HANDBOOK OF QUALITY CONTROL FOR CONSTRUCTION OF ROADS AND RUNWAYS (Second Revision) by (Pepsin & PoaSP : 11-1988 First Pblishod in Jy, 1973 First Revision : Desember, 1977 Reprinted = October, 1983 Second Revision: April, 1984 September, 1989 Bamary, 1998 January, 1997 September, 2000 April, 2002 printed: Janus 2003 Reprinted: December, 2004 Reprinted: October, 2005 Reprinted Reprited Reprinted Reprinted Repeated (Phe Rights of Publication and Translation are reserved) Pins at Saga Pier & Publishers, New Del-110 003 (sooo), EEE contents Intodsetion CHAPTER—1 Genera CHAPTER—2 Earthwork CHAPTER—3 —Sub-base Courses CHAPTER—4 Bove Cosrecs CHAPTER—S —Aitominove Serisce Courses CHAPTER—6 Concrete Pavements CHAPTER—7 Control of Alignment, Profle and Surfice Evenness CHAPTER—B —Statitical Approuch to Quality Control. 85, 1. Leo Seindarpattons oan 2. mp fase en fc ting (vcore ype sandr wsemmopvcriow a rity control of contraction materials and prodvel isa ten forebuining improved and uniform standard ese rants. end, a treeday Spmposinn on QUaiy SLrmadeTercoourvction of Roads and Ronways” waserganned ontrol i Ceices af the Inoion Roads Congres and the rder te Jot urereh Lasioe in New Delt fom 276 10 Sentral Roe oes At he concoding Sain of thi Sympona, tbe fatowingveotetions were adopted vangamy eee marinate ot te sce of tn nde, gh tenn ere roe te gota eget Geto come! ee 19 ca Commo ea ta pusuance of Resolution No. 4a Commies coasting of te memmns ger was conte for dating the Handbook BRE Shoe om (0 De MP. Dai . aes : Peas : iets : eet Ret :inwroduetion ‘The above Commitee, i ture, costa’ four Subsomat ‘eno prepare drafis of vavios Sections. Later, the Commies Gesided thn, efore felisig he Handbook, ty main tettive ‘ecommendatont regnding. the quantum of ising, cone tet, Scceplble tolerances nnd method of interpretation of resus a 2 fumed form, be placed before the Natlonal Seminar on Rowds and Bridges at Bombay im Ontober, 1968 for wer dice sion. For th purpose, 3 Working Grovp consisting of Dr ML. Posh De. MP DhirsndShri RP. Sitka wim eotroted ‘ith espoaslly of preparing the required summary for cred ‘onto the delegate stendng the Nations Seminar ‘The Recommendations of he National Seminar were iscosed by the Commitee and night ofthe aicussons, ral lng Suhcommitee comprising Prof. CG. Swaminathan, Shi AC Watnajan wna Dr Mle Part was formed tn compete be at Theda pepe by the Socmmiee was diced by ste come n't ees af mesg and «Weng ronp comitogof ht RP St, Dre WLR Dt ag Dr ML Ps roca te mews ten snd bye Eicnve Elms othe hn Rese ove ie etn lds Stathnngar on 811°2, Thee he Comal ote ides Route Cogs ai eating eld Hi sadn ete SpE Spmve ea af he stato a Cote to bing poblnd» Sys! Polaos ot nd Rat Sone ‘The Manual was eeisd in 1917 (list Revision) to incorpo ‘tothe new standards on surface evennets approved bythe LL Counc ws Meeting held ia Madras on. 268.16 The second revision includes te preseibed equipment for dideret labors foris andthe forms. to be used for recordag the result of ‘obeertin/eat ale bythe els offers. GeneralAPTER 1k. Need for Quay Contr! TLL Quality control sam esentia_ past of any production saad highs). consrutons ae no exception. Quaiy [onic san imporant requirement (or highway constrstion for ‘Ruining qutiyand.forereuing. dara. oatonal aes, The ‘Sted ine qutity conc on these conrretons hs increase con- Geeablydn recent times due. t0,sgnifeant increase in ae {neni andthe level of ecioe expected of highay asi, Improved level afsesice of the bighways. will esol In coniera: [savings in vehicle operating, sat end In fvovrable ond wer ‘action and public opinion, Qual) contol inthe form of se Tey‘ciecs wai oe, iinsaly ewbjectve. and quliave ‘italy nadeuate for povent-ay neede and est stead be ase En