BENGALURU-VIJAYAWADA EXPRESSWAY PACKAGE-1 LIMITED

DBL-SO/NHAI/Banglore-Vijayawada PKG-1/23-24/59 19th February 2024

To,
The Team Leader,
NH-544G Phase —I (Construction PKG-1)
Dhruv Consultancy Services Limited Joint Venture
With G-Eng Advisory Services Pvt. Ltd.
Associate with Kaius Consulting Pvt. Ltd.
ANR Residency, Flat No. 201, 202 and 302
Prashanthigram, Sri Sathya Sai District,
Andhra Pradesh, 515134.

Sub:- Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch.0+000)
to Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijayawada Economic Corridor on
HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1). — Submission of “QUALITY ASSURANCE PLAN (QAP)”— Reg.

Ref:- 1. Concession Agreement dated 26'h April 2023.

2. BVEPIL-HO/NHAI/Ben-Vij/Pkg-1/2023-24/31 dated 13-09-2023.
3. NHAI/PIU-KDP/14002/1/2023/NH-544G/PKG-1/Conc./13449 dated 16-09-2023.

Dear Sir,

Adverting to the above subject matter, the Concessionaire is herewith submitting the
”QUALITY ASSURANCE PLAN (QAP)” in accordance to the provision outlined in clause
12.1(a) under Article 12 of the Concession Agreement. The clause is cited under for your
ready reference

12.1 In addition to its obligations of maintain the Project Highway during the
Development Period, prior to commencement of Construction Works, the
Concessionaire shall:

(a) Submit to the Authority and the Independent Engineer its detailed design,
construction methodology, quality assurance procedures, and the procurement,
engineering and construction time schedule for completion of the project in
accordance with the project Completion Schedule as set forth in Schedule-G;

In accordance to the above clause, the Concessionaire is hereby submitting the Quality
Assurance procedures for your kind review and approval of the same at the earliest.

Thanking you and assuring our best services, at all times.

Yours faithfully,
For Be -Vijayawada Expressway Package-1 Limited,

Auth to

Regd. Office : Plot No. 5, Inside Govind Narayan Singh Gate,Chuna Bhatti,
CIN: U42101MP2023PLC065253 Kolar Road, Bhopal - 462 016 (M.P.), Ph.: 0755-4029999, Fax : 0755-4029998
E-mail : db@[Link], Website : [Link]
DBL-SO/NHAI/Banglore-Vijayawada PKG-1/23-24/59 19thFebruary 2024

Enclosure: Credentials of “QUALITY ASSURANCE PLAN [QAP).”

Copy to:
1. The Project Director, PIU-Kadapa, for your kind information.
 NATIONAL HIGHWAYS AUTHORITY OF INDIA

Project: - " Development of Six-Lane Access Controlled Highway from Kodur

(Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru - Vijayawada Economic
Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra
Pradesh (Package-1). "

QUALITY ASSURANCE PLAN

Prepared and Submitted By:

Bengaluru Vijayawada Expressway Package-1 Limited

0
 Section Clause Description
Sr No
No.
1 REVISION RECORD SHEET
2 GENERAL
3 INTRODUCTION
4 PROJECT SCOPE
5 1.0 DEFINITIONS
6 1.1 Quality Management System (QMS)
7 1.2 Quality Assurance (QA)
8 1.3 Client, Independent Engineer, Concessionaire
9 1.4 Quality Assurance Manual (QAM)
10 1.5 Quality Control (QC)
11 1.6 Quality Audit
12 2.0 OBJECTIVE
15 3.0 PROJECT QUALITY OBJECTIVES
16 4.0 ORGANISATION
17 5.0 ORGANIZATION POLICIES
18 6.0 ASSIGNED DUTIES AND RESPONSIBILITIES OF PROJECT
19 7.0 SITE INSPECTIONS, DAILY REPORTS
20 7.1 Site Inspection
21 7.2 Daily Inspection Reports
22 7.3 Internal Audits
23 7.4 Control of Non-conforming Product
24 8.0 CALIBRATION PLAN FOR PLANTS AND LABORATORY
25 9.0 QUALITY CONTROL
26 9.1 Types of Quality Control
27 9.1.1 Control of Methods
28 9.1.2 Control of End-Results
29 9.2 Performance of Quality Control
30 9.2.1 Testing Facilities
31 9.2.2 Test Specifications
32 9.2.3 Inspection & Test Plan
33 9.2.4 Method Control
34 9.2.5 Reporting of Test Result
35 9.2.6 Monitoring of Quality Control
36 9.3 Approval of Quarries and Borrow Areas
37 9.4 Approval of Materials
38 9.4.1 Reporting and Recording Material Approvals
39 9.4.2 Approval of Layers of Road Works
40 9.4.3 Approval of Structure work
41 9.5 Sampling of Materials
42 9.6 Field Testing Laboratory
43 9.7 Acceptance Testing
44 9.7.1 General
45 9.7.2 Routine Acceptance Tests
46 9.7.3 Quality Control Test Statement (Monthly Progress Report)
47 10.0 SITE WORK NON-CONFORMING REPORTS & PREVENTIVE
48 11.0 QUALITY ASSURANCE PLAN (RESPONSIBILITY MATRIX) FOR

49 12.0 DOCUMENTATION
50 12.1 General
51 12.2 As-built Drawings
52 12.3 Reporting of the Test Results
Annexure - I - Inspection and Test Plan
Annexure - II - Organization Chart
Annexure - Ill - Laboratory Equipment's & Calibration Frequency
Annexure --IV - Methodology for Execution of Key items of works.

Annexure --V - Test formats & Check list

 GENERAL
The Quality Assurance Plan (QAP) is the methodology that is selected for ensuring that the project
incorporates all elements that are needed for the successful construction of a project. The QAP deals
with all aspects of selection and testing of materials, acceptance criteria, guidelines for non-
conforming materials and works and documentation. The Concessionaire monitors the process of
testing to make sure that the product meets the specifications of contract agreement and MORTH.
This manual provides procedures for carrying out tasks related to inspection, testing and reporting.

The Technical Specifications applicable to the Project are provided for Quality Control and Quality
Assurance of the work executed by use of a Quality Management System. The basic concept of this
process is that the Concessionaire performs adequate testing and inspections to ensure a quality
product and the Independent Engineer, to ensure that the Concessionaire's Quality Control test results
are adequate. The general idea is that the Concessionaire has to perform the necessary tests and
inspection to ensure the likelihood that all his works in construction meets the specification.

The Concessionaire is responsible to mobilize competent personnel to perform his quality control.

The Concessionaire's part of this QMS system is referred as Quality Control (QC) and Quality
Assurance (QA).

This project specific quality plan is prepared for " Development of Six-Lane Access Controlled
Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru - Vijayawada
Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of
Andhra Pradesh (Package-1). " Project to systemize all activities associated with planning, design,
construction, quality control and quality assurance and thus meet the requirements of contract
agreement.
 INTRODUCTION
The National Highways Authority of India is undertaking development of National Highways and as
part of this endeavour, it has awarded M/s Dilip Buildcon Limited, Bhopal to undertake " Development
of Six- Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
Bengaluru - Vijayawada Economic Corridor on HAM Mode under Bharatmala Pariyojana
Phase-I in the State of Andhra Pradesh (Package-1) "
 PROJECT SCOPE
Scope of the project:

Project : Development of Six-Lane Access Controlled Highway from

Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client National Highways Authority of India

Independent Engineer Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng
Advisory Services Pvt. Ltd. In association with M/s Kaius
Conslting Pvt. Ltd.

State Andhra Pradesh

 DEFINITIONS

The following definitions shall apply:

1.1 QUALITY MANAGEMENT SYSTEM (QMS)
The Quality System is defined as the organization structure, responsibilities, procedures, processes
and resources needed for implementing quality management.

1.2 QUALITY ASSURANCE (QA)

Quality Assurance is defined as all the planned and systematic activities implemented within the
Quality System and demonstrated as needed to provide adequate confidence that an entity will fulfil
the requirements.

1.3 CLIENT, INDEPENDENT ENGINEER, CONCESSIONAIRE

Client National Highways Authority of India

Independent Engineer Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt. Ltd.
Concessionaire Bengaluru Vijayawada Expressway Package-1 Limited

1.4 QUALITY ASSURANCE MANUAL (QAM)

Quality Assurance Manual (QAM) is a base document outlining policy, procedures, responsibilities,
compliance, acceptance criteria and documentation needed for the successful implementation of a
project.

1.5 QUALITY CONTROL (QC)

Quality Control is the operational techniques and activities that are used to fulfil requirements for
quality. All those planned and systematic actions are necessary to provide confidence that a product or
service will satisfy the given requirements for quality.

1.6 QUALITY AUDIT

A systematic and an independent examination to determine whether quality activities and related results
comply with planned arrangements that have been implemented effectively.
 2.0 OBJECTIVES

The fundamental objectives of the QAM related to construction activities are:

1. To ensure correct setting out of works.
2. To ensure that the construction works are done in accordance with the appropriate procedures.
3. No material is incorporated in the work unless tested and accepted.
4. To achieve the desired workmanship.
5. To prevent any damage or deterioration of the works partially completed during execution of job.
6. To ensure maintenance of quality records conforming to the required quality and
effective operation of the quality system.
7. To monitor the implementation of the QAM by regular surveillance and scheduled audits and
where necessary, to suggest corrective action.
8. To carry out analysis of non-conformances and to implement corrective actions when required.
9. To collect and uniquely identify all documentation generated by quality control test
and inspections as per ITP
10. To monitor all performance tests.
11. To ensure that the QAM meets the needs of the Contract Agreement by on-going review and
regular meetings with the Client and Independent Engineer.
 3.0 PROJECT QUALITY OBJECTIVES

To ensure proper establishment of project management function and co- ordination Among engineering,
design, procurement and construction functions to Authority Engineer satisfaction, To ensure proper co-
ordination and effective communication between the Authority Engineer and Concessionaire.

 To ensure completion of Project stages within stipulated time.

 Construction with quality which will ensure the satisfaction of Independent Engineer.
 To improve the work environment by developing team work, leadership, Quality and effective
communication.
 4.0 ORGANIZATION

Project Organization Chart shall be developed by Project Director based on Manual of Project
Management. Project Director is an interface between various HO Service departments and their relevant
departments at Project site and will ensure that all the Project requirements/services are extended from HO
in a systematic and effective manner. Project Director is responsible for entire Project Operations and
shall interact with Client/Independent Engineer and other involved agencies in all project related
matters, policies, systems etc.
 QA/QC ORGANIZATION CHART

QA/QC
MANAGER

MATERIAL ASST.
ENGINEER MATERIAL
ENGINEER

QC ENGINEER 2 QC ENGINEER 2
QC ENGINEER 2 QC ENGINEER 2 NOS
NOS (SOIL NOS
NOS (CONCRETE, (BITUMINOUS
FIELD & LAB (CTSB,CTB,AIL
DLC,PQC SITE& SITE & LAB
TESTING) SITE & LAB
LAB TESTING) TESTING)
TESTING)

LAB
TECHNICIANS 2 LAB TECHNICIANS LAB TECHNICIANS LAB
NOS. 2 NOS. 2 NOS. TECHNICIANS 2
NOS.
 5.0 ORGANIZATION POLICY

We aspire to fulfil the expectations of our customer by a dedicated and organized approach, which is
amenable to skill and knowledge enhancement.
We shall improve the competence of our Quality management System continually.
Our focus to accomplish this aim shall be on:
 Effective Implementation of planning and Methodology
 Effective Supplier Management
 Proficient Management of Workforce.
 Training and development of Human Resource.
 Quality System.
The Quality System has been designed to ensure that the Quality Policy, objectives and the requirements
of ISO 9001:2008 are implemented. The system has been determined in terms of the following main
processes.

1. Quality planning and Control

2. Planning, Monitoring and Control
3. Plant and Machinery provision
4. Project Operation
5. Commercial, Contract and Procurement
6. Personnel and training
7. Quality System
ORGANIZTION
POLICY
 QUALITY POLICY

The Company Delivers Projects to Its Clients with defect Free

Design, Engineering, Procurement, Construction and
Maintenance within the stipulated time as per the Approved
Standards and using Good Engineering Practices with
Continuous improvement to ensure client satisfaction.

Director
 F
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This is to certify that

DILIP BUILDCON LIMITED

PLOT NO.-5, INSIDE GOVIND NARAYAN SINGH GATE, CHUNA BHATTI,
KOLAR ROAD, BHOPAL-462016(M.P.), INDIA.
has been independently assessed by QRO
and is compliant with the requirement of:

ISO 9001:2O15
Quality Management System
For the following scope of activities:
CONSTRUCTION OF ROADS, HIGHWAYS, PATHWAYS, SPECIAL BRIDGES, RAILS &
METRO, TUNNEL CONSTRUCTION, RUNWAY, AIRPORT, MINING, CULVERS,
BULDINGS, SEWAGE, WATER SUPPLY, IRRIGATION PROJECTS & OTHER ALLIED CIVIL
STRUCTURE

Date of Certification: 10th January 2024

1" Surveillance Audit Due: 9th January 2°d Surveillance Audit Due: 9th January
2025 2026 Certificate Expiry: 9th January 2027

Certificate Number: 305024011045Q

E GAC Head of Certification

Validity of this certificate is subject to annual surveillance audite to be done successfully on or before 365 days from date of the audit.
(In case surveillance audit is not allowed to be conductedi this certificate shall be suspended / withdrawn).
Tke Validity of this certificate csn be verified zt [Link]
This certificate of registration remains the property of QR0 Certification LLP, and shall be returned immediately upon request.

India Oiiiee : QRO Certification LLP

142, llnd Floor, Avtar Enclave, Near Paschim Vihar West Metro Station, Delhi- 110063, (INDIA)
This Certi6cate certify tbat tbe Ea›Jroaa›rataIMaaageaieat5*steoi of

DIUP BUILDCON UMNED

PLOT NO. - 5, INSIDE GOVIND NARAYAN SINGH GATE, CHUNABHATTI,
KOLAR ROAD, BHOPAL, MADHYA PRADESH - 462016, INDIA.

Jo compliance wills tfse requlreraen¢s of ¢be staodez°zI

ISOt400t:20t6
This cextcficate is valid for
tbe Following seope
CONSTRWTION OF RDAOS. HIGHWAYS. I?ATHWAYS. AIRPORT, BRIEFGES, METRO, TUNNEL
CDNSTRLICTION, MINING, RMNWAY. CABLE STAY BRIDGES, CLILVERTS. BUILOI SGS. SEWAGE.
YYATER SUPPLY, IRRIGATION PROJECTS 6 VARI0M9 ALMED CIVI1 STRLICTLRE.

CEO
lC't" WSEBShd EISTS PVT. LTD.
Z!2, fret Floor. Prabhu Complex, Shiva Markel, Pitampura New Ddlzi - 11IXI34
+91 - JR-4154&3 15, info@ [Link], [Link] [Link]
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Certiÿcate ofRegistratíon
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ŚR΀Ș’Mcaageæ‹at Sy1teø of
DUP BUILDCON LIMPED
PLOT NO. - 5, INSIDE GOVND NARAYAN SINGH GATE, CHUNABHATTI,
KOLAR ROAD, BHOPAL,”MADHYAPRADESH -461016, INDIA
bøs been audited bv EN” and fouod to be
to cozapŁ\aace w\tb tbe requlzemeoŁs of tbe s¢eodørd

ISO 41001:9018
This we:ctificate is valid for
the following grope
CONSTRWTION OF RDAOG, HIGHWAYS. IDA.THWAY5, AIRPORT. BRIPEES, METRD. TUNNEL
CDNI2TRLICTI0N. MINING. RMNWAY, CABLE STAY BRIDGES CULVERTS, BUIL0I8GS. SEYYAGE.
YYATER SUPPLY, IRRIGATION PROJECTS 6 VARIOU9 ALM£D CIVIL STRLICTLRE.

for Survedlance Due

2od SurveÏlJazice be
v‹xiu,wsv

CED
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+91 - 11-4154B315, info@ [Link], wvnv icvassessrnents
ASSIGHED DUTIES
AND
RESPOSSIBIzivirs
 6.0 ASSIGNED DUTIES AND RESPONSIBILITIES OF
PROJECT MANAGEMENT FUNCTIONS

Project Director: -  Organize & manage all resources and field activities to achieve
an efficient and effective completion of the contract, within the
agreed time, whilst paying due regard to safety and meeting
Quality requirements.
 Accountable for Quality / productivity improvements through
process
 changes
 To sort out issues escalated by site process, QA/QC on
product quality
 Roll out major programs / process changes
 Give feedback on monthly reports from site and planning engineer
 Preparation and implementation of Project Quality Plan, Liaison with
 Customer, Head Office and local authorities.
 Improving Customer satisfaction including handling customer
complaints.

Construction Manager: -  Prepare Daily, weekly and monthly schedule as per 3 months
look ahead program in consultation with planning engineer.
 Allocate the resource for activities as per the schedule
 Preparation and Implementation of Work procedures.
 Implementation of OAP
 Planning training requirements and arranging for training to site
staff.

Planning In  Integration of project schedules for all works & monitoring

charge/Planning Manager  Contract review, process control and service requirement
 Coordinate with HO for arranging required materials & resources
in time.
 Synchronize the activities of all departments to achieve the
planned cycle times/ overall schedule
 Arranging required information to Customers regarding project
control & progress monitoring as per contract
Contract Manager  Thorough study & identification of contractual obligations of both
parties
 Develop the list & timing of obligations
 Review & monitor the fulfillment
 Preparation for issue of notices
 Preparation of Customers correspondence

Surveyors  To establish control points as per survey plan.

 Responsible for day-to-day survey activities and maintain records,

during respective shifts
 To carryout post construction survey and record as built status.
 Conduct calibration of any survey equipment as per plan with
QC Engineer

Electrical Engineer  Supervision of the Electrical works activities to ensure strict

conformance to methods, quality & safety.

EHS Engineers /  Carry out EHS inspection of Work Area, Work Method,

EHS officers Men, Machine & Materials, P&M and other tools and

(EHSO) tackles.
 Creating EHS awareness through Pep Talk.
 Co-ordinate in preparation of Group Risk Assessment.
 Conduct investigation of all near Fatal / dangerous
occurrences & recommend appropriate corrective
measures.
 Assemble EHS Committee meeting & minute the proceedings for
circulation
 & follow-up action.
 Advice & co-ordinate for implementation of Work Permit
Systems.
 Plan procurement of PPE & safety devices and inspect before
use as per
 laid down norms.
 Facilitate screening of workmen and conduct EHS induction.
 Monitor administration of First Aid.
 Conduct Fire Drill, Procure, inspect and arrange to
maint
ain
Fire
  Extinguishers.
 Organize campaigns, competitions & other special emphasis
program's to
 promote EHS in the workplace.
 Register Customer complaints and take corrective action.
 Deploy Safety Steward suitably.
 Notify site personnel if non-conformance to EHS norms
observed during site
 visits/site inspections.
 Recommend to Site In-charges, immediate discontinuance of
work until
 Rectification, of such situations warranting immediate action
in view of
 imminent danger to life / property / environment.
 Decline acceptance of such PPE / safety equipment that do
not conform to specified requirements and report to EHS Head
on the deficiencies identified during receiving inspection.

QA/QC In charge  Preparation of Quality Assurance plan and take approval

from Site Management and Customer if contractually
required.
 Custodian of all process
 Facilitate the formulation and dissemination of
customer requirements, Quality objectives & POP
 Induct new joiners into QMS
 Monitor conduct of internal audits as per schedule
 Conduct review meeting in an effective manner with focus
on quality objectives and processes
 Report on effectiveness of QMS in review meeting and
ensure improved results.
 Escalate quality issues to Project Director.
 Co-ordinate for timely disposal of non-conformity reports
 Set up and monitor QA/QC activities at site
 Identify, Calibrate and maintain Master List of Testing and
Measuring Equipment.
 Identify material sources, and conduct material tests and ensure
conformity with specifications & standards
 Conduct Routine Tests on materials as per ITP for conformance
 and maintain records.
 Inspection and approval for incoming materials
 Escalate issues to QA /QC In charge
 Ensure preparation and incorporation of all the Work Methods as
required by the contract and corresponding Inspection &
Test Plans and Formats.
 Assist Site Management in effective implementation of approved
quality plans and QC procedures
 7.0 SITE INSPECTIONS and DAILY REPORTS

7.1 Site Inspections

 To ensure the strict Contract compliance, it is mandatory that all personnel In charge of
construction and inspection responsibilities properly prepare themselves in advance through
detailed study and understanding of the Quality Plans, Technical Specifications and drawings.
 The Section Heads of the various sections will monitor construction activities related to his
section.
 Concessionaire is responsible to inspect all works done and materials used in project work. Such
inspection will extend to all parts of the works related to the project and to the preparation,
fabrication or manufacture of the materials to be used.
 The section head is responsible for keeping Project Director informed as to progress of the work
and the manner in which it is being done, and also to call the attention to any non-compliance
with the drawings or specifications.
 As per CA the Independent Engineer may check the quality of the work at least 20% on the
quantity basis.

7.2 Daily Inspection Reports

A Daily Report will be completed by each Engineer. These Daily Reports will be reviewed and compiled
by the Site in charges / Planning In charge will inform the Project Director about the progress of the work
on daily basis.
The Daily Report shall include but not be limited to the following items:

 Quantities of work performed and accepted under his inspection

 Site Instructions
 Unusual or unsatisfactory conditions
 Delays encountered
 Number of men or man-hours employed
 Equipment, Plant, methods used by the Concessionaire
 Tests performed to satisfy quality control keeping in view the frequency of sampling as laid
down
 Weather conditions and effects on the Works
 Day-work records, if any
7.3 Internal Audits
 This procedure describes how internal audits are planned and conducted to check the level
of implementation and measure the effectiveness of QMS.

 Internal quality audits for all functions are conducted at least once in four months.
 The objectives of this audit are to ensure conformance to the requirements of ISO
9001:2015, the Quality Management System established as documented in the Quality
Manual, Procedure Manual and the statutory & regulatory requirements to determine
effective implementation and maintenance of the QMS.

 The internal quality audits are scheduled on the basis of the status and importance of the
Activities, areas to be audited and the results of previous internal & external quality audits. An
annual schedule is prepared.

 For each audit the audit plan is prepared by the Management Representative in which the
auditors are identified.

 Competent and trained internal quality auditors conduct these internal quality audits. If required,
the internal quality audit can be outsourced from external contracted auditors within or external
to Mehgama-Hansdiha Highways Limited.

 The competence of the internal auditors is ensured by the Management Representative

and reviewed every year.

 Based on the plan, each internal quality auditor carries out the audit. At the end of the audit,
the audit report is prepared and jointly signed by the auditor and auditee.

 Based on the audit report, the auditee makes corrections and takes corrective action on each non-
conformity, latest within 21 days. The effectiveness of corrective action taken is verified in a
follow-up audit by the same auditor or any other auditor and recorded in the audit report.
Management Representative then closes the non-conformity report.

 The results of internal and external quality audits are presented by the
Management Representative and reviewed in the Management Review Meeting.
 QUALITY AUDIT

AUDIT
PROGRAMME

FUNCTIONS, FREQUENCY TO CORRECTIVE

PERSONNEL TO REPORTING TO
SYSTEMS TO BE BE DECIDED ACTION TO BE
BE IDENTIFIED PROCEDURES
AUDITED AGREED

PROCESS AND
PRODUCT AUDIT

SYSTEM
DOCUMENT PROCESS AUDIT END PRODUCT
PROCEDURES,
AND RECORDS AUDIT
INSTRUCTION

DOCUMENTATI DOCUMENTATI DOCUMENTATI

DOCUMENTATI
ON AND ON AND ON AND
ON AND
REPORTING REPORTING REPORTING
REPORTING

Fig:- Flow chart of Quality Audit Process.

 Notes:
• Prepare audit schedule - distribute to sections.
• Issue audit notification.
• Prepare audit check list prior to audit.
• Conduct audit.
• Complete audit report.
• Complete non-conformance and corrective action report.
• Monitor compliance to audit recommendations
• Close non-conformity report

7.4 Control of Non-Conforming Product

The procedure defines identification, documentation, evaluation and disposition of non - conforming
products.

Review & disposition of non – conforming products:

The procedure defines personnel responsible for review and those authorized for taking decision for
disposition. Where required by contract, the proposed use or repair of product, which does not
conform to specified requirements are referred to the Independent Engineer for their approval.

Corrective action

 Corrective actions are taken to prevent the recurrence of non-conformities. The actions taken are
based on the magnitude of the problem and are commensurate with the risk involved to the
Independent Engineer. The changes arising out of such actions are documented.
 Corrective actions are triggered by Authority Engineer complaints or non-conformities
related to product, process and system. Identification of cause of problem & corrective actions to
eliminate the problem is carried out as necessary.
 Corrective actions are taken to eliminate the cause of non-conformity so that the non-conformity
does not occur again. The corrective action taken is appropriate to the extent of the actual
nonconformity encountered.
 Investigate the non-conformity or problem and establish the root cause.
 Determine the corrective action based on the root cause and implement them.
 Keep records of Corrective actions.
 Concerned Head of Department reviews the corrective actions taken for effectiveness.
 Corrective Actions taken are reviewed in the Management Review Meeting.

Preventive action: -

 Preventive actions are taken to eliminate the cause of a potential non conformity in order to prevent
its occurrence (i.e. first time occurrence).
 The potential non-conformity is analysed for cause and the cause identified.
 Investigate the potential non-conformity or problem and establish the root cause.
 Then determine the appropriate preventive actions necessary to eliminate the cause.
 Record the preventive actions taken
 Concerned Head of Department reviews the preventive actions taken for effectiveness.
 Review the preventive actions in Management Review Meeting.
 The preventive actions taken are appropriate to the effects of the potential problems.

Procedure for Preventive actions defines the source and planning for preventive actions.
They are generally based on

• Process control record.

• Management Review.
• Audit results
• Performance review.
• Independent Engineer Satisfaction
 8.0 CALIBRATION PLAN FOR PLANTS & LABORATORY
INSTRUMENTS
Prior to testing of any material in the Site Laboratory, Calibration shall be carried to check the
accuracy of the Instruments either In-House or at an External calibration Agency (with traceability of
NABL Accredited). The frequency of calibration is described in the calibration schedule. The
calibration reports shall be compiled & kept at the respective laboratory.
 LAB EQUIPMENT
CALIBRATION SCHEDULE

Description of Equipment Frequency Calibration

by
SOIL TESTING EQUIPMENT
1 Casagrande apparatus 2 Years In house
2 Cone Penetrometer Yearly Third party
3 Proctor Mould & Rammer 6 Months In house
4 CBR Mould, Annular & Slotted weight & measures, 6 Months In house
Spacer disc
5 CBR Testing Machine Yearly In house
6 Hot air Oven Yearly Third party
7 Moisture Container 6 Months In house
8 Sand Pouring Cylinder 1 Month In house
9 Rapid Moisture Meter 3 Months In house
CONCRETE TESTING EQUIPMENT
10 AIV Machine Yearly In house
11 Cube Mould 15x15x15cm Yearly In house
12 Permeability Test cylindrical mould Yearly In house
13 Grouting Cube Mould Yearly In house
14 Flexure Beam Mould Yearly In house
15 Slump Cone 3 Months In house
16 CTM 2000 KN Yearly Third party
17 Flexure Testing Machine Yearly Third party
18 Cement Mortar Vibrating Machine Yearly Third party
19 Mortar Cube Mould Yearly In house
20 Le-Chatelier Mould 6 Months In house
21 Vicat Apparatus with Plunger, Setting Time Needle Yearly In house
22 Los Angeles Abrasion Testing Machine Yearly In house
ASPHALT TESTING EQUIPMENT
23 Water Bath Yearly Third party
24 Elongation & Thickness Gauge Yearly In house
25 Digital Thermometer Yearly In house
26 Bitumen Penetrometer Yearly In house
27 Ring & ball apparatus Yearly In house
28 Ductility machine Yearly In house
29 Viscosity tube Yearly Third party
30 Tack coat / Prime coat tray 6 Months In house
31 Marshall Rammer Yearly In house
32 Bitumen Extractor 6 Months In house
33 Bump Integrator 2 Year Third party
WEIGH & MEASURES
34 Electronic Balance Yearly Third party
35 Standard weights Yearly Third party
36 Proving Ring Yearly Third party
37 Digital Stop Watch Yearly Third party
38 Rain Gauge Yearly In house

39 Hygrometer Yearly Third party

40 Vernier Caliper Yearly Third party
41 IS Sieves Yearly Third party
PLANTS
42 Concrete Batching Plant 6 Months In house
43 WMM Plant 6 Months In house
44 Hot Mix Plant 6 Months In house

LAB EQUIPMENT LIST

Sr. Description Qty Remark's
No.
1 Proctor Compact Test Appratus 2250 Cc 2
2 Proctor Compact Test Appratus 1000 Cc 2
3 Proctor Compact Rammer (Heavy) 4
4 Proctor Compact Rammer (Light) 4
5 Liquied Limit Device Casagrand Appratus 2
6 Soil Cone Penetrometer 1-Point LL Device 2
7 Speedy Moisture Meter (Rmm) 2
8 Sand Pouring Cylinder 100 Mm With Tray 2
9 Cutting Plate 100 Mm Dia 2
10 Sand Pouring Cylinder 150 Mm With Tray 2
11 Cutting Plate 150 Mm Dia 2
12 Sand Pouring Cylinder 200 Mm With Tray 2
13 Cutting Plate 200 Mm Dia 2
14 CBR Load Frame 1
15 CBR Mould 12
16 Perforated Plate 12
17 Spacer Disc 2
18 Surcharge Weights 2.5 Kg (U Shape) 12
19 Swell Stand Tripod 3
20 Proving Ring 50 Kn 2
21 Proving Ring 30 Kn 2
22 Proving Ring 10 Kn 2
23 Proving Ring 20 Kn 2
24 Proving Ring 2.5 Kn 2
25 Hot Plate (1500 Watt) 2
26 Marsh Cone Viscometer 1
27 Surcharge Weight 2.5 Khs Central Hole 12
28 Direct Shear Test Appratus 1
29 Aggregate Bulk Density Cylinder 50 Ltr 1
30 Aggregate Bulk Density Cylinder 30 Ltr 1
31 Aggregate Bulk Density Cylinder 15 Ltr 1
32 Aggregate Bulk Density Cylinder 3 Ltr 1
33 Riffle Sample Devider 20 Mm Slot 1
34 Density Basket 1
35 Pycnometer 4
36 Sieve G.I Frame 45cm Dia X 125mm 2
37 Sieve G.I Frame 45cm Dia X 106mm 2
38 Sieve G.I Frame 45cm Dia X 100mm 2
39 Sieve G.I Frame 45cm Dia X 90mm 2
40 Sieve G.I Frame 45cm Dia X 80mm 2

41 Sieve G.I Frame 45cm Dia X 75mm 2

42 Sieve G.I Frame 45cm Dia X 63mm 2
43 Sieve G.I Frame 45cm Dia X 53mm 2
44 Sieve G.I Frame 45cm Dia X 50mm 2
45 Sieve G.I Frame 45cm Dia X 45mm 2
46 Sieve G.I Frame 45cm Dia X 40mm 2
47 Sieve G.I Frame 45cm Dia X 37.5mm 2
48 Sieve G.I Frame 45cm Dia X 31.5mm 2
49 Sieve G.I Frame 45cm Dia X 26.5mm 2
50 Sieve G.I Frame 45cm Dia X 25mm 2
51 Sieve G.I Frame 45cm Dia X 22.4mm 2
52 Sieve G.I Frame 45cm Dia X 20mm 2
53 Sieve G.I Frame 45cm Dia X 19mm 2
54 Sieve G.I Frame 45cm Dia X 16mm 2
55 Sieve G.I Frame 45cm Dia X 14mm 2
56 Sieve G.I Frame 45cm Dia X 13.2mm 2
57 Sieve G.I Frame 45cm Dia X 12.5mm 2
58 Sieve G.I Frame 45cm Dia X 11.2mm 2
59 Sieve G.I Frame 45cm Dia X 10mm 2
60 Sieve G.I Frame 45cm Dia X 9.5mm 2
61 Sieve G.I Frame 45cm Dia X 9.0mm 2
62 Sieve G.I Frame 45cm Dia X 8mm 2
63 Sieve G.I Frame 45cm Dia X 6.7mm 2
64 Sieve G.I Frame 45cm Dia X 6.3mm 2
65 Sieve G.I Frame 45cm Dia X 6.0mm 2
66 Sieve G.I Frame 45cm Dia X 4.75mm 2
67 Sieve G.I Frame 45cm Dia X 2.36mm 2
68 Sieve G.I Frame 45cm Dia X 1.18mm 2
69 Gi Standard Test Sieve 450 Mm -Lid & Pan 2
70 Brass Sieve Size 200mm X 10mm 2
71 Brass Standard Test Sieve 200 Mm-4.75 Mm 2
72 Sieve Brass Frame 20cm Dia X 2.80 Mm 2
73 Brass Standard Test Sieve 200 Mm-2.6mm 2
74 Sieve Brass Frame 20cm Dia X 2.36 Mm 2
75 Sieve Brass Frame 20cm Dia X 2 Mm 2
76 Sieve Brass Frame 20cm Dia X 1.80mm 2
77 Sieve Brass Frame 20cm Dia X 1.70mm 2
78 Standard Test Sieve 200 Mm-1.14 Mm 2
79 Sieve Brass Frame 20cm Dia X 1.40mm 2
80 Sieve Brass Frame 20cm Dia X1 Mm 2
81 Standard Test Sieve 200 Mm-850 Mic 2
82 Sieve Brass Frame 20cm Dia X 800 Microns 2
83 Sieve Brass Frame 20cm Dia X710 Microns 2
84 Standard Test Sieve 200 Mm-700 Mic 2
85 Sieve Brass Frame 20cm Dia X600microns 2
86 Sieve Brass Frame 20cm Dia X 500microns 2
87 Sieve Brass Frame 20cm Dia X425 Microns 2
88 Sieve Brass Frame 20cm Dia X355 Microns 2
89 Sieve Brass Frame 20cm Dia X300 Microns 2
90 Standard Test Sieve 200 Mm-250 Mic 2
91 Sieve Brass Frame 20cm Dia X 212microns 2
92 Standard Test Sieve 200 Mm-200 Mic 2
93 Sieve Brass Frame 20cm Dia X 180microns 2
94 Standard Test Sieve 200 Mm-125mic 2

95 Sieve Brass Frame 20cm Dia X150microns 2

96 Sieve Brass Frame 20cm Dia X 90 Microns 2
97 Sieve Brass Frame 20cm Dia X 75 Microns 2
98 Standard Test Sieve 200 Mm-55 Mic 2
99 Sieve Brass Frame 20cm Dia X 53microns 2
100 Sieve Brass Frame 20cm Dia X 45 Microns 2
101 Brass Standard Test Sieve 200mm-Lid & Pa 2
102 Riffle Sample Devider 13 Mm Slot 1
103 Aggregate Crushing Value 1
104 Elongation Gauge 2
105 Flakiness Gauge 2
106 Hot Air Oven (Size 24''x24''x24'') 1
107 Sand Equivalent. App. With Chemical 1
108 Los Angles/Abrasion Testing Machine 1
109 Sieve Shaker (Electrically Operated) 1
110 Aggregate Impact Value Testing Machine 1
111 Laboratory Hot Air Oven 24"X24"X36" 1
112 Blain Air Permeability Apparatus 1
113 Vicat Apparatus 1
114 Slump Test Apparatus 6
115 Vibrating Table (1mtr X 1 Mtr ) 1
116 Cube Mould (100x100x100mm) 12
117 Mortar Cube Mould (70.6 X 70.6 X 70.6mm) 12
118 Beam Mould (700x150x150 Mm) 12
119 Diamond Core Bit (100 Mm Dia) 2
120 Diamond Core Bit (150 Mm Dia) 2
121 Air Entrainment Meter 5ltr Capacity 1
122 Lee Chatlier Apparatus 1
123 Concrete Penetrometer 1
124 Flow Table 1
125 V Funnel 1
126 U Shape Box Apparatus 1
127 L Shape Box Apparatus 1
128 Concrete Mixer (Lab Type) 1
129 Mortar Cube Vibrator 1
130 Vibrating Hammer For DLC Mould Casting 1
131 Compaction Factor Apparatus 1
132 Flexural Testing Machine Capacity 100kn 1
133 Core Cutting Machine With Honda Eu 30 Genset 1
134 Compression Test M/C 2000 Kn Digital Typ 1
135 Cube Mould (150x150x150mm) 50
136 Cube Mould (50x50x50mm) 12
137 Cube Moulds 150mmx150mmx150mm ISI Marked 50
138 Standard Penetrometer Penetration Test 1
139 Saybolt Viscometer 1
140 Tar Viscometer 1
141 Compact Pedestal (100 Mm Dia) 1
142 Hammer For Marshal Mould Casting 100 Mm 1
143 Compact Pedestal (150 Mm Dia) 1
144 Hammer For Marshal Mould Casting 150 Mm 1
145 Absolute Viscosity Test Apparatus 1
146 Kinematic Viscosity Test Apparatus 1
147 Vacuum Pump With 2.5 Ltr Flask (For Gmm) 1
148 Water Bath (50 Ltr Capacity, 0 To 100 0c 1

149 Bitumen Specific Gravity Bottle 50 Ml 1

150 Straight Edge 30cm 1
151 Tack Coat Trays 1
152 Ductility Moulds 1
153 Ring And Ball Apparatus 1
154 Viscosity U Tube Size 6 1
155 Viscosity U Tube Size 12 1
156 Marshal Breaking Head 100mm Dia 1
157 Marshal Breaking Head 150mm Dia 1
158 3 Meter Straight Edge & Measuring Wedge 1
159 Ductility Testing Apparatus 1
160 Hydraulic Extractor (100mm &150mm Dia) 1
161 Bitumen Extractor Manual 1
162 Bitumen Extractor Electrically Operated 1
163 Modified Marshal Stability Apparatus 1
164 Thin Film Oven Test Apparatus 1
165 Bitumen Laboratory Mixer 1
166 Automatic Compactor For Bituminous Mixs 1
167 Marshal Mould (100 Mm Dia) 12
168 Marshal Mould (150 Mm Dia) 12
169 Water Still -4ltr. 1
170 Alum Potri Dish 4" 2
171 Alum Potri Dish 2" 2
172 Aluminium Containers Big 50
173 Aluminium Containers Small 50
174 Balance 30 Kg Cap Indicate Accuracy 1 Gm 1
175 Beakers (Borosil)100 Ml 1
176 Beakers (Borosil)1000 Ml 1
177 Beakers (Borosil)250 Ml 1
178 Beakers (Borosil)500 Ml 1
179 Benzene 50
180 Borosil Glass Jar Capacity 1000ml 2
181 Borosil Glass Jar Capacity 100ml 2
182 Borosil Glass Jar Capacity 250ml 2
183 Borosil Glass Jar Capacity 500ml 2
184 Calcium Carbide 2
185 Circular Trays 12
186 Coating Thickness Gauge 1
187 Deisel Hydrometer (0.8-0.85) 1
188 Depth Gauge 12" 1
189 Depth Gauge 6" 1
190 Dial Gauge 25 Mm Travel 1
191 Diesel Hydrometer (0.8-1) 1
192 Diesel Hydrometer (1-1.2) 1
193 Digital Ph Meter 1
194 Digital Stop Watch 1
195 Digital Thermometer (Pen Type ) 1
196 Digital Thermometer (Wired ) 1
197 Digital Thickness Gauge 1
198 Digital Vernier Scale 1
199 Digital Tds Meter 1
200 Elect. Bal. 600 Gm Cap. Accuracy 0.01 Gm 1
201 Electric Hand Mixture 1
202 Electronic Balance 05 Kg Cap 1

203 Electronic Balance 10 Kg Cap 1

204 Electronic Balance 15 Kg Cap 1
205 Electronic Balance 20 Kg Cap 1
206 Electronic Balance 30 Kg Cap 1
207 Electronic Balance 40 Kg Cap 1
208 Electronic Balance 50 Kg Cap 1
209 Electronic Platform Balance 100 Kg Cap 1
210 Enamel Trays 15 Cms X 20 Cms Size 1
211 Enamel Trays 15 Cms X 45 Cms Size 1
212 Enamel Trays 25 Cms X 30 Cms Size 1
213 Enamel Trays 30 Cms X 45 Cms Size 1
214 Enamel Trays 45 Cms X 60 Cms Size 1
215 Filter Papers 10cm 1
216 Filter Papers 15cm 1
217 Filter Papers 24cm 1
218 French Curves 1
219 G.I Trays 25cms X 30cms X 5cms Size 1
220 G.I Trays 30cms X 30cms X 5cms Size 1
221 G.I Trays 45cms X 60cms X 5cms Size 1
222 G.I Trays 60cms X 60cms X 5cms Size 1
223 Glass 600mm X 600mm X 10mm Thick 1
224 Glass Funnel 1
225 Glass Plate Size 60x60x12mm 1
226 Glass Rod, 8 – 10” Long 1
227 Glass Thermo Meter Up To 300 0c 1
228 Glass Thermometer 100 Deg 1
229 Glass Thermometer 250 Deg 1
230 Gauging Trowels 1
231 Hydro Meter (1.000 -2.000, 20 Deg C) 1
232 Hydro Meter O.4 To 1.5 1
233 Hydrometer For Bentonite 1
234 Hydrometer Soil 1
235 Hygrometer 1
236 Laser Thermometer 1
237 Maximum & Minimum Thermometer 1
238 Measuring Cylinders Pvc Jars 1000 Ml 1
239 Measuring Cylinders Pvc Jars 100ml 1
240 Measuring Cylinders Pvc Jars 250 Ml 1
241 Measuring Cylinders Pvc Jars 500 Ml 1
242 Metal Mud Balance 1
243 Nylon Hammer 1
244 Pan Balance With Weights (Cap.20kg ) 1
245 Ph Meter 1
246 Rain Gauge Std. 200 Cm2 Collection Bowl 1
247 Rubber Hammer 1
248 [Link] 50ml Capacity 1
249 Sampling Tins Size-100mmx75 Mm 1
250 Sampling Auger 1
251 Sampling Pipettes Fitted With Pressure 1
252 Scoop Small (500gms) 1
253 Scoops 1500 Grams 1
254 Scoops 2000 Grams 1
255 Screw Gauge (Micro Meter) (0-125) 1
256 Shore Hardness Meter 1

257 Silicon Oil - 25Ltr 1

258 Spatulas (Big Size) 1
259 Spatulas Small Size 1
260 Specific Gravity Apparatus (Pycnometer) 1
261 Specific Gravity Of Cement Bottles 1
262 Sprit Level 1
263 Standard Sand Bag Zone - I 1
264 Standard Sand Bag Zone - Ii 1
265 Standard Sand Bag Zone - Iii 1
266 Vacuum Flask 5 Ltrs Capacity 1
267 Wash Bottle 1
268 Water Testing Kit 1
269 Wheel Barrow (Troly) 1
270 Wind Velocity Meter 1
QUALITY CONTROL
 9.0 QUALITY CONTROL

9.1 Types of Quality Control

One of the most important tasks of the supervision during the execution of a road contract is technical
quality control, i.e., control as to whether the materials and work supplied by the
Supplier/manufacturer meet the technical requirements in the Agreement specifications. There are
two types of Quality Control, which are described below:

9.1.1 Control of Methods

Method control is usually carried out by the Site Engineer whose job is to be on the site and the
execution of the works. At the same time, the Concessionaire Quality control personnel will perform
sample measurements, such as the recording of the thickness of fill layers, the temperature of asphalt
material, and the slump of cement concrete. Confirmation of quality of material being used in work by
carrying out series of lab test.

9.1.2 Control of End-Results

End-result control includes field tests e.g. control of the evenness of completed pavement layers and
laboratory tests, e.g., Marshall Tests on asphalt materials. Other tests are a combination of field and
laboratory tests. An example of this is the compaction control of earthworks where the achieved
density is determined by means of a field test, and where the IS/ AASHTO density with which the
result should be compared is found by means of a laboratory test. End-results control is carried out by
laboratory technicians/Assistants, and most of the work consists of laboratory tests.

9.2 Performance of Quality

Control Quality Work

The basic concept for production of a quality work is illustrated in the model below:

Process
Quality Periodic Quality
Control
Inputs Check Product
Specification

The main inputs are Men, Material, Machineries and Time. Qualified & experienced key personnel for
the job will monitor the quality work. The materials, their qualities and acceptable dimension limits for
their use will be ensured as per established guidelines. Process control specifications are incorporated in
the specification. These specify the functional requirements of the machinery and equipment to be used
in the production process. The periodic checks during manufacturing process are carried out as laid down
in the Contract documents and the codes mentioned therein jointly by the Concessionaire & and reviewed
by Independent Engineer Team. The application of these activities would nearly assure a quality product
at the end.

9.2.1 Testing Facilities

A list of minimum equipment to be deployed for the site laboratory is enclosed. If required, may get the
tests carried out in recognized testing laboratories in third party laboratory for tests of a special nature not
covered by the equipment indicated in or till the establishment of the site lab. The testing equipment will
be regularly serviced as recommended by the suppliers. A calibration chart shall be available for each
equipment.

