specified condition of
test.
SCOPE : It gives the properties of bitumen to be used as per

the climatic condition. Hard grade bitumen possesses higher
softening point than the soft grade bitumen.
APPARATUS REQ. : Ring and ball instrument, water bath thermostatically

controlled, glass thermometer.
PROCEDURE : Sample is heated to a temp. between 75 to 1000C

above the approx. softening point until it is completely fluid
and is poured in heated ring placed on the metal plate after
coating is done with Glycerin and Dextrin.
After cooling the rings in air for 30min. excess bitumen is
trimmed and the rings are placed on the support.
Initial temperature of water is kept at 50C and maintained
for 15 min. after which the balls are placed in position.
The temperature of water is raised at uniform rate of 50C
per minute with a controlled heating unit, until the bitumen
softens and touches the bottom plate by sinking of balls.
The temperature at the instant when each of the ball and
sample touches the bottom plate of support is recorded as
softening point value.
LIMITS : Softening points Repeatability Reproducibility

0
Below 30 C 2 0C 4 0C
300C to 800C 1 0C 2 0C
Above 800C 2 0C 4 0C
31
4. C NAME OF TEST : FLASH & FIRE POINT
DEFINITION : Flash point - Flash point of a material is the lowest
temperature at which the vapour of a substance
momentarily takes fire in the form of a flash under specified
condition of test.
Fire point - Fire point is the lowest temperature at which the
material gets ignited and burns under specified condition of
test.
SCOPE : It gives the guideline for preheating of Bitumen for
mixing without causing any accident.
APPARATUS REQ. : Pensky - martins closed cup apparatus, heater,
Thermometer
PROCEDURE : The material is filled into the cup upto a filling mark.
The bitumen sample is then heated, the test flame is lit and
adjusted in such a way that the size of a beed is of 4mm
diameter.
The heating is done at the rate of 5 0C to 6 0C per min.
The stirring is done at the rate of 60 rev. per min.
The test flame is applied at intervals depending upon the
expected flash and fire point.
First application is made atleast 17 0C below the actual flash
point and then at every 1 to 3 0C.
The stirring is discontinued during the application of the test
flame.
Flash point is taken as the temp. read on the thermometer at
the time of the flame application that causes a bright flash in
the interior of the cup in closed system.
The heating is continued until the volatiles ignite and the
material continues to burn for 5 sec. Recorded as the fire
point.
LIMITS : It is specified that in closed cup system, the test
result should not differ from the mean by more than 3 0C for
material flashing above 1040C and not more than 10C from
the mean for materials flashing below 1040C.
32
4. D NAME OF TEST : DUCTILITY
DEFINITION : Ductility is expressed as the distance in centimeters

to which a standard briquette of bitumen can be stretched
before the thread breaks.
SCOPE : This test is believed to measure the adhesive
properties of bitumen and its ability to stretch.
APPARATUS REQ. : Ductility m/c, standard briquette mould for preparing
the sample, knife, constant temperature water bath &
glycerin.
PROCEDURE : Bitumen sample is melted to a temperature of 75 to
0
100 C above the approximate softening point and strained
through IS SIEVE 30 , it is poured in the mould assembly
and placed on a brass plate , after a solution of Glycerin
and Dextrin is applied at all surfaces of the mould exposed
to Bitumen.
Mould is placed in water bath at 27 0C for 30 min.
Excess Bitumen is trimmed and the mould assembly is kept
in the water bath at 27 0C for 85 to 95 min.
The sides of the mould are now removed and the clips are
carefully hooked on the machine without causing any initial
strain.
The pointer is set to read zero.
The m/c is started and the two clips are thus pulled apart
horizantally. The distance at which the Bitumen thread
breaks is recorded in cms to report as DUCTILITY VALUE.

LIMITS : Repeatability 5%, Reproducibility 10%
33
4. E NAME OF TEST : SPECIFIC GRAVITY OF BITUMEN
DEFINITION : The specific gravity of bituminous material is defined

as the ratio of the mass of a given volume of the substance
to the same of an equal volume of water, the temperature of
both being 27 0C.
SCOPE : Useful in mix designs and as an aid to classify the
binders for use in paving jobs.
APPARATUS REQ. : Specific gravity bottle, wire basket, weighing

balance.
PROCEDURE : a) Pycnometer
The specific gravity bottle is cleaned, dried and weighed
along with the stopper. It is then filled with the fresh distilled
water and kept in water container for min. half an hour.
The bottle is then removed and cleaned from outside. The
specific gravity bottle containing water is now weighed.
The bitumen is heated to a pouring temp. and is poured in
the above empty bottle taking all the precaution that it is
clean and dry before filling sample material. The material is
filled upto the half and weighed.
b) Balance method
Liquefied sample is poured in the brass mould to provide the
sample of required dimension and is cooled.
The sample is weighed in air and in distilled water
maintained at 270C to the nearest 0.1mgs.
Weight of dry specimen to the weight of specimen immersed
in distilled water will give the specific gravity of the bitumen.
LIMITS : 0.97 TO 1.02 (Pure bitumen)
34
4. F NAME OF TEST : BITUMEN EXTRACTION
DEFINITION : It is the amount of bitumen added in the HMP for

producing the bituminous mix.
SCOPE : Useful in checking the bitumen added in the plant in

producing the mix.
APPARATUS REQ. : Bitumen extractor, benzene, oven, weighing balance.
PROCEDURE : About 500 gms of the mix is taken in the bitumen

extractor and washed with benzene till the coating in the
aggregates is completely washed. Then place the washed
aggregate in the oven at 105 to 110 0C for drying. Weight
the dry aggregate to the nearest gram. Then the percentage
of bitumen in the mix is calculated.
LIMITS : + 0.3% of Bitumen percentage in the mix.
35
4. G NAME OF TEST : STRIPPING VALUE TEST
DEFINITION : It is defined as the amount of Bitumen striped off

from the aggregate surface to the total area in percentage.
SCOPE : This test is suitable to assess whether the binder

would adhere to the aggregate when immersed in water.
APPARATUS REQ. : IS sieve 20mm & 12.5mm, Beaker 500 ml capacity,