prope objective snd quantitative easuremen, Lh. teis common knowledge that quality onto, besides leading to construction of mpuoved. quality and wofory, and Shnuinga more exonomscal lation of materia, so ards 3 “igen redtom in user cot, terms of lower cous of vice Speraion transportation and maintenance, The eXta cost of Stercning quality conto eiag only a taction ofthe resuing benef b highly economia! proposition nav tach 2 on an nertpe prot itv etinnted that the cost of exereing goaity Sontrt "would be. just tt 2 por cent of the construction cost ‘Oerte other hand he. dest and sadect economic retomn from Guely contol cook be ofthe order of 5 to 10 percent of the otal ‘pestraton eos and even more 1.2, Preaqabtes for Quay Comet “The preteqises for effective coatel of higheay conse © Cte eos a tim he ie trGonerat (Acer lod wand espe sey or ees. ‘nto Tavranine Sng coatesin afar ong Sect creme ay cone ne core 12 Onn! afr Qty Cent {Te eee of guy ented south Be cone vain wit iat ayo ee poe Seeing eee ‘Spa tend ay Forse oem a niyo oe ey oes re tp edb on gte ee et ee sed [eta er oy ad era ‘ane ry comet "wb oad peso iltavp maybe caed he Che ote et 7 crs aronea” Fore pgp of fat Scnotscapin hbo splat Clans sep Sinn pan ston bow ‘Orgeltonl Chart of Quay Contre Sot | Tesesariatetoaoie a tt a eld Laboratory [Smee General 5 12:2. tnany ongeistionsl set-up, che central agency Ba unimportant sale a repards implementation of quality cone were by way of deang. apd. constont review ofthe avait saan rea inclded. in the onsaction speciation The pane Staton et quality sontel inthe field would normlly ive rrr oabcagencs the controcton sao the Enginesrdo~ ae ee eenaracing agency andthe quay contol tam. THe CEA lon att and quality conte) cams, amust have distinctly Seam eens nnd’ intersennsbips. so asf avoid posible sees te quality cone fost may sonst of sal of regional Fanti jean eld oratories working onder the techoicl ‘duceson ofthe Central Laboratory. 13. As fara the fel laboratories are concerned, the per adic ay costo! data soected. by them shoal be promptly sai a coetipee atthe, iter responsible fr enseiog wesrep and speed of contraction. In addin, the data wil aso quali ane Tobe, Superintending, EnalnceeChiee Engineer a3 ve te fiend ofthe. Cental Laboratory, 10 the formes with cee ca cnsure continuity aswell as comprbiiy ofthe tiation in pce, and tothe ister for prpote of fed- oti nny be reeaded ss a teiaive cxommendaton, racks roview and. mediesion, ab nd when experince a> 13, The expenditure on gulity contol may be charged to the wots aa he ma a wel ae equipment shied fowtpofet ime Rergepening open, the requlrements, The quai control otf mat be on wovkceharged bats bu orm part of reguie sae eb gcapeny, rained forthe. work they are required 0 ‘Miote for which suitable teioiog ocites shoud be aorded ty tance, ehber in their own Central Laboratory or sn eer tory Tw peovie for the cox of quality conto, i ee Tape ta ny be ieided a tint Hem la the various fron enn 1A, Types Quality Cone at, Over he years two types of methods ave emerted for enching quatty outa! dering the construction of works, ra er einly Enowa se Process contol” andthe oer an "End_ General result typh of contol, a the former, he detgner aes he Tedlom regarding the ype ef equipment, the procedure of com eocdon ae the smount of ork" reuired. to obiin te desired ‘oun. inthe Ead reaul gpe of eontol the construction agene), “inien ray bea pvate contractor, bas fee band i the selection reomarucie methods and equipment to achive the desired end rode. Lad, The choice of ithe typeof contol is arely «mater wt jdgment, depending om the magoitude ofthe jb, diferent fas, erauwaly the tend is towards “End resuit typeof working tm hgheny pavement and embankment consracion