9.2.2 Test Specifications

Specifications and standards usually describe test methods by referring to publications issued by the
Ministry of Road Transport and Highways (MORTH) / the Indian Roads Congress (IRC). Where the said
specifications are silent in regard to the specification in question, in that case, the specifications under the
Bureau of Indian Standards (BIS), British Standards (BS), the American Association of State Highway
and Transportation Officials (AASHTO) and the American Standards for Testing Materials (ASTM) shall
apply in that order.

9.2.3 Inspection & Test Plan

The frequency of technical control is usually laid down at the beginning of a Project and is generally
related to the specifications. The testing plan shows the test frequency, standards, and acceptance
criteria for the specified test.

9.2.4 Method Control

Method control is carried out according to the type of work. Where the work method is of considerable
importance and requires constant supervision to achieve the quality or where in some case, the quality is
difficult to improve upon; there shall always be a Section In charge on the site. Where work methods are
of less importance or quality is constantly being achieved by the Engineer, there may be less need for
continuous surveillance.

9.2.5 Reporting of Test Results

The test results shall be recorded systematically in a register, which shall be signed by the Concessionaire
Lab Technician/ QA/QC Engineer. The format for routine tests on highway works has been enclosed in
this OAP.

9.2.6 Monitoring of Quality Control

The Concessionaire has the responsibility for monitoring the use of the QAM and for ensuring that the
above policies are being implemented and to consider the need for changes. The Concessionaire QAQC
In charge is responsible for sampling of all construction materials to be used in the permanent works prior
to commencement of the works. Independent Engineer may join at the time of sampling. The testing shall
be carried out under the supervision of the QAQC In charge of the Concessionaire. Independent Engineer
may witness at least 20% of activities during the time of testing.

9.3 Approval of Stone Quarries And Soil Borrow Areas

The Concessionaire’s Engineer will search the Soil Borrow area and stone quarry well in advance before
the start of any construction activity. QA/QC team will ensure the quality of material by conducting series
of test at site lab/Third party lab. As recommended by MORT&H before its use in the project work.
After obtaining satisfactory report material will be approved for use. Finally test result along with details
of the borrow area will be sent to Independent Engineers for their review.

9.4 Approval of Materials

All materials proposed to be used in the Project Works are to be checked by the QAQC In charge of
Concessionaire. In general, there are Natural Materials, Processed Materials, Manufactured Materials and
Designed Materials.

9.4.1 Reporting and Recording Material Approvals

The Concessionaire QA/QC engineer shall maintain the record of approved Borrow area/Quarry. This
information is to be included in the Monthly Quality Control Report to be submitted with the Monthly
Progress Report.

9.4.2 Approval of Works

Road Work

Road Works involve placement of earth, other pavement courses in layers, etc. Site/Section In
charge will raise the RFI to carry out the necessary test to check its conformance with the specifications.
If RFI is approved, next operation will be carried outer! shall be closed after 48hours of their inspection
time/date.

9.4.3 Approval of Works

Structure Work

Structure Works involve Setting out, Pouring of concrete, etc. Site / Section in-charge will raise the RFI
to Quality control section/Survey section to carry out the necessary test to check its conformance with the
specifications. If RFI is approved, next operation will be carried out.

9.5 Sampling of Materials

All construction materials to be used in the permanent works are to be sampled prior to commencement
of the Works. This includes sampling for materials to be tested for proposing approval of the material
source as well as sampling of materials for approval of the individual construction materials. In both
cases, and for each instance, the site incharge

must give notification for such sampling to the QA/QC In charge/ Engineer of the Concessionaire in
advance way of the Request for Inspection Form (RFI) responsibility identifying All sampling is to be
carried out in accordance with instructions given by the QA/QC In charge of Concessionaire

9.6 Field Testing Laboratory

The Field-Testing Laboratory, including all furniture, testing equipment and apparatus as required by the
Specifications shall be provided and maintained by Concessionaire with the provision of all necessary
utilities. The design and layout of the laboratory shall be convenient enough to conduct all tests.

Testing equipment and apparatus are to be initially approved and periodically checked by the QA/QC In
charge of the Concessionaire to assure proper operation, accuracy, correct calibration and complete
conformance to all Specifications requirements. Likewise, all testing procedures detailed in the
Specifications and procedures as part of Quality Control and Quality Assurance Plan are to be strictly
adhered. The QAQC charge of Concessionaire is to supervise, monitor and check all aspects of the testing
procedures, including sample storage, preparation, testing and analysis and reporting of testing results.
All relevant material testing details related to sample preparation, testing and analysis of results are to be
recorded on the relevant standard testing formats enclosed in this QAP.

9.7 Acceptance Testing

9.7.1 General

All materials included in the construction works for which quality control tests are specified and for
which approval has been given previously, are to be inspected and checked for acceptability in
accordance with the Specifications requirements.

9.7.2 Routine Acceptance Tests:

The frequency of testing should conform to the Minimum Quality Control Testing Requirements of
the MORTH Specifications-5” Revision. Sampling and Testing should be in accordance with the relevant
MORTH/IRC/IS. Tests are to be reported on proper formats.

9.7.3 Quality Control Test Statement (Monthly Progress Report)

This summary of field and laboratory test results is referred to as a Quality Control Test Statement.
 INSPECTION AND TEST PLAN :- TEST METHODS, FREQUENCY AND ACCPETANCE CRITERIA

1 Earthwork in Embankment, Subgrade, Shoulder and Median

2 Granular Sub Base
3 Wet Mix Macadam for Base and Profile Corrective Course
4 Cement Treat Sub Base
5 Cement Sub Base
6 Prime Coat/ Tack Coat
7 Dense Bituminous Macadam
8 Bituminous concrete
9 Supply of Mineral Aggregates for Pavement Course
10 Open graded Premix Surfacing
11 Mastic Asphalt
12 Surface Regularity
13 Cement for Structural Work
14 Coarse Aggregate for Structures
15 Reinforcement Sand /Fine Aggregate for Structures
16 Steel
17 Water for Concrete
18 Concrete mix Design
19 Paving Bitumen
20 Crumb Rubber Modified Bitumen
21 Pre-Stressing Materials
22 RCC Hume Pipes
23 Concrete Admixture
24 POT/ PTEF Bearing
25 Strip Seal Joint
26 Road Marking Paint
27 Pavement Quality Concrete
28 Traffic signs
29 Dry Lean Concrete

QUALITY CONTROL TESTS DURING CONSTRUCTION

To ensure the requisite quality of Construction, the Material and works Shall be subjected to
quality control tests described hereinafter Engineer shall have the full authority to carry out
additional tests as frequently as he may deem necessary however , the engineer may relax the
frequency if the consistency in quality of materials can still be maintained with the reduced
number of tests.
 Materials Control Tests – Tests Methods & Frequencies
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
(i)Atterberg’s limits IS:2720 – Part 5 2 tests per 3000m³ of Liquid limit not >50,
soil Each type to be Plasticity index not >25,
1 Earth work tested.
(ii)Modified Proctor Test. IS: 2720 – Part 8 2 tests per 3000m³ of MDD Sub- grade &Shoulders – not < 17.5
soil Each type to be KN/m³ Embankment more than 3Mtr height
(Borrow Area / tested. – not < 16.0 KN/m³ Embankment up to 3m
Subgrade) height – not < 15.2 KN/m³
(iii)Slope stability Analysis for IRC 75 Once for each structure C & Ø value shall not be less than the value
high embankment approach /highway mentioned in the drawings
(iv) Deleterious content Test IS:2720 Part 27 1 test for 3000 m³or as Not > 0.5%by Mass
required by the Engineer
(v)Field dry density of compacted IS: 2720 Part 28 1 test per 2000 m² Not < 97% of MDD for Sub- grade and
Layer earthen shoulders
1 test per 3000 m² Not < 95%of MDD for Embankment
(vi)CBR test for subgrade IS: 2720 Part 16 1 test for 3000 m³or as Min 10%for sub grade
Material required by the Engineer
(vii)Moisture Content during field IS: 2720 Part 2 1 test per 250 m² OMC +1% to -2%
Compaction
(viii)Layer thickness of By Scaling 1 test per 1000 m² Max. 250mm
compacted
(ix)Free swell index for expansive IS: 2720 Part 40 1 per source Not > 50%
clays

(x)Max Particle Size IS: 2720 Part 4 2 test per 3000 cum Subgrade not>50mm
Embankment not > 75mm
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
(i) Grading for Close – graded IS:2386 – Part 1 1test per 400 cum Sieve Size % Passing for
Material (Granular Sub Base ) & Grading -V
2 Granular Sub (Profile Corrective Course) 75.0 mm 100
– Base 53.0 mm 80-100
26.5 mm 55-90
9.50 mm 35-65
4.75mm 25-50
2.36mm 10-20
0.85 mm 2-10
0.425 mm 0-5
(ii)water Absorption IS: 2386 – Part 3 At the beginning for Max 2%
Approval of each source
and Change of Source.
(iii)Soundness in sodium Sulphate IS 383 At the beginning for Max 12
(when Water Absorption > 2% ) Approval of each source
and Change of Source.
(iv) CBR at 98% Compaction IS:2720 Part 16 As required 30% Min.
(v)MDD & OMC IS: 2720 Part 08 As required ---

(vi) MC for Field Compaction Speedy tester 1 test per 450 Sqm OMC +1% to -2%
/Nuclear Meter

(vii) Degree of Compaction IS: 2720 Part 28 1 test per 1000 m² Min 98%

(viii)Layer thickness MoRT&H Every layer 100 mm in 1 layer

401.4.2
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
(ix) LL and PI for Material IS 2720 - Part 5 1 test per 400 cum 25% and 6% (max) respectively
Passing 425micron

(x) Deleterious Constituents Visual As required Nil

(i) Aggregate impact value Los IS: 2386 – Part 4 1test per 1000cum AIV – Max 30%
Angeles Abrasion value LAAV – Max 40%
3 Wet mix
Macadam (ii)Flakiness and Elongation IS: 2386 – Part 1 1test per 500 cum Max 35%
Base and Index (Combined Total)
Profile (iii) Plasticity Index for Material IS: 2386 – Part 5 1test per 100 cum Not exceeding 6%
Corrective finer than 425 micron
Course (iv) Water absorption IS: 2386 – Part 3 At the beginning for Max 2%
Approval of each
source and Change of
Source.
(v) Soundness in sodium Sulphate IS: 2386 – Part 5 At the beginning for
(if Water Absorption exceeds 2% Approval of each source Max 12%
) and Change of Source.
(vi) Grading MoRT&H table 1 test per 100 cum IS Sieve % Passing
no 400 - 13 53.0 mm 100
45.0 mm 95 – 100
22.4 mm 60 – 80
11.2 mm 40 – 60
4.75 mm 25 – 40
2.36 mm 15 – 30
0.600 mm 8 – 22
0.075 mm 0–5
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
(vii) OMC & MDD (by heavy IS:2720 – part 8 As required ---
compaction)
(viii)MC during Compaction at Speedy Moisture As required 80 – 105 %of OMC
site tester
(ix) Degree of Compaction IS:2720 –Part 28 1 test per 1000 sqm Min 98% of MDD

(x) Layer thickness (designed) -- Pavement Design Max 200mm

(xi)Layer thickness after Scaling As required

compaction Special Specification
IS Sieve % Passing
(i) Grading aggregate (combined) MoRT&H table 1 test per 100 cum 53.0 mm 100
4 Cement no 400 - 4 37.5 mm 95 – 100
Treated Base 19.0 mm 45 – 100
9.50 mm 35 – 100
4.75 mm 25 – 100
0.600 mm 8 – 65
0.300mm 5 – 40
0.075 mm 0 – 10
(ii) OMC & MDD IS:2720 – part 8 As required Not specified
(by heavy compaction)
(iii) Atterberg’s Limit IS:2720 – part 5 As required LL < 45% & PI < 20%

(iv) Unconfined Compressive IS:516 As required 4.5 – 7.0 MPa

Strength IRC 37- 2018
(v)Moisture content Prior to IS:2720 – part 2 1 set of 2 test per 500 m² OMC +1% to -2%
Compaction
(vi) Field Compaction Test (By IS:2720 part -28 1 set of 2 test per >98%
sand Replacement Method) 500 m²
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
(i) Grading aggregate (combined) Mort&H table 1 test per 100 cum IS Sieve % Passing
no 400 - 1 53.0 mm 100
5 Cement 26.5 mm 50 – 80
Treated 4.75 mm 15 – 35
Sub Base 0.075 mm <5
(ii) OMC & MDD (by heavy IS:2720 – part 8 As required Not specified
compaction)
(iii) Atterberg’s Limit IS:2720 – part 5 As required LL < 45% & PI < 20%

(iv) Unconfined Compressive IS:516 As required Up to 10 msa 0.75– 1.5 MPa

Strength IRC:37 2018
>10 msa 1.5 – 3.0 MPa

(v)Moisture content Prior to IS:2720 – part 2 1 set of 2 test per 500 m² OMC +1% to -2%
Compaction
(vi) Field Compaction Test (By IS:2720 – part 1 set of 2 test per 500 m²  98%
sand Replacement Method ) 28
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
(i) Quality of binder IS:8887 – 2004 Sample test at source for
IS:73 - 2018 selection of source and
6 Prime coat & each lot to be test at site
Tack coat for conformity with
specification in addition
to MTC
(ii) Rate of Spread of IRC – SP11 Three test per day per Prime coat 7 – 10 kg/10 Sqm
Binder stretch. Or one test/500 Tack coat 2 – 3 kg/10 Sqm
sqm whichever is more
(iii)Temperature of Thermometer Close interval Emulsion 20 to 70 °C
application

1. Quality of Binder IS: 73 (2018) Third Party test for Special specifications
(VG-40) IRC : SP 53 selection of source and 2
7 Dense Graded test per lot to be tested in
Bituminous addition to MTC
Macadam 2. cleanliness(dust) IS:2386 – part1 As required Max 5% passing 0.075 mm sieve
3. Los Angeles IS:2386 – part4 1 per 350 cum For DBM 35% (Max)
Abrasion Aggregate For DBM 27% (Max)
impact Value
4. Flakiness index and IS:2386 – part1 1 per 350 cum Max 35%
Elongation index
(combined)
IS:2386 – part1 1 set per Day ---
5. Gradation of aggregate
(individual)
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
6. Mix Grading IS:2386 – part1 Two tests per day per Sieve Size % of Passing
plant .or one test /400 (mm)
1. Grading 1 for 75 – 100 MT whichever is more Nominal Gr-1 Gr-2
mm Thickness Aggregate
2. Grading 2 for 50 – 75 Size 37.5mm 26.5mm
mm Thickness 45.0 mm 100 --
37.5 mm 95 – 100 100
26.5 mm 63 – 93 90 – 100
19.0 mm --- 71 – 95
13.2 mm 55 – 75 56 – 80
4.75 mm 38 – 54 38 – 54
2.36 mm 28 – 42 28 – 42
0.300 mm 7 – 21 7 – 21
0.075 mm 2–8 2–8
Bitumen
content% by Min 4.0 Min 4.5
mass of
total mix
7. coating and stripping if IS: 6241 Min retained Coating 95%
the Minimum retained
coating is < 95%, retained ----
tensile strength shall be
carried out : specified
value is Minimum 80%
(Water Sensitivity )
8. Water Absorption IS:2386 Part 3 At the beginning for Max 2%
approval of each source
and change of source
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
9. Soundness in Sodium IS: 2386 - Part 5 At the beginning for Max 12%
Sulphate / Magnesium approval of each source Max 18%
Sulphate and change of source
[Link] Content % by ASTM D2172 One test per day per plant
mass of total mix .or one test /400 MT ---
whichever is more

11. JOB mix Formula Mix Design Every Change of As per Table No- 500-13
Material
12. Sand Equivalent Value IS: 2720 Part 37 1 test for Source Max.50
Approval
13. Plasticity Index IS :2720 Part 5 As required Max 4.0
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
14. Requirement of mix ASTM D-1559 Three tests per day per [Link] Description Requirement
MS - 2 plant. or one test /400 1 Marshall Min 9KN
MT whichever is more Stability
2 Marshall Flow 2-4
Air
3 Voids 3–5
4 VFB 65% - 75%
5 Binder content Min 4%
6. VMA as per Table No- 500 - 12
Nominal Minimum VMA (%) related to
Max. Design air Voids (%)
Particle 3 4 5
size mm
9.5 14 15 16
12.5 13 14 15
19.0 12 13 14
26.5 11 12 13
37.5 10 11 12
1) The nominal maximum Particle size is one
size lower than first sieve to retain more
than 10%
2) Interpolate minimum voids in the mineral
aggregate (VMA) for design Values
between those listed
3) Compaction level – 75 Below on each
face
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
[Link] Variations Bitumen Two tests per day per SI. % Permissible
from job Mix Formula extraction & plant .or one test /400 NO Description Variation
(JMF) by Weight of total Sieving MT whichever is more For For
mix in percent Base Wearing
binder Course
1 [Link] ±8 ±7
19mm or
larger
2 [Link] ±7 ±6
13.2mm 9.5
mm
3 [Link] ±6 ±5
4.75mm or
larger
4 [Link] ±5 ±4
2.36mm,1.18m
m,600 mic
5 [Link] ±4 ±3
300mic,ISO
mic
6 [Link] ±2 ±1.5
75mic
7 Binder ±0.3 ±0.3
Content%
8 Mixing ±10°C ±10°C
temperature
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
[Link] of binder Bitumen Two tests per day per Job Mix Formula ( JMF )
Content and gradation in extraction and plant. or one test /400
the mix sieving MT whichever is more
(appendix 5of
IRC: sp-11)
ASTM – D2172

[Link] Control --- --- 60 - 70 80 – 100 Bitumen

a) Binder at mixing time 160 - 170 140 - 160
b) Agg at mixing time 160 - 175 140 - 165
c)Discharge temp of mix 160 - 170 140 – 160
d)Laying Temperature 150 Min 130 Min
e) compaction of rolling 100 Min 80 Min
[Link] thickness Site check 1 test for 250 Sqm Special Specification

19. Density of compacted Density of Core I test per 700 Sqm Min 92% of Marshal specimen Theoretical
layer (10%of tests shall be ASTM – D2041 Gmm
done on edges
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
1. Quality of Binder IS:73/2013 Third Party test for Special Specifications
(CRMB with base Binder IRC: SP selection of source and 2
VG-30 53/2010 test per lot to be tested in
8 Bituminous IS:17079/2019 addition to MTC
Concrete
2. cleanliness(dust) GSA IS:2386 – part1 As required Max 5%passing 0.075 mm sieve
3. Los Angeles Abrasion IS:2386 – part4 1 Test per Source For BC 30% (Max)
Aggregate impact Value 1 Test per 350 cum For BC 24% (Max)
4. Flakiness index and IS:2386 – part1 1 per 350 cum Max 35%
Elongation index
(combined)
5. coating and stripping if IS: 6241 Min retained Coating 95%
the Minimum retained AASHTO T 283
coating is < 95%, retained ----
tensile strength shall be
carried out : specified
value is minimum 80%
(Water Sensitivity )
6. Plasticity Index IS 2720 Part 5 One test per Each source Max 4.0
7. Water Absorption IS:2386 Part3 At the beginning for Max 2%
approval of each source
and change of source
8. Soundness in IS: 2386 Part 5 At the beginning for Max 12% , !8% respectively
Sodium Sulphate approval of each source
Magnesium Sulphate and change of source
9. Sand Equivalent Value IS 2720 Part 37 1 test per Source Max.50
Approval
10. Stone Polishing Value BS 812 part 114 1 test for Source Min 55
IS:2386 Part 4 Approval
[Link] of mixed IS:2386 Part 1 Two tests per day per Sieve Size % Passing
Aggregate plant or one test /400 MT (mm) Grading -1 Grading -2
whichever is more 26.5 100 --
Layer Nor. 19.0 90 – 100 100
Thick Agg 13.2 59 – 79 90 – 100
size 9.5 52 – 72 70 – 88
Gr-1 50mm 19mm 4.75 35 – 55 53 – 71
2.36 28 – 44 42 – 58
Gr-2 30 to 13.2 1.18 20 – 34 34 – 48
40mm mm 0.600 15 – 27 26 – 38
0.300 10 – 20 18 – 28
0.150 5 – 13 12 – 20
0.075 2–8 4 – 10
Min 5.4% Min 5.6%
12. Job mix Formula Mix Design Every Change of As per Table 500 - 1
Material
13. Requirements of mix Each mix Design SI. Descripti Requirment
a) Minimum Each mix Design NO on
b) Maximum Each mix Design 1 Min Min 9KN at 60°C
Stability
2 Min 2mm
Flow
3 Max 4mm
Flow
4 Air voids 3–5%
in mix
Nomi [Link]%
nmax. reiated to
5 VMA particl design air
e size voids
mm 3.0 4.0 5.0
 9.5 14 15 16
12.5 13 14 15
19.0 12 13 14
26.5 11 12 13
37.5 10 11 12
Note:
1. The nominal max particles size is
one size larger than first sieve to
retain more than 10%
2. Interpolate Min Voids in the mineral
aggregate (VMA) for design air
Voids Value between those listed
6 VFB 65 – 75%
7 Binder Content Min 5.4% Gr-1
Min 5.6% Gr-2
8 Loss of Stability Min 80%
on immersion in Retained
Water at 60°C Strength
9 Compaction 75 on each of
level (No of two faces of
blows) Specimen
14, Permissible Variations Extraction & Two tests per day per Aggregate Passing 19mm sieve ± 7%
from JMF (wearing Sieving plant or one test /400 MT or larger
Course) (appendix 5 of whichever is more Aggregate Passing 13.2 ± 6%
IRC : SP 11) mm,9.5mm
Aggregate Passing 4.75mm ± 5%
Aggregate Passing ± 4%
2.36mm,1.18mm,0.6mm
Aggregate Passing ± 3%
0.3mm,0.15mm
Aggregate Passing 0.075mm ± 1.5%
 Binder Content ± 0.3%
Mixing Temperature ± 10%
15. Temperature Control Indicated Temperature (°C )
a)Binder at mixing time IRC SP-53 2010 Through out 165 – 185
b)Aggregate at mixing Table No - 4 Through out 165 - 185
time
c) Discharge temperature Through out 150 - 170
of mix
d) laying temperature Through out 130 – 160
e) Completing of rolling Through out 115 - 155
16. Control of binder Bitumen Two tests per day per JMF
content and gradation Extraction and plant or one test /400 MT
sieving whichever is more
17. Layer thickness Site check 1 test per 250 sqm Special Specifications
18. Density of Compacted Density of core 1 test per 250 sqm Min 98% of Marshall Specimen (10% 0f
layer (10% of density tests tests Shall be Conducted near edges)
Shall be done on edges

9 Supply of Mineral Size Requirement IS:2386 -Part 1 Each lot Standard Wholly Wholly Remarks
Aggregate for size Pass Retained
Pavement 75.0 mm 106mm 63.0 mm
Courses 63.0 mm 90.0 mm 53.0 mm
45.0 mm 53.0 mm 26.5 mm
26.5 mm 45.0 mm 22.4 mm
22.4 mm 26.5 mm 13.2 mm
13.2 mm 22.4 mm 11.2 mm
11.2 mm 13.2 mm 6.7 mm
6.7 mm 11.2 mm 2.8 mm
 [Link] of binder IS :73 2per lot Special Specifications
[Link] Angeles Abrasion IS 2386 – part 4 1 test per 350 cum LAAV max 40%
10 Open Graded Value AIV Max 30%
Premix Surfacing Aggregate Impact Value
3. Flakiness index and IS:2386 – part1 1 per 350 cum Max 35%
Elongation index
(combined)
4. coating and stripping IS: 6241 At the beginning for Min retained Coating 95%
AASHTO T 182 approval of each source
and change of source
[Link] Absorption IS:2386 Part 3 At the beginning for Max 2%
approval of each source
and change of source
6. Stone Polishing Value BS 812 part 114 1 test for Source Min 55
IS:2386 Part 4 Approval
[Link](dust) GSA IS:2386 – part1 As required Max 5%passing 0.075 mm size
8. Soundness in Sodium IS: 2386 Part 5 At the beginning for Max 12% 18% respectively
Sulphate / Magnesium approval of each source
Sulphate and change of source
[Link] sensitivity to be AASHTO T-283 At the beginning for Retained tensile Strength Min 80%
carried out of mm retained approval of each
coating in stripping is less source and change of
than 95% source
10. Filler Gradation MoRT&H 500-9 As required

11. Grading of 13.2 IS:2386 Part-1 1 Test per 25 cum 100% Passing 22.4mm & retained or
chippings 11.2mm
12. Grading of 13.2 IS:2386 Part-1 1 Test per 25 cum 100% Passing 13.2mm & retained or 5.6mm
chippings
[Link] content for Site check Two tests per day per 52kg per cum for 13.2 mm Chipping
Premixing plant or one test /500 MT 52kg per cum for 11.2 mm Chipping
 whichever is more
14. Temperature Control
a) Binder at the time of --- Frequently 165 – 185
mixing
b) Aggregate at the time of -- Frequently 165 – 185
Mixing
c) Discharge Temperature -- Frequently 150 -170
of mix
Compaction of Rolling -- Frequently 130 - 160
[Link] of Spread of Site check of Regularly Min 25mm thick
Mixed Material Material and
layer Thickness
1. Quality of Binder
(i) Penetration at 25°C IS:1203 2 Test per lot 30 t0 50
11 Mastic Asphalt (ii) Softing Point IS:1205 2 Test per lot Min 60
(iii) Lose on heating for IS: 1212 2 Test per lot Max 2.0
5hour @163°C
(iv) Solubility in IS:1216 2 Test per lot Min 95
trichloroethylene %by
mass
(v) Ash (mineral matter ) IS:1217 2 Test per lot Max 1.0
% by mass
(vi) Cleanliness(dust) GSA IS:2386 – part1 1 test per 50 cum Max 5%passing 0.075 mm size
(vii) Flakiness index and IS:2386 – part1 1 test per 350 cum Max 35%
Elongation index
(combined)
(viii) Los Angeles IS 2386 – part 4 1 test per 350 cum LAAV max 40%
Abrasion Value AIV Max 30%
Aggregate Impact Value
(ix) Soundness in Sodium IS: 2386 Part 5 At the beginning for Max 12% ,18% respectively
Sulphate / Magnesium approval of each source
Sulphate and change of source
 (x) coating and stripping IS: 6241 3 Test per Source Min retained Coating 95%
AASHTO T 182
(xi) Water sensitivity test AASHTO T-283 1 test per 50 cum Retained tensile Strength Min 80%
is to be carried out if the
min retained coating in
stripping is less than 95%
(xii) Calcium Carbonate IS 1514 Sample test at source per Min 80%
content of filler selection and third party
testing of each lot
addition to MTC
(xiii) Grading of filler MoRT&H 500-9 1 test per lot MoRT&H 500-9
(xiv) Binder content for Site check 2 Test per day per Plant As per design
Premixing Or one test/500 cum
whichever is more
(xv) Rate of spread of MoRT&H 500- Regular control through --
mixed material 30 Cheeks of Layer
Thickness
(i)Surface regularity check Checking with One test per Km Length
3m king
12 Surface Straight edge at
Regularity middle
lane
(ii)Camber Board Checking with One in 250 Mtr 300mm Max Permitted number of
Camber board 75mm Irregularities
7mm 2
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
(a) Ordinary Portland IS: 8112 1 test per Consignment & Relevant Specifications
13 Cement for Cement (43/53) Grade for IS: 12269 Third party Test from
Structural Works Physical and Chemical NABL Approved lab for
Properties selection of source &
change in source and
every 500 MT or 3
Months which ever
Occur earlier with MTC
for all Properties
(b)initial and final setting IS:4031,IS:1226 Batch wise Testing in Initial setting – Min 30 minutes
time 9 addition to MTC Final setting – Max 600 Minutes
IS:8112
(c) Compressive Strength IS:4031,IS:1226 Batch wise Testing in Min 53 MPa at 28 days
9 Addition to MTC
IS:8112
(d)Fineness & Soundness IS:4031,IS:1226 Batch wise testing in Min 225m²/Kg
9 addition to MTC
IS:8112
(e) Chemical analysis of IS:4031,IS:1226 MTC in Each Batch As per Specification
cement 9, IS:8112
[Link] Angeles Abrasion IS: 2386 Part 3 1 Test per Selection of Max 30% for Wearing Surface, Max 50%
Value / Aggregate Impact Source and repeat if for Work , AIV – Max.45 for Structural
14. Coarse Aggregate value change work and 30 for Wearing Coats
for structures 2. Soundness in sodium IS: 2386 Part 5 1 Test per source /Month Max 12%
Sulphate
[Link] Gravity (SSD) IS: 2386 Part 3 1 Test per source/Month --
[Link] Absorption IS: 2386 Part 3 1 Test per source/Month Max 2%
[Link] moisture IS: 2386 Part 3 2Test per Day ---
Content (free moisture)
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
[Link] of Course IS:2386 – Part1 1 Test for Source /Month Sieve % of Passing
Aggregate Size 40mm 20mm 12.5mm
63mm 100 -- --
40mm 95 – 100 100 --
20mm 30 – 70 95 – 100 100
12.5mm -- -- 90 – 100
10mm 10 - 35 25 – 55 40 – 85
4.75mm 0-5 0 - 10 0 - 10
[Link] requirement Visual Every Batch Clean, hard and free from deleterious
Inspection material except in traces
[Link] modulus of -- 1Test per Source /Month Min2.0 and Max 3.5
15 Sand / fine Fine Aggregate
Aggregate. For [Link] in IS:2386-Part 5 1 Test per Source Max 12% and 18% respectively
Structures Sodium Sulphate
Magnesium Sulphate
4. Deleterious
Constituents:
a) Coal and lignite IS: 2386 Part 2 1 Test per Source Max 1%
b) Clay lumps IS: 2386 Part 2 /Month 1 Test per Max 1%
c) Soft fragment IS: 2386 Part 2 Source /Month 1 Test Max 3%
d) Total of all -- per Source /Month 1 Max 5%
Deleterious Test per Source /Month
matters
[Link] Passing 75 IS:2386 Part 1 1 Test per Source /Month Max 3% (15%if crushed Aggregate)
micron
[Link] gravity (SSD) IS:2386 Part 3 1 Test per Source /Month --
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
7. Water Absorption IS: 2386 Part 3 1 Test per source/Month Max 2%

[Link] Moisture IS: 2386 Part 3 2 Test per day --

Content (free moisture)
[Link] Aggregate IS: 2386 Part 7 1 Test per Source Non - reactive
reactivity
[Link] Requirement IS: 2386 Part 1 1 Test per day Sieve % of Passing
Size Zone I Zone II Zone III
10 mm 100 100 100
4.75mm 90 – 100 90 – 100 90 – 100
2.36mm 60 – 95 75 – 100 85 – 100
1.18mm 30 – 70 55 – 90 75 – 100
600mic 15 – 34 35 – 90 60 – 79
300mic 5 – 20 8 – 39 12 – 40
150mic 0 - 10 0 - 10 0 - 10

16 Reinforcement Physical and chemical IS 1786- 2008 Sample test at source As per the Specification in IS 1786
Steel Properties of HYSD Bar IS 1608 After Confirming as Witnessed by IE
(Tested steel from IS 1599 original and main
original Producer for Selection of
Producers only) Source and change in
Source apart from third
party test. Each
Consignment to be tested
in external lab in addition
to MTC
SI. Type of Test Test Method Frequency(minimum) Acceptance Criteria
NO Construction
1. PH Value of Water PH Paper 1 Test per Source and Min 6
[Link] limit by IS:3025 Change in Source Max 25ml 0.02N NaOH to neutralize 100ml
17 Water for Titration Including seasonal Water
Concrete and [Link] limit by Titration IS:3025 Variations Max 5ml 0.02N NaOH to neutralize 100ml
mortar Water
[Link] in water IS: 3025 Maximum limits Per litre
Organic – 200mg: Inorganic – 3000mg
Sulphate – 400mg: Chloride – 500mg
Suspended matter 2000mg
18 Concrete Mix a) General requirement MoRT&H Throughout As Proposed in the Trial Mix Design report
Design Workability, Target Mean section-1700
Strength and finishing IS 456, IS
10262, IS 1199
& IS 516
Note: 1) Severe exposure conditions: Alternate wetting and drying due to sea spray: alternate wetting and drying Combined with freeing,buried in
soil having corrosive effect
2) Moderate exposure: other than serve Exposure

b) Mix design method IS: 10262 - 2019 All Cases Methodology as per IS Codes , but MOST
IS: SP 23 recommendations are binding
c) Cement content for PSC Mix Design Throughout PCC member Min 240 – Max 450 Kg/cum
bridge ir RCC bridges IS 456- 2000 RCC member Min 320 – Max 450 Kg/cum
exceeding 30 meter PSC member: Min 380 – Max 550 Kg/cum

d) Max Water /cement Mix Design Throughout Member Normal Severe

Ratio for PSC Bridges or Exposure exposure
RCC bridges exceeding 30 PCC members 0.45 0.45
Meter RCC members 0.45 0.40
PSC members 0.45 0.40
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
e) Minimum Strength of Mix Design Throughout Member Normal Severe
Concrete for Bridges other Exposure Exposure
than mentioned at above PCC member M15 M15
RCC M20 M20
members
F) Cement content for Mix Design -- Member Normal Severe
Concrete for small bridges, Exposure Exposure
culverts, other structures PCC MIN 240 Min 250
(Kg /Cum) Max 450 Max 450
RCC Min 300 Min 320
Max 450 Max 450

g) Max Water/Cement Mix Design Throughout Member Normal Severe

ratio for Concrete for Exposure Exposure
Bridges other Than PCC 0.50 0.45
mentioned at above. RCC 0.45 0.40
Culverts, other structures
h) Optimum Consistency IS:1199 Each Trial Mix a) PCC 25mm
by slump test b) RCC structures inclined exposed surface:
25mm
c) RCC with widely Spaced reinforcement:
40 – 50 mm
d) RCC with fairly congested
Reinforcement:75 - 125 mm
e) under Water Concreting
Through termie:150 –
200mm
i) Sampling of cubes for -- For each Mix. Set of 6 Total 6×3=18
each mix design Cube Per each of 3 batch
SI. Type of Test Test Method Frequency(minimum) Acceptance Criteria
NO Construction
j) Cube Strength (9cube on IS: 516 Each Trial Mix a) 7days strength: (for Preliminary
7th day & 9 cubes on 28th assessment only)
days b) 28 days strength: Average 9 cubes
shall exceed target means minus 3.5 MPa
k) Density of fresh IS:1199 Each trial mix Mean of 4 Compressive samples shall not
Concrete less than specified and any individual result
not less than 95% of specified.
19. Paving Bitumen As per table 1of of is IS:1203 Third Party test for As Specified in Table 73:2013
VG – 40 Grade 73:2013 IS:1205 selection of source and 2
IS:1208 test per lot to be tested in
addition to MTC
20. Crumb Rubber As Specified in Table 500 IS:1203 , Third Party test for As Specified in Table 500–46 of the
Modified – 46 of the MORT &H IRC: SP selection of source and 2 MORT &H Specifications.
Bitumen Specifications. 53 IS:1205 test per lot to be tested in
ASTM: D5976 addition to MTC
21. Prestressing [Link] Ducts IS:513 IRC 18 Sample test at source and per sec. 1800 of the MoRT&H ,IS:14268
Material [Link] strands Sec 1800 of the Third Party testing for As per drawing UTS not less than 183.7
breaking stress 2% Proof MORT&H Source and third Party N/mm²
Stress specifications testing for Each lot in
3. Anchorages BS:4447, addition to MTC
IS : 14268
22 RCC Home Pipes 1. Dimensions IS:458 Sample test at Source for As per table 3 of IS:458 based on nominal
2. Barrel thickness selection and testing for internal diameter of Pipes.
3. Three edge bearing each lot
test [Link] test
[Link]
[Link]
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
23 Concrete 1. Chloride Content As per IS 6925 Each lot/Batch Chl0ride Content < 0.2%
Admixture 2. Dry Material Content As Per IS 9103 Dry Material Content 3% of MTC
3. Ash Content Value Ash Content 1% of MTC Value
4. Relative density Relative density2%of MTC Value
Steel IS 1786 As per standards
PTFE As per standards
24 POT PTFE Coefficient of friction As per IS:226 & --
Bearing IS 2062
Thickness of friction As per BS 3784 --
As per Sample test at source for
MoRT&H 2006 selection and acceptable
5.4 testing for each lot before
Thickness of Cylinder delivery As per standards
Wall
Direct load As per 2.5% of the max. Dimension /12mm min
Combined Load IRC:83 1.25 Times of the design Vertical load
Rotation Load part-3 1.1 Times the design load
Friction Test As per design load
Tests on Welding As per Standards
Steel Hardness !20 BHN
1. Hardness Sample test at source for 63 + - shore A
25 Strip seal [Link] Strength Selection of source and Min 11 MPa
Expansion Joint [Link] at Fracture Third party testing for Min 3.5%
4. Tear propagation IRC:83 Part-2 each lot in addition to Min 10 N/mm²
Strength Longitudinal MTC
[Link] Min 10 N/mm²
[Link] elasticity Min 25%
[Link] Min 220mm²
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
9. Change in Hardness Max.+5 Shore A
10. Change in Tensile Max 20%
Strength
[Link] in Elongation Max 20%
12. Aging in Ozone No Cracks
[Link] Change Max 25%
[Link] in Hardness Max 20 Shore
[Link] Hardening point Min 35°c
[Link] Luminance AASHTO - Min 65%
M/249
26. Road Marking [Link] Time MORT&H 800- Not more than 15 Min
Paint 3
[Link] Resistance BS 6044 Not less than 45
[Link] Resistance ASTM D-36 Sample test at source and No cracks after concrete application
[Link] Point AASHTO – third party testing at 102 + - 9.5°C
M/249 NABL Accredited labs
[Link] resistance -- for selection of source Not more than 2.5%
7. Yellowness Index AASHTO – and MTC for each lot Not more than 0.12
M/249 and third party testing if
8. Gradation of glass beads MORT&H 800- doubt. Both Type 1&2 of MoRT&H - 800 - 4
4
9. Roundness of glass MORT&H 803- Min 70%
beads 4.3.3
10. Refractive index of MORT&H 803- Min 1.5
Glass Beads 4.3.3
11. Free flow Properties MORT&H 803- Shall be free from hard lumps and clusters
4.3.3
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
[Link] OPC – 33/43/53 IS:8112 One test per each lot As per the Grade of Cement
Grade IS: 269
27 Pavement Quality [Link]/Clay content & IS: 2386 Part- II One test per every Day Max 3%
Concrete Organic Matters & IV work
[Link] limit IS:2386 Part-1 One test per every Day --
work
[Link] absorption IS:2386 Part-III 1 test for source Max 2%

[Link] IS:2386 V One test per source and Max. 12

every Month

[Link] limit IS:2386 Part1 One Test per source and --

every Month
[Link] Angeles Abrasion IS: 2386 Part IV One Test per source and Max. 30%
Value every Month

[Link] Aggregate IS:2386 Part VII 1 test per source --

Reactivity
[Link] Water IS: 3025 One Test per source and --
every Month
10. Control of [Link] -- At regular close intervals 1550°c to 1630°c
plant
11. Cube / Beam Test for IS:516 One set of Test per 50 Flexural 4.5 and Cube 40 MPa
Concrete cum
[Link] of IS:1199 One test per 50 cum As per Requirement
Fresh Concrete
SI. Type of Test Test Method Frequency (minimum) Acceptance Criteria
NO Construction
Physical & Chemical IS 2062 Testing of External lab As per relevant IS codes
Properties of Steel Witnessed by IE for
28 Traffic Signs Plates and Supports IS:226 & approval of Source As per relevant IS codes
IS:2062 and
MTC for each lot
High Intensity retro IS:736 Sample test at source for AS per table 800 -1 MoRT&H
reflective sheets Selection of source and
third party test for each
lot in addition to MTC
Metal Beam Crash Barrier IS: 5986 Sample test at source for Ass per Relevant IS Codes
Selection and testing at
External lab witnessed by
IE in addition to MTC
Road Studs IS:617 Sample test at source for As per relevant is codes
selection and MTC for
each lot
Cement OPC – 33/43/53 IS:8112 / IS:269 One test per each lot
Grade
29 Dry lean Silt/clay content Organic IS:2386 ll & VI One test per everyday Max:3%
Concrete Matters Work
Grading limit IS: 2386 Part1 One test per every day
work
Grading limit IS: 2386 Part1 One test per every day
work
Specific Gravity IS:2386 III One test per source and
every Month
Cube Test for Concrete IS:516 One set of test per 150 Individual min. 7 and Avg .Min 10
cum
 10.0 SITE WORK NON-CONFORMING REPORTS &
PREVENTIVE ACTIONS.

The Quality ln-charge/QCE shall check the Day’s activity in random with the help of Approved work
method Statements & Checklists. If any Non-conformance work found then Quality charge will issue a
Site Non- Conformance Report -NCR to the concern site Engineer/ Site in Charge & the same shall be
conveyed to the Concern section In Charges as well as Independent Engineer. The NCR shall be received
by the concern site Engineer & shall give the required corrective action (which shall be acceptable as per
approved methodology) to ensure the product conformity. The concern site Engineer shall give the Target
Date for closing the NCR. The site NCR shall be closed by respective Quality ln• charge/QCE. The
NCRS shall be reviewed by QA/QC In charge along with Section In charge and Project Director.