Thermometer, Bitumen Mixer.
PROCEDURE : 200 gms of dry and clean aggregate passing 20mm

IS sieve and retained on 12.5mm sieve are heated up to 150
0
C when these are to be mixed with bitumen and are heated
up to 100 0C when these are to be mixed with tar.
Five percent by weight of bitumen binder is heated to 1600C.
The aggregate and binder are mixed thoroughly till they are
completely coated and the mixture is transferred to a 500ml
beaker and allowed to cool at a room temp. For about 2 hrs.
Distilled water is then added to immerse the coated
aggregate. The beaker is covered and kept in a water bath
maintained at 400C, maintaining level of water in the water
bath atleast half the height of the beaker.
After 24 hrs the beaker is taken out and extent of stripping is
estimated visually, as the ratio of the uncovered area
observed visually to the total area of aggregates.
LIMIT : Minimum retained coating 95%.
4. H Name of test : MARSHALL STABILITY TEST
As Per Specifications
36
DOC NO
REV NO
CALIBRATION OF DENSITY SAND
DATE OF
IS 2720 Part-28 REV
PAGE
MINISTRY OF ROAD TRANSPORT & HIGHWAYS
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual
plan for the year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of
Assam.
CONTRACTOR CONSULTANT
Source/location: Date of Sampling:

Type of Material: Sampled By:
Lab Job No: Date of Testing:
Tested By:
Sl Test Numbers
Unit
No. 1 2 3
1 Wt of empty cylinder gm
Wt of cylinder + sand before pouring into level
2 gm
platform
Wt of cylinder + sand after pouring into level
3 gm
platform
4 Wt of sand in cone(3-2) gm
5 Avg Wt of sand in cone gm
Wt of cylinder + sand before pouring into
6 gm
calibration can
Wt of cylinder + sand after pouring into
7 gm
calibration can
Wt of sand in calibration can + inside the cone
8 gm
of cylinder(7-6)
9 Wt of sand in calibration can only(8-5) gm
10 Depth of calibrated can cm
11 Diameter of calibrated can cm
12 Volume of calibrated can cub. cm
gm/cub.
13 Bulk density of sand(9/12)
cm
gm/cub.
14 Avg Bulk density of sand
cm
Remarks :
(CONTRACTOR'S Rep) (CONSULTANT'S Rep)

DOC NO
LIQUID LIMIT AND PLASTIC LIMIT REV NO
IS 2720 Part-V DATE OF REV

PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan
for the year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam.

Tested By:
Liquid Limit Plastic Limit

Sr.
Determination No.
No. 1 2 3 4 5 1 2
1 Number of Blows/Penetration in mm
2 Container No.
3 Wt. Of container in gm
4 Wt of container + wet soil in gm
5 Wt. Of container + dry soil in gms
6 Wt. Of water in gms
7 Wt. Of oven dry soil in gms
8 Water content in % (6/7*100)
LIQUID LIMIT FROM GRAPH ( LL ) = PLASTIC LIMIT =
PLASTICITY INDEX = (LL - PL) =
Remarks:

DOC NO
SPECIFIC GRAVITY OF SOILS
REV NO
DENSITY BOTTLE/PYCNOMETER METHOD DATE OF
IS 2720 Part III REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for
the year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam.

Sp. Gr. Of Liquid: Sampled By:
Temp. of Lequid: Date of Testing:
Ambient Temp: Tested By:
Lab Job No:
Trail No 1 2
(A)Mass of Density Bottle/Pycnometer(g)
(B)Masss of Bottle /Pycnometer & dry Material(g)
(C)Masss of Bottle /Pycnometer,Material & Liquid(g)
(D)Masss of Bottle /Pycnometer when full of liquid only (g)

Sp. Gr. Gcal=(B-A) / (D-A) - (C-B)
Mean
Gcal=(Gcal X temperature Correction ) X Gi
Remarks :

MODIFIED PROCTOR TEST DOC
(MDD/OMC) REV NO
IS:2720(Part-8) DATE OF REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for the
year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam.
Client
Engineer :
Contractor UCN Construction Company Pvt. Ltd.
Sample No : ………………
Source : ……………… Date of Testing : …………
Material Description : ……………… Date of Sampling : ……......
Mould No
% of Water Added
Mould Volume, cc
Mass of mould & Wet material, gm
Mass of mould, gm
Mass of wet material, gm
Wet density, gm/cc
Container No
Mass of Container & Wet material, gm
Mass of Container & dry material, gm
Mass of Container
Mass of water , gm
Mass of dry Material , gm
Moisture content %
Dry density , gm/cc
Remarks : ………………………………………………………………………………………………………..
……………………………………………………………………………………………………………
Max dry Density, gm/cc: …………………. Optimum moisture content %: ......................
Contractor 's Representative Consultant Representative

