quality control manual wrd

8/15/2019 Quality Control Manual WRD

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GOVERNMENT OF RAJASTHAN

WATER RESOURCES DEPARTMENT

QUALITY CONTROL MANUAL

March – 2011

Chief Engineer

Water Resources Department

Rajasthan, Jaipur


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PREFACE

Status of water in Rajasthan is critical and complex. Ground water table is depleting

at fast rate across the state due to over exploitation. The availability of water is also

decreasing regularly due to abnormal growth of population. After independence,

major concentration was extended to water sector and 90% of state's water is utilized

by irrigated agriculture. But the major concerns in water sector are sustainability,

productivity, water management, pricing etc.

It will be our endeavor that the works are executed with strict quality standards

confirming to technical specifications with deployment of good constructionmodalities. To achieve the objectives of an effective Quality Control Monitoring and

Quality Assurance Management System, an independent quality control unit has

been established and made operational. The important aspect is to develop quality

concept and capacity of field engineers to be continuously vigilant on quality

control. Accordingly a manual to promote procedure and guidelines of quality

control systems on the works of Water Resources Department has been prepared,

after detailed discussions and feedback experience from the prevailing practices.

The manual shall provide in depth understanding of the need of quality control,

including prescribing the tests required to be conducted for the materials during

construction and placement activities along-with post construction scenario. The

manual is designed to introduce various formats to be followed at various stages or

construction to achieve proper quality control and to transmit necessary reports. It

also provides an opportunity for the engineering personnel for deployment of their

skills in quality control procedures to increase useful life of structures being

constructed in confirmation with the international standards.

Although every care has been taken to check mistakes and misprints, yet it is

difficult to claim perfection. Any errors, omissions and suggestions for the

improvement and corrections in the Quality Control Manual are most welcome from

all the quarters, which may please be sent to the undersigned.


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Quality Control Manual for Water Resources Department has been made under

valuable guidance and support of the Committee officers Sh.P.L.Solanki, Chief

Engineer Quality Control & Vigilance, Jaipur and Sh.G.R.Bhansali, Chief Engineer

SWRPD, Jaipur .Their valuable support for the finalization of Quality Control

Manual applicable to the construction works of Water Resources Department by

Sh. Narendra Mertia SE & TA and his team is thankfully acknowledged.

Date: 17th March, 2011 (Kundan Lal)Place: JAIPUR Chief Engineer


Rajasthan, Jaipur


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INDEX

CHAPTER NO. PARTICULARS PAGE

NO.

LIST OF INDIAN STANDARDS (i)-(iii)

CHAPTER-I QUALITY ASSURANCE AND CONTROL 1

CHAPTER-II ORGANISATIONAL SET-UP 5

CHAPTER-III GENERAL FUNCTIONS OF LABORATORIES 8

CHAPTER-IV DUTIES OF STAFF INCHARGE OFLABORATORIES

16

CHAPTER-V DUTIES OF FIELD STAFF IN RELATION TOQUALITY OF WORKS

20

CHAPTER-VI CO-ORDINATIONS 24

CHAPTER-VII QUALITY ASSURANCE 27

CHAPTER-VIII O.K. CARDS 29

CHAPTER-IX TESTS TO BE PERFORMED ON MATERIALS 39

CHAPTER-X LIST OF EQUIPMENT FOR CEMENT ANDCONCRETE TESTING

41

CHAPTER-XI FORMATS OF TEST RESULTS 43

CHAPTER-XII IMPORTANT SPECIFICATIONS 58

CHAPTER-XIII FREQUENCY OF TESTING 96

CHAPTER-XIV MONITORING THROUGH CONTROL CHARTS 102

CHAPTER-XV COMPILATION OF QUALITY CONTROL DATA 107

CHAPTER-XVI PROCEDURE FOR EXECUTING EARTH WORK 108

CHAPTER-XVII PROCEDURE FOR EXECUTING CONCRETELINING

112

CHAPTER-XVIII PROCEDURE FOR EXECUTING RCC WORK &CONCRETE FOR STRUCTURES

117

CHAPTER-XIX PROCEDURE FOR SHOT-CRETING AND

GUNITING

122

CHAPTER-XXDETERMINATION OF FIELD MOISTURE & DRYDENSITY OF COMPACTED EARTH FILL

129

CHAPTER-XXIDETERMINATION OF FIELD DENSITY BYSAND REPLACEMENT METHOD

130

CHAPTER-XXIICHECK LIST FOR QUALITY CONTROL UNIT

132

ANNEXURE-I SKETCH SHOWING THE ROLES ANDRESPONSIBILITY MATRIX

139

ANNEXURE-II ORGANISATIONAL CHART 142

ANNEXURE-III SKETCH SHOWING CONSTRUCTION – JOINTIN LINING 143


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ANNEXURE-IV INSPECTION OF TESTING ACTIVITIES 144

ANNEXURE-V-A SKETCH SHOWING AIR – WATER GUN 145

ANNEXURE-V-B AIR – MORTAR GUN 146

ANNEXURE-VI ILLUSTRATIVE SKETCH SHOWINGTREATMENT OF CANAL PRISM IN EXPANSIVESOILS WITH CNS MATERIALS

147

ANNEXURE-VII TYPICAL CROSSECTION OF A DISTRIBUTARYWITH C.N.S. SUB GRADE

148

ANNEXURE-VIII CURVE SHOWING RELATION BETWEENSPECIMEN SIZE AND STRENGTH OFCONCRETE CORE

149

ANNEXURE-IX DATA OF THE CORES TAKEN FROM IN SITUCONCRETE CANAL LINING

150

ANNEXURE-X ILLUSTRATION OF PREPARATION OFCONTROL CHARTS FOR CEMENT AND

CONCRETE

151

ANNEXURE-XI GRAPH SHOWING CORRECTION FACTOR FORHEIGHT/ DIAMETER RATIO OF A CORE

161

ANNEXURE-XII STATEMENT SHOWING CAPACITY OF PAVERAND MECHANICAL TRIMMER

162

ANNEXURE-XIII GOVERNMENT OF RAJASTHAN ,IRRIGATIONDEPPARTMENT ORDER OF DATED 4-11-96

163

ANNEXURE-XIV GOVERNMENT OF RAJASTHAN ,WRD ORDER

OF DATED 27-9-10

165

ANNEXURE-XV PHOTOGRAPHS OF KEY/CRITICALEQUIPMENTS

168


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LIST OF INDIAN STANDARDS

S.

No.Short Title

IS. to various

Standards

(A) Cement

1 Specification for 33 grade ordinary Portland cement IS:269 -1989

2 Specification for Rapid-hardening Portland cement IS:8041 -1990

3 Specification for Portland pozzolona cement IS:1489 (Part 1&2)

1991

4 Methods of physical test for hydraulic cement IS:4031 -1988

5 Method of chemical analysis of hydraulic cement IS:4032 -1985

6 Method of sampling for hydraulic cement IS:3535 -1986

7 Standard sand for testing of cement IS:650 -1991

8 Specification for 43 grade ordinary Portland cement IS:8112 -1989

9 Specification for 53 grade ordinary Portland cement IS:12269-1987

(B) Coarse / Fine Aggregate

1 Specification for coarse & fine aggregates IS:383-1970

2 Methods of test for aggregates for concrete

particle size and shape.

IS:2386 (Part I)-1963


estimation of deleterious materials and organic

impurities.

IS:2386 (Part II)-1963

4 Methods of test for aggregates for concrete specificgravity, density, voids, absorption & bulking.

IS:2386 (Part III)- 1963


Mechanical properties.

IS:2386 (Part IV)-1963

6 Methods of test for aggregate for concrete

Soundness.

IS:2386 (Part V)- 1963

7 Methods of test for aggregate for concrete

measuring mortar making properties of fine

aggregates.

IS:2386 (Part VI)-1963


alkali aggregate reactivity.

IS:2386 (Part VII)-

1963


petrographic examination.

IS:2386 (Part VIII)-

1963

(C) Bricks

1 Method for sampling of clay building bricks IS:5454 -1978

2 Method of tests of burnt-clay building bricks IS:3495 (Parts 1 to 4)-

1992

3 Common burnt clay building bricks IS:1077 -1992


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S.

No.Short Title

IS. to various

Standards

(D) Masonry Mortar

1 Specification for sand for masonry mortars IS:2116 -19802 Code of practice for preparation and use of

masonry mortar.