jobs. Boti8 ‘verl stations, for oxnmpe om smal jobs, or where janet Pe tens lie materi gradstion and parity of ine are to be cared St capediency would bein adopting. rocts ie" of cont ‘ecoue of rconsances combination ofthe Proves and “End fevutt types ov conta wil eninge to be adopted in Indl, dpe ‘ing on the nate and Ste ofthe jo. 1.43. fa dheEnd result type of speciation, the Geld caginecring personnel story out tests on Gis work at regular fneeats to evaluate whether R- meets ce specication require: Imenr ny aol. On fhether hands. "Process type contra the Fespensibiy of field persnsel ito make sre tat the work its ‘ferent phases is excented in the manner, predetermined aod lad down in apecentons. 14, The deals give in this Mandbook are for a combine tion of -Process snd‘ result typetof quot cotel which sencrlly bog practised in wis country. 1.5, Speen fr Work ‘The bandboot draws heavily opon the ening Standards) Specifenions. of Indian, Ronde, Congres by way of tbsraction Ghenielrequlrements of consttaclion forte various ems of Sort Reference piven tothe relevact Standards at appropri Jinoce fe he andbook, A compet ist ofall the standards re fed to with thir fa te inladed st Append 7 General 16, Conte of Mates 161 The quay contol tert on materials indicated in the sobsoqeen chapter, are intended exsentlly (0 Beets out on fhevaktedh rough. to te. However, a tne, rom praca! coin eonstereions, some feting cout be done advantageon- pat the material sutee. In these circumstances, Ge WSharge may co addiooal tenga se as may Be found neces Sto vure thet the materi Delo focorporsted in he const ‘ho are of pected gual. 1.62, All the materiale brought othe site shal b aod sored as specited wo art prvent_ deterioration or By foreign medcr and. to emure tbe preservation of thie quality 2d for works Materiie nick bave been improperly sored Sehave been stored for log peios shal be ceested where thee ia for incorporation i Oe work Iss 0b Ln, Tat Praswdors Lina, The procedure for testing of diferent materials and work sai be iw accordance wit the relevant standards of Indian Boveau of Standerds wher there are available. Reference hss Been draw to theae standards at appropiate placer ia the, Handboot. Se pnsoiated nt of the sapdnrds ich thir fall ei at ‘dopenix 2 1.12, Where specie prosedute of testing isnt indicted he test shall be curried out a er the prevalent aceeped enginesias rates to the diction of the Enginesin-Charse. 1.8 Rregoeney ond lat of Tetag ‘The fequency and extent of testngindested ia the Handbook iste minimum conifered necesary for corms conditions. tie Covlsged tha sdtonal eng sll be carried out for rbnormtl onde whore variations may be exeesve or where cieumstam™ 1.9, Aeonpance Catern 19.1. Acceptance Catera for dierent items of work where sofceat ezpericnce, wat avaiable ave been setford in the landbook in respective chapter. For othr isms acespiance1.9.2. For efecve contol on quay of maerias and work, Ssully bo wesesry Lo lay data the acceptance cites the coestdacement, ‘Tog Labortery L101. Reage of equipment required for x cence, regional oi eld testing 20d conic laboratories finden in Apper fi 2 for guidance. ‘The lit inclades such. equipment at ail foray be required for quay contre} erations spel oot in he Handbook, insvinaly, quit cote! unis could be rtably quipped with the help of ths It depending om the tpeand ‘ele of work to be eoutrolled. Special eauputeat as given in the {pomaleeze be procared depeniog upon the regultemeet 5 Conta, Rogloal and sit 1102, ‘Tag ate: Teng fies souk comprise Laboratori at Cental, Regional and Bald level The Cental Sonny cet sthendgmtctoil- (9 prone ene ites ote of specu sate, 0 et cei oes tor for wostcrae@) at hendgntar (et th ihe nota Inbrstary fo