Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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3. Section-400 6.3 Quality Control Checks by AE/EE Table 404.3: QUALITY CONTROL TESTS DURING CONSTRUCTION The quality control checks by AE/EE are indicated in Table 404.4. B. Do’s and Don’ts Type of Test Frequency 1. Pulverization of soil clods Atleast 3 tests daily, well spread over the day’s work. 2. Placement Moisture Content (IS:2720 Part 2) -do- 3. Insitu Density measurements (IS:2720 Part 28) -do- (i) Average of 3 test results shall not be less than the specified degree of compaction. (ii) Individual test values of the degree of compaction attained shall not be less than 1% of the specified degree of compaction. 4. Thickness of Compacted layer At random 1. Insist on uniformity of mixing of soil with cement by using tractor–towed implements. 2. Look for soft patches, if any, and rectify them by removing or adding fresh material and compacting the same thoroughly. 3. It must be ensured that the compaction of cement stabilized materials is completed within two hours of its mixing. 4. Lime, if used for pretreatment should have a minimum purity of 70% by weight of CaO. 5. A sample of the field mix should be brought to the laboratory for conducting various tests. TABLE 404.4: QUALITY CONTROL CHECKS BY AE/EE Stage Test Frequency Designation of Inspecting Officer 1. Top of the (i) Degree of Minimum 3 tests for each two km length or AE compacted Compaction part thereof; allowable tolerance in test values cement-treated layer (IS:2720 Part 28) as per Table 403.3 (ii) Unconfined (a) One test for each 250 m length or part AE Compressive Strength there of. (IS:4332 Part 5) (b) One test for each 500 m length or part EE sample extracted from the compacted layer. there of. (iii) Surface Regularity and Transverse Profile. Random Checking AE Do’s Don’ts 1. Do not allow soil clods larger than 26.5 mm in size before mixing of soil with cement. 2. Do not permit any organic or other deleterious material in the soil. 3. Do not carry out soil-cement stabilization with air temperature less than 100C. 4. Do not allow any traffic other than mixing equipment to pass over the spread cement till mixing has been completed. 5. Do not allow any traffic until the surface is cured for 7 days. 54
55 Quality Assurance Handbook for Rural Roads 405. WATER BOUND MACADAM SUB-BASE/BASE/SURFACING A Methodology 1. The surface to receive the WBM course should be prepared to the lines, grade and cross fall. It should be made free of dust and extraneous material. Large irregularities, where predominant, should be made good by providing profile corrective course. 2. Where the WBM is laid over a fine grained soil subgrade, it is advisable to lay a 100 mm thick intervening layer of screenings or coarse sand. 3. Any existing bituminous surface over which WBM is to be laid shall be completely removed before laying WBM layer. 4. The coarse aggregate should meet the physical and grading requirements laid down in Table 405.1 and Table 405.2. Coarse aggregate can be crushed or broken stone, crushed slag, over burnt brick aggregate, kankar, laterite meeting the prescribed requirements. 5. The spreading of coarse aggregate shall be done from stockpiles along the side of the roadway or directly from vehicles. In no case the aggregate shall be dumped in heaps directly on the surface prepared to receive the aggregates nor shall hauling over uncompacted or partially compacted base be permitted. 6. The coarse aggregate shall be spread uniformly on the prepared subgrade, sub-base or base, as the case may be, to proper profile (by using templates placed across at 6.0 m intervals) in such quantities that would give the required compacted thickness. The thickness of compacted layer should be 100 mm for Grading 1 and 75 mm for Gradings 2 and 3. The appropriate quantity of aggregates is given in Table 405.4. The surface should be checked with templates and all high or low spots remedied. 7. Roll the surface with suitable road rollers till aggregates are partially compacted with sufficient void space left for application of screenings. However, where screenings are not to be applied as in the case of soft aggregates, compaction shall be continued until the aggregates are thoroughly keyed. Rolling shall proceed from inner edge to outer edge at the super-elevated portions and from the edges towards the centre in other portions. The edge should be first compacted with roller running forward and backward. 8. Check the profile transversely and longitudinally with templates/ straight edge. Correct the irregularities by loosening the surface, adding or removing the needed amount of aggregates and re-rolling until the entire surface conforms to the specified camber/ cross fall and grade. 9. Apply screenings to completely fill the interstices maintaining a slow and uniform rate, in three or more applications. The screenings should not be damp at the time of application. 10. Do not apply screenings so fast and thick as to form cakes or ridges on the surface. 11. Continue dry rolling and brooming till no more screenings can be forced into the voids of coarse aggregates. 12. Sprinkle water on the surface taking care that the underlying layer is not damaged. 13. Sprinkling, sweeping and rolling should continue till aggregates are thoroughly keyed, well bonded and firmly set in its full depth and a grout has been formed of screenings.
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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
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 18 and 19: 2. Quality Management System (iii)
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
Page 36 and 37: 31 Quality Assurance Handbook for R
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
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Page 64 and 65: 3. Section-400 5.3 Quality Control
Page 66 and 67: 3. Section-400 (ii) Grading Require
Page 68 and 69: 3. Section-400 C Do’s and Don’t
Page 70 and 71: 3. Section-400 408. Local materials
Page 72 and 73: 3. Section-400 B. Quality control r
Page 74 and 75: 3. Section-400 409. LIME-FLYASH STA
Page 76 and 77: 3. Section-400 4. Surface Regularit
Page 78 and 79: 3. Section-400 (ii) Slag The broad
Page 80 and 81: 3. Section-400 6. The thickness of
Page 82 and 83: 3. Section-400 2. Horizontal Alignm
Page 84 and 85: SECTION 500 BITUMINOUS 81 Quality A
Page 86 and 87: 3. Section-500 (iii) In the final l
Page 88 and 89: 3. Section-500 3. The primer should
Page 90 and 91: 3. Section-500 B. Quality Control R
Page 92 and 93: 3. Section-500 TABLE 504.2: PHYSICA
Page 94 and 95: 3. Section-500 5.3 Quality Control
Page 96 and 97: 3. Section-500 (b) Bitumen The bind
Page 98 and 99: 3. Section-500 TABLE 506.1 RATE OF
Page 100 and 101: 3. Section-500 TABLE 507.1: NOMINAL
Page 102 and 103: 3. Section-500 5. Quality Control T
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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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