Nature & Potential of the NCR shall be evaluated accordingly. The corrective action shall be set in the
Management Review Meetings.
METHODOLOGY FOR EXECUTION
OF KEY ITEMS OF WORKS.
 SUMMARY SHEET FOR METHOD STATEMENT FOR SITE
EXECUTION

Method Page
SI
Detail of method statement Statement Number
No.
Number

(A) SURVEY WORK

1 METHOD STATEMENT FOR SURVEY WORK 07
01
(Fixing of road alignment, Center line & Toe line)
(B) SITE CLEARANCE WORK & OGL WORK
2 OGL SAMPLING AND TESTING 02 09
METHOD STATEMENT FOR CLEARING AND
03 10
3 GRUBBING (Including cutting of tree and removal of
stamps)
(C) EARTH WORK
METHOD STATEMENT FOR EXCAVATION FOR ROAD 11
4 04
WORK IN SOIL
METHOD STATEMENT FOR EARTHWORK IN 13
5 05
EMBANKMENT(FILLING)
METHOD STATEMENT FOR EARTHWORK IN 15
6 06
SUBGRADE (FILLING)
METHOD STATEMENT FOR EARTHWORK IN 17
7 07
MEDIAN/ISLAND
METHOD STATEMENT FOR EARTHWORK IN WELL 19
8 08
FILLING
(D) BASE COURSE AND SUB-BASE
METHOD STATEMENT FOR GRANULAR SUB-BASE 22
9 09
CONSTRUCTION
METHOD STATEMENT FOR WET MIX 24
10 10
MACADAM/CRACK RELIEF LAYER CONSTRUCTION
METHOD STATEMENT FOR CEMENT TREATED 26
11 11
SUBBASE CONSTRUCTION
METHOD STATEMENT FOR CEMENT TREATED BASE 31
12 CONSTRUCTION 12

2
 BITUMINOUS COURSE AND RIGID
(E)
PAVEMENT
METHOD STATEMENT FOR PRIME COAT & TACK 36
13 13
COAT
METHOD STATEMENT FOR BITUMINOUS 38
14 14
CONSTRUCTION (BM, DBM, BC)
15 METHOD STATEMENT FOR DRY LEAN CONCRETE 15 41
16 METHOD STATEMENT FOR PAVEMENT QUALITY 44
16
CONCRETE
CULVERTS /MINOR & MAJOR BRIDGES &
(F)
ROB
METHOD STATEMENT FOR LAYOUT & BASE 50
17 PREPRATION FOR STRUCTURES 17
(CULVERTS/BRIDGES)
18 METHOD STATEMENT FOR PIPE CULVERTS 18 51
METHOD STATEMENT FOR FOUNDATION 54
19 19
EXCAVATION OF STRUCTURES IN SOIL
METHOD STATEMENT FOR FORMWORK, 57
20 REINFORCEMENT & CONCRETING IN STRUCTRAL 20
WORK
METHODOLOGY FOR CONSTRUCTION OF BOX 62
21 21
CULVERT
METHODOLOGY FOR CONSTRUCTION OF 66
22 22
MAJOR/MINOR BRIDGE
METHOD STATEMENT FOR BACK FILLING IN 71
23 23
STRUCTURES
METHODOLOGY FOR INSTALLATION OF 73
24 24
ELASTOMERIC BEARING
METHOD STATEMENT FOR PRESTRESSING OF I 75
25 25
CONCRETE GIRDERS
METHOD STATEMENT FOR ERECTION OF PRE-CAST 82
26 26
PSC/ RCC- I GIRDER & SLAB PANELS
METHODOLOGY FOR APPLICATION OF ASPHALT 87
27 27
SEAL ON CONCRETE BRIDGE DECKS

3
 METHODOLOGY FOR INSTALLATION OF STRIP SEAL 89
28 28
EXPANSION JOINTS
OTHER/MISCELLANIOUS ACIVITY
METHODOLOGY FOR CONSTRUCTION OF 91
29 29
REINFORCED EARTH WALL
METHOD STATEMENT FOR LAYING OF CEMENT 99
30 30
CONCRETE KERB
31 METHODOLOGY FOR MEDIAN FILLING 31 101
METHODOLOGY FOR KERB PAINT/OBJECT PAINT 103
32 32
/STRUCTURE CRASH BARRIER PAINT MARKING
33 METHODOLOGY FOR ROAD MARKING 33 108
110
34 METHOD STATEMENT FOR TRENCH FILLING 34
METHODOLOGY FOR TURFING WITH SODS ON 111
35 35
EMBANKMENT SLOPES
METHODOLOGY FOR STONE PITCHING / 113
36 36
REVETMENT ON SLOPES
37 METHODOLOGY FOR REINFORCEMENT WELDING 37 115
METHODOLOGY FOR CONSTRUCTION OF BORED 117
38 38
CAST IN SITU PILES
METHODOLOGY FOR HIGH STRAIN DYNAMIC LOAD 120
39 39
TEST ON PILES

40 METHODOLOGY FOR LOAD TEST ON BRIDGE 124

40
METHODOLOGY FOR MEASUREMENT OF SURFACE 127
41 UNEVENNESS BY AUTOMATIC ROAD UNEVENNESS 41
RECORDER
METHODOLOGY FOR FINISHING OF SUB 130
42 42
STRUCTURES
43 132
43 METHOD STATEMENT FOR ROAD SIGNS

TESTING PROCEDURES FOR SOIL

44 FREE SWELL INDEX 44 134
45 GRAIN SIZE ANALYSIS 45 135

46 ATTERBERG LIMITS (Casagranda Apparatus) 46 136

47 ATTERBERG LIMITS (Cone Penetrometer Apparatus) 47 137

48 PROCTOR COMPACTION TEST (MDD/OMC) 48 139

4
49 CALIFORNIA BEARING RATIO TEST (C.B.R) 49 141
FIELD DRY DENSITY BY SAND REPLACEMENT 143
50 50
METHOD
DETERMINATION WATER CONTENT 144
51 51
(By Rapid Moisture Meter (Alternative)
TESTING PROCEDURES FOR AGGREGATE
52 AGGREGATE IMPACT VALUE TEST 52 145

53 FLAKINESS & ELONGATION INDEX 53 146

SPECIFIC GRAVITY AND WATER ABSORPTION OF 147
54 54
COARSE AGGREGATE
SPECIFIC GRAVITY AND WATER ABSORPTION OF 148
55 55
FINE AGGREGATE
TESTING PROCEDURES FOR CEMENT
56 FINENESS BY DRY SIEVING 56 149

57 CONSISTENCY OF STANDARD CEMENT PASTE 57 150

58 SOUNDNESS OF CEMENT 58 151

59 INITIAL AND FINAL SETTING TIME OF CEMENT 59 152

60 COMPRESSIVE STRENGTH OF CEMENT 60 153

TESTING PROCEDURES FOR CONCRETE

61 SLUMP TEST OF CONCRETE 61 154

62 COMPRESSIVE STRENGTH OF CONCRETE 62 155

63 FLEXURAL STRENGTH OF CONCRETE 63 156

TESTING PROCEDURES FOR BITUMEN

64 PENTRATION TEST 64 158

65 SOFTNING POINT TEST 65 160

66 DUCTILITY TEST 66 161

67 ABSOLUTE VISCOSITY TEST 67 162

68 KINEMATIC VISCOSITY TEST 68 164

69 BINDER CONTENT OF PAVING MIXTURES 69 166

70 MARSHAL STABILITY AND FLOW 70 167

5
 METHOD STATEMENT FOR SURVEY WORK -01

(Fixing of road alignment, Center line & Toe line)

1. Scope:
 To provide permanent grid lines and construct working benchmarks for level control and road alignment.

2. Reference
 MORT & H Clause No: 109 and technical specifications of the project.

3. Equipments:
 Auto level, Levelling staff, total station etc.

4. Tools:
 Measuring tape, pegs, Nails, Paint Tins, Safety cones, safety board etc.

5. Procedure:
 The Project Reference centre line of proposed cross section will fix by surveyor and marked on ground
by either pegs/chainage boards or by suitable means at site for ready reference. This marking shall be
done @ 50m interval on straight portion & 20m interval on curve portion.
 TBM shall be fixed at every 250m on ROW line. The pillar shall be 150*150*750 mm in square or
150mm dia in case of round shape with a steel rod embedded in it. The pillar shall be established on hard
ground and concreted with M15 Grade.
 Reduced levels shall be established on the marked pillars and closed at every GPS and abstract copy of
TBM list shall be distributed to Section In charge at every month.
 Field notes shall be kept in standard, bound field books as approved by the engineer.
6. Safety Precautions:
 Do not aim the telescope at the sun it will damage the EDM of the instrument.
 Never place the instrument directly on the ground it will damage the instrument bottom.
 Never carry the instruments along with stand from one station to another station.
 Avoid heavy shocks and vibrations.
 Remove the battery before keeping the instrument in the box.
 Never keep wet instrument inside the box, allow it to dry before that.
 Before removing the instrument from the case see the lay out position to keep back the instrument in
same position.

6
 Calibration shall be carried out internally at every 6 months for auto levels and every year for total
stations.
 All staff and workmen shall wear reflective jackets, PPEs at work area.
 Minimum No of cones, “Men at work” board shall be used for survey work on road.
 All staff and workmen shall not use mobile phones while moving on road.

7
 METHOD STATEMENT FOR COLLECTION OF OGL-02 (ORIGINAL
GROUND LEVEL) SOIL STRATA SAMPLES
1. Scope:
 The work shall consists of removing of all materials up to 150mm of top soil and collecting samples of
existing ground strata (Soil etc) up to 500 mm in depth from OGL.
2. References:
 MORT & H specification of clause No: 305 & ITP.
3. Equipments:
 Excavator may use, etc.
4. Tools:
 Measuring Tape, Crow bar, spade, line rope etc.
5. Procedure:
 Location will take at every 250m interval by means of zigzag in LHS & RHS (Figure attached) way at the
offset of approximate 3 to 5 meter from toe line of existing embankment.
 First top layer of 150mm thickness will be removed by means of manual for stripping of soil and then
sample will be collected in between 150mm to 500mm from OGL. (Figure attached)
 After sample collection pit will be refilled with the same excavated material.
 Raised the RFI for collection of sample.
6. Safety Measures:
 Care shall be taken while removing topsoil.
 The cutting material shall not disturb the live traffic
 The cutting crew shall wear PPE‟s, reflective jackets
 The cutting area shall be protected with cones during the work.
 Take care of nearby passing electrical lines and utilities.

8
 METHOD STATEMENT FOR CLEARING AND GRUBBING – 03
(Including cutting of tree and removal of stamps)
1. Scope:
 The work shall consists of cutting, removing, and disposing of all materials such as trees up to 300mm in
Girth, bushes, shrubs, stumps, roots, grass, weeds, rubbish, top organic soil, etc to an average depth of 150
mm. It shall include necessary excavation; back filling of pits resulting from uprooting of trees and stumps
to required compaction, handling, salvaging and disposal of cleared material with all leads and lift.
2. References:
 MORT & H specification of clause No: 201, Technical specification of contract.
3. Equipments:
 Dozer, backhoe, dumpers, etc.
4. Tools:
 Measuring Tape, Crowbar, spade, line rope etc.
5. Procedure:
 By using suitable tools and machinery cut the trees manually or
mechanically, Whatever may be the trees coming in to the layout of the
construction.
 Trees and stumps shall be disposed by approved manner and place.
 Clearing and grubbing process shall be followed after disposal of material using dozer.
 Dozing shall be done to the maximum thickness up to 150mm.
 Unwanted material after dozing shall be disposed.
 Raised RFI for checking for C&G.
6. Safety Measures:
 Care shall be taken while cutting the trees
 The cutting material shall not disturb the live traffic
 The cutting crew shall wear PPE‟s, reflective jackets
 The cutting area shall be protected with safety boards and cones
 Take care of nearby passing electrical lines and utilities.
 Flagmen shall be provided on both side of cutting area to regulate live traffic

9
 METHOD STATEMENT FOR EXCAVATION OF ROAD IN SOIL - 04
1. Scope:
 This work shall consist of excavation, removal and disposal of material by mechanical means in all types of
strata, including dressing to final line, level, grades, cross section as shown in drawings for roadway, side
drains, shoulders, median and foundation for structures, including hauling suitable excavated materials to
site for embankment and sub-grade construction, also disposal of unsuitable cut materials in specified
manner with all leads and lifts.
2. References:
 MoRT&H specifications clause No: 301 to 304 and technical specification of Contract.
3. Equipments:
 Excavators, Dumpers, Dewatering arrangement.
4. Tools:
 Line rope, lime powder, pegs etc.
5. Procedure:-
General:
 The excavation shall be set out true to lines, curves, grades and sections as per drawings.
 In works involving MCW shall be excavated to the full width and to the required levels, after satisfying
CBR and density requirement, as shown in drawings without disturbing. After reaching to the required
depth, it shall be compacted at OMC to achieve a minimum of 95% of MDD.
 In structure works involving excavation for structures to construct foundations, for bridges, culverts,
retaining walls, etc., shall be excavated to required depth or level as shown in drawings but excavation is
not done outside the limit of excavation. Where the nature of soil, depth of trench, season does not permits
vertical sides, excavation shall be done with necessary shoring, strutting, planking or cut to slopes with safe
angles with due regard to the safety of personnel and works.
 Excavated soil shall be tested for its suitability and shall be used as per requirement.
 All debris and loose material on the slopes of cuttings shall be removed. No backfilling shall be allowed to
obtain required slopes excepting that when boulders or soft materials are encountered in cut slopes. These
shall be excavated to approved depth on instructions of engineer and the resulting cavities filled with
suitable material and thoroughly compacted in an appropriate manner.
 While executing excavation all adequate precautions of soil erosion, water pollution etc. shall be taken and
appropriate drainage measures to keep the site free of water shall be taken.
 The suitable material obtained from excavation shall be used for filling of roadway embankment, filling of
existing pits in the ROW, landscaping etc. All other unsuitable and surplus materials shall be disposed off
from site.
 RFI raised for checking of levels & foundation.
6. SAFETY requirements:

10
 The area shall be restricted from public entrance.
 All trucks shall be provided with reverse horns/lights.
 Wherever required, Flagman shall be provided.
 During night work sufficient lighting shall be provided.
 The excavated pits shall be properly barricaded.
 Proper access shall be provided to go down to pit excavated for structures.
 Road working area shall be demarcated using Sand bags.
 All workmen at work area shall wear PPE‟s and reflective jackets.

11
 METHOD STATEMENT FOR EARTHWORK IN EMBANKMENT
(FILLING) - 05
1. Scope:
 This work shall consists construction of embankments with approved material obtained from approved
source, including material from roadway and drain excavation.
2. References:
 MoRT&H Specifications, Clause no: 305, Technical specifications of Contract, Relevant IRC, IS Codes.
3. Equipments:
 Excavator/ Back hoe, Dozer, Motor Grader, Dumpers, Vibratory roller, Water tanker, Auto Level,
measuring tape.
4. Tools:
 Hammer, crow bar, spade, strings, pegs, lime powder, etc.
5. Materials:
 The material used in embankment shall be soil, moorum, gravel, fly ash, pond ash and such materials shall
be free from logs, stumps, roots, rubbish or any other ingredients likely to affect the stability of the
embankment. The material that have LL less than 50%,PI less than 25%,Free Swell Index Less than 50%
,shall be used for Embankment construction. The material which is having lab MDD as per table no 300-1
for filling in Embankment shall be used. The sample from the barrow areas shall be brought to the
laboratory and tested for the above requirements.
6. Procedure:
 Before commencing the earth work the Toe limits of Embankment shall be marked.
 The original ground shall be levelled, scarified, mixed with water and compacted to achieve 95 % of lab
MDD. When the soil of the original ground for embankment is not suitable as per clause No: 305.2.1 of
MORTH, 500mm of such material must be removed and replaced by acceptable fill material. and
compacted in layers as identified in trial stretch, to achieve 95% of MDD.
 The materials for the Embankment shall be excavated at borrow areas by excavators and hauled to site by
dumpers.
 The dumped material shall be spread in uniform thickness by means
of Graders/mechanical means to achieve specified slopes, grades and
Compacted layer of 200mm.
 Clods and hard lumps of earth will be broken to a maximum size of 75 mm for embankment.
 If the moisture content (NMC) is less than OMC, the water shall be added above 1% to 2% below by
sprinkling considering evaporation losses.
 If NMC is more than OMC, the material can be allowed to dry by exposure to the sun.

12
  The compaction shall be done with a vibratory roller of 8.0 – 15.0 tons static weight to achieve 95 % of
MDD.
 The rolling shall commence from lower edge and proceeded towards upper edge.
 Each pass of roller shall overlap 1/3rd of the preceding pass.
 Level checks for top layer of embankment shall be recorded in the field books.
7. Acceptance Criteria:
 Field Dry Density Shall be greater than 95% of MDD
 Layer thickness tolerance shall be +/-25mm
 Optimum moisture content shall be +1 to -2%.
8. Safety requirements:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour if being used in the job for surveying shall be screened and trained.
 During night work sufficient lighting shall be provided.
 All workmen at work area shall wear PPE‟s and reflective jackets
 Mobile phones shall not be used, near and while operating the equipment‟s.

13
METHOD STATEMENT FOR EARTHWORK IN SUBGRADE (FILLING) -
06
1. Scope:
This work shall consist construction of subgrades, earthen shoulders and miscellaneous backfills with approved
material obtained from approved source, including material from roadway and drain excavation
2. References:
 MoRT&H Specifications, Clause no: 305, Technical specifications of Contract.
 Relevant IRC & IS Codes
3. Equipments:
 Excavator/ Back hoe, Dozer, Motor Grader, Dumpers, Soil compactor, Water tanker,
 Auto Level.
4. Tools:
 Hammer, crow bar, spade, line rope, pegs, lime powder, measuring tape, etc.
5. Materials:
 These materials shall be free from logs, stumps, roots, rubbish or any other ingredients likely to affect the
stability of the Subgrade. The material that have LL less than 50%,PI less than 25%,Free Swell Index Less
than 50% ,shall be used for Subgrade construction. The material which is having Lab MDD of min.
17.5KN/cum and CBR Value shall be as per design for filling in Subgrade shall be used. The sample from
the barrow areas shall be brought to the laboratory and tested for the above requirements.
6. Procedure:
 Before commencement, Toe width of sub-grade shall be marked.
 The approved Borrow area / Cut section material as per MORT&H clause 305.2.1 is brought on the stretch.
 The dumped material shall be spread in uniform thickness by means of graders/mechanical means to
achieve specified slopes and grades.
 The dumped material shall be spread in uniform thickness by means of graders/mechanical means to
achieve specified slopes and grades.
 Clods and hard lumps of earth will be broken to a maximum size of 50 mm for subgrade.
 The stretch is to be watered with required quantity of water to bring from natural moisture content of
material to optimum moisture content by sprinkling of water with water tanker uniformly at control rate of
flow.
 If the moisture content (NMC) is less than OMC, the water shall be added above 1% to 2% by sprinkling
considering evaporation losses.
 If NMC is more than OMC, the material can be allowed to dry by exposure to the sun.

14
  Each layer of the material shall be thoroughly compacted to 97% of MDD by a vibratory roller having a
static weight of 8-15 tons and compacted each layer thickness of 200mm maximum shall be executed as per
level.
 Rolling shall be commenced from the lower edge and proceeded towards the upper edge. Each pass of
roller shall overlap 1/3rd of the preceding pass.
 After rolling & level checking for specific layer, tests shall be carried out to check its degree of compaction
by any suitable method and the results are recorded in the format.
 Level check for top layer of sub grade shall be recorded in the field books.
7. Acceptance Criteria:
 Field Dry Density Shall be greater than 97% of MDD
 Layer thickness tolerance shall be -20mm to +20mm
 Optimum moisture content shall be +1% to -2%.
8. Safety requirements:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided.
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour if being used in the job for surveying shall be screened and trained.
 During night work sufficient lighting shall be provided.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 Mobile phones shall not be used, near and while operating the equipments.

15
 METHOD STATEMENT FOR MEDIAN & ISLAND FILLING - 07
1. Scope:
 This work shall consist constructing of median in the road dividing the carriage way in to separate lanes to
channelize the traffic in accordance with the lines, grades and cross sections shown on the drawings.

2. Reference:

 Section 408 of MoRT&H specification.

3. Equipments:
 Dumpers, Motor grader/Loader, Roller/Plate compactor, Wooden Rammer, and Water tanker
4. Materials:
 The materials used in the median and island shall be soil, moorum, gravel, recycled material, a mixture of
these or any other suitable material approved by the engineer. Such materials shall be free of logs, stumps,
roots or any other materials likely to deteriorate the stability of the median.
 The materials shall satisfy the Physical and chemical requirements as per MoRT&H Clause No: [Link],
[Link], and [Link].
5. Procedure:
 Unwanted plants, roots, boulders, concrete and bituminous material shall be removed and got checked by
raising RFI prior to start of median filling.
 Place/Dump the approved borrow material or any other suitable material approved by the engineer in the
median by dumpers. In case of Existing road in used after ensuring road safety by placing barricades 50m
before the spot with adequate information sign boards and markings.
 Care shall be taken to avoid spilling of soil over adjacent pavement while dumping.
 Soil shall be spread in uniform layers of 200mm using motor grader, Dozer, loader or manually as per the
site condition. Water shall be added to the material to achieve the moisture content in the range of +1 % to -
2% of OMC before rolling takes place.
 Compaction shall be done with 8-10 Ton roller in 4.5m median where as in 2.5m median compaction shall
be done with 2.5 ton roller or plate compactor for 1.2 m median.
 The top most layers shall be compacted lightly in order to facilitate sufficient growth of roots of grass and
plants/shrubs.
 The filling shall be raised centrally by 3% on either side for easy flow of rainwater to the adjacent pavement
and avoid any water logging in median.
 Raise the RFI for checking of Median/Island.

6. Safety Precautions:

16
 All dumpers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided.
 The speed of construction vehicles plying in stretch shall be restricted to 30kmph. Any labour, if being used
in the job shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 Median filling work shall not disturb the live traffic.

17
 METHOD STATEMENT FOR EARTHWORK IN WELL
FILLING - 08
Scope:
This work consists of
 Removal and disposal of all unsuitable and obstructingmaterial.
 Demolition of well lining, placing of selected material in layers and compaction of the same.
This methodology is applicable for open wells with size < 6m dia over which roadembankment would be
built.
.
Reference:
 MoRTH – Specifications for Road and Bridge Works ( Fifth Revision).

Definitions :
Abbreviations
 NHAI : National Highway Authority of India.

 M.D.D : Maximum Dry Density.

 O.M.C. : Optimum Moisture Content.

 HAM : Hybrid Annuity Mode.

CLASSIFICATION OF WELLS:-
The open wells will be classified as
 Lined
 Unlined.
The casing / Lining of wells may be of masonry, burnt clay, concrete rings or any other type.

MATERIALS:-.

 The fill material shall be non-compressible type and free from any hazardous material/sewage.

 The fill material is as given in thetable.

 The size of coarse material in soil not exceeds 25mm and incase of sand and gravel mixture, the
maximum size not more than 75mm.

 The selected material (Soil and sand-gravel mixtures) shall have MDD as per IS:2720,part 8)not less
than 16.0kN/m3 .The Sand-Gravel mix shall be as per sub clause 2504.

18
 1 Well with standing Water  Mixture of Sand And Gravel(80:20) up to
1.5m height below natural groundlevel.

 The Selected granular soil with plasticity

Index (PI) <6 for the remaining depth
ofwell.

 Toachievedesiredcompactionthetop1.5mshall
be executed by lowering the standing water
level by more than 1.5m below natural ground
level.

Dry Well with Depth  Mixtureofsandandgravelupto1.5mheight

below natural groundlevel.
2
 Theselectedgranularsoilwithplasticity
Index (PI)<6 for there maining depth of
well.

3
Well size less than 1m  Mixture of natural sand andgravel
diameter

CONSTRUCTION OPERATION:-
 All the debris such as pump, metal wires, rods, etc., and floating material will be removed
 In case of lined wells the lining shall be dismantled up to the level of natural ground level or one meter in
height whichever is higher.
 Upper 1m of well casing /lining shall be removed when the fill material within 1m of the existing
groundsurface.
 Stagnated water shall be treated by adding Chlorine bleach @ 5lit /2500 liters of standing water.
 Inspection of the well after the above steps are completed shall be done before filling operation.
 The placing and compaction of operation will be done as per Clause A-10,4d(I tov)
 The layer so compacted is inspected to carryout next layer for placing andcompaction.
 The details of construction operation is explained in the Flow Chartattached.

19
FLOW CHART FOR FILLING OF OPEN WELLS AS PER
TECHNICAL SPECIFICATIONS

Treat the stagnated water

NO
Inspecied and cleaned for
filling by Engineer‟s
Representative

YES

Blend the Sand–Gravel and Test the conformly

NO

Sand-Gravel Mix
acceptable

YES
Fill the material in layers of 500mm as specified
And compact

NO
The compacted layer
accepted

YES
Proceed With the next layer and repeat the filling
all 1.5m below natural around

Fill granular Soil (PI<6) in layer of 500mm to

the normal ground level.

20
 METHOD STATEMENT FOR CONSTRUCTION
OF GRANULAR SUBBASE COURSE - 09
1.
Scope:

 This work shall consist of laying and compacting well graded material on prepared subgrade in accordance
with the requirement of MoRT&H Specifications, Clause no: 401 and with approved materials from either
crushed GSB .
2. References:
 MoRT&H Specifications, Clause no: 401, Technical specifications of Contract with grade-5.
 Relevant IS & IRC Codes.
3. Equipments:
 Excavator/ Back hoe, Dozer, Motor Grader, Dumpers, Vibratory roller, Water tanker, Auto Level.
4. Tools:
 Hammer, crow bar, spade, line rope, pegs, and lime powder, measuring tape, etc.
5. Materials:
 The crushed material to be used for the work shall be natural sand, morum, gravel, crushed stone, or
combination thereof depending upon the grading required. The material shall have a 10% fines value of
50KN or more (for sample in soaked condition
6. Procedure:
 Before commencement, Toe width of GSB shall be marked
 The material shall be brought from borrow area, and the deficient material if any shall be added at site to
satisfy table 400-1 Grading- 5 requirement of MORTH Rev. 4.
 GSB layer shall be constructed on the sub grade top layer, which is already constructed as per MORT&H
clause 305.
 Calculated quantity of GSB material shall be placed on the entire bed. If any segregation is observed, the
same is rectified by processing with the help of grader blade. GSB material gradation shall be checked at
QC lab.
 Material shall be spread uniformly with the help of motor grader where each layer should not exceeds 250
mm in compacted thickness.
 Required amount of water will be sprinkled, calculation based on OMC (+1% to 2% tolerance limits).
 Final grading shall be done carefully as per required slope and level without segregation.
 The graded material shall be thoroughly compacted to the specified densities by a vibratory roller having a
static weight of 8-10 tons.
 Rolling shall be commenced at the lower edge and proceeded towards the upper edge longitudinally with
overlapping of one third of roller drum width for each passes for areas of unidirectional cross fall (camber)

21
and super elevation.

22
  The number of heavy vibratory passes shall be established after doing trial stretch to achieve required
density.
 All the depressions, high spots, segregated locations shall be made correct during initial rolling itself.
 Camber shall be checked and corrected if required before final rolling.
 Finally one plain pass shall be given on the entire length of the stretch.
 Speed of the roller shall be maintained uniformly (not exceeding 5km/hr.) during rolling.
 After rolling compaction test shall be carried out to check its degree of compaction by any suitable method.
 Levels shall be checked and recorded in the Level Book for the top layer.
 RFI will be raised for checking of compaction & level.
7. Acceptance criteria:
 The Field Dry density shall be more than 98% of MDD
 The tolerance on the surface level shall be +-10mm.
8. Safety Requirements:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.
 Mobile phones shall not be used, near and while operating the equipment‟s.

23
 METHODOLOGY FOR CONSTRUCTION OF AIL/AGGREGATE INTER
LAYER - 10
1. Scope:
 This work consist of laying and compacting clean, crushed, graded aggregate and granular material
premixed with water on prepared granular sub-base for flexible pavement.
2. References:
 MORT&H specifications Clause No 406 and technical specifications of contract.
3. Equipments:
 Paver, Motor grader, Dumpers, Vibratory roller, water tanker, Auto level,
4. Tools:
 Measuring Tape ,Line rope, lime powder, pegs, String wire etc…
5. Materials:
 The aggregate shall be produced from the multiple stage crushing and screening plant.
Physical requirements:
 The aggregate blend for WMM for roads shall confirm to grading requirements mentioned in table 400-13
in MoRTH specification. The material to be used shall have Los Angeles abrasion value not more than 40%
or aggregate impact value not more than 30%, combined flakiness and elongation Indices not more than
35%, PI value not more than 6%.
6. Procedure:
 Wet Mix Macadam shall be prepared, as per the approved design proportion, in the Pug mill plant with
controlled addition of water.
 Gradation of the mix shall be checked as the production starts for the day at the site laboratory itself.
 Generally 1.0 to 2% extra moisture shall be maintained in the mix to compensate the evaporation losses
depending up on lead and season.
 Mix shall be transported from the plant to the laying site by dumpers.
 Water shall be sprinkled on the entire GSB surface, before placing the WMM.
 Before laying and spreading of material, the shoulder on both sides shall be constructed in advance. This
will laterally confine the wet mix macadam while compacting.
 The wet mix shall be spread uniformly and evenly upon the prepared granular sub-base by a paver finisher /
motor grader.
 The required camber, grade, and thickness shall be checked. The high and low spots are to be rectified by
removing or adding new material.
 The number of heavy vibratory passes shall be established after doing trial stretch to achieve required
density.

24
  Vibratory pass shall overlap 1/3 of preceding pass, and make sure the speed of the roller shall not exceed
5km/hr. The places not accessible to roller shall be compacted with mechanical tampers or by a plate
compactor
 All the depressions and segregated portions if any will be rectified during initial rolling itself.
 After the rolling is completed the stretch is to be tested for degree of compaction with respect to MDD of
design mix of WMM.
 Field compaction test shall be conducted as per MORTH clause No. 406.3.5.
 Surface levels will be maintained as per table no. 900-1, and recorded in the specified format.
 All the Field density readings / results will be recorded in the specified format.
 Any rectification in WMM layer will be done after scarifying the layer for proper bonding.
 RFI will be raised for checking of field density and top layer level checking.
7. Safety Requirements:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.

25
 METHODOLOGY FOR CONSTRUCTION OF
CEMENT TREATED SUB BASE - 11
Description:

The work shall consist of construction of Cement treated sub-base (CTSB) pavement in accordance with the

requirements of MoRT&H clause 403 Specifications and in conformity with the lines, grades and cross-

sections shown on the drawings or as directed by the Engineer and after appropriate trail(s) on a previously

prepared and approved Sub grade. The work shall include furnishing of all plant equipment materials, labor

and performing all operations, in connection with the work, as approved by the Engineer.

Materials:

 Cement :
a) OPC 43 & 53 Grade conforming to IS 269 - 2015,
 All in Aggregate:
 The aggregates shall be Conforming IRC SP - 89.
 Water : Conforming to IS: 456 and MoRT&H Clause 403.2.7.

Equipment’s:

 Pug mill Plant

 Hydraulic grader or Paver

 Vibratory Roller minimum 80Kn - 100 KN static weights

 Water Tanker

 Tippers.

Weather Limitation:

Stabilization shall not be done when the air temperature shade is the less than 10 degree centigrade.

Mix Design of Cement Treated Sub Base (CTSB)

 Physical testing of aggregate, cement, water.
 Selection of Proportion of Material All in Aggregate 97.5 % and Cement 2.5 % to form CTSB is done
with as per MoRTH table 400-4.
 Gradation of final CTSB is done and compared with MoRTH table 400-4.

26
  Modified Proctor test is done to determine Max Dry Density (MDD) and Optimum Moisture Content
(OMC) of CTSB with min. cement content according to IS 2720 (Part 8).
 Find Liquid Limit, Plastic Limit and Plasticity Index according to IS 2720 (part 5).
 Plasticity Modulus and Product are determined according to IS 2720 (part 5).
 Find Uniformity Coefficient as specified.
 Cubes are casted with the help of Vibro Hammer.
 Cubes are cured for 7 days and its 7 days Unconfined Compressive Strength (UCS) is measured With
the help of Compressive Testing Machine
Preparation of Mix
Approved job mix of CTSB mix will be prepared in a mechanized Pug mill Mechanical Plant
calibrated. While mixing, moisture content shall not be less than the Optimum moisture content and
no more than 2% above it. The capacity of the batching /Pug mill plant shall be at least 25% higher
than the proposed capacity of the laying arrangements.

Trial length:

A trial length of 60 mtr shall be made for the 5.25 mtr width of the pavement and rolled, by involving
at least on transverse construction joint involving Stabilized mix and fresh laid mix. The in-situ
density of the freshly laid concrete shall be determined by sand replacement method with 200 mm
dia density cone, by making 3 density holes at equal distances that diagonally bisects the trial length,
these shall not be made in the strip of 500 mm from the edges. The average of these shall be
considered as 100%, and with this the field density of the regular work shall be compared. The
hardened concrete may be cut for 3m width in the trial length and reversed to check the bottom
surface for any segregation or honey- combing, if found necessary adjustments shall be made in the
mix design.
Transportation and placing
The Stabilized mix shall be transported by sufficient number of tipping trucks to ensure continuous,
uniform supply of mix to feed the laying equipment. The mix shall be protected from the weather, by
covering the tippers/dumpers with tarpaulin during the transit. The CTSB Material shall be laid to
the required widths, grades, camber and thickness with Motor Grader or Paver. The equipment shall
be capable of laying the materials in an even manner without segregation, to the specified thickness
after the compaction.

27
Compaction:

The compaction shall commence as soon as the Material laid and leveled to the full width till
there is no further movement under the roller and the surface is closed. Vibratory rollers of 80-
100kN static weight shall be used for this purpose. Rolling shall commence at edge and progress
towards the center, except at super elevated portion of the carriageway with unidirectional closs -
fall where it shall commence at the inner edge and progress towards the outer edge. During
rolling, the surface shall frequently checked for grade and cross fall (Camber) and any irregularity
corrected by loose the material and removing/adding fresh material, In addition to the number of
passes required for compaction, there shall be a pass without vibration as preliminary pass and
another at the end as final pass. The minimum dry density obtained shall be 98% of the maximum
dry density.
No traffic of any kind shall ply over the completed sub- base for 7 days or unless permitted by the
Engineer.
, j
Curing:

The cemented sub-base shall be cured for a minimum of three days before the construction of the
next layer. In case sufficient strength of cementitious sub-base is not achieved as per the requirement
of IRC:SP:89(28)in 3 days of Curing ,7days curing shall be done for Sub-base before the
Construction of the upper layer can be started.

Data & Its Analysis:

Unconfined Compressive Strength Tests (UCS)

As per the Clause 403.2.6 of MoRTH the quantity of cement added shall not be less than 2% by
weight of the dry soil. The design mix shall be done on the basis of 7 day unconfined compressive
strength (UCS) and/or durability test prepare two identical set (containing 3 specimens each) of UCS
specimen which are cured in a normal manner at constant moisture content for 7 days. At the end of
7 days period one set is immersed in water while the other set is continued to cure at constant
moisture content. When both sets are 14 days old they are tested for UCS. The strength of the set
immersed in water as a percentage of the strength of set cured at constant moisture content is
calculated. This index is a measure of the resistance to the effect of water on strength. If this value is
lower than 80 percent it is considered that stabilizer content is low and its value should be increased.

28
 Sieve Analysis of CTSB as per MoRT&H Table 400-1 Grading IV

IS Sieve (mm) 53 26.5 4.75 0.075

Specification Limit
Percentage by wt. passing 100 50-80 15-35 <5

Physical Properties:

TEST Results SPECIFIED LIMIT

Maximum dry density (MDD) gm/cc --- Not Specified
Optimum Moisture contents (OMC)
% --- Not Specified

Construction Methodology:

TEST RESULTS SPECIFIED LIMIT

Liquid Limit --- Max. 25 %
Plasticity Index --- Max. 6 %
Uniformity Coefficient --- >10
Water absorption --- Max. 2 %
Aggregate Impact Value --- Max. 40 %
7 Days Uncon fined
Compressive Strength (UCS) as per 150mm Cube
IRC 37 & IRC SP 89 (CTSB)

 Routine testing to be carried out as stipulated with in MORT& H Clause 900-3 and reduced to
acceptable levels during continuous production from established stockpiles reference aggregates
properties.
 Quality Control tests for Cement shall be done for every Consignment/ every Week.
 Cement content- Regularly, through procedural checks
 Unconfined compressive strength: One set of three cubes per required
 Moisture content & Density of compacted Layer: One test per 500 m2

Safety precautions:

 All tippers‟ tankers shall be provided with reverse horns.

 Flagman shall be provided at all exit points of the trucks / tippers.
 The speed of vehicles plying in the work area shall be restricted to 40 kmph maximum.
 Night work is to be carried out the area shall be sufficiently provided with lighting.
 The tipplers when being positioned in front of the Mortar grader shall be move very slowly as per the

29
 Directions given by the supervisor or by the helper provided.
 Check for the working condition of safety valves of air compressors, if compressed air is being used for
cleaning.

30
 METHODOLOGY FOR CONSTRUCTION OF
CEMENT TREATED BASE - 12
Description:

The work shall consist of construction of Cement treated base (CTB) pavement in accordance with
the requirements of MoRT&H clause 403 Specifications and in conformity with the lines, grades and
cross-sections shown on the drawings or as directed by the Engineer and after appropriate trail(s) on
a previously prepared and approved CTSB. The work shall include furnishing of all plant equipment
materials, labour and performing all operations, in connection with the work, as approved by the
Engineer.

Materials:

 Cement :
b) OPC 43 & 53 Grade conforming to IS 269 - 2015,

 All in Aggregate:
 The aggregates shall be Conforming IRC SP - 89.
 Water : Conforming to IS: 456 and MoRT&H Clause 403.2.7.

Equipment’s:

 Pug mill Plant

 Hydraulic grader or Paver

 Vibratory Roller minimum 80Kn - 100 KN static weights

 Water Tanker

 Tippers

Weather Limitation:

Stabilization shall not be done when the air temperature shade is the less than 10 degree centigrade.

Mix Design of Cement Treated Base (CTB)

 Physical and chemical testing of aggregate, cement, water

 Proportion of all in aggregate 96 % and cement 4 % to form CTB is done as per MoRTH table 400-4
 Sieve Analysis of final CTB is done and compared with MoRTH table 400-4
 Modified Proctor test is done to determine Max. Dry Density (MDD) and Optimum Moisture Content

31
 (OMC) of CTB with min. cement content according to IS 2720 (Part 8)
 Find Liquid Limit, Plastic Limit and Plasticity Index according to IS 2720 (part 5)
 Find Uniformity Coefficient as specified
 Water absorption of material is found out according to IS 2386 (part 3)
 Cubes are casted with the help of Vibro Hammer
 Cubes are cured for 7 days, and its Strength is measured with the help of Compressive Testing
Machine
 If all results are found within limits as specified, then Design of CTB material is finalized

Preparation of Mix
 Approved job mix of CTB mix will be prepared in a mechanized Pug mill Mechanical Plant
calibrated. While mixing, moisture content shall not be less than the Optimum moisture content and
no more than 2% above it. The capacity of the batching/Pug mill plant shall be at least 25% higher
than the proposed capacity of the laying arrangements.

 Check the bottom surface for any segregation or honeycombing, if found necessary adjustments shall
be made in the mix design.

Trial length:

A trial length of 60 mtr shall be made for the full width of the pavement and rolled, by involving at
least on transverse construction joint involving Stabilized mix and fresh laid mix. The in-situ density
of the freshly laid concrete shall be determined by sand replacement method with 200 mm dia
density cone, by making 3 density holes at equal distances that diagonally bisects the trial length,
these shall not be made in the strip of 500 mm from the edges. The average of these shall be
considered as 100%, and with this the field density of the regular work shall be compared.
The hardened concrete may be cut for 3m width in the trial length and reversed to check the bottom
surface for any segregation or honey- combing, if found necessary adjustments shall be made in the
mix design.

Transportation and placing:

The Stabilized mix shall be transported by sufficient number of tipping trucks to ensure continuous,
uniform supply of mix to feed the laying equipment. The mix shall be protected from the weather, by
covering the tippers/dumpers with tarpaulin during the transit. The CTB Material shall be laid to the
required widths, grades, camber and thickness with Motor Grader or Paver. The equipment shall be
capable of laying the materials in an even manner without segregation, to the specified thickness
after the compaction.

32
Compaction:

The compaction shall commence as soon as the Material laid and levelled to the full width till
there is no further movement under the roller and the surface is closed. Double drum smooth
wheeled vibratory rollers of 80-100kN static weight shall be used for this purpose. Rolling shall
commence at edge and progress towards the center, except at super elevated portion of the
carriageway with unidirectional cross - fall where it shall commence at the inner edge and
progress towards the outer edge. During rolling, the surface shall frequently checked for grade
and cross fall (Camber) and any irregularity corrected by loose the material and removing/adding
fresh material, In addition to the number of passes required for compaction, there shall be a pass
without vibration as preliminary pass and another at the end as final pass. The minimum dry
density obtained shall be 98% of the maximum dry density.
No traffic of any kind shall ply over the completed sub- base unless permitted by the Engineer.
, j
Curing:

The cemented sub-base shall be cured for a minimum of three days before the construction of the
next layer. In case sufficient strength of cementitious sub-base is not achieved as per the requirement
of IRC:SP:89 (28) in 3 days of Curing, 7 days curing shall be done for Sub-base before the
Construction of the upper layer can be started.

Data & Its Analysis:

Unconfined Compressive Strength Tests (UCS)

As per the Clause 403.2.6 of MoRTH the quantity of cement added shall not be less than 2% by
weight of the dry soil. The design mix shall be done on the basis of 7 day unconfined compressive
strength (UCS) and/or durability test under 12 cycles of wet-dry conditions. The laboratory strength
values shall be at least 1.5 times the minimum field UCS value. The mix design shall be done to
achieve strength of 1.75 mpa when tested on cylindrical specimens compacted to the density at
optimum moisture content, tested. In accordance with IS: 2720 after 7 days moist curing.

Sieve Analysis of CTB as per MoRT&H Table 400-4

IS Sieve 53 37.5 19 9.5 4.75 0.600 0.300 0.075

Specification 100 95 - 100 45 - 100 35 - 100 25 - 100 8 - 65 5 - 40 0 - 10

Limit

33
 Physical Properties:

TEST SPECIFIED LIMIT

Maximum dry density (MDD) -
Optimum Moisture contents (OMC) -

Construction Methodology:

TEST RESULTS SPECIFIED LIMIT

Plasticity Index --- Max. 10 %
Uniformity Coefficient --- >10
Water absorption --- Max. 2 %
Aggregate Impact Value --- Max. 40 %
7 Days Unconfined Compressive Strength (UCS) as 150MM
per IRC 37 & IRC SP 89 4.5 to 7.0 Mpa
Cube
(CTB)

 Routine testing to be carried out as stipulated with in MoRT& H Clause 900-3 and reduced to
acceptable levels during continuous production from established stockpiles reference aggregates
properties.
 Quality Control tests for Cement shall be done for every Consignment/ every Week.
 Cement content- Regularly, through procedural checks
 Unconfined compressive strength: One set of three cubes as per required
 Moisture content & Density of compacted Layer: One set of two tests as per required.

Safety precautions:

 All tippers tankers shall be provided with reverse horns.

 Flagman shall be provided at all exit points of the trucks / tippers.
 The speed of vehicles plying in the work area shall be restricted to 40 kmph maximum.
 Night work is to be carried out the area shall be sufficiently provided with lighting.
 The tipplers when being positioned in front of the Mortar grader shall be move very slowly as per the
Directions given by the supervisor or by the helper provided.
 Check for the working condition of safety valves of air compressors, if compressed air is being used for
cleaning.

34
 CONSTRUCTION METHODOLOGY FOR PRIME COAT AND TACK
COAT - 13
1. Scope:
This work consists of
 Preparing base layer in advance.
 Application of single coat of bituminous low viscosity liquid on WMM,
 Application of tack coat on bituminous layer before laying DBM, SDBC, and BC.
2. Reference:
 MORT&H Revision-5, Clause Nos: 502 & 503.
 Relevant IS & IRC Codes.
3. Equipments:
 Bitumen sprayer, Power broom, blower, Electronic balance etc..
4. Tools:
 Trays, cotton Waste etc.
5. Materials:
 Binder: The material shall be emulsion as per IS: 8887 for prime coat and tack coat.
6. Procedure:
a) Prime coat:
 This work shall consists of application of a single coat low viscosity, low porous bituminous material over
wet mix macadam granular surface at the rate of 7 -10 Kg per 10sqm, to the width and lines as shown in
drawing.
 The type and viscosity of primer shall comply with requirements of IS 8887.
 The bituminous primer shall not be applied on flooded surface, during rain and dust storm.
 The primer distributor shall be self-propelled, self-heating bitumen pressure sprayer, spraying the material
uniformly at a proper temperature.
 Immediately prior to applying prime coat, the surface shall sweep clean of dust and loose particles, and care
shall be taken not to disturb the interlocking of aggregates.
 A primed surface shall be allowed to cure at least by 24 hours before
any Subsequent surface treatment or mix is laid

b) Tack Coat:
 This work shall consists of the application of a single coat of low viscosity liquid bituminous material (as
per IS: 8887, IS 217) on granular surface treated with primer/ hungry bit surface @ 2.5 – 3 Kg per
[Link] normal bituminous surface @ 2 – 3 Kg / 10sqm.

35
  The bituminous tack coat shall not be applied on wet surface or weather is rainy or during a dust storm/
wind.
 The tack coat distributor shall be self-propelled, self-heating bitumen pressure sprayer, spraying the
material uniformly at a temperature between 20-70‟ degree C.
 Immediately prior to applying tack coat the surface shall swept clean of dust and loose particles.
 RFI will be raised for checking of Rate of Spread for Prime Coat/Tack Coat.

7. Quality control tests and their frequencies:

 Rate of spread of binder at a frequency of three test per day.
 Quality of binder as per IS: 8887, IS: 73, IS: 217.

8. Safety Precautions:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30 kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.
 Keep the work area cleared off any person or workmen before applying tack / prime coat using bitumen
sprayer.

36
 METHOD STATEMENT FOR CONSTRUCTION OF BM,DBM AND
BITUMINOUS CONCRETE -14
1. Scope:
 The work shall consists of mixing, laying and compacting of bituminous macadam, dense bituminous
macadam, Semi Dense Bituminous Concrete and bituminous concrete.
2. References:
 MoRT&H specifications Clause No: 504, 505, 507, 508, 509 and technical specifications of contract.
 Relevant IS & IRC Codes
3. Equipments:
 Sensor paver, Tandom roller, Pneumatic tyred roller, water tanker, dumpers, Asphalt plant, Wheel loader,
Auto level, levelling staff.
4. Tools:
 Lime powder, string, sensor pegs, measuring steel tape, straight board, thermo meter, steel scale.
5. Materials:
 Binder: The material shall be VG-30 grade bitumen for BM, SDBC, and DBM and for bituminous
concrete.
 Aggregate:
The coarse and fine aggregate shall consist of crushed stone.
 These shall be clean, hard, durable, dry and free from soft or friable, organic or deleterious matter. These
shall satisfy the physical requirement set forth for the individual relevant materials/mixes. Before approval
of the source it shall be tested for stripping.

6. Procedure:
 This work shall consists of construction in a single course or in multiple course of crushed aggregates
premixed in HMP, with approved grade bitumen with respect to bituminous design.

 The aggregate blended with course and fines shall consist of crushed rock and it shall satisfy the following
physical requirements of grading – as per design-drawing and MORT&H.

 The pre-mixed bituminous material shall be prepared in an electronically controlled hot mix plant of
adequate capacity and capable of yielding a uniform quality mix.
 At the time of mixing the temperature of aggregate shall be 150-175*C, bitumen shall be 150-165*C and
the mix temperature shall not be more than 165 to 165*C.
 The material shall be transported in clean vehicles, a thin coating of lubricating oil may be applied to the
interior of the vehicle to prevent sticking.