DOC NO
FIELD DENSITY TEST REV NO
BY SAND REPLACEMENT METHOD DATE OF
IS 2720 Part 28 REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for the year
2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam.
UCN Construction
Company Pvt. Ltd.
RFI No:
Source of material: Max dry Density:
Location/Chainage: Optimum Moisture Content:
Type of Material: Date of Testing:
Cylinder Calibration report No: Tested By:
Bulk Density of Sand: Weight of Sand in cone:
Lab Job No:
No of Holes Unit 1 2 3 4 5 6
Offset from Center of alignment m
Depth of Hole mm
Wt. Of wet material from hole gm
Initial Wt.(Sand & Cylinder) gm
final Wt.(Sand & Cylinder) gm
Wt. Of Sand in Hole & Cone gm
Wt. Of Sand in Hole gm
Volume of sand in Hole gm
Wet density of material gm
Wet wt. Of sample for M.C.+ Container gm
Dry wt. Of sample for M.C.+ Container gm
Dry Wt. Of Material gm
Moisture Content gm
Field Dry Density gm/cc
Field Compaction %
Standard Deviation of Field compaction
Acceptance Criteria:
Accepted YES / NO
Remarks:

DOC NO
LABORATORY CALIFORNIA BEARING RATIO
REV NO
TEST DATE OF REV
IS 2720 Part XVI PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for the year 2018-19
under EPC mode under PWD, NH Division, Silchar in the state of Assam.
Soaked/Unsoaked: Date of Sampling :

Source/location: Sampled By
Type of Material: Date of Testing :
Layer Thickness: Tested By :
Proving Ring Factor: MDD/OMC of Material:
Plunger Area: Surcharge weight:
Lab Job No: Immersed on:
LOAD
Penetration in mm Sample No. 1 Sample No. 2 Sample No. 3
Div Load (kg/cm2) Div Load (kg/cm2) Div Load (kg/cm2)
0.00
0.50
1.00
1.50
2.00
2.50
3.00
4.00
5.00
6.00
7.50
10.00
12.50
Sample No. 1 2 3 Swelling Data
No. of Layers Sample Nos. 1 2 3
No. of Blows Initial Reading
Sample Condition Unsoaked Soaked Unsoaked Soaked Unsoaked Soaked Final Reading
Wt. Of soil(gm) Ht. of Sample
Water used(ml) % Swell
Mould+Wet Soil
Wt of Empty Mould
Wt. Of Wet Soil From Graph
Volume of Mould Sample No. 1 2 3
Wet Density gm/cc 2.5 mm
Load (kg/cm2)
Container + Wet Soil 5.0 mm
Container + Dry Soil 2.5 mm
CBR (%)
Wt. of Container 5.0 mm
Wt. of Dry Soil Avg CBR (%)
Wt. of Water
Moisture Content %
Dry Density gm/cc
%Comp. of MDD
Remarks:

DOC NO
GRADING ANALYSIS FOR SOIL REV NO
IS 2720 Part IV DATE OF REV
PAGE

Weight of Sample: Date of Testing:
Lab Job No: Tested By:
Cumulative
Seive size Weight Cumulative % Cumulative %
weight retained Specific Limit
(mm / mic) Retained (gm) retained Passing
(gm)
Gravel content
Sand Content
Silt & Clay content
Remarks:

DOC NO
REV NO
DETERMINATION OF FREE SWELL INDEX
DATE OF
IS 2720 Part 40
REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for the year
2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam.

Tested By:
TEST NUMBERS
DESCRIPTION UNIT
1 2 3
Mass of Dry soil passing 425 micron sieve gms
Volume of soil in water upto 24 hrs(Vw) -
Volume of soil in kerosene upto 24 hrs(Vk) -
Free Swell Index (Vw-Vk)/Vk X 100 %
Remarks :

DOC NO
DETERMINATION OF TEN PERCENT FINES VALUE REV NO
BS - 812 Part-III DATE OF REV
PAGE
year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam
Source / location : Date of Sampling:

Type of material : Sampled By:
Tested By:
Sl. No. Description Force Force Force Force Force
Weight of Cylinder + weight of sample before

1
test(gm)
2 Weight of cylinder(gm)
3 Weight of sample before Test(gm)
Weight of fine sample passing 2.36 mm seive after

4
test(gm)
5 Percentage fine(Crushing Value)
6 Force required to produce 10 % Fine =14 X /(Y+4)
Remarks:

DOC NO
AGGREGATE IMPACT VALUE REV NO
(IS:2386 -PART-IV) DATE OF REV
PAGE
Assam

Tested By:
Sl. No. Description Test - 1 Test - 2 Test - 3
Total weight of aggregate Passing 12.5 mm &

1 retained on 10 mm IS seive, filling the
cylindrical measure = W1g
Weight of aggregate retained on 2.36mm

2
sieve after the test = W2g
Weight of aggregate passing through 2.36mm

3
sieve after the test = W3gm=(W1-W2)
Aggregate Impact value=

4
(W3/W1)*100%
5 Average A.I.V. (%)
Remarks:

DOC NO
REV NO
GRADATION
DATE OF REV
PAGE

Assam.

Wt of Sample: Date of Testing:
Cu.
IS Sieve Size Wt retained Cum. wt Total passing
Wt.retained Limits
mm/mic gms retained %age %age
gms
Remarks:

DOC NO
FLAKINESS & ELONGATION INDEX REV NO
IS:2386 Part-I DATE OF REV
PAGE

Assam
UCN Construction Company Pvt.
Ltd.

