field quality plan

Ispat Industries Ltd.Field Quality Plan

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FIELD QUALITY TESTS

Frequency of Test Remarks

A Civil Work1 Earth Work Marking 100% Site Engineers

ExcavationSide SlopeElevation

2 Back filling IS2720 - Part 5 Site lab

3 Total deleterious materials, IS 2386 Part-II Twice per source Approved lab

Silt & Clay Content, IS 2386 Part-II Every day before start of work, Site lab,

3 Alkali Content IS 2386 - Part-VII Approved lab

Site lab

Sl No

Item of Quality Test

Type of Quality Test To be conducted

Reference IS Codes or

Specification

Measurement Visual

IS1200

Liquid limit & Plastic limit & Plasticity Index

2 tests / 500 Cum or change of location or as directed by EIC

Compaction test (Proctor Density)

IS2720 - Part (2 & 28)

1 Test / 500 Cum or change of location or as directed by EIC

Fine aggregates (Sand) Particle Size Distribution

Specific gravity

IS 2386 Part-I & III IS 383

Every 100 Cum or change of source whichever is earlier,

Site lab and one test for each source to be conducted at approved lab other than site lab

Fine aggregates (Sand)

Once initially and with the change of source if any and thereafter every 6 months interval

Moisture Content IS 2386 Part-III IS 383 IS 456

Once per 100 Cum except during Monsoon when this has to be checked every day before start of work.


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Frequency of Test RemarksSl No




Specification

4 IS 2386 Part-I & III Site lab,

IS 383

IS 2386 Part-II Approved lab / site lab

Moisture Content Site lab,

Flakiness Index IS 2386 Part-I Approved lab / site lab

Elongation index IS 2386 Part-I Do

4 Impact Value IS 2386 Part-IV Approved labCrushing Value IS 2386 Part –IV Do

Soundness IS 2386 Part-V Do

Alkali Aggregates reactivity IS 2386 Part -VII Do

5 Water IS 3025 Approved lab

pH Value IS 456 Site Lab

Coarse Aggregates

Particle Size Distribution Specific garvity

1 No every 100 Cum and change of source if any One test for each source to

be conducted at approved lab other than site lab

Percentage of Soft deleterious materials

Twice per Source

IS 2386 Part-III IS 383 IS 456

Once per 100 Cum except during Monsoon when this has to be checked every day before start of work.

Once initially and subsequently with the change of source if any.

Coarse Aggregates

Once initially and with the change of source if any and thereafter every 6 months interval

Chemical & Physical properties

Water from each source before start of work and thereafter every 6 monthsOnce initially thereafter every month


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Specification

5 Water

IS 456 Site LabChloride and Sulphate content

Once initially thereafter every 6 months


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Specification

6 Cement Every batch of supply

Once in a month Approved labCompressive Strength IS 4031 Part-VI Every batch of supply

Once in a month Approved labSpecific gravity IS 4031 Every batch of supply

Once in a month Approved labChemical Analysis

Once in a month Approved labFineness & Soundness IS 4031 Every batch of supply

Once in a month Approved lab7 Fly Ash Chemical Analysis IS 3812 Approved lab

Initial and final setting time & Normal Consistency

IS 4031 Part-V Manufacturer Test Certificate / Site lab/ Approved lab

Manufacturer Test Certificate / Site lab/ Approved lab


IS 4032 IS 4031 Part-II

Every batch of supply or once in every type of cement



Once in the beginning and subsequently after every six months or cahnge of source whichever is earlier

Physical test - Compressive strength at 28 days


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Specification

8 Concrete Trial Mix Design IS 10262

Slump Test

Approved lab

100%

Site lab

9 Admixture Chemical Composition IS 9103Solid ContentSpecific gravitypH ValueCompatibility

Once during starting of any Project or cahnge in ingradients of concrete or change in any source

Approved Lab / Site lab (both)

IS 456 IS 1199

Every 30 Cum or part thereof or as decided by the Engineer In Charge

At place of manufacturing and place of Pouring.