37
  The surface on which the bituminous layer to be laid shall be swept clean of all loose and extraneous
materials by mechanical or by any other suitable method.
 The material which is to be laid shall be mix designed in accordance
with Marshall Method.
 The material shall be spread by means of self-propelled paver finisher of with
Electronic sensor device, except in inaccessible areas, to the required thickness, lines and camber as
shown in the drawings.
 The thickness of compacted layer shall not exceed to approve design.
 In the inaccessible areas the mix shall be laid with suitable hand tools.
 At the time of laying a minimum temperature of 140*C shall be maintained.
 Required Stability value should be followed as per IRS SP 53 for modified bitumen.
 As soon as the material was spread, compaction shall commence and completed within the rolling
temperatures.
 Rolling shall be completed at min. 90*C for VG-30 of Mix. Rolling of longitudinal joints shall commence
behind the paving operations, after this the rolling shall start from the lower edge towards upper edge
parallel to the centre line of road, and each pass shall overlap 1/3rd preceding pass.
 All deficiencies in the surface shall be made good behind the paver before
the Initial rolling commenced.
 The initial rolling shall be done with a smooth wheeled roller of 80-100Kn static weight, followed by
intermediate rolling with a vibratory roller of 80-100Kn static weight.
 The finishing rolling shall be done a smooth wheeled tandem roller of 80-100Kn weight. In uni-directional
camber and super-elevated portions the rolling shall progress from lower to the upper edge. Rolling shall be
done as per approved rolling pattern, which is decided in trial stretch.
 All the joints shall have offset of , at least, 300mm from parallel joints in the layer beneath, longitudinal
joints shall coincide with either the lane edge or the lane markings and shall not situated in wheel track
zones.
 RFI will be raised for Checking of Laying, Density Checking and level checking of top layer.
7. Acceptance criteria:
 The tolerance in level shall be in between +6 to -6mm.
 The core density shall be as per specification with design.& lab results 92% of Gmm on day of compaction.
8. Safety Requirements:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour, if being used in the job for surveying shall be screened and trained.

38
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.
 The tippers when being positioned in front of the paver shall move very slowly as per the directions given
by the supervisor or by the helper provided.
 All workmen who are spreading the hot mix asphalt shall wear shoes and hand gloves.
 The hot mix paver shall be provided with first aid box containing at least to provide treatment for minor
burns.
 Keep the work area cleared off any person or workmen before applying tack coat using bitumen sprayer.
 Mobile phones shall not be used, near and while operating the equipments.

39
 METHODOLOGY FOR CONSTRUCTION OF
DRY LEAN CONCRETE -15
1.
Scope:

 This work shall consist of construction of dry lean concrete sub-base with approved materials and mix, to
the lines, grades, camber and thickness as shown in the drawing.
2. References:
 MoRT&H specifications clause No: 601 and technical specifications of contract.
3. Equipments:
 Batching plant, Sensor paver/grader, Dumpers, water tanker, and 8-15 ton roller.
4. Tools:
 Shovels, broom, wire brush, straight edge, and measuring tape.
5. Materials:
 Cementitious materials: OPC-53 grade cement shall be used. These shall approved grade and approved
source, to achieve the desired average compressive strength of 15 N/mm2 at 7days of concrete grade.
 Coarse aggregate: These shall be in confirmation with IS 383. The coarse aggregate shall be dry, clean,
hard, and durable of crushed stone with max size of aggregate 26.5mm.
 Fine aggregate: These shall be in confirmation with IS 383 and shall be free from clay, loam, shale, mica,
etc., and of natural sand or crushed stone sand or combination. The blended aggregate of coarse and fine
aggregate shall confirm to the following gradations per table 600-1 of MoRT&H.
 Fly ash:- Up to 20% of Cementitious material we may use fly ash with proper mixing.
6. Procedure:
a) Mix:
 The mix shall be proportioned with a maximum aggregate cement ratio of 15:1 and with minimum cement
content of 150kg/cum in case of no mixing of fly ash and in case fly ash mixing 120 kg cement may use.
However the proportions of aggregate to cement can be increased based on the mix and machine
performance during the trail [Link] mixes with moisture contents at different water content shall be
made using the above stated cement and blended aggregates.
 Optimum moisture and density were obtained by making cubes. These cubes shall be made in three layers,
each layer being compacted with electronic/pneumatic vibratory hammer of 300-400N downward force.
 After the determination of moisture a set of 6 cubes shall be cast for determination of compressive strength
on 3 and 7 days.
 If the required compressive strength is not achieved, increasing the cement shall make trials and the above
stated procedure shall be repeated to achieve the required strength.
 Before production of concrete, natural moisture in the aggregate shall be determined and adjusted on day-
to-day basis.
40
b) Mixing:
 The materials shall be mixed in a mechanized batching plant, with weighing balances calibrated. While
mixing, moisture content shall be kept optimum +2, to avoid the evaporation losses with zero slump.
c) Trial length:
 A trial length of 100metre shall be made as per specification for the full width of the pavement and rolled
,by involving at least on transverse construction joint involving hardened concrete and fresh laid concrete.
 The in-situ density of the freshly laid concrete shall be determined by sand replacement method with
200mm dia density cone, by making 3 density holes at equal distances that diagonally bisects the trial
length, these shall not be made in the strip of 500mm from the edges.
 The average of these shall be considered as 100%, and with this the field density of the regular work shall
be compared.
 The hardened concrete may be cut for 3m width in the trial length and reversed to check the bottom surface
for any segregation or honeycombing, if found necessary adjustments shall be made in the mix design.
d) Transportation and placing:
 The plant mix concrete shall be transported by sufficient number of tipping trucks to ensure continuous,
uniform supply of concrete to feed the laying equipment.
 The mix shall be protected form the weather, by covering the tippers/dumpers with tarpaulin during the
transit.
 The lean concrete shall be laid with the help of moor grader to the required widths, grades, camber and
thickness.
 The equipment shall be capable of laying the materials in an even manner without segregation, to the
specified thickness after the compaction.
e) Compaction:
 The compaction shall commence as soon as the concrete laid and levelled to the full width till there is no
further movement under the roller and the surface is closed.
 Double drum smooth wheeled vibratory rollers of 80-100kN static weight shall be used for this purpose. In
addition to the number of passes required for compaction, there shall be a pass without vibration as
preliminary pass and another at the end as final pass.
 The minimum dry density obtained shall be 98% of that achieved in trial length, and at a distance of
500mm from edge it shall be 96% of that achieved in the trial length.
 The final surface shall be inspected immediately, and all loose, segregated or defective areas shall be
corrected by using fresh lean concrete.
 Honeycombed areas, any level/ thickness deficiency and surface irregularities shall be corrected by
concrete with 10mm and down aggregates.
 Special care and attention shall be exercised during compaction near joints, kerb, channels, side forms,
around gullies and manholes.

41
  Longitudinal and transverse joints are to be provided as shown in drawings. At these joints unless vertical
forms are used, the edge shall be cut back to a vertical face where correct thickness of compacted layer has
obtained.
 Covering the surface with gunny bags/ Hessian cloth, which shall be kept continuously moist for 7days by
sprinkling water, shall do curing.
 Level tolerance shall be + 6mm.
7. SAFETY requirements:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided

42
 METHODOLOGY OF CONSTRUCTION PAVEMENT QUALITY
CONCRETE -16
1. Scope:
 This work shall consist of construction of Un-reinforced, dowel jointed, Plain Cement Concrete of Design
grade pavement in accordance with the lines, grades, camber and thickness as shown in the drawings.
2. References:
 MoRT&H specifications clause No: 602 and technical specification of contract.
3. Equipments:
 Batching plant, Wheel loader, transit mixers, needle vibrator and screed vibrator, concrete - power saw, and
levelling floats.
4. Tools:
 Floor Form, Jacks, Steel pegs, and measuring tape.
5. Materials:
 Cementitious materials: OPC-53 grade cement shall be used. These shall approved grade and approved
source, to achieve the desired average compressive strength at [Link] should be used to replace
cement up to 20 %.
 Admixtures: The admixtures shall confirm to IS 6925 and IS 9103 shall improve the workability of
concrete or extension of time and they will not have any effect on the properties of concrete. The
performance of these admixtures will be proved both on laboratory trials and in trial paving works. The
admixtures containing calcium chloride shall not be used.
 Aggregates: The aggregates shall be of crushed stone or naturally available confirming to IS 383. The
coarse aggregate shall be clean, hard, strong, dense and durable of crushed stone, for Airport pavements the
size and gradation and physical properties of mix will be as per the technical specifications of airport
pavements. The fine aggregate shall be of clean natural sand or crushed stone sand or combination of both.
These shall be free from clay, shale, loam, mica and other organic matter.
 Fly ash:- Up to 20% we may use fly ash with proper mixing & design.
 Water: Water used for mixing and curing of concrete shall be free from oil, salt, acid and other substances,
which are harmful to concrete, as per IS:456.
 Mild steel bars for dowel and tie bars: Dowel bars shall confirm to IS:432 grade and tie bars to FE-500 of
IS:1786.
 Joint sealing compound: This shall be hot poured Elastomeric type as per IS:1834 or ASTM:3406 or
IS:11433(P-1) having flexibility, resistance to age hardening and durability.
 Separation membrane: A separation membrane of impermeable plastic sheeting 125 microns thick shall
lay between the concrete slab and sub-base by nailing with concrete nails to the lower layer. Where overlap
is necessary the same shall be laid by at least 300mm

43
  .
6. Procedure:
a) Mix:

 The mix shall be designed as per IS 10262 or ACI method. And the design shall be based on the flexural
strength of concrete.
 The water content shall be minimum required to provide workability for full compaction of the concrete to
the required density. The maximum free water cement ratio shall be 0.5.
 The mix shall be proportioned to give an average strength at 28 days exceeding the specified strength
(4.8Mpa) by 1.65 times the standard deviation calculated from the flexural strength of the first 30 beams
first during the trial length and then the job control test beams (during the actual execution).
 The workability requirements at the batching plant and at site shall be established by slump tests while
doing trial length. The ratio of 7 days strength to 28 days strength shall be maintained, by testing pairs of
beams and cubes batch wise for at least six batches of trial mix.
b) Mixing:

 The materials shall be mixed in a mechanized batching plant consisting air-conditioned centralized control
cabin, minimum 4bins, weigh hoppers, separate scales for cement, fine and coarse aggregate with weighing
balances calibrated, aggregates being proportioned by automatic weighing devices using load cells.
 The concrete ingredients shall be mixed thoroughly by a mixer with automatic timing/alarm device to mix
and discharge (in case of failure of timing/alarm device concrete shall be mixed as per Manufacturer‟s
recommendations) capable of mixing to get a homogenous mix without being segregated while discharge.
c) Joints, dowel and tie bars:

 The location and type of joint shall be as shown in the drawings.

i. Contraction Joints

 Transverse joints shall be contraction and expansion joints, cut with mechanical saw could start as early as
6-8 hours, i.e. initial hardening of concrete, after laying. The contraction joints shall consist of mechanical
sawn joint groove, 3 to 5mm wide and ¼ to 1/3 depth of the slab+-5mm. The expansion joints shall consist
of a joint filler board positioned vertically with the prefabricated assemblies along the line of joint.
ii. Dowel bars:

 The dowel bars shall mild steel with details and dimensions as indicated in the drawings. Unless otherwise
shown in the drawings the dowel bars shall be positioned at the mid depths of the slab with suitable
tools/means within +/-20mm tolerances. The dowel bars shall be covered with plastic sheath for at least
2/3rd from one end for contraction joint, and ½ length +50mm for expansion joint. For expansion joints, a
closely fitting cap of 100mm long shall be provided at the sheath end. To block the entry of cement slurry
between dowels and cap a compressible sponge may be used.

44
  The dowel bars shall be supported on cradles / chairs in pre-fabricated joint assemblies positioned prior to
the construction of slab or mechanically inserted with vibration into the plastic concrete by a method which
ensures correct placement of the bars besides full re-compaction of the concrete around the dowel bars.
iii. Longitudinal Joints

 The longitudinal joints shall be saw cut as shown in the drawings. A groove of 1/3rd the depth of the slab
may be cut after the final set of the concrete. The tie bars shall be deformed steel bars of 415 mpa
complying to IS 1786. Tie bars shall be painted with bituminous paint for 75mm at the both ends and
positioned with suitable tools/means.
 Tie bars shall be placed within the middle third of the slab depth.
 Tie bars in the longitudinal joints shall be made up into rigid assemblies with adequate supports to remain
firmly in position during the construction of slab.

iv. Construction Joints

 Transverse construction joints shall be placed whenever concreting is completed for the day‟s work or is
suspended for more than 30 minutes. These shall be provided at regular location of contraction joints using
dowel bars as stated above. Using sealants, not before 14days after construction of slab shall seal all
transverse and longitudinal joints, but prior to allowing the traffic ply on the new construction.
d) Separation membrane:

 A separation membrane of impermeable plastic sheeting 125 microns thick shall lay between the concrete
slab and the sub base by nailing with concrete nails to the lower layer. Wherever overlap is necessary, the
same shall be laid by at least 300mm. Before placing the separation membrane the sub-base shall be swept
clean of all extraneous materials using high pressure water jetting or compressed air.
e) Construction by fixed form:

 This shall consist of straight side forms made of steel of thickness not less than 5mm and of minimum
3000mm length. These shall have a depth equal to the prescribed thickness of the pavement. These forms
shall be straight and free from bends and warps. Side forms shall be of sufficient rigidity in the form and in
the interlocking connection with adjoining form such that springing will not occur under the weight of the
sub grade and paving equipment or from pressure of concrete.
 The vibrators for concreting shall be either surface pan type or internal type with immersed tube or multiple
spuds. The surface vibrators shall a frequency not less than 3500 impulse per minute and the internal type
vibrators shall have frequency more than 5000 impulse per minute.
f) Trial length:

 A trial length of 50m shall be made for the full width of the pavement and rolled, by involving at least one
transverse construction joint involving hardened concrete and freshly lay concrete.

45
  After the side forms are removed, edges of slabs shall be corrected wherever irregularities have occurred by
using fine concrete consisting 1:3 ratio of cement to fine chips and aggregate.
 After the final regulation of the slab and before the application of curing membrane, the surface of the
concrete shall be brush-textured at right angles to the longitudinal axis.
 The wire brush used for this purpose shall be made of 32 gauge type wired grouped together in tufts at
10mm centres and of width not less than 450mm.
 The total time taken from addition of water to the mix, until the completion of surface finishing and
texturing shall not exceed 120minutes when the concrete temperature is less than 250C and 90minutes
when the temperature of concrete is between 250C-300C.
 Immediately after the surface texturing, the surface and sides shall be cured by application of curing
compound, which hardens in to impervious film with the help of mechanical sprayer. The curing compound
shall have a water retention efficiency of 90%. After 3hours, the pavement shall be covered with moist
Hessian cloth or pond with Water for at least a period of 14 days.
 Level tolerance shall be + 5mm.
g) Joints sealing:

 When saw cuts joints are adopted in construction, they are not made to provide the minimum width
specified in the drawings, they shall be widened subsequently by sawing before sealing, and the width and
depth are controlled by gauges. When sealants are applied, an appropriate primer shall also be used, if
recommended by the manufacturer and it shall be applied in accordance with their requirements. The
sealant shall be applied within the minimum and maximum drying time of the primer recommended by the
manufacturer. Before sealing, the temporary seal provided for blocking the ingress of dirt, soil, etc. should
be removed. A highly compressible heat resistant paper backed de-bonding strip as shown in drawing shall
be inserted in the groove to serve the purpose of breaking the bond between sealant and the bottom of the
groove and to plug the joint groove, so that the sealant may not leak through the cracks.
 The road may be opened for regular traffic after completion of curing period and after sealing of joints.
h) Sand Patch Test (for measuring the texture depth):

 The surface to be tested shall be dried; any extraneous mortar and loose material shall be removed and
swept clean, using a wire brush at right angles and parallel to the carriageway. A cylindrical container of
25ml capacity shall be filled with sand passing
 300microns sieve and retained on 150microns sieve, compacted by tapping the base and excess sand
stroked off to level with the top of cylinder. Then the sand shall be poured on the surface to be tested into a
heap and spread with the help of flat wooden disc of 64mm diameter of 1.5mm thick, with its face kept flat,
in a circular motion, so that the sand is spread into a circular patch, with the surface depressions filled with
sand to the level of peaks.
 The diameter of the patch shall be measured to the nearest 5mm. The texture depth of concrete shall be
calculated as follows:

46
  Texture depth in mm = 31000/ D2
 Where, „D‟ is the diameter of the patch.
 Five such texture depth tests shall be taken along the diagonal line across the lane width at least 2m apart,
between 50m points along the road. No measurement shall be taken within the 300mm of longitudinal
edges of the slab constructed in one pass.

7. Safety requirements:
 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.
 Hand gloves shall be used while application of joint sealants.

47
 METHOD STATEMENT FOR LAYOUT & BASE PREPARATION OF
STRUCTURES(CULVERTS/ BRIDGES/VUP/PUP) - 17
01. Scope:
 This work shall consist of Layout and base preparation of Culverts/ Bridges/VUP/PUP before constructing
foundation.
02. Reference:
 MoRT&H specifications, Technical Specifications.
 Relevant IS & IRC Codes.

03. Eqipments:
 Total station, Auto level, leveling staff, Excavator and shuttering material.
04. Tools:
 Measuring tape, crow bar, spade, Line rope, Lime powder, Pegs etc.
05. Procedure:
 Layout of the culvert/Bridges shall be done as per the approved drawing.
 OGL shall be recorded and excavation up to proposed foundation level as per approved drawing shall be
taken up, manually or by mechanically.
 On reaching the required level of foundation the entire construction width shall be removed if any loose
material and bottom surface shall be compacted in such a way that firm ground is available for starting of
work.
 The bottom cleaned surface shall be wetted prior to start of foundation PCC activity.
 Prior to laying of PCC, the layout as per drawing shall be again marked on the prepared ground.
06. Safety precautions:
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.
 Wherever required, Flagman shall be provided.
 Warning and cautionary boards shall be displayed at the work.
 The excavated pits shall be properly barricaded.
 The area shall be restricted from public entrance.

48
 METHOD STATEMENT FOR PIPE CULVERTS -18
1.
Scope:
 This work shall consist construction of new Hume pipe culverts as per approved drawings. The work
shall consist of carriage Hume pipe to site, preparation of bed for laying pipe, laying of required dia of
Hume pipe, Construction of head wall, floor protection and slope pitching etc.
2. References:
 MoRT&H specification of Clause 2900, 1006, 1700, Relevant IRC & IS Code and Technical
Specifications of Contract.
3. Equipments:
 Batching plant & Transit mixture /Excavator, Hand rammer/ vibrator, Trailer/Open body truck, Water
tanker, Hydra crane/Tripod/JCB.
4. Tools:
 Measuring Tape, Crow bar, spade, chisel, line rope etc.

5. Materials:
 Sand shall be used from approved source.
 Aggregate from approved source shall be used in concrete work.
 NP-4 Hume pipes of different diameter and 2.5 mtr length or in the length required at few places will be
used as per IS: 458 in conformation to the requirement of section 1000 of MORT&H(5 th
Revision).Each consignment of RCC pipes shall be inspected and tested before incorporation in the
work.
 Bedding material shall be as per approved Drawings.

6. Procedure:
 After layout of the structure as per approved drawing, excavation of foundation for bed of pipe and head
walls will be done to proper lines, length, grade and level shown in the working drawing on the natural
ground.
 In case during the excavation soft, spongy or other unsuitable soil shall be removed. The bed shall be
compacted with approved granular materials. The lifting, loading, unloading and lowering of pipes
shall be done by means of tripod, manual labour, cranes.
 At the time of loading, unloading and setting the pipes ,Proper precaution shall be taken so that the
pipes are placed without damage.
 The gap between two rows of pipes shall be kept at least min 450mm or half the diameter of the pipe,
which is maximum.

49
 The laying of NP-4 pipes will start from the out let end & shall be completed at the inlet end to the
specified lines & grades.
 The pipes shall be jointed with tongue and groove joint and then filled with cement mortar in ratio of 1:2
shall be used. The jointing made with care so that the interior surface is smooth and match with the
interior surface of the pipe.
 The joints shall be kept damp for at least 4 days.
 The Concreting of head wall shall be carried out in two stages or single stage according to site conditions
&no of rows of pipe.
 In two stage concreting, first lift will be done up to bottom of pipe & then the last pipe resting on the
same will be placed .Second stage concreting shall be carried after that.
 Material for form work shall confirm to section-1500& I.R.C-87.
 Specification for road &bridge work section -1700 & 2200 shall be followed for construction of
Headwall, cradle & catch pit.
 Concrete shall be made with Batching plant or weigh batch Mixer machine at site. Curing with damp
sacks/Hessian or by direct sprinkling of water shall be done to the structure for a minimum period of 14
days.
 The form work shall be removed in case of vertical shuttering after 24 hours of casting. After removal of
shuttering any irregularity found in the surface shall be neatly finished.
 Backfilling material shall be free from boulders, large roots& other vegetable matters.
 Backfilling up to 300 mm above the top of the pipe shall be carefully done & thoroughly rammed,
tamped or vibrated in layers not exceeding 150mm.
 Care shall be taken to thoroughly consolidate the materials under the haunches of pipes.
 Filling of the haunch shall be carried out simultaneously on both sides of the pipes in such a manner that
unequal pressures do not occur.
 Apron will be done as per MORT&H specification section 2500 after completion of pipe culvert.
 Pitching shall be carried out as per working drawing along with other pitching work as per specification
section 2500 after doing earth work.
 RFI will be raised for all construction stage required as per site.

7. Safety Measures:
 The working area shall be fully protected with barricading or safety ribbon.
 All trucks shall be provided with reverse horns/lights.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 Regular inspection for all dumpers at unloading point shall be required.
 Warning and cautionary boards shall be displayed at work area.
 The levelling staff should be wooden or fibre.

50
 METHOD STATEMENT FOR FOUNDATION EXCAVATION OF
STRUCTURES IN SOIL -19
1. Scope:
 This work shall consists of Excavation for structures and removal of material for the construction of
foundations for bridges, culverts, retaining walls, head walls, cutoff walls, pipe culverts and other similar
structures, in accordance with the requirements of the specifications and the lines and dimensions shown
on the drawings or as indicated by the Engineer.
2. Reference:
 Section 304 of MoRTH specification & Technical specification of contract.
 Relevant IRC & IS Codes.

3. Equipments:
 Excavators, Dumpers, Auto level, staff, and electric chipper etc.
4. Procedure:
a) Setting out:
 The excavation shall be set out true to lines, curves, grades and sections as per Drawings.
b) Excavation:

 In works involving excavation for structures to construct foundations, for bridges, culverts, retaining walls,
etc., shall be excavated to the required depth or level as shown in drawings. Where the nature of soil, depth
of trench, season does not permits vertical sides, excavation shall be done with necessary shoring, strutting,
planking or cut to slopes with safe angles with due regard to the safety of personnel and works and to the
satisfaction of the Engineer.
 The depth to which the excavation is to be carried out shall be as shown on the drawings, unless the type of
material encountered is such as to require changes, in which case the depth shall be as ordered by the
Engineer. Propping shall be undertaken when any foundation or stressed zone from an adjoining structure is
within a line of 1 vertical to 2 horizontal from the bottom of the excavation.
 While executing excavation all adequate precautions of soil erosion, water pollution etc., shall be taken and
appropriate drainage measures to keep the site free of water shall be taken.
 The suitable material obtained from excavation shall be used for filling of roadway embankment, filling of
existing pits in the ROW, landscaping etc. All other unsuitable and surplus materials shall be disposed of
from site.
e) Dewatering & Protection:
 Normally, open foundations shall be laid dry. Where water is met with in excavation due to stream flow,
seepage, springs, rain or other reasons, adequate measures such as bailing, pumping, constructing
diversion channels, drainage channels, bunds, depression of water level by well-point system to keep the
foundation trenches dry when so required and to protect the green concrete/masonry against damage by
erosion or sudden rising of water level.

51
  If the percolation is too heavy for keeping the foundation dry, the foundation concrete shall be laid under
water by tremie pipe only.
f) Preparation of Foundation:
 The bottom of the foundation shall be levelled both longitudinally and transversely or stepped as directed
by the Engineer. Before footing is laid, the surface shall be slightly watered and rammed. If the excavation
is made deeper than that shown on the drawings, the extra depth shall be made up with concrete of the
foundation. Ordinary earth filling shall not be used for the purpose to bring the foundation to level.
 For the foundation work of the structure in prior to concreting SBC of the particular structure base at the
foundation level shall ensure according to the approved designs/drawings.
 When rock or other hard strata is encountered, it shall be freed of all soft loose material, cleaned and cut
to a firm surface either level and stepped . All seams shall be cleaned out and filled with cement mortar or
grout. In the case of excavation in rock, annular space around footing shall be filled with lean concrete
(M10) up to the top level of rock.
g) Backfilling:
 Backfilling shall be done with approved material after concrete is fully set and carried out in such a way
as not to cause undue thrust on any part of the structure. All space between foundation concrete and the
sides of excavation shall be refilled to the original surface in layers not exceeding 150 mm compacted
thickness. The compaction shall be done with the help of suitable equipment such as mechanical tamper,
rammer, plate vibrator etc., after necessary watering, so as to achieve a density not less than the field
density before excavation or as shown in drawing.
6. Safety Precautions:
 The area shall be restricted from unauthorized persons.
 All trucks shall be provided with reverse horns/lights.
 Wherever required, Flagman shall be provided.
 Blasting shall be done at pre-fixed hours.
 All persons including the workmen shall be excluded from the blasting area at least 10minutes before
blasting.
 Only licensed blaster shall be allowed to take out the blasting operations.
 During night work sufficient lighting shall be provided.
 The excavated pits shall be properly barricaded.
 Proper access shall be provided to enter in to the pit excavated
for structures.
 Road working area shall be demarcated using Sand bags/sign boards.
 All workmen at work area shall wear PPE‟s and reflective jackets.

52
 METHODO STATEMENT FOR FORMWORK, REINFORCEMENT &
CONCRETING IN STRUCTURAL WORK -20
1. Scope:
 Form work: This work shall consists of furnishing and fixing of form work (shuttering) of approved quality
for cast- in- situ / pre-cast/ pre-stressed plain or reinforced concrete with necessary props, staging,
centering, scaffolding and any temporary construction required for their support.
 Reinforcement: This work shall consist of furnishing and placing of high yield strength deformed bars of
the shape and dimensions as shown in approved drawings.
 Concrete: This work shall consist of furnishing and placing of plain or reinforced concrete of all grades
with 40 or 20mm down graded aggregates as defined in technical specifications of contract, machine mixed
and mechanically vibrated to the required level, slope, etc. as per approved drawings.
2. References:
 MORT&H specifications clause No: 1000, 1500, 1600, 1700 and
technical specification of contract.
 Relevant IRC & IS codes.

3. Materials:
 The source of materials (for cement, coarse aggregate, fine aggregate, water, admixture, reinforcement
steel) shall be identified as per specification.
 Cement: The cement to be used in the works shall be Ordinary Portland Cement of 43/53 grade confirming
to IS 8112/ IS 12269. The manufacturer test certificate shall be furnished, and cement shall be stored as per
IS 4082.
 Water: The water to be used shall be as per clause 1010 of MoRT&H specification.
 Coarse aggregate: Coarse aggregate shall confirm to IS 383, when tested in accordance to IS 2386 parts 1 to
8. The grading of coarse aggregate shall confirm to table 1000-1 of MOST specification.
 Fine aggregate: Fine aggregate shall consist of clean, hard, strong, dense, and durable pieces of crushed
stone or natural sand or a combination of both. All fine aggregates shall confirm to IS 383, when tested in
accordance to IS 2386 parts 1 to 8. The grading shall confirm to table 1000-2 of MOST specification.
 Admixtures: Admixtures shall be high water reducing agents, retarders, super-plasticizers, air entrainers or
a combination confirming to the requirements of IS 9103. The manufacturer test certificate shall be
obtained and submitted to Concessionaire. The appropriate dosage of admixture shall be determined at the
mix design stage. The admixture-cement compatibility shall be tested for every type, grade or source of
cement.

53
  Reinforcement: For plain or reinforced cement concrete the reinforcement shall be of grade Fe-500
confirming to IS 1786- HYSD bars. The steel supplied with test certificate shall be assembled in accordance
with approved drawings and shall ensure storing to avoid deterioration and corrosion.
4. Equipment:
 Batching plant, Wheel loader, Boom placer, Static concrete pump, Crane, crane bucket, transit mixers,
trailors, Bar bending and shearing machine ,Auto level with staff etc.
5. Tools:
 Measuring tape, plumb bob, Line rope etc…
6. Procedure:

a) FORM WORK:
 The formwork shall provide a smooth finish of uniform texture and appearance.
 Ensuring necessary care will be taken, the formwork in true to line, levels, plumb, etc., rigid, adequately
braced both horizontally and vertically. Form joints shall be minimized as much shall be tight and shall not
permit any leakage of slurry from concrete.
 Required formwork shall be made out off plywood/ steel shutters to suit the site
 Conditions. Formwork materials shall be rigid, even surface, and sufficiently strong to prevent deformation
during concrete. Releasing agents such as diesel mixed with grease, shuttering oil, etc. shall be applied
before fixing formwork, and shall not allowed to come into contact with any reinforcement or prestressing
tendons and anchorages. The formwork shall be cleaned carefully, dried and releasing agents shall be
applied before re-use.
 The formwork shall be so removed as not to cause any damage to the concrete.
 Formwork shall be gradually and uniformly lowered so as the concrete to take stresses due to its own
weight uniformly and gradually to avoid any shock or vibration.
 Before re-use all components of formwork shall be examined for damage and damage pieces shall be
rectified. Before re-use all components shall be cleaned of deposits of soils, concrete or other unwanted
materials. Threaded parts shall be oiled after cleaning.
b) REINFORCEMENT STEEL:

 Bar bending schedule shall be strictly as per approved drawings, and reinforcement steel shall be cut and
bent as per approved bar bending schedule. Bars shall be bent cold to the specified shape and dimensions,
using a proper bar bender, operated by hand or power to obtain correct radius of bends and shape.
 Reinforcement bars shall be placed accurately in position as shown in the drawings.
 The bars, crossing one another shall be tied together at every intersection with binding wire (dia of binding
wire shall not be less than 1mm) where the spacing is more than150mm and at alternate intersection where
the spacing of bars is less than 150mm,to make the skeleton of reinforcement rigid such that it does not get
displaced during placing.

54
  Spacer bars at approx. 2m intervals shall separate layers of reinforcement. Cover blocks of thickness equal
to the specified cover shall be placed between formwork and bars made of concrete/ cement mortar of
specified grade of concrete/ strength as those of the member.
 Necessary stays, blocks, chairs, spacers, hangers, etc. or other subsidiary reinforcement shall be provided to
fix the reinforcement firmly in its correct position.
 Laps shall be staggered.
c) CONCRETE:

 The grades of concrete shall be as specified in the drawings/ contract. Necessary mix designs shall be
submitted to client. The mix design of concrete shall be as per clause 1700 of MoRT&H specifications /
IS456:2000 / IS10262 / IS SP23. the workability of concrete when determined by slump cone test shall be
75-125mm.
d) Mixing:

 The mixing of concrete shall be done in batch type concrete mixer or by concrete batching and mixing
plant. All measuring devices shall be maintained in a clean and serviceable condition. Its accuracy shall be
checked periodically.
 Mixing of concrete shall be continued till the individual particle of coarse aggregate shows complete
coating of mortar containing its proportionate amount of cement.
 Corrections in water and aggregate with respect to moisture present in
the aggregates shall be done on day-to-day basis.
 The mixing shall also be done in 10/7 mixers at site and weigh batchers shall be used for the weighment of
CA and FA.
e) Transportation and placing:

 Concrete shall be transported and placed as near as practicable to its final position, so that no
contamination, segregation or loss of its constituent materials takes place.
 Concrete from batching plants shall be transported by scoop tippers or transit mixers.
 Concrete shall be placed in horizontal layers to a compacted layer not exceeding 450mm. Concrete when
deposited shall have a temperature neither less than 5*C nor more than 40*C.
f) Compaction:

 The concrete shall be compacted within 30minutes of its discharge from the mixer.
 To maintain required slump, it is necessary to add retarding/plasticising admixtures.
 This shall be controlled by taking slump at batching plant and site.
 Concrete shall be thoroughly compacted with vibrators or other means
 Where immersion vibrators are used contact with reinforcement and all inserts shall be avoided. Standby
vibrators in serviceable conditions shall be kept at site so that they can be used in the event of breakdowns.

55
g) Construction joints:

 Construction joints shall be minimised as far as possible. The old surface shall be thoroughly cleaned and
soaked with water. Standing water shall be removed and surface shall be wetted with neat cement slurry
shortly before placing of fresh concrete and shall be thoroughly compacted.
 For a vertical construction joint, a supporting board shall be fixed at predetermined position and shall be
properly stayed to prevent displacement or bulging when concrete is compacted against it. Concreting shall
be continued right up to the board.
h) Curing:

 Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by ponding or by
covering with a layer of sacks, canvas, Hessian or by similar materials and shall be kept constantly wet at
least for a period of 7 days. Curing compounds can also be used.

i) Finishing:

 Immediately after removal of forms, exposed tie rods or bolts, if any, as far as possible shall be removed, or
if necessary, shall be cut inside the concrete member to a depth at least 50mm below surface of concrete
and the resulting hole shall be filled by fresh cement mortar.
7. Safety requirements:

 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Levelling staff shall be fibre or Wooden.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.
 It shall be ensured that the safety belts were wore, tied and anchored properly while Working at heights.
 All working platforms shall be tied at the both ends firmly.
 The working condition of the reinforcement cutting and bar bending machines limit Switch shall be ensured
before starting the day‟s work.
 Hand gloves shall be used for cutting, bending and shifting of reinforcement rods.
 The electrical connections for vibrators / lighting shall be given by qualified /Experienced P&M personnel
and through ELCB only.
 Ensure that all moving parts of vibrator / compressor if any, shall be provided with guards.
 If concrete is being done by crane, the capacity of crane and its reach shall be Reviewed.

56
 METHODOLOGY FOR CONSTRUCTION OF BOX CULVERT -21
1. Scope:
 This work shall consist of construction of box culverts as per design and details as shown in drawing.
2. References:
 MORT&H specifications clause No: 1000, 1500, 1600, 1700 and technical specification of contract..
 Relevant IRC & IS codes.
3. Materials:
 All materials shall be used in pipe culvert shall confirms to the requirements in MORT&H clause no. 1000.
4. Equipment:
 Batching plant, Wheel loader, Boom placer, Static concrete pump, Crane, crane bucket, transit mixers,
trailors, Bar bending and shearing machine ,Auto level with staff etc.
5. Tools:
 Measuring tape, plumb bob, Line rope etc…
6. Procedure:.
a) Setting Out:

 The centerline of the road will be marked, in the portion where the culvert is to be constructed, based
on the GPS points (already available). Subsequently, the exact location and center-point of the culvert
will be marked. Reference pillars will be provided. All the above will be got approved by the Engineer.

b) Excavation:

 After fulfilling the safety measures, an excavator/JCB of required capacity will be used for excavation.
Excavation width and depth shall be checked as per approved drawing. Working space should be
maintained in both sides. Extreme care will be taken to avoid any caving in and safety measures like
shoring and strutting, wherever required, will be provided.
 Excavation by machine will be stopped just before reaching of the foundation bed level. Manual
dressing will be resorted, to get a level and firm surface. Surface will be compacted by rammers. The
finished surface will be got approved.
 Any unsuitable material from the excavation activities will be cleared away from the site, to avoid any
environmental hazards.
 Where water is met within excavation due to stream flow, Seepage, Springs, rain or other reasons, there
adequate measures such as, bailing, Pumping, constructing diversion channels, drainage channels,
bunds, depression of water level by well point systems cofferdams and other necessary works will be
used to keep the foundation trenches dry.

57
  In the event of excavation if the depth of excavation because deeper than the PCC bottom level, then
sand filling shall be done for the purpose to bring at the PCC level.
c Laying of base concrete:

 The concrete provided for laying shall be as per approved mix design.
 Batching plant will be provided for concrete production for use in box culverts. Care will be taken to
ensure the quality of the concrete.
 Adequate number of needle vibrator will be used for proper compaction of concrete.
 Concrete M15 shall be laid as per drawing to reach the require raft bottom level. No construction joint
shall be provided in the lean concrete.
e) Form work:

 Form work will be rigidly constructed and ensure that the finish concrete true to shape, line, level and
dimensions. Cleaning and oiling of plates will be carried out before every use.
 The formwork should be coated with shuttering oil to all surfaces coming into contact with concrete to
allow easy removal of forms without any damage to concrete. The release agent shall not come in
contact with reinforcement.
 Required staging will be provided for deck slab Concreting.
 Formwork will be as per MORTH Clause No. 1500.
f) Reinforcement Steel:

 Bar Bending Schedule will be prepared according to the drawing and submitted for I/C's approval.
 The reinforcement bars should be storage and protected against any damage
 The reinforcement bar should be tied together properly at every intersection and lapping.
 Reinforcement Steel will be as per MORTH Clause No. 1600.
g) Concrete of Box Cell:

 Before laying concrete for box culvert raft, the lean concrete surface should be clean from all loose
materials and lightly moistened.
 For raft, haunch, and wall, concrete of required dimension and shape shall be laid continuously up to
the construction joint shown on the drawing. The concrete surface should be smooth finished by means
of trowel.
 For Deck slab concreting expansion joint shall be provided as shown in the drawing.
 The surface of the deck slab shall be finished rough but true to lines and level shown on the drawing
before the concrete has hardened.
 Concrete is Sub structure & Super structure will be as per MORTH clauses No. 2200 & 2300.

58
h) Construction of wing wall & curtain wall:

 For concrete of wing wall, the surface of foundation shall be prepared in the same manner as above.
 No horizontal construction joint shall be provided.
 Vertical expansion joint shall be provided as per drawing.
 Thermocol will be provided for vertical expansion joint.
 Weep holes shall be provided as per the drawing.
 The finish of the surface on the earth side shall be rough, while front face shall be smooth finished.
g) Curing :

 Conventional water curing will be carried out for the stipulated duration.
 Hessian cloth will be used for ensuring the proper curing work.
h) Apron Work ( Floor Apron / Stone Apron ) :

 The surface on which the apron is to be laid shall be leveled and prepared for length and width as
shown in the drawing.
 The stone, which will be used in apron should be sound, hard and regular in shape.
 Apron will be laid as per [Link] no 2500

g) Filter Media:

 Filter media shall be provided behind the surface of wing wall.

 Material used for filter media will be as per MORTH clause no 309.
h) Back filling work:

 After the structure is completed, immediately backfilling will be done with suitable material. Light
mechanical rammer would be used for compaction.
 Backfilling will be done as per MORTH clause no 305.

8. Safety requirements:
Provisions for workmen:
 It is required that all persons working at the site shall be provided with the safety equipments,
protection means such as hand gloves, safety helmets and other necessary kinds.
 All persons working on the site shall be trained by conducting the training course for safety to ensure
that they are fully aware of the contents.
Provisions for Equipment, Machine:
 All equipment will be ensured to operate safely, maintained and repaired periodically.
 All power equipment should be insulated and covered to all exposed live parts.

59
  A competent person shall inspect equipment during shift duty.
Provisions for Job Site:
 Relevant Caution boards, such as “Deep Excavation”,” Go Slow”,” Work in Progress”,‟ Speed Limit
30Km/hr”and sufficient lighting system shall be installed at the working area to ensure safety for
construction activities at night time.
 The working area shall be free from hazards before starting the work.
 Unnecessary materials such as empty bags and rubbish shall be removed periodically.
 Proper safety measures like barricading, guard poles painted with florescent in alternate bands, flags
etc. will be provided prior to the commencement of excavation operations.

60
METHODOLOGY FOR CONSTRUCTION OF MAJOR/MINOR BRIDGE -
22

1. Scope:
 This work shall consist of construction of box culverts as per design and details as shown in drawing.
2. References:
 MORT&H specifications clause No: 1000, 1500, 1600, 1700 and technical specification of contract..
 Relevant IRC & IS codes.
3. Materials:
 All materials shall be used in pipe culvert shall confirms to the requirements in MORT&H clause no. 1000.
4. Equipment:
 Batching plant, Wheel loader, Boom placer, Static concrete pump, Crane, crane bucket, transit mixers,
trailors, Bar bending and shearing machine ,Auto level with staff etc.
5. Tools:
 Measuring tape, plumb bob, Line rope etc…
6. Procedure:.
a) Setting Out:
 The centerline of the road will be marked, in the portion where the open bridge is to be constructed,
based on the GPS points already available. Subsequently, the exact location and center-point of the
open bridge will be marked. Reference pillars will be provided. All the above will be got approved by
the Engineer.
b) Excavation:

 After fulfilling the safety measures, an excavator/JCB of required capacity will be used for excavation.
Excavation width and depth shall be checked as per approved drawing. Working space should be
maintained in both sides. Extreme care will be taken to avoid any caving in and safety measures like
shoring and strutting, wherever required, will be provided.
 Excavation by machine will be stopped just before reaching of the foundation bed level. Manual
dressing will be resorted, to get a level and firm surface. Surface will be compacted by rammers. The
finished surface will be got approved.
 Any unsuitable material resulting from the excavation activities will be cleared away from the site to
avoid any environmental hazards.
 Where water is met within excavation due to stream flow, Seepage, Springs, rain or other reasons, there
adequate measures such as, bailing, Pumping, constructing diversion channels, drainage channels,
bunds, depression of water level by well point systems cofferdams and other necessary works will be
used to keep the foundation trenches dry.

61
  In the event of excavation if the depth of excavation because deeper than the PCC bottom level, then
sand filling shall be done for the purpose to bring at the PCC level.
 Where there is a disturbance to the running traffic, proper diversions, meeting the requirements of
specifications will be made before the excavation starts.

c) Filling of Sand:

 After excavation sand filling will be done as per drawing and get compacted by means of plate
compactor as per MORTH Clause No. 304.

d) Laying of Base Concrete:

 Concrete will be provided as per approved mix design.

 Concrete will be prepared in Batching Plant located as given in the general description in this
methodology. The same will be transported to site in adequate numbers of transit mixers.
 Adequate number of needle vibrator will be used for proper compaction of concrete.
 Concrete M15 shall be laid to the thickness as shown in the drg. to reach the required level. No
construction joint shall be provided in the lean concrete.

e) Formwork:

 Steel shuttering plate and plywood shuttering will be used for required shuttering work. Form work will
be rigidly constructed and ensure that the finish concrete true to shape, line, level and dimensions.
Cleaning and oiling of plates will be carried out before every use.
 The form work should be coated with form oil to all surfaces coming into contact with concrete to allow
easy removal of forms without any damage to concrete. The release agent shall not come in contact with
reinforcement.
 Required staging will be provided for deck slab Concreting.
 Design of Form work and staging arrangement will be submitted shortly for approval.
 Form work will be as per MORTH Clause No. 1500.
f) Reinforcement Steel:

 Bar Bending Schedule will be prepared according to the drawing and submitted for Engineer's
approval.
 The reinforcement bars should be protected against any damage
 The reinforcement bar should be tied together properly at every intersection and lapping.
 Reinforcement Steel will be as per MORTH Clause No. 1600.

62
g) Concrete for curtain wall :
 Before laying of concrete in curtain wall for minor bridges, the lean concrete surface should be cleaned
thoroughly from all loose materials and lightly moistened.
 Concrete of required grade as per the dimension and shape as given in the drawing. shall be laid
continuously up to the construction joints.
 In the curtain wall concreting expansion joints shall be provided as indicated in the drawing.
 Concrete will be as per MORTH clause No. 2200 and 2300.

h) Concrete for Box Cell:

 Before laying concrete for bridge raft, the lean concrete surface should be cleaned from all loose
materials and lightly moistened.
 For raft, wall and deck slab concrete of required grade, dimension and shape shall be laid continuously
up to the construction joint shown on the drawing. The concrete surface should be smooth finished by
means of trowel.
 For Deck slab concreting expansion joint shall be provided as shown in the drawing
 The surface of the deck slab shall be finished rough but true to lines and level shown on the drawing
before the concrete has hardened.
 Concrete in Sub structure & Super structure will be as per MORTH Clauses No. 2200 & 2300.

i) Construction of Toe Wall & Stone Pitching :

 The surface on which the PCC for toe wall to be laid shall be leveled and prepared for length and width
as shown in the drawing.
 The surface on which the stone pitching will be done shall also be leveled and prepared.
 The stone which will be used in pitching should be sound, hard and regular in shape.
 Stone pitching will be done as per MORTH clause No.2500.

j) Curing:

 Conventional water curing will be carried out for the stipulated duration.
 Hessian cloth will be used for ensuring the proper curing work.
 Curing shall be done as per MORTH Clouse No. 1713

k) Apron Work ( Floor Apron / Stone Apron):

 The surface on which the apron is to be laid shall be leveled and prepared for length and width as shown
in the drawing.
 The stone, which will be used in apron should be sound, hard and regular in shape.
 Apron will be laid as per MORTH Clause No. 2500.

63
l) Filter Media :

 Fillter media shall be provided below the stone pitching in the embankment for length and width as
shown in the drawings.
 Materials used for filter media will be as per MORTH clause No. 309.

m) Back filling Wok:

 After the structure is completed, immediately backfilling will be done with suitable material. light
mechanical rammer would be used for compaction.
 Backfilling will be done as per MORTH Clause No. 305.

