Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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3. Section-800 c. The strength of any sample shall not be less than the specified compressive strength minus 3 MPa. d. The quality of concrete represented by test results shall include the batches from which the first and last samples were taken, together with all intervening batches. (vii) Sulphate and Chloride Content The total water soluble sulphate and chloride contents in concrete shall not exceed the values given in Table 800.9 TABLE 800.9: SULPHATE AND CHLORIDE CONTENTS Details Content Sulphate content as (SO ) 3 4 percent Chloride content 0.3 percent by mass of cement (Moderate condition) (As Chloride ion) 0.20 percent by mass of cement (Severe condition) (viii) Use of plums in ordinary concrete Stone plums shall not be used in RCC or Concrete laid in water. The general requirements for the usage of plums are given in Table 800.10 TABLE 800.10 REQUIREMENT FOR USAGE OF PLUMS Size 160-300 mm (Maximum dimension not to exceed 1/3 least dimension of member) Quantity of Plums in works Not to exceed 15 percent by volume (ix). Storage of Materials (Cement, Fine and Coarse Aggregates) a. The requirements of storage for cement and fine aggregates are as per Sub-section 600. b. Store different sizes of coarse aggregates in separate stock piles sufficiently away from each other to prevent intermixing. Keep the height of individual stockpile below 120 mm, unless otherwise permitted. When placed directly on hard ground, do not remove them from stockpile within 300 mm of the ground. Use the bottom 300 mm of stockpile only after thorough cleaning of the material. 2. Tolerances The accuracy of the measuring devices used for different ingredients shall fall within the limits given in Table 800.11 TABLE 800.11: ACCURACY OF MEASURING DEVICES Measurement Quantity in each batch Cement ± 3% of cement quantity Water ± 3% of water Aggregate ± 3% of aggregate Admixture ± 5% of admixture 144
3. Mechanical Vibrators 145 Quality Assurance Handbook for Rural Roads The capacity/size of the vibrators for compaction of concrete is given in Table 800.12 TABLE 800.12: CAPACITY/SIZE OF VIBRATORS Type of Vibrator Conforming to Capacity/size Internal Vibrators IS: 2505 25-70 mm Form Vibrators IS: 4656 Minimum 500 Watts Screed Vibrators IS: 2506 Full width of carriageway (upto two lanes) 4. Quality Control Tests / Checks 4.1 Tests prior to construction The tests and checks to be carried out prior to construction are indicated in Table 800.13 TABLE 800.13: QUALITY CONTROL TESTS PRIOR TO CONSTRUCTION S.No. Material / Work Test / Check Frequency 1. Cement a) Setting Time (IS:4031 Part 5) One test for 10 tonnes of cement (same brand & grade) b) Soundness (IS:4031 Part 3) - do – c) Compressive strength of mortar cube (IS:4031 Part 6) (Table 800.3) 3 specimens for each lot 2. Coarse Aggregates a) Gradation for PCC or RCC works (Table 800.4) 3 samples for each quarry source b) Flakiness index (IS:2386 part 1) -do - c) Deleterious constituents (IS:2386 part 2) If in doubt d) Water absorption / content (IS:2386 part 3) Once for each source of supply e) Aggregate Impact value (IS:2386 part 4) One test per source of supply f) Soundness (IS:2386 part 5) [if water - do - absorption exceeds 2%] g) Alkali Silica reactivity (IS:2386 part 7) If in doubt one test at approved test house 3. Fine Aggregates a) Gradation (IS:2386 part 1) ( Table 800.5) 3 samples for each source of supply b) Deleterious Constituents (IS:2386 part 2) If in doubt, one test c) Alkali silicate reactivity (IS:2386 part 7) If in doubt, one test 4. Water Normally potable water is good enough for making concreteDetermination of Impurities - Suspended matterIS:3025 (Part 17) For large works If the quality is in - OrganicIS:3025 (Part 16) doubt Samples taken from each - Inorganic IS:3025 (Part 19) source and tested at an approved - Sulphates (as SO 3 )IS:3025 (Part 24) test house - Chlorides (as Cl)IS:3025(Part 32) (Table 800.6 for limits) 5. Concrete Mix Design (for each work) To be approved by EE for cement content, W/C ratio and use of plasticizers, if any.
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Ministry of Rural Development Gover
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FOREWORD PREFACE ABBREVIATIONS QUAL
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Section 1100 PIPE CULVERTS 163 to 1
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PREFACE A good road network has an
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AE : Assistant Engineer AIV : Aggre
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1. BACKGROUND 1 Quality Assurance H
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3 Quality Assurance Handbook for Ru
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Material tests Workmanship tests Se
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2. Quality Management System (iii)
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2. Quality Management System A typi
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105. CONSTRUCTION EQUIPMENT 13 Qual
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B Do’s and Don’ts Do’s Don’
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201 & 202. SITE CLEARANCE A Methodo
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301. EMBANKMENT CONSTRUCTION A Meth
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(vii) Materials in a frozen conditi
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B. Earthwork for Subgrade (Cutting
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302. EARTHWORK IN CUTTING A. Method
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31 Quality Assurance Handbook for R
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B. Quality Control Requirements 1.