Chloride and Sulphate content

IS 456 In the beginning and with the change of source of any ingredients

Placing before concrete (Pour Card)

As per drawing & tender specification

By Site Engineer & Quality Engineer

Compressive Strength (each test sample shall consist 6 cubes of 15cm cube)

IS 516 IS 1199 IS 456

As per IS 456:2000, Clause No: 15.2.2

Each Batch of Supply / Each type of materials / Change of vendor

Manufacturer Test Certificate


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Specification

10 Sand Content Each Lot of SupplyLiquid Limit & Plastic limitpH Value

11 Bentonite Fluid Specific Gravity Do Twice per shift of 8 hrs working Site lab

12 WBM IS 2386 - Part 1 Site lab / approved lab

IS 2386 - Part 4

IS 2720 - Part -4IS 2386 - Part 4

13 Each batch of supplyTensile

14 Each batch of supply

Tensile

15Insulation bricks IS 2024

Approved agency

16 Each lot wise & Source wise

17Fire Bricks

IS 6 (group-A) Approved agency

18 IS 4860 Approved agency

Bentonite (Raw Matetrial)

IS 2911 Part-I (Sec-2)

Manufacturer TC / Site Lab/ Approved Lab

Flakiness Index & elongation index

Every 100 Cum or change of source whichever is earlier

Los Angeles Abration Value GradingAggregate impact value

Reinforcement Tor & Mild

Bend & Re bend, IS 1786 IS 432

Manufacturer Test Certificate / Approved lab

CSPFoundation Bolt &

Anchor Bolt Bend & Re bend, IS 2062

IS 432 Manufacturer Test Certificate / Approved lab

CSPAll test as recommended by relevant IS codes

Each and every lot wise and source wise

Anti Corrosive Painting

As per manufacturer specification including pH value

As per instruction of EIC

Manufacturer TC / Approved Lab

All test as recommended by relevant IS codes


Acid resistant bricks

All test as recommended by relevant IS codes



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Specification

19 Compressive Strength Site lab / approved lab

Soundness & Colour Water AbsorptionEfflorescenceDimensions

20 Masonry Works VerticalityDimensionsPlasteringFinal Inspection

21 Water proofing compound Do

Methodology22 RCC Hume Pipes Class of Pipes IS 458 Each lot wise & Source wise

Size of Pipes 3 Nos Per lot Site lab / approved labThicknessPressure Test

23 Hand railing pipes Mechanical Properties IS 1239 Part-I &II Dia wise lot wise& source wise

Galvanising Quality IS 4736 do

24 100% Site Engineer before laying

Physiacl appearance

Moisture absorption Each lot wise & Source wise Site lab / approved lab

Common Burnt Clay Bricks

IS 3495 IS 1077


IS 2222 IS 2250 & as per drawing

100 % & as per drawing and tender Specification

Site Engineers / Quality Engineers

Water proofing Treatment

Manufacturer Specification




Manufacturer Test Certificate /Approved lab

Marble / Granite/ Kotah / sahabad/

tandoor Stone

Dimensions including thickness

IS 1124 & Tender Specification


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Specification

24

Mhos Scale Hardness

Each lot wise & Source wise Site lab / approved lab

Marble / Granite/ Kotah / sahabad/

tandoor Stone

IS 1124 & Tender Specification


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Specification

25 Terrazo tiles Dimensions IS 1237 Site Lab

Water Absorption Site labWet Transverse Strength Site lab / approved lab

Abrasion Test26 Water Absorption IS 13630

Crazing TestImpact StrengthChemical Resistance

27 PVC Sheet tiles MaterialThicknessPVA based adhessive IS12830

28 False Flooring Floor PanelPedestalStringersTop Head

29 Dimensions One test per lot

30 Glass One test per lot

31

32 IS 10146 For each tank before installation

One test per 10000 Nos or batch wise whichever is earlier & each source wise

Ceramic (Glazed & Unglazed) Vitreous tiles

One test per 10000 Nos or batch wise whichever is earlier & each source wise

Manufacturer Test Lab/ Approved Lab/ Site lab

IS 3462 & IS 5318

One test in the beginning and subsequently one test per lot

Manufacturer Test Certificate / Approved Lab

As per Tender Specification

One test in the beginning and subsequently one test per lot


PVC Water Stopper

Tender Specification


Properties like R.I. Thickness



Stainless Steel Pipes & Sheets

Diameter, Thickness & SS Garde


Easch Lot wise or change of source


Ployethelene water storage

tank

Wall Thickness & Weight & leakage test

Manufacturer Test Certificate & simultaneously by site lab


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Specification

33 Timber Moisture content For each Cum or part thereof Site lab or approved lab

34 Flush Door

35 As per tender For each lot Manufacturer test certificate

36 Mortice Lock Test for Spring IS 2209 Approved lab

37 One no in the beginning

IS 5523

38 Diameter & thickness Each lot wise & Source wise

Weight per metre do

Pressure Test Each section of length 100% at site before back filling

As per Appendix C, chapter 9 of CPWD specfication or as per tender specification

1. End immersion Test, 2. Knife Test, 3. Adhession Test

IS 2191 (Part-I&II) IS 2202 -Part -I & II IS 4020,

For each lot of 25 shutters or as per tender specification

One test for each source to be conducted at approved lab and subsequently manufacturer test certificate

PVC Single shutter with frame

As per manufacturer specification

One test per 100 nos of locks or part thereof unless specified otherwise.