IS:2250 -1981

(E) Cement Concrete

1. Specification for coarse and fine aggregate IS:383 - 1970

2 Specification for compressive strength, flexural

strength.

IS:516 -1959

3 Code of practice for plain & reinforced concrete IS:456 -2000

4 Methods of sampling and analysis of concrete IS:1199 - 1959

5 Recommended guide lines for concrete mix design IS:10262 - 1982

(F) Curing Compound

1 Standard test method for water retention & day

light reflection test on concrete.

ASTM-C-156809

2 Standard method of test for effect of organic

materials in fine aggregate on strength of mortar.

ASTM-C-87-69

3 Standard specification for liquid membranes

forming compounds.

ASTM- C-309-89

(G) PVC Water Stops

1 Code of practice for provision of water stops IS:12200 - 1987

2 Procedure for Testing Parts of IS:8543

3 Standard Test methods for Tensile properties of

Plastics.

ASTM : D 638-1991

4 Standard Test methods for Thermoplastic

Elastomers Tension.

ASTM : D 412-1992

(H) HYSD BARS

1 Specifications for HYSD bars. IS:1786 - 1985

2 Specification for Mild Steel and Medium Tensile

steel bars for concrete reinforcement.

IS:432 (Part I) -1982

3 Method for Tensile testing of steel wires IS:1521 - 1972

4 Hard drawn steel wire for concrete reinforcement IS:432 (Part II) -1982

5 Method for Tensile testing of Steel IS:1608 - 1995

6 Code of practice for bending & fixing of bars for

concrete reinforcement.

IS:2502 - 1963

(I) Precast R.C.C. Pipes

1 Specifications for precast concrete pipes IS:458 - 1988

2 Methods of test for concrete pipes IS:3597 – 1985


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S.

No.Short Title

IS. to various

Standards

1 Preparation of dry soil samples IS:2720 (Part I) -1983

2 Determination of water content (moisture content) IS:2720 (Part II) -1973

3 Determination of specific gravity of fine grained

soils.

IS:2720 (Part III) -1980

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4 Determination of specific gravity of fine, medium

& coarse grained soils.

IS:2720 (Part III) -1980

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5 Grain size analysis IS:2720 (Part IV) -1985

6 Determination of liquid and plastic limit IS:2720 (Part V)- 1985

7 Determination of shrinkage factors IS: 2720 (Part VI)- 1972

8 Determination of water content -dry density

relation using light compaction.

IS:2720 (Part VII) -1980

9 Determination of water content -dry densityrelation using heavy compaction.

IS:2720 (Part VIII) -1983

10 Determination of water content -dry density

relation using constant weight of soil method.

IS:2720 (Part IX) -1971

11 Determination of unconfined compressive strength IS:2720 (Part X) -1973

12 Determination of shear strength parameters

(tri-axial) without measurement of pore water

pressure (tri-axial compaction).

IS:2720 (Part XI) -1971

13 Determination of shear strength parameters with

measurement of pore water pressure.

IS:2720 (Part XII)- 1981

14 Direct shear test IS:2720 (Part XIII) -1986

15 Determination of density index (relative density)

of cohesionless soils.

IS:2720 (Part XIV)-

1983

16 Determination of consolidation properties IS:2720 (Part XV) -1986

17 Determination of permeability IS:2720 (Part 17)- 1986

18 Determination of dry density of soils, in- place by

the sand replacement method.

IS:2720 (Part 28)- 1974

19 Determination of dry density of soils, in- place by

core-cutter method.

IS:2720 (Part 29)- 1975

20 Laboratory vane shear test. 1S:2720 (Part 30) -198021 Determination of the density in place by the ring

and water replacement method.

IS:2720 (Part 33)- 1971

22 Determination of free swell index of soils IS: 2720 (Part 40)- 1977

23 Measurement of swelling pressure of soils IS: 2720 (Part 41)- 1977

24 Classification and identification of soils for

general engineering purposes.

IS:1498-1970


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CHAPTER – I

QUALITY ASSURANCE AND CONTROL

1. INTRODUCTION

Evaluation of water resources projects involves enormous expenditure. They are

time bound programme and require assistance from various technical bodies for

investigation, design, planning and execution. To have a safe durable structure, it is

necessary that the materials and standard of execution fully satisfy the

specifications. It is to be recognized that the ultimate efficiency of the performance

of a project will depend upon proper layout and designs, the ultimate health of the

project during life scale of its operational phase will depend largely on the quality

achieved during its construction.

Each and every job whether big or howsoever small shall require to be executed to

acceptable construction quality duly confirming to sound design principles,

specifications and deployment of good methodology or modern technique and

procedures. To achieve the requisite objectives, it is essential to introduce a result

oriented quality management system.

This system is planned to orient the whole range of quality effort on a continuous

basis covering quality assurance and quality control, broadly out lined below

including steps initiated for its meticulous implementation.

1.1 Orientation and training of construction supervision/quality control

staff

A capable and functional construction supervision (CS) and quality control / quality

assurance team is needed to ensure implementation of contract specifications. To

achieve this objective intensive training will be given to all related staff of

construction / quality control in suitable batches covering specifications for the

works to be executed and also the procedure to conduct various tests in the field and

laboratories. Recommendation of I.S. codes will be explained in the training so as to

cover key construction and QC / QA aspects.


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1.2 Laboratory system for testing of Input and Outputs

Looking to the overall quantum of work and the scattered area in different

zones, establishment of laboratories at different levels and places forms an

important link of project organisation for quality control. The system is

required to provide reliable and accurate testing support to fulfill the

objectives. Accuracy and reliability in testing will depend upon the

competence of testing personal, accuracy of apparatus, quality of reagents

used, and maintenance of requisite environmental conditions. Introduction of

"Mobile testing laboratory system" will prove to be highly result-oriented.

This can be supplemented by adequate nos. of site labs, field laboratories and

zonal laboratories.

1.3 O.K. Card System

It provides a systematic approach towards assuring quality construction and

has proved to be practical mechanism for enforcement of technical

specifications. For the purpose, each work is divided in various activities in

proper sequence/order of construction and listed in chronological order of

occurrence in O.K. Card. The cards are maintained in 2 colors (Pink and

Green) to be operated by construction and quality control units separately.

During execution of work both cards are operated simultaneously and will be

kept on record by Executive Engineer concerned.

2. OBJECTIVES AND SCOPE OF QUALITY CONTROL

The objective of quality control management is to collect, process and thencommunicate the data related to the quality of inputs and outputs as well as

finished item of work to those who are responsible for the quality. Any

programme of quality control seeks to ensure adequacy and uniformity of

quality through the following operations.

1. To ensure that the works are being executed in conformity with the

prescribed specification.


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2. Inspection of storage, handling and processing facilities for all materials

in conformity with accepted or specified practice.

3. Monitoring the variation in specification of the materials and quantities

used in the operation of production and in the final product by suitable

observation, measurements or tests.

4. In order to achieve the common goal – Construction quality in the

execution of project, the roles and responsibility matrix, as depicted in

Annexure-I shall be broadly followed by :

1. GOR 2. Contractor 3. Project Construction Team

4. Project QC/QA Team and 5. Project Design Team

5. Analysis of the observed variations by statistical or other techniques.

6. Feed-back of the results of analysis for exercise of control at each stage

and to take corrective steps for maintaining the variations within

specified limits.

7. Indicating expeditiously the possible remedial measures, wherever

warranted to ensure execution of works as per drawings / specifications.

8. Rejecting, where warranted, the material or the product at any

intermediate or final stage in case acceptance criteria is not satisfied. The

rejected material should be removed from work site immediately.

3. QUALITY CONTROL MANUAL

It is very important constituent of the quality management system. It is a

document encompassing specific requirement, which if fulfilled, shall help in

effectively implementing the quality control system to achieve the objective

of good construction quality. It covers broadly, the objectives, functions and

operations of the Q.C. organisation; duties and responsibilities of Q.C.

personnel; Q.C. Laboratory System; O.K. Cards; Monitoring through Control

Charts; Control on workmanship; Tests on materials; Important

specifications; Standards to be adopted for materials and works; Frequency

of testing and reporting; Compilation of Q.C. Data and Statistical Analysis

etc.; Documentation and Feed-back; Inspection etc.


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4. CONFIGURATION OF QUALITY MANAGEMENT SYSTEM

QUALITY MANAGEMENT SYSTEM

Quality planning,

Q.C. Manual;

Training of Q.C./Q.A.