Size of seives Wt. of Aggregate

Wt. of aggregate Wt. Of aggregate
in gms Wt. Of Non-
passing through retained on
= W1(min 200 Flaky Aggregate
Passing through Retained on IS thickness gauge length gauge
pieces in each =W3 gms
IS Sieve mm Sieve mm = W2 gms = W4 gms
sieve)
63.00 50.00
50.00 40.00
40.00 25.00
25.00 20.00
20.00 16.00
16.00 12.50
12.50 10.00
10.00 6.30
Total Weight
Flakiness Index = 100*W2/W1 =
Elongation Index = 100*W4/W3 =
Combined FI & EI =
Remark :

DOC NO
LOS ANGELES ABRASION TEST FOR
REV NO
AGGREGATE
DATE OF REV
IS 2386 Part-IV PAGE

Assam
Ltd.

Tested By:
IS Sieve Size(mm) Number of

Passing Retained A( ) B( ) C( ) D( ) Sphers
40 25
25 20
20 12.5
12.5 10
10 6.3
6.3 4.75
4.75 2.36
Total Wt. In Gms
No of Revolution
Original Wt……………………. gm
Material Retained on IS:Sieve 1.70 mm………………………gm
LAV ………………………..
Remarks:
(CONTRACTOR'S Rep)
DOC NO
MOISTURE CONTENT DETERMINATION FOR
REV NO
AGGREGATE
DATE OF REV
IS 2386 Part-III
PAGE

Tested By:
AGGREGATE SIZE:…………….. 1 2 Average
Wt. Of wet Agg + Container W1,(gm)
Wt. Of Oven Dry Agg + Container W2,(gm)
Wt. Of Container W3,(gm)
Wt. Of Dry Aggregate W4=W2-W3,(gm)
Total M.C. (W1-W2)/W4 X 100(%)
Absorption Ab,(%)
Free M.C =TMC-Ab,(%)
Total M.C. (W1-W2)/W4 X 100(%)
Absorption Ab,(%)
Total M.C. (W1-W2)/W4 X 100(%)
Absorption Ab,(%)
Remarks:

DOC NO
ORGANIC IMPURITIES TEST REV NO
IS 2386 Part-II DATE OF REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km

under Annual plan for the year 2018-19 under EPC mode under PWD, NH Division,

Tested By:
Solution: Dissolve 3 Parts by Weight of Sodium Hydroxide(NaOH)in 97 Parts of Water
Gardener Colour Standard No. Colour Index
Result of Testing: At the end of the 24 Hrs standing Period ,the colour of the supernatant Liquid above
the test sample is matching with Gardener Colour Standard
No…………………………………………………………………………
Remarks:

DOC NO
GRADATION FOR ALL IN
REV NO
AGGREGATE(COARSE+FINE) DATE OF REV
IS 2386 Part-1 PAGE
Ltd.

IS Sieve Size Wt retained Cu. Wt.retained Cum. wt retained Total passing Limits as per
mm/mic gms gms %age %age IS:383
40 100
20 95--100
4.75 30--50
600 10--35
150 0--06
Remarks :

DOC NO
GRADATION FOR COARSE AGGREGATE
REV NO
FOR CONCRETE
DATE OF REV
IS:383
PAGE
Ltd.

IS Sieve Size Wt retained Cu. Wt.retained Cum. wt retained

Total passing %age Limits as per IS:383
mm/mic gms gms %age
40
20
12.5
10
4.75
2.36
Pan
Remarks :

DOC NO
GRADATION FOR FINE AGGREGATE REV NO
IS:2386 Part-1 DATE OF REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km

under Annual plan for the year 2018-19 under EPC mode under PWD, NH Division,
Ltd.

IS Sieve Size Wt retained Cu. Wt.retained Cum. wt retained Total passing

Limit
mm/mic gms gms %age %age
10
4.75
2.36
1.18
600
300
150
Pan
Fineness Modulas= ZONE:
Remarks :

DOC NO
REV NO
SILT CONTENT BY WEIGHT
DATE OF REV
PAGE
Ltd.
Material Type Report No.

Source Sampling Date
Location Testing Date
Tested By
Description Unit Details Remarks
Dry Wt. Before Washing Grams
Dry Wt After Washing Grams
Wt Passed Through 75 mic IS Sieve Grams
Silt Content %
Remarks:

DOC NO
SOUNDNESS TEST OF AGGREGATE REV NO
IS 2386 Part-V DATE OF REV
PAGE

Wt of Sample: Date Started:
Dtae Completed:
Wt. Of sample
Weight of test % passing
Grading of passing Corrected loss
IS Sieve Size fraction before designated sieve Remarks
original sample designated sieve (%)
test(gm) after test
after test(gm)
63 TO 40
40 TO 20
20 TO 10
10 TO 4.75
4.75 TO 2.36
2.36 TO 1.18
1.18 TO 0.600
0.600 TO 0.300
0.300 TO 0.150
Total % loss
Remarks :

DOC NO
SPECIFIC GRAVITY & WATER
REV NO
ABSORPTION TEST FOR AGGREGATE DATE OF REV
IS 2386 Part-III PAGE
UCN Construction
Company Pvt. Ltd.)

