Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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1. SECTION 100: GENERAL 1.1: Quality Arrangements On-going 247 Quality Assurance Handbook for Rural Roads At any particular stage of construction e.g, Setting Out, Earthwork/ Subgrade, Sub-base, Base, Surfacing, and Cross-Drainage works, it is necessary to check the following:- (a) Check, if the field laboratory has been set up at an appropriate location and has the basic facilities to carry out the needed quality control tests. (b) Check, if out of the specified List of Essential Equipment pertaining to that stage of construction, any items are missing. (c) Check whether all the items needed are indeed in working order and that, wherever needed, the necessary calibrations have been done. For example, standard sand used in the insitu density test by Sand Replacement method and calibration of Rapid Moisture Meter or any other equipment. (d) Check, if the Laboratory Technician/ Junior Engineer carrying out the quality control tests is adequately trained and is competent to carry out all the needed field and laboratory tests reliably. 1.2 ATTENTION TO QUALITY 1. Verification of Quality Control Registers Check the dates for which the test results have been entered for different stages of construction in the Quality Control Registers. Ascertain if the Registers are uptodate and for each day, the type and number of tests carried out are as specified and that all calculations have been done properly. Spot checking of the Abstract of tests with the filled-in proformae of various tests is also necessary. 2. Verification of Test Results on the basis of Field Tests Check on the criterion adopted for acceptance, rejection or conditional acceptance of the work in progress. For example, adequacy of the level of compaction in a finished layer, based on a minimum of 3 insitu density tests carried out on the finished layer (Table 301.5). Where the acceptance criterion was not satisfied, check if a Non-Conformance Report was filled up or any other action was taken. Check, whether adequate action was taken on each of the Non-Conformance Reports to rectify the defects. Check, the compliance of observations made earlier by Quality Monitors. 1.3: SETTING OUT AND GEOMETRICS 1. Setting Out (a) Check the Reference Bench Mark and the Working Bench Marks. (b) Check, if the centre line of the carriageway is accurately established and referenced every 50 m intervals in plain and rolling terrain and 20 m intervals in hilly terrain with a closer spacing of 10 m on sharp curves, 5 m on hairpin bends with marker pegs and chainage boards.
4. Section-100 2. Width of Roadway (a) Take atleast 3 measurements of the Roadway width per km length, or part thereof. Measuring Tapes (available in the Field Laboratory) can be used for the purpose. The three locations for measurements per km length or part thereof may be selected at random. (b) Determine the mean of the 3 measurements per km length and compare with the specified width of roadway. Permissible tolerances are as under: ±30 mm in plain and rolling terrains ±50 mm in hilly terrain 3. Carriageway Width (a) Take atleast 3 measurements of the carriageway width per km length or part thereof. Measuring Tapes (available in the Field Laboratory) can be used for the purpose. The three locations for measurements per km length or part thereof may be selected at random. (b) Determine the mean of the 3 measurements per km length and compare with the specified width of carriageway. Permissible tolerances are as under: 4. Camber ±20 mm in plain and rolling terrains ±30 mm in hilly terrain Take atleast 3 measurements of camber, using a Camber Board (available in the Field Laboratory) per km length, or part thereof, following the procedure as shown in Annex 100.1. Note the discrepancies between the specified camber and the camber actually provided. Two designs of the commonly used Camber Board are shown in Annex 100.2. 5. Superelevation and Extra Widening at Curves (a) Along the circular curve portion of the road, measure the carriageway width at three selected chainages, using a measuring tape. The mean of the three observations will give the width of the carriageway provided along the circular curve. The difference between the mean carriageway width along the curve and the carriageway width along the straight reaches gives the extra widening provided along the curve, which should be compared with the design value of extra widening. (b) The widening should be effected by increasing the width at an approximately uniform rate along the transition curve. The extra width should be contained over the full length of the circular curve. (c) The amount of superelevation provided along a curve can be determined by using a straight edge as shown in Annex 100.3, spririt level and measuring tape. The measured amount of superelevation should be compared with the superelevation designed for the curve. 6. Longitudinal Gradient in Case of Road in Hilly/ Rolling Terrain Longitudinal gradients can be checked expeditiously, using simple Dumpy Level and staff. Reasonably accurate checks on gradient can be considered by using suitable Hand Level or even Calibrated Spirit Levels, depending on availability. These checks should be carried out at 3 critical locations per km length or part thereof and mean of the three observations determined. 248
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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 (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 (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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165 Quality Assurance Handbook for
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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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SECTION 1300 179 Quality Assurance
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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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Page 204 and 205: 3. Section-1600 The prescribed road
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Page 208 and 209: 1700. TRAFFIC SIGNS AND MARKINGS A.
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Page 244 and 245: 6. SECTION 1300: PROTECTION WORKS A
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Page 250 and 251: Appendix-1 1.4 Estimating Plasticit
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Page 260 and 261: Appendix-3 Sr. Code/ Title of the P
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Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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