Staff, Infrastructure

etc.

Quality Control Quality Assurance

5.1 QUALITY CONTROL: (Q.C.)

The operational techniques and activities that are used to fulfill the

requirements for quality.

5.2 QUALITY ASSURANCE: (Q.A.)

All the planned and systematic activities implemented within the quality

system and demonstrated as needed to provide adequate confidence that an

entity will fulfill requirements for quality; and making sure that the quality of

a product is what it should be. Purpose of Quality Assurance is to prevent

problems before they occur, to identify and correct them swiftly if they occurand to uncover the root cause.

5.3 QUALITY MANAGEMENT

All activities of the overall management function that determine the quality

policy, objectives and responsibilities, and implement them by means such as

Quality Planning, Quality Control, Quality Assurance, and Quality

Improvement within the quality system.

The QUALITY CONTROL MANUAL being adopted for Water Resources

Department (the salient requirements of which are being outline in the

various chapters) aims at a “System Approach” to ensure that upon

implementation , the quality levels as set and defined in the specifications

and contract documents and relevant Indian Standards would be met in the

execution of project works.


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CHAPTER – II

ORGANISATIONAL SET-UP

GENERAL

I. Anyone connected with quality control work, should possess adequate

knowledge and experience of quality control works and be well conversant

with testing of construction materials. The object of quality control should be

clearly understood by them in letter and spirit so as to help in construction

and achieve high order of quality as laid down in specifications for works by

controlling various factors responsible for deterioration in quality,investigating reasons therefore and suggesting ways and means for

improvement.

II. To have proper and independent quality, quality control formation shall

consist of an independent unit headed by Chief Engineer Quality Control.

The C.E. shall have three S.E.'s in-charge of Quality Control Circle for the

various construction activities of different zones and the S.E.'s shall have a

team of E.E.'s to look after the work of different circles. Thus there will be

separate streams of construction and quality control assurance respectively

up to the level of C.E. (Organisational Chart attached at Annexure-II).

III. Every Q/C Circle shall be divided in number of division and each division

shall be headed by the Executive Engineer for the purpose of effective

quality control, every divisional jurisdiction shall be sub-divided in number

of units and each unit is to be put under the charge of A.En. The E.E. quality

control shall make all arrangements for the demarcating the areas of

operation of every quality control staff and issue a duty chart for each

member after approval from the C.E / S.E. Field Laboratory will be situated

at important nodal points which shall cover all the adjoining works and in-

charge will be T.A. to Executive Engineer. Site Laboratories as per

requirement in field shall be maintained by concerned site in-charge

(construction) and also utilized by Assistant Engineer Q/C for carrying out

necessary tests whenever site is inspected by him.


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IV. One of the fundamental principles to be understood and kept in mind is that

the overall responsibility for achieving construction quality in each sub-

project – rests with the execution unit and construction staff shall be fully

responsible for quality of work. Requisite assistance is to be provided by the

Q.C. Staff for ensuring construction quality.

Functions of Quality Control Units

The main function of Q.C. units is to have independent checking and control

of works. Since the works in the zones are of scattered nature, the quality

control units can not exercise concurrent quality control, but it has been

planned that these units should act in such a manner that necessary quality

control requirements are fulfilled jointly with the execution staff. It will be

the responsibility of quality control staff to ensure that all-requisite test as

per IS / relevant standards and specifications are carried out in site / field /

zonal or central laboratories. The quality control units will carry out periodic

inspections of works and conduct field tests so that any deficiencies in the

execution of works are properly brought to the notice of concerned

authorities and execution staff for taking corrective measures. The following

broad indications of functions of quality control units are given which may

be supplemented by issue of any further instructions by the Chief Engineer,

Quality Control, Jaipur from time to time.

(1) They should monitor that all required tests are carried out before start of

work as well as during execution. At least 10% tests are to be conducted by

the quality control units for reliability of the results and counter checking.

(2) They should ensure that all arrangements for carrying out routine field tests

in the field laboratories and site laboratories are duly made including

provisions and up-keeping of equipments, personnel etc. and record of these

field tests in prescribed formats are maintained. They should check this

record and also sign in the relevant registers in token of their inspection.

They should conduct field tests whenever they visit site of construction work

and record results of such tests in the registers maintained for the purpose.


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(3) They shall be empowered to order the suspension of work if deficiencies or

defects are noticed during execution. Order for stoppage of work if given by

the officer below the rank of S.E. should be got examined and confirmed by

S.E. Q.C. very promptly, preferably within 24 hours. However, order for

suspension of work can only be passed by the Chief Engineer Quality

Control.

(4) Inspection Book should be maintained at site wherein remarks should be

recorded by quality control staff whenever they visit site which should be

noted for compliance by the construction unit. They should specifically

record any deficiency noted to bring the same to the notice of appropriate

authority through remarks in the inspection book or inspection note. The

execution staff shall ensure the compliance of such deficiency and intimate

to the concerned officer of Quality Control Unit.

(5) The Chief Engineer, Quality Control shall ensure at least one test check of all

the works costing more than Rs.250.00 lacs in a year. This does not preclude

him for conducting more than one test check of any work for important

works; frequent checking is to be carried out.

The test check shall be thorough to ensure the quality of work and shall

include -

a. Observation of DBD and moisture contents of earthwork in filling

reaches.

b. Fineness modulus of sand, grading of sand and coarse aggregate.

c. Checking of water cement ratio for concrete.

d. Checking of lining work / masonry work / concrete work.

e. Any other requisite tests as per case.


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CHAPTER – III

GENERAL FUNCTIONS OF LABORATORIES

The laboratory system, in addition to evaluate and monitor the inputs and outputs,

would also evaluate and monitor the workmanship as well as construction plant,

machinery and equipment. This would, thus, be accompanied by testing as well as

inspection.

FUNCTIONS OF CENTRAL LABORATORY AT JAIPUR

I. To conduct laboratory tests on samples of sand, coarse aggregate, stone,

cement and steel for use in masonry and concrete works.

II. To conduct laboratory tests for foundation soil, and for selection of soils

from proposed borrow areas, for use in the various zones of embankment as

per specifications, proctor density & optimum moisture content of soils

before start of earth work.

III. For masonry and concrete, the strength of mortar and concrete has to be as

specified in agreement. Laboratory has to design the proportions of different

ingredients through tests for the specified strength. The proportioning shall

be done by weight. It should be co-related with volume for volumetric

batching of concrete where quantity of concrete to be placed is of small

magnitude. Volume batching may be allowed by the Engineer-in-charge

where weight batching is not practical and provided accurate bulk densities

of materials to be actually used in concrete have been established. Allowance

for bulking shall be made in accordance with IS: 2386 (Part III)-1963. The

mass volume relationship shall be checked at periodical frequency to ensure

that specified grading is maintained.

IV. For concrete and mortars where strength is not given and only proportions

have been specified, the strength should be treated as standard for execution.

V. When controlled concrete is specified, it is essential that mix design is to be

done.

VI. Since the strength of cement varies from batch to batch in a cement factory

itself, it is essential that a relation between strength of cement versus strength


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of concrete may be worked out in the lab, well in advance of the starting of

the work. This would facilitate in furnishing the proper proportion of the mix

for adopting in the field and also it entails adding or reducing cement content

based on the strength of the cement.

VII. Results of tests performed in central laboratory should be documented in

prescribed Performa pertaining to following tests.

A. SOIL :

Disturbed grain size analysis IS: 2720 (Part IV) -1985.

Proctors compaction IS: 2720 (Part VII & VIII).

Atterberg's limit IS: 2720 (Part V) -1985.

Permeability IS: 2720 (XVII) - 1986 (at OMC. MDD)

Shear test (remoulded at OMC. MDD drained / undrained) IS: 2720 (Part

XIII) -1986.

Specific gravity IS: 2720 (Part III) -1980. Undisturbed density and natural

moisture content, permeability, consolidation, shear test (drained/undrained)

at OMC or saturation.

Free swell index; Swelling pressure of soil sample.

Dispersibility of soils.

Total Soluble salts.

Chemical test for carbonates & sulphates (Chlorides Gypsum test).

B. SAND :

For IS: 383-1970 Grading, IS: 2386 (Part I) Fineness Modulus, IS: 2386

(Part III) Bulkage , IS: 2386 (Part II) Organic and silt content.

