Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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2. Quality Management System (iii) Ensuring that: (a) Contractors have brought the necessary machinery and equipment to site. (b) Field laboratory has been established. (c) Key engineering personnel have been deployed by the Contractor and (d) The work programme has been approved. (iv) Supervising Site Quality Control arrangements including materials and workmanship, primarily through testing as per provisions of the Quality Assurance Handbook. (v) The following frequency of inspection visits to site by PIU staff is recommended while the work is in progress: (a) Junior Engineer – Daily (b) Assistant Engineer – Twice a week (c) Executive Engineer – Once a week (vi) Taking timely action to ensure replacement of defective material and rectification of defective workmanship. 3.2 To ensure effective Quality Control on materials and workmanship, the procedure described in para 3.1 of Chapter 1 shall be followed: 3.3 A monthly return of the tests shall be submitted in the prescribed proforma by the AE to the EE in the first week of every month. The EE will review this return regularly to see that the Quality Control tests are being performed at the desired frequency and with the desired accuracy. The EE will also verify that the Non Conformance Reports (NCR) are being issued by the AE whenever nonconformance occurs and the Contractor is taking action promptly on the NCR. Payment to the Contractor shall be regulated by the EE as per the returns of the Quality Control tests. Any deviation will be the personal responsibility of the EE. 3.4 The SE in charge of the circle and the Chief Engineer having jurisdiction are responsible for the proper functioning of the PIU as part of their normal administrative duties. Their inspection and quality testing supervision will therefore be counted as part of effective supervision of the first tier of quality management (and not as a second tier of quality management). The SE/CE shall: (i) During his visits to the work, oversee the operations of the quality control testing procedure and record his observations in the Quality Control Register. The SE/CE will also verify that the Non-Conformance Reports are issued in time and action is being taken by Contractor promptly. (ii) Prepare Inspection Reports which shall be sent to the PIU for taking remedial action. The State Govt. /State Rural Roads Development Agency shall prescribe frequency of inspections by various officers and formats for furnishing inspection reports by SE/CE. 4. SECOND TIER 4.1 The first tier of quality management has the primary function of quality control through enforcement of technical standards and quality control requirements through regular testing, close 8
9 Quality Assurance Handbook for Rural Roads supervision and inspection. Function of the second tier of independent quality management is to ensure that the Quality Management System at the site is functioning satisfactorily and suggest possible improvements where required. For this, they may be required to carry out and report: (a) Independent quality tests to verify that the quality management system achieving its intended objectives. (b) Systemic flaws in the quality control process and action to improve the process. 4.2 The role of second tier in monitoring the quality of the work is of crucial importance during construction stage and therefore the State Quality Monitors are required to carry out inspections at appropriate stages of work under progress. 4.3 The independent Quality Management Division of the executing agency may function as the second tier. The State Rural Roads Development Agency will frame suitable guidelines for proper functioning of second tier. 5. THIRD TIER The National Rural Roads Development Agency shall prescribe the guidelines for the third tier from time to time. The objective of this third tier of quality mechanism is to monitor the quality of road works executed by the States with a view to ensuring that the road works under the programme conform to standards and to see whether the quality management mechanism in the State is effective. The role of this tier is to provide guidance to State implementation machinery and the field engineers rather than ‘fault finding’. As such, the shortcomings are identified by the third tier and a feedback is provided to the States for improvement. 6. QUALITY CONTROL The requirement of a quality control organization will vary for different projects depending on departmental set-up and also size of the project. The minimum suggested organization of quality control laboratory set-up at Field, District and Central level shall be as follows: 6.1 Field Laboratory The Contractor shall be responsible to set up and maintain an adequately equipped Field Laboratory for routine tests for quality control required to be conducted on a day to day basis. The Field Laboratory will have normally those test equipment that do not require electric power supply and are relevant to the project specifications. Field Laboratory will be manned by suitably trained personnel in material testing and quality control works. 6.2 District Laboratory The tests which are required to be done during the project preparation stage such as those pertaining to suitability of construction materials, selection of quarries etc. to be carried out before incorporation in the work as part of quality control or the tests which cannot be carried out in the Field Laboratory shall be conducted in the District Laboratory. The District Laboratory will cover the testing requirements for the entire District. Such a Laboratory shall be equipped with facilities for most of the tests, including those required for DPR preparation.