7. Safety requirements:
a) Provisions for workmen:

 It is required that all persons working at the site shall be provided with the safety equipment‟s,
protection means such as hand gloves, safety helmets and other necessary kinds.
 All persons working on the site shall be trained by conducting the training course for safety to ensure
that they are fully aware of the contents.

b) Provisions for Equipment, Machine:

 All equipment will be ensured to operate safely, maintained and repaired periodically.
 All power equipment should be insulated and covered to all exposed live parts.
 A competent person shall inspect equipment during shift duty.

c) Provisions for Job Site:

 Relevant Caution boards, such as “Deep Excavation”,” Go Slow”,” Work in Progress”,‟ Speed Limit
30Km/hr” and sufficient lighting system shall be
 installed at the working area to ensure safety for construction activities at night
 The working area shall be free from hazards before starting the work.
 Unnecessary materials such as empty bags and rubbish shall be removed periodically.
 Proper safety measures like barricading, guard poles painted with florescent in alternate bands, flags etc.
will be provided prior to the commencement of excavation operations.

64
 METHOD STATEMENT FOR BACK FILLING IN STRUCTURES -23
g) Scope:
 This work shall consist of back filling of trenches after the abutment, wing wall, return wall, Box
culvert & pipe culvert is completed. The filter media shall be provided where weep holes are
provided.
h) References:
 MORTH specifications clause No: 2900, 2504.2.2 and technical specification of contract.

i) Equipments:
 Dumpers, wheel Loader, roller& water tanker.

j) Tools:
 Measuring Tape, Crowbar, spade & line rope etc.

k) Procedure:
A) Back filling of Pipe culverts:

 After the pipe installation has been completed and approved,

 The backfill material shall be suitable material and free from boulders, large roots, other vegetable
matters.
 The back fill material shall be placed in layers and thoroughly consolidated or compacted.
 The minimum thickness of the material for cushion above the top of pipe shall be 300mm and shall be
thoroughly consolidated.
 Filling of trench shall be carried out simultaneously on both sides of the pipe in such a manner that the
unequal pressures do not occur.
 Particular care being taken to thoroughly consolidate the materials under the haunches of the pipe.
 Pneumatic or light mechanical tamping equipment can be used.
 Above the cushion layer, approved Borrow Area material shall be placed and compacted with 10-15
tonne roller to the required density of 95% for embankment & 97% for sub grade. The thickness of
layer shall be 200mm.

B) Back filling of Box culverts:

 The additional excavated area for work space up to raft level shall be filled with granular material and
thoroughly consolidated.
 The Backfill material shall be suitable material as per clause 401.4.2of MORTH.
 The proper material shall be laid as per approved drawing.
 The GSB material shall be filled in layers & the thick ness of the layer shall be 200 mm.

65
  The rolling shall be carried out to achieve the required density.

C) Back filling of Box Minor bridges, MNB, MJB, & Return walls:

 The filter media shall be provided behind the abutment, wing wall, return wall and where weep holes
are provided.
 The width of the filter media shall consist of two layers of each 300mm as per approved mix design.
 The material for the filter shall consist of sand, gravel, stone or crusher sand to prevent escape of the
embankment material through the voids of weep holes in abutments as well as to allow free
movement of water without creating any uplift head.
 The gradation of the filter material shall satisfy the requirements of clause 2504.2.2 of MORTH. The
filter shall be compacted to a firm condition.
 The back fill soil shall be approved Embankment & sub grade material as per clause 305 of MORTH.
 The backfill soil shall be clean, free from boulders, large roots, excessive amounts of sods or other
vegetable matter and lumps.
 The backfilling shall be done in layers and thoroughly compacted to the required density.
l) Safety requirements:

 All dumpers, rollers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided.
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
Levelling staff shall be fibre or Wooden.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.

66
METHODOLOGY FOR INSTALLATION OF ELASTOMERIC BEARING -
24
1. Scope:
 The work shall consist of fixing of elastomeric bridge bearings in position as per details shown in
drawings.
2. .References:
 MoRT&H specifications clause no 2005 and Technical specifications of contract.
 Relevant IS & IRC Codes.
3. Equipments:
 Auto level, levelling staff.
4. Tools:

 Measuring steel tape, line rope.

5. Responsibility:

 Responsibility of Implementation of this procedure lies with Site engineer and incharge of structures.
 Centerline marking responsibility lies with surveyor.

6. Materials:
 Elastomeric bearings, Fosroc conbextra GP2 or Equivalent material, Fosroc Nitto bond –EP or
equivalent material and as per MoRT&H clause 2005.1.

7. Procedure:
 The location where the bridge bearing to be installed shall be swept clean and made free from debris
and other foreign matter which will effect the adhesion of bearing to the surfaces.
 The bridge bearing shall be kept in the recess made in concrete on the pier cap /pedestals.
 The concrete surface where the bridge bearing will sit shall be free from local irregularities within
1mm tolerance in height.
 Bridge bearings shall be placed in between true horizontal surface within a maximum tolerance of
0.2% perpendicular to the load and at true plan positions on their control line marked in receiving
surface within 3mm.
 An epoxy adhesive such as ‟FOSROC - Nitobond EP‟ or equivalent material will be uniformly applied
to form a film of 2mm thick to the both surface of concrete and the face of the bridge bearing, which
will be in contact with the each other.
 After elapsing of 15-20minutes the bridge bearing will be pressed gently on the surface where adhesive
is applied by keeping the glued surfaces opposite to each other.

67
  To rectify the local irregularities and to make the concrete surface truly plane, in the recess of 5mm
deep provided for bridge bearing to sit, the following method would be adopted. First the concrete
surface will be swept clean to remove all the debris or dust by using wire brushes or water. A thin coat
of epoxy adhesive will be applied on the dried concrete. After a lapse of 15-20minutes a non-shrink
self-leveling cement grout such as „FOSROC – Conbextra GP2‟ or Equivalent material will be poured
to a maximum thickness of 2mm. This grout will be kept continuously moist for 3 days, before
installation of bearing.
The exposed surface of the concrete shall be finished and kept moist for the first 24hours and
cured further until attains sufficient strength as shown in drawings.

8. Safety Requirements:

 Wherever the bearing Installation is under process bottom area shall be properly barricaded.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets, safety belts.
 During night work sufficient lighting shall be provided.
 Leveling staff shall be wooden or fiber.

68
 METHOD STATEMENT FOR PRESTRESSING OF GIRDERS -25
1. SCOPE:
 The purpose of pre-stressing is as per design requirement for Post Tensioning of Concrete I Girders at
Major Bridge.
 This work shall consist of:

1. Profiling
2. Cutting and threading of tendons
3. Stressing of tendons
4. Grouting of tendons
5. End Cap Concreting
2. Reference:
1. Contract Agreement with Bangarupalem Gudipala highways ltd..
2. MoRT&H Specifications for Road and Bridge works published by Indian Roads Congress, New
Delhi, (Fifth Revision).

3. IRC : 18-2000: Design Criteria for Pre-stressed Concrete Road Bridges, (Post-Tensioned Concrete),
Third Revision
4. IRC: SP 47-1998: Guidelines on quality systems for road bridges (Plain, reinforced, pre-stressed and
composite concrete).
5. IS: 2502-1967: Code of practice for bending and fixing of bars for concrete reinforcement.
6. IS: 1786-1985: Specification for high strength deformed steel bars and wires for concrete
reinforcement.
7. IS: 8112-1989:43 grade ordinary Portland cement-Specification.
8. IS: 12269-1987: Specification for 53 grade ordinary Portland cement.
9. IS: 516-1959: Methods of tests for strength of concrete.
10. IS: 383-1970: Specification for coarse and fine aggregate from natural sources for
concrete. 11.
2. Procedure:
The following sequence of activities has been described as under.
a) Profiling
b) Installation of tendons
c) Stressing of tendons
d) Grouting of tendons
e) End Cap Concrete

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 a) Profiling:

 Profiling (layout of prestressing tendon) shall be carried out according to the ordinates given in the
reference drawings.
 Cable supports/Chairs shall be welded to the vertical stirrups and sheathing will be tied with the
help of binding wire so as to avoid displacement of cable during concreting. However, care should
be taken in providing smooth profile and there should be no sudden kinks.

Precautions during profiling:

The following precautions should be taken during profiling.

 Between the points given the cable must retain a regular curvature without undulations or sharp
changes in the direction, which will cause entries in the friction loss at the time of stressing.
 The cable axis must coincide with anchorage axis for a length.
 The cable must be placed in the concrete section in such a way so as to allow easy concreting and
sufficient cover.

Steps in profiling:

 Preparing cone boxes and fixing guides to it.

 Profiling and fixing of sheathing.

b) Installation of tendons
 Checking of Identification Tag details.
 The packing of HTS strands shall be removed just prior to use.
 The strand shall be de coiled on an elevated platform along its length and the required length of catch
strand shall be marked, cut and recorded in the format correlating the Cable No. to Coil No. The
coils may be mounted on a rotating table to facilitate unpacking.
 Cut-strands shall be inspected for defects like opening of wires, if any.
 The cut strands shall be threaded inside the duct for full length.
 Strand shall be cleaned up before the threading operation.
 In case any Delay in stressing operation after inserting the strands, the ends of strands protruding
beyond the face of girders should be wrapped with plastic sheets to protect from water/dust.
b) Stressing of Tendons
 Jack Efficiency test shall be carried out at site before commencement of stressing activity.
 Pressure gauges third party calibrated certificate shall be made available at site.
 Pressure gauges shall be calibrated once in 3 months or once for every 200 cables are stressed.
 Pressure gauges shall be calibrated either against a master proving ring or preferably by a dead weight
tester at regular intervals. Calibration certificate required for Master proving ring.

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 The stressing operation shall be undertaken by the pre-stressing technicians.
 Before commencing the stressing operation, Tube Unit & strands projecting outside the anchorages
shall be cleaned.
 The Bearing plates, Wedges shall be cleaned and visually checked for any damages before using.
 Bearing plates shall be assembled on both sides and the threaded strands shall be secured with compact
wedges by tamping with pipe.
 Multi strand jacks will be fixed at the both ends.
 The stressing pumps shall be connected to the jack through the hose pipes.
 The stressing sequence shall be observed as indicated on the post-tensioning drawings.
 When reaching the design stressing load, measure the elongation.
 Stressing shall proceed on the indicated elongation.
 In case elongation reached earlier and corresponding jack pressure is not reached, further jacking 5%
extra elongation or desired jack pressure which earlier, shall be done.
 In case jack pressure is reached and elongation is not reached, stressing shall be continued up to a
maximum jack pressure of 1.05 times the calculated pressure or desired elongation whichever obtained
earlier.
 In case of variation more than the prescribed limits, the matter shall be referred to the design office.
 Initial slackness in pre-stressing cables shall be removed by applying tension of 1/3 the maximum
pressure.
 The pressure shall then be increased gradually by intervals of 50kg/[Link] and elongation shall be
recorded.
 When conformity of the design elongation with the measured one are ascertained, the tendon force
shall be anchored.
 On reaching the Full load, the wedges shall be locked of hydraulically at 250 to 280 kg/[Link] lock off
Pressure.
 Upon successfully completed stressing of the tendon, the jacking unit shall be removed and installed to
the next tendon.
 After removal of jack, a mark shall be done on strands at a distance of 100 mm to observe 24 hrs for
any further wedge slip. If any slip is observed, the observation shall be submitted to Designer for their
review & approval.
 The strands protruding from the anchor head shall be cut off at a distance of not less than 50 mm from
the anchor-head surface by means of an abrasive disc cutter.
 The 1st stage stressing shall be done after 3 days or on achieving 30N/mm2 whichever is later.
 After checking the slip for 24 hours the Girder shall be shifted from casting bed to stacking bed.
 The 2nd stage Stressing shall be done after 21 days or on achieving 45Mpa whichever is later.

71
 After checking the 24 hours slip the strands protruding from the anchor heads shall be cut and grouting
shall be carried out.
 A stressing record shall be prepared for each cable to be stressed on which all steps and occurrences of
the procedure are recorded. The stressing record sheet shall be filled up by the pre-stressing technician
in charge of the operation.

c) Grouting of tendons
 The tendon shall now be prepared for grouting. Between stressing and grouting of a tendon with in
10days after tensioning, but not before 24 hours after tensioning.
 Grout vents at least 20 φ shall be provided at both end anchorages for each cable.
 Grout caps shall be fixed on both sides of anchor heads and tightly secured.
 Ducts shall be flushed with lime water for cleaning as well as wetting the duct walls. The entire water
shall be drained through lowest drain pipe or by blowing compressed air through the duct.
 As soon as flushing is completed the grout operation shall be started.
 The proportions of grout materials shall be based on field trials conducted before commencement of
grouting.
 Water shall be added in mixer first, followed by cement and admixture.
 The additive admixture is mixed with cement in proportion as recommended by additive manufacture.
 The grout mix shall have water cement ratio not exceeding 0.45(as per IRC 18-2000) Cebex 100 in
right proportion shall be added to the grout mix to avoid the shrinkage of the grout mix.
 The compressive strength of 100mm cubes of the grout shall not be less than 17 Mpa at 7 days.
 The temperature of the Grout shall not Exceed 25 degrees Celsius.
 Mixing time of grout shall be 2 to 3 minutes so as to obtain uniform and thoroughly blended grout. The
grout shall be continuously agitated with agitator till it is injected. Water shall not be added once the
grout is mixed thoroughly.
 The locking pressure 5 kg/[Link] is to be maintained for approximate one minute. Consistency of grout
shall be ensured.
 Once the desired pressure of injection reaches, the valve at the entry point shall be closed.
 Records for grouts shall be maintained.

d) End Cap Concrete

 The rebar shall be tied as per the approved drawings.
 The side formwork shall be placed and secured properly.
 Before placing the end shutter, Nitobond EP shall be applied on the old concrete to achieve
proper bonding between old & new concrete.

72
  After the concreting is done, it shall be cured to achieve the strength.
 The formwork shall be removed and now the girder is ready for erection after being stressed.

3. Health, Safety & Environment:

 Safety stewards shall be engaged for monitoring to avoid unsafe conditions & unsafe acts.
 Green helmets shall be provided for safety stewards.
 All the persons involved shall be given Pep talk before start of the Pre-stressing activity.
 All the staff and work men shall be provided with necessary personal protective equipment (Safety
helmets, safety hand gloves, safety shoes, safety belts, safety goggles, retro-reflective jackets etc)
always at site.
 Drinking water facility shall be provided at site.
 First aid box with necessary medicines shall be available at site office.
 General Lighting shall be provided in work place.
 Only certified plant & machineries shall be put in operation.
 The operators shall have relevant experience and valid license to operate machineries.
 A warning sign, “Stressing Operations in Progress” shall be put up at locations where stressing
operations would be carried out.
 Strand bundle protruding from the bearing plate must be encased in a plastic or sheet metal pipe to
prevent injury by the sharp ends of the strands.
 During the process of strand cutting, only abrasive disc cutters with guard shall be used, and goggles
shall be worn during the process.
 Only intact and tight pressure hoses shall be used.
 No stranger shall be allowed in the immediate vicinity of the stressing equipment during stressing to
avoid injury in event the tendon or concrete should fail.
 The pump and jack shall be securely tied to a solid object when working at an elevated level.
 No stressing equipment or accessories shall be used that are not complete as supplied from the
manufacturer or post-tensioning supplier.
 Stressing shall take place on a proper working platform, as required by the regulation agency. Hands
shall be kept out of jack while stressing operation is taking place and while retracting.
 All persons shall stand clear of equipment, hoses or electric cords while stressing is taking place;
always use the remote switch and not the toggle switch located on the pump unit. If a tendon shall fail
or a blowout occur, or the jack grippers fail; the jack, pump, hoses and electrical cords shall be thrown
off the structure. If this occurs anyone standing close the hoses or cords shall be dragged off the
structure with the equipment

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 METHOD STATEMENT FOR ERECTION OF PRE-CAST PSC/ RCC- I
GIRDER & SLAB PANELS -26

1. Scope:
This scope of method statement is as follows:
Erection of I-Girders in position.
 Construction of diaphragm.

2. Reference Documents:

 Contract Agreement with DBL Limited & UPEIDA.

 MoRT&H Specifications for Road and Bridge works published by Indian Roads Congress, New Delhi,
(Fifth Revision).
 IRC:21-2000: Standard specification for codes of practice for road bridges, Section-3(Cement
concrete-Plain & reinforced)
 IRC: SP 47-1998: Guidelines on quality systems for road bridges (Plain, reinforced, pre-stressed and
composite concrete).
 IS: 456-2000: Plain and reinforced concrete (code of practice).
 IS: 2502-1967: Code of practice for bending and fixing of bars for concrete reinforcement.
 IS: 1786-1985: Specification for high strength deformed steel bars and wires for concrete
reinforcement.
 IS: 8112-1989: 43 grade ordinary Portland cement-Specification.
 IS: 12269-1987: Specification for 53 grade ordinary Portland cement.
 IS: 516-1959: Methods of tests for strength of concrete.
 IS: 383-1970: Specification for coarse and fine aggregate from natural sources for concrete.

3. Procedure:

The following sequences of activities are narrated as under.

1. Pre-stressing of I-Girders (Covered in separate method statement)

2. Installation of Bearing (Covered in separate method statement)
3. Erection of I-Girders
4. Construction of Diaphragm
5. Erection of Deck Slab

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A. PRE-STRESSING OF I-GIRDERS (REFER SEPARATE METHOD STATEMENT)

 Top of girder shall be cleared from laitance by wire brush.

 The stressing operation shall be commenced as per drawing.
 Detailed methodology for Pre-stressing of I-Girders shall be submitted separately.

B. INSTALLATION OF BEARING (REFER SEPARATE METHOD STATEMENT)

 Once the bearings are received from the approved supplier, it shall be ensured that they are
accompanied by all relevant test certificates.
 The bearings shall be stored in such a place that they remain free from dust.
 The bearing installation shall be done when the arrangement for girder erection is being organized.
 The grout underneath the bearing shall be allowed to gain strength equal to strength of the girder,
before erections of the girder over them are taken up.
 Detailed methodology for the installation of bearings shall be submitted separately.

C. ERECTION OF I-GIRDERS

 The ground shall be compacted all around the structure to facilitate the crane movement.
 The slings & D shackles of capacity 80 T shall be used for handling the girders during erection.
 Adequate clearance for crane movement shall be maintained. Two Cranes of 150 T capacity shall be
engaged.
 The sequence of girder erection shall be followed as indicated in the drawings.
 The level of the ground shall be maintained in such a way that no crane at the time of combined
handling has to travel in an undulated ground profile during its forward/backward travel.
 The exact location on the bearing shall be marked so that the girder is placed perfectly over it.
 Once the girder is placed at its designated location over the bearing, the gap between the girder and
the bearing is grouted with epoxy cementitious grout.
 Proper access to the top of the pier-cap shall be made available with the help of DBL-tower.
 The working space for the workmen, when they align & place the girder over the bearing shall be
protected, so that a sense of security against the working at height is ensured for the workers working
at the pier cap level.
 Once the girder is erected over the bearing, as a precautionary measure, lateral support shall be
provided from the pier-cap against any lateral tilt.
D. CONSTRUCTION OF DIAPHRAGM

 After the erection of PSC girders, the diaphragm activity shall be taken up.

75
  Bar bending schedule shall be prepared as per approved drawings, and reinforcement steel shall be
cut and bend as per approved bar bending schedule.
 The tying / welding for the diaphragm reinforcement shall be taken up at location itself as per IS:
2502 & IS: 9417.
 Reinforcement bars shall be placed accurately in position as shown in the drawings.
 The bars, crossing one another shall be tied together at every intersection with binding wire, to make
the skeleton of reinforcement rigid such that it does not get displaced during placing of concrete or
any other operation.
 Adequate cover shall be maintained on all sides except on the top surface to achieve proper cover as
per the drawing.
 Required formwork shall be made out of steel shutters to suit the site conditions.
 Releasing agent shall be applied before fixing the form work.
 The formwork shall be erected in true to line, levels, plumb, etc., rigid, adequately braced both
horizontally and vertically.
 Form joints shall be as much as minimized shall be tight and shall not permit any leakage of slurry
from concrete.
 Formwork materials shall be rigid, even surface, and sufficiently strong to prevent deformation
during concrete.
 Concrete shall be placed carefully at designated position.
 Concrete shall be placed by concrete pump/ crane with bucket arrangement / Boom Placer as per the
specified grade of concrete and vibrated properly using needle vibrator.
 Concrete pumps and pipe lines shall be primed before commencement of concrete pumping
operations.
 The concrete shall be supplied by batching plant and transported through transit mixers.
 Concrete shall be thoroughly compacted with immersion type vibrators and worked around
reinforcement and into corners of formwork to produce a dense homogeneous void-free mass having
a required surface finish.

E. ERECTION OF PRECAST DECK SLAB

 The erection of precast deck slab shall be done as per Drawing.

 Before the erection of deck slab is taken up, the rebar protruding out of the precast deck slab shall be
cleaned properly of the dirt, cement slurry etc.
 The portion of the erected girder, wherein the precast deck panels are proposed to be supported shall
be cleared of all dirt and shall be leveled by hacking & chipping to the extent possible.

76
 As per the approved drawings, the adjustment strips shall be positioned on the top of the girder with
the help of glue so that they are not disturbed while the precast deck slabs are placed over them.
 Once entire gap between the girders are covered by the precast deck slab, the in-situ concrete for the
balance thickness of the deck slab shall be taken up. The concreting of the in-situ portion of the deck
slab shall be done as per approved method.

6. SAFETY PRECAUTIONS:
 Safety stewards shall be engaged for monitoring to avoid unsafe conditions & unsafe acts.
 Green helmets shall be provided for safety stewards.
 All the persons involved shall be given Pep talk before start of the work.
 All the staff and work men shall be provided with necessary personal protective equipment (Safety
helmets, safety hand gloves, safety shoes, safety belts, safety goggles, retro-reflective jackets etc)
always at site.
 Drinking water facility shall be provided at site.
 First aid box with necessary medicines shall be available at site office.
 General Lighting will be provided in work place.
 Working area shall be barricaded properly & necessary display boards shall be provided on either
ends.
 Only certified plant & machineries shall be put in operation.
 The operators shall have relevant experience and valid license to operate machineries.
 While erection of girder is in progress on the top of the pier-cap, special precaution shall be taken to
barricade the area under operation.
 No other person other than involved in that particular activity shall be allowed in the zone of
erection.
 The Construction Manager shall have full knowledge of the people engaged for the activity.

77
 METHODOLOGY FOR APPLICATION OF ASPHALTO SEAL ON
CONCRETE BRIDGE DECKS -27
1. Scope:
 This work shall consist of furnishing and laying of 6mm thick Asphalto seal on concrete bridge decks
for water proofing.
2. Reference: Asphaltoseal Brochure supplied by approved source.
3. Equipments:
 Gas Cylinder, trowel, wire brushes, Gas cutter, measuring tape, knife, compressor, and wooden
flat/PVC Pipe.
4. Materials:
 Asphalto Seal: It is a water proofing membrane consists of high strength reinforcement in layers of heat
resistant rubberized asphalt. The reinforcement and rubberized asphalt interact to form a tough
membrane that remains flexible through a wide range of temperature and movements. The tacky
rubberized asphalt assures quick adhesion to the deck.
 Primer: It is a special primer which affords a good adhesion of the membrane to the concrete deck. It
provides a tight water seal and the same time allows gases in the concrete to escape.
5. Procedure:
 The surface of the concrete bridge deck shall be water proofed and cleaned completely.
 Make sure the bridge deck shall be free from dust, oil, protrusions, ribs, hooks, and nails, rebar‟s etc.
 Heat the surface to release the moisture if any from the bridge deck.
 If any protrusions visible on the bridge deck, shall be cut completely to avoid puncture to the asphalt
seal membrane.
 Apply a coat of Bitumen primer on the bridge deck surface at the rate of 200 to 250g/m2 and allow it to
dry completely for 30 to 45min.
 The asphalto seal rolls shall be lined up and spread open over the deck area with proper side laps and
end laps without any wrinkles.
 The membrane shall be rolled back without changing its orientation.
 The roll shall be unrolled once again and torch the underside with the help of LPG Gas cylinder evenly
and sufficiently to cause surface melting.
 The membrane shall be pressed with the help of wooden flat/PVC Pipe from top of the membrane from
inside to outside ensuring that there is no entrapped air and proper adhesion to the deck.
 The overlap joints shall be heated from the top to produce a thin bead of molten bitumen as the seam,
should be smoothened out with a hot travel, ensuring a proper joint.

78
  Make sure that the overlapping of the subsequent rolls shall be 50mm in longitudinal direction and
100mm in transverse direction.
 Repeat the same procedure for further layers and make a firm, water proof surface.
 Prior to allow the traffic over asphalt seal, a BC layer of 25mm thick shall be laid.
6. Safety Precautions:
 The deck area to be barricaded
 Workman shall wear PPE
 Only trained workmen shall be deployed

79
METHODOLOGY FOR INSTALLATION OF STRIP SEAL EXPANSION
JOINTS -28
1. Scope:
 The work shall consist of fixing/placing of Expansion joints as indicated in drawings.
2. References:
 MoRT&H specifications clause no 2607 and Technical specifications of contract.
3. Equipments:
 Auto level with staff, welding aids, compressor, Asphalt cutter, Needle vibrators.
4. Tools:
 Measuring steel tape, line rope.
5. Responsibility:
 Responsibility of Implementation of this procedure lies with Site engineer and incharge of structures.
6. Materials:
 Strip seal Expansion joint Assembly.
7. Procedure:
 A recess of 300x180 mm shall be left in concrete on either side deck slab as well as on crash barrier
locations for future-provision of expansion joint.
 The portion of recess as well as of expansion gap shall be filled with temporary sand bags/sheets in
order to continue the laying of BC over the deck slab without any discontinuity.
 BC shall be laid over the deck slab in full width as per the required level and grade, which afterwards,
shall be cut and removed from the portion of recess and the gap.
 The recess shall be shuttered in such a way that the dimensions in the drawing are maintained. The
form work shall be tight.
 The joint shall be lowered in a pre determined position. The joint shall be levelled and finally aligned

and anchor loops on one side of the joint welded to exposed reinforcement bars of the deck slab. The

same procedure shall be followed for the other side of joint.

 The Transverse reinforcement bar shall be provided on either side of expansion gap at the locations as
shown in approved drawing.
 The recess-area shall be chipped and cleaned of any loose concrete or asphalt material with compressed
air jet.
 Epoxy to be done prior to concreting for avoiding cold joints. Concrete (Grade as shown in drg) shall
be poured within the recess and compacted using pokers. Top level of the concrete shall be flushed to

80
 the road FRL maintaining the level and grade as per the approved drawing. Top Surface shall be
textured after finishing of concrete.
 Water Curing of freshly poured concrete within the recess shall be continued for a period of 14 days
with hessian cloths/gunny bag.
 Rolled up neoprene strip seal shall be cut in to the required length and inserted between the edge beams
by using crow bar pushing the bulb of the seal in to steel groves of edge beams.
8. Safety Requirements:
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets, safety belts.
 During night work sufficient lighting shall be provided.
 Leveling staff shall be wooden or fiber.

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 METHODOLOGY FOR CONSTRUCTION OF REINFORCED EARTH
WALL -29
1. Scope:
 This work shall consist Excavation & foundation preparation, casting of leveling pad, erection of RE
Wall panels, filling of reinforced earth, laying of geo-grid, filling of retained earth, placing drainage
system, and casting of coping beam as per the drawing.
2. Reference:
 MoRT&H specifications and as shown in drawings.
3. Equipments:
 Batching plant, transit mixers, Dumpers, Motor grader, Loader, Roller, Plate compactor, Excavator,
Hydra, water tanker, straight edge, Total station, Auto level etc.
4. Materials:
a) Aggregate:
 Coarse Aggregate used in the concrete for precast panels, leveling pad, and drainage system shall
consists of clean, hard, strong, dense, and durable pieces of crushed stone. They shall not contain soft,
flaky, elongated, and deleterious materials. Coarse aggregate having positive alkali-silica reaction shall
not be used. All coarse aggregate shall conform to IS: 383 and IS: 2386 (Part 1 to VIII).
 The fine aggregate used in the concrete for precast panels and leveling pad shall consists of clean, hard,
strong, dense, and durable pieces of crushed stone or with a suitable combination of crushed stone,
natural sand. They shall not contain dust, lumps, soft, flaky, and deleterious materials. Fine aggregate
having positive alkali-silica reaction shall not be used. All fine aggregates shall conform to IS: 383 and
IS: 2386 (Part 1 to VIII). The fineness modulus of the fine aggregate shall be in between 2 - 3.5.
 The drainage material shall consists of clean crushed stone or gravel with particle sizes in the range of
9.5mm – 19.1mm (as per IS:383) and fines content less than 5% in accordance with the approved
drawing
5. Reinforced Fill:
 The reinforced fill shall be compacted to a minimum of 95% of the max dry density (MDD) obtained
from the proctor test performed as per IS:2720(part-8).Fill with in 0.5 m of the bottom of the pavement
(subgrade) shall be compacted to a min of 97% of the MDD. The coefficient of uniformity (C u) of the
reinforced fill shall be ≥2. Recommended guidelines for gradation are as given below;

82
 Particle size (mm) % Passing
75 100
0.425 0-60
0.075 0-15

c) Retained Fill:
 Peak effective angle of internal friction of compacted fill obtained from direct shear test (IS: 2720, Part-
13) shall have a min. angle of internal friction as per design shall be taken for execution and shall be
free from deleterious matter. The fill shall be compacted to a min. of 97 % of the mix dry density
obtained from the proctor test performed as per IS: 2720, Part-8. The fill within 0.5m of the bottom of
the part (sub grade) shall be compacted to a min. of 97% of the MDD.
d) Geogrid:
 The Geogrid used as reinforcement shall be Tec grid polyester geogrids from TechFab geosystems with
designations U-40, U-60, U-80, U-100, U-120, U-150, U-200, and U-250. The material specifications
are as per approved drawing.
e) Bearing pads and joint Filler:
 Bearing pads for horizontal bedding joints between panels shall be made of EPDM. All vertical joints
between the panels shall be covered with a geotextile strip (200mm width) meets the min requirements
for type-II sub surface drainage geotextile as per IRC: SP: 59-2002.
f) Leveling pad:
 The leveling pad shall consist of Plain Cement Concrete (PCC) strip footing of 600mm width and
200mm thickness. The PCC shall have a minimum 28 days compressive strength of 15Mpa.
g) Precast Concrete Panels:
 The dimensions of discrete panels are as per approved drawing. The panels shall be cured for a
sufficient length of time as approved by the Engineer using clean water. Sufficient care shall be taken to
ensure that panels are not damaged during handling, storage, and transportation. One sample of six
cubes shall be taken for each lot of 5 cum of concrete used in the production. Acceptance of panels shall
be on the basis of the compressive strength of cubes.
5. Procedure:
a) Excavation & Foundation preparation:
 Excavation shall be done to the full width and depth as shown in the drawing with the help of
excavator.

 The trench for the leveling pad shall be excavated to the correct dimensions

83
 Any unsuitable soil shall be removed and replaced with suitable approved borrow material and compact
accordingly.

 The base shall be watered and compacted thoroughly to ensure a firm surface for placing the leveling
pad and subsequent panels.

 Ensure whether the foundation meets the SBC mentioned in the drawing. If not, inform the same to
designer and the work shall be carried out as per Designer approval/Instructions.

b) Construction of leveling Pad:

 Mark the center line of the leveling pad on bottom of the trench.
 Fix side forms for the leveling pad.
 Place the concrete of grade M-15 and compact with needle vibrators to the correct level and finish with
wooden floats to a flat and smooth finish with a tolerance of +/- 5mm.
 Cure the leveling pad for period of min 24hrs prior to the commencement of panel placement.

c) Erection of Precast Panels, placement of reinforced fill, and geogrid (1st course):

 Mark centre lines of the leveling pad to coincide to the front face of the bottom most panels.
 Position the first SF panel on the leveling pad with its front face aligned along the centre line. Set the
panel to the correct inward batter by inserting the hard wood wedges below the base of the panels. The
required batter will depend up on type of fill, type of compaction equipment, degree of compaction,
length of reinforcement etc. Batter of 17mm/mt height or 10 may be adequate, but this could be varied
based on observation of panel movements. Install bracings (use 100*50mm timbers or steel props) for
the panel and mark ch. On rear side of panel.
 Place a BH panel, next to SF panel such that width of vertical joints is 20 mm and with its face flush
with the chalk line. Set the panel to the required batter.
 Continue the sequence till all the panels in first row are placed. Fix the clamps loosely. Check
alignment of the panels by sighting along the panel face and adjust the panels to obtain a true line if
required. Check the horizontal level of the panels using a spirit level. If require insert the shim at the
base to correctly level the panels. Tighten clamps and bracings.
 Install geotextile strips for vertical joints which shall have a min width of 200mm and shall be fixed to
the panels using suitable/approved adhesive in such a way that it will not be displaced during fill
placement and compaction.
 Spread the approved borrow material uniformly with loose thickness not exceeding 250mm and
compact layer wise up to 1st layer of Geogrid reinforcement.
 Spreading, grading, compaction of the fill shall be carried out parallel to the panel facing.

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  No plant or equipment with a weight exceeding 1500 kg shall be allowed to operate within 1.5m from
the facing.
 Compaction of the fill shall be carried out using appropriate equipment, which will not induce
excessive loads on the panels and at the same time achieves the required compaction. Towards this
following equipments are recommended to for different zones;
 The drainage layer of 300mm width shall be provided from the facing. The fill/drainage material shall
be compacted by a lightweight plate compactor or by hand tamping.
 Beyond 300mm and within 1.50m from the facing the fill shall be compacted using a vibratory roller
with a total weight less than 1500kg.
 Beyond a distance of 1.50m from the facing, the fill shall be compacted using a 8 – 10ton smooth drum
vibratory roller.
 Fill shall be placed and compacted in layers. Thickness of each layer shall be consistent with the
compaction used and the degree of compaction to be achieved. If necessary sprinkle water to bring the
water content close to the OMC.
 The dry density of the compacted fill must be at least equal to the following requirement:
 The required degree of compaction shall be 90% to 95% of Max dry density from panel to 1.5mt width.
 Beyond 1.5mt from panel, the fill shall be compacted to 95% of the max laboratory density measured
as per IS: 2720 (Part-VIII).
 Fill within 0.5m below the road crust shall be compacted to 97% of the laboratory density.
 Position the geogrid to the required depth and length as shown on the drawing with the longitudinal
direction perpendicular to wall face. Adjacent rolls of the geogrid shall be butting each other. Fold the
frond end of the geogrid back by 1.0m. Align the front edge of the geogrid with rare face of the panels.
If requires transverse ribs along the tie rod may be cut. Insert connector bars through the tie rods and in
between the two legs of the geogrid.
 Fix the rear end of the geogrid by placing small heaps of fill or using U pins. Pull the front end of the
geogrids and fix ensuring that geogrid is reasonably tight and free from wrinkles and folds. Check and
ensure that the anchorage length is at least 1.0m.

d) Place and compaction of fill up to the top of First course BH Panels:

 Placing and compaction of the fill shall be done up to the top of BH Panel. Care shall be taken during
filling, spreading, leveling and compaction of the fill to avoid any damage, disturbance or
misalignment of facing panels and geogrids. Fill placement method near the facing shall ensure that no
voids exist directly below the sub grade and tie rods.
 Construction equipment shall not be allowed to move directly over the geogrids. Avoid abrupt
stopping, turning etc. of the equipment to minimize misalignment of geogrid. Movement of compaction
equipment shall always be parallel to the facing.

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e) Erection of Panel, Placing and compaction of fill, laying of geogrid (2nd layer) :
 Top surface of the BH Panels shall be cleaned with stiff broom or brush to remove all soil, debris etc.
Remove the clamps.
 Reduction in batter shall be checked due to outward movement of panels during placement and
compaction of fill. If the batter has not reduced, use a lower batter for the next course of panels.
 Bearing pads shall be fixed as shown on the drawings on the top of the BH Panels.
 A row of SF Panels shall be placed over the 1st row of BH Panels and accurately align them to get a
vertical joint width of 20mm. Set them to the required batter using wooden wedges.
 Levels and alignment of the panels shall be checked.
 Geotextile filter strips shall be fixed behind vertical joints.
 Placing and compaction of the fill shall be done up to the 2nd layer of the geogrid reinforcement.
 2nd layer of geogrid reinforcement shall be installed.
 Placing and compaction of the fill shall be done up to the top of 1st row of SF Panels.

f) Erection of subsequent course of panels, filling and installing geogrid reinforcement:

 3rd and subsequent of panels shall be erected to the correct alignment and required batter. Fix bearing
pads on horizontal joints. Ensure uniform joint width of 20mm.
 Alignment of walls shall be checked at regular intervals using a Straight edge.
 For each course of panels, the wedges shall be removed after three courses have been erected. At any
point of time more than three levels of wooden wedges shall not be allowed. Otherwise it may become
difficult to remove them later on.
 Before the wall reaches half of its total height or 5m (which ever is less) the foundation trench shall be
filled in front of the wall with approved material.
 The top most rows of panels may be required to be varying height to achieve the required profile at the
top.
 Place and compact fill in layers, compaction of each layer must be checked before subsequent layers to
be placed on it. At the end of each day slope the surface of the fill away from the facing to drain away
surface runoff.
 Geogrid reinforcement shall be installed at each level as per the drawing.
 The placement and compaction of fill shall be carried out so that all layers of geogrids are fixed at the
appropriate levels (as per approved drawings) on top of the compacted fill. The deposition, spreading,
leveling and compaction of the fill shall be carried out generally in a direction parallel to the facing and
shall be executed in stages to alternate with the erection of facing panels and fixing geogrid
reinforcement. At reinforcement level, the fill should be placed and compacted to the level of the
connection. Fill placement methods near the facing shall ensure that no voids exist directly below the
tie-rods and geogrids reinforcement.

86
g) Placement of Drainage System:
 The drainage fill shall be placed in the same manner as the reinforced earth fill. During the placement
and compaction of the drainage material, care must be taken to ensure that there is no contamination
with undesirable materials. The drainage fill should be brought up at the rate as the adjoining reinforced
fill material. Graded granular filter shall be provided behind the drainage bay for purpose of filtration.
Perforated outlet pipes shall be installed at 6m interval along the length of the wall. At the inner end of
the pipes slotted caps shall be provided to prevent the entry of drainage fill into the pipe. The pressure
resistance capacity should be minimum 4kg/[Link]. The diameter of hole should be minimum 6 to 8 mm.
The triangular minimum distance between holes should be 25 mm & maximum 40mm.

h) Coping Beam:
 At the top of the upper most panels, provide a cast in-situ coping beam to achieve the required
longitudinal profile. The reinforcement shall be provided as shown in drawing.

6. Safety Precautions:
 Trenches excavated for RE Wall shall be barricaded properly.
 While excavating the trench, concerned authorized personnel shall be deployed to safeguard the utilities.
 Sufficient lighting shall be provided during night hours.
 All dumpers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided.
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 Persons shall not be seated on erected panels during construction.

87
 METHOD STATEMENT FOR LAYING OF
CEMENT CONCRETE KERB -30

1. Scope:

 This work shall consist of constructing cement concrete kerbs in the central median and/or along the foot
paths or separators in conformity with lines, levels and dimensions as specified in the drawings.

2. References:

 MORT & H specification of clause No: 408, Sec 1700 and technical specification of contract.

3. Equipments:

 Mechanized Kerb casting machine, (Make& Model: Arrow-750XL, Capacity:3.5mt/min)

 Batching plant, Schiwing Stetter, Model: CP-30 and 30 cum /hour capacity.
 Transit Mixer, Auto level with staff and kerb cutting machine etc.

4. Tools:

 Measuring Tape, spade, string wire, winch, pegs, Aluminium square bar, Trowels etc.

5. Procedure:
 The area, where kerb is laid shall be identified with respect to the drawing.
 Pegs & piano wire/string shall be fixed in line and level as shown in drawing, at 10 m interval.
 In curved portion the pegs shall be fixed at smaller intervals, say 5 m.
 The mechanized, sensor controlled Kerb Casting Machine shall be set properly over the reference marks
for the casting of the kerb.
 The M20 grade concrete shall be used. The slump of concrete at site shall be maintained between10-
30mm.
 Required quantity of Concrete shall be brought from the batching plant in transit-mixer to the site &
shall be fed to the machine.
 The mechanized Kerb Casting Machine shall be operated and casted the kerb to be checked for line and
level along with casting.
 Laying of PCC foundation on the existing road only, (if found necessary).
 Finishing / touch up on surface shall be done manually (if required) to get the final kerb within tolerance
limit.
 Joint of end & middle portion of kerb shall be finished manually after completion of concreting.
 Casting of cubes frequency shall be done as per clause 1716.2.4 of MORTH.

88
 The kerb thus cast shall be allowed to set & shall be cured with water or curing compound accordingly.
 The kerb shall be cut at 5m intervals. The cutting process shall start once the concrete attains sufficient
strength, which can able to with stand during cutting operation with cutting machine. The Blade
thickness shall be 3 to 5mm.
 Manual casting of kerb shall be restored to where machine casting is not possible. Shuttering and forms
of proper size & shape shall be used for such manual castings.
 All necessary Survey checks shall be conducted before and after kerb casting.
 Vertical and Horizontal tolerances with respect to true line and level shall be +/- 6mm.
6. Safety Measures:
 Care shall be taken while Kerb casting on main carriage way.
 The Kerb casting shall not disturb the live traffic.
 The Kerb casting crew shall wear PPE‟s, reflective Jackets.
 Take care of near by passing electrical lines and utilities.
 Where ever required Flagmen shall be provided to regulate live traffic.
 Reverse Horn shall be provided for all transit mixers using for kerb concrete.
 Traffic control shall be taken care by providing traffic signs and safety measures.

89
 METHODOLOGY FOR MEDIAN FILLING -31
1.
Scope:
 This work shall consist constructing of median in the road dividing the carriage way in to separate lanes
to channelize the traffic in accordance with the lines, grades and cross sections shown on the drawings.
2. Reference:
 Section 407 of MoRT&H specification
3. Equipments:
 Dumpers, Motor grader/Loader, Roller/Plate compactor, Wooden Rammer, and Water tanker.
4. Materials:
 The materials used in the median shall be soil, moorum, gravel, recycled material, a mixture of these or
any other suitable material approved by the engineer. Such materials shall be free of logs, stumps, roots
or any other materials likely to deteriorate the stability of the median.
 The materials shall satisfy the Physical and chemical requirements as per MoRT&H Clause No:
[Link], [Link], and [Link].
5. Procedure:
 Unwanted plants, roots, boulders, concrete and bituminous material shall be removed and got checked
by raising RFI prior to start of median filling.
 Place/Dump the approved borrow material or any other suitable material approved by the engineer in the
median by dumpers. In case of Existing road in used after ensuring road safety by placing barricades
50m before the spot with adequate information sign boards and markings.
 Care shall be taken to avoid spilling of soil over adjacent pavement while dumping.
 Soil shall be spread in uniform layers of 200mm using motor grader, Dozer, loader or manually as per
the site condition.
 Water shall be added to the material to achieve the moisture content in the range of +1 % to -
 Compaction shall be done with 8-10 Ton roller in 4.5m median where as in 2.5m median compaction
shall be done with 2.5 ton roller or plate compactor for 1.2 m median.
 The top most layers shall be compacted lightly in order to facilitate sufficient growth of roots of grass
and plants/shrubs.
 The filling shall be raised centrally by 3% on either side for easy flow of rainwater to the adjacent
pavement and avoid any water logging in median.

6. Safety Precautions:

 All dumpers shall be provided with reverse horn & light.

 Wherever required, Flagman shall be provided.
 The speed of construction vehicles plying in stretch shall be restricted to 30kmph.
 Any labour, if being used in the job shall be screened and trained.

90
 All workmen at work area shall wear PPE‟s and reflective jackets.
 Median filling work shall not disturb the live traffic.

91
 METHODOLOGY FOR KERB PAINT/OBJECT PAINT /STRUCTURE
CRASH BARRIER PAINT MARKING -32

1. Scope:
 The work shall consist of paint marking on kerb /object/Structure crash barrier by use of the solvent
based paint meeting the requirements specification as shown in drawings.

2. References:
 As per IRC:35 and MORT& H specifications clause no 803.3 OR Technical specifications of contract.

3. Tools:
 Measuring steel tape, wire/coir Brush, tins, other tools ,stencils.

4. Responsibility:
 Primary responsibility of implementation of this procedure lies with Site engineer and in charge of Road
section.
 Secondary responsibility of implementation of this procedure lies with QC engineer for material quality
control.

5. Materials:
 Paint as per grade 1 of IS: [Link], Black, Yellow colour. Suitable thinner as allowed by manufacture.

6. Procedure:
a) Kerb Painting:-
 The traffic will be diverted by placing proper safety barricades/safety cones/flag man.
 Ensure the Kerb surface shall be free from dust, grease, oil and all other foreign matter.
 The Kerb surface shall be cleaned with wire brush and cotton waste prior to application of primer.
 Apply a coat of approved primer on cleaned kerb surface and allow for drying for min 4 hours.
 The paint shall be properly mixed prior to use.
 The surface should be thoroughly dry and free from moisture before painting.