Deleterious material and mica content, and presence of organic impurities, if

any.

C. Cohesive – Non-Swelling Soils

Requirement should broadly confirm to IS: 9451-1994

D. CEMENT

Fineness, consistency, specific gravity, compressive strength, setting time,

soundness by Le-Chatelier test.

E. COARSE AGGREGATE :

Grading IS: 2386 (Part I) -1963


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Soundness, crushing value, impact test.

Abrasion, Absorption, Specific gravity IS: 2386 (Part III):1963 Flakiness.

F. BOULDERS :

Soundness, weight and size, absorption, specific gravity, weathering

conditions (visual) abrasion after breaking to proper sizes.

G. FILTER MATERIALS :

Grading, uniformity co-efficient, weathering conditions (visual) and tests for

fine and coarse aggregate fulfillment of filter criteria as per I.S.Code.

H. WATER:

pH value, silt content, soluble salts and any other impurities.

H1. STEEL

Ultimate tensile strength / Elongation.

I. CONCRETE :

Air Content

Mix Proportions; Test on admixture (if used); Test on Super-plasticiser (if

used)

J.

HARDENED CONCRETE AND MORTARS :

Proportion by chemical analysis and compressive strength.

K. BRICKS :

Dimensions and physical properties including water absorption and

compressive strength.

L. TESTS FOR FOUNDATION INVESTIGATION AND INSITU

PERMEABILITY BEARING CAPACITY :

Other properties, if tested shall be reported in the remarks column or foot

note.

M. LDPE Film wherever used shall be tests.

N. IMPROVED DEVICES FOR QUALITY CONTROL :

It is planned to introduce improved devices for achieving speedy and

efficient quality control. Monitoring the characteristics of fresh concrete is

important from the point of view of quality control. The 28 days strength of

concrete is the criteria for acceptance and is the basis of quality evaluation.


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However, one has to wait for 28 days to get the results of compressive

strength of concrete cubes / cylinders. Even the accelerated compressive

strength tests take considerable time.

The portable electronic devices, commercially available now, have made it

possible for rapid on-site measurements of slump, temperature, water-cement

ratio (the most important factor influencing the strength of concrete) and the

likely 28 days strength of fresh concrete mixes. Software supplied with the

electronic unit also produces 'quality control certificates' based on the

measurements taken by this unit. This evidence of the properties of concrete

gives the site Q.C. /Q.A. Engineer, the confidence to accept or, if necessary,

to reject the concrete mix before it is placed.

Central laboratory at Jaipur is planned to be equipped with such a portable

electronic unit with software.

On embankment construction and compacted earth fill placement it is

planned to procure an engineering device of the type "Nuclear Guage" to

enable much more rapid and economic compaction and quality control than

the conventional methods, without any loss in accuracy. Such a device is

capable of quickly computing and displaying wet density, moisture content,

dry density, and percentage of compaction in terms of Proctor density.

The central laboratory at Jaipur is planned to be equipped with two Nuclear

Guage Device. Inspection of testing activities is illustrated in Annexure -IV.

FUNCTIONS OF ZONAL LABORATORY

To carry out tests of soils, filter materials, ingredients of concrete, tests of cement

and mortar etc. of the samples collected by the quality control staff and also such

samples collected by construction staff whose facility of testing is not available at

site as well as field laboratories. Results of tests performed will be reported to

Executive Engineer construction and Superintending Engineer and Chief Engineer

of Quality Control unit in the prescribed Performa pertaining to the following tests:


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SOILS:

1. Density, moisture content and compaction efficiency.

2. Sieve analysis

3. Proctor density & O.M.C.

4. Atterberg's limits

5. Specific gravity

SAND:

1. Gradation analysis & silt content.

2. Presence of deleterious materials including organic impurities.

3. Bulkage

COARSE AGGREGATE:

1. Grading

2. Specific gravity

3. Impact Value, Soundness, Crushing Value, Flakiness.

FRESH CONCRETE & MORTAR:

1. Water cement ratio, slump test

2. Compressive strength of Concrete & Mortar

3. Mix Proportions

BOULDER SAMPLE:

1. Absorption

2. Dimensions

3. Visual observation as regards weathering etc.

4. Specific gravity, impact value, soundness, specific gravity.

CEMENT:

1.

Setting time by Vicat needle test2. Strength of cement

BRICKS:

1. Dimensions and physical properties including compressive strength.

WATER:

1. Chemical

2. Cl, SO4, Organics & Inorganic Solids

3. pH value, Alkalinity, Acidity


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FUNCTIONS OF FIELD LABORATORIES

To carry out daily routine tests of soils, filter materials, ingredients of concrete and

mortar of the samples collected by the construction staff and report the results to

concerned J.En., A.En. & Executive Engineer of construction. The results will also

be reported to the quality control unit in the prescribed Performa pertaining to

following tests:

SOILS & EARTH WORK:

1. Density, moistures content and compaction efficiency.

2. Sieve analysis.

3. Proctor density & OMC.

CNS:

1. Gradation analysis

2. Shear Parameters

3. Index properties

SAND:

1. Gradation and Fineness Modulus.

2.

Bulkage3. Organic impurities through quick "Colour test".

CEMENT:

Casting of cubes for strength; Fineness by Sieve.

COARSE AGGREGATE:

1. Grading

2. Physical Properties


1. Water cement ratio & slump test

2. Physical properties of ingredients & silt content of sand.

3. Casting of concrete & mortar cubes.

BOULDER SAMPLE:

1. Water absorption

2. Dimensions

3. Physical properties including weathering etc.


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BRICKS:

Dimensions & physical properties including water absorption.

SITE LABORATORIES:

To carry out daily routine tests of soils, filter material, ingredients of concrete and

mortar for the on-going works and material carted at site before use. Results will be

recorded in registers kept at site for inspection purposes and will be reported to J.En.

& A.En. Construction and Quality Control, in the prescribed Performa pertaining to

the following:

SOILS & EARTH WORK:

1. D.B.D. & Moisture content layer wise.

SAND:

1. Gradation analysis & Fineness Modulus.

2. Bulkage

COARSE AGGREGATE:

1. Gradation analysis

2. Physical properties

CEMENT:

Casting of cubes for strength


1. Slump test

2. Physical properties of Ingredients; Proportion of cement and sand in mortar.

3. Casting of concrete / mortar cubes.

BOULDER SAMPLE:1. Dimensions & physical properties including weathering etc.

2. Water absorption

BRICKS:

1. Dimension & physical properties

2. Sampling of bricks for testing.


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Record of daily activities / tests will be maintained at site in the registers such as:-

1. Inspection Register

2. D.B.D. Register

3. Cement Consumption Register

4. Slump Test Register

5. Daily progress register – progress to be compared with consumption of various

ingredients including cement.

FUNCTIONS OF MOBILE LABORATORY (FIELD TESTS)

(i) To carry daily routine tests on compaction efficiency. Field density and moisture

content determination test.

(ii) To carry out daily routine tests like silt content, fineness modulus and gradation of

fine aggregates and coarse aggregates.

(iii) To carry out slump test, unit weight and temperature of concrete by using fresh

concrete in-situ testing equipment, and to take fresh concrete as per the required

frequency.


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CHAPTER – IV

DUTIES OF STAFF INCHARGE OF LABORATORIES

DUTIES OF ASSISTANT ENGINEER / A.R.O. INCHARGE OF

LABORATORY

i) To ensure proper up-keep and maintenance of laboratory equipment in

laboratory.

ii) To ensure proper up-keep of records of all samples being tested in the

laboratory as per prescribed norms and communication of the results to the

concerned.

iii) To supervise the testing works of Junior Engineer, Laboratory Assistants and

personally to check the tests to the extent of 25%.

iv) To prepare fortnightly review of all the tests results and submit to the

Executive Engineer, Quality Control & Construction.

v) To conduct any research work as may be assigned by the Executive

Engineer.

vi) The Central Laboratory & Zonal Laboratories have to conduct tests for the

suitability of materials proposed from various quarries, well in advance of

the actual execution of work, for which the construction staff shall send the

material to the lab well in advance.

vii) Steel rods as proposed to be used shall be tested for ultimate tensile strength

elongation and bond etc. as per standards.

viii) Samples of welded rods, welded at site shall be collected and tested to the

quality of welding.