Page 2 and 3: Ministry of Rural Development Gover
Page 4 and 5: FOREWORD PREFACE ABBREVIATIONS QUAL
Page 6 and 7: Section 1100 PIPE CULVERTS 163 to 1
Page 8 and 9: PREFACE A good road network has an
Page 10 and 11: AE : Assistant Engineer AIV : Aggre
Page 12 and 13: 1. BACKGROUND 1 Quality Assurance H
Page 14 and 15: 3 Quality Assurance Handbook for Ru
Page 16 and 17: Material tests Workmanship tests Se
Page 20 and 21: 2. Quality Management System A typi
Page 22 and 23: 105. CONSTRUCTION EQUIPMENT 13 Qual
Page 24 and 25: B Do’s and Don’ts Do’s Don’
Page 26 and 27: 201 & 202. SITE CLEARANCE A Methodo
Page 28 and 29: 301. EMBANKMENT CONSTRUCTION A Meth
Page 30 and 31: (vii) Materials in a frozen conditi
Page 32 and 33: B. Earthwork for Subgrade (Cutting
Page 34 and 35: 302. EARTHWORK IN CUTTING A. Method
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Page 42 and 43: B. Quality Control Requirements 1.
Page 44 and 45: SECTION 400 39 Quality Assurance Ha
Page 46 and 47: 3. Section-400 (ii) Atterberg limit
Page 48 and 49: 3. Section-400 C Do’s and Don’t
Page 50 and 51: 3. Section-400 TABLE 402.2: GRADING
Page 52 and 53: 3. Section-400 2. The pulverization
Page 54 and 55: 3. Section-400 Table 403.3 : QUALIT
Page 56 and 57: 3. Section-400 6. The cement stabil
Page 58 and 59: 3. Section-400 6.3 Quality Control
Page 60 and 61: 3. Section-400 14. In case the scre
Page 62 and 63: 3. Section-400 TABLE 405.4: APPROXI
Page 64 and 65: 3. Section-400 5.3 Quality Control
Page 66 and 67: 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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3. Section-500 TABLE 504.2: PHYSICA
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3. Section-500 5.3 Quality Control
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3. Section-500 (b) Bitumen The bind
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3. Section-500 TABLE 506.1 RATE OF
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3. Section-500 TABLE 507.1: NOMINAL
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3. Section-500 5. Quality Control T
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3. Section-500 TABLE 508.1.1 : QUAN
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3. Section-500 Table 508.1.3: QUALI
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3. Section-500 B. Quality Control R
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3. Section-500 (ii) Immediately the
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3. Section-500 512. MODIFIED BITUME
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3. Section-500 TABLE 512.5 : REQUIR
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Annex-III & IV DETERMINATION OF IN-
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SIMPLE/HANDFEEL TESTS 600 600.1 Bri
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119 Quality Assurance Handbook for
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SECTION 600 121 Quality Assurance H
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3. Section-600 4. Build the courses
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3. Section-600 (v) Storage of mater
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3. Section-600 3.3. Quality Control
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700 : STONE MASONRY FOR STRUCTURES
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(v) Stone Masonry 133 Quality Assur
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4.2. Tests / checks during construc
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SECTION 800 CONCRETE FOR STRUCTURES
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3. Section-800 2. Proceed with conc
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3. Section-800 TABLE 800.3: REQUIRE
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3. Section-800 c. The strength of a
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3. Section-800 4.2 Tests / checks d
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SECTION 900 149 Quality Assurance H
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3. Section-900 2. Lower centering g
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3. Section-900 C. Do’s and Don’
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1000 STEEL REINFORCEMENT A. Methodo
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3.2 Tests during construction 159 Q
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1100: PIPE CULVERTS A. Methodology
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SECTION 1200 167 Quality Assurance
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3. Section-1200 A2 Substructures Th
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3. Section-1200 4. Provide 75 mm ce
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3. Section-1200 (2) Tolerances 1200
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3. Section-1200 3.2 Tests / checks
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3. Section-1300 A-3 Toe Protection
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3. Section-1300 2. Stones for pitch
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3. Section-1400 3. Give streamline
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3. Section-1400 2. Tests during con
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3. Section-1500 5 Mark location and
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3. Section-1500 (iv) Water Water us
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3. Section-1500 TABLE 1501.3: QUALI
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3. Section-1500 2. Check the in-sit
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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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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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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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