Sr. Samples
Description
No. I II III
1 Wt. Of vessel + Sample + Water = W1 gm
2 Wt. Of vessel + Water = W2 gm
3 Wt. Of saturated & surface dry sample = W3 gm
4 Wt of oven dry sample = W4 gm
5 Bulk Specific Gravity = W4 / W3-(W1-W2)
6 Apparent Sp. Gravity = W4 / W4-(W1-W4)
7 Water Absorption = (W3-W4)*100 / W4
Average Sp.Gr(Bulk)
Average Sp.Gr(Apparent)
Average Water Ab.
Remarks :

DOC NO
REV NO
BATCHING FOR FRESH CONCRETE DATE OF REV
PAGE
Ltd.
Batching Starting: Finishing: Date:

Location/Chainage of pour:
Lab Job No:
Moisture content measured by oven dry method

Fraction
Moisture(%)
Water absorption measured
Fraction
Moisture(%)
BATCHING OF CONCRETE(In Kgs) Slump:
Mix Class: W/C Ratio: Cement/Cum:
Fraction DRY SSD WA NMC PLANT BATCH
Cement
Water
Additive
Sand
Dust
Aggregate 1
Aggregate 2
Aggregate 3
Toatal
Remarks:

DOC NO
REV NO
CONCRETE DISPATCH CARD DATE OF REV
PAGE
Assam.
Grade of Concrete: Date :

Location:
Dispatch Time:
Slump Slump
Sr. Quantity
Type of Structure at Plant at Site Remarks
No. (m3)
(mm) (mm)
Time of Receiving:
(Signature) (Received By)

DOC NO
REV NO
CONCRETE POUR CARD DATE OF
REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for the year 2018-19 under EPC mode
under PWD, NH Division, Silchar in the state of Assam.
RFI No. : Chainage No. : Recorded By :

Grade of Concrete : Total Volume of Concrete : Source :
Type of Placing Structure: Lift No. Starting Time: Finishing Time:
Concrete
Time Time Time Ambien
Load No./ Truck No. / Concret Slump Quantity Cumulative Quantity Sample /
Concrete Start Finish t Temp. Remarks
Batch No. T.M. No. Temp. (0C) (mm) (M3) (M3) Cube
Batch Pour Pour (0C) Record

DOC NO
REV NO
BITUMEN EXTRACTION TEST
DATE OF REV
PAGE

Tested By:
Sl No. Descriptiopn Test 1
1 Weight of Mix(gm)
2 Weight of Mix + Filter Paper(gm)
3 Weight of Mix + Filter Paper(After Extraction)(gm)
4 Weight of Bitumen (2)-(3) in gm
5 Weight Of Sample after Extraction (1)-(4) in gm
6 Bitumen Content By weight of Mix (4)/(1) in %
WASH GRADING OF AGGREGATES
IS Sieve Wt
Cu. Wt.retained Cum. wt retained Total passing Limits as per
Size retained Remarks
gms %age %age spec %age
mm/mic gms
Remarks :

DOC NO
DETERMINATION OF RATE OF SPREAD OF REV NO
PRIME/TACK COAT DATE OF
IRC-SP-11(App:5,Sec:A) REV
PAGE
Spraying Temp:
Weather: Tested By:
Wt.Of
Empty Wt. Area of Wt. of Rate of
Plate +
S.No. Plate No. Chainage of Plate Plate Emulsion Spray Remark
Emulsion
Kg. M2 Kg. Kg/M2
Kg.
Remarks:

DOC NO
SOFTENING POINT TEST FOR BITUMEN REV NO
DATE OF
( IS 1205 - 1978 ) REV
PAGE
Grade of Bitumen : Date of Sampling :

Approximate Softening Point : Sampled By :
Liquid used in bath : Date of testing :
Period of cooling : Tested By :
In Air : Lab job No. :
In water bath : Vehicle No. :
Sample No.1 Sample No.2

Test Property
Ball No.1 Ball No.2 Ball No.1 Ball No.2
Temperature (0C) at which Sample
touches bottom plate
Mean softening point
Avg. Softening point
Remarks :

SPECIFIC GRAVITY OF TAR AND BITUMINOUS DOC NO
MATERIAL REV NO
DATE OF
DENSITY BOTTLE/PYCNOMETER METHOD REV
IS:1202 PAGE
Grade of Bitumen:
Sp. Gr. Of Liquid: Sampled By:
Temp. of Lequid: Date of Testing:
Ambient Temp: Tested By:
Lab Job No: Lequid used:
Trail No 1 2
(A)Mass of Density Bottle/Pycnometer(g)
(B)Masss of Bottle /Pycnometer & dry Material(g)
(C)Masss of Bottle /Pycnometer,Material & Liquid(g)
(D)Masss of Bottle /Pycnometer when full of lequid only (g)

Sp. Gr. Gcal=(B-A) / (D-A) - (C-B)
Mean
Gcal=(Gcal X temperature Correction ) X Gi
Remarks :

DOC NO
FLASH & FIRE POINT TEST REV NO
IS 1208-1958 DATE OF REV
PAGE
Grade of Bitumen: Date of Sampling:

Approximate Flash & Fire Point: Sampled By:
Vehicle No: Date of testing:
Tested By:
Lab Job No:
Test Property Sample No. 1 Sample No. 2 Mean
Temperature in 0C at which sample Flash for a seconds
Temperature in 0C at which sample Burns for few

seconds
Remarks :

DOC NO
DENSITY OF BITUMINOUS CORE REV NO
ASTM D 1559 DATE OF REV
PAGE
Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for the year 2018-19 under EPC mode under PWD, NH Division,

