Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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Section 1100 PIPE CULVERTS 163 to 166 Section 1200 RCC SLAB CULVERTS AND MINOR BRIDGES 169 to 177 Section 1300 PROTECTION WORKS AND DRAINAGE 181 to 185 Section 1400 CEMENT CONCRETE CAUSEWAY 189 to 193 Section 1500 CEMENT CONCRETE PAVEMENT 197 to 215 1501 Plain Cement Concrete Pavement 1502 Roller Compacted Concrete Pavement 1503 Rectangular Concrete Block Pavement 1504 Interlocking Concrete Block Pavement Section 1600 HILL ROAD CONSTRUCTION 219 to 222 Section 1700 TRAFFIC SIGNS, MARKINGS & OTHER ROAD APPURTENANCES 225 to 227 Section 1900: MAINTENANCE 231 to 241 1901, 1902 & 1903 Maintenance of Earthworks 1904 Maintenance of Bituminous Surface Road 1905 Maintenance of Gravel Road 1906 Maintenance of WBM Road 1908,1909 Maintenance of Culverts and Causeways 1910,11,12,13,14 &15 Maintenance of Road Signs, Markings & Appurtenances CHAPETR 4 QUALITY MONITORING BY NATIONAL/STATE 243 to 274 QUALITY MONITIORS Appendices Appendix-1 Handfeel Tests App. 1/1 to 1/8 Appendix-2 Guidelines for Appropriate Technology for Rural Road Construction App. 2/1 to 2/2 Appendix-3 List of IRC Publication App. 3/1 to 3/7 Appendix-4 List of MORD and MOSRTH Publications App. 4/1 to 4/2 EQUIPMENT AND PROCEDURES FOR TESTS VOLUME II V
FOREWORD Focus on quality has been a singular feature of the Pradhan Mantri Gram Sadak Yojana (PMGSY) right from its inception. In fact, the report of the National Rural Roads Development Committee, which formed the conceptual basis of this programme, specifically highlighted the need for inbuilt quality assurance mechanisms, as a first step towards institutionalizing quality assurance system in the programme implementation, a quality control handbook for rural roads was brought out in 2002 by the National Rural Roads Development Agency (NRRDA) covering various tests to be conducted, frequency of these tests and details of the test procedures. However, at that time separate specifications were not available for the low volume rural roads. In 2004 the Ministry of Rural Development brought out Specifications For Rural Roads, which was published by the Indian Roads Congress (IRC). Following this technical experts as well as the programme managers felt that there was a consequential need to revise the Quality Control Handbook. Accordingly, the work of revising the handbook was entrusted to the IRC which constituted a group of experts headed by Shri S. C. Sharma, former Director General (Road Development) and Additional Secretary, Ministry of Road Transport and Highways. The other members of this expert group were Shri D. P. Gupta, Dr. V. M. Sharma, Dr N. B. Lal, Shri M. V. B. Rao, Shri G. S. Khinda and Shri S. P. Singh. This revised version of the quality Assurance Handbook for rural roads does not restrict itself to quality control only. It has widened the scope by adopting the principles of quality assurance as laid down by the IRC. Volume-I of this handbook deals with the quality management system and quality control requirements and Volume-II covers the equipments and test procedures. Quality monitoring of the projects through independent, third party monitors at the State level as well as at the Central level has also been dealt with in Volume-I. Unlike the earlier practice of seeking quality control only during construction, this handbook recommends exercising quality control at three stages – at the stage prior to construction, during the construction phase and quality checks by the field engineers after completion of each stage of construction, which is termed as “stage passing”. A number of carefully thought out “Do’s and Don’ts” for each activity and item of work have also been prescribed for the guidance of users. In its present form, this handbook incorporates valuable suggestions and recommendations which were received during a workshop which was specifically organized to review the draft on April 16-17, 2007 at Central Road Research Institute, New Delhi. I would like to express my sincere appreciation to the IRC, the members of the expert group for their painstaking efforts, to all the members of the peer review group for their meticulous and methodical scrutiny, and to all the participants of the national workshop which was held in April 2007 for their valuable contributions. I do believe that in the implementation of PMGSY in substantial measure. V (J. K. Mohapatra) Joint Secretary (RC) Ministry of Rural Development & Director General National Rural Roads Development Agency
Page 2 and 3: Ministry of Rural Development Gover
Page 4 and 5: FOREWORD PREFACE ABBREVIATIONS QUAL
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
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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
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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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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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