Research cheer te, Su und Cetra sector, (@) bingo nents frtesing oecdnes The Cental bo tory tenes byte Discs may fave for uty cote oth Selene fom Gna, Chey Piper Sepies,"The inf aes eprops Cea ebay The Regionllaborsioriesloeted a circle evel wil be her= ded ty Hsesave Engineers (Qualty Control) ated by scent fom Geoiogy, Physics and Cheers dicpines, Regional labor= stories wt provide testing sappor to the (a) Engineers working in the cies and (b) Research tearm rt Comal and Ste igh ay RD inwiiuone. In adit they sal prove af fete oe tuning of tl the Qualcy Control sa the Regio, The lt of suagested equipment tobe ovided fo Regional laboratories tiven a Append 3. ‘stor fenible nor advable to end staples far rutne 2 General evs all the ay tothe Regions laboratories and delay the ork for wan of fest eset Seting wp ales fr Basie et tthe level of Junior Ensineesaginse ing subordinale i thetefore neces fry. Some. other equipments may have to be provided at sab DivsionaiDiviivnsl fvel- A. tit of equipment suggested to be provided at Site/Sub divionl/DiviionlTevel can be seen at Tippend 3 The tests shal be cried out in asondance with he ndard peovedures te te sls sa be ecorde in the proforma ven ECSpvends is cstable tes ofthe total ten, 70 por cent srcbtradon by toe Junior Eaginsr2 pr seat 8y the Amant Beaty Engine andthe rug io per cnt by the Executive Engine the teste record cepts tal be_preseted th every thiteconing so ton he pment BE inked SA Rese gonty of werk a2, Teli foe Quy Cont In erde to bring awareness nthe offers of department and to update thls inoulge smth oftesing, reason Workbope ‘qi conte shld be ei To abe the arpa ST be newest ike specications, request acceptance Sten ffoqeney of eng and tehodsogy of ese for ander Sting {he gualy conto ecm sod operation a eioafld {Notre The’ ining could be imparted by Hawn road recur ater o thong on jb sn 13, Scope a he Baadook Lint, Thi Handbook ir ntende ato be «handy cterence tor he pecral wooo usity contr vous ighway coon ‘Gu actin anyvay seat bea bata forthe ee ‘nr epurneatl specu for contruction and mater but nly ara. guide i complemen there or sei tems; where scck wus fel broad gaelos om aint contacto feature bate Teen incoded i he Handbook. These ate for godnace oly and ‘Routd bot be ken to conse peciextions 1132. Even thooph te Handbook intended mainly for sighway.cosetcton, il be ound eqplly advantages fora inber of acto one constroconm tell2a, era Dud. Tes the tesponbility of he Geld engineer to ensure that the densi assumed by the-designce is Achieved. at the fapeced moisteve-eonten, The way f0 ensure this to test Smps for moistve ad density and to take appropriate correc the menses ne necczay. The toe of testing On # ten project Would depend ov several factor, rich ax te homogensity oF theese of te, material from the Rorrowpls, the nature and {Quantum of machinery manual Inbowr employed, and terain Sondions, so that the number of paetculas tests 10 be conducted foray 10a cube metres ofthe mater avowed, would entirely tea matter stengnceing judgment, Terefore, the frequency testing idested tthe end se chapter should De reparded Ss indicative ofthe imam numberof teststo be conducted with faa wetaton of the nc thatthe rte of testing wold have toe increed i svcumstancor 20 warrant 2:12. Discusion of other apts sbeh as the minimum Aeosies to be abuaned sleton of rolling. equipment thickness Ot layers eles are comidered to be outside the scope of his per For’ gadance s0 is fespect, reference shoud be made {o the relevant specications, IRE> 361970. "Recommended Practice for Consinusion of Earth Embankeents for Road 22. arthwork Materia ond Proce Selection o Sits 221. Tae soll to be wed for making 9p the embankment shalt be tee from sump and root rebbi Which mae affect the eblity of he eure 2.22, “The slecio of materials for const vetion of the ems bnokineat sal be made after condecting necessary soil surveys tnd laboratory investigation, a set out a IRC = 36-190,Eershwork. 