100 % Marshall density: Date of Testing:
Sl Core Nos
Descriptiopn
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 Chainage
2 Thickness(mm)
3 Weight in air(gm)
4 Weight in water (gm)
5 SSD Weight(gm)
6 Density of Core (g/cc)
7 % Compaction
Acceptance Criteria:
Remarks :

DOC NO
REV NO
STRIPPING TEST FOR AGGREGATES
DATE OF
IRC SP-11(App-5,Sec-c) REV
PAGE

Aggregate Size: Date of Testing:
Tested By:
Weight of aggregate taken(Passing through Weight of Binder Material(5 %
20 mm,Retained on 12.5 mm seive): of Aggregate taken):
Temperature of Agg. While Temperature of Binder while
mixing(Between 100 to 150 deg C): mixing(Above 160 deg C):
Temperature of Water bath where in Mix Mix Beaker kept in water Bath
Beaker Kept(To be Kept at 40 deg C): (Min 24 Hrs):
Testing Time:
Determination Unit Sample Mean

Uncovered Area observed Visually (A) Sq.M
Total Area (B) Sq.M
Percentage of Stripping (A/B) X 100 %
Average Stripping value of Aggregate (Rounded off value)
Specific Limit
Remarks:

DOC NO
GRADATION For DBM REV NO
Table 500-10 of MORT & H DATE OF REV
PAGE
year 2018-19 under EPC mode under PWD, NH Division, Silchar in the state of Assam.

IS Sieve Size Wt retained Cu. Wt.retained Cum. wt retained Total passing

Limits
mm/mic gms gms %age %age
37.5 100
26.5 90-100
19 71-95
13.2 56-80
4.75 38-54
2.36 28-42
0.300 7-'21
0.075 2-'8
Pan
Remarks:

DOC NO
PENETRATION TEST FOR TAR AND REV NO
BITUMINOUS MATERIAL DATE OF
IS:1203 REV
PAGE
Grade of Bitumen: :
Pouring Temperature in Deg. C: : Date of Sampling: :
Period of cooling in atmosphere: : Sampled By: :
Room temperature in Deg. C: : Date of testing: :
Period of cooling in water bath: : Tested By : :
Actual test temperature in Deg C: : Invoice No.: :
Vehicle No.: : Lab Job No: :
Sample No. 1 Sample No. 2

Observation
Test 1 Test 2 Test 3 Test 1 Test 2 Test 3
Penetrometer dial reading initial
Penetrometer dial reading final
Penetration value
Mean value
Average Penetration in 1/10 th of mm:
Remarks:

DOC NO
REV NO
DUCTILITY TEST FOR BITUMEN
DATE OF
( IS 1208 - 1958 ) REV
PAGE
Grade of Bitumen = Date of Sampling

Pouring Temerature in deg cen. = Sampled By
Actual Temperature in Deg.cen = Date of testing
Period of cooling Tested By
In Air = Lab job No.
In water bath before trimming = Vehicle No.
In water bath after Trimming =
Briquette number Mean Value

Test Property
1 2 3
Initial Reading (cm)
Final Reading (cm)
Ductility Value (cm)
Remarks :

DOC NO
REV NO
COMPRESSIVE STRENGTH OF CONCRETE CUBES / MORTOR CUBES DATE OF REV
PAGE

Strengthening of 2 lane with paved shoulder of NH-54 from 12th km to 40th km under Annual plan for the year 2018-19 under EPC mode under
UCN Construction Company
Pvt. Ltd.
Source/location: Date of Casting:

Grade of Concrete: Date of Testing:
Grade of Cement & Week: Days:
Part of Structure: Tested By:
Lab Job No: Calibration Factor:
Failure Load Compressive Average
Sample Specimen Weight of Dimension Volume of Density Test Area
Strength Strength
No. No. Cubes(gm) (cmxcmxcm) Cube (Cub.cm) (gm/cub. Cm) (Sq.cm) Observed R Corrected K X R
(N/mm2) (N/mm2)
Remarks :

DOC NO
INITIAL & FINAL SETTING TIME
REV NO
TEST FOR CEMENT
DATE OF REV
IS:4031 Part-V PAGE
Ltd.

Description of Cement: Sampled By:
Batch No: Date of Testing:
Testing Temp:
Time of
Water Actual
Sr. Wt. Of adding Initial Final setting
Required = water LIMITS
No. Cement water in setting time time
0.85*P Required
cement
1 2 3 4 5 6 7 8
As per IS standards
1 1) Initial setting time
not less than 30
minutes.
2) Final setting time
2 not more than 600
minutes
Initial Setting Time = (6 - 5) =
Final Setting Time = (7 - 5) =
Remarks :

DOC NO
SOUNDNESS TEST FOR CEMENT REV NO
IS:4031 Part-III DATE OF REV
PAGE
Ltd.

Temperature: Tested By:
Lab Job No:
Distance between
Qty. of water Distance between Difference
Sr. Wt. Of pointer after
added = tips of pointer after between LIMITS
No. Cement boiling of three
0.72*P 24hrs boiling mm Reading 5 & 4
hrs
1 2 3 4 5 6 7
1
2
3 As per IS Le-
chatlier mould
4 expansion < 10mm.
5
6
Remarks :

DOC NO
CONSISTENCY TEST FOR CEMENT REV NO
IS:4031 Part -IV DATE OF REV
PAGE

Testing Temp:
Vol. Of water
Wt. Of cement % of water Reading of
added in dry
Sr. No. taken for test added Vicats app. From LIMITS
cement
bottom
gms Cc P
1 400
2 400 As per IS Standard P
3 400 = 25% to 30% of
water required to
4 400 produce a paste of
5 400 standard consistency
6 400
Remarks :

DOC NO
FINENESS TEST FOR CEMENT REV NO

IS:4031 Part-I DATE OF REV
PAGE
Assam.