Aluminium doors & windows

Mechanical properties of extruded sevtions

IS 1285 IS 1948 & 1949

Approved lab & Manufacturer test certificate & site lab

Anodising & powder coating thickness

One no Door & window per lot & per source

Water Supply C.I. (L.A. Class) Pipes

IS 1536 IS 1538

Mfg. Test Certificate for each lot


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Specification

39 Mechanical properties IS 1239 Part-I &II

Galvanising Quality IS 4736

Pressure Test As per Tender Each section of length 100% at site before back filling

40 UPVC water pipes Dimensions IS 4985


41 UPVC Agri pipes Dimensions IS 12231


42 Dimensions IS 15328


43 Valves Pressure Test As per Tender 100% at site

44 IS651 Site lab


45 Relevant IS 100% Site Quality Engineer

Leakage test

46 Steel Windows Dimensions As per drawing Site lab

Setional Weight

GI Water Supply pipes

Each lot wise, Source wise & dia wise






UPVC Sewrage pipes



Glazed Stone ware Pipes

Dimensions including thickness


Sanitary Fittings and fixture

Dimensions & Physical Inspection & ISI Marks

Each lot wise & Source wise & Size wise

IS 1038 IS 1361 IS 7452

Mfg.Test certificate of section used and rest by Site lab


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Specification46 Steel Windows

Nomemclature as per IS

IS 1038 IS 1361 IS 7452




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Specification

47 IS 4351 Do

48 Rolling Shutter IS 6248 Site lab

Setional Weight


49 IS 3614 Site lab

Setional Weight


50 Once in every six months Approved agency

51 Batching Plant Site lab

Performance of plant Visual At random52 Table balance IS 4925 Once in 12 months Approved agency

HMPS & ordinary Door Frames &

Shutter

Dimensions & Setional weight

Mfg. Test Certificate for each lot Or site lab

Dimensions including profile thickness



Fire check Door & Rolling Shutter

Dimensions including profile thickness



Cube Testing Machine

Calibration of pressure gauge

Manufacturer Specification

Calibration of all measuring equipment

IS 4925 Once in every month or 80% of monthly rated productionas described by the manufacturer considering 8 hrs working, whichever is earlier.

During day to day operation Calibration of equipment as well as the weights


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Specification

B. Road work

1 Sand Content IS 2720 - Part -4 Approved lab or site labLiquid limit IS 2720 - Part -5

Plasticity Index IS 2720 - Part -5

Modified Proctor IS 2720 - Part -8

Deleterious Content IS 2720 - Part -27

Soaked CBR in 4 days IS 2720 - Part -16

Moisture content IS 2720 - Part - 2

Field density IS 2720 - Part - 28

Embankment, Sub grade and

shoulder

2 tests / 300 Cum or change of location or as directed by EIC

Once in the beginning and subsequently after every six months or cahnge of source whichever is earlier


1 test per 1000 Cum or change of source whichever is earlier


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Specification

2 IS 2720 -Part-4 1 test per 200 Cum Approved lab or site lab

Modified Proctor IS 2720 - Part- 8 2 tests per 3000 Cum

Soaked CBR in 4 days IS 2720 - Part -16 1 test per 3000 Cum

Aggregate impact value IS 2386 - Part-4 1 test per 500 Cum

IS 2386 - Part -4 1 test per 500 Cum

IS 2386 - Part -I 1 test per 500 Cum

Water Absorption IS 2386 - Part - 3 1 test per 500 Cum

IS 383 1 test per 500 Cum

IS 2720 (part-5) 1 test per 200 Cum

Moisture content IS 2720 ( Part- 2) do

Field density IS 2720 (Part- 28) 1 test per 500 Cum

Surface level level survey

Granular Sub Base 150mm

thick

Gradation as per Table 400.1 Grading-II / table 400.2 Grading -I

Los Angeles Abration Value

Combined flakiness and elongation indices

Sodium Sulphate (5 Cycles)