DUTIES OF ASSISTANT ENGINEERS / A.R.O. / S.R.A. (LABORATORY)

Shall perform important tests as mentioned below:

A) CEMENT :

1. Fineness by Blaine

2. Normal Consistency

3. Setting time


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4. Soundness

5. Specific gravity

6. Compressive strength

7. Adulteration test

B) SAND :

1. Sieve Analysis & Fineness Modulus

2. Test for organic impurities silt & clay

3. Decantation test for silt

4. Specific gravity

5. Unit weight and bulkage factor

C)

COARSE AGGREGATE :

1. Sieve Analysis and gradation

2. Specific gravity

3. Water absorption

4. Examination of deleterious materials

5. Crushing strength

6. Impact

7. Abrasion

8. Flakiness index

9. Alkali – Silicate reactivity

D) CONCRETE :

1. Consistency – slump or compaction factor

2. Compressive strength

3. Air content

4.

Yield per unit quantity of cement5. Mix design test

6. Cement content

E) MORTAR :

1. Consistency

2. Compressive Strength

3. Yield per unit quantity of cement

4. Cement Content


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F) SOILS :

1. Gradation (Grain size analysis)

2. Consistency limits

3. Porosity & Voids ratio

4. Specific gravity

5. Swell pressure

DUTIES OF LABORATORY TECHNICIANS / JUNIOR RESEARCH

ASSISTANTS

i) To assist Assistant Engineer / Executive Engineers whenever required in

laboratory and field work.ii) To perform tests in laboratory such as :

a) Compaction tests

b) Limit tests

c) Analysis of fine & coarse aggregates

d) Silt in fine aggregate

e) Slump test

f) Collection of samples of concrete and mortars for filling moulds for

compaction test.

DUTIES OF LABORATORY ATTENDANTS

a) To keep instruments clean.

b) To assist Assistant Engineer / Executive Engineer and Laboratory

Technicians in conducting tests.

c) To prepare samples for test.

d) To arrange samples systematically.

CONTROL OF INSPECTION, TESTING AND MEASURING EQUIPMENT

The identification, calibration, and adjustment of all inspection, measuring and test

equipment and devices will be done at prescribed intervals as stated below against

certified equipment having a known valid relationship to nationally recognised

standards. The equipment will be capable of controlling the delivery of material for

weighing so that in accuracies in feeding and measuring during normal operation


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will not exceed 1% for water and 3% for all aggregates. Periodical test will be made

at least once in a month in case of equipment for measuring water, cement,

admixtures, sand and coarse aggregate. Other measuring equipments will be tested

once in a year unless some defects are noticed earlier, in which case these will be

attended immediately.

Documents will be established and calibration procedures will be maintained

including details of the following:

1. Equipment type 2. Identification number

3. Location 4. Frequency of Checks

5. Check method 6. Acceptance criteria

7. Action to be taken for unsatisfactory results, to ensure that the inspection,

measuring, and test equipment are capable of the required accuracy and

precision.


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CHAPTER – V

DUTIES OF FIELD STAFF IN RELATION TO QUALITY OF

WORKS DUTIES OF ASSISTANT ENGINEER

ASSISTANT ENGINEER

CONSTRUCTION

ASSISTANT ENGINEER QUALITY

CONTROL

1. Shall see that the markout of the area

to be tackled is properly given,

shuttering, centering, reinforcement

are done as per drawing and

technical specifications, to record the

Pre levels / foundation levels, and tosee that mark-out for canal

excavation is perfectly given as per

drawings. Pre levels, classification

levels and final levels of canal shall

be taken as per specification.

1. Shall check the markout of

foundation and centering/ shuttering

reinforcement arrangement and

inform the Assistant Engineer

construction to rectify the defects if

any.

2. Shall see that the construction

equipment like mixers, vibrators,

compaction equipment, pumping

arrangements for curing / watering

are arranged before starting of any

work.

2. Shall check the adequacy of the

construction equipment and curing/

watering arrangements before start of

work and during excavation.

3. Shall see that sufficient quantities of

input materials as per agreement

specifications are made available at

site of work and to arrange testing

equipment, men and material

required for conducting field tests,

sending samples of input materials

for testing to central lab, field

laboratories as per norms.

3. Shall conduct / get conducted by

different laboratories the field tests

on input materials and record the

results and to inform the Assistant

Engineer construction to rectify the

defects if any.

4. Shall write O.K. Cards after area is

ready to start the work and to inform

the Assistant Engineer Quality

Control and Executive Engineer

construction and take permission to

start the work on O.K. Card. Shall

also permit OK in case quality control

A.En. is not available.

4. Shall check and write the O.K.

card and record the deviations,

defects if any or otherwise to record

the final OK and to inform

Executive Engineer quality control

and to permit to start the work.

5. Shall supervise and ensure that

correct quantities of input materials as

per mix design communicated by the

5. Shall make regular checks of the

feeding of input materials mixing

time and suggest the quantity of


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ASSISTANT ENGINEER

CONSTRUCTION

ASSISTANT ENGINEER QUALITY

CONTROL

central laboratory are fed into the

mixers/batching plants etc., and shall

ensure specified mixing time.

(minimum 2½ minutes)

water depending on the moisture

content of sand as and when

required.

6. Shall ensure proper vibration, rolling

etc., during course of day to day

work. Shall conduct D.B.D. test of

earth work, gradation of material,

slump test, core drill test and to

extract field samples of material and

finished products to be sent to

different laboratories also provide

men and material required forextracting samples of finished product

for quality control staff.

6. Shall ensure slump test, core tests,

proctor density etc., conducted as

per norms by the construction and

quality control staff and to extract

field samples of finished product to

be sent to central laboratory later.

7. Shall ensure proper curing of samples

extracted till the curing time is over

and to make arrangements to send the

samples to central lab or other

suitable lab.

7. Shall assist the Assistant Engineer in

Proper handling / transport of

samples to central lab.

8. Shall ensure timely green cutting of

concrete with proper air – water gun;

nicking & chipping (wherever so

warranted) so as to prepare the

surface for next concrete lift for

effective bond at the lift / construction

joints.

8. Shall check and see that the

preparation of the surface is

adequately done for starting the next

lift.

9. Shall ensure proper curing / watering

and allow removal of shuttering only

after the time limit prescribed in the

specifications and to see that the

surface are finished to the

plumb/straight lines etc., afterremoval shuttering.

9. Shall check the adequacy of

curing/watering and see that the final

surfaces are finished neatly

plumb/straight lines etc.

10. Shall maintain (1) mark-out register

(2) OK Card files (3) Load Register.

10. Shall maintain registers of field tests

conducted.


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DUTIES OF EXECUTIVE ENGINEER

EXECUTIVE ENGINEER

CONSTRUCTION

EXECUTIVE ENGINEER QUALITY

CONTROL

1. Shall supervise, check, advice, andinstruct the J.E.N. /A.E.N.

Construction regarding discharge

of their functions properly.

1. Shall supervise, check, advice andinstruct the A.E.N. Quality Control

regarding discharge of their

functions properly.

2. Shall intimate the Executive

Engineer quality control regarding

signing of agreement for starting of

any new work, duly endorsing a

copy of work order. Shall supply

copies of contract documents,

drawings construction programmeetc., to Executive Engineer Quality

Control, and Superintending

Engineer.

2. Shall maintain copies of approved

Designs, reports, contract

document, drawings, construction

programme, extracts of inspection

notes etc., and shall see that his

subordinates go through the above

documents.

3. Shall get all ingredients of

concrete, masonry got tested

before use. Shall see that the soils

are tested for various properties

like OMC, MDD, etc., before

starting of Embankment work.

3. Shall remind and verify whether

test results are available or not

before starting up of any new work

and during execution of work.

4. Shall see that all the Machinery/Equipment being used by the

contractor is got periodically

calibrated.

4. Shall assist in upkeep andcalibration of equipment.

5. Shall see that OK Cards are written

and kept at site of work before

starting of any work. Also will

ensure rectification of work before

releasing payments.

5. Shall inspect and sign on OK Cards

during field visits. Defects of

construction will be pointed out and

remedies suggested for achieving

good quality construction.

6. Shall order the suspension of work

if any defects are noticed orreported by quality control staff

and resume the work only after

rectification of defects in the

presence of quality control staff.

6. Shall order the stopping of work if

major defects are noticed orreported by quality control staff and

intimate his counterpart to see that

defects are rectified. Also defects

noted during construction are to be

reported to the S.E./Quality Control

& Construction.