Temperature: Tested By:
Lab Job No:
Wt. Of cement Wt. Of cement % Residue

Sr.
before sieving Time of sieving retained on IS sieve retained = LIMIT
No.
= W1 in gms 9 = W2 W2/W1 * 100
1 2 3 4 5 6
1
As per IS 4031 Part
1, fineness should
2 not be more than
10%.
3
Remarks :

APPENDIX IV
DESIGN
QUALITY PLAN
Quality Assurance Procedures & Standards
The quality assurance procedures and standards proposed to be followed for carrying out
various surveys, investigation and designs are given in the following Forms:
Forms
1 Study or Report Review Attestation
2 Manual Calculation Checklist
3 Computation Calculation Checklist
4 Engineer’s Drawings Checklist
5 Preparation and Review of Technical Specifications
6 Format for revision details
7 Format for design verification and review
Form No. QAP - 1
STUDY ON REPORT REVIEW ATTESTATION
Project
Title : ________________________________________
Date _____________
Version : ________________________________________
Prepared by : ________________________________________
Reviewed by : ________________________________________
Comments :
Non-compliance:
__________________________
Design Director
___________________________
Authority’s Engineer
Form No. QAP - 2
MANUAL CALCULATION CHECKLIST
Project :
Subject : ________________________________ Computation Ref : ___________________________
Computed By : __________________________ Date : _____________________________________
Purpose of Computations : _______________________________________________________________________
Theories Used / Reference : _______________________________________________________________________
Input Data Source :
_____________________________________________________________________________
Comments
Yes No
• Purpose of calculation clearly defined.
• Input data taken from reviewed and accepted calculations.
• Test data appropriately factored into the calculations.
• Design criteria referenced.
• Data from interfacing sections appropriately factored in calculations .
• Assumptions clearly defined and applicable.
• Theories are applicable.
• Design methods used are consistent and accurate or results are reasonable.
• Originator or calculations initialized and dated calculations.
• Reviewer initialized the calculations.
• Calculations are legible and, in a form, suitable for reproduction and filling.
• Copies of pertinent graphs or tables are attached.
• All works intended to be covered by the calculations was performed.
• Calculations are listed in project index.
Remarks : ___________________________________________________________________________________
_____________________________________________________________________________________________
_______________ ______________________
Reviewer Officer Quality Control Officer / Date
Revision Description:
No. Orig. Date Reviewer Date
Form No. QAP - 3

COMPUTATION CALCULATION CHECKLIST
Project :
Subject : ____________________________________ Computation Ref : _________________________
Computed By : ______________________________
Date : _____________________________________
Level of Design Effort Conceptual :
Date : _____________________________________
Purpose of Computations : _____________________________________________________________________
Theories Used / Reference : _____________________________________________________________________
Input Data Source : ___________________________________________________________________________
Comments
Yes No
• The Programme was previously verified.
• Methods used are consistent with accepted practice.
• Theories used are applicable.
• The input data were reviewed for the following.
• Latest issue of design criteria was used.
• Test data were appropriately factored into the input data.
• Data for interfacing Sections were appropriately factored into the input data.
• Assumptions are clearly defined and reasonable.
• Originator of input data initiated and dated the input sheets including revisions.
• Input data were taken from reviewed and accepted calculations.
• The output data were reviewed for the following.
❖ Programme was clearly on the output data.
❖ Purpose of calculation was clearly identified on the output data.
❖ Results are reasonable.
❖ Superseded or “void” output data are so identified.
❖ Calculations are listed in project index.
Remarks : ___________________________________________________________________________________
_____________________________________________________________________________________________
_______________ ______________________
Reviewer Officer Quality Control Officer / Date
Revision Description:
No. Orig. Date Reviewer Date