92
 Drawing 01
 After drying of primer apply a coat of solvent thinnable paint and allow for a drying period of min 2
hours.
 The colour of the paint shall be yellow & black in median openings length and White & black in
remaining portions of road. The width of strip shall be 500 MM.(As per Drawing no-01)
 Then apply the second coat of paint after drying of previous coat.

b) Object Paint Marking within the carriage way :-

 The traffic will be diverted by placing proper safety barricades/safety cones/flag man.
 Ensure the surface shall be free from dust, grease, oil and all other foreign matter.
 The object surface shall be cleaned with wire brush and cotton waste prior to application of primer.
 Apply a coat of approved primer on cleaned kerb surface and allow for drying for min 4 hours.
 The paint shall be properly mixed prior to use.
 The surface should be thoroughly dry and free from moisture before painting.
 After drying of primer apply a coat of solvent thinnable paint and allow for a drying period of min 2
hours.
 Obstruction of carriageway shall be marked with minimum five numbers alternative strips of black and
yellow colour.
 The strips shall be slope at an angle 45 degree towards the side of obstruction on which traffic
passes.(As per Drawing no-02)
 The width of strips shall be minimum 100mm and can vary up to 500mm as per the obstruction size(As
per IRC:35).

93
 Drawing 02
 The strips wide enough to provide visibility depending upon size object and speed of speed of
approaching traffic.
 On structure with insufficient vertical clearance, if the obstructing object does not easily lend itself to
paint the marking ,the marking may be placed on an independent surface attached to or mounted
immediately in front of the object
 The colour of the paint shall be yellow & black.
 Then apply the second coat of paint after drying of previous coat.
b) Crash barrier Paint marking:-

 The traffic will be diverted by placing proper safety barricades/safety cones/flag man.
 Ensure the surface shall be free from dust, grease, oil and all other foreign matter.
 The crash barrier surface shall be cleaned with wire brush and cotton waste prior to application of
primer.
 Apply a coat of approved primer on cleaned kerb surface and allow for drying for min 4 hours.
 The paint shall be properly mixed prior to use.

94
 The surface should be thoroughly dry and free from moisture before painting.
 After drying of primer apply a coat of solvent thinnable paint and allow for a drying period of min 2
hours(Or as per manufacturer recommendation).
 Shoulder side crash barrier of structure shall be marked with alternative vertical strips of black and
yellow colour of width 300mm as shown in drawing-3.
 Median side crash barrier of structure shall be marked with alternative strips of black and yellow colour
strips at an angle of 45 degree of width 300mm, arrow marking towards the side of traffic flow as shown
in drawing 3.
 At both end of crash barrier, the paint marking will be with alternative strips of black and yellow colour
strips at an angle of 45 degree of 100mm width as shown in drawing-3.
 Then apply the second coat of paint after drying of previous coat.
 Check the self-life/expiry of paint prior to use.

Drawing 03

7. Safety Requirements:
 The paint shall be stored in a cool, dry and covered place.
 Wherever the kerb marking is under progress the area shall be properly protected.
 All workmen shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.

95
 During night work sufficient lighting shall be provided.
 Please refer Material safety data sheet prior to use.

96
 METHODOLOGY FOR ROAD MARKING -33
1.
Scope:

 The work shall consist of marking traffic stripes using a thermoplastic compound meeting the
requirements as shown in Drawings.

2. References:

 MoRT & H specifications clause no 803 and technical specifications of contract.

3. Equipments:

 Thermo plastic material heating Equipment, Road marking machine, Total station.

4. Tools:

 Measuring steel tape, line rope.

5. Responsibility:
 Responsibility of Implementation of this procedure lies with Site engineer and in charge of Road
section.

6. Materials:
 Thermo plastic material as per clause No: 803.4.2, Glass reflectorizing beads Type 2 as per Clause No:
803.4.3.

7. Procedure:
 The traffic will be diverted by placing proper safety barricades/safety cones/flag man.
 Median and shoulder work shall be completed prior to Road marking.
 The BC surface shall be thoroughly cleaned of all dust, dirt, grease, oil and all other foreign matter
before application of paint.
 The thermoplastic powder is put in to the container of machine and it is to be heated. The material is
mixed uniformly by operating the mechanical agitator in the container. The thermostat is adjusted to a
temp of 180-2000C. The material is added to the container to its full capacity and melted till it achieves
smooth consistency.
 Thermoplastic materials shall be applied in hot condition either by screeding or extrusion process.
 After transferring the thermoplastic paint to the laying apparatus, the material shall be laid at a
temperature within the range of 180 to 200 degree centigrade.
 The application properties of the thermoplastic material shall be such that it shall readily get screeded
or extruded at applied temperature.
97
  The paint shall be applied with a thickness of 2.5 mm exclusive of surface glass beads. The width shall
be as per drawing.
 The Glass beads shall be applied at the rate of 250 grams per square meter area.
 The finished lines shall be free from ruggedness on sides and ends. The upper surface of the lines shall
be level, uniform and free from streaks.
 Traffic shall be allowed after 60 minutes of application at specified temperature.

8. Safety Requirements:
 Wherever the road marking is under process the area shall be properly barricated.
 The pavement temperature shall not be less than 100C during application.
 The thermoplastic material shall not be maintained in a molten condition for more than 4 hours.
 All workmen shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 During night work sufficient lighting shall be provided.

98
 METHOD STATEMENT FOR TRENCH FILLING -34

1. Scope:

 This work shall consist of filling of Trenches encountered in the alignment.

2. References:

 MoRT&H specifications and technical specification of Contract.

3. Equipments:

 Dumpers, Grader, Water tanker, Wheel loader, Dozer, Excavator/JCB, Roller and Auto level etc.

4. Tools:

 Measuring Tape, Crow bar, spade, etc.

5. Procedure:

 Prior to start of back-filling, the dimensions of trenches shall be measured.

 The trench sides shall be cut to enable the roller to enter, shall be filled in layers with cut / suitable
Embankment / sub grade material and compacted with roller to the required density as per MORT&H
table No: 300-2. Alternatively trenches shall be filled in layers of 300-500mm with locally available
sand and shall be fully saturated (flooded) with water.

6. Safety Measures:

 Where-ever required the Trench area shall be protected with barricading or safety ribbon.
 All trucks shall be provided with reverse horns/lights.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 Regular inspection for all dumpers at unloading point shall be required.
 Wherever required, Flagman shall be provided.
 Where-ever required, warning and cautionary boards shall be displayed at Trenches.

99
 METHODOLOGY FOR TURFING WITH SODS ON EMBANKMENT
SLOPES -35
1. Scope:
 This work shall consist of furnishing and laying of the live sods of perennial turf forming grass on
embankment slopes and earthen shoulders as shown in the drawing.
2. Reference:
 Section 307 of MoRTH specification.
3. Equipments:
 Template with 1:2 slopes, Spirit level, JCB, Spade, Lime powder, Line rope, measuring tape etc.
4. Materials:
 The sod shall consist of dense, well rooted growth of permanent and desirable grass indigenous to the
locality where it is to be used. The sods shall be free from weeds or other undesirable matter. While
cutting the sod, make sure the grass on the sod shall have a length of approximately 50mm and free
from debris.
 Thickness of the sod shall be as uniform as possible with 50 to 80mm. The sod shall be cut in
rectangular strips of uniform width, not less than about 250mm x 350mm in size.
5. Procedure:

 Prepare the Template of 1V:2H with spirit level at top shall be fixed.
 Embankment slopes shall be prepared by trimming as per the approved drawing with the help of JCB
and spade. Ensure/Check the side slopes with Template.
 The dressed/Cut soil shall be kept min 500mm away from the bottom starting point of slope.
 Trimmed surface shall be loosened and stones having size more than 50mm, stumps or any undesirable
foreign materials shall be removed.
 Ensure the trimmed side slopes shall be made of fine granular texture to a depth of not less than 25mm.
 The length of grass Over the Sods shall be min 50mm.
 Prepared embankment slopes shall be moistened to the loosened depth and sods shall be laid thereon
within approximately 24 hours after the same had been cut. The sod shall be laid from bottom of the
slope towards the top where side slope steeper than 2 (Horizontal) to 1 (Vertical) with the help of
template.
 Each sod strip shall be laid in staggered manner. Strips of sods shall be lightly tamped with suitable
means.
 After placing and tamping the surface shall be cleaned of loose sods, excess soil or any foreign
materials.
 The sods shall be watered regularly for a period of 4 weeks.

100
7. Safety Precautions:

 The turfing area shall be protected from live traffic.

 Put warning sign boards at turfing area.
 Any labour, if being used in the job shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 Ensure the soft shoulder width as per approved drawing.

101
METHODOLOGY FOR STONE PITCHING / REVETMENT ON SLOPES
-36
1. Scope:
 The work shall consist of covering the slopes of Guide bunds, road embankments with stone, boulders
over a layer of granular material called filter.
2. Reference:
 Section 2500 of MoRTH specification & Technical specification of contract.
3. Equipments:
 Tractors, Excavators, water tanker etc…
4. Materials:
 Pitching: The stone shall be sound, hard, durable and fairly regular in shape. Quarry stone shall be
used. The stones subject to marked deterioration by water or weather shall not be accepted. The weight
of stone shall be minimum 40Kg. The size of spalls shall be minimum 25mm and suitable to fill the
voids in the pitching.
 Filter media: The material for filter shall consist of sand, gravel, stone, coarse sand or approved
material. To prevent escape of Embank material through the voids of stone pitching as well as to allow
free movement of water without creating any uplift head on pitching, one layer of filter material shall
be provided underneath the pitching. The gradation of the filter media shall satisfy the requirements of
clause No; 2504.2.2 of MoRTH.
5. Procedure:
5.1 stone pitching:
 The banks, side slopes of Embankment shall be trimmed to the required depth as shown in Drawing.
 To maintain uniform slope and profile put up by means of line and pegs at the interval of 3 meter.
 Depressions shall be filled and thoroughly compacted.
 The approved filter granular material shall be laid over prepared base and suitably compacted to the
thickness as shown in Drawing.
 The lowest course of pitching shall be started from the toe wall and built up in courses upwards.
 The toe wall shall be constructed as per drawing.
 The stone pitching shall be commence in a trench below the toe of the slope.
 Stone shall be place by hand to the required length and depth confirming to the drawing.
 Stones shall be set normal to the slope, and placed so that the largest dimension is perpendicular to the
face of the slope.
 The pattern of laying shall be such that the joints are broken and voids are minimum by packing the
spalls wherever is necessary and top surface is as smooth as possible.

102
5.2 Procedure for Dry rubble flooring:
The work shall consist of constructing dry rubble flooring at cross drainage works.

 The base of the flooring shall be prepared to the specified levels and slopes and compacted suitably
with hand rammers or other means to have an even bedding.
 The thickness of flooring shall be made with one stone only.
 The stones shall then be laid closely on prepared base in one layer.
1.3 Procedure for Flexible Apron:
 The flexible apron comprising loose stone boulders shall be provided beyond curtain walls.
 The weight of stone shall not be less than 40 kg.
 The dimensions of apron shall be provided as shown in the drawing.

6. Safety Precautions:
 All dumpers, tankers shall be provided with reverse horn & light.
 Wherever required, Flagman shall be provided.
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 Leveling staff shall be fiber or Wooden.
 Any labour, if being used in the job for surveying shall be screened
and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets.
 The pitching work shall not disturb the live Traffic.

103
 METHODOLOGY FOR REINFORCEMENT WELDING -37
1.
Scope:
 The work shall consist of Welding of Fe 415/Fe 500 Reinforcement bars as per specification.
2. Reference:
 As per IS: 9417 and MoRTH specification.
3. Equipments:
 Welding machine with electrodes.
5. Procedure:
 If the dia of rebar up to 20mm lap welding shall be done. If more than 20mm Butt welding shall be
done.
 E -7018 grade electrode only be used for welding.
 The size of electrode shall be used based on the diameter of Rebar.
a) If the dia of bar up to and including 10mm – size of electrode 2.5mm.
b) Over 10mm and Up to and including18mm – 3.15 mm
c) Over 18mm and up to and including 28mm - 4.0mm
d) Over 28mm – 5.0mm
 The arc shall be start in the Groove /joint, which will be subsequently welded over.
 The movement of electrode for welding lap joints in horizontal and vertical position shall be as per IS:
9417.
 The Lap welding for same diameters of rebar shall be greater than or equal to 5d at both ends.
 The min gap between the end welding shall be minimum 5d.
 Welding directions for horizontal or near-horizontal lap joints, In case of Vertical lap joints, the
welding shall be performed from bottom to top (rising).
 Lift - off the Electrode.
 The visual Inspection and other tests shall be carried out as per IS: 9417.

6. Safety Precautions:
 Welding cable is checked for its tightness by the welder.
 Return earth is given through the welding lead only and no rebar to be used for return path.
 Double earthing shall be provided. All electrical connections is routed through RCCB.
 Welding holders shall be replaced when found damaged.
 Only experienced/Qualified welder shall be allowed for the welding job.
 Leather hand gloves, Glass shield shall be used.
 All workmen at work area shall wear PPE‟s.

104
 METHODOLOGY FOR CONSTRUCTION OF BORED CAST IN SITU
PILES -38
1. Scope:
 The work shall consist of construction of bored cast in situ piles for structures in accordance with the
details shown on the drawings and confirming to the requirements of these specifications.
2. References:
 MoRT & H specifications clause no 1115.2 and Technical specifications of contract cl:7.10.3.

 IS: 2911 (Part –IV): IS 2911: Part 1: Sec 2: 1979 Code of practice for design and construction of pile
foundations: (Part-1: Section-2:Bored cast-in-situ piles )

 IS2911: Part-4: 1985 Code of practice for design and construction of pile foundations ( Part 4: Load
test on piles)

3. Equipments:
 Excavator, Batching plant, Transit mixers, Hydra crane, casing, tripod, tremie pipes, winch, Auto level,
levelling staff. Welding machine.
4. Tools:
 Cube moulds, slump cones, trays, Steel pins/wooden pegs, Hammer, chisel, Measuring steel tape, line
rope.
5. Responsibility:
 Responsibility of Implementation of this procedure lies with Site engineer and incharge of structures.
 Centerline marking responsibility lies with surveyor.
6. Materials:
 Bentonite, Aggregate, river sand, cement, Reinforcement etc.

7. Procedure for Casting of Piles:

a) Setting Out:
 Prior to the start of piling operations, setting out stations and bench marks will be established at site.
Pile point will be established using total station and marked with a steel pin/wooden peg. After casing
installation the casing will be again surveyed to determine that it is within tolerance.
b) Boring of Piles:
 The excavation of clay-based material down to the top of first sand layer will be excavated by auger. At
the sand layer, bentonite will be added to the pile bore and boring will continue by drilling bucket.
Constant level of bentonite will be maintained to stabilize the shaft and level of bentonite will be kept
at a minimum of 1.5 m above the water table. Continuous supply of bentonite solution will be

105
 maintained to avoid any collapse of adjacent soil. This process will continue until pile toe level has
been reached. The drilling tools are designed to allow adequate free flow of bentonite during tool
extraction. Operation of boring, lowering of cage, flushing of bore and concreting of pile for full length
will be accomplished in one continuous operation as far as possible.
c) Reinforcement Cage:
 The reinforcement cages will be fabricated at site as far as possible near the pile location. To prevent
damage and distortion the cages will be lifted at two points and carried vertically to the pile.
Reinforcement cage will be made either in one piece of entire length of pile or in two / three pieces and
splicing of bars will be done with sufficient lap length. Cage will be lowered with the service crane.
d) Bentonite Replacement:
 During excavation specific gravity of bentonite becomes high. Prior to concreting, this heavy bentonite
must be replaced by light one. To achieve this, 250 mm dia tremie pipe will be lowered to the pile base
with flushing head on top. Fresh bentonite will be pumped through the tremie to replace the existing
solution till the specific gravity of bentonite becomes less than 1.05 g/cc. However this procedure must
be limited to prevent over excavation and loosening of the pile base material.

e) Concreting:
 As soon as possible, after the pile and bentonite have been cleaned, high workability retarded concrete
(slump – 150 to 180 mm) will be delivered to the pile location in transit mixer. A concrete hopper with
plug will replace the flushing head. The first charge of concrete will be placed with a plug when pulled
will push down the concrete. The concrete will be poured rapidly into the hopper and continue until
flow ceases in the pipe. The tremie pipe will be raised slightly until flow recommences and concrete
discharge will continue. Tremie pipe should always be kept full of concrete. To ensure compaction by
hydraulic static heads, rate of placing concrete in the pile shaft shall be maintained at minimum 6m per
hour. After each truckload of concrete, the depth of concrete will be measured & recorded. The tremie
will be split as the concrete proceeds to ensure a free flow and a minimum embedment depth of tremie.
The concreting operation will continue until its level is at least 1.0m above pile cut-off level. Incase of
interruption during concreting, guidelines mentioned in clause 7.5 and subsequent sub clause 7.5.1,
7.5.2 & [Link] of IS: 2911 (Part I/ sec 2) 1979 will be followed. The casing will be extracted by heavy-
duty crane.

8.0: Records

 Rebar casing dimensions

 Pile depth measuring format (shall be checked by chain method).

106
  Compressive strength & Slump record
 Liquid limit of bentonite.
9. Safety Requirements:
 The work area shall be properly barricaded.

 Any labour, if being used in the job for surveying shall be screened and trained.

 All workmen at work area shall wear PPE‟s and reflective jackets, safety belts.

 During night work sufficient lighting shall be provided.

 Levelling staff shall be wooden or fiber. & All vehicles shall have reverse horn.

107
 METHODOLOGY FOR HIGH STRAIN DYNAMIC LOAD TEST ON
PILES -39
1. Scope:
 The work shall consist of Preparation of pile head and Conduct the High strain Dynamic load test on
working pile.
2. References:
 MoRT & H specifications clause no 1113, IS: 2911( part IV) and ASTM D 4945-96
3. Equipments:
 A tripod, Lifting Mechanism to lift 4.0 MT weight to 3.5 mt height, 7.5 KV DG set with single phase
power supply,
4. Tools:
 Measuring steel tape, line rope, sensors.
5. Responsibility:
 Responsibility of Implementation of this procedure lies with Site engineer and in charge of structures
6. Materials:
 MT weight hammer, Steel helmet of 40mmthick plate, 40mm plywood cushion,
7. Procedure:

PILE HEAD AND TEST PREPARATION :

 The pile top shall be re‐built for a length equal to 1.8‐2.0 times the pile diameter with an at least 4mm
thick steel casing to provide smooth finish. Alternatively shuttering / formwork can be used (to achieve
smooth surface). Two openings / windows (300mm x 300mm) diametrically opposite to each other
shall be made if casing is used. This is for fixing gages to pile. The opening shall be located about 1.5
times the pile diameter below the pile top.
 Dowel bars shall be kept intact and shall be spliced with additional reinforcement provided in the built‐
up portion. Minimum cover of 75mm shall be provided even in the built‐up portion of the pile.
 The strength of concrete in the built‐up portion shall be equal to or one grade higher than the pile
concrete in order to withstand the impact of the falling ram.
 40 mm plywood cushion with diameter equal to pile diameter shall be placed over pile at the time of
testing.
 Steel helmet of 40mm thick shall be kept ready at the time of testing. Helmet should not be welded to
the pile casing.
 A suitable guide shall be provided to ensure a concentric fall.

108
 A 4.0 MT (1-2 % 0f test load) hammer with diameter not more than pile diameter shall be used for
testing the pile of capacity approximately 400 MT. The hammer should have 8mm thick liner/casing
with 40mm thick base plate. Also steel cage should be welded to liner.
 Central hook shall be provided for lifting the hammer without ant tilt to avoid eccentric blows.
 Start the fall of hammer at a height of 1.0 mt and increase to interval of 0.5 mt till test load is achieved.
The fall off height is expected to vary from 1.0 mt to 3.5 mt.
 For each hammer blow, the strain transducers measure strains whereas accelerations are measured
by accelerometers connected on either sides of the pile. These signals are then converted to digital form
by the equipment and then converted to force and velocity respectively by integration.
 The force and velocity curve shall be generally as defined in ASTM D4945.
 A suitable power source supply shall be provided for fixing sensors and for the test equipment.

SKETCH FOR PILE TEST 

109
8. Reports:
The final report shall consists of the following
 Introduction
 Over view
 Equipment Details
 Methodology
 CAPWAP analysis
 Discussion of results
 Conclusions
The complete CAPWAP analysis report shall be submitted with the final report and shall include the
following in addition to above.
 Total pile capacity in friction and end bearing.
 Frictional distribution along the sides of the pile.
 Changes in pile cross section if any.
 Simulated static test curve.
 Force and velocity curve obtained on field.

9. Safety Requirements:
 The work area shall be properly barricaded. Care shall be taken during testing; the sensors shall not be
disturbed.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets, safety belts.
 During night work sufficient lighting shall be provided.
 Leveling staff shall be wooden or fiber.

110
 METHODOLOGY FOR LOAD TEST ON BRIDGE -40
1. Scope:
 The work shall consist of Preparation of load test on new constructed structures for deflection on
designed load as per IRC.
2. References:
 IRC – SP 51:Clause No. 5.0 and IRC – SP 37: Clause No. 6.6.2.
3. Equipments:
 Movable loads arrangement for loading, Dial gauge of accuracy 0.01mm, Total/Auto level station with
leveling staff- tripod , 7.5 KV DG set with single phase power supply and light mask for proper
lighting arrangement.
4. Tools:
 Measuring steel tape, line rope, temperature and humidity sensors. All size spanners.
5. Responsibility:
 Responsibility of Implementation of this procedure lies with Site engineer and in charge of structures
with QC person.
6. Materials:
 Load as per IRC Class – A / 70 R loading, Steel towers (Scaffolding) for dial gauge fixing at bottom of
slab/girder, Hard wooden blocks for base arrangement, lubricant oil,
7. Procedure:
 DEFLECTION MEASUREMENT:
Vertical deflections on the bridge (up to 25mm) will be measured by Displacement Dial Gauges, having
least count of 0.01mm, fixed on firm supports. Dial Gauges are positioned along the longitudinal &
transverse alignment of the bridge. Displacement Dial Gauges are placed in longitudinal direction along
the mid point of Girder bottom . There will be 12 nos of gauges, 4 nos will be placed at mid span (one
each for a girder).Similarly 4 nos each on both end of girder bear bearing.. Dial gauges are supported by
firm scaffolding beneath the bridge so as to avoid any disturbance to the dial gauges.

 POSITION OF LOAD FOR TESTING: The method of loading adopted is point load reaction
method. Loading is according to the IRC standard .

111
  LOADING & UNLOADING SEQUENCE: The test load is applied in six stages viz; 30 %, 50%,
70%, 80 % , 90% and 100% of load. Unloading is also carried out in the same sequence.

 MEASUREMENT OF DEFLECTIONS: Deflections are measured by Displacement Dial Gauges of

25mm (Min.) having least count of 0.01mm.

 CORRECTION FOR TEMPERATURE: Temperature measurement is done at the bottom of the

test span or adjoining span. The temperature is measured by probe/thermometer. Appropriate
correction is made for the temperature variation.

 Testing steps by step: Displacement Dial Gauges are fixed at place and deflection is measured prior to
loading for 24hrs at regular one hour interval for compensating for temperature correction. Next day
loading is started and simultaneously deflection is measured. First increment of (0.3W) is
maintained for 1 or 2 hrs and next stage of loading is applied and will be maintained up to 2 hrs ,
and similar procedure is adopted till 100 percent load is applied. This 100 perecent load is
retained for next 24 hrs, and deflection reading will be noted for each one hour. After 24 hrs of
retainment of 100 % load, unloading is started immediately by removing load in the reversal
sequence as was been loaded. Rebound readings are measured.

 ACCEPTANCE CRITERIA
IRC – SP 37: Clause No. 6.6.2 and IRC SP 51 Clause no 5.

The load for rating should be taken as the least of: -

(i) The loading causing deflection of 1 / 1500 of the span in any of the main girders for simply
supported spans or as per design load.
(ii) The load causing tension cracks of width more than 0.3mm in any of the girders for normal cases
and 0.2mm for structures exposed to very severe and adverse conditions.
(iii) The load causing appearance of visible new diagonal cracks of width more than 0.3mm for normal
cases and 0.2mm for structures exposed to very severe and adverse conditions or opening/widening
of existing cracks close to the supports in concrete girders.
(iv) The load at which recovery of deflection on removal of load is not less than 75% for R.C.C.
structures and composite structures and 85 % for prestressed concrete structures as given in table
below
(v) PSC and RCC superstructures are given in Table below:

112
 Duration of Minimum percentage recovery of
Sr.
Types of Bridges Retention of Test Deflection at 24hrs. after removal of
No.
Load (Hrs.) Test Load
1. Reinforced Concrete 24 75
2. Pre-stressed Concrete 24 85
3. Steel 24 85
4. Composite 24 75

8. Reports and measurements: -

 All measurements will be noted down in formats with loading and deflection for final analysis.
9. Safety Requirements:
 The work area shall be properly barricaded. Care shall be taken during testing; the sensors shall not be
disturbed.
 Any labour, if being used in the job for surveying shall be screened and trained.
 All workmen at work area shall wear PPE‟s and reflective jackets, safety belts.
 During night work sufficient lighting shall be provided.

113
METHODOLOGY FOR MEASUREMENT OF SURFACE UNEVENNESS
BY AUTOMATIC ROAD UNEVENNESS RECORDER – 41
1. Objective:
 Towed fifth wheel bump integrator Test is to be conducted on bituminous surface to evaluate surface
regularity.
2. Scope:
 This work shall consist of measurement and determination of surface unevenness by “Automatic Road
Unevenness Recorder” also known as “Bump Integrator” on finished Bitumen layer (BC) before
allowing the traffic.
3. Reference:
 ARUR Model II Brochure, IRC specifications.
4. Equipments:
 It comprises of a trailer of Single wheel with a pneumatic tyre mounted on a chassis over which an
integrated device is fitted. The machine has a panel board fitted with two sets of electromagnetic
counters for counting the unevenness index value.
 Four Wheeler/Utility vehicle for attaching the bump integrator, pilot vehicle and broomer for cleaning
the bituminous surface.
5. Manpower:
 The below mentioned Personnel will be deployed to look after the operation and measurement of Road
unevenness values by the Bump Integrator
a) Quality Control In charge/Engineer or site Engineer from EPC Contractor
b) Material Engineer or Field Engineer from PMC
c) One QC Lab Assistant from EPC Contractor
d) Assistant material Engineer or Assistant Highway engineer from I/C.

6. Testing Procedure:
 Operation of the Bump integrator:
a) EPC contractor shall raise Request for Inspection (RFI) for checking the unevenness of bituminous
surface.
b) The Bump integrator should be towed by a vehicle at a speed of 32 +1 km/hr. A jeep or Utility
vehicle with a canvass body is eminently suitable because it affords opportunities for the driver to
keep a watch on the unit. The jeep or utility should have sound suspension system. The tyre pressure
of 2.1 kg/cm2 in the rear wheels of the jeep or utility should be same.
c) Before carrying out tests it is advisable to check the following items:
1) Tyre pressure is 2.1 kg/cm2 (30 PSI).

114
 2) All the bolts of the towing hitch and the bracket fixed with the towing vehicle are tight.
3) The caster-wheel adjustable jacks are removed from the Bump integrator.
4) Tyre pressure gauge and foot pump kept in towing vehicle.
5) Spare like integrator cords, toolkit, dipstick and fluid for the dashpots kept in the
towing vehicle.
6) The relevant result-recording forms are also kept with the counter-board.
Comprehensive notes should be taken giving particulars of test length, width of road,
type of surfacing and any other relevant details needed. The machine drive over the test section of
road at a speed of 32 +/- 1 kmph. Normally in the nearside wheel track of the nearside lane (position
of machine on road is dependent on purpose of measurements). At the beginning of the section, the
observer having set the counters to zero operates the on/off switch to on-position on the instrument
board.
At the end of the section the observer changes over to the second set of counters, which are then set
to zeros thus allowing continuous measurements. The readings of the integrating and wheel-
revolution counters are entered. The test section should not be less than 1000m.
Processing of results obtained with Bump integrator:
 The results obtained with Bump integrator are the following for a test section over which it has been
run to evaluate its riding quality:
i) Integrator value of irregularities in cm (BI counter reading).
ii) The Distance travelled in Kms.
 Each set of readings (BI reading and corresponding distance travelled) are
required to be converted to the unevenness index value (UI value) in terms of
cms/km.
 Readings of bump integrator has to be noted down from the display for each 100m Jointly by
EPC/PMC/IE.
 The unevenness index value for the test section is arrived for each 100m stretch using the equation
given by CRRI.
Y=0.951* X-32.73, where X= Observed/Measured roughness value with ARUR (STECO-145) in mm/KM.
 The unevenness index value is calculated by dividing the BI counters values (in cms.) by the distance
traveled in kms.
The Unevenness Index = Integrator Counter value Distance travelled (km)
7. Safety:
 One flagman will guide the traffic from rear side of the jeep or utility
 All the personnel shall wear the PPE.
 Only trained personnel shall be Deployed.

115
 METHODOLOGY FOR FINISHING OF SUB STRUCTURES -42
1. Scope:
 This work shall consist of finishing of sub structures like Pier, abutments, pier cap, abutment cap,
Dirt/ballast wall, Return wall, and wing wall etc to the lines, grades and cross sections shown on the
drawings.
2. Reference:
 Section 1714 of MoRT&H specification.
3. Equipments:
 Trowel, Sponge, wooden flat, and plumb bob.
4. Materials:
 Cement: The cement to be used in the works shall be Ordinary Portland Cement of 43/53 grade
confirming to IS 8112/ IS 12269. The manufacturer test certificate shall be furnished, and cement shall
be stored as per IS 4082.
 Fine aggregate: Fine aggregate shall consist of clean, hard, strong, dense, and durable pieces of crushed
stone or natural sand or a combination of both. All fine aggregates shall confirm to IS 383, when tested
in accordance to IS 2386 parts 1 to 8. The grading shall confirm to table 1000-2 of MOST
specification.
 Water: The water to be used shall be as per clause 1010 of MoRT&H specification.
5. Procedure:
 Immediately after removal of the forms, exposed bars or bolts, if any, shall be cut inside the concrete
member to a depth of at least 50 mm below the surface of the concrete and the resulting holes filled
with cement mortar.
 All fins caused by form joints, all cavities produced by the removal of form ties other holes and
depressions, honeycomb spots, broken edges or corners, and other defects, shall be thoroughly cleaned,
saturated with water, and carefully pointed and rendered true with mortar of cement and fine aggregate
mixed in the proportions used in the grade of concrete that is being finished and of as dry a consistency
as is possible to use.
 Considerable pressure shall be applied in filling and pointing to ensure thorough filling in all voids.
 Surfaces which have been pointed shall be kept moist for a period of twenty-four hours.
 Special pre-packaged proprietary mortars shall be used where appropriate or where specified in the
drawing.
 All construction and expansion joints in the completed work shall be left carefully tooled and free from
any mortar and concrete. Expansion joint filler shall be left exposed for its full length with clean and
true edges.

116
6. Safety Precautions:
 All workmen at work area shall wear PPE‟s and reflective jackets.
 It shall be ensured that the safety belts were wore, tied and anchored properly while working at heights.
 All working platforms shall be tied at both ends firmly.
 Wherever required, Flagman shall be provided.
 Experienced personnel shall be deployed.

117
 METHOD STATEMENT FOR ROAD SIGNS -43

1. Scope:
 This work shall consist of manufacturing, fixing and erection, commissioning ,painting of all type Road
signs board ,will be provided wherever required in accordance with IRC 67 & MORTH -800 section
and agreement

2. References:
 IRC 67 & MORTH -800 section.

3. Machinery-Equipment & Material:

 Hydra/crane
 Concrete
 Bolts-Nut, plates, post etc with full set of spanners,

4. PROCEDURE
After complete printing of sheet and fitting on board with bolted/welded on post as per IRC-67 the
further work procedure will as follow:-
a. Sequence of work
 Manual Excavation for pit.
 Fixing the support channel / angle.
 Concreting of the foundation.
 Fixing the signs with channel / angle and painting with commissioning.
b. In detail work process
 Exact location where by road signs are to be erected, will be marked by surveys in accordance with the
relevant approved drawings.
 Excavation will be carried out manually to the adequate depth to suit the respective signboard
considering the type & purpose.
 Steel post of the signboard will be erected using adequate supports to make it vertical. Care will be
taken to ensure the post painted with 3 coats of red lead paint for the portions below the ground and the
remain part is painted according to the required ground level.
 Concrete of grade M-20 will be poured & well compacted after making the earthen surface moist.
 Next day, the supports will be removed and signboards will be fixed and foundation will be cured.
 After completing erection direction of board or verticality of post should be checked for final clearance
and approval.

118
5. Important Safety Precautions:
 The area shall be restricted from public entrance until final setting of concrete.
 All truck shall be provided with reverse horns.
 Only experienced and licensed operators / drivers shall be engaged for excavation and hauling.
 Flagmen shall be provided at all working points or near the job to be done.
 The pit shall be barricaded.
 Proper access shall be provided for traffic and public movement.
 During Crain or hydra operation one guide man for machine operation must be available for safe
movement and erection of post.

119
 FREE SWELL INDEX - 44
(As per IS: 2720 Part 40-1977)
Apparatus:

Glass jars of 100 ml capacity, Distilled water, kerosene, hot air oven and 425-micron sieve.
Procedure:

1. Take two 10 g soil specimens of oven dry soil passing through 425-micron IS Sieve each soil
specimen shall be poured in each of the two glass graduated cylinders of 100 ml capacity.
2. After removal of entrapped air (by gentle shaking or stirring with a glass rod), the soils in both the
cylinders shall be allowed to settle. Sufficient time (not less than 24hr) shall be allowed for the soil
sample to attain equilibrium state of volume without any further change in the volume of the soils.
3. The final volume of soils the level of the soil in the kerosene (VK) graduated cylinder shall be read
as the original volume of the soil samples, kerosene being a non-polar liquid does not cause swelling
of the soil.
4. The level of the soil in the distilled water cylinder (Vw) shall be read as the free swell level. The free
swell index of the soil shall be calculated as follows.
(Vw- VK)
Free swell index = ----------- (%)
VK

120
 GRAIN SIZE ANALYSIS
(As per IS: 2720, Part 4)
Procedure: -

1. Take sufficient quantity of the dry soil, the sample is separated into various fractions by sieving
through the set of sieves of sizes 100, 75, 19 and 4.75 mm IS sieves.
2. After initial sieving, the material retained on each sieve carefully collected and weighed. And Take
500g of 4.75mm IS sieve passing material and wash thoroughly with 75 micron IS sieve. After
washing the material shall be kept in oven at 1050c to 1100c for 24 hrs.
3. The oven dried sample is separated into various fractions by sieving through the set of sieves and the
material retained of each sieve carefully collected and weighed.
4. A curve will be plotted to find out Cu and Cc and classify soil using IS: 1498. Find C u and Cc from
Curve.

121
 ATTERBERG LIMITS - 47
(As per IS: 2720, Part 5.)
Liquid Limit (Casagranda Apparatus)

Apparatus:
Casagranda Apparatus with grooving tools, Balance of 0.01 gm accuracy, Moisture Containers, porcelain
dish, hot air oven, and mixing spatula
Procedure:
1. About 120g of dry pulverized soil sample passing 425 micron IS sieve is weighed and mixed
thoroughly with distilled water in the evaporating dish to form a uniform thick paste.
2. The liquid limit device is adjusted to have a free fall of cup through 10 mm.
3. A portion of the paste is placed in the cup above the lowest spot and squeezed down with the spatula to
have a horizontal surface.
4. The specimen is trimmed by firm strokes of spatula in such a way than the maximum depth of soil
sample in the cup is 10mm.
5. The soil in the cup is divided along the diameter through the center line of the cam followed by firm
strokes of the grooving tool to get a clean sharp groove.
6. The crank is rotated at the rate of two revolutions per second (either by hand operated) so that the cup
is lifted and dropped.
7. This is continued till the two halves of the soil cake come into contact at the bottom of the groove
along a distance of about 10 mm, and the number of blows given is recorded.
8. A representative soil is taken, placed in the moisture container, lid placed over it and weighed.
9. The container is dried in oven and dry weight determined the next day for finding the moisture content
of the soil.
10. The operations are repeated for at least four trials with slightly increased moisture content each time,
noting the number of blows so that there are at least four uniformly distributed readings of number of
blows between 15 and 35 blows.

122
 ATTERBERG LIMITS - 47
(As per IS: 2720, Part 5.)

Liquid Limit Using Cone Penetrometer Apparatus

Apparatus:
Casagranda Apparatus with grooving tools, Balance of 0.01 gm accuracy, Moisture Containers,
porcelain dish, hot air oven, and mixing spatula
Procedure:
1. About 150g of soil sample thoroughly mixed portion of the soil passing 425 micron IS sieve shall be
worked well into a paste with addition of distilled water.
2. In the case of highly clayey soils, to ensure uniform moisture distribution, it is recommended that the
soil in the mixed state is left for sufficient time (24 hours) in an air-tight container.
3. The wet soil paste shall then be transferred to the cylindrical cup of cone penetrometer apparatus,
ensuring that no air is trapped in this process. Finally, the wet soil is leveled up to the top of the cup
and placed on the base of the cone penetrometer apparatus.
4. The penetrometer shall be so adjusted that the cone point just touches the surface of the soil paste in
the cup clamped in this position. The initial reading is either adjusted to zero or noted down as is
shown on the graduated scale.
5. The vertical clamp is then released allowing the cone to penetrate into the soil paste under its own
weight. The penetration of the cone after 5 seconds shall be noted to the nearest millimeter.
6. If the difference in penetration lies between 14 and 28mm the test is repeated with suitable adjustments
to moisture either by addition of more water or exposure of the spread paste on a glass plate for
reduction in moisture content.
7. The test shall then be repeated at least to have four sets of values of penetration in the range of 14 to
28mm as per IS: 2720 part 5.
8. A representative soil is taken, placed in the moisture container, lid placed over it and weighed and
place it in oven. Soil shall be at least of
9. The container is dried in oven and dry weight determined the after 24 hours minimum for finding the
moisture content of the soil as per IS:2720 part 2.
10. A Graph will be plotted for moisture content verses Penetration and moisture content at 20mm
penetration will be reported as the Liquid limit (%).

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 PROCTORS COMPACTION TEST - 48
(As per IS;2720, Part 8-1983)
Purpose:

For the determination of relation between water content and the dry density of soils using heavy
compaction.
Apparatus:

1. Cylindrical metal mould of 150mm dia and 2250cm3 volume.

2. Rammer of 4.9 kg weight. Steel straight edge, 37.5/19 mm sieve and mixing tools.
Procedure:

1. About 6kg of air-dried soil sample passing 37.5mm sieve shall be taken.
2. The sample shall be mixed thoroughly with a suitable amount of water depending on the soil type. The
mould shall be weighed.
3. Soil should compact in five layers; each layer being given 55 blows of 4.9kg rammer dropped from a
height of 450mm above the soil.
4. The extension shall be removed and the compacted soil shall be leveled off carefully to the top of the
mould by means of the straight edge.
5. The mould and soil shall be weighed.
6. The compacted soil specimen shall be removed from the mould and placed on the mixing tray. The water
content shall be determined as per IS: 2720, Part 2.
7. Suitable increments of water shall be added successively, and above procedure shall be repeated for each
increment of water added.
8. The maximum dry density shall be corresponding to the maximum point on the dry density/moisture
content curve. The % moisture content shall be corresponding to the maximum dry density on the same
curve.

124
 CALIFORNIA BEARING RATIO TEST - 49
(As per IS: 2720, Part-16)
Apparatus:
1. Moulds with base plates and collar.
2. Spacer disc, expansion measuring apparatus, annular weights and dial gauges. Loading machine of
capacity 5000kg and penetration plunger.
Procedure:
1. The material shall pass a 19mm sieve, replacement of 19mm pass and 4.75mm retained shall be done
for larger material.
2. The mass of wet soil at required OMC to give the desired density shall be calculated and soil shall be
thoroughly mixed with water to give the required water content.
3. The correct mass of soil shall be placed in the mould and compaction obtained by pressing in the
displacer disc. A filter paper should place between disc and the soil. The mould with the soil should
be kept in water for 4days soaking.
4. Water Content should be determined before compaction and after soaking as per IS:2720 part-2
5. The tripod for expansion measuring device shall be mounted on the edge of the mould and the initial
& final dial gauge reading shall be noted for swelling.
6. After 4 days soaking the mould with the soil shall be placed on the lower plate of the testing machine
and the surcharge weights shall be placed on the specimen.
7. The plunger shall be seated and load applied to the plunger into the soil at the rate of 1.25mm per
minute. Reading of load shall be taken at penetrations of 0.5, 1.0, 1.5, 2.0, 2.5, 4.0, 5.0, 7.5, 10.0 and
12.5mm.
8. About 50gm of soil should be collected from the top 30mm layer for water content determination as
per IS: 2720, Part2.

125
RESULT:
The CBR values shall be calculated for penetrations of 2.5 and 5.0mm from the load penetration curve.
Generally, CBR value at 2.5mm penetration is higher and this value is adopted. However, if CBR value at
5.0mm is high, test is to be repeated and is higher again CBR at 5.0mm
value is reported as CBR value

126
 FIELD DRY DENSITY BY SAND REPLACEMENT METHOD-
50
(As Per IS: 2720, PART XXVII)
Apparatus:

1. FDT Cylinder, FDT GI tray, Balance of Suitable capacity,

2. Rammer of 4.9 kg weight. Steel straight edge, 37.5/19 mm sieve and mixing tools.
Procedure:

1. About 6kg of air-dried soil sample passing 37.5mm sieve shall be taken.
2. The sample shall be mixed thoroughly with a suitable amount of water depending on the soil type.
The mould shall be weighed.
3. Soil should compact in five layers; each layer being given 55 blows of 4.9kg rammer dropped from
a height of 450mm above the soil.
4. The extension shall be removed, and the compacted soil shall be leveled off carefully to the top of
the mould by means of the straight edge.
5. The mould and soil shall be weighed.
6. The compacted soil specimen shall be removed from the mould and placed on the mixing tray.
The water content shall be determined as per IS: 2720, Part 2.
7. Suitable increments of water shall be added successively, and above procedure shall be repeated for
each increment of water added.

127
DETERMINATION WATER CONTENT BY RAPID MOISTURE
METER (ALTERNATIVE) - 51
(As per IS: 2720 Part II-1973)
Apparatus:
Rapid Moisture Meter (RMM), Counter poised Balance,
Absorbent (Calcium carbide).

Sampling: This test requires about 6 gms of Soil Sample.

Principle:
The principle is used in Rapid moisture meter is when
Calcium carbide comes in contact with moisture acetylene
gas is generates Will develops pressure. This will measure in
gauge attached show the reading after conversion from
pressure to moisture by total dry weight.

Procedure:

1. Take 6gm soil Unclamp the clamping screw of the instrument sufficiently to move the U-clamp off the
cup. Lift off the cup and place the sample and place it horizontally.
2. Put the Balls inside and absorbent too and clamp instrument
3. Turn the meter vigorously for 5 seconds and shake it and wait for 1 minute. repeat above procedure 2-3
tomes
4. Observe the gauge and take the reading (M) when comes to rest.
5. Calculate the Moister (%) =100 X RMM reading(M)÷(100-M)

128
 AGGREGATE IMPACT VALUE TEST - 52
(As Per IS:2386, Part 4-1963)

Apparatus:-
1. Impact testing machine, cylindrical steel cup of 102mm diameter and 50mm depth, Hammer
of weight 13.5 to 14.0 kg & Height of fall – 380mm, I.S. Sieves 12.5,10.0 & 2.36mm
2. Cylindrical metal measure of 75mm diameter and 50mm depth, Tamping rod of 10mm diameter
and 230mm long
Procedure: -
1. The test sample shall pass through 12.5mm and retained on 10mm sieve.
2. The sample shall be dried in an oven for a period of four hours at a temp. of 100 to 110oC and
cooled.
3. The test sample shall be prepared by filling the measure in three layers giving 25 strokes after
each layer.
4. The net weight of aggregate in the measure shall be taken. And the same weight will be taken for
remaining determinations.
5. The test sample shall be placed in the cup and compacted by a single tamping of 25 strokes.
6. The test samples shall be subjected to a total of 15 blows at an interval of one second.
7. The crushed aggregate shall be sieved on the 2.36mm sieve. The fraction passing the sieve shall be
weighed.
8. The ratio of weight of fines formed to the total sample weight shall be expressed as a percentage
of A.I.V.

129
 FLAKINESS & ELONGATION INDEX - 53
(As Per IS 2386, PART – 1)

Apparatus:

1. Length Gauge and Thickness Gauge.

2. Weighing Balance.

Procedure:

1. Take a sample of about 3 kg

2. Divide the sample into four quadrants.

3. Select two opposite quadrants and sieve them through the sieves arranged in the following order 63
mm,50 mm,40 mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5 mm, 10 mm, 6.3 mm
4. Take the aggregate sample sieved through 63 mm and retained on 50 mm sieve. Find the weight
of fraction gauged (gm).

5. Pass that sample through 63-50 mm size of thickness gauge

6. Find the weight of the aggregate passing through the respective slot (i.e., through 63-50 mm) of the
gauge.

Repeat the same procedure with 50-40mm, 40-25mm, 31.5-25mm, 25-20 mm, 20-16 mm, 16-12.5
mm, 10-6.3 mm, size of the thickness gauge.