7. Foundations and reinforcement,

shuttering, centering where heavy

reinforcement is involved is to be

checked by Executive Engineer

7. Foundations and reinforcement,

shuttering, centering where heavy

reinforcement is involved is to be

tallied by Executive Engineer


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EXECUTIVE ENGINEER

CONSTRUCTION

EXECUTIVE ENGINEER QUALITY

CONTROL

invariably before starting the work. invariably before starting the work,

during his field visits.

8. Shall personally see that the

samples to the laboratories are sent

regularly, obtain the results and

communicate the same to

Executive Engineer quality

control.

8. Shall pursue and keep track of

sending of samples various

laboratories and to keep record of

results received.

9. Shall take the help of quality

control Executive Engineer

whenever a dispute is referred.

9. Shall co-ordinate with the EE/

Construction division render

assistance in resolving the issues

referred to him.10. Shall jointly inspect the site with

quality control Executive Engineer

in case variation in classification is

less than 10% (+/-) and finalize the

classification.

10. Shall jointly inspect the site with

Construction Executive Engineer in

case variation in classification is

less than 10% (+/-) and finalize the

classification.


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CHAPTER – VI

CO-ORDINATIONS

The construction staff and quality control staff must act in tandem to achieve good

quality of the finished product and construction as per the contract specifications.

Construction staff should make it a point to inform the quality control staff, the date

of starting of any activities or component of the work well in advance so as to enable

the quality control staff to schedule their work plan and attend the particular work on

the particular date.

In turn quality control staff should schedule their programme, so as to attend to the

work on the dates required by the construction staff and ensure that, the progress of

work is not hampered.

The quality control staff shall be responsible for exercising the various field checks

with reference to drawing and specifications laid down in respective I.S. code during

construction and carrying out all the laboratory and field tests on materials used for

construction and reporting through their higher officer, to the field staff for ensuring

quality.

The Assistant Engineer / Executive Engineer (Quality Control) can address Assistant

Engineer / Executive Engineer construction regarding defects, rectification testing

etc.

As far as possible the defects are to be rectified in the presence of the Quality

Control staff and the payment shall be effected only after the Quality Control Staff

are fully satisfied with the rectification and quality of work. Any rectification done

subsequently any intimation and presence of Quality Control Staff shall be at the

sole responsibility of the construction staff.

The defects, if any, noticed by the quality control staff during their course of

inspection shall be brought to the notice of the construction staff then and there. It is

the primary responsibility of the Quality Control & Inspections staff to draw the

attention of the construction staff, whenever they notice defective work during their

course of inspection. It is duty of the construction staff to attend to the rectification

and maintain proper specifications as pointed out by their counter part of the Quality

Control organisation.


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Quality Control staff will monitor that all tests required as per agreement and I.S.

Codes are carried out in different laboratories by the field staff they will also test

check to the extent of minimum 10% (or as decided by Chief Engineer QC) of the

required tests and co-relate with the other tests conducted in different laboratories.

All observations regarding substandard or below specification work will be dully

recorded in the inspection / visit books kept at site by inspecting officer. Such

substandard or below specification works should be got stopped / dismantled

immediately by execution unit. The defects pointed out by Quality Control Unit will

be communicated to the execution unit for compliance immediately. The compliance

report should be sent by execution unit within ten days.

The quality control staff cannot supervise the placement of concrete on a mix to mix

basis continuously. They can only conduct random check of input materials, mixing

time, placement of concrete, vibration etc. It's the primary responsibility of the

construction staff to ensure adequate supervision of mix to mix placement of

concrete.

The Operations of the Quality Control Staff shall not interfere in any way, with the

executive powers vested with the officers in-charge of execution. They will also inno way diminish the responsibility of the officers in-charge of execution. The field

officers in-charge of works are primarily responsible for the quality of all works and

to carry out the work as per the technical specifications.

In case of difference of opinion between quality control staff and construction staff,

it should be sorted out by way of discussions in cordial atmosphere and mutual trust

as per the guide lines indicated below. In case it involves any design feature /

problem / aspect, the design office should be duly consulted and the advice given by

the designer should be accepted.

In case of difference of opinion between Executive Engineer, Construction and

Executive Engineer, Quality Control it would be referred to Superintending

Engineer, Construction, who would discuss the matter with Superintending

Engineer, Quality Control and settle the issue. Similarly, when the Superintending

Engineer, Quality Control is not readily available, the Superintending Engineer,

Construction can over-rule after recording the reasons in writing. In such cases the


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Superintending Engineer, Construction has to discuss with Superintending Engineer,

Quality Control at the earliest opportunity and modify his earlier orders, if

necessary. Similar action will be taken in case of difference of opinion on the

comments of Superintending Engineer, Quality Control.

In case there is a difference of opinion between both the Chief Engineer /Additional

Chief Engineer, Construction and Quality Control the matter would be referred to

Chief Engineer Water Resources Jaipur, whose decision shall be final and binding

on all. Work should immediately be suspended and not allowed to resume until the

defects pointed out by Quality Control and Inspection staff are rectified.

The construction and quality control staff shall keep a regular liaison with theGeologist in respect of all Geo-technical problems and enlist his input on

foundations of structures & dams; Cut Off Trenches, tunneling; contract/

consolidation/curtain grouting; Rock / Excavation Slopes (stability of slopes);

protection measures; permeability / Water loss tests etc., as well as any geological

problem. The advice rendered by the Geologist should be discussed with the

Designers and duly respected and implemented.


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CHAPTER – VII

QUALITY ASSURANCE

All planned and systematic strategies and actions necessary to generate adequate

confidence that Input and Output product will satisfy given requirements of quality

and all the components of works perform satisfactory during life period of service,

adequate quality checks as analysed during construction is a record which speaks of

"Quality Assurance". It comprises planning and policies, education and training

standards and specifications, contracts and agreements, and quality control. Quality

assurance is to assume that the materials as per standard and as per the requirements

have gone into the production of concrete, earth, masonry work etc. This is achieved

by evaluating the quality checks during construction and post construction tests

made and compared.

LIST OF DOCUMENTS

Each QC laboratory should hold the following documents:

Quality control manual.

Technical Records: Specification, Contract documents, inspection and Test

Procedures, relevant standards / code of practice.

Mill Certificates.

Material test reports, test reports of cores.

Inspection Reports.

Photographic / Video film records of construction which may not remain

accessible after commissioning of the project.

Non-conformance reports.

Statistical evaluation reports. Technical Literature.

Standardization of records.

Quality Control Personnel should hold the following Documents:

Data of test.

Area where material is used.

Test method with reference to standards.

Testing results, including those of cores of concrete.


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Acceptance criteria.

Remarks

Test personnel signature.

Junior Engineer and Assistant Engineer (Site In-charge at site) should always have a

kit consisting of equipments i.e. measuring tapes, scale, Vernier – calipers, Plumb

rule & bob, spirit level, square, Gunia (small), hammer, measuring glass etc. to

facilitate quality checking at site.


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CHAPTER – VIII

O.K. CARDS

Since O.K. Cards contain important entries/information on execution of works at all

stages and are liable to be referred/perused at a later stage also, the O.K. Cards shall

be maintained in duplicate in two colours. The green coloured card shall form a part

of the record of Q.C. /Q.A. Wing and the pink coloured card remains in the custody

of Construction wing. The O.K. Cards, relating to any particular work, shall be put

in a round shaped tin box and placed right at the construction site. The exterior of

the tin box shall be painted red. Senior officers shall also check the O.K. Cards

during their field inspections to ensure that those are being maintained and

proper/genuinely filled.

An O.K. Card is a condensed form of specifications and essential requirements for

achieving specified workmanship and quality level of output. Each work is sub-

divided into various construction activities in proper sequence / order of

construction. Such activities are listed in chronological order on the O.K. Cards.

For various stages of construction activities where laboratory tests or checks with

reference to drawing and specification are required from quality control unit, O.K.

Cards System shall be followed. The O.K. Cards should be made available on the

site in regular manner. Approval of the component of work in progress at the times

of inspection should be recorded by the inspecting officer.

The O.K. Card consists of two parts for each work. Part first covers the initial

preparedness for the work and indicates pre-requisites where as the second part

covers the daily performance of activities based on pre-requisites and also giving

permission to perform the job by the construction as well as Quality Control staff.