Liquid limit/ Plasticity index of materials finer than 425 micron

6.25 m longitudinal and 3.5m transverse grid


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Specification

3 Aggregate impact value IS 2386 - Part-4 1 test/ 200 Cum Approved lab or site lab

Soaked CBR in 4 days IS 2720 - Part -16

Modified Proctor IS 2720 - Part- 8 2 Tests / 3000cum

Gradation IS 2720 -Part-4 1 test / 100 Cum

IS 2386 - Part -I 1 test / 200 cum

Water absorption IS 2386 - Part - 3 1 test / 3000 Cum

IS 2720 (part-5) 1 test per 100 Cum

Moisture content IS 2720 ( Part- 2) 1 Test / 250 Cum

Field density IS 2720 (Part- 28)

Surface level level survey

Wet Mix Macadam (200 mm thick per

layer)



Liquid limit/ Plasticity index of materials finer than 425 micron




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Specification

4 Quality of binder IS 73 & 217 & 8887 2 samples per lot Approved lab or site lab

Binder Temp for application as per EIC

Rate of spread of binder

Quality of binder IS 73 & 217 & 8887 2 samples per lot Approved lab or site lab

Binder Temp for application as per EIC

Rate of spread of binder

Primer Coat ( with emulsion to

IS 8887) Tender Specification

1 test per 500 sqm and not less than 2 tests per day

Tack Coat ( with emulsion to

IS 8887) Tender Specification

1 test per 500 sqm and not less than 2 tests per day


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Specification


Aggregate impact value IS 2386 (Part 4) 1 test per 50 Cum

do do

IS 2386 (part 1) do

Stripping value IS 6241 3 samples per sourceIS 2386 (Part 5) 1 test per source

IS 2386 (Part 3) 3 samples per source

Grading of aggregates IS 2386 (Part -1)

Water Sensitivity of Mix 3 samples per source

Bituminious macadam upto

maximum 100mm compacted

thickness (Using 60/70 grade

bitumen)

Los Angeles Abration ValueCombined flakiness and elongation indices

Soundness (Magnesium and Sodium Sulphate)Water Absorption of aggregates

2 tests per day per plant for individual constituents and mixed aggregates from dryer



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Specification

6 Binder content ASTM-D-2172 2 tests/day/plant Approved lab or site lab

At regular interval as per EIC

do

do

Level control of paver do doField density IS 2720 (Part -28)

Tolerance in surface level level survey

During laying & Compaction Temp of binder in boiler

and aggregate in drier before mixing

As per Specification

Temp of mix at the time of laying and rolling


Rate of spread of mixed material


1 test/ 250 Cum of which 10% tests to be done on edges



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Specification



do do

IS 2386 (part 1) do

Stripping value IS 6241 3 samples per sourceIS 2386 (Part 5) 1 test per source




Plasticity Index IS 2720 (Part 5) as per EIC

Sand equivalent Test as per EIC

Dense Bituminious

macadam 50mm to 100mm compacted

thickness (Using 60/70 grade

bitumen)

Los Angeles Abration ValueCombined flakiness and elongation indices

Soundness (Magnesium and Sodium Sulphate)Water Absorption of aggregates

1 set of test on individual constituents and mixed aggregates from dryer/ 400 t mix and minimum 2 tests /plant /day




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Specification

8 Binder content ASTM-D-2172 Approved lab or site lab


do

do

Level control of paver do do

Marshal Stability ASTM-D- 1559

Marshal Flow

Air Voids ASTM - D -2726

ASTM- D - 1559

Field density IS 2720 (Part -28)


During laying & Compaction

1 test / 400 T mix subject to 2 tests/ day/ plant

Temp of binder in boiler and aggregate in drier before mixing






A set of 3 samples / 400 T mix to a min 2 sets /plant/day

Voids in mineral Aggregates (VMA)

Voids in mineral Aggregates (VFB)

1 test/ 250 Cum of which 10% tests to be done on edges



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Specification

9 Quality of modified binder Approved lab or site lab

softening point IS 1205

IS 1203 & 1205

Elastic Recovery

IS 1208

IS 1209

IS 9381

Viscosity at 150 deg C IS 1206

Bituminious concrte (25 -

50mm compacted thickness) using

PMB-40, CRMB50 modified

bitumen

Initially once thereafter daily if site blended or weekly if pre blended

Penetration at 25oC and 4oC

ASTM -D5976-1996

Ductility at 27oC

Flash point COCoC

Frass breaking point in deg C

Thin film oven test, penetration, softening point, elastic recovery of residue, loss on heating