130
 SPECIFIC GRAVITY AND WATER ABSORPTION OF
COARSE AGGREGATE - 54
(As Per IS: 2386, Part 3 – 1963)
Apparatus: -

1) Wire basket of not more than 6.3mm mesh.

2) Absorbent cloths and balance.
Procedure:-
1) A sample of not less than 2000g of the aggregate shall be tested. The sample shall be thoroughly
washed to remove fine particles and dust.
2) The sample shall placed in the wire basket and immersed in distilled water at a temperature
between 22 to 32oC.
3) The entrapped air shall be removed by lifting the basket 25 times at the rate of about one drop per
second and kept immersed for 24+1/2 hours.
4) The basket and the sample shall then be weighed (A).
5) The basket and the aggregate shall then be removed from the water and allowed to drain for a
few minutes.
6) The aggregate shall be gently surface dried with the cloth and then weighed (B).
7) The aggregate shall then be placed in the oven at a temperature of 100 to 110oC for 24 hours and
then weighed
8) Specific gravity and water absorption shall be calculated as follows:
Specific Gravity = C/(B-A)
Water Absorption = 100(B-C)/C

131
 SPECIFIC GRAVITY AND WATER ABSORPTION OF FINE
AGGREGATE - 55
(As Per IS:2386, Part 3 - 1963)
Apparatus:

Pycnometer, Balance and trays.

Procedure:
1. A sample of about 1kg shall be immersed in the tray at a temperature of 22 to 32o C for 24+1/2
hours.
2. The water shall be carefully drained from the sample and the aggregate shall be exposed to a gentle
current of warm air to evaporate surface moisture and shall be weighed (A).
3. The aggregate shall then be placed in the pycnometer which shall be filled with distilled water. Any
trapped air shall be eliminated by rotating the pycnometer on its side.
4. The pycnometer shall be dried on the outside and weighed (B).
5. The contents of the pycnometer shall be emptied and refilled with distilled water, dried on the outside
and weighed (C).
6. The water shall be carefully drained from the sample by decantation through a filter paper and placed
in the oven at a temperature of 100 to 110oC for 24+1/2 hours.
7. It shall be cooled and weighed (D).
8. The Specific gravity and water absorption shall be calculated
Specific Gravity = D/A-(B-C)
Water Absorption = 100(A-D)/D

132
 FINENESS BY DRY SIEVING - 56
(As per IS:4031, Part 1)

Apparatus:-

90micron sieve, Balance & brush.

Procedure:-

1) Fit the tray under the sieve, weigh approximately 10gm of cement to the nearest 0.01gm and place it on

the sieve being careful to avoid loss.

2) Fit the lid over the sieve and agitate the sieve by swirling, planetary and linear movement until no more

fine material passes through it.

3) Remove and weigh the residue. Express its mass as a percentage of fineness.

Fineness of cement can be done by wet sieving as per IS: 4031 Part-15.

133
 CONSISTENCY OF STANDARD CEMENT PASTE - 57
(As per IS: 4031, Part 4-1988)
Apparatus:

Vicat apparatus and gauging trowel.

Procedure:

1. Prepare a cement paste with a weighed quantity of cement and water taking care that the time of
gauging should be between 3 to 5 minutes.
2. Fill the vicat mould with this paste and smoothen the surface of the paste making it level with the
mould. Slightly shake the mould to expel the air.
3. Place the test block in the mould together with the non-porous resting plate, under the rod bearing the
plunger; lower the plunger gently to touch the surface of the test block and quickly release, allowing it
to sink into the paste.
4. Prepare trial pastes with varying percentages of water and test as described above until the penetration
comes 5 to 7mm from the bottom of the vicat mould.

134
 SOUNDNESS OF CEMENT - 58
(As per IS:4031, Part 3)
Apparatus:-

Le- chartelier mould IS -5514- 1969.

Procedure:-

1. A representative sample of 200gms is to be taken and mixed thoroughly with 0.78 times the water
required to give a paste of standard consistency.
2. The gauging time of the paste shall be between 3 to 5 minutes.
3. Place the lightly oiled mould on a lightly oiled glass sheet and fill the mould with cement paste. Cover
the mould with another piece of lightly oiled glass sheet and, place small weight on the glass sheet and
immediately kept in water at a temperature 27 ± 2 0 C for 24 hours.
4. After 24 Hours, measure the distance of separating indicator points, and submerge the mould again in
water.
5. Bring the water to boiling point with the mould kept submerged in 25 to 30 minutes and keep it boiling
for three hours.
6. Remove the mould from water, allow it to cool and measure the distance between the indicator points

135
 INITIAL AND FINAL SETTING TIME OF CEMENT – 59
(As per IS:4031: Part 5)

Apparatus:

Vicat apparatus with mould and Guaging trowel.

Procedure:

1. Prepare a cement paste by gauging the cement with 0.85 times the water required to give a paste of
standard consistency.
2. Fill the vicat mould with a cement paste gauged as above and smoothen the surface of the paste making
it level with the mould. Compact it to remove pores in mould.
3. Place the test block under the rod bearing the needle; lower the needle gently until it comes in contact
with the surface of the test block and quickly release, allowing it to penetrate the test block and observe
the penetration once plunger rests in paste.
4. Repeat this procedure until the penetration measured from bottom should be 5.0+0.5mm.
5. The period elapsing between the time when water is added to the cement and the time at which the
needle fails to pierce the test block to a point 5.0+0.5mm shall be the initial setting time.
6. Replace the needle of the vicat apparatus by the needle with an annular attachment.
7. The period elapsing between the time when water is added to the cement and the time at which the
needle makes an impression on the surface of test block shall be the final setting time.

136
 COMPRESSIVE STRENGTH OF CEMENT – 60 (As per IS:4031
Part-6)

Apparatus:
Mortar cube Moulds, Frequency vibrator, Porcelain dish, standard sand, Spatula, Compression testing
machine

Procedure:

1. The mould shall be clean apply oil if required.

2. 200 grams of cement and 200 grams of Sand to be taken for each zone-I, Zone-II, and Zone-III
respectively.
3. Water shall be calculated from (Consistency/4) +3% of combined mass water.
4. Cube will be placed in frequency vibrator and run the machine for [Link] the mould trim the
excess portion and place it in curing tank after 24 hrs.
5 Test the cubes at the age of 72 ±1 hour, 168 ±2 hour, and 672 ±4 hour. As mentioned in IS:4031 part
6 (1988)
6 Test the cubes as per IS: 516-1959 and report the strength of cement in N/mm2 which conform
Grade.

137
 SLUMP TEST OF CONCRETE - 61
(As per IS: 1199-1959)
Scope:

It is used for the determination of the consistency of freshly mixed concrete, where the maximum size of the
aggregate does not exceed 38 mm.

Apparatus Specification:

Equipment Conforms IS: 7320. The size of the slump cone is 20cm Día base. 10 cm Día top and 30 cm
height. One graduated steel tamping rod 16 mm Día & 600 mm long rounded at one end graduated in mm.

Procedure:-
1. The internal surface of the mould shall be thoroughly cleaned and shall be placed on a smooth,
horizontal, place.
2. Shall be filled in four layers, each approximately one-quarter of the height of the mould. Each layer
shall be tamped with 25 strokes of the rounded end of the tamping rod. The strokes shall be distributed
in a uniform manner over.
3. struck off to level and the mould shall be removed from the concrete immediately by raising it slowly
and carefully in a vertical direction. This allows the concrete to subside, and the slump shall be
measured immediately by determining the difference between the height of the mould and that of the
highest point of the specimen being tested. And report the value in mm

138
 COMPRESSIVE STRENGTH OF CONCRETE - 62
(As per IS:516-1959)
Apparatus:
Compression testing machine, Cube Moulds, Slump rod

Procedure :
1. The mould shall be cleaned and oiled if required.
2. Place the fresh concrete in 3 layers and compact the mould with the standard tamping bar and the
strokes of the bar shall be distributed in a uniform manner over the cross-section of the mould. the sides
of the mould shall be tapped to close the voids
3. The test specimens shall be stored on the site for 24 hours ± ½ hour from the time of adding the water.
4. The Cube shall be placed in the machine in such a manner that the load shall be applied to opposite
sides of the cubes as cast.
5. The load shall be applied without shock and increased continuously at a rate of approximately
140kg/cm2/min until the resistance of the specimen to the increasing load breaks down and no greater
load can be sustained.
6. The compressive strength of the specimen shall be calculated by dividing the maximum load applied to
the specimen by the cross-sectional area. Minimum of 3 cubes will be tested for a sample.
7. The machine shall be calibrated frequently, and the allowable errors are ±2% of maximum load.

139
 FLEXURAL STRENGTH OF CONCRETE - 63
(As per IS: 516 -1959)
Apparatus:
 Standard moulds of size 15 X 15 X 70 cms for preparing the specimen, Tamping bar, Testing Machine

Procedure:
Test specimens stored in water at a temperature of 25°C to 30°C for 48 hours before testing shall be
tested immediately on removal from the water, whilst they are still in a wet condition. The dimensions of
each specimen shall be noted before testing. No preparation of the surface is required.

Placing the specimen in the testing machine:

The bearing surfaces of the supporting and loading rollers shall be wiped clean, and any loose sand or
other material removed from the surfaces of the specimen where they are to make contact with the
rollers. The specimen shall then be placed in the machine in such a manner that the load shall be applied
to the upper most surface as cast in the mould, along two lines spaced 20 or 13.30 cms apart. The axis of
the specimen shall be carefully aligned with the axis of the loading device. No packing shall be used
between the bearing surface of the specimen and the rollers. The load shall be applied with shock and
increasing continuously at a rate such that the extreme fiber stress increases at approximately 7
kgs/cm2/mm for the 10 cm specimens, the load shall be increased until the specimen falls, and the
maximum load applied to the specimen during the test shall be recorded. The appearance of the fractured
faces of the concrete and any unusual features in the type of failure shall be noted.

Calculation:
The flexural strength of the specimen shall be expressed as the modules of rapture ' fb' which if 'a' equals
the distance between the line of fracture and the nearer support measured on the centerline of the tensile
side of the specimen, in cm, shall be calculated to the nearest 0.5 kg/cm2 as follows.

fb=( px l ) / ( bx d 2 )
When 'a' is greater than 20.0 cm. for 15.0 cm specimen or greater than 13.30 cm for a 10.0 cm
specimen, or

fb = (3p x a) / (b x d2)
When 'a' is less than 20.0 cms. but greater than 17.0 cms for 15.00 cms specimen, or less than 13.30 cms
but greater than 11.0 cms for a 10.0 cms specimen,

Where, b = measured width in cms of the specimen,

d = measured depth in cms of the specimen at the point of failure,
l = length in cm. of the span on which the specimen was supported, and p =
maximum load in kg. applied to the specimen.

Note: If 'a' is less than 17.0 cm. for a 15 cm specimen or less than 11.0 cm for a 10.0 cm specimen, the
result of the test shall be discarded.

140
 PENETRATION TEST - 64
(As per IS: 1203-1978)

Apparatus:
1. Standard Penetration apparatus
2. A metal or glass cylindrical flat-bottomed container essentially with the following dimensions:

For penetration below - 225

Diameter - 55mm
Internal depth - 35mm

For penetration between 225 and 350

Diameter - 70mm
Internal depth - 45mm

3. Needle shall be made up of straight, highly polished, cylindrical, hard steel rod.
4. Water bath 10 liters capacity thermostatically controlled and maintained within the temperature
of 25±0.10C.
5. Thermometer capable of reading temperature up to 250 0C.

Procedure:

1. Soften the material to a pouring consistency at a temperature not more than 60 0C for tars and pitches
and not more than 90 0C for bitumen above the approximate respective softening points.
2. Stir it thoroughly until it is homogeneous and free from air bubbles and water.
3. Pour the melt in to the container to a depth of at least 10mm in excess of the expected penetration.
4. Protect the sample from dust and allow it to cool in atmosphere at a temperature between 15 to 30 0C
for 11/2 to 2hours for 45mm deep container and 1 to 11/2 hours for 35mm deep container.
5. Unless otherwise specified carry out testing at a temperature of 25 + 0.1oC.
6. Place it along with the transfer dish in the water bath at 25 + 0.10C and allow it to remain for 11/2 to
2hours for 45mm deep container and 1 to 11/2 hours for 35mm deep container.
7. Fill the transfer dish with water from the water bath to a depth sufficient to cover the mould
completely.
8. Remove the transfer dish along with the mould from water bath after specified period of time and put it
upon the stand of penetration apparatus.

141
9. Adjust the needle (previously washed, cleaned well with benzene and dried) just to make contact with
the surface of the sample.
10. The sum of the weights of the needle, carrier and super imposed weights i.e, the total moving weight
shall be 100  0.25grams.
11. Bring the pointer to zero.
12. Release the needle for five seconds and measure the distance penetrated.
13. Make at least three determinations at points on the surface of the sample not less than 10mm apart and
not less than 10mm from the side of the dish.
14. After each test, return the sample and transfer dish to the water bath and wash the needle with benzene
and dry.
15. In case of material of penetration greater than 225 make three determinations on each of two identical
test specimens using a separate needle for each determination, leaving the needle in the sample on
completion of each determination to avoid disturbance of the specimen.

142
 SOFTNING POINT TEST - 65
(As Per IS:1208-1978)
Scope:
This method covers for the determination of softening point of bitumen.
Apparatus:
Ring and ball apparatus, stopwatch, Thermometer, Bath & Stirrer.

Preparation of Test Sample:

1. Heat the material to a temperature between 75ºc -100ºc above its softening point.
2. Stir until, it is completely fluid and free from air bubbles and water.
3. Place the rings, previously heated to a temperature approximating to that of the molten material on a
metal plate which has been coated with moisture of equal parts of glycerin and destrin
Procedure:
1. Assemble the apparatus with the rings, thermometer, and ball guides in position
2. Till the bath with distilled water to a height of 50mm above the upper surface of the rings. The starting
temperature may be kept 5ºc.
3. Note: Use glycerin in place of water if the softening point is expected to be above 80ºc: The
4. Starting temperature may be kept 35ºc).
5. Apply heat to the bath and stir the liquid so that the temp rises at a uniform rate of 5 + 0.5ºc per minute.
6. As the temp increases the bituminous material systems and the ball since through the ring, carrying
portion of the material with it.
7. Note down the temperature when any of the steel ball with bituminous coating touches the bottom plate
8. Record the temperature when the second ball also touches the bottom plate.
9. The average of the two reading to nearest 0.5ºc is reported as the softening point
Report: -
The temperature for each ring and ball, at the instant the sample surrounding the ball touches the bottom
plate of the support.
Report the mean of two determinant to the nearest 0.5 0 C

143
 DUCTILITY TEST - 66
(As Per IS:1208-1978)
Scope:
To determine the ductility of bituminous products.
Apparatus:
Briquette mould, Water bath, Thermometer & Testing machine.
Procedure:
1. Melt the bituminous material to a temperature of 75 to 100oC.
2. Assemble the mould and thoroughly coat the interior surfaces with a mixture of glycerin and dextrin to
prevent sticking.
3. Pour the material into the mould until it is more than level full and leave it to cool at the room
temperature for 30 to 40 min.
4. Then place it in a water bath maintained at the specified temperature for 30 min after which cut off the
excess bitumen.
5. Place the mould with briquette specimen in the water bath at a temperature of 27+0.5 oC for about 85 to
95 min.
6. Then remove the briquette from the mould, detach the side pieces, and test the briquette immediately.
7. The water in the tank of the testing machine should cover the specimen both above and below by at least
25mm.
8. Attach the rings to the pins in the testing machine and pull the two clips horizontally at a uniform speed
of 50+2.5mm/min until the briquette ruptures.
9. Measure the distance in centimeters through which the clips have been pulled to produce rupture.
Report: -
Report the average of three normal tests as the ductility of the sample

144
 ABSOLUTE VISCOSITY TEST - 67
(IS: 1206 (Part II – 1978)
Introduction:

 Viscosity is defined as inverse of fluidity. Viscosity thus defines the fluid property of bituminous
material. The degree of fluidity at the application temperature greatly influences the ability of
bituminous material to spread, penetrate into the voids and also coat the aggregates and hence affects the
strength characteristics of the resulting paving mixes.

Object:

To determine the viscosity of bitumen by Tar Viscometer.

Apparatus:

 Tar Viscometer with 4mm and 10mm orifices – The apparatus consists of main parts like cup, valve,
water bath, sleeves, stirrer, receiver, and thermometers etc.

Procedure:

Heat the sample to a temperature not more than 60 0C for the tars and pitches and not more than 90 0C for
bitumen above their respective approximate softening point temperature respectively until it has become
sufficiently fluid to pour. Transfer about 20 ml into a suitable container and maintain it to a temperature of
135 ± 5.5 0C string occasionally to prevent local overheating and allow the entrapped air to escape.

Charge the viscometer by pouring the prepared sample to within ±2 mm of fill line E. Place the charged
viscometer in an oven or bath maintained at 135±5.5 0 C for a period of 10±2 min to allow large air bubbles
to escape.

Testing:

Maintain the bath at the test temperature within ±0.1 0C. Place the charged viscometer vertically in the
water bath with the help of a holder so that the uppermost timing mark is at least 2 cm below the surface of
the bath liquid. Establish a vacuum of 30±0.05 cm of mercury in the vacuum system and connect it to the
viscometer with the value closed. After the viscometer has remained in the bath for 30±5 min opens the
value and allow the asphalt to flow into the viscometer. Measure to within ±0.5 s the time required for the
leading edge of the meniscus to pass between successive pairs of timing marks. Upon completion of the test,
remove the viscometer from the bath and place it in an inverted position in an oven maintained at 135±5 0C
until asphalt is drained off thoroughly from the viscometer. Clean the viscometer thoroughly by rising
several times with an appropriate solvent completely. Dry the tube by passing a slow stream of filtered dry

145
air through the capillary for 2 minutes. Periodically clean the instrument with chromic acid to remove
organic deposits. Rinse thoroughly with distilled water and acetone and dry with clean air.

Calculation:

Calculate and report the absolute viscosity to three significant figures, by the following equation:

Viscosity Poises=Kt
Where; K=selected calibration factor, in poises per second: and t=flow time, in seconds.

Bitumen grade VG-10 VG-20 VG-30 VG-40

Absolute Viscosity at 60 0 C, As Per IS 73: 2013
800-1200 1600-2400 2400-3600 3200-4800
Poises

Results:

The time in seconds for 50ml of the test sample to flow through the orifice is defined as the viscosity at a
given test temperature.

145
 KINEMATIC VISCOSITY TEST - 68
(IS: 1206(Part III – 1978)
Introduction:

Viscosity is defined as inverse of fluidity. Viscosity thus defines the fluid property of bituminous material.
The degree of fluidity at the application temperature greatly influences the ability of bituminous material to
spread, penetrate into the voids and also coat the aggregates and hence affects the strength characteristics of
the resulting paving mixes.

Procedure:

To change the Cannon-Fenske viscometer invert the viscometer and apply suction to the tube L, immersing
tube N in the liquid sample. Draw liquid through tube N filling bulbs D to fill mark G. Wipe excess sample
off tube N and invert the viscometer to its normal position. Align the viscometer vertically in the bath.
Visual observation is sufficient. However, it can be done more accurately and quickly by suspending a
plumb bulb in the tube L. Allow the viscometer to remain in the constant temperature bath for a sufficient
time to ensure that he sample reaches temperature equilibrium. It can takes about 20 min at 38 0C, 25 mm at
100 0C and 30 min at 135 0C. When the test temperature is reached, remove the stopper in the tubes N and
L respectively and allow the sample to flow by gravity. Measure to the nearest 0.1 s the time required for the
leading edge of the meniscus to pass from timing mark E to timing mark f. If this efflux time is less than 60
s, select a viscometer of smaller capillary diameter and repeat the operation.

Upon completion of the test, clean the viscometer thoroughly by several rinsings with an
appropriate solvent completely miscible with the sample, followed by a completely volatile solvent. Dry the
tube by passing a slow stream of filtered dried air through the capillary for 2 min or until last trace of solvent
is removed.

Mount the BS U-tube viscometer in the constant temperature bath keeping tube L vertical. Pour sample
through tube N to a point R, taking care that the liquid column remains unbroken until the lower mark H and
then arrest its floe by closing the timing tube with a cork or rubber stopper in tube L. Add more liquid, if
necessary to bring the upper meniscus slightly above mark G. After allowing the sample to attain bath
temperature and any air bubble to rise to the surface (usually about 20-30 min is required), gently loosen the
stopper allowing the sample to flow until it is approximately at the lower filling mark H and press back the
stopper to arrest flow. Remove the excess sample above filling mark G by inserting the special pipette until
its cork rests on top of the tube N and apply gently suction until air is down through, The upper meniscus
shall coincide with mark G. Allow the viscometer to remain in the constant temperature bath for a sufficient
time to ensure that the sample reaches temperature equilibrium. It takes about 20 min at 38 0C, 25 min at
100 0C and 30 min at 1350C. Remove the stopper in the tube N and L respectively and allow the sample to

146
flow by gravity Measure to the nearest 0.1 s the time required for the leading edge of the meniscus to pass
from timing mark E to timing mark F. If this efflux time is less than 60 s, select a viscometer of smaller
capillary diameter and repeat the operation.

Upon completion of the test, clean the viscometer thoroughly by several mixing with an appropriate solvent
completely miscible with the sample followed by a completely volatile solvent. Dry the tube by passing
slow stream of filtered dry air through the capillary until the last trace of solvent is removed.

Calculation:

Calculate the kinematic viscosity up to three significant figures with the help of following equation:
Kinematic Viscosity c St =Ct
Where C=calibration constant of the viscometer in centistokes per second, and t= efflux time in seconds

Bitumen grade VG-10 VG-20 VG-30 VG-40

Kinematic Viscosity at 135 0 As Per IS 73: 2013
250 300 350 400
C, cSt,Min

147
 BINDER CONTENT OF PAVING MIXTURES - 69
(As per SP: 11-1976)

Definition:
 Softening point is the temperature at which the substance attains a particular degree of softening
under specified conditions of test.

Apparatus:
 Centrifugal extraction machine electrically operated.
 Balance - 15 kg capacity - sensitivity 0.1 gm.
 Cold solvent - Commercial grade of Benzene.
 Filter paper - Wat 60.
 Oven.

Procedure:
1. A representative sample about 1000gm is exactly weighed and placed in the bowl of the extraction
apparatus and covered with commercial grade of benzene. Sufficient time (not more than 1 hour) is
allowed for the solvent to disintegrate the sample before running the centrifuge.
2. The filter paper of the extractor is dried, weighed and then fitted around the edge of the bowl. The
cover of the bowl is clamped tightly. A beaker placed under to collect the extract.
3. The machine is revolved slowly and then gradually increases the speed, maximum of 3600 rpm.
This speed is maintained till the solvent ceases to flow from the drain. The machine is allowed to stop
and 200ml of benzene is added and the above procedure is repeated. A number of 200ml solvent
additions (not less than three) are used till the extract is clear and not darker than a light straw
colour.

The filter paper removed from the bowl, dried in air then in oven to constant weight at 115°C and
weighted the fine materials that might have passed through the filter paper are collected back from the
extract preferably by centrifuging. The material is washed and dried to constant weight as before.

148
 MARSHAL STABILITY AND FLOW - 70
(ASTM D 1559)
Purpose :
1. To determine the density – voids analysis for the given bituminous Mixture.
2. To determine strength (Marshal‟s Stability Value) and flexibility (flow value) for the given
bituminous mixture.
3. To determine the suitability of the bituminous mixture to meet the specified criteria for the
surface course.

Significance :
1. The test procedure is used in designing and evaluating bituminous paving mixes.
2. To determine the strength and flexibility of mixture.

Definition:
Marshall Stability of mixture as defined as the maximum load carried by a compacted
specimen at standard test temperature of 60ºC. The temperature represents the weakest
condition for a bituminous pavement in use.

Apparatus:
1. Specimen mould assembly comprising mould cylinders 10cm diameter by 7.5 cm height, base plate, and
extension collars. Specimen extractor for extracting the compact specimen from the mould.
2. A suitable bar is required to transfer load from the extension collar to the upper proving ring attachment
while extracting specimen.
3. Compaction hammer having a flat circular tamping face 4.5kg sliding weight constructed provide free
fall 45.0 cm.
4. Compaction pedestal consisting of a 20 x 20 x 45 cm wooden block capped with a 30 x 30 x 2.5 cm
M.S. Plate to hold the moved assembly in position during compaction. Mould holder is provided
consisting of spring tension device designed to hold compaction mould in place on the compaction
pedestal.
5. Breaking head: The breaking head consists of upper and lower cylindrical segments or test heads having
an inside radius curvature of 5 cm. The lower segment is mounted on a base having two perpendicular
guide rods which facilitate insertion in the holes of upper test segment.
6. Loading machine
7. Oven

149
8. Mixing apparatus
9. Water bath
10. Thermometers of range upto 200ºC with sensitivity of 2.5ºC
11. Containers, mixing and handling tools.

Procedure :
A. Preparation of Test Specimen
1. Take 1200g of aggregates blended in the desired proportions.
2. Heat the aggregates in the oven to the mixing temperature
B. Add bitumen at the mixing temperature to produce viscosity of 170 centistokes at various percentage
both above and below the expected optimum content.
C. Mixture materials in a heated pan with heated mixing roots.
D. Return the mixture to the oven and reheat it to the compacting temperature (To produce viscosity of
280 ± 30 centistrokes)
E. Place the mixture in a heated marshal mould with a collar and base.
F. Spade the mixture around the sides of the mould.
G. Place fitter portion under the sample and on top of the sample.
H. Place the mould in the Marshal Compaction Pedestal.
I. Compact the material with 50 blows of the hammer, insert the sample, and compact the other face with
the same number of blows.
J. After compaction, insert the mould with the collar on the bottom, remove the base and extract the
sample by pushing it out the extractor.
K. Allow the sample to stand for a few hours to cool.
L. Find the mass of the sample.

Test :
i. Specimens are heated to 60° ± 1° (37.8° + 1° C for specimens for which tar has been used in place of
bitumen), either in a water bath for 30-40 minutes or in an oven for minimum of two hours.
ii. Remove the specimen from the water bath (or oven) and place in the lower segment of the breaking
head.
iii. Place the upper segment of the breaking head on the specimen and place the complete assembly in
position on the testing machine.
iv. Place the flow meter over one of the post and adjust it to read zero.
v. Apply a load at rate of 50mm per minute until the maximum load reading is obtained.

150
vi. Record the maximum load in Newtons. At the same time obtain the flow as recorded on the flow
meter in units of mm.

151
CMECMISTS FOR INSPECTION AND
APPROVAL OF WORKS.
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR CLEARING &

GRUBBING

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

Removal and disposed of trees, shrubs, bushes, stumps, roots,

1 grass, weeds, top organic soil and other rubbish

Required excavation carried out

2

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from Kodur
(Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru - Vijayawada
Economic Corridor on HAM Mode under Bharatmala Pariyojana
Phase-I in the State of Andhra Pradesh (Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR EMBANKMENT /

SUBGRADE TESTING

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Found loose surface

2 Found bumping in the surface
3 Toe width is sufficient
4 Sand used for testing as per specification.
5 Moisture meter calibrated
6 Sand bulk density and cone calibrated
7 Frequency of the test is as per specification.
8 Levels found with in tolerance

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR CTSB TESTING

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Whether subgrade Approved
2 Whether Toe line marked
3 Whether Water sprinkled on SG before CTSB placed
4 Whether CTSB source approved
5 Whether oversize greater than 75mm removed
6 Whether loose thickness checked
7 Whether control Test passed (Gradation & Atterberg limit)
8 Whether sufficient qty of water added to obtain OMC
9 Whether pegs fixed & marked for levels
10 Whether no. of roller passes applied as per trial stretch
11 Whether FDD Test conducted & passed
12 Whether CTSB final levels checked & approved

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR CTB TESTING

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Whether subgrade Approved
2 Whether Toe line marked
3 Whether Water sprinkled on CTSB before CTB placed
4 Whether CTB source approved
5 Whether oversize greater than 53mm removed
6 Whether loose thickness checked
7 Whether control Test passed (Gradation & Atterberg limit)
8 Whether sufficient Qty of water added to obtain OMC
9 Whether pegs fixed & marked for levels
10 Whether no. of roller passes applied as per trial stretch
11 Whether FDD Test conducted & passed
12 Whether CTB final levels checked & approved

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR AIL TESTING

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Whether CTB Approved
2 Whether Toe line marked on CTB layer
3 Water sprinkled on CTB before AIL placed
4 Whether CTB source approved
5 Whether AIL Mix Design is Approved
6 Whether RFI raised for AIL laying
Whether sufficient Qty of AIL uniformly placed without
7 segregation
8 Whether sample taken for control test &Test passed
9 Whether pegs fixed & marked for levels
10 Whether no. of roller passes applied as per trial stretch
11 Whether rolling started immediately after laying
12 Whether no. of rolling passes applied as per trial stretch
13 Whether FDD Test conducted & passed
14 Whether AIL final levels checked & approved

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR PRIME COAT / TACK

COAT

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Previous layer approved
2 Surface cleaned properly before spraying prime coat / Tack coat
3 Lab. equipment’s available for spray test
4 The surface to be primed shall be free from moisture
5 Weather is foggy, rainy, dusty or windy
6 Rate of spraying is as per calibrated
7 Quantity of spraying as per spec.
8 Surface temperature is more than 100C
9 Proper barricading is arranged for traffic management

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR BM / DBM / BC

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Previous layer approved
2 Weather is foggy, rainy, dusty or windy
Tack coat required (if yes follow the check list for
3 Prime/Tack coat)
4 Adequate Machinery available
5 Mix transported to site are covered properly
7 Thermometer for recording temperature is available
8 Temperature record sheet available
Are the finish levels of asphalt in conformance with
9 tolerable specification limits
10 Surface regularity test is found OK
11 Samples tested at lab are found OK

Concessionaire
Representative Independent Engineer

Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR DLC

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Location/ Chainage is identified

2 Center line marking is available at laying site
3 The drawing is available at site relevant to DLC layers
4 The underlying layer is checked for level, lines and grades
5 The underlying layer is cleaned of any foreign & loose
materials
7 String line & deep sticks are fixes in level, line, grade
8 Optimum Moisture content is checked
9 Degree of compaction achieved after Laying is checked
10 Curing done properly
11 Safety measures have been taken

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR PQC

Location : Date :

Layer : RFI No. :

[Link]. Description YES NO NA

1 Location/ Chainage is identified

2 Center line marking is available at laying site
3 The drawing is available at site relevant to PQC layers
4 Methodology as well as specification available at site
5 The underlying layer is checked for level, lines and grades
7 The underlying layer is cleaned of any foreign & loose
materials
8 Separation membrane is placed properly
9 Form works are placed in level, line & grades
10 Dowel bars & Tie bars are place in properly as per drawing
11 Plants & Equipments available as per method statement
12 Temperature of concrete checked for every load
13 Surface texturing
14 Curing done after final setting of concrete
15 Joints are cut as per drawing
16 Safety measures have been taken

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR CONCRETE WORKS

(RCC & PCC)

Location : Date :

Layer : RFI No. :

[Link].
Description YES NO NA

1 Concerned drawing available

2 Strata/levels found acceptable
3 Mix and its materials approved
4 Formwork/scaffolding approved
5 Bar bending schedule / Reinforcement approved
6 Adequate cover blocks/chairs/spacers provided
7 Slump found within the range
8 Required cubes casted
Placing/compaction/finishing/workmanship for concrete found
9 acceptable
10 Pre-stressing sheathing approved
11 Required equipment/lighting/communication provided
12 Concrete conveying arrangement found acceptable
13 Curing arrangement made

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

CHECK LIST FOR DECK SLAB

CONCRETE WORKS

Location : Date :

Layer : RFI No. :

[Link].
Description YES NO NA

1 Concerned drawing available

2 Strata/levels found acceptable
3 Mix and its materials approved
4 Formwork/scaffolding approved
5 Bar bending schedule / Reinforcement approved
6 Adequate cover blocks/chairs/spacers provided
7 Adequate approved strip for expansion joint provided
8 Slump found within the range
9 Required cubes casted
Placing/compaction/finishing/workmanship for concrete found
10 acceptable
11 Grove cut at expansion joint satisfactory
12 Pre-stressing sheathing approved
13 Required equipment/lighting/communication provided
14 Concrete conveying arrangement found acceptable
15 Curing arrangement made

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
Project: - Development of Six-Lane Access Controlled Highway from
Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
Client: - National Highways Authority of India
Independent Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Engineer: - Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt.
Ltd.
Concessionaire: - Bengaluru Vijayawada Expressway Package-1 Limited

BORED CAST INSITU PILES-PILE REINFORECEMENT CHECKLIST

Structure Chainage : Drawing No:

Structure element : Date :
Pile No:

Sr no. Description Yes No Remarks

1 Is Reinforcement clean
2 Is Reinforcement conforming to drawing
3 Is Reinforcement binded in proper
4 Is Reinforcement properly welded
5 Is cover blocks provided
6 Is adequate Lapping is provided

Concessionaire Independent Engineer

Representative
Sign : Sign:
Name : Name:
Date : Date:
 11.0 QUALITY ASSURANCE PLAN FOR DIFFERENT
CONSTRUCTION ACTIVITIES:

The Quality Assurance Plan (QAP) shall consist of different stages of verification for construction
activities by Concessionaire along with Independent Engineer, Documentation & record keeping of the
inspection through different Quality Formats & RFI.
FORMATS FOR MAINTINING TEST
RECORDS
 FORMATS FOR MAINTINING TEST RECORDS

[Link]. DESCRIPTION Page No.

I REQUEST FOR INSPECTION AND APPROVAL OF WORKMANSHIP

A SAMPLE CARD

II EARTH WORK AND BORROW AREAS

1 Liquid Limit &` Plasticity index Test

2 Maximum Dry Density test

3 Field Density Test by Sand Replacement method

4 California Bearing Ratio Test

5 Free Swell Index Test

6 Grain Size Analysis Test

7 Direct Shear Test

III SUB BASE & CEMENT TREATED SUB BASE/BASE/AIL

1 Gradation Test for Granular Sub-Base

2 Gradation Test for Cement Treated Sub-Base

3 Gradation Test for Cement Treated Base

4 Gradation Test for Aggregate Interlayer

IV AGGREGATES

1 Specific Gravity & Water Absorption of Coarse Aggregate

2 Specific Gravity & Water Absorption of Fine Aggregate

3 Gradation test for Coarse Aggregate

4 Gradation test for Fine Aggregate

5 Combined Index (Flakiness & Elongation indices)

6 Los Angeles Abrasion Test

7 Impact Value Test

8 Silt content of Fine Aggregate Test

9 Ten Percent Fines Value Test

V BITUMINIOUS WORKS

1 Specific Gravity of Bitumen

2 Penetration test

3 Softening point test

4 Kinematic Viscosity

5 Ductility test

6 Stripping value Test

7 Bituminous Mix Temperature

8 Elastic Recovery test (Modified binder)

9 Rate of spread of Prime Coat & Tack Coat

10 Individual Gradation Test for DBM GR-II

11 Individual Gradation Test for BC GR-II

12 Marshall Stability Test

13 Bitumen Extraction & Gradation Test for DBM GR-II

14 Bitumen Extraction & Gradation Test for BC GR-II

15 Bituminous Core test Results

VI CONCRETE

1 Summary of Cement Test Reports

2 Test on Cement (Consistency, Initial & Final setting time)

3 Test on Cement (Compressive Strength of Mortar cubes)

4 Compressive Strength of concrete cubes

5 Concrete Dispatch Slip

6 Flexural Strength of Concrete Beams

7 Daily Programme
 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300)
of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the
State of Andhra Pradesh (Package-1).
Client National Highways Authority of India.
Independentent M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
Engineer association with M/s Kaius Conslting Pvt. Ltd.
Concessionaire M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
Contractor M/S Dilip Buildcon Limited.

Request for Inspection (RFI)

Part - I : To be Completed by Contractor

Name of Representative :…….......…………………………. Date of Submission :…...……………...

Time of Inspection :……..…….………………..……………….. Date of Inspection :……..……………..
RFI No: DBL/BVEL-PKG1/…….......…/……........

Highway Structure QC Survey Location :....………………………………………………

1 ) Clearing and Grubbing 8 ) Prime Coat

2) Excavation 9) Tack Coat
3) Embankment 10 ) DBM / BM / BC / PQC
4) Subgrade 11 ) Dismantling
5) GSB / Drainage/CTSB/CTB 12 ) PCC / RCC
6) AIL/WMM /DLC 13 ) Reinforcement / Shuttering
7) OGL / TBM Traversing 14 ) Other's
Work Description ............................................................................................................................................................................................
.........................................................................................................................................................................................................................
.

Enclosures : 1 ) FDD 2 ) Level 3)

Gradation 4 ) Measurement Sheet 5 ) Drawing 6 ) Other's

Received By Submitted By

Consultant Contractor
Part - II : Remarks
Remarks:- Contractor Representative
……………………………………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………………

Concessionaire Representative
……………………………………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………………
IE Representative
……………………………………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………………

Whether previous Layer Approved / Not Approved

……………………………………………………………………………………………………………………………………………………

Contractor Representative Concessionaire Representative IE's Representative ( TL/RE/BE/ME )

 National Highways Authority of India
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to
Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode
under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
Client National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Independent Engineer
Services Pvt. Ltd. in association with M/s Kaius Conslting Pvt. Ltd.
Concessionaire M/s Bengaluru-Vijayawada Expressway Package-1 Ltd.
EPC Representative M/s Dilip Buildcon Ltd.
SAMPLE CARD
Date of Sampling :-
Name of Sample :-
Sample Location :-
Source of Sample :-
Sampled By :-

Contractor Concessionaire Independent Engineer

National Highways Authority of India

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to
Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode
under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
Client National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Independent Engineer
Services Pvt. Ltd. in association with M/s Kaius Conslting Pvt. Ltd.
Concessionaire M/s Bengaluru-Vijayawada Expressway Package-1 Ltd.
EPC Representative M/s Dilip Buildcon Ltd.
SAMPLE CARD
Date of Sampling :-
Name of Sample :-
Sample Location :-
Source of Sample :-
Sampled By :-

Contractor Concessionaire Independent Engineer

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the
State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
EPC CONTRACTOR M/S Dilip Buildcon Limited.
DETERMINATION OF ATTERBERG LIMIT BY CASAGRANDE APPARATUS
IS: 2720 (Part – 5)
Lab Job No. / RFI No. Date of Sampling
Location / Source Date of Testing
Type of Material Sampled By
Proposed Use Tested By
Liquid Limit Plastic Limit
Description 1 2 3 4 1 2
No. of blows
Container No.
Wt. of Empty Container (W1) gm
Wt. of Container + Wet Soil (W2) gm
Wt. of Container + Dry Soil (W3) gm
Wt. of Water (W4=W2-W3) gm
Wt. of dry Soil (W5=W3-W1) gm
Moisture Content =100*(W4/W5) %
MOISTURE CONTENT %

1 10 100
15 20 25 30 40 50

NUMBER OF BLOWS
LIQUID LIMIT (%) PLASTIC LIMIT (%) PLASTICITY INDEX (%)

1. The PI Calculated as the difference between its Liquid Limit and Plastic Limit.

2. In Case of Sandy Soil PL should be determined first, In case of of this is not determined PI Should be reported as NP.

3. When the PI is equal to or greater than the LL , the PI shall be reported as Zero

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State
of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
EPC CONTRACTOR M/S Dilip Buildcon Limited.
DETERMINATION OF ATTERBERG LIMIT BY CONE PENETROMETER
IS: 2720 (Part – 5)
Lab Job No. / RFI No. Date of Sampling
Location / Source Date of Testing
Type of Material Sampled By
Proposed Use Tested By
Liquid Limit Plastic Limit
Description 1 2 3 4 1 2
Penetration in mm
Container No.
Wt. of Empty Container (W1) gm
Wt. of Container + Wet Soil (W2) gm
Wt. of Container + Dry Soil (W3) gm
Wt. of Water (W4=W2-W3) gm
Wt. of dry Soil (W5=W3-W1) gm
Moisture Content =100*(W4/W5) %
MOISTURE CONTENT %

10 15 20 25 30

PENETRATION IN MM
LIQUID LIMIT (%) PLASTIC LIMIT (%) PLASTICITY INDEX (%)

1. The PI Calculated as the difference between its Liquid Limit and Plastic Limit.

2. In Case of Sandy Soil PL should be determined first, In case of of this is not determined PI Should be reported as NP.

3. When the PI is equal to or greater than the LL , the PI shall be reported as Zero.

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State
of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

MODIFIED PROCTOR'S COMPACTION TEST

As per IS 2720 (PART 8)
Chainage Date of Sampling
Type of Material Date of Testing
Source Sampled By
Proposed Use Tested By
Mould No Wt. of Mould, W1 (g) Volume of mould, V (cc)
% of Water added
Wt. of wet soil + mould, W2

(g)
Wt. of wet soil, W3=(W2-W1)

(g)
Wet density, Yb = W3/V

(g/cc)
Container No.
Wt. of container,W5

(g)
Wt. of wet soil + cont., W6

(g)
Wt. of dry soil + cont.,W7

(g)
Wt. of water, W8=(W6-W7)

(g)
Wt. of dry soil, W9=(W7-W5)

(g)
Moisture content w =W8/W9 x 100

(%)
Dry density Yd = [Yb/1+w(%)] (gm/cc)
Rammer Wt.
4.89kg
[Link] Blows 25/55
Dry Density (g/cc)

[Link] Layer 5
RESULTS

MDD (gm/cc).

OMC (%) .
Remarks

Contractor's Representative Concessionaire's Representative IE's Representative

10

7
Denisty (g/cc)

0
0 1 2 3 4 5 6 7 8 9 10
 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
INDEPENDENT M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association
ENGINEER with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
FIELD DRY DENSITY TEST
IS: 2720 (Part 28)
Chainage RFI NO

Layer Date

Cylinder No Source of Material

Diameter of The Cylinder MDD gm/cc

Weight of Sand in Cone ( W1) OMC %

Bulk Density of Sand (Ys) (g/cc)

FIELD DRY DENSITY

Representing test chainage
Offset from centre line
Depth of Hole
Weight of Wet Material from Hole ( Ww ) (gm)
Weight of Sand+Cylinder Before Pouring (W2)(gm)
Weight of Sand+Cylinder After Pouring (W3) (gm)
Weight of Sand in Hole , W4=(W2-W3-W1) (gm)
Bulk Density of Material Yb= (Ww/W4)*Ys (%)

Moisture Content
Weight of Wet soil ( W1 ) (gm)
Weight of Dry soil ( W2 ) (gm)
Weight of Water , W3= (W1-W2) (gm)
Moisture Content W=(W3/W2)x100 (%)

Rapid Moisture Meter Reading

Corrected Moisture Content (%)
Results
Field MDD ( YbX100)/(100+W) (%)
Compaction Obtained Field DD/MDDX100 (%)
Avg Compaction
Compaction Required ( % )

Contractor's Representative Concessionaire's Representative IE 's Repersentative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of NH-
544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra
Pradesh (Package-1).
CLIENT National Highways Authority of India
INDEPENDENT M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association with
ENGINEER M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
California Bearing Ratio IS : 2720 (Part -16)
Source of Sample Date of Casting :
Description of Materials Date of Testing :
Location Period of Soaking :
Static / Dynamic MDD…............(gm/cc) :
Volume of the mould (cc) OMC……………..(%) :
Surcharge wt Applied : 5Kgs
Before Soaking After Soaking Before Soaking After Soaking Before Soaking After Soaking
Description

Mould No.
Wt. of mould + Compacted soil in gms (m1) (gms)
Wt. of mould in gms (m2) (gms)
Wt. of compacted soil in gms m3 = (m1-m2) (gms)
Wet Density in γЬ = m3/v (gms/cc)
Container No.
Wt. of container (W1) (gms)
Wt. of container + wet soil (W2) (gms)
Wt. of container + dry soil (W3) (gms)
Wt. of water ( W2- W3) (gms)
Wt. of dry soil ( W3 - W1) (gms)
Moisture Content, W =W2-W3/W3-W1x100 (%)
Dry density γd = γb / (1+W/100) (gms/cc)
Percentage of Compaction = (γd/MDD)×100 (%)
Proving Ring No : Calibration Factor, 1 Division = Kg.
Mould No. Mould No. Mould No.
Sl. No Penetration (mm) Proving ring Proving ring Proving ring
Load (Kgs) Load (Kgs) Load (Kgs)
Reading (Div) Reading (Div) Reading (Div)
1 0.5
2 1.0
3 1.5
4 2.0
5 2.5
6 3.0
7 4.0
8 5.0
9 7.5
10 10.0
11 12.5
Corrected CBR Value at 2.5 mm.
Corrected CBR Value at 5.0 mm.
CBR Value @
Remarks :-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300)
of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in
the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
FREE SWELL INDEX
As per IS: 2720 (PART - 40 )

Location/Source (km) Date of Sampling

Type of Material Date of Testing

Proposed Use Sampled By

Tested By

Sample No.
Description Mean

1 2

Volume of Specimen in Graduated Cylinder Containing

vd
Distilled Water after 24 hrs = (ml)

Volume of Specimen in Graduated Cylinder Containing

vk
Kerosene after 24 hrs = (ml)

Difference of Volume in Water & Kerosene (ml) (vd-vk)

(vd -
Free Swell Index = (%)
vk)X100 vk

Remarks :-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State
of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
GRAIN SIZE ANALYSIS OF SOIL
As per IS: 2720, Part - 4
Location Date of Sampling
Source of Material Date of Testing
Proposed Use Sampled by
Wt. of Sample (gm) Tested by

Cumulative
Weight Retained Cum % of Wt
Sieve size weight % of Passing Remark
(gms) Retained
Retained (gms)

100 mm

75 mm

19 mm

4.75 mm

2 mm

425 mic.