Besides the location and type of work, the first column of O.K. Card is to be filled

by the construction agency (contractor) by preparing each feature and making it

ready for inspection by the project construction engineer who Okay through his

signatures and then puts up to the Q.C. /Q.A. Engineer is not available at site then

O.K. given by construction Engineer will be treated as final. If anything otherwise is


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not observed. Should anything otherwise be found, the O.K. Card shall not be signed

by him and ask the Construction Engineer / agency for necessary rectification.

Subsequently, O.K. Card should refer to the defects removed, if pointed out

previously in O.K. Card and counter reference to the previous check and should be

signed of Okayed.

It must be borne in mind that work cannot be held up unduly for disposal of O'K

Card. The Assistant Engineer (Quality Control) / Construction will be okaying

authority for concentrated work like dam, spillway, head regulator etc. and Assistant

Engineer / Junior Engineer construction will be okaying authority for scattered

works like canals and small structures. Random checks by supervising officersshould be recorded on O'K Cards at site. Weekly report of O'K Cards maintained by

construction unit should be submitted to S.E. / Q.C. of the area who has to monitor

and ensure that adequate check is being maintained by field staff. Confirmation

regarding rectification of defects be obtained from A.En. /Q.C. before making

payment once in three bills and final bill of the contractor.

After processing through various levels and entering observations and rectification

O'K Card will be closed at the time of taking measurements for releasing paymentsto the contractor. Photocopy of the O'K Cards (pink) will be kept at site and original

copy will be attached with the bill and will be kept on record by the division office

while making payments to the contractor. Photo copy of O'K Card of Quality

Control will also be enclosed with the bill & kept on record with the bill by the

division office. However O.K. Card of Quality Control will not be closed till the

work is finalized and will be kept on record by the Executive Engineer, Quality

Control after the rectification is completed by the construction wing and final

comments are recorded by both the Assistant Engineer.

Specimen of O.K. Cards for various works such as embankment, concrete, masonry

etc. have been enclosed below.


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O.K. Card No. 1


O.K. Card for raising / Strengthening of Earthen Embankments / Fill Placement &

Compaction (Part-I)

Name of Work ______________________________________________________

Agency ____________________ Contract / Package No. ___________________

Location ___________________ Date ___________________

Description of Activities Remarks& DatedSignature

ofAgency

Remarks and DatedSignature of

Construction staff

Remarks &Dated

Signature ofQC/

InspectionEngineer

Super-visor

JEN AEN

Layout / Demarcation / Fixing & checkingT.B.M.

Removal of Vegetation, debris & Siteclearance

Benching, stripping of base (20 cm)

PRE-REQUISITES

(1) Proctor's density of borrow area

(2) Designation of borrow area & checking ofrequired moisture

(3) Excavation and shaping of rain cuts and

its refilling

(4) Weather key- trench made and/or plowingof old embankments done if required

(5) Watering of base

OK FOR FILL PLACEMENT

Thickness of loose layer (cm)

Removal of oversize (more than 7.5 cm size)layer

Moisture content (%) – initial

Moisture content (%) final (OMC = %)

Weather soil laid as per profile

OK FOR COMMENCING COMPACTION

Checking of Type of Compaction Equipment /Roller

Checking of In place density (D.B.D.)

Compaction Efficiency (%)

Specified Compaction (%) of Proctor

Re-Rolling / Re-compaction if required

D.B.D. after Re-Rolling

OK FOR NEXT LAYER

Removal of extra/loose earth from – U/S & D/Sfaces


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O . K . C a r d N o . 2

W a t e r R e s o u r c e

s D e p a r t m e n t

S u p p l e m e n t a r y O . K . C a r d f o r s u b s e q u e n t l a y e r s ( P a r t I I )

N a m e o f W o r k_______________________________________________________________________________________

A g e n c y_____________________________________

C o n t r a c t / P a c k a g e N o .______________

_______

L o c a t i o n____________________________________

D a t e______________________________________

D a t e

D e s c r i p t i o

n o f A c t i v i t i e s

( C h a i n a g e l a y e r )

W e a t h e r P r e -

R e q u i s i t e s

f u l f i l l e d

W e a t h e

r

s a t i s f a c t o

r y

c o n s o l i d a t i o n

a c h i e v e d

W e a t h e r

p e r m i t t e d f o r

n e x t l a y e r

D a t e d

S i g n a t u r e o f

A g e n c y /

C o n t r a c t o r

R e m a r k s a n d D a t e d

S i g n a t u r e o f C

o n s t r u c t i o n

s t a f f

R e m a r k s &

D a t e d


Q C /

I n s p e c t i o n

E n g i n e e r

S u p e r -

v i s o r

J E N

A E N


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O.K. Card No. 3


O.K. Card for Sub grade preparation for placement of lining (Part I)

Name of Work ______________________________________________________


Location ___________________ Date ___________________

Description of Activities

Dated

Signatur es of

Agency


Construction staff

Remarks &Dated

Signature ofQC/

InspectionEngineer

Super-visor

JEN AEN

ChainageRemoval of Vegetation, debris

Completion of dewatering

Filling of over excavation, depressions/

Pockets in soil/rocky strata as per

specification

Watering of sub-grade

Compaction of sub-grade (bottom & sides)through slope compaction/Pneumatic rammer /

power roller to specific density (..... %)Final Lip cutting & checking sub-grade surfaceto ensure within permissible tolerances (up to6.5 mm on sides, up to 12.5 mm on Bed)

Laying of under-drainage arrangement(a) Porous Plugs (b) Longitudinal &Transverse Drains (c) Porous Panels

Final wetting of sub-grade to 15 cm depth

Checking of quantity and quality of materialstacked at site

Cement, Aggregate, Sand, Water

Checking of mixer, vibratos & power

Checking of form work/ Shuttering true to lineand grade

O.K. for lining placement


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3 4

O . K . C a r d N o . 4

W a t e r R e s o u r c e

s D e p a r t m e n t

O . K . C a r d f o r p l a c e m e n t o f c a s t - i n - S i t u C o n c r e t e l i n i n g ( P a r t I I )

N a m e o f W o r k_______________________________________________________________________________________

A g e n c y_____________________________________

C o n t r a c t / P a c k a g e N o .______________

_______

L o c a t i o n____________________________________

D a t e______________________________________

D a t e

D e s c r i p t i o n o f

A c t i v i t i e s

& l o c a t i o n

W e a t h e r P r e -

R e q u i s i t e s o f

S u b - g r a d e

p r e p a r a t i o n

d o n e

S a t i s f a c t o r y

Q u a l i t y &

Q u a n t i t y o f

m a t e r i a l

s t a c k e d a t s i t e


C o n t r a c t o r /

E n g i n e e r

W h e t h e r s l u m p

c h e c k e d &

c u b e s c a s t e d

W h e t h e r

s p e c i f i e d

c o n t r a c t i o n

j o i n t s p r o v i d e d

R e m a r k s

a n d D a t e d


C o n s t r u c t i o n S t a f f

R e m a r k s &

D a t e d S i g n .

o f Q C /

I n s p e c t i o n

E n g i n e e r

S u p e r -

v i s o r

J

E N

A E N


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O.K. Card No. 5


O.K. Card for Random Rubble Stone Masonry

Name of Work ______________________________________________________


Location ___________________ Date ___________________

Description of ActivitiesDated

Signaturesof Agency

Remarks and DatedSignature of Construction

Staff

Remarks &Dated

Signature ofQC/

InspectionEngineer

Super-visor

JEN AEN

Stone – Quality SizeSuitability of

a) Cement

b) Sand

c) Water

Mortar

a) Mix measurement

b) Mixing, Consistency

Pointing, thickness of joints,staggering of joints, laying of stones,hearting stones, bond stones spacing.

Whether samples of mortar collectedin cubes for testing

Green cutting with proper air watergun / sand blasting

Adequacy of curing for masonrywork

Verticality of structure check by

using plumb bob

Embedded Materials

Final OK for masonry work


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O.K. Card No. 6


O.K. Card for Plain & Reinforced Cement Concrete

Name of Work ______________________________________________________


Location ___________________ Date ___________________

Description of ActivitiesDated

Signaturesof Agency


Construction Staff

Remarks &Dated Signature

of QC/InspectionEngineer

Super-visor

JEN AEN

Material Suitability

i. Cement

ii. Steeliii. Aggregate 40 mm, 20 mmiv. Sandv. Watervi. Admixture

O.K. for materials

Form work & Centering

i) Tightness, Stability, Smoothness

ii) Cleaning, oiling, perfectness ofform work.

iii) R.L. of Centering

iv) Checking of reinforcement.O.K. for reinforcement

Tools & Plants

i) Mixers & Vibratorii) Adequacy of concrete production

/ transportation, placement,consolidation.