223, nly wpproved materiale should be wlsed in the out, Pvc v0 picemeat © To sisi adequate com- pecion, s nubentmens hal be onsracted in waforn Hyer Sos tw abet be coerced to ongare that Lose thikness of Src layer doc oe cnsead the peeled Him. Stecessea Lyers Pombentonent shut ot be placed anche layer undes con event hee bose thoroughly sompacedto tity the specifed 22.5, After adjusing e mowture content wheter at the jas oo boweom ara, (otrng dv llowanes fr evapora ‘on lowes, she sel shall be proceed by siams of graders, frrowe, roy rains, ster salable equipmeet or even manually jPo cqipene ie avalebte athe osstere dist ution ie ra50- iy urge Clods cd tosoe of earth where present hal be Vrovun sata Loos posrabiy afte ore7 of S.cm ut under fo ircumlancc hall se. magioom see of lode exced 15 om Sf bo tug pleco in the body oF ke embankment sd 6 cm Shon ie being peed e the tp 8B rf the embankment 2.26, ‘Moloney cases ot the Gene af compton Unless ortarie spent the mole content ofeach fyer of sil st ie dn of compton except in the cate of igh expansive soil houle be avoptimer snare content subject o the permite Tctorsnoee. iighlysapaasive sie sech a8. black cotton ‘Soule fe compacted at the epeided obture content sich ie anvally on the higher side of the optinum moisture. com fine “The eleranos lit for variten of moisture content from the apecited taster content are normelly + 1 per een and —2 2.21. Densities to be simi atin the compaction process tht! be chosen thaw regard fo fetes atcha sil yf, Beat Steubeetient, drsitnge conditions, postion of the individu layers end pe of pant svaable fr compton 2.8. ach compacted Inger sal be tested inthe Held or evely an neared before the opertions for the next layer Earthwork 6 2.3. ‘Test Compaction 23.1, In sitsatons whece no previo ecard or experience ‘ovserning the nesied number of passes ih 2 panicolr ling ‘auipment clang so = parulse so type avaiable, it may be ‘esrable tp conduct Seld tne on compton so as to obtain dat Which wosld serve ss sm id to panning af comption operations 2.2.2, A tes aces about 20. Ioog ands m wie ie prepared iter removing the top sol. Te il sateal co be used Is spread ter this aren, the depth of the loa layer being 25cm. The tottre content of the sll should Beas spied subject tthe tolernce lsat 233, The tes Iyer is then somacted ith the type of compaction plant dosed spon, snd the mean dry dasa fo te Til depth determined ever the range of sbowt $c 6 pases. The ‘numberof purse reqied are dependent upon the welgM and type ‘troller employed. ‘The dry density sail be deirmined in nec ance wih 5: 2720 (PareVIN) sad the mean of 5 determin Son thuld be sbisined foreach compaction condition. The mean fry dense ave pleted agaat the umber of role passes, From {hie grant the spprosinate numberof pases required fo the come clon equpaoeat vo obtain the specie dy density determined 24. Quily Cootrol of Baibwer, 2A.l, Quality of fl material and ts compaction shall be controlled through exerceofehecks on the borrow materi, com action proces, or the end-product, singly or in combination os firectes. "However, in every ote, he snd:produet must conform {othe sotraction secieatons 24.2. eta of contol tees on borrow materials and com ction ae dealt mith in Clases 2. and 26 2S, Control Teet.en Borrow Matec! 2S. Tue particular type af ets required tobe conducted fon the borrow sateis] and thee frequeney would depend on interpiayof several store zach asthe nature of plant o- machi tory employed on be project, the quantom of aman abou In-