IS 1203, 1205,9382 & ASTM-D5976-1996


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Specification

9 Do Aggregate impact value IS 2386 (Part 4) 1 test per 50 Cum Approved lab or site lab

do do

IS 2386 (part 1) do

Stripping value IS 6241 3 samples per source

IS 2386 (Part 5) 1 test per source




Plasticity Index IS 2720 (Part 5) as per EIC

Sand equivalent Test as per EIC

Polished Stone Value BS 812-114



Soundness (Magnesium and Sodium Sulphate)

Water Absorption of aggregates

1 set of test on individual constituents and mixed aggregates from dryer/ 400 t mix and minimum 2 tests /plant /dayAs per Tender

Specification


One set of 3 specimen for each source of supply


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Specification

10 Binder content ASTM-D-2172 Approved lab or site lab


do

do

Level control of paver do do

Marshal Stability ASTM-D- 1559

Marshal Flow

Air Voids ASTM - D -2726

ASTM- D - 1559

ASTM -D-1075 As required


1 test / 400 T mix subject to 2 tests/ day/ plant

Temp of binder in boiler and aggregate in drier before mixing






A set of 3 samples / 400 T mix to a min 2 sets /plant/day

Voids in mineral Aggregates (VMA)

Voids in mineral Aggregates (VFB)

Loss of stability on immersion in water at 60 deg C


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Specification

10 Swell test As required Approved lab or site lab

Field density IS 2720 (part-28)




do do

IS 2386 (part 1) do

Stripping value IS 6241 3 samples per source

IS 2386 (Part 5) 1 test per source


Grading of aggregates IS 2386 (Part -1)Polished Stone Value BS 812-114


Asphalt Institute Manual MS-2 No-2

1 Test per 250 Sqm of which 10% tests shall be carried out at edges


Liquid Seal Coat Type-A using 60/70 Grade

Bitumen



Soundness (Magnesium and Sodium Sulphate)

Water Absorption of aggregates

1 set of test on individual constituents and mixed aggregates from dryer/ 400 t mix and minimum 2 tests /plant /day

One set of 3 specimen for each source of supply


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Specification

12 At regular interval as per EIC Approved lab or site lab

Rate of spread of material do


Temp of binder at application




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Specification

13

Axial load test

a) 5 Mpa 50 %

b) 15 Mpa 50%Test for Elasticiti Modulus 2 nosShear Modulus 2 nos

Adhession strength 2 nos14 Overall dimensions As per MORTH Specification

Elastometric Neoprene Bearing

Physical Test & Chemical Composition Test no:2

As per Specification & IRC 83 Part-II

As per Specification & IRC 83 part-II

Pre Delivery inspection at Manufacturer's test lab

Ultimate Compressive Strength 2 nos

POT Cum PTFE Bearing

MORTH Specification

Pre Delivery inspection at Manufacturer's test labLoad test to 1.1 times of

Max Design load (including Seismic force)

Test for Coeff of friction value < 0.05 of design load

Check for permissible rotation


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Specification

C

1 Materials Physical & Chemical Test IS 2062 & IS 1599 Each lot wise & Source wise

Ultrasonic test Approved Spec

Welding Rod Properties of electrodes IS 814Connection Bolts Properties of Bolts IS 1367 & IS 1363

2 Welding Parameter Site lab / approved lab

3 WorkmanshipFit-Up Inspection Measurement / Visual Site Engineers

Site lab / approved lab

Structural Steel Work


Welding Procedure/

Qualifiaction/ Records

ASME - Sec IX/ AWS D1.1


100% or as directed by EIC or as stipulated in the contractWelding

inspectionWeld size & Surface imperfection


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Specification

4 Radiography Test IS 1182 Do

Ultrasonic test Approved Spec Do

Approved Spec Do Site lab / approved lab

Paints DFT check IS 8629 (Part- I to III)

Do Site Engineers

Final Punch list Over all completeness

As per Spec or as directed by EIC

Approved & authorised Testing Agency

Dye Penetration Test

As per Spec or as directed by EIC

Dimensional inspection before

erection

Over all dimensions and straightness


Dimensional inspection after

erection

Verticality Horizontality, Alignment, Height, Tightening of bolt & inspection of welding after


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