Form No. QAP – 4
ENGINEER’S DRAWINGS CHECKLIST
Project :
Discipline : ________________________________________________________
Drawing Number(s). : ____________________________________________________
Comments
Yes No
• Is the scope of the set of drawings satisfactory?
• Do the structures, equipment or components satisfactorily meet the functional needs and
requirements.
• Have the results of the latest design calculations been incorporated?
• Are the interfaces with other discipline drawings correct?
• Have comments on previous check printing including interdisciplinary
review have been made by REDCHECK method?
• Deleted.
• Have the designer and drafter signed and dated the ‘checked by’ Space in the title blocks?
• Are applicable codes, standards, loadings etc, shown on drawings?
• Deleted
• In construction phasing or staging clearly shown?
• Are dimensions and tolerances correct and consistent?
• Does drafting technique conform to be standard specified?
• Have duplications and redundancy of information, data
and dimensioning been eliminated.
• Are the drawings legible, reproducible?
• Do the titles and drawing numbers agree with the cover?
sheet list of drawings?
Remarks: __________________________________________________________________
Quality Control Officer / Date
Form No. QAP – 5
PREPARATION AND REVIEW OF TECHNICAL SPECIFICATIONS
Project :
Discipline : ____________________________ Date of Draft Reviewed : ______________
Specification Section : _______________________________________________________________________
Comments
Yes No
• Is specification as per the contract agreement?
• Is specification complete and clear to the extent necessary to properly
Specify construction and performance requirements?
• Have duplications between drawings and specifications been eliminated?
• Are proper codes, standards, processes etc. referenced?
• Have all new or unusual technical sections been approved by the Authority’s Engineer?
• Are requirements for shop drawings properly specified? Both as to content
and timely submission?
• Are material identification requirements properly specified?
• Are new materials employed and installed in the manner approved by the
Manufacturer?
• Is proper test and inspection documentation specified? specified and
are they adequate, realistic and in line with ordinary construction practice?
• Are provisions made for the qualification and approval of special construction
processes and for the personal performing these processes?
• Are measuring and test equipment calibration requirements and clearing,
storage handling requirements properly specified?
• Are measurement units and basis of payment properly specified?
• In nomenclature used in specification exactly as used on drawings?
Remarks : ___________________________________________________________________________________
______________________________________________________________________________________________
Attach sheet if additional space is required. Record number of sheets here : ________________________________
______________________
Quality Control Officer / Date
___________________________
Team Leader / Date
Revision Description
APPENDIX – I
.
Form No. QAP – 6
FORMAT FOR REVISION DETAILS
Sheet.…... of … .....................................................................................................................
Project:
Job No:
Document Title:
Revision Details
Rev Stretch Page Revision Description Approved Date

Form No. QAP – 7
FORMAT OF DESIGN VERIFICATION AND REVIEW REPORT
Project:
Document Identification Number: Rev:
Verification Report
Check List Yes Comments Corrections Verified

`NO')
(if (Please tick)
General /No/NA
• Legibility
Compilation Details as Applicable
• Completeness of cover sheet
• List of Contents
• Approved format used
• Document number and revision no.
Input
• Inputs listed and referenced
• Assumptions (if any) documented
• Inputs and assumptions are reviewed for
adequately
adequacy and selection
• Codes listed with title, number and year
publication
of
• Critical elements identified for alternative
calculations as appropriate
Output
• Correctness of calculations
• Conformance to Design basis/criteria/
philosophy
• Field test input data used
• Validated computer programme used
Verified by :
Date:
Signature:
Name:
Review Report
Yes/ No/ Comments Corrections Verified

Check List
NA (if NO') (Please tick)
• Correction/changes indicated by
incorporated
verifier
• Design conforms to Layout/General
arrangement
• Design method appropriate to
• Variation in alternative design
requirement
Acceptable.
results
• Interface information incorporated
• Design review meeting decisions
incorporated
• Signature of verifier on all pages
Approved:
Reviewed by:
Date:
Signature:
Name:

QAP 31-01-2020 Silchar Project

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QUALITY ASSURANCE PLAN

Name of Work: Strengthening of 2 lane with paved shoulder of NH-54 from

Authorised Signatory Date:

Quality Audit Project Engineer

HR & Safety Construction Plant and Design Director, Q A Engineer

Planning Material Engineer Special Agencies

6.1 Control of Data and Documentation

6.1.2. Quality related records and documents

(1) Longitudinal Profile 15/2 20/9 15/12

(2) Cross-Sections CH 140-155 20/2

Architectural Details Minor

This is to be expanded to suit project needs

Sl. No Activity Action by Check By Remarks

(3) Float enquires enclosing Purchase Planning

(4) Collect samples, test Planning QA

(8) If routine tests not QCE QA

Material Description 20 mm aggregate

Vehicle No. Delivery Challan No. ECC SOL1265

Source: - Unloaded and stored at

Tests Certificates, if any Source tested by QCE

Material identification boards inspected / Not inspected / Approved

Purchase order No. ______________

(1) Material Description: Reinforcement dia 32 mm high yield

(3) DC Reference: Nil

• Tick as applicable strike items not applicable

Copy to stores, purchase, planning

LOAD DIAL GAUGE READINGS

CLIENT'S REPRESENTATIVE CONTRACTOR'S REPRESENTATIVE

LOAD DIAL-GAUGE READINGS

DATE OF CALIBRATION TEMP.

CLIENT’S REPRESENTATIVE CONTRACTOR’S REPRESENTATIVE

SAMPL : DATA OF SAMPLING :

QUANTITY OF AGGREGATE : MATHOD OF TEST :

SOURCE : DATA OF TESTING :

TO BE USED IN STRUCTURE : SAMPLING & TESTED BY:

IS SIEVE CUMULATIVE %CUMULATIVE ACCEPTABLE

Piot a Grain Size Distribution Curve

For Contractor For Contractor

Inspected by : Name Signed Date

Approved by : Name Signed Date

2. Latest revision being used

3. Bar schedules approved

4. Reinforcing steel material approved

5. Bar bending and cutting satisfactory

6. Corrosion treatment of bars, if required, satisfactory

7. Bar sizes correct

8. Bar spacing correct

9. Bar lap lengths correct

10. Bar laps at correct locations

11. Bar tied as specified

12. Bar assembly rigid and adequately supported

13. Cover to bottom bars correct

CONTRCTORS INSPECTION REQUEST NO. YES/NO

1. Method statement approved

Inspected by : Name Signed Date

Approved by : Name Signed Date

Date of Pour Date of inspection

5 Any other Defect

*S= Satisfaction, NS= Satisfactory

Name Signature Date

Name Signature Date

Approval/ non Name Signature Date

Prepared by Checked by Approved by

Acceptable Not acceptable* Not Applicable See Comments