75 mic.

Gravel (%)

Sand Content (%)

Silt/Clay Content (%)

Remarks :

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of NH-544G
Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
CLIENT National Highways Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association with
INDEPENDENT ENGINEER
M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
DIRECT SHEAR TEST (IS 2720 PART-13)
Chainage Date of sampling
Source Date of testing
Deseription of Material Sampled by & Tested by
[Link] LXW (MM) Proving ring factor
MDD & OMC
Normal Stress 0.5 Kg/cm2 Normal Stress 1.0 Kg/cm2
Corrected Shear
Deformation Load (N) Load (KG) Deformation Corrected Area Load (N) Laod (KG) Shear Stress (kg/cm2)
Area Stress
(kg/cm2)

0.00 36.00 0 0.00 0.00 0.00 36.00 0 0.00 0.00

0.50 35.40 0.50 35.40
1.00 34.80 1.00 34.80
1.50 34.20 1.50 34.20
2.00 33.60 2.00 33.60
2.50 33.00 2.50 33.00
3.00 32.40 3.00 32.40
3.50 31.80 3.50 31.80
4.00 31.20 4.00 31.20
4.50 30.60 4.50 30.60
5.00 30.00 5.00 30.00
5.50 29.40 5.50 29.40
6.00 28.80 6.00 28.80
6.50 28.20 6.50 28.20
7.00 27.60 7.00 27.60
7.50 27.00 7.50 27.00
8.00 26.40 8.00 26.40
Normal Stress 1.5 Kg/cm2
Stress Dial Corrected
Normal Shear stress
Gauage Shear Force Displaceme Area AC=
Corrected Shear Stress [Link] (1) stress kg/cm² Remarks
Deformation Load (N) Load (KG) [Link] (kg) (4) nt (cm) (5) AD(
Area (kg/cm2) Aplied (4/6) (7)
failure (3) 1-ᴔ/3)cm²
(kg/cm²) (2)
(6)
0.00 36.00 0.00 0.00 0.00 1
0.50 35.40 2
1.00 34.80 3
1.50 34.20
2.00 33.60
2.50 33.00
3.00 32.40 0.50
3.50 31.80
4.00 31.20 1.00
4.50 30.60
5.00 30.00 1.50
5.50 29.40
6.00 28.80 c =
6.50 28.20
7.00 27.60 ø =
7.50 27.00
8.00 26.40
Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State
of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
EPC CONTRACTOR M/S Dilip Buildcon Limited.
DETERMINATION OF ATTERBERG LIMIT BY CONE PENETROMETER
IS: 2720 (Part – 5)
Lab Job No. / RFI No. Date of Sampling
Location / Source Date of Testing
Type of Material Sampled By
Proposed Use Tested By
Liquid Limit Plastic Limit
Description 1 2 3 4 1 2
Penetration in mm
Container No.
Wt. of Empty Container (W1) gm
Wt. of Container + Wet Soil (W2) gm
Wt. of Container + Dry Soil (W3) gm
Wt. of Water (W4=W2-W3) gm
Wt. of dry Soil (W5=W3-W1) gm
Moisture Content =100*(W4/W5) %
MOISTURE CONTENT %

10 15 20 25 30

PENETRATION IN MM
LIQUID LIMIT (%) PLASTIC LIMIT (%) PLASTICITY INDEX (%)

1. The PI Calculated as the difference between its Liquid Limit and Plastic Limit.

2. In Case of Sandy Soil PL should be determined first, In case of of this is not determined PI Should be reported as NP.

3. When the PI is equal to or greater than the LL , the PI shall be reported as Zero.

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State
of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

MODIFIED PROCTOR'S COMPACTION TEST

As per IS 2720 (PART 8)
Chainage Date of Sampling
Type of Material Date of Testing
Source Sampled By
Proposed Use Tested By
Mould No Wt. of Mould, W1 (g) Volume of mould, V (cc)
% of Water added
Wt. of wet soil + mould, W2

(g)
Wt. of wet soil, W3=(W2-W1)

(g)
Wet density, Yb = W3/V

(g/cc)
Container No.
Wt. of container,W5

(g)
Wt. of wet soil + cont., W6

(g)
Wt. of dry soil + cont.,W7

(g)
Wt. of water, W8=(W6-W7)

(g)
Wt. of dry soil, W9=(W7-W5)

(g)
Moisture content w =W8/W9 x 100

(%)
Dry density Yd = [Yb/1+w(%)] (gm/cc)
Rammer Wt.
4.89kg
[Link] Blows 25/55
Dry Density (g/cc)

[Link] Layer 5
RESULTS

MDD (gm/cc).

OMC (%) .
Remarks

Contractor's Representative Concessionaire's Representative IE's Representative

10

7
Denisty (g/cc)

0
0 1 2 3 4 5 6 7 8 9 10
 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
INDEPENDENT M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association
ENGINEER with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
FIELD DRY DENSITY TEST
IS: 2720 (Part 28)
Chainage RFI NO

Layer Date

Cylinder No Source of Material

Diameter of The Cylinder MDD gm/cc

Weight of Sand in Cone ( W1) OMC %

Bulk Density of Sand (Ys) (g/cc)

FIELD DRY DENSITY

Representing test chainage
Offset from centre line
Depth of Hole
Weight of Wet Material from Hole ( Ww ) (gm)
Weight of Sand+Cylinder Before Pouring (W2)(gm)
Weight of Sand+Cylinder After Pouring (W3) (gm)
Weight of Sand in Hole , W4=(W2-W3-W1) (gm)
Bulk Density of Material Yb= (Ww/W4)*Ys (%)

Moisture Content
Weight of Wet soil ( W1 ) (gm)
Weight of Dry soil ( W2 ) (gm)
Weight of Water , W3= (W1-W2) (gm)
Moisture Content W=(W3/W2)x100 (%)

Rapid Moisture Meter Reading

Corrected Moisture Content (%)
Results
Field MDD ( YbX100)/(100+W) (%)
Compaction Obtained Field DD/MDDX100 (%)
Avg Compaction
Compaction Required ( % )

Contractor's Representative Concessionaire's Representative IE 's Repersentative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of NH-
544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra
Pradesh (Package-1).
CLIENT National Highways Authority of India
INDEPENDENT M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association with
ENGINEER M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
California Bearing Ratio IS : 2720 (Part -16)
Source of Sample Date of Casting :
Description of Materials Date of Testing :
Location Period of Soaking :
Static / Dynamic MDD…............(gm/cc) :
Volume of the mould (cc) OMC……………..(%) :
Surcharge wt Applied : 5Kgs
Before Soaking After Soaking Before Soaking After Soaking Before Soaking After Soaking
Description

Mould No.
Wt. of mould + Compacted soil in gms (m1) (gms)
Wt. of mould in gms (m2) (gms)
Wt. of compacted soil in gms m3 = (m1-m2) (gms)
Wet Density in γЬ = m3/v (gms/cc)
Container No.
Wt. of container (W1) (gms)
Wt. of container + wet soil (W2) (gms)
Wt. of container + dry soil (W3) (gms)
Wt. of water ( W2- W3) (gms)
Wt. of dry soil ( W3 - W1) (gms)
Moisture Content, W =W2-W3/W3-W1x100 (%)
Dry density γd = γb / (1+W/100) (gms/cc)
Percentage of Compaction = (γd/MDD)×100 (%)
Proving Ring No : Calibration Factor, 1 Division = Kg.
Mould No. Mould No. Mould No.
Sl. No Penetration (mm) Proving ring Proving ring Proving ring
Load (Kgs) Load (Kgs) Load (Kgs)
Reading (Div) Reading (Div) Reading (Div)
1 0.5
2 1.0
3 1.5
4 2.0
5 2.5
6 3.0
7 4.0
8 5.0
9 7.5
10 10.0
11 12.5
Corrected CBR Value at 2.5 mm.
Corrected CBR Value at 5.0 mm.
CBR Value @
Remarks :-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300)
of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in
the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
FREE SWELL INDEX
As per IS: 2720 (PART - 40 )

Location/Source (km) Date of Sampling

Type of Material Date of Testing

Proposed Use Sampled By

Tested By

Sample No.
Description Mean

1 2

Volume of Specimen in Graduated Cylinder Containing

vd
Distilled Water after 24 hrs = (ml)

Volume of Specimen in Graduated Cylinder Containing

vk
Kerosene after 24 hrs = (ml)

Difference of Volume in Water & Kerosene (ml) (vd-vk)

(vd -
Free Swell Index = (%)
vk)X100 vk

Remarks :-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State
of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
GRAIN SIZE ANALYSIS OF SOIL
As per IS: 2720, Part - 4
Location Date of Sampling
Source of Material Date of Testing
Proposed Use Sampled by
Wt. of Sample (gm) Tested by

Cumulative
Weight Retained Cum % of Wt
Sieve size weight % of Passing Remark
(gms) Retained
Retained (gms)

100 mm

75 mm

19 mm

4.75 mm

2 mm

425 mic.

75 mic.

Gravel (%)

Sand Content (%)

Silt/Clay Content (%)

Remarks :

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of NH-544G
Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
CLIENT National Highways Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association with
INDEPENDENT ENGINEER
M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.
DIRECT SHEAR TEST (IS 2720 PART-13)
Chainage Date of sampling
Source Date of testing
Deseription of Material Sampled by & Tested by
[Link] LXW (MM) Proving ring factor
MDD & OMC
Normal Stress 0.5 Kg/cm2 Normal Stress 1.0 Kg/cm2
Corrected Shear
Deformation Load (N) Load (KG) Deformation Corrected Area Load (N) Laod (KG) Shear Stress (kg/cm2)
Area Stress
(kg/cm2)

0.00 36.00 0 0.00 0.00 0.00 36.00 0 0.00 0.00

0.50 35.40 0.50 35.40
1.00 34.80 1.00 34.80
1.50 34.20 1.50 34.20
2.00 33.60 2.00 33.60
2.50 33.00 2.50 33.00
3.00 32.40 3.00 32.40
3.50 31.80 3.50 31.80
4.00 31.20 4.00 31.20
4.50 30.60 4.50 30.60
5.00 30.00 5.00 30.00
5.50 29.40 5.50 29.40
6.00 28.80 6.00 28.80
6.50 28.20 6.50 28.20
7.00 27.60 7.00 27.60
7.50 27.00 7.50 27.00
8.00 26.40 8.00 26.40
Normal Stress 1.5 Kg/cm2
Stress Dial Corrected
Normal Shear stress
Gauage Shear Force Displaceme Area AC=
Corrected Shear Stress [Link] (1) stress kg/cm² Remarks
Deformation Load (N) Load (KG) [Link] (kg) (4) nt (cm) (5) AD(
Area (kg/cm2) Aplied (4/6) (7)
failure (3) 1-ᴔ/3)cm²
(kg/cm²) (2)
(6)
0.00 36.00 0.00 0.00 0.00 1
0.50 35.40 2
1.00 34.80 3
1.50 34.20
2.00 33.60
2.50 33.00
3.00 32.40 0.50
3.50 31.80
4.00 31.20 1.00
4.50 30.60
5.00 30.00 1.50
5.50 29.40
6.00 28.80 c =
6.50 28.20
7.00 27.60 ø =
7.50 27.00
8.00 26.40
Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch.
0+000) to Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic
Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra
Pradesh (Package-1).
Client National Highway Authority of India
Independent Engineer M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Concessionaire M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
Contractor M/S Dilip Buildcon Limited.

SIEVE ANALYSIS OF GRANNULAR SUB BASE (Gr-V)

AS Per MoRT&H (Table 400-1)

Source of Material RFI No

Chainage Date of Sampling

Proposed Use Date of Testing

Wt. of sample (gms) Sampled By

Tested By
Cumulative
Sieve size Weight Cum % of Specification
weight retained % of Passing
(mm) retained Wt Limit
(gm)
(gm) Retained
75 100

53 80-100

26.50 50-90

9.50 35-65

4.75 25-50

2.36 10-20

0.85 02-10

0.425 0-5

0.075

Pan

Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana
Phase-I in the State of Andhra Pradesh (Package-1).
Client National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association
Independent Engineer
with M/s Kaius Conslting Pvt. Ltd.
Concessionaire M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
Contractor M/S Dilip Buildcon Limited.

SIEVE ANALYSIS OF CEMENT TREATED GRANNULAR SUB BASE (CTSB)

As Per MoRT&H (Table 400-1,Grade-IV)

Source of Material : RFI No :

Chainage : Date of Sampling :

Proposed Use : Date of Testing :

Wt. of sample (gm) : Sampled By :

Type of Material : Tested By :

Cumulative Cum % of Specification Limit as per

Sieve size (mm) Weight retained (gms) % of Passing
weight retained weight MORTH Table 400-1
(gms) Retained

53 100

26.50 50-80

4.75 15-35

0.075 0-5

Pan
Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana
Phase-I in the State of Andhra Pradesh (Package-1).
Client National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
Independent Engineer
association with M/s Kaius Conslting Pvt. Ltd.
Concessionaire M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
Contractor M/S Dilip Buildcon Limited.

SIEVE ANALYSIS OF CEMENT TREATED BASE (CTB)

As Per MoRT&H (Table 400-4)

Source of Material : RFI No :

Chainage : Date of Sampling :

Proposed Use : Date of Testing :

Wt. of sample (gms) : Sampled By :

Type of Material : Tested By :

Weight retained Cumulative weight Cum % of Wt Specification Limit as per

Sieve size (mm) % of Passing
(gm) retained (gm) Retained MORTH Table 400-4

53.0 100

37.5 95-100

19.0 45-100

9.50 35-100

4.75 25-100

0.600 8-65

0.300 5-40

0.075 0-10

Pan

Remarks:

Contractor's Representative Concessionaire's

Representative IE's Representative
 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch.
0+000) to Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic
Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra
Pradesh (Package-1).
Client National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
Independent Engineer
Services Pvt. Ltd. In association with M/s Kaius Conslting Pvt. Ltd.
Concessionaire M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
Contractor M/S Dilip Buildcon Limited.

SIEVE ANALYSIS OF AIL (WET MIX MACADAM)

AS Per MoRT&H (Table 400-13)

Source of Material RFI No

Chainage Date of Sampling
Proposed Use Date of Testing
Wt. of sample (gms) Sampled By
Tested By
Cumulative
Sieve size Weight Cum % of Specification
weight % of Passing
(mm) retained Wt Limit
retained (gm)
(gm) Retained
53 100

45 95-100

22.40 60-80

11.20 40-60

4.75 25-40

2.36 15-30

0.60 8-22

0.075 0-5

Pan

Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to
Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode
under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).

CLIENT National Highways Authority of India

M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
INDEPENDENT ENGINEER
Services Pvt. Ltd. In association with M/s Kaius Consulting Pvt. Ltd.

CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.

CONTRACTOR M/S DILIP BUILCON LTD.

SPECIFIC GRAVITY OF COARSE AGGREGATE

IS: 2386 (Part 3) 1963

Source Date of sampling

Location Date of testing

Activity Type of material

[Link] Determination Test 1 Test 2 Remark

A Weight of SSD sample in air (g)

B Weight of Saturated sample in water (g)

C Weight of dry sample (g)

D Bulk specific gravity (Oven dry) C/(A-B)

E Bulk specific gravity (SSD) A/(A-B)

F Apparent specific gravity C/(C-B)

G Water Absorbtion ((A-C)/C*100) (%)

Remarks:

EPC Contractor Representative Concessionaire Representative Independent Engineer Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to
Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM
Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).

CLIENT National Highways Authority of India

M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
INDEPENDENT ENGINEER
Services Pvt. Ltd. In association with M/s Kaius Consulting Pvt. Ltd.

CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.

CONTRACTOR M/S DILIP BUILCON LTD.

SPECIFIC GRAVITY OF FINE AGGREGATE

IS: 2386 (Part 3) 1963

Source Date of sampling

Location Date of testing

Activity Type of material

[Link] Determination Test 1 Test 2 Average

A SSD weight of sample in air

B Weight of pycnometer + water + sample

C Weight of pycnometer + water

D Oven dry weight of sample

E Bulk specific gravity (Oven dry) D/A-(B-C)

F Bulk specific gravity (SSD) A/A-(B-C)

G Apparent specific gravity D/D-(B-C)

H Water Absorbtion ((A-D)/D*100) (%)

Remarks:

EPC Contractor Representative Concessionaire Representative Independent Engineer Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu
(Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services
INDEPENDENT ENGINEER
Pvt. Ltd. In association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

SIEVE ANALYSIS OF COARSE AGGREGATE

As per IS : 383 -2016 (T-7)

Lab Job No. Date of Sampling

Source of Material Date of Testing
Type of Material Sampled By
Proposed Use Tested By

SIZE OF AGGREGATE = 40 MM Total Wt. Sample : gms

Cumulative
IS Sieve Size Weight Cum. % Wt.
weight retained Passing % Specified Limits %
(mm) Retained(gms) Retained
(gms)
63 100
40 85-100
20 0-20
10 0-5
Pan

SIZE OF AGGREGATE = 20 MM Total Wt. Sample : gms

Cumulative
IS Sieve Size Weight Cum. % Wt.
weight retained Passing % Specified Limits %
(mm) Retained(gms) Retained
(gms)
40 100
20 85-100
10 0-20
4.75 0-5
Pan

SIZE OF AGGREGATE = 10 MM Total Wt. Sample : gms

Cumulative
IS Sieve Size Weight Cum. % Wt.
weight retained Passing % Specified Limits %
(mm) Retained(gms) Retained
(gms)
12.5 100
10 85-100
4.75 0-20
2.36 0-5
Pan

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch.

0+000) to Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic
Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of
CLIENT National Highways Authority of India.

M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services
INDEPENDENT ENGINEER
Pvt. Ltd. In association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

SIEVES ANALYSIS OF FINE AGGREGATE (IS: 383)

Location : Date of Sampling

Source : Date of Testing

Type of Material : Sampled By :

Purposed Use : Tested By :

Wt. of Sample :

Specification Limit ( IS:383 )

Weight Cumulative
IS Cum. Wt Percentage
Retained Percentage
Sieves Retained of Passing Zone- I Zone- II Zone- III
(gms) Retained
(mm) (gms)

10 100 100 100

4.75 90-100 90-100 90-100

2.36 60-95 75-100 85-100

1.18 30-70 55-90 75-100

0.600 15-34 35-59 60-79

0.300 5-20 8-30 12-40

0.150 0-20 0-20 0-20

Pan - - -
Fineness Moduls 2.0 - 3.5

Remarks:-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to
Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM
Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services
INDEPENDENT ENGINEER
Pvt. Ltd. In association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

FLAKINESS & ELONGATION INDEX

[As per IS 2386, (Part - I)]

Location/Source Date of Sampling

Type of Materials Date of Testing
Proposed use: Sampled by
Tested by

Fraction
Mass of Agg. Mass of pieces Mass of agg retained
Mass of Agg.
Passing @ 200 pieces passing on Length gauge
Retained on Retained on
through IS taken in each through the (after ret. on
IS sieve (in appropriate
sieve (in fraction in appropriate appropriate gauge)
mm) gauge in gms
mm) gms [A] gauge in each [D] (g)
[C=A-B]
fraction[B]
63.00 50.00
50.00 40.00
40.00 31.50
31.50 25.00
25.00 20.00
20.00 16.00
16.00 12.50
12.50 10.00
10.00 6.30
Total

Flakiness Index (FI) = B/A x 10 = %

Elongation Index (EI) = = %
D/Cx10 Combined FI & EI = %
Specification Limit (Max.) = %
Remarks :

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Project:-Development of Six-Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
Bengaluru - Vijayawada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of
Andhra
Pradesh (Package-1).
CLIENT National Highway Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd.
INDEPENDENT ENGINEER In association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru Vijayawada Expressway Package-1 Limited.

CONTRACTOR M/S Dilip Buildcon Limited.

LOS ANGELES ABRASION TEST

As per IS 2386 Part - 4

Lab Job No. Date of Sampling

Source Date of Testing

Type of Material Sampled by

Grading Tested by

Determination Trial No. 1

Weight dry sample (W1) (gms)

Weight of fraction passing 1.70 mm IS sieve, after

(gms)
Impact , (W2)

Weight of fraction retained on 1.70 mm IS sieve after

(gms)
the test, (W3)

L.O.S = (W2 / W1)X100 (%)

Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.

CONTRACTOR M/S Dilip Buildcon Limited.

AGGREGATE IMPACT VALUE TEST

As per IS 2386 Part - 4

Source Date of Sampling

Type of Material Date of Testing

Proposed Use Sampled by

Tested by

Determination Trial No. 1 Trial No. 2

Weight of surface dry sample passing 12.5 mm

(gms)
and retained on 10 mm IS sieves, (W1)

Weight of fraction passing 2.36 mm IS sieve,

(gms)
after Impact (W2)

Weight of fraction retained on 2.36 mm IS sieve after

(gms)
the test, (W3)

A.I.V. = (W2 / W1)X100 (%)

Average Impact Value (%)

Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch.

0+000) to Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic
Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of
Andhra Pradesh (Package-1).
Client M/s. National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng
Independentent
Advisory Services Pvt. Ltd. In association with M/s Kaius
Engineer
Conslting Pvt. Ltd.
Concessionaire M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
Contractor M/s. Dilip Buildcon Limited.
DETERMINATION OF SILT CONTENT OF FINE AGGREGATE
As per IS 2386 (Part - I)

Sample No. Date Sampling

Location/Source Date of Testing

Type of Material Sampled by

Proposed Use Tested by

Descreption 1 2

1) weight of Oven dry sample before washing taken (gm) W1

2) Weight of Oven dry sample after washing through 75 micron sieve (gm)
W2

3) Silt & Clay Content % W3 = (W1 - W2/W1)x100

Limits:

Silt Content Average = % Natural Sand : 3%

Crushed Sand : 15 %
Combined Sand : 12 %
Remarks :

Contractor Representative Concessionaire Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu
(Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

TEN PERCENT FINES VALUE TEST

As per IS: 2386 - Part 4

Source : Date of Sampling :

Type of Material : Date of Testing :

Grade of Bitumen : Sampled By :

Proposed Use : Tested By :

Description Units Test 1 Test 2 Test 3

Weight of surface dry sample passing 12.5 mm and

(gms)
retained on 10 mm IS sieves, (W1)

Weight of fraction retained on 2.36 mm IS sieve after

(gms)
the test, (W2)

Weight of fraction passing through 2.36 mm IS sieve

(gms)
after the test, (W3) = W1-W2

% Fines, F = W3/W1 x 100 (%)

Total force applied P (KN)

10 % Fines Value = (14 X P)/ F+4 `

Average 10 % Fines Value KN

Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 National Highways Authority of India
Development of Six-Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
Bengaluru - Vijayawada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the
State of Andhra Pradesh (Package-1).
Client National Highways Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd.
Independent Engineer In association with M/s Kaius Consulting Pvt. Ltd.
Concessionaire Bengaluru Vijayawada Expressway Package-1 Limited
Contractor M/S Dilip Buildcon Limited.

SPECIFIC GRAVITY OF BITUMEN

As per IS 1202

Sample No.: ………………………………………………………………………

Location : …………………………………………………………………………. Date of Sampling : ..…………………….

Type of Material : …………………………………………………………….. Date of Testing : ..……………………….

Description of Material : …………………………………………………… Sampled by : .……………………………..

Source of Material : …………………………………………………………… Tested by : .…………………………………

OBSERVATIONS
Description 1 2 3

Wt. of Density Bottle. (W1) g

Wt. of Density Bottle Filled with Water. (W2) g

Wt of Density Bottle+ Bitumen. (W3) g

Wt of Density Bottle+ Bitumen+Water. (W4) g

Specific Gravity of Bitumen

(W3-W1)/((W2-W1)-(W4-W3))

Average Specific gravity of Bitumen

Remarks:…………………………………………………………………………………………………………..

Concessionaire Representative Independent Engineer Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu
(Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India

M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services
INDEPENDENT ENGINEER
Pvt. Ltd. In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

PENETRATION TEST OF BITUMEN

As per IS : 1203 - 1978

Laboratory No : Date of sampling :

Source of Sample : Date of testing :

Type of material : Sampled by :

Grade of Bitumen : Tested by :

Sr. No. S - 01 S - 02 S - 03 Mean Value

Initial Reading

Final Reading

Penetration in
1/10 mm
Acceptance Criteria Specified :

Remarks:-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana
Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt.
INDEPENDENT ENGINEER
Ltd. In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

SOFTENING POINT TEST

As per IS:1205

Invoice no : Date of sampling

Source : Sampled by

Grade of Bitumen : Date of Testing

Location : Tested by

Vehicle no :

Rate of heating : 50˚C ± 0.50˚C / minute

Time (Min) Temperature (0C) Time (Min) Temperature (0C)

1 11

2 12

3 13

4 14

5 15

6 16

7 17

8 18

9 19

10 20

OBSERVATIONS:-

Ball No. 1 Ball No.2 Remarks

Temperature at which sample
touches the bottom plate (0C)

Contractor's Representative Concessionaire's Representative IE'S Repersentative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000)
to Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM
Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt.
INDEPENDENT ENGINEER
Ltd. In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

KINEMATIC VISCOSITY TEST OF BITUMEN

(IS:1206 Part-III)

Source : Date of Sampling :

Grade of Bitumen : Sampled By :
Purpose of Use : Date of Testing :
Tested By :

[Link]. Description Bulb-B

1 Specific Test Temperature in Centigrade

2 Actual Test Temperature in Centigrade

3 Flow time in seconds(t)

4 Calibration Factor(k)

5 Viscosity in Poise(k x t) cst

REMARKS:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu
(Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt.
INDEPENDENT ENGINEER
Ltd.
In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

DUCTILITY
As per IS: 1208 - 1978

Source : Date of Sampling :

Location : Date of Testing :

Grade of Bitumen : Sampled By :

Tested By :

Description Units Test 1 Test 2 Test 3

Pouring temperature o
C
Period of cooling in atmosphere minutes

Room tempearture o
C
Period of cooling in water bath minutes

Actual test temperature o

C
Rate of pull mm/min

Ductility cms

Average Ductility cms

Remarks:

Contractor's Representative Concessionaire's Representative IE'S Representative

 National Highways Authority of India
Development of Six-Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu
(Ch.
24+300) of Bengaluru - Vijayawada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng
INDEPENDENT ENGINEER Advisory Services Pvt. Ltd. In association with M/s Kaius
Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru Vijayawada Expressway Package-1 Limited
CONTRACTOR M/S Dilip Buildcon Limited.

STRIPPING VALUE OF AGGREGATES

As Per : IS 6241

Description of Material : Date of Sampling :

Source of Material : Date of Sampling
: Sample No. :

OBSERVATIONS
SL No. Description Trial 1 Trial 2
1 Temperature of Aggregate at mixing
2 Temperature of Bitumen at mixing
3 Constant temperature of the water bath maintained
4 Observation made after 24 hours of water submergence
5 Grade of Bitumen Used
6 [Link] agg taken, g
7 [Link] Bitumen added, g
8 Stripping Percentage
9 Coating Retained
10 Stripping Value

Specification Limit as per MORTH Minimum Retained Coating

95%

Remarks:…………………………………………………………………………………..

Concessionaire Representative Independent Engineer's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

SITE LAYING TEMPERATURE

As Per MoRT&H (Table 500-2)

Source : RFI No :
Chainage : Date of Laying :
Side : Type of Material :
Qty :
Laying Rolling
Cum. Time of Time of
Sl. No. Vehicle No. Tonnage Temperature Temperature Remarks
Tonnage Arrival Unloading
(OC) (OC)

REMARKS:

Conctractor's Representative Concessionaires's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300)
of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the
State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd.
INDEPENDENT ENGINEER
In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

ELASTIC RECOVERY TEST OF BITUMEN

As per IRC : SP : 53 -2010

Laboratory No : Date of sampling :

Source of Sample : Date of testing :

Type of material : Sampled by :

Grade of Bitumen : Tested by :

Sr. No. S - 01 S - 02 S - 03 Mean Value

Length of re-combined
specimen, D (cm)

Elastic Recovery, %
= 100(10-D)

Acceptance Criteria Specified :

Remarks:-

Contractor's Representative Concessionaire's Representative IE's

Representative
 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to
Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under
Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

RATE OF SPRAY TEST FOR PRIME/TACK COAT

As per IS : 8887 - 2004

Chainage : RFI :

Activity : Date of Testing :

Spray Temperature : Description of material :

Area of Tray (G) :

Wt of Empty Wt. of tray + Wt. of material Rate of Rate of

Locatio
Sl. No Tray No. (A) Tray (gm) material (Kg) Spray Spraying
n (B)
(C) (gm) ( D ) E = (D-C/1000) (Kg/m2) F=(E/G)x10
F=E/G Kg/10m2

Average Rate of spray ( kg /10m2)

Remarks

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana
Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority Of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Consuulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

Individual Gradations of Hot Bin Samples for DBM (Grade-2)

Source of Material Date of Sampling

Location/Chainage Date of Testing

Type of Material Sampled by

Tested by
HOT BIN :1 Total Wt. (gm's) HOT BIN :2 Total Wt. (gm's)
= =
Cum. Cum.
Sieve
Sieve Size weight Cumulative % of Weight weight Cumulative % of
Weight retained (gm's) Size
in "mm" retained % Retained Passing retained retained % Passing
in "mm"
(gm's) (gm's) (gm's) Retained
37.5 37.5
26.5 26.5
19.0 19.0
13.2 13.2
4.75 4.75
2.36 2.36
0.300 0.300
0.075 0.075
HOT BIN :3 Total Wt. (gm's) HOT BIN :4 Total Wt. (gm's)
= =
Cum. Cum.
Sieve
Sieve Size weight Cumulative % of Weight weight Cumulative % of
Weight retained (gm's) Size
in "mm" retained % Retained Passing retained retained % Passing
in "mm"
(gm's) (gm's) (gm's) Retained
37.5 37.5
26.5 26.5
13.2 13.2
4.75 4.75
2.36 2.36
0.300 0.300
0.075 0.075
Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority Of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

Individual Gradations of Hot Bin Samples for BC (Grade- 1 /2)

Source of Material Date of Sampling

Location/Chainage Date of Testing

Type of Material Sampled by

Tested by
HOT BIN :1(7-3mm) Total Wt. (gm's) HOT BIN :2 Total Wt. (gm's)
= =
Cum. weight Cum. weight
Sieve Weight Cumulative % of Sieve Weight Cumulative % of
retained retained
Size in retained % Retained Passing Size in retained % Retained Passing
(gm's) (gm's)
"mm" (gm's) "mm" (gm's)
26.5 26.5
19 19
13.2 13.2
9.5 9.5
4.75 4.75
2.36 2.36
1.18 1.18
0.600 0.600
0.300 0.300
0.150 0.150
0.075 0.075
HOT BIN :3 Total Wt. (gm's) HOT BIN :4 Total Wt. (gm's)
= =
Cum. weight Cum. weight
Sieve Weight Cumulative % of Sieve Weight Cumulative % of
retained retained
Size in retained % Retained Passing Size in retained % Retained Passing
(gm's) (gm's)
"mm" (gm's) "mm" (gm's)
26.5 26.5
19 19
13.2 13.2
9.5 9.5
4.75 4.75
2.36 2.36
1.18 1.18
0.600 0.600
0.300 0.300
0.150 0.150
0.075 0.075
Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru - Vijayawada
Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).

Client National Highway Authority of India

M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
Independent Engineer
association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru Vijayawada Expressway Package-1 Limited
CONTRACTOR M/S Dilip Buildcon Limited.

MARSHALL STABILITY TEST

As Per ASTM: D-1559, AASHTO T-245

Date of Casting: Date of testing:

Source of Material Bulk Sp,Gr. (Gsb)
Type of material Sp,Gr. Of Bitumen (Gb)
Location: Porving Ring No:
Calibration Factor:1 Div=

Descreption 1 2
Specimen height (mm)
Wt of Specimen in Air (gm) Wa
Wt of Specimen in Water (gm) Ww
Wt of SSD Specimen in Air (gm) Ws
Volume of Specimen (cc) V=Ws-Ww
Bulk Density of specimen (gm/cc) Gmb=Wa/V
Avg. Bulk Density (gm/cc) Gmb
% of Bitumen (Pb)
% of Aggregate (Ps)
Max. Theoretical Spec. Gravity

% of Air Voids(Va) Va= (Gmm-Gmb)/(Gmm*100)

Voids in Minerals Agg (VMA)% VMA=100-(Gmb*Ps/Gsb)

Voids filled with Bitumen (VFB%) VFB=(VMA-Va)/VMA*100
Load in Div
Load in kg
Correction Factor for Volume
Corrected Stability (kgs)
Avg. Stability in (kgs)
Flow (mm)
Avg. Flow (mm)
Avg. Stability/Avg. Flow
Remarks:-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300)
of Bengaluru - Vijayawada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in
the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru Vijayawada Expressway Package-1 Limited
CONTRACTOR M/S Dilip Buildcon Limited.

BITUMEN EXTRACTION AND GRADATION (DBM GR-2)

As per IRC SP: 11-1984 & ASTM D-2172

A) BITUMEN CONTENT DETERMINATION

Laboratory No : RFI No :

Type of Mix : Grade of Bitumen :

Source : Date of Sampling :

Chainage : Date of Testing :

Carriageway :

Wt of Filter Paper
Wt of Sample before extraction Wt of Sample after Wt of Filter Paper
before extraction Bitumen Content (%)
Test No. (gms) extraction (gms) after extraction
(gms)
(gms)
A B C D E=(A-(B+(D-C)))/Ax100

B) SIEVE ANALYSIS AFTER COMPACTION

Wt of sample after extraction

Sample 1 : Sample 2:
Design Mix Spec. limits
Sieve
Cum Wt %Cum wt Wt Cum gradtion as per
Size % %Cum %
Wt Retained Retaine Retained Retaine Wt (JMF) MORT&H
Cum wt Cum
d (gms) (gms) d (gms) retaine
passin retained passin
(gms) d (gms)
g g
37.5 100

26.5 90-100

19 71-95

13.2 56-80

4.75 38-54

2.36 28-42

0.300 7--21

0.075 2--8
Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of Bengaluru - Vijayawada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINEER
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru Vijayawada Expressway Package-1 Limited
CONTRACTOR M/S Dilip Buildcon Limited.

Bitumen Extraction and Gradation (BC GR-II)

As per IRC SP: 11-1984 & ASTM D-2172

A) BITUMEN CONTENT DETERMINATION

Laboratory No : RFI No :

Type of Mix : Grade of Bitumen :

Source : Date of Sampling :

Chainage : Date of Testing :

Carriageway :

Wt of Sample before Wt of Sample after Wt of Filter Paper Wt of Filter Paper

Bitumen Content (%)
extraction (g) extraction (g) before extraction after extraction (g)
Test No.
(g)
A B C D E=(A-(B+(D-C)))/Ax100

B) SIEVE ANALYSIS AFTER EXTRACTION

Wt of sample after extraction

Sample 1 : Sample 2:
Design Spec. limits
Sieve
Cum Wt %Cum wt Wt Cum Wt Mix as per
Size Wt % Cum %Cum %
Retaine Retained Retained retaine gradtion MORT&H
Retained passin wt Cum
d (gms) (gms) (gms) d (gms) (JMF)
( gms) g retained passin
g
19.0 100

13.2 90-100

9.5 70-88

4.75 53-71

2.36 42-58

1.18 34-48

0.600 26-38

0.300 18-28

0.150 12--20

0.075 4--10
Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of Bengaluru -
Vijayawada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh
(Package-1).
CLIENT National Highway Authority of India
M/S Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association with
INDEPENDENT ENGINEER
M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru Vijayawada Expressway Package-1 Limited
CONTRACTOR M/S Dilip Buildcon Limited.

CORE DENSITY TEST OF BITUMINOUS LAYERS

AS Per MoRT&H (Clause 505.3.5)

Lab Job No. : Layer :

Stretch : Date of Paving :
Location Area : Date of Testing :
(m²) :
Type of Mix :
Theoritical
Gmm
Offset Dry Weight in SSD
Core Thickness Volum Densit %
Location from Sample Water Sample
ID of e y Compaction
C/L Wt.(gm) (gm) Wt.
No. Core(mm) (cc) (gm/cc
(m) (gm)
)

Contractor Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300)
of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the
State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services
INDEPENDENT ENGINEER
Pvt. Ltd. In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

CEMENT TESTS ( IS : 4031)

Job No. : Grade of Cement : Date of Sampling
:
Source of Cement : Week No.: Date of Testing
:
FINENESS OF CEMENT ( IS : 4031 / PART - I ) STANDARD CONSISTENCY OF CEMENT (IS : 4031 / PART - IV)

Wt. Of Average Permissibl Wt. Of

Trial IS Sieve Wt. Of % of Percentage of Wt. Of Penetratio
Cement Weight e Limit, IS Cemen Remarks
. No. (mm) Sample Retaine Water Water n (mm)
Retaine Retaine : 269- t (gm)
d (gm)
d d 2015
1 90mic
< 10 % on
2 90mic
90mic IS
3 90mic Sieve

INITIAL AND FINAL SETTING TIME (IS: 4031 / PART - V)

Time when
Water Time when needle
Wt. Of Time the needle Initial Setting
Sl. 0.85% of makes an impression Final Setting Time
Cemen of fails to Time Remarks
No. Standard but the attachment < 600 minutes
t (gm) Addin penetrate > 30 minutes
Consistency fails to do so
g test block by
(gm)
Water 5+/-
0.5mm
1 2 3 4 5 6 (5-4) (6-4)

SOUNDNESS OF CEMENT (IS: 4031/PART - III)

Sl.
Mould No. Initial Distance in (mm) Final Distance in (mm) Difference in (mm) Average
No.

COMPRESSIVE STRENGTH OF CEMENT (IS : 4031 / PART VI)

Compressive Average
Sl. Date of Date of Weight of Densit Compressive strength as per IS :
Load in KN Strength in Strength
No. casting Testing Cube ( Kg. y 269/8112/12269
N/mm2 N/mm2
) (gm/cc
)
1
2 3 days Strength-----------N/mm2
3
4
5 7 days Strength-----------N/mm2
6
7
8 28 days Strength---------N/mm2
9
Contractor's Representative Concessionaire's Representative IE's Representative
 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
INDEPENDENT M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
ENGINEER association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

COMPRESSIVE STRENGTH OF CONCRETE

As Per IS: 516
[Link]. Date of Casting
RFI No Date of Testing
Location Grade of
concrete
Structure Qty in M³

Element of Structure Age in days 7/28

Weight of Density of Failure Load [Link] Average

Sl No.
Cube Cube in KN h N/mm2 Strength
(gms) (gm/cc) N/mm2

Average Strength :- N/mm²

Remarks:

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu
(Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINE
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

Concrete Delivery Challan

Batching Plant No : Location: Vehicle No : Date:
1 Grade of concrete
2 Structure Chainage
3 Part of the structure
4 Quantity (M3)
5 Cumulative Quantity (M3)
6 Required Quantity (M3)
7 Slump at Plant (mm)
8 Time of dispatch
9 Slump at Site (mm)
10 Unloading time

Operator Q.C Representative

NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu
(Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In
INDEPENDENT ENGINE
association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

Concrete Delivery Challan

Batching Plant No : Location: Vehicle No : Date:
1 Grade of concrete
2 Structure Chainage
3 Part of the structure
4 Quantity (M3)
5 Cumulative Quantity (M3)
6 Required Quantity (M3)
7 Slump at Plant (mm)
8 Time of dispatch
9 Slump at Site (mm)
10 Unloading time

Operator Q.C Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana
Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
INDEPENDENT M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association with
ENGINEER M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

CONCRETE POURING CARD

RFI No. : Date :
Chainage : Grade Of Concrete :
Type Of Structure: Qty :
Description :
Slump at Qty of Concrete
Time of No. of
Sl. Time of Arr. Time of Batching Concrete
T.M No. Dispatche Site Cubes Per Miller
N At site Completio plant Temp(ᵒC Cum( m³)
d from (mm Caste (m³)
o n (mm) )
Plant ) d

Remark :-

Contractor's Representative Concessionaire's Representative IE's Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of
NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of
Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd.
INDEPENDENT ENGINEER
In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Bengaluru-Vijayawada Expressway Package-1 Limited.

COMBINED GRADATION FOR DRY LEAN QUALITY CONCRETE (DLC)

(AS PER MORT&H TABLE 600 - 01)

Source of Material : Date of sampling :

Sampling location : Date of Testing :

Type of Mix : Total Wt.(gms) :

Specification Limits
Sieve Size Weight Cum wt
% Retained % Passing Mid Limit
in mm Retained(gms) Retained(gms) Lower Limit Upper Limit

26.5 100.0 100 100

19.0 85.0 75 95

9.5 60.0 50 70

4.75 42.5 30 55

2.36 29.5 17 42

0.600 15.0 8 22

0.300 12.0 7 17

0.150 7.0 2 12

0.075 5.0 0 10

REMARKS:

Contractor's Representative Concessionaire Representative IE Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch.
24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala
Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highway Authority of India
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services
INDEPENDENT ENGINEER
Pvt. Ltd. In association with M/s Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Bengaluru-Vijayawada Expressway Package-1 Limited.

COMBINED GRADATION FOR PAVEMENT QUALITY CONCRETE (PQC)

(AS PER MORT&H TABLE 600 - 03)

Source of Material : Date of sampling :

Sampling location : Date of :

Testing
Type of mix : Total Wt.(gms) :

Specification Limits
Sieve Size Weight Cum wt
% Retained % passing Mid Limit
in mm Retained Retained(gms) Lower Limit Upper Limit
(gms)
31.5 100 100 100

26.5 90.0 85 95

19.0 78.0 68 88

9.5 55.0 45 65

4.75 42.5 30 55

0.600 19.0 8 30

0.150 10.0 5 15

0.075 2.5 0 5

REMARKS:

Contractor's Representative Concessionaire Representative IE Representative

 NATIONAL HIGHWAY AUTHORITY OF INDIA
Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to
Vanavolu (Ch. 24+300) of NH-544G Bengaluru - Vijaywada Economic Corridor on HAM
Mode under Bharatmala Pariyojana Phase-I in the State of Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory
INDEPENDENT ENGINEER Services
Pvt. Ltd. In association with M/s Kaius Conslting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

FLEXURAL STRENGTH OF CONCRETE BEAMS

As per IS 516 – 1959

RFI No. Date of Casting

Location Date of Testing
Part of structure Tested By

Grade of Concrete Age of Beams (Days)

Averag
Position Flexura
Sr. Wt. of Densit Load in e
Beam ID Fraction l Remarks
No. Beam y (KN) (“P”) Flexural
(mm) Strengt
(Kg) (gm/cc Strengt
“a” h
) h
N/mm2 N/mm2
Contractor's Representative Concessionaire's Representative IE's Representative
 NATIONAL HIGHWAY AUTHORITY OF INDIA

Development of Six-Lane Access Controlled Greenfield Highway from Kodur (Ch. 0+000) to Vanavolu (Ch. 24+300) of NH-
544G Bengaluru - Vijaywada Economic Corridor on HAM Mode under Bharatmala Pariyojana Phase-I in the State of
Andhra Pradesh (Package-1).
CLIENT National Highways Authority of India.
INDEPENDENT M/s Dhruv Consultancy Services Pvt. Ltd. With M/s G Eng Advisory Services Pvt. Ltd. In association with M/s
ENGINEER Kaius Consulting Pvt. Ltd.
CONCESSIONAIRE M/S Bengaluru-Vijayawada Expressway Package-1 Limited.
CONTRACTOR M/S Dilip Buildcon Limited.

DAILY PROGRESS REPORT

Date :

RainFall (mm) Temp (Cº) Himudity

Min. Max. Min. Max.

Done (or)
SI. No Description Remarks
Not done

Contractor's Representative Concessionaire's Representative IE's Representative

 12.0 DOCUMENTATION

12.1 General

Upon completion of each Contract (section-wise) and on completion of the Project, there are several
documents to be prepared and submitted to the Client. The following should be checked with the
Independent Engineer as the project nears completion:

• As-built drawings

• Final Completion report

Although the final documentation is to submitted at the end of the Construction period, they have to be
prepared as the work progresses and finalized when works are nearing completion.

12.2 As-built Drawings

The Concessionaire to prepare the As-built Drawings before nearer the completion. The preparation of
these drawings must be undertaken and completed as the work proceeds and must not be left until
"substantial completion". As the works are completed, they are to be surveyed and the drawings prepared.

12.3 Reporting of the Test Results

As and when tests are carried out in Site laboratory/ Site as per Laboratory Daily program. Test results are
signed by QAQC Engineer. Test results are written in the approved test formats in and the formats are
signed by Concessionaire QA/QC In charge. Signed copies are filed in the site lab. For record purpose
and Duplicate copies may be given to Independent Engineer, if the test is witnessed.