O.K. for Placement

1. Design mix, measurement2. Mixing / Consistency3. Slump

4. Compaction of Concrete5. Joints6. Finishing7. Casting of Cubes8. Curing9. Compressive strength 28 days

Final O.K.

Note: Before pouring of concrete the reinforcement should be got checked by the Q.C. Unit.Working standby vibrator & mixer should be kept at site before start of concreting.


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O.K. Card No. 7


O.K. Card for PCC Slab Canal Lining

Name of Work ______________________________________________________


Location ___________________ Date ___________________

Description of Activities

Remarks& Dated

Signaturesof Agency


Construction Staff

Remarks &Dated Signature

of QC/InspectionEngineer

Super-visor

JEN AEN

A. Materials Suitability :

i. Cement

ii. Aggregate 40 mm, 20 mmiii. Sandiv. Waterv. Treatment of soil if any

O.K. for materials

B. Formation of Canal Banks :

i) Stripping/Removal of vegetation

ii) Cutting canal bed & sides to thegeometric section/shape

iii) Consolidation

iv) Trimming

C. Casting of PCC Slabs :i) Mix, Measurement by weight

ii) Mixing, consistencyiii) Slumpiv) Water Cement Ratiov) Casting of PCC Slabsvi) Casting of cubes of concrete mix

vii) Providing sub base if necessityviii) Laying/Placing in position PCC

slabsix) Construction jointsx) Contraction joints

xi) Pointing with CMxii) Curingxiii) Pressure Relief Holexiv) Flexural Strength of PCC Slabs

Final O.K.


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O.K. Card No. 8


O.K. Card for Grouting

Name of Work ______________________________________________________


Location ___________________ Date ___________________

S.No. Description Dated Signature of Contractor/QC Remarks

GENERAL

1. R.L. and area surface to be grouted.

2. Classification of the rock strata.

3. Salient feature of the strata such

as a fault zone cavities, fissures etc.

4. Permeability value of the strata before grout.

GROUP

5. Pattern of Grout adopted

6. Depth and dia. of the hole

7. Pressure adopted for grout

8. Proportion of grouting mix

9. Intake of slurry mortar per unit area per unit time

10. Total quality of intake

11. Final permeability value of the strata after grout

12. Whether the grout strata is OK.


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CHAPTER – IX

TESTS TO BE PERFORMED ON MATERIALS

MATERIAL TEST METHOD

Cement a) Chemical IS:4032-1985i) Sio2, A12O3, Fe2O3, Cao ,MgO, SO2,

Insoluble residue & Loss on ignitionii) Alkalies & Chloridesiii) Free Lime

b) Physical IS:4031-1988i) Specific gravityii) Finenessiii) Soundnessiv) Compressive strengthv) Drying shrinkage

Water Chemicalsi) Cl, SO4, Organic & Inorganic Solids, pH,

Alkalinity / AcidityIS:3025-1987

ii) Setting time of mortariii) Relative strength of concrete IS:1199-1959

Fine Aggregate i) Sieve Analysis & Fineness Modulus IS:383, IS:2386ii) Test for organic impurities silt & clay (Part I & IV)

iii) Decantation test for silt IS:2386 (Part II)iv) Specific gravity IS:2386 (Part III)v) Unit weight and bulkage IS:2386 (Part III)

IS:2386 (Part III)CoarseAggregates

i) Sieve Analysis IS:2386-1963

ii) Flakiness indexiii) Elongation Index PART - Iiv) Deleterious materialsv) Specific gravity PART-IIvi) Bulk Densityvii) Moisture content PART-III

viii) Absorption value

Mechanical tests PART-IVix) Aggregate crushing valuex) Impact Value PART - Vxi) Abrasion Valuexii) Potential reactivity of aggregatexiii) Petro-graphic examinationxiv) Alkali Aggregate reactivity test

PART-VIPART-VII


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Embankment i) Proctors compaction IS:2720 Part(vii & viii) -1980

ii) Atterberg‟s Limits IS:2720 Part (v)-1985iii) Permeability IS:2720 Part (xvii)-

1966iv) Shear Test IS:2720 Part (xiii)-1986v) Specific gravityvi) Disturbed grain size analysis

IS:2720 Part (iii)-1980IS:2720 Part (iv)-1985

Concrete a) Fresh Concretei) Air Contentsii) Vibrationiii) Temperature measurementiv) Mix proportionsv) Water cement ratiovi) Yield

b) Workability testi) Slump Test Usual procedureii) Compaction Factor test IS:CED2(CESS) ASTM

C 597-83c) Hardened Concrete BS: 4408i) Compressive strengthii) MDT Tests

IS : 516-1959IS : CED 2 (3890)

d) Special Testi) Microscopyii) Non-destructive

iii) Core Testing

Admixtures i) Bleeding IS:9103-1999ii) Relative Strength IS:516-1959iii) Setting Timeiv) Relative water contentv) Relative length change

IS:8142-1974IS:9103-1999IS:1199-1959

Masonry i) Gradation of Sandii) Slump Testiii) Compressive strength of stones IS:1121(Part I)-1974iv) Tests for stone - IS:1124 -1974

- Water absorption- Specific gravity- Porosity- Weathering of natural building stone IS:1125 -1974


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CHAPTER – X

LIST OF EQUIPMENT FOR CEMENT AND CONCRETE TESTING

TEST EQUIPMENT

A. CEMENT Flame Photometer

a. Chemical

i) Alkalies

ii) Minor, major oxides byCalorimetry

iii) Chloride Hot plate, Balance (Acc. 0.0002 g) Muffle

Furnace (up to 1200 c). Platinum Crucibles‟,

conductivity Bridge, pH Meter, physical balance

(Cap. 150 g)

iv) General

b. Physical

i) Fineness Blaine Apparatus, stop watch.

ii) Soundness Le- Chatelier Le-Chatelier Moulds, hot water bath Autoclave

iii) Consistency and settingtime

iv) Heat of Hydration

v) General

B. AGGREGATES &

CONCRETE

Vicat Apparatus, moulds, setting time needles and

plunger compression testing machine (50 tonnes).

vibrating machine, moulds 50 sq.cm. Area,calorimeter thermometer, flow table, stop watch,

timer temperature controlled oven, humidity

chamber incubator, physical balance (ACC 0.001

g), balance (cap. 5 kg ACC 1 g), set of standard

sieves lid and receiver.

a) General

i) Crushing value

ii) Impact value

iii) Abrasion value

vi) Alkali Aggregate

Reactivity

vii) Flakiness &

Elongation indices

viii) Unit weight

Containers

ix) Sampling (Sand)

viii) Specific Gravity andAbsorption

Electric Driver, hot plates, set of standard sieveslid and receiver, balance 10 kg (ACC 1g), 100 kg

(ACC 0.001 kg), 200 kg (ACC 0.5 kg) scop,

Enamel trays, balance, shovels, compression

testing machine (200 tonnes), crusher and ball

mill prevailing rigs 2,25,50,100 tones.

Crushing apparatus

Aggregate impact test machine

Apparatus for measuring flakiness

Minimum Capacity of Measures.


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TEST EQUIPMENT

C. CONCRETE

a. Fresh Concrete

Max. C.A. Size of Capacity of

Measure dm3

i. Vibration 2.50 6

ii. Temperature

measurement

37.50 11

iii. Mix proportions 50.00 14

75.00 28

b. Workability Tests:

i. Slump Test 114.00 71

ii. Compaction factor test 152.00 99

c. Hardened concrete Refer sample Divideri) Compression, tension

bending & Brinnel

hardness tests.

Pycnometer

Internal Vibrator, table vibrator

constituents, Slump cone Apparatus

Compaction Factor apparatus, Universal Testing

Machines with accessories (Cap. 100 tonnes),

Concrete workability meter, Capping moulds

Laboratory concrete mixer, Reluctance meter.

d. Special Tests Optical microscope, grinding and polishing

i) Microscopy equipment, ultrasonic pulse velocity, reboundii) Non-Destructive hammer core drilling machine, RCC cutting

iii) Core Testing machine, RCC cutting machine, t