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SECTION 400 39 Quality Assurance Ha
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3. Section-400 (ii) Atterberg limit
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3. Section-400 C Do’s and Don’t
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3. Section-400 TABLE 402.2: GRADING
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3. Section-400 2. The pulverization
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3. Section-400 Table 403.3 : QUALIT
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3. Section-400 6. The cement stabil
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3. Section-400 6.3 Quality Control
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3. Section-400 14. In case the scre
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3. Section-400 TABLE 405.4: APPROXI
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3. Section-400 5.3 Quality Control
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3. Section-400 (ii) Grading Require
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3. Section-400 C Do’s and Don’t
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3. Section-400 408. Local materials
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3. Section-400 B. Quality control r
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3. Section-400 409. LIME-FLYASH STA
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3. Section-400 4. Surface Regularit
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3. Section-400 (ii) Slag The broad
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3. Section-400 6. The thickness of
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3. Section-400 2. Horizontal Alignm
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SECTION 500 BITUMINOUS 81 Quality A
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3. Section-500 (iii) In the final l
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3. Section-500 3. The primer should
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3. Section-500 B. Quality Control R
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Page 96 and 97: 3. Section-500 (b) Bitumen The bind
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Page 100 and 101: 3. Section-500 TABLE 507.1: NOMINAL
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Page 108 and 109: 3. Section-500 B. Quality Control R
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Page 112 and 113: 3. Section-500 512. MODIFIED BITUME
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Page 116 and 117: Annex-III & IV DETERMINATION OF IN-
Page 118 and 119: SIMPLE/HANDFEEL TESTS 600 600.1 Bri
Page 120 and 121: 119 Quality Assurance Handbook for
Page 122 and 123: SECTION 600 121 Quality Assurance H
Page 124 and 125: 3. Section-600 4. Build the courses
Page 126 and 127: 3. Section-600 (v) Storage of mater
Page 128 and 129: 3. Section-600 3.3. Quality Control
Page 130 and 131: 700 : STONE MASONRY FOR STRUCTURES
Page 132 and 133: (v) Stone Masonry 133 Quality Assur
Page 134 and 135: 4.2. Tests / checks during construc
Page 136 and 137: SECTION 800 CONCRETE FOR STRUCTURES
Page 138 and 139: 3. Section-800 2. Proceed with conc
Page 140 and 141: 3. Section-800 TABLE 800.3: REQUIRE
Page 144 and 145: 3. Section-800 4.2 Tests / checks d
Page 146 and 147: SECTION 900 149 Quality Assurance H
Page 148 and 149: 3. Section-900 2. Lower centering g
Page 150 and 151: 3. Section-900 C. Do’s and Don’
Page 152 and 153: 1000 STEEL REINFORCEMENT A. Methodo
Page 154 and 155: 3.2 Tests during construction 159 Q
Page 156 and 157: 1100: PIPE CULVERTS A. Methodology
Page 158 and 159: 165 Quality Assurance Handbook for
Page 160 and 161: SECTION 1200 167 Quality Assurance
Page 162 and 163: 3. Section-1200 A2 Substructures Th
Page 164 and 165: 3. Section-1200 4. Provide 75 mm ce
Page 166 and 167: 3. Section-1200 (2) Tolerances 1200
Page 168 and 169: 3. Section-1200 3.2 Tests / checks
Page 172 and 173: 3. Section-1300 A-3 Toe Protection
Page 174 and 175: 3. Section-1300 2. Stones for pitch
Page 178 and 179: 3. Section-1400 3. Give streamline
Page 180 and 181: 3. Section-1400 2. Tests during con
Page 184 and 185: 3. Section-1500 5 Mark location and
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3. Section-1500 TABLE NO. 1502.3: P
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3. Section-1500 1503: RECTANGULAR C
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3. Section-1500 3.2 Tests during co
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3. Section-1500 1504: INTERLOCKING
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3. Section-1500 2. Quality Control
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SECTION 1600 217 Quality Assurance
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3. Section-1600 The prescribed road
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3. Section-1600 C. Do’s and Don
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1700. TRAFFIC SIGNS AND MARKINGS A.
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227 Quality Assurance Handbook for
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1904 : MAINTENANCE OF BITUMINOUS SU
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4.6 Settlement and Upheaval 235 Qua
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2. Surface Finish 237 Quality Assur
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1908 : MAINTENANCE OF CULVERTS AND
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4. Quality Monitoring only in excep
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1. SECTION 100: GENERAL 1.1: Qualit
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10 5R 60 106 25 DIA WELDED 21 DIA 1
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4. Section-300 (b) Carry out an ins
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4. Section-300 Photo 1. Visual Clas
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Test 1 261 Quality Assurance Handbo
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4. Section-500 (iii) Check the aggr
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5. SECTION 1100:PIPE CULVERTS 267 Q
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6. SECTION 1300: PROTECTION WORKS A
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4. Section-1500 In case of cracked
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4. Section-1700 2. Road Markings C
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Appendix-1 1.4 Estimating Plasticit
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Appendix-1 1.8 Simple Gadgets for E
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Appendix-1 (ii) Make two identical
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Appendix-1 (ii) Workability: Take a
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Appendix-2 Curing : Covering the c
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Appendix-3 Sr. Code/ Title of the P
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Quality Assurance Handbook for Rura
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Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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