Quality Assurance Handbook for Rural Roads Volume-I - pmgsy

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PREFACE A good road network has an important bearing on the economic growth of the country. Rural Connectivcity is perceived as one of the major component in increasing the agricultural output and earning capacity of the rural population. There is a marked improvement in quality of life by way of better educational facilities, improved health services, improved attendance by the school teachers as well as students. Accessibility also provides improvement in governance and provision of other facilities like post offices, access to police in case of emergencies and other communication system like telephones. As a measure of poverty reduction, Government of India has launched Pradhan Mantri Gram Sadak Yojana (PMGSY) in December, 2000. The management systems developed for implementation of the programme are centered on quality and the guidelines clearly prescribe to provide good all-weather connectivity to target habitations. Construction of quality roads requires concerted efforts on many fronts, therefore, a three tier quality mechanism has been operationalized under the programme. The first tier provides for in-house quality control, wherein, the Programme Implementation Unit (PIU) is required to control the quality of work through performing mandatory tests for the material and workmanship. The second and third tier of quality mechanism provides for monitoring of quality by the independent quality monitors at the State Level and at the National Level. The PMGSY Guidelines provides that the NRRDA will issue general guidelines on quality control and prescribe a Quality Control Hand Book to regulate the quality control process at works level. Accordingly, a Quality Control Hand Book was brought out in 2002. Based on feedback received from States, executing agencies and other organizations, it was felt that handbook may also contain details about the tests involved in construction of cross drainage works, rigid and semi-rigid pavements and protection works etc. The Rural Roads Specifications provide for mandatory testing of material and workmanship and feedback of the field formations regarding the frequency of tests indicated that there is a scope to revisit these frequencies. Therefore, National Rural Roads Development Agency decided to review the Quality Control Hand Book and the work of review was entrusted to Indian Roads Congress (IRC). The IRC was requested to review the content of Quality Control Hand Book with a view to include details about all the tests required for construction of roads and related cross drainage works etc. It was also requested that the IRC may review the prescription of frequency of tests and examine whether the concept of stage passing may be introduced to ensure clear accountability. The IRC constituted Expert Group headed by Shri S. C. Sharma, Former Director General, Ministry of Road Transport and Highways. The Expert Group prepared the contents of the Handbook and based on the level of work and its utility, the title of the handbook was decided as ‘Quality Assurance Hand Book for Rural Roads’. The drafts of Quality Assurance Hand Book were reviewed in a series of meetings and deliberations by a Peer Review Committee, constituted by NRRDA as below: Prof. C. E. G. Justo, Emeritns Fellow, Bangalore University – Chairman Shri Prabha Kant Katare, Director (Projects-III), NRRDA – Convener MEMBERS Dr. Ashok Kumar, Rural Roads Specialist, World Bank Dr. Praveen Kumar, Indian Institute of Technology, Roorkee VII
Shri H. L. Meena, Chief Engineer PWD, Rajasthan Engineer-in-Chief, PWD (R&B), Nagaland Shri V. V. Gulati, Former Chief Engineer P.W.D, Uttarakhand. Shri Vidya Sagar Singh, Former Chief Engineer, U.P.P.W.D. Shri H. K. Srivastava, Director (Projects-I), NRRDA Dr. B. P. Chandrasekhar, Director (Technical), NRRDA Shri S. Baliga, Director (Projects-II), NRRDA State Quality Coordinator (PMGSY), MPRRDA, Madhya Pradesh State Quality Coordinator (PMGSY), HPPWD, Himachal Pradesh The suggestions of members of Peer Review Committee and officers of NRRDA on the draft Hand Book were incorporated and final draft document was prepared. A National Workshop on Quality Assurance Hand Book was organized on 16-17 th April, 2007 at CRRI to review of the contents of Draft Handbook. Dr. Subas Pani, Secretary, Ministry of Rural Development inaugurated the Workshop and in addition to his valuable guidance about internalizing the quality consciousness, he mentioned that enormous efforts have been made in preparation of the Hand Book and it should be used extensively by the field officers engaged in implementation of PMGSY. It was suggested by him that the Quality Assurance Hand Book should be made available on the Programme Website, so that the officers, contractors and other construction agencies can have easy access to the provisions of quality assurance. The workshop was attended by representatives of almost all the States and experts. A number of valuable suggestions and comments made at the Workshop were suitably incorporated in the present form of Quality Assurance Hand Book. Volume I of the Handbook covers quality management system and details about quality control requirements. The revised frequency of tests and requirements about stage passing in form of quality control checks have been elaborated in this Volume. Volume II gives detailed description about equipment and test procedures. I would like to express my sincere gratitude to members of Expert Group, members of Peer Review Committee and Shri R. S. Sharma, Former Secretary, IRC whose pains taking efforts have brought out this wonderful document. I would also like to express my sincere appreciation to the efforts made by Shri V. K. Sinha, Secretary General IRC, officers and other staff of IRC in bringing out this handbook in the present form. I thankfully acknowledge the contribution made by the participants of the workshop organized at CRRI in April, 2007. The document of this nature cannot remain static with continuous upgradation of technology. User of this handbook would be the best judge of the deficiencies, if any still left in the document. We would greatly value the feedback and suggestions in this regard to keep this document updated. I am confident that this document would serve its intended purpose. New Delhi (Prabha Kant Katare) Director (Projects) & Chief Quality Coordinator May, 2007 National Rural Roads Development Agency VIII
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 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
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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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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Page 264 and 265:
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Quality Assurance Handbook for Rura
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